Reelmaster® 3550 Traction Unit

1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.

2. Remove the reel motors from the shipping brackets.

3. Remove and discard the shipping brackets.

4. Remove the cutting units from the cartons. Assemble and adjust as described in the cutting unit Operator's Manual.

5. Make sure that the counterweight (Figure 3) is installed to the proper end of the cutting unit as described in the cutting unit Operator's Manual.

   

   Figure 3

   1. Counterweight

6. All the cutting units are shipped with the turf compensation spring mounted to the right side of the cutting unit. The turf compensation spring must be mounted to the same side of the cutting unit as the reel drive motor. Position the turf compensation as follows:

   1. Remove the 2 carriage bolts and nuts securing the rod bracket to the cutting unit tabs (Figure 4).

      

      Figure 4

      1. Turf compensation spring
      2. Rod bracket
      3. Spring tube

   2. Remove the flange nut securing the spring tube bolt to the carrier frame tab (Figure 4), and remove the assembly.

   3. Mount the spring tube bolt to the opposite tab on the carrier frame and secure it with the flange nut.

      Note: Position the bolt head to the outer side of the tab as shown in Figure 4.

      

      Figure 5

      1. Opposite carrier frame tab
      2. Rod bracket

   4. Mount the rod bracket to the cutting unit tabs with the carriage bolts and nuts (Figure 5).

   Note: When installing or removing the cutting units, make sure that the hairpin cotter is installed in the spring rod hole next to the rod bracket. Otherwise, the hairpin cotter must be installed in the hole in the end of the rod.

7. Lower all the lift arms completely.

8. Remove the snapper pin and the cap from the lift-arm pivot yoke (Figure 6).

   

   Figure 6

   1. Snapper pin
   2. Cap

9. For the front cutting units, slide a cutting unit under the lift arm while inserting the carrier frame shaft up into the lift-arm pivot yoke (Figure 7).

   

   Figure 7

   1. Lift arm
   2. Carrier frame shaft
   3. Lift-arm pivot yoke

10. Use the following procedure on the rear cutting units when the height of cut is above 1.2 cm (3/4 inch).

    1. Remove the lynch pin and washer securing the lift-arm pivot shaft to the lift arm and slide the lift-arm pivot shaft out of the lift arm (Figure 8).

       

       Figure 8

       1. Lift-arm shaft lynch pin and washer

    2. Insert the lift-arm yoke onto the carrier frame shaft (Figure 7).

    3. Insert the lift-arm shaft into the lift arm and secure it with the washer and lynch pin (Figure 8).

11. Insert the cap over the carrier frame shaft and lift-arm yoke.

12. Secure the cap and the carrier frame shaft to the lift-arm yoke with the snapper pin.

    Note: You can use the slot for a steering cutting unit or use the hole to lock the cutting unit in position (Figure 9).

    

    Figure 9

    1. Slot
    2. Hole

13. Secure the lift-arm chain to the chain bracket with the snapper pin (Figure 10).

    Note: Use the number of chain links specified in the cutting unit Operator's Manual.

    

    Figure 10

    1. Lift-arm chain
    2. Chain bracket
    3. Snapper pin

14. Coat the spline shaft of the reel motor with clean grease.

15. Oil the reel-motor O-ring and install it onto the motor flange.

16. Install the motor by rotating it clockwise so that the motor flanges clear the locknuts (Figure 11). Rotate the motor counterclockwise until the flanges encircle the nuts then tighten the nuts.

    Important: Make sure that the reel motor hoses are not twisted, kinked, or at risk of being pinched.

    

    Figure 11

    1. Reel-drive motor
    2. Mounting nuts

The turf compensation spring (Figure 12) transfers weight from the front to the rear roller. This helps to reduce a wave pattern in the turf, also known as marcelling or bobbing.

Important: Make spring adjustments with the cutting unit mounted to the traction unit, pointing straight ahead and lowered to the shop floor.

1. Make sure that the hairpin cotter is installed in the rear hole in the spring rod (Figure 12).

   

   Figure 12

   1. Turf compensation spring
   2. Hairpin cotter
   3. Spring rod
   4. Hex nuts

2. Tighten the hex nuts on the front end of the spring rod until the compressed length of the spring (Figure 12) is 12.7 cm (5 inches).

   Note: When operating on rough terrain, decrease the spring length by 2.5 cm (1/2 inch). Ground following will be slightly decreased.

Parts needed for this procedure:

If this machine will be used for CE, affix the warning decal 120-1686 over English warning decal 120-1683.

Parts needed for this procedure:

1. Unhook the hood latch from the hood-latch bracket.

2. Remove the 2 rivets securing the hood-latch bracket to the hood (Figure 13) and remove the hood-latch bracket from the hood.

   

   Figure 13

   1. Hood-latch bracket
   2. Rivets

3. While aligning the mounting holes, position the CE lock bracket and the hood-latch bracket onto the hood.

   Note: The lock bracket must be against the hood (Figure 14). Do not remove the bolt and nut from the lock-bracket arm.

   

   Figure 14

   1. CE lock bracket
   2. Bolt and nut

4. Align the washers with the holes on the inside of the hood.

5. Rivet the brackets and the washers to the hood (Figure 14).

6. Hook the latch onto the hood-latch bracket (Figure 15).

   

   Figure 15

   1. Hood latch

7. Screw the bolt into the other arm of the hood-lock bracket to lock the latch in position (Figure 16).

   Note: Tighten the bolt securely but do not tighten the nut.

   

   Figure 16

   1. Bolt
   2. Nut
   3. Arm of hood-lock bracket

Parts needed for this procedure:

Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand to make sure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 17).

Figure 17

1. Cutting unit kickstand

Secure the kickstand to the chain bracket with the snapper pin (Figure 18).

Figure 18

1. Chain bracket
2. Snapper pin
3. Cutting unit kickstand

Press the forward traction pedal (Figure 19) to move forward. Press reverse traction pedal (Figure 19) to move backward or to assist in stopping when moving forward. Also, allow the pedal to move or move it to the NEUTRAL position to stop the machine.

Using your heel, move the mow/transport slide (Figure 19) to the left to transport and to the right to mow. The cutting units will only operate in the MOW position and not lower in the TRANSPORT position.

Important: The mow speed is set at the factory to 9.7 km/h (6 mph). It can be increased or decreased by adjusting the speed stop screw (Figure 20).

Figure 20

1. Speed stop screw

Pull the tilt-steering lever (Figure 19) back to tilt the steering wheel to the desired position. Then push the lever forward to secure the position.

The ignition switch (Figure 21), used to start, shut off, and preheat the engine, has 3 positions: OFF, ON/PREHEAT, and START. Rotate the key to the ON/PREHEAT position until the glow-plug indicator light goes out (approximately 7 seconds); then rotate the key to the START position to engage the starter motor. Release the key when the engine starts. The key moves automatically to the ON/RUN position. To shut off the engine, rotate the key to the OFF position. Remove the key from the switch to prevent accidental starting.

Figure 21

1. Parking brake
2. Ignition switch
3. Enable/Disable switch
4. Diagnostic light
5. Lower mow/raise control lever
6. Hour meter
7. Oil-pressure light
8. Temperature light
9. Light switch
10. Glow-plug indicator light
11. Throttle
12. Alternator light

Move the throttle (Figure 21) forward to increase the engine speed and rearward to decrease the engine speed.

Use the enable/disable switch (Figure 21) in conjunction with the lower mow/raise control lever to operate the cutting units. You cannot lower the cutting units when the mow/transport lever is in the TRANSPORT position.

The hour meter (Figure 21) indicates the total hours of machine operation. It starts to function whenever the key switch is on.

This lever (Figure 21) raises and lowers the cutting units and also starts and stops the reels when the reels are enabled in the mow mode. You cannot lower the cutting units when the mow/transport lever is in the TRANSPORT position.

Note: When the cutting units are enabled, you do not need to hold the lever in the forward position while the cutting units are lowered or raised.

The temperature warning light (Figure 21) glows if the engine coolant temperature is high. At this temperature, the cutting units are disabled. If the coolant temperature rises another 5.5° C (10° F), the engine shuts off to prevent further damage.

The oil-pressure warning light (Figure 21) glows if the engine oil pressure drops below a safe level.

The alternator light (Figure 21) should be off when the engine is running. If it is on, check the charging system and repair it as necessary.

The glow-plug indicator light (Figure 21) glows when the glow plugs are operating.

Whenever the engine is shut off, engage the parking brake (Figure 21) to prevent accidental movement of the machine. To engage the parking brake, pull up on the lever. The engine stops when you press the traction pedal with the parking brake engaged.

The diagnostic light (Figure 21) will illuminate if the system recognizes a system fault.

The fuel gauge (Figure 22) indicates the amount of fuel in the tank.

Figure 22

1. Fuel gauge

The power point, located on the outside of the control panel, is a 12 V power supply for electronic devices (Figure 23).

Figure 23

1. Power point

The reel speed control controls the speed of the cutting units (Figure 24). The reel speed increases as you turn the knob counterclockwise. Refer to the reel speed chart decal (Figure 33), to determine the proper reel speed.

Figure 24

1. Backlap lever
2. Reel speed control knob

Use the backlap lever in conjunction with the lower mow/raise control lever for the reels (Figure 24).

A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories.

To best protect your investment and maintain optimal performance of your Toro equipment, count on Toro genuine parts. When it comes to reliability, Toro delivers replacement parts designed to the exact engineering specification of our equipment. For peace of mind, insist on Toro genuine parts.

The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started.

Crankcase capacity is approximately 3.8 L (4 US qt) with the filter.

Use high-quality engine oil that meets the following specifications:

• API Classification Level Required: CH-4, CI-4 or higher.

• Preferred oil: SAE 15W-40 (above 0ºF (-17ºC))

• Alternate oil: SAE 10W-30 or 5W-30 (all temperatures)

Note: Toro Premium Engine Oil is available from your distributor in either 15W-40 or 10W-30 viscosity. Refer to the Parts Catalog for part numbers.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine. If the oil level is between the Full and Add marks, no oil addition is required.

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Remove the dipstick (Figure 25) and wipe it with a clean rag.

   

   Figure 25

   1. Dipstick

3. Push the dipstick down into the dipstick tube and make sure that it is seated fully. Pull the dipstick out and check the oil level.

4. If the oil level is low, remove the oil-fill cap (Figure 26) and gradually add small quantities of oil, checking the level frequently, until the level reaches the Full mark on the dipstick.

   

   Figure 26

   1. Oil-fill cap

5. Install the oil-fill cap and close the hood.

Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.

The fuel tank capacity is approximately 42 L (11 US gallons).

Use summer-grade diesel fuel (Number 2-D) at temperatures above -7°C (20°F) and winter-grade diesel fuel (Number 1-D or Number 1-D/2-D blend) below -7°C (20°F ). Using winter-grade fuel at lower temperatures provides lower flash-point and cold-flow characteristics that ease starting and reduce plugging of the fuel filter.

Using summer-grade fuel above -7° C (20° F) will contribute toward longer fuel pump life and increased power compared to winter-grade fuel.

Biodiesel Ready

This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra-low sulfur. Observe the following precautions:

• The biodiesel portion of the fuel must meet specification ASTM D6751 or EN14214.

• The blended fuel composition should meet ASTM D975 or EN590.

• Painted surfaces may be damaged by biodiesel blends.

• Use B5 (biodiesel content of 5%) or lesser blends in cold weather

• Monitor seals, hoses, and gaskets in contact with fuel as they may be degraded over time.

• Expect plugging of the fuel filter for a time after converting to biodiesel blends.

• Contact your authorized Toro distributor for more information on biodiesel.

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Clean the area around the fuel-tank cap (Figure 27).

3. Remove the fuel-tank cap.

4. Fill the tank to the bottom of the filler neck. Do not overfill the tank. Install the cap.

5. Wipe up any spilled fuel.

   

   Figure 27

   1. Fuel-tank cap

   Danger

   Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.

   Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.

Clean debris off the radiator daily (Figure 28). Clean the radiator hourly if conditions are extremely dusty and dirty; refer to Cleaning the Engine Cooling System.

Figure 28

1. Radiator

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. Check the coolant level at the beginning of each day before starting the engine.

The capacity of the cooling system is approximately 5.7 L (6 US qt).

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Check the coolant level in the expansion tank (Figure 29). With a cold engine, the coolant level should be approximately midway between the marks on the side of the tank.

3. If the coolant level is low, remove the expansion-tank cap and replenish the system. Do not overfill the tank.

4. Install the expansion-tank cap.

   

   Figure 29

   1. Expansion tank

The reservoir is filled at the factory with approximately 13.2 L (3.5 US gallons) of high-quality hydraulic fluid. The best time to check the hydraulic fluid is when the fluid is cold. The machine should be in its transport configuration. If the fluid level is below the Add mark on the dipstick, add fluid to bring the fluid level to the middle of the acceptable range. Do not overfill the reservoir. If the fluid level is between the Full and the Add marks, no fluid addition is required.

Use Toro Premium All Season Hydraulic Fluid (available in 19 L (5 gallon) containers or 208 L (55 gallon) drums—see the parts documentation or your Toro distributor for part numbers).

Alternative fluids: If the Toro fluid is not available, you may use other conventional, petroleum-based fluids, provided that they meet all the following material properties and industry specifications. Check with your fluid supplier to see whether the fluid meets these specifications.

Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

The proper hydraulic fluids must be specified for mobile machinery (as opposed to industrial plant usage), multiweight-type, with ZnDTP or ZDDP anti-wear additive package (not an ashless-type fluid).

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 fl oz) bottles. One bottle is sufficient for 15 to 22L (4 to 6 US gallons) of hydraulic fluid. Order Part No. 44-2500 from your authorized Toro distributor.

Synthetic, Biodegradable Hydraulic Fluid is available in 19 L (5 gallon) containers or 208 L (55 gallon) drums—see the parts documentation or your Toro distributor for part numbers.

This high-quality, synthetic, biodegradable fluid has been tested and found compatible for this Toro model. Other brands of synthetic fluid may have seal compatibility problems and Toro cannot assume responsibility for unauthorized substitutions.

Note: This synthetic fluid is not compatible with the Toro Biodegradable Fluid previously sold. See your Toro distributor for more information.

Alternative fluids:

• Mobil EAL Envirosyn H 46 (US)

• Mobil EAL Hydraulic Oil 46 (international)

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Clean the area around the filler neck and cap of the hydraulic tank (Figure 30). Remove the cap.

   

   Figure 30

   1. Hydraulic-tank cap

3. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the fluid level. The fluid level should be within 6 mm (1/4 inch) of the mark on the dipstick.

4. If the level is low, add the appropriate fluid to raise the level to the Full mark.

5. Install the dipstick and cap onto the filler neck.

Each day before operating, check the reel-to-bedknife contact, regardless of whether the quality of cut had previously been acceptable. There must be light contact across the full length of the reel and the bedknife (refer to Adjusting the Reel to Bedknife in the cutting unit Operator's Manual).

The tires are over-inflated for shipping. Therefore, release some of the air to reduce the pressure. The correct air pressure in the tires is 83 kPa (12 psi).

Note: Maintain the recommended pressure in all tires to ensure a good quality of cut and proper machine performance.

Torque the wheel nuts to 61 to 88 N∙m (45 to 65 ft-lb).

1. Start the engine, raise the cutting units, disengage the parking brake, and move the machine to an open flat area.

2. Engage the parking brake (Figure 31).

   

   Figure 31

3. Press the traction pedal to move the machine forward.

   Note: If the machine moves forward with the parking brake engaged, adjust parking brake; refer to Adjusting the Parking Brake.

   Note: Moving the machine forward with the parking brake engaged will cause the engine to shutoff.

4. If you adjusted the parking brake, repeat steps 2 and 3.

   Note: If the machine moves forward with the parking brake engaged: service the parking brakes, check left and right brake linkage for damage, and check the brake lever pivot for damage; refer to Servicing the Parking Brakes.

5. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s seat.

You may need to bleed the fuel system if any of the following situations have occurred; refer to Bleeding the Fuel System:

• Initial startup of a new engine

• The engine has ceased running due to lack of fuel.

• Maintenance has been performed upon the fuel system components; i.e. filter replaced, etc.

To achieve a consistent, high quality of cut and a uniform after cut appearance, it is important that you set the reel speed controls (located under the seat) correctly. Adjust the reel speed controls as follows:

1. Select the height of cut at which the cutting units are set.

2. Choose the desired ground speed best suited for conditions.

3. Use the graph on the reel speed chart decal (Figure 33), to determine the proper reel speed setting.

   

   Figure 33

   1. 8-blade reel adjustment
   2. 11-blade reel adjustment
   3. Read the Operator’s Manual for information on adjusting the reel.

4. To set the reel speed, rotate the knob (Figure 34) until the indicator arrow is in line with the number designating the desired setting.

   

   Figure 34

   1. Reel speed control knob

   Note: You can increase or decrease the reel speed to compensate for turf conditions. When using baskets, increase the reel speed to improve collection performance.

You can adjust the counterbalance on the rear cutting unit lift arms to compensate for different turf conditions and to maintain a uniform height of cut in rough conditions or in areas of thatch buildup.

You can adjust each counterbalance spring to 1 of 4 settings. Each increment increases or decreases counterbalance on the cutting unit by 1.4 kg (3 lb). Position the springs on the back side of the first spring actuator to remove all counterbalance (fourth position).

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key from the ignition switch.

2. Insert a tube or similar object onto the long spring end to relieve the spring tension during the adjustment (Figure 35).

   Caution

   The springs are under tension and could cause personal injury.

   Use caution when adjusting them.

3. While relieving the spring tension, remove the bolt and locknut securing the spring actuator to the bracket (Figure 35).

   

   Figure 35

   1. Spring
   2. Spring actuator
   3. Additional hole locations

4. Move the spring actuator to the desired hole location and secure it with the bolt and the locknut.

5. Repeat the procedure on the remaining spring.

1. Park the machine on a level surface, lower the cutting units, engage the parking brake, shut off the engine, and remove the key.

2. Ensure that the fuel tank is at least half full.

3. Unlatch and raise the hood.

   Danger

   Under certain conditions, fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage.

   Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.

4. Open the air-bleed screw on the fuel-injection pump (Figure 36).

   

   Figure 36

   1. Fuel-injection pump bleed screw

5. Turn the key in the ignition switch to the ON position. The electric fuel pump will begin operation, thereby forcing air out around the air-bleed screw.

   Note: Leave the key in the ON position until a solid stream of fuel flows out around the screw.

6. Tighten the screw and turn the ignition key to OFF.

Note: Normally the engine should start after the above bleeding procedures are followed. However, if the engine does not start, air may be trapped between the injection pump and injectors; refer to Bleeding Air from the Injectors.

The machine comes with a diagnostic light that indicates if the electronic controller senses an electronic malfunction. The diagnostic light is located on the control panel (Figure 37). When the electronic controller is functioning correctly and the key switch is moved to the ON position, the controller diagnostic light will turn on for 3 seconds and turn off to indicate that the light is working properly. If the machine stalls, the light will turn on steady until you change the key position. The light blinks if the controller detects a malfunction in the electrical system. The light stops blinking and automatically resets when you turn the key switch to the OFF position once the fault has been resolved.

Figure 37

1. Diagnostic light

When the controller diagnostic light blinks, one of the following problems has been detected by the controller:

• 1 of the outputs has been shorted.

• 1 of the outputs is open circuited.

Using the diagnostic display, determine which output is malfunctioning; refer to Checking the Interlock Switches.

If the diagnostic light is not illuminated when the key switch is in the ON position, this indicates that the electronic controller is not operating. Possible causes are as follows:

• Loop-back is not connected

• The light is burned out.

• Fuses are blown.

• It is not functioning correctly.

  Check the electrical connections, input fuses, and diagnostic light bulb to determine the malfunction. Ensure that the loop-back connector is secured to the wire harness connector.

The machine is equipped with an electronic controller which controls most machine functions. The controller determines what function is required for various input switches (i.e., seat switch, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the requested machine function.

For the electronic controller to control the machine as desired, each of the input switches, output solenoids, and relays must be connected and functioning properly.

Use the Diagnostic ACE display to help verify and correct electrical functions of the machine.

The purpose of the interlock switches is to prevent the engine from cranking or starting unless the traction pedal is in the NEUTRAL position, the Enable/Disable switch is in the DISABLE position, and the Lower Mow/Raise control is in the NEUTRAL position. In addition, the engine should shut off when you press the traction pedal with no one in the seat or if the parking brake is engaged.

• Use full-width ramps for loading the machine onto a trailer or truck.

• Tie the machine down securely.

In case of an emergency, you can tow the machine for a short distance; however, Toro does not recommend this as a standard procedure.

Important: Do not tow the machine faster than 3 to 4 km/h (2 to 3 mph) because the drive system may become damaged. If you must move the machine farther than 1 km (0.6 mile), transport it on a truck or trailer.

1. Locate the bypass valve on the pump (Figure 41) and rotate it 90°.

   

   Figure 41

   1. Bypass valve

2. Before starting the engine, close the bypass valve by rotating it 90° (1/4 turn).

   Important: Do not start the engine when the valve is open.