Toro 03550 Reelmaster 5500-D Operator'S Manual Download Page 1

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Operator’s Manual

English (EN, GB)

Form No. 3354–505 Rev A

Reelmaster

5500–D

2 and 4 Wheel Drive Traction Units

Model No. 03550—260000001 and Up
Model No. 03551—260000001 and Up

Summary of Contents for 03550 Reelmaster 5500-D

Page 1: ...Operator s Manual English EN GB Form No 3354 505 Rev A Reelmaster 5500 D 2 and 4 Wheel Drive Traction Units Model No 03550 260000001 and Up Model No 03551 260000001 and Up ...

Page 2: ...o Bedknife Contact 22 Check the Torque of the Wheel Nuts 22 Operation 23 Controls 23 Starting and Stopping 25 Bleeding the Fuel System 25 Setting the Reel Speed 25 Adjusting the Rear Lift Arm Counterbalance 26 Towing the Traction Unit 27 Diagnostic Light 27 Diagnostic ACE Display 28 Checking the Interlock Switches 28 Hydraulic Valve Solenoid Functions 29 Operating Characteristics 30 Maintenance 31...

Page 3: ...phasizes general information worthy of special attention Safety This machine meets or exceeds CEN standard EN 836 1997 ISO standard 5395 1990 and ANSI B71 4 1999 specifications in effect at the time of production when 40 lb 18 kg of ballast is added to the rear wheel Improper use or maintenance by the operator or owner can result in injury To reduce the potential for injury comply with these safet...

Page 4: ...confined space where dangerous carbon monoxide fumes can collect Mow only in daylight or in good artificial light Before attempting to start the engine disengage all blade attachment clutches shift into neutral and engage the parking brake Remember there is no such thing as a safe slope Travel on grass slopes requires particular care To guard against overturning do not stop or start suddenly when ...

Page 5: ...ed do this outdoors Be careful during adjustment of the machine to prevent entrapment of the fingers between moving blades and fixed parts of the machine On multi cylinder multi reel machines take care as rotating one cylinder reel can cause other cylinders reels to rotate Disengage drives lower the cutting units set parking brake stop engine and remove key and disconnect spark plug wire Wait for ...

Page 6: ... mowing until the area is cleared Maintenance and Storage Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system Keep your body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not your hands to search for leaks Hydraulic fluid escaping under ...

Page 7: ... 93 6696 1 Stored energy hazard read the Operator s Manual 93 6686 1 Hydraulic oil 2 Read the Operator s Manual 93 6687 1 Do not step here 93 6697 Model 03551 only 1 Read the Operator s Manual 2 Add SAE 80w 90 API GL 5 oil every 50 hours 93 6699 1 Machine speed 2 Slow 3 Continuous variable setting 4 Fast 104 2052 105 7506 1 Read the Operator s Manual 2 Engine stop 3 On 4 Engine preheat 5 Engine st...

Page 8: ...erator s Manual 2 Do not tow the machine 3 Warning read the Operator s Manual 4 Cutting hazard of hand or foot stay away from moving parts 5 Warning keep bystanders a safe distance from the machine 6 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine 7 Warning use a roll over protection system and wear the seat belt 8 Tipping hazard lower the cutt...

Page 9: ...oving parts 5 Warning keep bystanders a safe distance from the machine 6 Warning lock the parking brake stop the engine and remove the ignition key before leaving the machine 7 Warning use a roll over protection system and wear the seat belt 8 Tipping hazard lower the cutting unit when driving down slopes and do not drive across or down slopes greater than 15 degrees 107 8841 ...

Page 10: ...op 3 For backlapping set the parking brake and move the throttle lever to Slow do not change the engine speed while the reels are running 93 8050 Model 03551 only 1 Warning read the Operator s Manual 2 Tipping hazard wear the seat belt 93 6693 1 Crushing hazard of hand wait for moving parts to stop 94 6767 1 Read the Operator s Manual 2 Headlights 3 Engine start 98 7976 1 Warning read the Operator...

Page 11: ...iquid chemical burn hazard 4 Wear eye protection 5 Read the Operator s Manual 6 Keep bystanders a safe distance from the battery 7 Wear eye protection explosive gases can cause blindness and other injuries 8 Battery acid can cause blindness or severe burns 9 Flush eyes immediately with water and get medical help fast 10 Contains lead do not discard 98 9335 1 Cutting dismemberment hazard fan stay a...

Page 12: ... weight and height Tool box at left side of seat Steering system Power steering with dedicated power source Tires Two rear steering tires 20 x 10 00 10 tubeless 6 ply rating Two front traction drive tires 26 5 x 14 00 12 tubeless 4 ply rating Recommended tire pressure for front and rear tires is 10 15 psi Brakes Individual drum type wheel brakes on front traction wheels Brakes controlled by indivi...

Page 13: ...thatching Cutting Unit Model No 03871 Grass Basket Kit Model No 03882 Arm Rest Kit Model No 30707 4 Wheel Drive Kit For use with model 03550 only Model No 03538 Turf DefenderT Electronic Leak Detector Model No 03521 Precleaner Bowl Extension Tube Clamp part number 20 4840 required to install extension tube Part No 43 3810 Diagnostic ACE Tool Part No 85 4750 Weight Kit Part No 94 2836 High Torque R...

Page 14: ...ting the hood latch for CE Capscrew 3 8 x 1 inch Flange nut 1 4 inch 1 1 Attaching the tipper chains to the front cutting unit Flange head capscrew 5 16 x 5 8 inch 1 Replacing the floor panel fastener for CE Counterweight O ring large 5 10 Mounting the counterweights and motors to cutting units Lynch Pin Steering Pin 5 5 Mounting the cutting units to the traction unit Diagnostic ACE display overla...

Page 15: ...battery cable before connecting the negative black cable Warning 1 Open the hood 2 Ensure battery is securely fastened in place and check battery charge with a hydrometer If battery needs charging be sure at least one battery cable preferable the positive cable is disconnected from the battery before connecting the charger Fig 2 2 1 Figure 2 1 Positive battery cable 2 Negative battery cable Danger...

Page 16: ...l to frame Fig 5 2 Replace with a flange head capscrew 5 16 x 5 8 inch supplied in loose parts Fig 5 1 Figure 5 1 Floor panel Checking the Tire Pressure The tires are over inflated for shipping Therefore release some of the air to reduce the pressure Correct air pressure in the front and rear tires is 10 15 psi Important Maintain even pressure in all tires to assure uniform contact with turf Insta...

Page 17: ... to Cutting Unit Operator s Manual for greasing procedure 6 Insert a thrust washer onto horizontal shaft of pivot knuckle as shown in Figure 8 1 2 3 5 4 Figure 8 1 Carrier frame 2 Pivot knuckle 3 Lift arm steering plate 4 Lynch pin 5 Steering pin 7 Insert the horizontal shaft of the pivot knuckle into the mounting tube of the carrier frame Fig 8 8 Secure pivot knuckle to carrier frame with a thrus...

Page 18: ...mounting instructions 1 Tighten lock nut on rear of spring rod until the gap C between rear of spring bracket and front of washer is 1 inch 26 mm Fig 11 2 Tighten hex nuts on front end of spring rod until the compressed length A of spring is 8 inches 203 mm Fig 11 Note When cutting rough or undulating turf increase compressed length A of the spring to 8 1 2 inch 216 mm and gap C between rear of sp...

Page 19: ...ront center cutting unit loosen the carriage bolts and nut securing the stabilizer saddle to stabilizer Fig 13 3 Slide saddle down until it contacts cutting unit carrier frame Tighten carriage bolts and nuts Note Additional holes are provided to further adjust if required Rear Ballast Model 03550 2 Wheel Drive complies with the CEN standard EN 836 1997 ISO standard 5395 1990 and the ANSI B71 4 199...

Page 20: ... oil level on dipstick Oil level should be up to the full mark Fig 14 1 2 Figure 14 1 Dip stick 2 Oil fill cap 3 If oil is below full mark remove fill cap and add oil until level reaches full mark on dipstick Fig 14 Do not over fill 4 Install oil fill cap and close hood Checking the Cooling System Clean debris off screen oil cooler and front of radiator daily more often if conditions are extremely...

Page 21: ...aulic Fluid The machines reservoir is filled at the factory with approximately 8 1 2 gallons of high quality hydraulic fluid Check the level of the hydraulic fluid before the engine is first started and daily thereafter The recommended replacement fluid is Toro Premium Transmission Hydraulic Tractor Fluid Available in 5 gallon pails or 55 gallon drums See parts catalog or Toro distributor for part...

Page 22: ...n a level surface 2 Remove check plugs 3 from axle and make sure lubricant is up to bottom of each hole Figures 19 and 20 3 If level is low remove center fill plug and add enough lubricant to bring the level up to the bottom of the center check plug hole Figures 19 and 20 4 Remove each end check plug and add enough lubricant to bring the level up to the bottom of each check plug hole 5 Install all...

Page 23: ... speed depends on how far pedal is depressed For no load maximum ground speed fully depress pedal while throttle is in the fast position To stop reduce foot pressure on traction pedal and allow it to return to center position 1 Figure 22 1 Traction pedal Brake Pedals Two foot pedals operate individual wheel brakes for turning assistance parking and to aid in obtaining better sidehill traction Lock...

Page 24: ...ates and engine shuts down when coolant reaches a dangerously high temperature Fig 24 Glow Plug Indicator Light When lit indicates glow plugs are on Fig 24 Charge Indicator Illuminates when system charging circuit malfunctions Fig 24 Throttle Control Move control forward to increase engine speed rearward to decrease speed Fig 24 Enable Disable Switch Used in conjunction with lower mow raise contro...

Page 25: ...ng the Fuel System 1 Raise hood over engine 2 Open the air bleed screw on the fuel injection pump Fig 26 with a 12 mm wrench 1 Figure 26 1 Fuel injection pump bleed screw 3 Turn key in ignition switch to the on position Electric fuel pump will begin operation thereby forcing air out around air bleed screw Leave key in the on position until solid stream of fuel flows out around screw Tighten screw ...

Page 26: ...ip visibility move the reel speed selector knobs one position lower than specified For a cut with less grass removed and slightly less clip visibility move the reel speed selector knobs one position higher than specified Note Reel speed can be increased or decreased to compensate for turf conditions Adjusting the Rear Lift Arm Counterbalance The counterbalance spring on the rear cutting unit lift ...

Page 27: ... Fig 30 Remove drive shaft 1 Figure 30 1 Drive shaft Important If drive shaft is not removed before towing the transmission input shaft will not be able to rotate thus not allowing the transmission to maintain its internal lubrication Severe damage to the hydrostatic transmission will occur 2 Attach a suitable chain strap or cable to the center of the front frame member Fig 31 1 Figure 31 1 Center...

Page 28: ...ller 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 pro...

Page 29: ...s to outputs 5 The outputs displayed LED on lower right column of Diagnostic ACE should be illuminated If inputs displayed LED is illuminated press the toggle button on Diagnostic ACE to change LED to outputs displayed Note It may be necessary to toggle between inputs displayed and outputs displayed several times to do the following step To toggle back and forth press toggle button once This may b...

Page 30: ...dentally Individual turning brakes may also be used to help maintain traction For example in some slope conditions the uphill wheel slips and loses traction If this situation occurs depress uphill turn pedal gradually and intermittently until the uphill wheel stops slipping thus increasing traction on the downhill wheel Important When operating machine always use the seat belt and ROPS together Wa...

Page 31: ...hoses Check the fan and alternator belt tension Every 200 hours Drain moisture from hydraulic tank Drain moisture from fuel tank Torque the wheel lug nuts Check the reel bearing preload Every 400 hours Service the air cleaner 1 Replace the fuel water separator filter Replace the fuel filter Inspect traction linkage movement Check the engine RPM idle and full throttle Torque the head and adjust val...

Page 32: ...f operation Lubricate bearings and bushings immediately after every washing regardless of the interval listed The grease fitting locations and quantities are Engine Drive shaft 3 Fig 35 Cutting unit carrier frame and pivot 2 ea Fig 36 Rear lift arm pivots 2 Drive shaft clutch 1 Fig 37 Rear axle tie rod 2 Steering cylinder ball joints 2 Axle steering pivots 2 Rear axle pivot 1 Fig 38 Traction contr...

Page 33: ...33 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 ...

Page 34: ...34 Service Interval Chart Figure 44 ...

Page 35: ... rough running is noted 2 Check with engine running and oil at operating temperature 3 Immediately after every washing regardless of the interval listed Servicing the Air Cleaner Before servicing or making adjustments to the machine stop the engine and remove the key from the switch Lower the cutting units to the ground Warning 1 Check air cleaner body for damage which could possibly cause an air ...

Page 36: ...the outside of dry filter element Do not exceed 40 psi to prevent damage to the element 5 Keep air hose nozzle at least 2 inches 52 mm from filter and move nozzle up and down while rotating the filter element Inspect for holes and tears by looking through the filter toward a bright light 1 Figure 46 1 Filter element 6 Inspect new filter for shipping damage Check sealing end of filter Do not instal...

Page 37: ...r under hood and place a clean container under it 2 Loosen drain plug on bottom of filter canister Tighten plug after draining 1 2 Figure 49 1 Fuel Filter Water Separator 2 Drain plug Replace filter canister after every 400 hours of operation 1 Clean area where filter canister mounts 2 Remove filter canister and clean mounting surface 3 Lubricate gasket on filter canister with clean oil 4 Install ...

Page 38: ...off position when solid flow is observed 4 Tighten pipe connector securely 5 Repeat steps on remaining nozzles Servicing the Engine Cooling System Removing Debris Remove debris from screen oil coolers and radiator daily clean more frequently in dirty conditions 1 Turn engine off and raise hood Clean engine area thoroughly of all debris 2 Loosen clamps and pull up on screen to slide it out of mount...

Page 39: ...eflection is incorrect proceed to step 3 If correct continue operation 1 2 Figure 54 1 Alternator belt 2 Brace 3 Loosen bolt securing brace to engine and bolt securing alternator to brace 4 Insert pry bar between alternator and engine and pry out on alternator 5 When proper tension is achieved tighten alternator and brace bolts to secure adjustment Servicing the Cooling Fan Belt 1 Loosen lock nut ...

Page 40: ...g from bottom of reservoir and let hydraulic fluid flow into drain pan Reinstall and tighten plug when hydraulic fluid stops draining 1 Figure 57 1 Hydraulic reservoir 3 Fill reservoir with approximately 8 1 2 gallons of hydraulic fluid Refer to Checking Hydraulic Fluid page 21 Important Use only hydraulic fluids specified Other fluids could cause system damage 4 Install reservoir cap Start engine...

Page 41: ...ittings are tight before applying pressure to hydraulic system Warning Using the Hydraulic System Test Ports The test ports are used to test pressure in the hydraulic circuits Contact your local Toro distributor for assistance 1 Test Port 1 is used to assist in trouble shooting the hydraulic circuit for the front cutting units and lift cylinders 2 1 Figure 59 1 Test port number 1 2 Test port numbe...

Page 42: ...damage the turf Adjust cutting units as follows Adjusting the Center Cutting Unit 1 Locate valve behind access panel above operator s platform Fig 61 2 Loosen setscrew on valve and rotate valve approximately 1 2 turn clockwise 3 Verify drop rate adjustment by raising and lowering cutting unit several times Readjust as required 4 After desired drop rate is attained tighten setscrew to lock adjustme...

Page 43: ...quired to stop is greater than 18 feet 5 5 meters an adjustment to the traction linkage is required Proceed to next step Adjusting the Traction Linkage 1 Park machine on a level surface lower cutting units to the floor and shut engine off 2 Connect brake pedals together with locking pin push both pedals down and pull parking brake latch out 3 Loosen outer hex nut securing eye bolt to spring anchor...

Page 44: ...44 Hydraulic Schematic ...

Page 45: ...suction line on bottom of transmission Place drain pan under line 1 2 Figure 66 1 Transmission suction line 2 Transmission oil filter 3 Remove line from transmission allowing fluid to drain into drain pan 4 Reinstall suction line to transmission 5 Fill with oil refer to Checking the Transmission Fluid page 21 6 Before starting the engine after changing transmission fluid disconnect the run ETR sol...

Page 46: ...ar measurement 1 Figure 68 1 Tie rod 2 To adjust loosen clamps at both ends of tie rod 3 Rotate tie rod to move front of tire inward or outward 4 Tighten tie rod clamps when adjustment is correct Servicing the Battery CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and repro...

Page 47: ... Using the Ace Diagnostic tool verify the brake sensor opens and closes properly The parking brake light on the Diagnostic tool should be on when engaged and off when disengaged If the light remains on when the parking brake is released the engine will stop when the traction system is engaged Should this condition exist adjust the sensor using the Diagnostic tool to verify its operation The adjust...

Page 48: ...48 Wiring Diagram ...

Page 49: ...d may be increased by moving the reel speed selector knob toward 13 Each position will increase speed approximately 100 rpm After changing selector wait 30 seconds for the system to stabilize at the new speed 4 Make initial reel to bedknife adjustments appropriate for backlapping on all cutting units which are to be backlapped 5 Start engine and run at idle speed Contact with the reels or other mo...

Page 50: ...ely sharpened a burr will form on the front edge of the knife Using a file carefully remove the burr without dulling the cutting edge Fig 74 Figure 74 2 Repeat procedure for all cutting units to be backlapped When backlap operation has been completed return the backlap knobs to the forward flow position lower seat and wash all lapping compound off cutting units Adjust cutting unit reel to bedknife...

Page 51: ...corrosion D Slowly recharge the battery every 60 days for 24 hours to prevent lead sulfation of the battery Charging the battery produces gasses that can explode Never smoke near the battery and keep sparks and flames away from battery Warning Engine 1 Drain the engine oil from the oil pan and replace the drain plug 2 Remove and discard the oil filter Install a new oil filter 3 Refill oil pan with...

Page 52: ...t limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the ...

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