Toro 03550 reelmaster 5500-d User manual

To understand this product, and for safety and

optimum performance, read this manual before

starting the engine. Pay special attention to

SAFETY INSTRUCTIONS highlighted by this

symbol.

It means CAUTION, WARNING or DANGER—

personal safety instruction. Failure to comply with

the instruction may result in personal injury.

OPERATOR'S

MANUAL

FORM NO. 3325-160 Rev B

MODEL NO. 03550—200000001 & UP

MODEL NO. 03551—200000001 & UP

REELMASTER® 5500-D

©The TORO COMPANY—2000

2
Table of Contents 2
Safety 3
Symbol Glossary 6
Specifications 9
Before Operating 11
Check the Engine Oil 11
Check the Cooling System 11
Fill the Fuel Tank 11
Check the Transmission Fluid 12
Check the Hydraulic Fluid 12
Check Rear Axle Lubricant 
(Model 03551 only) 14
Check Reel-To-Bedknife Contact 14
Check Wheel Nut Torque 14
Controls 15
Operation 17
Starting and Stopping 17
Bleeding the Fuel System 17
Setting Reel Speed 18
Adjusting Rear Lift Arm Counterbalance 19
Towing the Traction Unit 19
Diagnostic Light 20
Diagnostic ACE Display 20
Checking Interlock Switches 21
Hydraulic Valve Solenoid Functions 23
Operating Characteristics 23
Minimum Recommended 
Maintenance Intervals 24
Maintenance 24
Fluid Specifications/Change Intervals 25
Service Interval Charts 25
Greasing Bearings and Bushings 26
General Air Cleaner Maintenance 28
Servicing the Air Cleaner Bowl 28
Servicing the Air Cleaner 28
Engine Oil and Filter 29
Fuel System 29
Replacing the Fuel Filter 30
Bleeding Air from the Injectors 30
Engine Cooling System 31
Servicing the Engine Belts 31
Adjusting the Throttle 32
Changing Hydraulic Fluid 32
Replacing the Hydraulic Filter 33
Checking Hydraulic Lines and Hoses 33
Hydraulic System Test Ports 34
Adjusting the Traction Drive for Neutra 34
Adjusting Cutting Unit Lift Rate 34
Checking and Adjusting Traction Linkage 35
Adjusting Service Brakes 36
Changing Transmission Fluid 36
Replacing the Transmission Filter 37
Changing Rear Axle Lubricant 
(Model 03551 only) 37
Rear Wheel Toe-In 37
Battery Care 38
Fuses 38
Cutting Unit Maintenance 39
Preparation for Seasonal Storage 41
Identification and Ordering 42
Table of Contents
This operator's manual has instructions on safety, operation, and maintenance. 
This manual emphasizes safety, mechanical and general product information. DANGER, WARNING and
CAUTION identify safety messages. Whenever the triangular safety alert symbol appears, understand the
safety message that follows. “IMPORTANT” highlights special mechanical information and “NOTE”
emphasizes general product information worthy of special attention.

Tra n ng

1. Read the instructions carefully. Be familiar

with the controls and the proper use of the

equipment.

2. Never allow children or people unfamiliar with

these instructions to use the lawn mower. Local

regulations may restrict the age of the operator.

3. Never mow while people, especially children,

or pets are nearby.

4. Keep in mind that the operator or user is

responsible for accidents or hazards occurring

to other people or their property.

5. Do not carry passengers.

6. All drivers should seek and obtain professional

and practical instruction. Such instruction

should emphasize:

• the need for care and concentration when

working with ride-on machines;

• control of a ride-on machine sliding on a

slope will not be regained by the

application of the brake. The main reasons

for loss of control are:

– insufficient wheel grip;

– being driven too fast;

– inadequate braking;

– the type of machine is unsuitable for

its task;

– lack of awareness of the effects of

ground conditions, especially slopes;

– incorrect hitching and load

distribution.

Preparat on

1. While mowing, always wear substantial

footwear and long trousers. Do not operate the

equipment when barefoot or wearing open

sandals.

2. Thoroughly inspect the area where the

equipment is to be used and remove all objects

which may be thrown by the machine.

3. WARNING—Petrol is highly flammable.

• Store fuel in containers specifically

designed for this purpose.

• Refuel outdoors only and do not smoke

while refueling.

• Add fuel before starting the engine. Never

remove the cap of the fuel tank or add

petrol while the engine is running or when

the engine is hot.

• If petrol is spilled, do not attempt to start

the engine but move the machine away

from the are of spillage and avoid creating

any source of ignition until petrol vapors

have dissipated.

• Replace all fuel tanks and container caps

securely.

4. Replace faulty silencers.

Operat on

1. Do not operate the engine in a confined space

where dangerous carbon monoxide fumes can

collect.

2. Mow only in daylight or in good artificial light.

3. Before attempting to start the engine,

disengage all blade attachment clutches and

shift into neutral.

4. Do not use on slopes of more than:

• Never mow side hills over 5°

• Never mow uphill over 10°

• Never mow downhill over 15°

5. 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 going

up or downhill;

Safety

• engage the clutch slowly, and always keep

the machine in gear, especially when

travailing downhill;

• machine speeds should be kept low on

slopes and during tight turns;

• stay alert for bumps and hollows and other

hidden hazards;

• never mow across the face of the slope,

unless the lawn mower is designed for this

purpose.

6. Use care when pulling loads or using heavy

equipment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely

control.

• Do not turn sharply. Use care when

reversing.

• Use counterweight(s) or wheel weights

when suggested in the instruction

handbook.

7. Watch out for traffic when crossing or near

roadways.

8. Stop the blades rotating before crossing

surfaces other than grass.

9. When using any attachments, never direct

discharge of material toward bystanders nor

allow anyone near the machine while in

operation .

10. Never operate the lawn mower with defective

guards, shields or without safety protective

devices in place.

11. Do not change the engine governor settings or

overspeed the engine. Operating the engine at

excessive speeds may increase the hazard of

personal injury.

12. Before leaving the operator’s position:

• disengage the power take-off and lower

the attachments;

• change into neutral and set the parking

brake;

• stop the engine and remove the key.

13. Disengage the drive to attachments when

transporting or not in use.

14. Stop the engine and disengage the drive to the

attachment

• before refueling;

• before removing the grass catcher;

• before making height adjustments unless

the adjustment can be made from the

operator’s position.

• before clearing blockages;

• before checking, cleaning or working on

the lawnmower;

• after striking a foreign object. Inspect the

lawnmower for damage and make repairs

before restarting and operating the

equipment.

15. Reduce the throttle setting during engine run-

out and, if the engine is provided with a shutoff

valve, turn the fuel off at the conclusion of

mowing.

Ma ntenance and Storage

1. Keep all nuts, bolts and screws tight to be sure

the equipment is in safe working condition.

2. Never store the equipment with petrol in the

tank inside a building where fumes may reach

an open flame or spark.

3. Allow the engine to cool before storing in any

enclosure.

4. To reduce the fire hazard, keep the engine,

silencer, battery compartment and petrol

storage area free of grass, leaves, or excessive

grease.

5. Check the grass catcher frequently for wear or

deterioration.

6. Replace worn or damaged parts for safety.

7. If the fuel tank has to be drained, this should be

Safet

done outdoors.

8. Be careful during adjustment of the machine to

prevent entrapment of the fingers between

moving blades and fixed parts of the machine.

9. On multi-bladed machines, take care as rotating

one blade can cause other blades to rotate.

10. When the machine is to be parked, stored or left

unattended, lower the cutting means unless a

positive mechanical lock is used.

Sound & V brat on Levels

SOUND PRESSURE LEVEL

This unit has an equivalent continuous A-weighted

sound pressure at the operator ear of: 88 dB(A),

based on measurements of identical machines per

Directive 84/538/EEC and amendments.

SOUND POWER LEVEL

This unit has a sound power level of: 102 dB(A)/l

pW, based on measurements of identical machines

per Directive 84/538/EEC and amendments.

VIBRATION LEVEL

Hand-Arm

This unit does not exceed a vibration level of 2.5

m/s2at the hands based on measurements of identical

machines per ISO 5349 procedures.

Whole Body

This unit does not exceed a vibration level of 0.5

m/s2at the posterior based on measurements of

identical machines per ISO 2631 procedures.

Symbol Glossary

Caust c l qu ds,

chem cal burns to

f ngers or hand

Po sonous

fumes or tox c

gases, asphyx at on

Electr cal shock,

electrocut on H gh pressure

flu d, nject on

nto body

H gh pressure

spray, eros on of

flesh

H gh pressure

spray, eros on of

flesh

Crush ng of

f ngers

or hand,

force

appl ed from

above

Crush ng of

toes or foot, force

appl ed from above

Crush ng of

whole body,

appl ed from

above

Crush ng of

torso, force

appl ed from s de

Crush ng of f ngers

or hand/, force

appl ed from s de

Crush ng of

whole body Crush ng of

head, torso and

arms

Cutt ng of

f ngers or hand Cutt ng of footCrush ng of leg,

force appl ed

from s de

Cutt ng or

entanglement of

foot, rotat ng auger

Sever ng of

foot, rotat ng

kn ves

Sever ng of

f ngers or hand,

mpeller blade

Wa t unt l all

mach ne

components have

completely stopped

before touch ng them

Sever ng of

f ngers or hand,

eng ne fan

Whole body entanglement,

mplement nput dr ve l ne F ngers or

hand entangle-

ment, cha n dr ve

Runover/back-

over, (relevant

mach ne to appear

n dashed box)

Mach ne t pp ng,

r d ng mower Mach ne rollover,

ROPS (relevant

mach ne to appear

n dashed box)

Stored energy

hazard, k ckback

or upward mot on

Hot surfaces,

burns to f ngers

or hands

Hand & arm

entanglement,

belt dr ve

Thrown or fly-

ng objects, whole

body exposure

Thrown or

fly ng objects,

face exposure

Explos on F re or open

flame

Secure l ft ng

cyl nder w th lock ng

dev ce before gett ng

n hazardous area

Stay a safe

d stance from

the mach ne

Stay clear of

art culat on area

wh le eng ne s

runn ng

Do not open

or remove safety

sh elds wh le

eng ne s

runn ng

Do not step on

load ng platform f

PTO s connected to tractor

& eng ne s runn ng

Do not step

Shut off eng ne

& remove key before

perform ng ma nten-

ance or repa r work

R d ng on th s

mach ne s allowed

only on a passen-

ger seat & only f the

dr ver’s v ew s not

h ndered

Consult

techn cal manual

for proper serv ce

procedures

Fasten seat belts Safety alert

tr angle outl ne safety

alert symbol Read operator’s

manual

Safet

F re, open l ght

& smok ng

proh b ted

Hydraul c

system Brake system O l Coolant (water) Intake a r Exhaust gas Pressure

Level

nd cator L qu d level F lter Temperature Fa lure/

Malfunct on Start sw tch/

mechan sm On/start Off/stop

Plus/ ncrease/

pos t ve polar ty

Engage D sengage Attachment

lower Attachment

ra se Spac ng d stance Snow thrower,

collector auger M nus/decrease/

negat ve polar ty

Horn Battery charg ng

cond t on

Hourmeter/elapsed

operat ng hours Fast Slow Cont nuous

var able, l near Volume empty Volume full

Mach ne travel

d rect on,

forward/rearward

Control lever

operat ng

d rect on, dual

d rect on

Control lever

operat ng

d rect on, mult ple

d rect on

Clockw se

rotat on Counter-clock-

w se rotat on Grease

lubr cat on

po nt

O l lubr cat on

po nt L ft po nt

Jack or

support po nt Dra n ng/

empty ng Eng ne lubr cat-

ng o l Eng ne lubr cat ng

o l pressure Eng ne lubr cat ng

o l level Eng ne lubr cat ng

o l f lter Eng ne

lubr cat ng o l

temperature

Eng ne coolant

Flush w th water Eng ne Transm ss on

Hear ng

protect on must

be worn

Caut on, tox c

r sk

Eye protect on

must be worn Head protect on

must be worn F rst a d

Safet

Transm ss on

fa lure/malfunct on Clutch Neutral H gh Low Forward Reverse Park

NHLFRP

F rst gear Second gear

Th rd gear (other #'s

may be used unt l

the max mum # of for-

ward gears s reached.)

Hydraul c o l Hydraul c o l

temperature

231

Hydraul c o l

pressure Hydraul c o l level Hydraul c o l f lter

Hydraul c o l

fa lure/malfunct on Park ng brake Fuel Fuel level Fuel f lter Fuel system

fa lure/malfunct on

D esel fuel Unleaded fuel

Headl ghts Lock Unlock D fferent al lock 4-Wheel dr ve Power Take-Off Power Take-Off,

rotat onal speed Reel cutt ng

element

Reel cutt ng

element, he ght

adjustment

Tract on Above work ng

temperature range

Dr ll ng Manual metal arc

weld ng Manual 0356 Water pump 0626 Keep dry

0430 we ght Do not d spose

n the garbage CE logo

Eng ne coolant

pressure Eng ne coolant f

lter Eng ne

lubr cat ng o l

pressure

Eng ne ntake/

combust on a r Eng ne ntake/

combust on a r

pressure

Eng ne ntake/

a r f lter Eng ne start Eng ne stop

Eng ne fa lure/

malfunct on Eng ne rotat onal

speed/frequency Choke Pr mer (start a d) Electr cal preheat

(low temperature

start a d)

Transm ss on o l Transm ss on o l

pressure

n/m n

Transm ss on o l

temperature

Engine: Kubota three-cylinder, 4-cycle, liquid-

cooled diesel. 26kW (35 hp) @ governed to 3200

rpm; 1123 cc displacement. Heavy-duty, 3-stage,

remote-mounted air cleaner. High water

temperature shutdown switch.

Main Frame: All welded formed steel frame,

includes three tie-down loops

Cooling System: Radiator capacity is 7.1 l of 50/50

mixture of ethylene glycol anti-freeze. Remote

mounted 0.95L expansion tank. Removable oil

cooler/radiator intake screen. Air-to-oil cooler,

mounted to front of radiator, tips forward for

cleaning

Fuel System: Fuel tank capacity is 37.9 l (10 gal.)

of #2 diesel fuel. Equipped with a fuel filter/water

separator to capture water in the fuel.

Traction System: Foot pedal controls forward/

reverse ground speed. Ground speed: 0–16.1 kmh

(0–10 m.p.h.) forward and 0–6.4 kmh (0-4 mph)

reverse. Hydrostatic transmission mounted directly

on a 20.9:1 ratio front axle. Axle/reservoir capacity

is 4.7 l (5 qts). Replaceable filter mounted directly

on transmission housing. Model 03551—

Mechanical rear axle is coupled to the front axle by

a drive shaft and overrunning clutch.

Cutting Unit Drive System: Hydraulic reel motors

feature quick disconnects to ease removal/

installation on cutting units. Hydraulic fluid

reservoir capacity is 32.2 l (8.5 gal.). System

protected by a filter assembly with service indicator.

Seat: Deluxe high back seat with adjustable fore

and aft travel, weight and height. Tool box at the

left side of the seat.

Steering System: Power steering with dedicated

power source.

Tires: Two rear tires: 20 x 10-8, tubeless, 6-ply

rating. Two front tires: 26 x 12.00-12 tubeless, 4-

ply rating. Recommended tire pressure for the

front and rear tires is 69–103 kPa (10–15 psi).

Brakes: Individual drum-type wheel brakes on the

front traction wheels. Brakes are controlled by

individual pedals operated by the left foot.

Hydrostatic braking through the traction drive.

Electrical System: Automotive-type electrical

system. 12-volt, maintenance-free battery with 530

cold cranking Amps @ –17° C and 85 minute

reserve capacity @ 29° C. 40-amp alternator with

I.C. regulator/rectifier. Seat switch, reel and traction

interlock switches. An electronic controller

monitors and controls safety and operational

functions. Parking brake switch and individual

circuit backlap switches.

Controls: Foot-operated traction and brake pedals.

Hand-operated throttle, traction speed control lever,

parking brake lock, ignition switch with automatic

preheat cycle, single joy stick control for cutting

unit on/off and lift/lower. Cutting unit backlap

switch and reel speed controls located under the

operator seat.

Gauges: Hour meter, speedometer, fuel gauge,

temperature gauge. 4 warning lamps: oil pressure,

water temperature, amps and glow plug.

Diagnostics: The Automatic Control Electronics 7

ACE™ system allows precise timing and control of

machine functions for maximum reliability.

Optional hand-held diagnostic display connects to

an electronic control unit to pin point any electrical

problems quickly and easily. Available DATA

LOG™ system allows mechanic to find intermittent

problems.

General Specifications (approx.):

Width-of-Cut : 254 cm (100 in.)

Overall Width:

Transport 222.5 cm (88 in.)

Outside of front tires 221 cm (87 in.)

Outside of rear tires 133.3 cm (52.5)

Overall Length:

Without grass baskets: 287 cm (113 in.)

With grass baskets: 305 cm (120 in.)

Height:

With Rollover protector: 208 cm (82 in.)

Without 150 cm (59 in.)

Spec f cat ons

Recommended Height-of-Cut:

5-Blade Cutting Unit: 2.54–4.5cm (1.00–1.75 in.)

7-Blade Cutting Unit: 1.27–2.54 cm (0.5–1.0 in.)

11-Blade Cutting Unit0.95–1.9 cm (0.375–0.75 in.)

Weight:

Model 03550 1,105 kg (2,962 lbs.)*

Model 03551 1,198 kg (3,210 lbs.)*

*With 7-Blade Cutting Units, baskets & full

fluid levels

Optional Equipment:

5-Blade Cutting Unit (7 in.) Model No. 03860

7-Blade Cutting Unit (7 in.) Model No. 03861

11-Blade Cutting Unit (7 in.) Model No. 03862

Dethatching Cutting Unit Model No. 03871

Grass Basket Kit Model No. 03882

Armrest Kit Model No. 30707

4 -Wheel Drive Kit Model No. 03538

(For use with model 03550 only)

Turf Defender™ Electronic Leak

Detector Kit Model No. 03521

Precleaner Bowl Extension Tube Part No. 43-3810

(Clamp, Part No. 20-4840 required to install

extension tube)

Diagnostic ACE Too] Part No. 85-4750

Weight Kit Part No. 94-2836

High Torque Reel Motor Part No. 98-9998

Wiehle Roller Scraper Part No. 100-9908

Basket Tipper Kit Part No. 100-9945

Rear Roller Scraper Kit Part No. 100-9920

Full Roller Scraper Kit Part No. 99-8668

Shoulder Wiehle Roller Part No. 100-9911

Shoulder Wiehle Scraper Part No. 100-9913

Low Height-of-Cut Bedknife* Part No. 93-9774

Gauge Bar Assembly** Part No. 98-1852

Angle Indicator Part No. 99-3503

Backlapping Brush AssemblyPart No. TOR2991 00

Bedknife Screw Tool Part No. TOR510880

Cutting Unit Tool Kit Part No. TOR4070

Reel Drive Tool Part No. TOR4074

* For height-of-cut below 13 mm kit

**Supplied with tractor

Specifications and design subject to change

without notice.

Safet

– 11 –

Check the Eng ne O l

1. Park the machine on a level surface, stop the

engine and remove the key from the ignition

switch. Open the hood.

2. Remove the dipstick, wipe it clean, then

reinstall it. Remove it again and check the oil

level on the dipstick; The oil level should be up

to the FULL mark.

F gure 1

1. Dipstick

2. Oil fill cap

3. If the oil is below the FULL mark, remove the

fill cap and add SAE 10W-30 CD, CE, CF-4, or

CG-4 classification oil until the level reaches

the FULL mark on the dipstick. DO NOT

OVERFILL. Crankcase capacity is 3.8 l with

filter.

4. Install the oil fill cap and close the hood.

Check the Cool ng System

Clean debris from the screen, oil cooler and the front

of the radiator daily, more often if conditions are

extremely dusty and dirty.

The cooling system is filled with a 50/50 solution of

water and permanent ethylene glycol anti-freeze.

Check the level of coolant in the expansion tank each

day before starting the engine. Cooling system

capacity is 9.1 l.

F gure 2

1. Expansion Tank

1. Check the level of coolant in the expansion

tank. It should be between the marks on the

side of the tank.

2. If coolant level is low, remove the expansion

tank cap and replenish the system. DO NOT

OVERFILL.

3. Install the expansion tank cap.

F ll the Fuel Tank

1. Remove the fuel tank cap.

2. Fill the tank to about 2.5 cm (one inch) below

the top of the tank, not the filler neck, with No.

2 diesel fuel. Then install the cap.

If the engine has been running, pressurized hot

coolant can escape when the radiator cap is

removed and cause burns.

CAUTION

Before Operat ng

F gure 3

1. Fuel tank cap

Check the Transm ss on Flu d

The front axle housing acts as the reservoir for the

system. The transmission and axle housing are

shipped from the factory with 4.7 l (5 quarts) of

Mobil 424 hydraulic fluid. However, check the

level of transmission oil before first starting the

engine and daily thereafter.

1. Position the machine on a level surface, lower

the cutting units and stop the engine.

2. Remove the access panel behind the foot rest.

3. Unscrew the dipstick cap from the transmission

filler neck and wipe it with a clean cloth.

Screw the dipstick into the filler neck. Remove

the dipstick and check the oil level. If the level

is not within 1.2 cm (1/2 inch) from the groove

in the dipstick, add enough oil to raise it to the

groove mark. DO NOT OVERFILL by more

than .6 cm (1/4 inch) above the groove.

3. Screw the dipstick filler cap finger-tight onto

the filler neck. It is not necessary to tighten the

cap with a wrench.

F gure 4

1. Transmission dipstick cap

Check the Hydraul c Flu d

The hydraulic system driving the reels is designed

to operate on anti-wear hydraulic fluid. The

machine’s reservoir is filled at the factory with 32.2

l (8.5 gallons) of Mobil 424 hydraulic fluid. Check

the level of hydraulic fluid before the first

starting the engine and daily thereafter.

Note: A red dye additive for the hydraulic system

oil is available in 20 ml bottles. One bottle is

sufficient for 15–22 l of hydraulic oil. Order Part

No. 44-2500 from your authorized Toro distributor.

F gure 5

1. H draulic tank cap

Group 1 Hydraul c O l (Recommended for

amb ent temperatures cons stently below 38° C

(100° F):

ISO type 46/68 ant -wear hydraul c flu d

Mobil Mobil Fluid 424

Before Operating

– 12 –

Because diesel fuel is flammable, use caution when

storing or handling it. Do not smoke while filling

the fuel tank. Do not fill the fuel tank while the

engine is running, hot, or when the machine is in an

enclosed area. Always fill the fuel tank outside and

wipe up any spilled diesel fuel before starting the

engine. Store the fuel in a clean, safety-approved

container and keep the cap in place. Use Diesel

fuel for the engine only; not for any other purpose.

DANGER

➀

Amoco Amoco 1000

International Harvester Hy-Tran

Texaco TDH

Shell Donax TD

Union Oil Hydraulic/Tractor Fluid

Chevron Tractor Hydraulic Fluid

BP Oil BP HYD TF

Boron Oil Eldoran UTH

Exxon Torque Fluid

Conoco Power-Tran 3

Kendall Hyken 052

Phillips HG Fluid

Note: Oils within this group are

interchangeable.

Group 2 Hydraul c O l—Recommended for

amb ent temperatures cons stently above 21° C

(70° F):

ISO type 68 ant -wear hydraul c flu d

Mobil DTE 26 or DTE 16

Shell Tellus 68

Amoco Rykon Oil 68

Arco Duro AW S-315

Boron Industron 53

BP Oil Energol HLP68

Castrol Hyspin AWS68

Chevron Chevron EP68

Citgo Citgo A/W68

Conoco Super Hydraulic Oil 31

Exxon Nuto H68

Gulf 68AW

Pennzoil AW Hyd Oil 68

Phillips Magnus A315

Standard Industron 53

Texaco Rando HD68

Union Unax AW 315

Note: Oils within this group are inter-

changeable.

IMPORTANT: Two groups of hydraulic oil are

specified to allow optimal operation of the

machine in a wide range of temperatures

encountered. The group 1 oils are a multi-

viscosity hydraulic oil that allow operation at

lower temperatures without the increased

viscosity associated with straight viscosity oils.

Using the Mobil 424-type oils in the higher ambient

temperatures may result in decreased efficiency in

some hydraulic components compared to using the

Mobil DTE 26 type oils.

The Mobil DTE 26 type oils are straight viscosity

oils which remain slightly more viscous at higher

temperatures than the multi-viscosity oils.

Using the Mobil DTE 26 type oils in the lower

ambient temperatures may result in harder starting,

increased engine laboring while cold, sluggish or

non-operating valve spools while cold and increased

filter back pressure due to the higher oil viscosity.

Select the set of conditions (either ambient

temperatures above 21° C or below 38° C, and use

that type of oil throughout the year, rather than

changing oil types several times per year.

Group 3 Hydraul c Flu d (B odegradable):

ISO VG 32/46 ant -wear Hydraul c flu d

Mobil EAL 224H

Note: This biodegradable hydraulic fluid in this

group is not compatible with the fluids in group 1 or

Note: When changing from one type of hydraulic

oil to the other, remove all the old oil from the

system, because some brands of one type are not

completely compatible with some brands of the

other type of hydraulic oil.

IMPORTANT: Use only the types of hydraulic

oils specified. Other fluids could cause system

damage.

1. Position the machine on a level surface, lower

the cutting units and stop the engine.

2. Clean the area around the filler neck and cap of

the hydraulic tank. Remove the cap from the

filler neck.

3. Remove the dipstick from the filler neck and

wipe it with a clean cloth. Insert it into the

filler neck; then remove it and check the fluid

level. It should be within 6 mm (1/4 inch) of

– 13 –

Before Operating

the mark on the dipstick.

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

the full mark.

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

Check Rear Axle Lubr cant

(Model 03551 only)

The rear axle has three separate reservoirs which

use SAE 80W-90 weight gear lube. Although the

axle is shipped with lubricant from the factory,

check the level before operating the machine.

1. Position the machine on a level surface.

2. Remove the check plugs (3) from the axle and

make sure lubricant is up to the bottom of each

hole.

3. If the level is low, remove the center fill plug

and add enough lubricant to bring the level up

to the bottom of the plug hole.

4. Remove each end check plug and add enough

lubricant to bring the level up to the bottom of

each plug hole.

5. Install all plugs.

F gure 6

1. Check plug

2. Fill plug

F gure 7

1. Left check plug (Rear of axle)

Check Reel-To-Bedkn fe

Contact

Each day before operating, check the reel-to-

bedknife contact, regardless of whether the quality

of cut has been acceptable. There must be light

contact across the full length of the reel and

bedknife.

Check Wheel Nut Torque

Before Operating

–14 –

WARNING

Tighten the wheel nuts to 61-75 Nm after 1–4

hours of operation and again after 10 hours of

operation and every 250 hours thereafter. Failure

to maintain correct torque could result in failure or

loss of a wheel, which may result in personal

injury.

Seat (Fig. 8)—The seat adjusting lever allows 10

cm (4 inches) fore and aft adjustment. The seat

adjusting knob adjusts the seat for operators’

weight. To adjust the seat fore and aft, pull lever on

the left side of the seat assembly outward. After

moving the seat to the desired location, release the

lever to lock the seat into position. To adjust for the

operator’s weight, turn spring tension knob—

clockwise to increase tension, counterclockwise to

decrease spring tension.

F gure 8

1. Seat adjusting level

2. Seat adjusting knob

Traction Pedal (Fig. 9)—Controls forward and

reverse operation. Depress the top of the pedal to

move forward and bottom to move backward.

Ground speed depends on how far the pedal is

depressed. For no load, maximum ground speed,

fully depress the pedal while throttle is in FAST. To

stop, reduce foot pressure on traction pedal and

allow it to return to center position.

Brake Pedals (Fig. 9)—Two foot pedals operate

individual wheel brakes for turning assistance,

parking and to aid in sidehill traction. A Locking

pin connects the pedals for parking brake operation

and transport.

Parking Brake Latch (Fig. 9)—A knob on the left

side of the console actuates the parking brake lock.

To engage the parking brake, connect the pedals

with the locking pin, push down on both pedals and

pull the parking brake latch out. To release the

parking brake, depress both pedals until the parking

brake latch retracts.

Traction Speed Limiter (Fig .9)—Preset this lever

to limit the amount the traction pedal can be

depressed in the forward direction to maintain a

constant mowing speed.

Fault Light (Fig. 9)— When lit, indicates a control

system problem.

Speedometer (Fig. 9)—Indicates ground speed at

which the machine is traveling.

Lower Mow/Raise Control Lever (Fig. 10)—The

lever raises and lowers the cutting units and also

starts and stops the reels.

Fuel Gauge (Fig. 10)—Shows the amount of fuel in

the tank.

Engine Oil Pressure Warning Light (Fig. 10)—

Indicates dangerously low engine oil pressure.

F gure 9

1. Traction pedal

2. Forward speed limiter

3. Reel control light

4. Speedometer

5. Brake pedals

6. Parking brake latch

7. Locking pin

8. Reverse speed limiter

Hour Meter (Fig. 10)—Shows the total hours the

machine has been operated.

Engine Coolant Temperature Warning Light

(Fig. 10)—The light illuminates and the engine

shuts down if the coolant reaches a dangerously

high temperature.

Glow Plug Indicator Light (Fig. 10)—When lit,

indicates glow plugs are on.

– 15 –

Controls

➁

➀➁

➃

➄

➆

➇

➅➂

➀

Controls

– 16 –

F gure 10

1. Lower mow/raise control lever

2. Speedometer

3. Fuel gauge

4. Engine coolant temperature gauge

5. Engine oil pressure warning light

6. Engine coolant temperature warning light.

7. Glow plug indicator light

8. Charge indicator

9. Ke switch

10. Throttle control

11. Enable/Disable switch

Charge Indicator (Fig. 10)—Illuminates when

system charging circuit malfunctions.

Key Switch (Fig. 10)—Three positions: OFF,

ON/Preheat and START.

Throttle Control (Fig. 10)—Move the control

forward to increase engine speed, rearward to

decrease speed.

Enable/Disable Switch (Fig. 10)—Used with lower

mow/raise control lever (Joystick) to operate reels.

Reels can be raised, but not lowered, when in mid

position.

Backlap Knobs (Fig. 11)—Used with lower

mow/raise control lever for backlapping operation.

Refer to Cutting Unit Maintenance, Backlapping.

F gure 11

1. Reel speed controls

2. Backlap knobs

Reel speed Controls (Fig. 11)—Control rpm of the

front and rear cutting units. The #1 position is for

backlapping. The remaining settings are for

mowing operations.

Start ng and Stopp ng

IMPORTANT: The fuel system must be bled

n the follow ng s tuat ons.

A. Initial start up of a new machine.

B. The engine has ceased running due to lack of

fuel.

C. Maintenance has been performed upon fuel

system components; i.e., filter replaced,

separator serviced, etc.

Refer to Bleeding The Fuel System

1. Sit on the seat, keeping your foot off the

traction pedal. Assure the parking brake is

engaged, the traction pedal is in NEUTRAL,

the throttle is in the FAST position and the

ENABLE / DISABLE switch is in the

DISABLE position.

2. Turn the ignition switch to the ON/Preheat

position. An automatic timer will control

preheat for six seconds. After preheat, turn the

key to START. CRANK THE ENGINE FOR

NO LONGER THAN 15 SECONDS. Release

the key when the engine starts. If additional

preheat is required, turn the key to OFF then to

the ON/Preheat position. Repeat the process as

needed.

3. Run the engine at idle speed or partial throttle

until the engine warms up.

Note: Move the throttle to FAST when

restarting a warm engine.

4. To stop, move all controls to NEUTRAL and

set the parking brake. Return the throttle to the

idle position, turn the key to OFF and remove

it from switch.

Bleed ng the Fuel System

1. Raise the hood.

2. Loosen the air bleed screw on top of the fuel

filter/water separator (Fig. 12)

F gure 12

1. Air bleed screw

3. Pump the lever on the fuel pump (Fig. 13) until

a solid stream of fuel flows out around the

screw. Tighten the air bleed screw.

F gure 13

1. Fuel injection pump lever

4. Open the air bleed screw on the fuel injection

pump with a 12 mm wrench.

– 17 –

Before servicing or making adjustments to the

machine, stop the engine and remove the key from

the switch.

CAUTION

Operat on

➀

F gure 14

1. Fuel injection pump bleed screw

5. Pump the lever on the fuel pump (Fig. 12) until

a solid stream of fuel flows out around the

screw on the fuel injection pump. Tighten the

air bleed screw.

Note: Normally the engine should start after

the above bleeding procedures. However, if

the engine does not start, air may be trapped

between the injection pump and the injectors;

refer to Bleeding Air From The Injectors.

Sett ng Reel Speed

To achieve a consistent, high quality of cut, and a

uniform after-cut appearance, it is important that the

reel speed be matched to the height of cut.

Adjust the reel speed controls as follows:

1. Select the height-of-cut at which the cutting

units should be set.

2. Choose the desired ground speed best suited

for conditions.

3. Using the appropriate graph (Fig. 15) for 5-, 7-

or 11-blade cutting units, determine the correct

reel speed setting.

4. To set reel speed, rotate knobs (Fig. 25) until

indicator arrows are in line with the number

designating desired setting.

F gure 15

F gure 16

1. Backlap Knobs

2. Reel Speed Controls

5. Operate the machine for several days, then

examine the cut to ensure satisfaction with the

quality of cut. The reel speed selector knobs

may be set one position on either side of the

position indicated on the chart to account for

Operation

– 18 –

differences in grass condition, grass length

removed, and personal preference of the

superintendent. For a cut with more grass

removed but slightly more clip 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.

Adjust ng Rear L ft Arm

Counterbalance

The counterbalance spring on the rear cutting unit

lift arms can be adjusted to compensate for different

turf conditions. Decreased counterbalance will help

keep the cutting units on the ground when mowing

at higher speeds and helps maintain a uniform

height-of-cut in rough conditions or in areas of

thatch build up.

Each counterbalance spring may be adjusted to one

of three settings. Each increment increases or

decreases down pressure on the cutting units.

1. Position the machine on a level surface, lower

the cutting units, stop the engine, engage the

parking brakes and remove the key from the

ignition switch.

2. Remove the capscrew and locknut while

relieving spring tension.

3. Move spring bolt to desired location and install

capscrew and locknut, while relieving spring

tension.

F gure 17

1. Counterbalance spring

2. Spring bolt

3. Adjustment locations

Tow ng the Tract on Un t

If it becomes necessary to tow the machine, tow it

forward only and at a speed no greater than 4.8 kmh

(3 mph).

Note: If you exceed these towing limits, severe

damage to the hydrostatic transmission may occur.

To tow a disabled machine:

1. Loosen and remove the capscrews securing the

drive shaft to the engine. Loosen the

capscrews clamping the drive shaft to

transmission (Fig. 18). Remove the drive

shaft.

F gure 18

1. Drive shaft

Important: If the drive shaft is not removed

before towing, the transmission input shaft will

not be able to rotate, and not allow the

transmission to maintain its internal lubrication.

Severe damage to the hydrostatic transmission

will occur.

– 19 –

Operation

Springs are under tension, use caution when

adjusting.

CAUTION

Operation

– 20 –

2. Attach a suitable chain, strap or cable to the

center of the front frame member (Fig. 19).

F gure 19

1. Center of front frame member

Note: Lock both brake pedals together before

towing.

3. Attach the other end of the towing device to a

vehicle that is capable of towing the machine

safely at speeds below 4.8 kmh.

4. An operator must be on the machine to steer it

and keep the traction pedal fully depressed in

the forward position while towing.

5. When towing is completed, reinstall the drive

shaft as shown in Figure 18. (The splines are

designed to allow assembly only when the two

halves of the shaft are properly oriented.)

D agnost c L ght

The RM 5500-D is equipped with a diagnostic light

that indicates if the electronic controller is

functioning correctly. The green diagnostic light is

located under the control panel, next to the fuse

block. When the electronic controller is functioning

correctly and the key switch is moved to the ON

position, the controller diagnostic light will be

illuminated. The light will blink if the controller

detects a malfunction in the electrical system. The

light will stop blinking and automatically reset

when the key switch is turned to the OFF position.

F gure 20

1. Electronic controller light

When the controller diagnostic light blinks, one of

the following problems has been detected:

1. One of the outputs has been shorted.

2. One of the outputs has an open circuit.

Using the diagnostic display, determine which

output is malfunctioning; refer to Checking

Interlock Switches.

If the diagnostic light is not illuminated when the

key switch is in the ON position, the electronic

controller is not operating. Possible causes are:

1. Connector is not connected.

2. The light is burned out.

3. Fuses are blown.

4. Not functioning correctly.

Check electrical connections, input fuses and the

diagnostic light bulb to find the malfunction. Make

sure the connector is secured to the wire harness

connector.

D agnost c ACE D splay

The RM5500-D is equipped with an electronic

controller that 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.

The Diagnostic ACE display is a tool to help the

➀

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Toro 03550 Reelmaster 5500-D User manual