Toro 03602, REELMASTER 3500-D, 03603 Operator's Manual
FORM NO. 3318-242 GB
®
MODEL NO. 03602—60001 & UP
MODEL NO. 03603—60001 & UP
REELMASTER
TRACTION UNITS
OPERATOR’S
MANUAL
®
3500-D
© The TORO COMPANY—1996
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.
TABLE OF CONTENTS
Page
SAFETY INSTRUCTIONS 4-5
SYMBOL GLOSSARY 6-7
SPECIFICATIONS 8-9
It means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply with the
instruction may result in personal injury.
FOREWORD
This operator’s manual has instructions on safety,
proper set-up and operation, adjustments and maintenance. Therefore, anyone involved with the product,
including the operator, should read and understand this
manual. This manual emphasizes safety, mechanical
and general product information. DANGER, WARN-
ING and CAUTION identify safety messages.
Whenever the triangular safety alert symbol appears,
understand the safety message that follows. For complete safety instructions, read pages 4–5. IMPOR-
TANT highlights special mechanical information and
NOTE emphasizes general product information wor-
thy of special attention.
Whenever you have questions or need service, contact
your local authorized Toro Distributor. In addition to
having a complete line of accessories and professional
turf care service technicians, the distributor has a complete line of genuine TORO replacement parts to keep
your machine operating properly. Keep your TORO
all TORO. Buy genuine
sories.
TORO parts and acces-
BEFORE OPERATING 10-13
CONTROLS 14-16
OPERATING INSTRUCTIONS 16-19
SERVICE INTERVAL CHART
—2-Wheel Drive 20
SERVICE INTERVAL CHART
—4-Wheel Drive 21
LUBRICATION & MAINTENANCE
FIGURES 22-25
2
Safety
Training
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 responsi-
ble 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;
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.
Operation
1. Do not operate the engine in a confined space
where dangerous carbon monoxide fumes can collect.
– 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 distribu-
tion.
Preparation
1. While mowing, always wear substantial footwear
and long trousers. Do not operate the equipment
when barefoot or wearing open sandals.
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:
3
Safety
• do not stop or start suddenly when going up
or downhill;
• 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.
• change into neutral and set the parking
brake;
• stop the engine and remove the key.
13. Disengage the drive to attachments when trans-
porting 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.
7. Watch out for traffic when crossing or near road-
ways.
8. Stop the blades rotating before crossing surfaces
other than grass.
9. When using any attachments, never direct dis-
charge 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;
15. Reduce the throttle setting during engine runout
and, if the engine is provided with a shutoff valve,
turn the fuel off at the conclusion of mowing.
Maintenance 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.
4
Safety
7. If the fuel tank has to be drained, this should be
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 & Vibration Levels
Sound Levels
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
84/538/EEC.
This unit has a sound power level of 98 dB(A)/1pW,
based on measurements of identical machines per procedures outlined in Directive 79/113/EEC and amendments
Vibration Levels
This unit has a vibration level of 9.0 m/s2at the posterior, based on measurements of identical machines per
ISO 2631 procedures.
This unit does not exceed a vibration level of 0.5 m/s
at the posterior based on measurements of identical
machines per ISO 2631 procedures.
2
5
Symbol Glossary
Caustic liquids,
chemical burns to
fingers or hand
Crushing of
whole body,
applied from
above
Cutting or
entanglement of
foot, rotating auger
Poisonous
fumes or toxic
gases, asphyxiation
Crushing of
torso, force
applied from side
Severing of
foot, rotating
knives
Electrical shock,
electrocution
Crushing of fingers
or hand/, force
applied from side
Severing of
fingers or hand,
impeller blade
High pressure
fluid, injection
into body
force applied
from side
Wait until all
machine
components have
completely stopped
before touching them
High pressure
spray, erosion of
flesh
Crushing of
whole body
Severing of
fingers or hand,
engine fan
High pressure
spray, erosion of
flesh
Crushing of
head, torso and
arms
Whole body entanglement,
implement input drive line
Crushing of
fingers
or hand,
force
applied from
above
Cutting of
fingers or hand
Crushing of
toes or foot, force
applied from above
Cutting of footCrushing of leg,
Fingers or
hand entangle-
ment, chain drive
Hand & arm
entanglement,
belt drive
Explosion Fire or open
Shut off engine
& remove key before
performing mainten-
ance or repair work
6
Thrown or fly-
ing objects, whole
body exposure
flame
Riding on this
machine is allowed
only on a passen-
ger seat & only if the
driver’s view is not
hindered
Thrown or
flying objects,
face exposure
Secure lifting
cylinder with locking
device before getting
in hazardous area
Consult
technical manual
for proper service
procedures
Runover/back-
over, (relevant
machine to appear
in dashed box)
Stay a safe
distance from
the machine
Fasten seat belts Safety alert
Machine tipping,
riding mower
Stay clear of
articulation area
while engine is
running
Machine rollover,
ROPS (relevant
machine to appear
in dashed box)
triangle
Do not open
or remove safety
shields while
engine is
running
Stored energy
hazard, kickback
or upward motion
Do not step on
loading platform if
PTO is connected to tractor
& engine is running
outline safety
alert symbol
Hot surfaces,
burns to fingers
or hands
Do not step
Read operator’s
manual
Safety
Eye protection
must be worn
Fire, open light
& smoking
prohibited
Level
indicator
Head protection
must be worn
Hydraulic
system
Liquid level Filter Temperature Failure/
Hearing
protection must
be worn
Brake system
Caution, toxic
risk
Oil Coolant (water) Intake air Exhaust gas Pressure
First aid
Malfunction
Flush with water Engine Transmission
Start switch/
mechanism
On/start Off/stop
Engage Disengage
Horn Battery charging
Machine travel
direction,
forward/rearward
Jack or
support point
condition
Control lever
operating
direction, dual
direction
Draining/
emptying
Attachment
lower
Hourmeter/elapsed
operating hours
Control lever
operating
direction, multiple
direction
Engine lubricating oil
Attachment
raise
Fast Slow Continuous
Clockwise
rotation
Engine lubricating
oil pressure
Spacing distance Snow thrower,
Counter-clockwise rotation
Engine lubricating
oil level
collector auger
variable, linear
Grease
lubrication
point
Engine lubricating
oil filter
Plus/increase/
positive polarity
Volume empty Volume full
Oil lubrication
point
Engine
lubricating oil
temperature
Minus/decrease/
negative polarity
Lift point
Engine coolant
7
Safety
Engine coolant
pressure
Engine coolant f
ilter
n/min
Engine failure/
malfunction
Transmission
failure/malfunction
Engine rotational
speed/frequency
Clutch Neutral High Low Forward Reverse Park
231
First gear Second gear
Engine
lubricating oil
pressure
Choke Primer (start aid) Electrical preheat
Engine intake/
combustion air
Engine intake/
combustion air
pressure
(low temperature
start aid)
Engine intake/
air filter
Transmission oil Transmission oil
Engine start Engine stop
pressure
Transmission oil
temperature
NHLFRP
Third gear (other #'s
may be used until
the maximum # of forward gears is reached.)
Hydraulic oil Hydraulic oil
Hydraulic oil
pressure
Hydraulic oil level Hydraulic oil filter
temperature
Hydraulic oil
failure/malfunction
Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,
Reel cutting
element, height
adjustment
Parking brake Fuel Fuel level Fuel filter Fuel system
Traction Above working
temperature range
Drilling Manual metal arc
0430 weight Do not dispose
welding
in the garbage
failure/malfunction
Manual 0356 Water pump
CE logo
Diesel fuel Unleaded fuel
rotational speed
Reel cutting
element
0626 Keep dry
8
Specifications
Engine: Peugeot, four-cycle, four cylinder, 1.9 liter
(1900 cc) displacement, liquid-cooled diesel engine.
23.5:1 compression ratio. Low idle—1600 rpm, high
idle—2500 rpm. Oil capacity is 5 l (5.3 qt) with the
filter.
Cooling System: Capacity is 13.2 l (3.5 gal) of a
50/50 mixture of Peugeot recommended anti-freeze.
Fuel System: Capacity is 53 l (14 gal) of #1 or #2
diesel fuel.
Hydraulic System: Reservoir capacity is 24.6 l (6.5
gal). Replaceable spin-on filter element.
Traction System: Ground speed: Low Range; 0—
10.5 km/h (0– 6.5 mph); 0–8.8 km/h (0–5.5 mph).
with mechanical speed limiter interlock forward and
0–4.8 km/h (0–3 mph) reverse. High Range; 0–24
km/h (0–15 mph); 0–20 km/h(0–12.4 mph) with
mechanical speed limiter interlock) forward and 0–8
km/h (0–5 mph) reverse.
Front Axle: Two-speed axle is designed to withstand
heavy-duty slope operation and side loading. Separate
mowing and transport selections for faster and more
efficient machine operation. Neutral position allows
easy towing. Lubricated with SAE 80—90 grade EP
gear lubrication. Capacity is 144 oz.
Rear Axles: T w o Wheel Drive—The large-diameter
wheel spindles are designed for durability and long
wear, yet provide superior stability and maneuverability. Four Wheel Drive—Heavy duty, agricultural type.
Hydraulic drive with “on demand” over running clutch
and balanced weight distribution provides superior
traction on hillsides. Lubricated with SAE 80—90 wt.
EP gear lubrication. Capacity is 80 oz.
Tires/Wheels: High flotation turf tread tires on demountable rims. Front tires: (2) 26 x 12.0-12, 8-ply.
Rear tires: (2) 20 x 10.0-10, 6 ply. Tire pressure
103–138 kPa (15-20 psi.)
Cutting Unit Drive System: Adjustable reel speed to
match clip to ground speed. Reel speed variable from
Approximately 500—1,200 rpm forward to 200—600
rpm reverse (for backlap operation).
Seat: (Model 30772) Adjustable fore and aft travel and
weight.
Diagnostic System: Test ports for forward traction,
cutting circuit, lift and counterbalance circuit, steering
circuit and charge circuit.
Steering System: Automotive type, full power.
Brakes: Totally enclosed, non asbestos, dry multi-
disc individual wheel and parking brakes on front traction wheels. Brakes controlled by individual pedals
operated by the left foot. Dynamic braking through a
closed-loop hydrostatic drive.
Electrical System: 12-volt battery with 530 coldcranking amps @ 0 degrees F. 55-amp alternator,
ammeter, starter, key switch and automatic temperature
controlled glow plug controller. Separately fused, run,
reel and instrument/accessory circuits.
Interlock System: Designed to stop the engine if the
operator gets off the seat while the cutting unit drive
switch is engaged. Prevents the engine from starting
unless the traction pedal is in neutral and the cutting
units are disengaged. Prevents the cutting units from
operating unless the axle shift is in the LO range and.
the cutting units are lowered. Prevents the engine
from starting unless the reel speed control is in
NEUTRAL.
Warning Lights:
Glow plug indicator
Engine oil pressure warning
Engine coolant temperature warning
Charge indicator
Indicators:
Engine coolant temperature gauge
Fuel gauge
Hour meter
9
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