15213SL - Toro Media

15213SL - Toro Media
Part No. 15213SL
Service Manual
ReelmasterR 3550- D
Preface
The purpose of this publication is to provide the service
technician with service information for service and
repair of major systems and components on the
Reelmaster 3550- D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Copies of the Operator’s Manuals and Parts
Catalog are available on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
EThe Toro Company - 2015
This page is intentionally blank.
Reelmaster 3550- D
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Electrical System Quick Checks . . . . . . . . . . . . . 5 - 18
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 - 47
2222-
1
1
2
3
Chapter 3 - Kubota Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Chapter 4 - Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
6666-
2
2
3
4
Chapter 7 - DPA Cutting Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 7 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Factors That Can Affect Cutting Performance . . 7 - 9
Set Up and Adjustments . . . . . . . . . . . . . . . . . . . . 7 - 13
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
Chapter 8 - Groomer (Optional)
Grooming Performance . . . . . . . . . . . . . . . . . . . . . 8 - 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
Chapter 9 - Foldout Drawings
Electrical Drawing Designations . . . . . . . . . . . . . .
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Diagram . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Drawing . . . . . . . . . . . . . . . . . . . . . .
99999-
2
3
4
5
6
Foldout
Drawings
Groomer
DPA Cutting
Units
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . 4 - 14
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . 4 - 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 31
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 62
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 - 63
EATON MEDIUM DUTY PISTON PUMP REPAIR
INFORMATION
MODEL
70160
VARIABLE
DISPLACEMENT PISTON PUMP
PARKER TORQMOTORTM SERVICE PROCEDURE
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER- DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Chapter 6 - Chassis
Electrical
System
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Chassis
Chapter 2 - Product Records and Maintenance
Product Records
and Maintenance
General Safety Instructions . . . . . . . . . . . . . . . . . . 1 - 2
Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 - 5
Kubota
Diesel Engine
Chapter 5 - Electrical System
Hydraulic
System
Chapter 1 - Safety
Safety
Table Of Contents
Reelmaster 3550- D
This page is intentionally blank.
Reelmaster 3550−D
Safety
Table of Contents
GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
Reelmaster 3550−D
2
2
2
3
4
5
Page 1 − 1
Safety
Safety
Chapter 1
General Safety Instructions
The Reelmaster 3550−D has been tested and certified
by Toro for compliance with existing safety standards
and specifications. Although hazard control and accident prevention partially are dependent upon the design
and configuration of the machine, these factors are also
dependent upon the awareness, concern and proper
training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death, comply with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Review and understand the contents of the Operator’s Manuals and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
Additional copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
4. Since diesel fuel is flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting units are DISENGAGED.
While Operating
1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Engage the parking brake.
4. Do not touch engine, exhaust system components or
radiator while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
A. Ensure that traction pedal is in neutral.
B. Engage parking brake.
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage
may be adjusted incorrectly; therefore, shut engine
off and adjust traction pedal linkage until machine
does not move when traction pedal is released.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
Safety
C. Disengage PTO and wait for cutting unit reels to
stop rotating.
D. Stop engine and remove key from ignition switch.
E. Toro recommends that anytime the machine is
parked (short or long term), the cutting units should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of cutting
units accidentally lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
Page 1 − 2
Reelmaster 3550−D
1. The Traction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general
maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine.
2. Before servicing or making adjustments, lower cutting units, stop engine, set parking brake and remove
key from the ignition switch.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
6. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
8. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
10.If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other moving parts. Keep bystanders away.
11. To assure safety and accuracy, check maximum engine speed.
Reelmaster 3550−D
12.Shut engine off before checking or adding oil to the
engine crankcase.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive battery cable first and negative
cable last.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.When welding on machine, disconnect both battery
cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness
connector from the machine TEC controller and disconnect the terminal connector from the alternator.
17.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
18.When changing attachments, tires or performing
other service, use correct jacks, hoists and jack stands.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use appropriate jack stands to support
the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall,
which may result in personal injury (see Jacking Instructions in this chapter).
19.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow all local codes and regulations when recycling or disposing of waste.
Page 1 − 3
Safety
Safety
Maintenance and Service
Jacking Instructions
Jacking the Rear End
CAUTION
1. Chock both front wheels.
When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid,
level surface such as a concrete floor. Prior to
raising machine, remove any attachments that
may interfere with the safe and proper raising of
the machine. Always chock or block wheels. Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
IMPORTANT: Make sure jack is as close to the rear
fork as possible when raising the machine.
2. Place jack securely under the rear lift arm support as
close to the fork as possible. Raise rear tire off the
ground.
3. Use appropriate jack stands under the frame to support the machine.
Jacking the Front End
1. If the front wheel or wheel motor is to be removed,
position jack securely under the round tube of the lower
frame as closely to the side plate as possible.
2. Use appropriate jack stands under the round tube to
support the machine.
Safety
Page 1 − 4
Reelmaster 3550−D
Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Reelmaster 3550−D. If any decal becomes illegible
or damaged, install a new decal. Decal part numbers are
listed in your Parts Catalog.
Reelmaster 3550−D
Page 1 − 5
Safety
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Safety
Page 1 − 6
Reelmaster 3550−D
Chapter 2
Product Records
and Maintenance
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Using a Torque Wrench with an Offset Wrench . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
2
3
3
3
4
5
6
6
Product Records
Insert Operator’s Manuals and Parts Catalog for your
Reelmaster at the end of this chapter. Additionally, insert
Installation Instructions, Operator’s Manuals and Parts
Catalogs for any accessories that have been installed
on your Reelmaster at the end of this section.
Maintenance
Maintenance procedures and recommended service intervals for your Reelmaster are covered in the Traction
Unit and Cutting Unit Operator’s Manuals. Refer to
those publications when performing regular equipment
maintenance. Several maintenance procedures have
break−in intervals identified in the Operator’s Manuals.
Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
Reelmaster 3550−D
Page 2 − 1
Product Records and Maintenance
Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 − 2
Reelmaster 3550−D
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Inch Series Bolts and Screws
Class 10.9
Metric Bolts and Screws
Figure 1
Figure 2
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.
If the listed torque recommendation for a fastener is
from 76 to 94 ft−lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft−lb.
Offset wrench
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 3550−D
Page 2 − 3
(effective length of
torque wrench)
A
Torque wrench
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Figure 3
Product Records and Maintenance
Product Records
and Maintenance
Torque Specifications
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
Grade 1, 5 &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in−lb
in−lb
N−cm
10 + 2
13 + 2
147 + 23
# 6 − 32 UNC
# 6 − 40 UNF
# 8 − 32 UNC
13 + 2
25 + 5
# 10 − 24 UNC
30 + 5
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in−lb
N−cm
in−lb
N−cm
15 + 2
169 + 23
23 + 3
262 + 34
17 + 2
192 + 23
25 + 3
282 + 34
29 + 3
328 + 34
41 + 5
463 + 56
31 + 4
350 + 45
43 + 5
486 + 56
42 + 5
475 + 56
60 + 6
678 + 68
48 + 5
542 + 56
68 + 7
768 + 79
282 + 30
# 8 − 36 UNF
18 + 2
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
339 + 56
# 10 − 32 UNF
1/4 − 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1130 + 113
140 + 15
1582 + 169
1/4 − 28 UNF
53 + 7
65 + 10
734 + 113
115 + 12
1299 + 136
160 + 17
1808 + 192
5/16 − 18 UNC
115 + 15
105 + 15
1186 + 169
200 + 25
2260 + 282
300 + 30
3390 + 339
5/16 − 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2542 + 282
325 + 33
3672 + 373
ft−lb
ft−lb
N−m
ft−lb
N−m
ft−lb
N−m
3/8 − 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 5
58 + 7
3/8 − 24 UNF
17 + 2
18 + 2
24 + 3
35 + 4
47 + 5
50 + 6
68 + 8
7/16 − 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 − 20 UNF
29 + 3
29 + 3
39 + 4
55 + 6
75 + 8
77 + 8
104 + 11
1/2 − 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 11
142 + 15
1/2 − 20 UNF
32 + 4
53 + 7
72 + 9
85 + 9
115 + 12
120 + 12
163 + 16
5/8 − 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 21
285 + 28
5/8 − 18 UNF
75 + 10
95 + 15
129 + 20
170 + 18
230 + 24
240 + 24
325 + 33
3/4 − 10 UNC
93 + 12
140 + 20
190 + 27
265 + 27
359 + 37
375 + 38
508 + 52
3/4 − 16 UNF
115 + 15
165 + 25
224 + 34
300 + 30
407 + 41
420 + 43
569 + 58
7/8 − 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 − 14 UNF
155 + 25
260 + 30
353 + 41
475 + 48
644 + 65
667 + 66
904 + 89
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance
Page 2 − 4
Reelmaster 3550−D
Thread Size
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8
57 + 6 in−lb
644 + 68 N−cm
78 + 8 in−lb
881 + 90 N−cm
M6 X 1.0
96 + 10 in−lb
1085 + 113 N−cm
133 + 14 in−lb
1503 + 158 N−cm
M8 X 1.25
19 + 2 ft−lb
26 + 3 N−m
28 + 3 ft−lb
38 + 4 N−m
M10 X 1.5
38 + 4 ft−lb
52 + 5 N−m
54 + 6 ft−lb
73 + 8 N−m
M12 X 1.75
66 + 7 ft−lb
90 + 10 N−m
93 + 10 ft−lb
126 + 14 N−m
M16 X 2.0
166 + 17 ft−lb
225 + 23 N−m
229 + 23 ft−lb
310 + 31 N−m
M20 X 2.5
325 + 33 ft−lb
440 + 45 N−m
450 + 46 ft−lb
610 + 62 N−m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Reelmaster 3550−D
Page 2 − 5
Product Records and Maintenance
Product Records
and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size
Recommended Torque
Recommended Torque**
Thread Size
Square Head
Hex Socket
1/4 − 20 UNC
140 + 20 in−lb
73 + 12 in−lb
5/16 − 18 UNC
215 + 35 in−lb
145 + 20 in−lb
3/8 − 16 UNC
35 + 10 ft−lb
18 + 3 ft−lb
1/2 − 13 UNC
75 + 15 ft−lb
50 + 10 ft−lb
7/16 − 20 UNF
Grade 5
65 + 10 ft−lb
88 + 14 N−m
1/2 − 20 UNF
Grade 5
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.25
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
M12 X 1.5
Class 8.8
80 + 10 ft−lb
108 + 14 N−m
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size
Baseline Torque*
No. 6 − 32 UNC
20 + 5 in−lb
No. 8 − 32 UNC
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A
Type B
No. 6
18
20
20 + 5 in−lb
30 + 5 in−lb
No. 8
15
18
30 + 5 in−lb
No. 10 − 24 UNC
38 + 7 in−lb
No. 10
12
16
38 + 7 in−lb
1/4 − 20 UNC
85 + 15 in−lb
No. 12
11
14
85 + 15 in−lb
5/16 − 18 UNC
110 + 20 in−lb
3/8 − 16 UNC
200 + 100 in−lb
* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Conversion Factors
in−lb X 11.2985 = N−cm
ft−lb X 1.3558 = N−m
Product Records and Maintenance
N−cm X 0.08851 = in−lb
N−m X 0.7376 = ft−lb
Page 2 − 6
Reelmaster 3550−D
Chapter 3
Kubota Diesel Engine
Table of Contents
Reelmaster 3550- D
Page 3 - 1
Kubota
Diesel Engine
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 4
Kubota Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 6
Air Cleaner and Muffler . . . . . . . . . . . . . . . . . . . . . . 6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Radiator and Oil Cooler Assembly . . . . . . . . . . . . 10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Kubota Diesel Engine
This page is intentionally blank.
Kubota Diesel Engine
Page 3 − 2
Reelmaster 3550−D
Specifications
Description
Item
Make / Designation
Kubota D1105- E3B or D1105- E4B
4- Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine
Bore x Stroke
3.07” x 3.09” (78 mm x 78.4 mm)
68.5 in3 (1123 cc)
Total Displacement
1 (fan end) - 2 - 3 (flywheel end)
Direction of Rotation
Counterclockwise (viewed from flywheel)
Fuel
Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low
Sulfur Content
Fuel Capacity
7.5 U.S. gallons (28.4 liters)
Fuel Injection Pump
Bosch MD Type Mini
Injection Nozzle
Mini Nozzle (DNOPD)
Governor
Centrifugal Mechanical
Low Idle (no load)
1400 + 50 RPM
High Idle (no load)
3220 + 50 RPM
Engine Oil
API CH- 4, CI- 4 or higher
Engine Oil Viscosity
See Traction Unit Operator’s Manual
Crankcase Oil Capacity
4 U.S. Quarts (3.8 Liters) with Filter
Oil Pump
Trochoid Type
Coolant Capacity
6 U.S. Quarts (5.7 Liters)
Starter
12 VDC 1.4 KW
Alternator/Regulator
Alternator Output
12 VDC
40 amp
Engine Dry Weight
Reelmaster 3550- D
205 lb. (93 kg)
Page 3 - 3
Kubota Diesel Engine
Kubota
Diesel Engine
Firing Order
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Reelmaster
3550- D.
General maintenance procedures are described in your
Traction Unit Operator’s Manual. Information on engine
troubleshooting, testing, disassembly and assembly is
identified in the Kubota Workshop Manual: 05 Series
Diesel Engine.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kubota Workshop Manual: 05
Series Diesel Engine. The use of some specialized test
equipment is explained. However, the cost of the test
equipment and the specialized nature of some repairs
may dictate that the work be done at an engine repair facility.
Service and repair parts for the Kubota engine in your
Reelmaster are available from your Authorized Toro
Distributor. If no parts list is available, be prepared to
provide your distributor with the Toro model and serial
number.
Operator’s Manual
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the Kubota diesel engine that
powers your Reelmaster 3550- D. Refer to this publication for additional information when servicing the machine.
Kubota Workshop Manual
The engine that powers your Reelmaster machine is a
Kubota model D1105. The Kubota Workshop Manual is
available for these engines. Make sure that the correct
engine manual is used when servicing the engine on
your Reelmaster 3550- D.
Kubota Diesel Engine
The Kubota D1105 engine used in your Reelmaster
3550- D is a naturally aspirated engine that complies
with either EPA emission regulations Tier 4i (model
D1105- E3B) or Tier 4 (model D1105- E4B) depending
on manufacture date. The engine includes a Bosch inline injection pump.
Figure 1
Kubota Diesel Engine
Page 3 - 4
Reelmaster 3550- D
Kubota
Diesel Engine
This page is intentionally left blank.
Reelmaster 3550−D
Page 3 − 5
Kubota Diesel Engine
Service and Repairs
Air Cleaner and Muffler
10
11
12
14
19
16
21
15
4
13
18
3
12
17
20
12
7
8
1
5
9
2
6
4
5
Figure 2
1.
2.
3.
4.
5.
6.
7.
Exhaust guard
Cap screw
Muffler
Flange head screw
Flange nut
Muffler bracket
Hex nut
Kubota Diesel Engine
8.
9.
10.
11.
12.
13.
14.
Lock washer
Exhaust gasket
Hose clamp
Air inlet hose (upper)
Hose clamp
Air cleaner body
Filter cover
Page 3 − 6
15.
16.
17.
18.
19.
20.
21.
Burp (Actuator) valve
Mounting band assembly
Shoulder bolt
Compression spring
Lock nut
Air inlet hose (lower)
Air filter mount
Reelmaster 3550−D
Check Air Filter, Dust Cup, & Burp Valve
The air cleaner body, air filter, dust cup, and burp valve
should be checked daily, prior to operation.
IMPORTANT: Any leaks in the air cleaner system
will cause serious engine damage. Make sure that
all air cleaner components are in good condition
and are properly secured during operation.
4
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
1
3. Check burp valve and dust cup for damage.
4. Make sure air hoses connecting the air cleaner to the
engine and radiator are secured tightly and free of possible air leaks.
3
Figure 4
1. Flange head nut
2. Flange head screw
3. Muffler plate
4. Muffler bracket
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Open engine hood to gain access to engine.
3. Remove exhaust guard.
4. Remove both flange head nuts and screws securing
the muffler plate to the muffler bracket (Fig. 4).
1
5. Remove four hex nuts and lock washers from the exhaust manifold studs. Separate muffler flange from the
exhaust manifold. Remove muffler from the machine.
6. Remove exhaust gasket. Replace gasket if damaged or torn.
2
Muffler Installation
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
3
1. Place exhaust gasket on the exhaust manifold.
IMPORTANT: Finger tighten all fasteners before securing the muffler plate to the muffler bracket so
there is no preload on the exhaust manifold.
Figure 3
1. Latch
2. Dust cup
3. Burp valve
2. Position muffler flange to the exhaust manifold with
four lock washers and hex nuts.
Muffler Removal
3. Position muffler plate to the muffler bracket with both
flange head screws and nuts (Fig. 4).
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
4. Tighten muffler flange hex nuts and then muffler
plate screws and nuts.
5. Install exhaust guard.
6. Close and latch engine hood.
Reelmaster 3550−D
Page 3 − 7
Kubota Diesel Engine
Kubota
Diesel Engine
2. Check air cleaner body for damage that could cause
possible air leaks. Make sure dust cup seals completely
to the air cleaner body (Fig. 3).
2
Fuel System
6
5
TO
PUMP
4
6
12
7
10
8
16 17
11
18
Thread
Sealant
(typical)
9
8
3
13
14
2
20
19
15
11
21
22
11
38
11
27
28
1
30
31
32
29
33
37
23
24
25
34
27
35
36
26
TO
TANK
Thread
Sealant
(typical)
11
7
39
RIGHT
40
FRONT
16
41
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Fuel tank
Grommet
Fuel gauge
Seat support strap (2)
Heat shield
Washer head screw (4)
Fuel hose (tank to pump)
Bushing (2)
Elbow fitting
Stand pipe
Hose clamp (7)
Fuel hose (tee to tank)
Cap screw (2)
Fuel hose strap
Kubota Diesel Engine
15. Fuel cap
16. Hose clamp (2)
17. Flange nut (2)
18. R−Clamp
19. Fuel hose (filter to engine)
20. Grommet
21. Barbed fitting
22. Fuel hose (pump to filter)
23. Clamp
24. Washer head screw
25. Washer head screw
26. Fuel pump
27. Hose clamp (2)
28. Fuel hose (engine return to tee)
Page 3 − 8
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Barbed fitting
Barbed fitting
Tee fitting
Barbed fitting
Elbow fitting
Fuel/water separator element
Pump mount plate
Cap screw (3)
Fuel/water separator head
Flange head screw (2)
Tank support
Flange head screw (2)
Fuel hose (tee to vent tube)
Reelmaster 3550−D
3
DANGER
4
Because diesel fuel is flammable, use caution
when storing or handling it. Do not smoke while
filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and
wipe up any spilled diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
5
1
Figure 6
Fuel Tank Removal (Fig. 5)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing waste fuel.
2. Drain fuel from the tank into a suitable container. If
necessary.
3. Disconnect seat switch from the electrical harness.
Remove seat and seat support straps from the frame.
4. Remove fuel hose strap and both fuel hoses from the
fuel tank (Fig 6). Remove fuel tank from the machine.
1. Seat support strap
2. Hex flange head screw
3. Electrical harness
4. Fuel hose strap
5. Fuel hose
4. Connect wire harness connector to the seat switch.
Route seat switch wire under seat support strap. Secure
seat support straps and seat to the frame (see Operator
Seat in Chapter 6 − Chassis in this manual).
5. Check that fuel tank support contacts the bottom of
the fuel tank but does not raise tank from machine
frame. Adjust location of support if necessary.
6. Check for correct seat operation. Also check that
seat switch wires and connector are not pinched and do
not contact any moving parts.
7. Fill fuel tank.
Clean Fuel Tank
Clean the fuel tank every 2 years. Also, clean the fuel
tank if the fuel system becomes contaminated or if the
machine is to be stored for an extended period.
1. Remove fuel tank from the machine (see Fuel Tank
Removal).
2. Flush fuel tank out with clean diesel fuel. Make sure
tank is free of contaminates and debris.
3. Install fuel tank to the machine (see Fuel Tank Installation).
Fuel Tank Installation (Fig. 5)
1. Position fuel tank to the machine.
2. Connect both fuel hoses to the tank and secure with
hose clamps.
3. Install fuel hose strap to top of tank making sure that
fuel lines are properly positioned in grooves in tank.
Reelmaster 3550−D
Page 3 − 9
Kubota Diesel Engine
Kubota
Diesel Engine
2
Radiator and Oil Cooler Assembly
2
21
18
25
20
9
9
27
10
22
19
5
10
8
3
16
4
11
12
24
14
13
21
29
28
33
26
23
34
16
21
30
15
1
2
Thread
Sealant
RIGHT
33
31 2
7
FRONT
17
32
6
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Draincock valve
Flange head screw (8)
Flange nut (4)
Carriage bolt (4)
Radiator/oil cooler assembly
LH fan shroud
RH fan shroud
Flange head screw (4)
Hose clamp (2)
Flange head screw (6)
Overflow bottle bracket
Radiator lower shield
Kubota Diesel Engine
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Magnet
Radiator hose (upper)
Radiator hose (lower)
Hose clamp (2)
Straight hydraulic fitting
Hose
Coolant expansion tank
Radiator cap
Flange nut (6)
Foam seal (2)
Adapter
Page 3 − 10
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
LH radiator bracket
RH radiator bracket
Bottom radiator bracket
Top radiator bracket
Plastic plug (2)
Flange nut (4)
Flange head screw (4)
Flat washer (4)
O−ring
O−ring
O−ring
Reelmaster 3550−D
Removal (Fig. 7)
Installation (Fig. 7)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
1. Inspect seals around radiator location for wear or
damage. Replace seals if necessary.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene- glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly
labeled container away from children and pets.
2. If hydraulic fittings were removed from oil cooler, lubricate and place new O- rings onto fittings. Install fittings into port openings and tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of Chapter 4 - Hydraulic System in this manual).
3. If draincock valve was removed from radiator, apply
thread sealant to draincock threads before installing it
into radiator.
4. Remove all plugs placed in radiator and hose openings during the removal procedure.
5. Carefully position radiator to the radiator brackets.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing engine coolant.
3. Drain radiator into a suitable container either by using the draincock near the lower left side corner of the
radiator or by removing the lower radiator hose from the
radiator.
4. Disconnect radiator hoses from the radiator.
5. Remove air cleaner inlet hose from radiator opening.
6. Read the General Precautions for Removing and
Installing Hydraulic System Components in the Service
and Repairs section of Chapter 4 - Hydraulic System in
this manual.
7. Thoroughly clean hydraulic lines at oil cooler ports.
Disconnect hydraulic lines and put caps or plugs on lines
to prevent contamination. Label disconnected hydraulic
lines for proper installation.
8. Remove coolant expansion tank and bracket from
machine.
9. Remove fan shrouds from machine.
6. Secure radiator to the side radiator brackets with four
(4) carriage bolts and flange nuts. Secure top and bottom of radiator to brackets with flange head screws.
7. Connect hydraulic lines to fittings in oil cooler ports
(see Hydraulic Hose and Tube Installation in the General Information section of Chapter 4 - Hydraulic System
in this manual).
8. Position fan shrouds to radiator and secure with removed fasteners.
9. Secure coolant expansion tank and bracket to machine.
10.Connect radiator hoses to the radiator and secure
with hose clamps.
11. Install and secure air cleaner inlet hose.
12.Make sure radiator draincock valve is closed. Fill radiator with coolant.
13.Install hood to the machine. Close and latch hood.
14.Fill the hydraulic fluid tank.
10.Remove fasteners that secure radiator to the upper,
lower and side radiator brackets.
11. Carefully separate radiator/oil cooler assembly from
brackets and remove from the machine.
15.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to distribute the hydraulic fluid
throughout the system.
12.If necessary, remove hydraulic fittings from oil cooler
and discard O- rings.
16.Stop the engine and check the hydraulic fluid and
coolant levels. Adjust as necessary.
13.Plug all radiator and hose openings to prevent contamination.
Reelmaster 3550- D
Page 3 - 11
Kubota Diesel Engine
Kubota
Diesel Engine
2. Open and remove hood from the machine.
Engine
1
Thread Sealant
6
8
5
2
6
9
10
7
3
13
11
12
4
26
41
42
15
31
40
30
16
43
36
44
38
14
35
17
18
19
34
37
32
26
20
23
24
25
27
46
45
28
29
30
21
22
4
31
32
39
39
33
17
34
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Engine mount bracket − RH
Cap screw
Hardened washer
Engine mount
Lower radiator hose
Hose clamp
Exhaust flange gasket
Coolant temperature switch
Upper radiator hose
Wire Harness − fusible link
Flat washer
Lock washer
Hex nut
Flange nut
Fuel filter bracket
External tooth lock washer
Kubota Diesel Engine
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Engine ground wire
Flat washer
Cap screw
Throttle cable bracket
Cable clamp
Cap screw
Throttle cable
Swivel clamp
Cable stop
Cap screw
Engine mount bracket − LH
Hardened washer
Cap screw
Flange head screw
Hardened washer
Hex nut
Page 3 − 12
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Lock washer
Flange nut
Engine mount bracket − front
Engine mount
Hardened washer
Cap screw
Cable tie
Spacer (1)
Spacer (4)
Pump mount plate
Hardened washer
Cap screw
Cap screw
Hardened washer
Reelmaster 3550−D
Removal (Fig. 8)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
4
3
5
2. Open and remove engine hood from the machine.
Slide seat all the way forward.
3. Disconnect air hose from the air cleaner and radiator.
Remove air cleaner assembly from the engine.
5. Remove muffler from the exhaust manifold and muffler bracket (see Muffler Removal in this Chapter).
1
Figure 9
1. Battery ground cable
2. Wire harness ground
3. Throttle cable
2
6. Drain radiator from the drain cock valve into a suitable container (see Radiator Removal in this Chapter).
Disconnect coolant hoses from the water pump and engine block.
4. Support bracket
5. Speed control lever
6. Fuel hose
1
4
3
7. Remove coolant expansion tank and bracket from
the top fan shroud. Remove top fan shroud from the radiator (see Radiator Removal in this Chapter).
8. Disconnect wire harness and electrical wires from
the following:
A. Battery, wire harness and engine grounds
(Fig. 9).
Figure 10
1. Glow plug wire
2. Rear injector nozzle
3. Fuel hose
4. Lift tab
B. Glow plug bus (Fig. 10) and fuel stop solenoid.
1
C. Engine temperature sensor, alternator, and low
oil pressure switch (Fig. 11).
9. Disconnect throttle cable from the support and swivel on the speed control lever (Fig. 9).
2
10.Disconnect fuel hose from the fuel pump (Fig. 9) and
front injector nozzle.
3
11. Remove traction control cable from the neutral arm
assembly on the piston pump. Remove all hydraulic
hoses from the piston and gear pumps (see Piston
Pump Removal in Chapter 4− Hydraulic System).
Figure 11
1. Engine temp. sensor
2. Alternator
3. Oil pressure switch
12.Remove cable ties securing the wire harness to the
front lift tab and other engine parts. Connect hoist or lift
to the front and rear lift tabs (Fig. 10).
Reelmaster 3550−D
Page 3 − 13
Kubota Diesel Engine
Kubota
Diesel Engine
4. Disconnect both battery cables at the battery (see
Battery Service in Chapter 5 − Electrical System).
2
6
CAUTION
CAUTION
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the engine and engine brackets.
One person should operate lift or hoist while the
other person guides the engine out of the machine.
13.Remove hex nuts, cap screws, and washers from the
center of the three engine mounts.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
14.Remove engine slowly from the machine.
1
RIGHT
FRONT
2
3
4
5
6
10
9
8
7
Figure 12
1.
2.
3.
4.
Engine mount bracket
Flange nut
Flange screw
Pump mount plate
Kubota Diesel Engine
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
Page 3 − 14
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
Reelmaster 3550−D
A. Remove traction belt from the engine flywheel
and hydrostat pulleys.
B. Remove five cap screws, washers, and spacers
securing the pump mount plate to the engine.
C. Remove two cap screws and flange nuts securing the pump support to the engine mount bracket
and remove the hydrostat and pump assembly from
the engine.
16.As necessary, remove engine mounts, front engine
mounting bracket, throttle support bracket and left engine mounting bracket.
Installation (Fig. 8)
1. If removed, install engine mounts, front engine
mounting bracket, throttle support bracket and left engine mounting bracket. Also, make sure that all switches
and sensors are installed on engine.
2. Install hydrostat and pump assembly to the engine
as follows (Fig. 12):
A. Secure the pump support to the engine mount
bracket with two flange nuts and cap screws.
B. Secure pump mount plate to the engine with five
spacers, washers, and cap screws.
C. Install traction belt to the engine flywheel and hydrostat pulleys.
3. Connect hoist or lift to the front and rear engine lift
tabs (Fig. 10).
CAUTION
One person should operate lift or hoist while the
other person guides the engine into the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while installing the engine.
4. Position engine slowly into the machine.
5. Secure all three engine mounts to the engine mounting brackets with cap screws, washers, and hex nuts.
6. Secure wire harness to the front lift tab and the engine with cable ties.
tion in Chapter 4− Hydraulic System).
8. Connect fuel hose to the fuel pump (Fig. 9) and front
injector nozzle.
9. Install top fan shroud to the radiator. Install expansion tank and bracket to the top fan shroud (see Radiator
Installation in this Chapter).
10.Connect wire harness and electrical wires to the following:
A. Engine grounds to the battery and wire harness
(Fig. 9).
B. Glow plug bus (Fig. 10) and fuel stop solenoid.
C. Engine temperature sensor, alternator, and low
oil pressure switch (Fig. 11).
11. Secure wire harness to engine with cable ties at locations noted during engine removal.
12.Connect coolant hoses to the water pump and engine block. Make sure drain cock valve is closed. Fill radiator with coolant.
13.Install muffler to the exhaust manifold and muffler
bracket (see Muffler Installation in this Chapter).
14.Connect throttle cable to the support and swivel on
the speed control lever (Fig. 9).
15.Connect both battery cables at the battery (see Battery Service in Chapter 6 − Electrical system).
16.Install air cleaner to the engine. Connect air hose to
air cleaner and radiator.
17.Adjust throttle cable.
18.Bleed air from the fuel system.
19.Install engine hood to the machine. Close and latch
hood.
20.Fill the hydraulic fluid tank.
21.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to distribute the hydraulic fluid
throughout the system.
22.Stop the engine and check the hydraulic fluid and
coolant levels. Adjust as necessary.
23.Adjust traction drive for neutral.
7. Install all hydraulic hoses to the piston and gear
pumps. Install traction control cable to the neutral arm
assembly on the piston pump (see Piston Pump InstallaReelmaster 3550−D
Page 3 − 15
Kubota Diesel Engine
Kubota
Diesel Engine
15.Separate hydrostat and pump assembly from the engine as follows (Fig. 12):
This page is intentionally blank.
Kubota Diesel Engine
Page 3 − 16
Reelmaster 3550−D
Chapter 4
Hydraulic System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relieving Hydraulic System Pressure . . . . . . . . . . 3
Traction Circuit Component Failure . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hose and Tube Installation . . . . . . . . . . 5
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 16
Traction Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cutting Unit Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lift Circuit: Lower . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lift Circuit: Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 26
General Hydraulic System Problems . . . . . . . . . . 26
Traction Circuit Problems . . . . . . . . . . . . . . . . . . . 27
Lift Circuit Problems . . . . . . . . . . . . . . . . . . . . . . . . 28
Steering Circuit Problems . . . . . . . . . . . . . . . . . . . 29
Mow Circuit Problems . . . . . . . . . . . . . . . . . . . . . . 30
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Traction Circuit Testing
Charge Pressure Test . . . . . . . . . . . . . . . . . . . . 34
Wheel Motor Efficiency Tests . . . . . . . . . . . . . . 36
Piston Pump/Hydrostat Flow and
Relief Pressure Test . . . . . . . . . . . . . . . . . . . . 40
Cutting Unit Circuit Testing
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Reel Motor Efficiency/Case Drain Test . . . . . . 46
Proportional Relief Valve (PRV)
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mow Control Manifold Relief Valve (RV)
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Gear Pump (P1) Flow Test . . . . . . . . . . . . . . . . 52
Steering/Lift Circuit Testing
Gear Pump (P2) Flow Test . . . . . . . . . . . . . . . . 54
Relief Valve Pressure Test . . . . . . . . . . . . . . . . 58
Steering Control Valve and
Steering Cylinder Test . . . . . . . . . . . . . . . . . . 60
Reelmaster 3550- D
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjust Control Manifold Relief Valves . . . . . . . . . 62
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 63
General Precautions for Removing and
Installing Hydraulic System Components . . . . 63
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 64
Priming Hydraulic Pumps . . . . . . . . . . . . . . . . . . . 64
Flush Hydraulic System . . . . . . . . . . . . . . . . . . . . . 65
Filtering Closed- Loop Traction Circuit . . . . . . . . 66
Charge Hydraulic System . . . . . . . . . . . . . . . . . . . 67
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Radiator and Oil Cooler Assembly . . . . . . . . . . . . 70
Hydraulic Pump Assembly . . . . . . . . . . . . . . . . . . 72
Piston Pump/Hydrostat . . . . . . . . . . . . . . . . . . . . . 76
Piston Pump/Hydrostat Service . . . . . . . . . . . . . . 80
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . 86
Front Wheel Motors . . . . . . . . . . . . . . . . . . . . . . . . 88
Rear Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wheel Motor Service . . . . . . . . . . . . . . . . . . . . . . . 92
Cutting Unit Reel Motor . . . . . . . . . . . . . . . . . . . . . 94
Cutting Unit Reel Motor Service . . . . . . . . . . . . . . 96
Mow Control Manifold . . . . . . . . . . . . . . . . . . . . . 100
Mow Control Manifold Service . . . . . . . . . . . . . . 102
Lift Control Manifold . . . . . . . . . . . . . . . . . . . . . . . 106
Lift Control Manifold Service . . . . . . . . . . . . . . . . 108
Control Manifold Cartridge Valve Service . . . . . 110
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 112
Steering Control Valve Service . . . . . . . . . . . . . . 114
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 116
Steering Cylinder Service . . . . . . . . . . . . . . . . . . 118
Front Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . 120
Rear Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . 122
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . 124
EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABLE DISPLACEMENT PISTON PUMP
PARKER TORQMOTORt TC, TB, TE, TJ, TF, TG,
TH and TL SERIES SERVICE PROCEDURE
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Page 4 - 1
Hydraulic System
Hydraulic
System
Table of Contents
Specifications
Item
Description
Piston Pump (Hydrostat)
Charge Pressure
Variable displacement piston pump
Specification:100 to 150 PSI (6.9 to 10.3 bar)
Tested: 150 to 200 PSI (10.3 to 13.8 bar)
1.44 in3/rev (23.6 cc/rev)
3500 PSI (241 bar)
Maximum Displacement
Traction Circuit Relief Pressure (Forward Only)
Tandem Gear Pump
Maximum Displacement Section 1 (P1 − mow)
Maximum Displacement Section 2 (P2 − steering & lift)
2 section positive displacement gear type pump
0.58 in3/rev (9.45 cc/rev)
0.33 in3/rev (5.34 cc/rev)
Wheel Motors (see note)
Front Wheel Motor Displacement
Rear Wheel Motor Displacement
Orbital geroller motor
12.0 in3/rev (195 cc/rev)
24.7 in3 (405 cc)
Mow Circuit Relief Pressures
Front Cutting Units (PRV)
Rear Cutting Units (RV)
3000 PSI (207 bar)
1500 PSI (103 bar)
Lift Circuit Relief Pressure (RV1)
Lower: 500 PSI (34.5 bar)
Raise: 1000 PSI (69 bar)
Cutting Unit Motors
Displacement
Gear motor
0.73 in3/rev (11.96 cc/rev)
Steering Control Valve
Displacement
Relief Valve Pressure
Distributor valve with rotary meter
6.1 in3/rev (100 cc/rev)
1000 PSI (69 bar)
Hydraulic Filters
In−line Suction Strainer
10 Micron, spin−on cartridge type
100 mesh (in tank)
Hydraulic Tank Capacity
6 U.S. Gallons (22.6 Liters)
Hydraulic Fluid
See Traction Unit Operator’s Manual
NOTE: The three wheel motors are similar in construction with only minor differences. The right front wheel motor and rear wheel motor have a
reverse timed manifold, and the front left wheel motor does not. The end cover of the rear motor has a check valve consisting of a ball and spring,
and both front motors lack this feature.
Hydraulic System
Page 4 − 2
Reelmaster 3550−D
General Information
Operator’s Manual
The Traction Unit and Cutting Unit Operator’s Manuals
provide information regarding the operation, general
maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine.
Relieving Hydraulic System Pressure
To relieve hydraulic pressure in traction circuit, move
traction pedal to both forward and reverse directions. To
relieve hydraulic pressure in steering circuit, rotate
steering wheel in both directions.
To relieve hydraulic pressure in lift circuit, fully lower the
cutting units to the ground. Turn ignition switch to OFF.
NOTE: Moving steering wheel with engine off may unseat implement relief valve. If steering or lift circuits appear weak or inoperative after machine is returned to
service, repeat relieving hydraulic system pressure procedure.
System pressure in mow circuit is relieved when the cutting units are disengaged (reel enable/disable switch in
DISENGAGE position).
Traction Circuit Component Failure
The traction circuit on Reelmaster 3550−D machines is
a closed loop system that includes the piston (traction)
pump, two (2) front wheel motors and the rear wheel motor. If a component in the traction circuit should fail, debris and contamination from the failed component will
circulate throughout the traction circuit. This contamination can damage other components in the circuit so it
must be removed to prevent additional component failure.
The recommended method of removing traction circuit
contamination would be to temporarily install the Toro
high flow hydraulic filter (see Special Tools in this chapter) into the circuit. This filter should be used when connecting hydraulic test gauges in order to test traction
circuit components or after replacing a failed traction circuit component (e.g. traction (piston) pump or wheel
motor). The filter will ensure that contaminates are removed from the closed loop and thus, do not cause additional component damage.
Once the Toro high flow hydraulic filter kit has been
placed in the circuit, raise and support the machine with
Reelmaster 3550−D
all drive wheels off the ground. Then, operate the traction circuit to allow oil flow throughout the circuit. The filter will remove contamination from the traction circuit
during operation. Because the Toro high flow filter is bi−
directional, the traction circuit can be operated in both
the forward and reverse direction. The filter should be
removed from the machine after contamination has
been removed from the traction circuit. See Filtering
Closed−Loop Traction Circuit in the Service and Repairs
section of this chapter for additional information on using the Toro high flow hydraulic filter.
The alternative to using the Toro high flow hydraulic filter
kit after a traction circuit component failure would be to
disassemble, drain and thoroughly clean all components, tubes and hoses in the traction circuit. If any debris remains in the traction circuit and the machine is
operated, the debris can cause additional circuit component failure.
NOTE: If traction circuit contamination exists, the traction pump case drain could allow contaminates to enter
other hydraulic circuits on the machine.
Page 4 − 3
Hydraulic System
Hydraulic
System
Before disconnecting or performing any work on the hydraulic system, all pressure in the hydraulic system
must be relieved. Park machine on a level surface, lower
cutting units fully, stop engine and apply parking brake.
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions or mishandling during operation and maintenance.
These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these
conditions than others. Inspect all machine hydraulic
hoses frequently for signs of deterioration or damage:
Hard, cracked, cut, abraded, charred, leaking or
otherwise damaged hose.
Kinked, crushed, flattened or twisted hose.
Blistered, soft, degraded or loose hose cover.
Cracked, damaged or badly corroded hose fittings.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint (layline) on
the hose. Use two wrenches; hold the hose straight with
one wrench and tighten the hose swivel nut onto the fitting with the other wrench (See Hydraulic Hose and
Tube Installation in this section in this chapter). If the
hose has an elbow at one end, tighten the swivel nut on
that end before tightening the nut on the straight end of
the hose.
WARNING
Before disconnecting or performing any work on
hydraulic system, relieve all pressure in system
(see Relieving Hydraulic System Pressure in this
section of this chapter).
Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
For additional hydraulic hose information, refer to Toro
Service Training Book, Hydraulic Hose Servicing (Part
Number 94813SL).
Hydraulic System
Page 4 − 4
Reelmaster 3550−D
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting)
C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The
markings on the nut and fitting body will verify that the
connection has been properly tightened.
1. Make sure threads and sealing surfaces of the hose/
tube and the fitting are free of burrs, nicks, scratches or
any foreign material.
2. As a preventative measure against leakage, it is recommended that the face seal O−ring be replaced any
time the connection is opened. Make sure the O−ring is
installed and properly seated in the fitting groove. Lightly
lubricate the O−ring with clean hydraulic oil.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
3. Place the hose/tube against the fitting body so that
the flat face of the hose/tube sleeve fully contacts the O−
ring in the fitting.
F.F.W.R.
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/2 to 3/4
1/3 to 1/2
1/3 to 1/2
Swivel Nut
Fitting Body
4. Thread the swivel nut onto the fitting by hand. While
holding the hose/tube with a wrench, use a torque
wrench to tighten the swivel nut to the recommended
installation torque (Fig. 3). This tightening process will
require the use of an offset wrench (e.g. crowfoot
wrench). Use of an offset wrench will affect torque
wrench calibration due to the effective length change of
the torque wrench. Tightening torque when using a
torque wrench with an offset wrench will be lower than
the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 − Product Records and Maintenance).
Tube or Hose
Figure 1
5. If a torque wrench is not available or if space at the
swivel nut prevents use of a torque wrench, an alternate
method of assembly is the Flats From Wrench Resistance (F.F.W.R.) method (Fig. 2).
A. Using a wrench, tighten the swivel nut onto the fitting until light wrench resistance is reached (approximately 30 in−lb).
Hydraulic
System
O−ring
Mark Nut
and Fitting
Body
Final
Position
Initial
Position
Extend Line
AT WRENCH RESISTANCE
B. Mark the swivel nut and fitting body. Hold the
hose/tube with a wrench to prevent it from turning.
AFTER TIGHTENING
Figure 2
Fitting Dash Size
Hose/Tube Side Thread Size
Installation Torque
4
9/16 − 18
18 to 22 ft−lb (25 to 29 N−m)
6
11/16 − 16
27 to 33 ft−lb (37 to 44 N−m)
8
13/16 − 16
37 to 47 ft−lb (51 to 63 N−m)
10
1 − 14
60 to 74 ft−lb (82 to 100 N−m)
12
1 3/16 − 12
85 to 105 ft−lb (116 to 142 N−m)
16
1 7/16 − 12
110 to 136 ft−lb (150 to 184 N−m)
20
1 11/16 − 12
140 to 172 ft−lb (190 to 233 N−m)
Figure 3
Reelmaster 3550−D
Page 4 − 5
Hydraulic System
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port)
Non−Adjustable Fitting (Fig. 4)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recommended installation torque (Fig. 5).
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fitting to 60% of listed F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 − Product
Records and Maintenance to determine necessary conversion information.
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Fitting
O−ring
Figure 4
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4
7/16 − 20
15 to 19 ft−lb (21 to 25 N−m)
9 to 11 ft−lb (13 to 15 N−m)
5
1/2 − 20
18 to 22 ft−lb (25 to 29 N−m)
11 to 15 ft−lb (15 to 20 N−m)
6
9/16 − 18
34 to 42 ft−lb (47 to 56 N−m)
20 to 26 ft−lb (28 to 35 N−m)
8
3/4 − 16
58 to 72 ft−lb (79 to 97 N−m)
35 to 43 ft−lb (48 to 58 N−m)
10
7/8 − 14
99 to 121 ft−lb (135 to 164 N−m)
60 to 74 ft−lb (82 to 100 N−m)
12
1 1/16 − 12
134 to 164 ft−lb (182 to 222 N−m)
81 to 99 ft−lb (110 to 134 N−m)
14
1 3/16 − 12
160 to 196 ft−lb (217 to 265 N−m)
96 to 118 ft−lb (131 to 160 N−m)
16
1 5/16 − 12
202 to 248 ft−lb (274 to 336 N−m)
121 to 149 ft−lb (165 to 202 N−m)
20
1 5/8 − 12
247 to 303 ft−lb (335 to 410 N−m)
149 to 183 ft−lb (202 to 248 N−m)
Figure 5
Hydraulic System
Page 4 − 6
Reelmaster 3550−D
Adjustable Fitting (Fig. 6)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is recommended that the O−ring be replaced any time the
connection is opened.
Lock Nut
3. Lightly lubricate the O−ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
Back−up Washer
4. Turn back the lock nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1 Fig. 7).
O−ring
Figure 6
IMPORTANT: Before installing fitting into port, determine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn
(Step 3).
7. Hold the fitting in the desired position with a wrench
and use a torque wrench to tighten the fitting to the recommended installation torque (Fig. 5). This tightening
process will require the use of an offset wrench (e.g.
crowfoot wrench). Use of an offset wrench will affect
torque wrench calibration due to the effective length
change of the torque wrench. Tightening torque when
using a torque wrench with an offset wrench will be lower
than the listed installation torque (see Using a Torque
Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 − Product Records and Maintenance).
Step 1
Step 3
Step 2
Step 4
Hydraulic
System
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
Figure 7
8. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.)
method. Hold the fitting in the desired position with a
wrench and, if port material is steel, tighten the lock nut
with a second wrench to the listed F.F.F.T (Step 4). If port
material is aluminum, tighten fitting to 60% of listed
F.F.F.T.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Reelmaster 3550−D
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Page 4 − 7
Hydraulic System
Special Tools
Order the following special tools from your Toro Distributor.
Hydraulic Pressure Test Kit
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each: 1000 PSI (70 Bar), 5000 PSI (350
Bar) and 10000 PSI (700 Bar) gauges. Use gauges as
recommended in Testing section of this chapter.
Toro Part Number: TOR47009
Figure 8
Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
and pressure capacities as recommended in the Testing
section of this chapter. This tester includes the following:
1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
3. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
4. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 1 to 15
GPM (5 to 55 LPM).
Figure 9
5. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
6. FITTINGS: An assortment of hydraulic fittings are included with this kit.
Toro Part Number: TOR214678
Hydraulic System
Page 4 − 8
Reelmaster 3550−D
40 GPM Hydraulic Tester (Pressure and Flow)
Use to test hydraulic circuits and components for flow
and pressure capacities as recommended in the Testing
section of this chapter. This tester includes the following:
1. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
2. PRESSURE GAUGE: Glycerine filled 0 to 5000 PSI
gauge to provide operating circuit pressure.
3. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated from 4 to 40
GPM (20 to 150 LPM).
Toro Part Number: AT40002
Figure 10
Hydraulic
System
NOTE: This tester does not include hydraulic hoses
(see Hydraulic Hose Kit TOR6007 below).
Hydraulic Hose Kit
This kit includes hydraulic fittings and hoses needed to
connect 40 GPM hydraulic tester (AT40002) or high flow
hydraulic filter kit (TOR6011) to machine hydraulic traction system components.
Toro Part Number: TOR6007
Figure 11
Reelmaster 3550−D
Page 4 − 9
Hydraulic System
High Flow Hydraulic Filter Kit
The high flow hydraulic filter kit is designed with large
flow (40 GPM/150 LPM) and high pressure (5000
PSI/345 bar) capabilities. This kit provides for bi−directional filtration which prevents filtered debris from being
allowed back into the circuit regardless of flow direction.
If a component failure occurs in the closed loop traction
circuit, contamination from the failed part will remain in
the circuit until removed. When connecting hydraulic
test gauges in order to test traction circuit components
or after replacing a failed traction circuit component (e.g.
piston (traction) pump or wheel motor), the high flow hydraulic filter can be installed in the traction circuit. The
filter will ensure that contaminates are removed from the
closed loop and thus, do not cause additional component damage.
Figure 12
Toro Part Number: TOR6011
NOTE: This kit does not include hydraulic hoses (see
Hydraulic Hose Kit TOR6007 above).
NOTE: Replacement filter element is Toro part number
TOR6012. Filter element canister tightening torque is 25
ft−lb (34 N−m).
Hydraulic Test Fitting Kit
This kit includes a variety of O−ring Face Seal fittings to
enable you to connect test gauges into the system.
The kit includes: tee’s, unions, reducers, plugs, caps
and male test fittings.
Toro Part Number: TOR4079
Figure 13
Hydraulic System
Page 4 − 10
Reelmaster 3550−D
Measuring Container
Use this container for doing hydraulic motor efficiency
testing (motors with case drain lines only). Measure efficiency of a hydraulic motor by restricting the outlet flow
from the motor and measuring leakage from the case
drain line while the motor is pressurized by the hydraulic
system.
The table in Figure 15 provides gallons per minute
(GPM) conversion for measured milliliter or ounce motor
case drain leakage.
Toro Part Number: TOR4077
Hydraulic
System
Figure 14
Figure 15
O−ring Kit
The kit includes O−rings in a variety of sizes for face seal
and port seal hydraulic connections. It is recommended
that O−rings be replaced whenever a hydraulic connection is loosened.
Toro Part Number: 117−2727
Figure 16
Reelmaster 3550−D
Page 4 − 11
Hydraulic System
Remote Starter Switch
After flushing the hydraulic system or replacing a hydraulic component (e.g. gear pump, piston pump, wheel
motor), it is necessary to prime the hydraulic pumps. A
remote starter switch (Fig. 17) can be used for this purpose. Obtain a remote starter switch locally.
IMPORTANT: When using a remote starter switch, it
is highly recommended to include a 20 amp in−line
fuse between the battery and switch connector for
circuit protection.
Figure 17
A remote stater switch can also be constructed using
Toro switch #106−2027, a length of 14 gauge wire, a 20
amp in−line fuse, two (2) alligator clips and necessary
connectors. Connecting the wire to switch terminals 1
and 2 will allow the momentary switch contacts to be
used for the remote starter switch (Fig. 18).
MACHINE
BATTERY
NOTE: For information on using the remote starter
switch to prime the hydraulic pumps, see Flush Hydraulic System in the Service and Repairs section of this
chapter.
TORO SWITCH
(#106−2027)
20 AMP
FUSE
STARTER
SOLENOID
MACHINE
STARTER
Figure 18
2
3
1
Figure 19
1. Starter motor
2. Starter solenoid
Hydraulic System
Page 4 − 12
3. B+ terminal
Reelmaster 3550−D
Wheel Hub Puller
Toro Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Hydraulic
System
Figure 20
Reelmaster 3550−D
Page 4 − 13
Hydraulic System
.73
.73
.73
Hydraulic System
G
BACKLAP
SWITCH
(SW)
FC
M1
Page 4 − 14
P
3000 PSI
OR1
.050”
CV1
MV
BREATHER
PRV
M2
REEL #4 REEL #1 REEL #5
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
OIL COOLER
RV
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
7.0 GPM
LIFT CONTROL
MANIFOLD
RV1
OR1
.040”
G1
P2
500 PSI
.33
P
S2
OR3
.040”
C3
.58
P1
S1
OR5
.040”
S3
T
OR7
.035”
Extend
To Lower
3500 PSI
G1
G2
P
6.1
R
T
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
12.0
E
24.7
All solenoids are shown as
de−energized
Reelmaster 3550−D
Hydraulic Schematic
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
NOTE: A larger hydraulic schematic is included
in Chapter 8 − Foldout Drawings.
C8
OR8
.055”
OR6
C6 .046”
OR4
C4 .046”
C2
OR2
.046”
C1
Extend
To Lower
1.50” Bore
0.625” Rod
2.25” Stroke
2x
1.50” Bore
0.625” Rod
2.25” Stroke
12.0
Hydraulic Schematic
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 15
Hydraulic System
Hydraulic System
.73
.73
Page 4 − 16
G
BACKLAP
SWITCH
(SW)
FC
M1
P
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
RV
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
OIL COOLER
3000 PSI
OR1
.050”
CV1
MV
BREATHER
PRV
M2
REEL #4 REEL #1 REEL #5
.73
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Reelmaster 3550−D
Traction Circuit (Forward)
C8
RV1
OR1
.040”
7.0 GPM
LIFT CONTROL
MANIFOLD
OR8
.055”
OR6
C6 .046”
OR4
C4 .046”
C2
OR2
.046”
C1
Extend
To Lower
G1
P2
500 PSI
.33
P1
.58
S1
OR5
.040”
S3
T
OR7
.035”
Extend
To Lower
3500 PSI
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
P
S2
OR3
.040”
C3
1.50” Bore
0.625” Rod
2.25” Stroke
2x
1.50” Bore
0.625” Rod
2.25” Stroke
G1
G2
P
6.1
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
T
R
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
12.0
E
24.7
12.0
Hydraulic Flow Diagrams
Reelmaster 3550−D
Traction Circuit
The mow/transport slide control on Reelmaster 3550−D
machines has positions for mow and transport. The
mow position allows traction pedal inputs that are appropriate for mow speeds by limiting the movement of the
traction pedal and the piston pump swash plate. The
transport position allows full movement of the traction
pedal so complete pump swash rotation is possible.
Forward
The engine drives traction pump (P3) indirectly through
pulleys and a V−belt. The traction pump is a variable displacement piston pump/hydrostat. The traction pedal
connects through a cable to the trunnion shaft and
swash plate of the pump. With the engine running and
the traction pedal in the neutral position, traction pump
(P3) supplies no flow to the wheel motors. When the
traction pedal is pressed to the forward position, the
cable from the pedal positions the swash plate in the
traction pump so fluid flows out of the hydrostat lower
port. Fluid flow out of the lower port goes to the front
wheel motors first, turning them in the forward direction.
Fluid flowing out of the front wheel motors flows to the
rear wheel motor, turning it in a forward direction. Fluid
flowing out of the rear wheel motor returns to the upper
port of the hydrostat and is continuously pumped out of
the lower port.
Operating pressure in the closed traction circuit is determined by the amount of load developed by the wheel
motors. As the load increases, circuit pressure can increase to the relief valve setting of 3500 psi (241 bar).
In forward operation, fluid flows through the internal hydrostat relief valve to the low pressure side of the traction circuit when circuit pressure exceeds the relief
setting.
Reverse
The traction circuit operates essentially the same in reverse as it does in forward. However, there are a few differences in operation.
When the reverse traction pedal is depressed, the cable
from the pedal positions the swash plate in the traction
pump (P3) so fluid flows out of the hydrostat upper port.
Fluid flow out of the upper port goes to the rear wheel
motor where an internal check valve allows the hydraulic fluid to bypass the motor. Fluid flow out of the rear
Reelmaster 3550−D
wheel motor flows to the front wheel motors, turning
them in the reverse direction. Fluid flow out of the front
wheel motors returns to the lower port of the hydrostat
and is continuously pumped out of the upper port.
NOTE: The rear wheel motor does not help propel the
traction unit in reverse.
Charge Circuit
The traction pump uses a small amount of hydraulic fluid
for internal lubrication. Fluid is designed to leak across
internal pump parts into the case drain. This leakage results in the loss of hydraulic fluid from the closed loop circuit that must be replenished via the charge circuit.
The gear pump (P2) is directly coupled to the hydrostat
through gear pump (P1) and driven by the engine. Gear
pump (P2) supplies hydraulic pressure for operating the
power steering system, raising and lowering the cutting
units, and operating the sidewinder unit. Gear pump
(P2) may also be referred to as the charge pump as flow
from the gear pump also replenishes the closed loop
traction circuit. Hydraulic fluid exits the lift/sidewinder
valve, passes through the hydraulic manifold where it
actuates logic cartridge (LC1), and continues on to the
hydrostat. A relief valve located in the hydrostat
provides sufficient resistance so that flow is guided to
the low pressure side of the traction circuit through one
of two check valves (charge circuit). Pump flow in excess of charge circuit requirements is relieved through
the relief valve back to the gear pump inlet and hydraulic
tank.
Traction Circuit Cooling
The traction circuit is cooled by a bleed off circuit in the
piston pump. The piston pump includes an internal
bleed valve which allows a small amount of hydraulic oil
to pass from the return side of the pump while operating
the traction unit in the forward direction. The charge circuit replenishes oil that is bled from the traction circuit by
the bleed valve.
When operating the traction circuit in the reverse direction, the bleed valve closes once reverse pressure
reaches 200 to 300 PSI (13.8 to 20.6) to allow normal
reverse operation.
NOTE: The bleed valve threads into the piston pump
back plate. Access to the bleed valve requires removal
of the back plate from the piston pump.
Page 4 − 17
Hydraulic System
Hydraulic
System
The traction circuit of the hydraulic system consists of a
hydrostat connected in a closed loop circuit to three orbital geroller wheel motors.
Hydraulic System
Page 4 − 18
Reelmaster 3550−D
.73
.73
G
BACKLAP
SWITCH
(SW)
FC
M1
P
BREATHER
3000 PSI
OR1
.050”
CV1
MV
PRV
M2
REEL #4 REEL #1 REEL #5
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
OIL COOLER
RV
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
.73
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Reelmaster 3550−D
Cutting Unit Circuit − Mow
C8
7.0 GPM
RV1
OR1
.040”
LIFT CONTROL
MANIFOLD
OR8
.055”
OR6
C6 .046”
OR4
C4 .046”
C2
OR2
.046”
C1
Extend
To Lower
G1
P2
500 PSI
.33
.58
P1
S1
OR5
.040”
S3
T
OR7
.035”
Extend
To Lower
3500 PSI
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
P
S2
OR3
.040”
C3
1.50” Bore
0.625” Rod
2.25” Stroke
2x
1.50” Bore
0.625” Rod
2.25” Stroke
G1
G2
P
6.1
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
T
R
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
E
12.0
24.7
12.0
Cutting Unit Circuit
Mow
The tandem gear pump is directly coupled to the piston
pump/hydrostat which is belt driven by the engine. The
front section of the gear pump (P1) supplies hydraulic
flow for the cutting unit circuit. The gear pump takes its
suction from the hydraulic tank.
.73
Proportional relief valve (PRV) in the mow control manifold is de−energized with the engine running when either the reel enable/disable switch is in the DISABLE
position, the cutting units are raised or the mow/transport slide is in the TRANSPORT position. The de−energized PRV allows gear pump flow directly to the
hydraulic tank by−passing the reel motors so the cutting
reel blades remain stationary.
Mow circuit oil flows through the front reel motors and
then the rear reel motors as it turns the motors in the
mow direction. Manifold relief valve (RV) provides relief
protection for the rear reel motors at a pressure less
than the proportional relief valve (PRV). If pressure to
the rear motors reaches 1500 PSI (103 bar), relief valve
(RV) opens.
.73
REEL #1
M1
REEL #5
.73
.73
REEL #2
REEL #3
MOW CONTROL
MANIFOLD
M2
MV
BACKLAP
SWITCH
(SW)
CV1
OR1
.050”
FC
OR2
.020”
1500 PSI
RV
M3
LC
PRV
G
3000 PSI
P
T
FROM GEAR
PUMP
TO HYDRAULIC
TANK
TO OIL
COOLER
Figure 21
Backlap (Fig. 21)
Backlapping operation is the similar to mowing operation, except for the position of the backlap valve (MV).
When the backlap valve (MV) is in the BACKLAP position, oil flows through the rear reel motors and then the
front reel motors as it turns the motors in the backlap
direction.
Oil flow from the reel motors returns into mow control
manifold port (M2), through backlap valve (MV), through
manifold check valve CV1 and exits the manifold
through pot (T). Oil returns to the hydraulic tank through
the oil cooler and oil filter.
Reelmaster 3550−D
Page 4 − 19
Hydraulic System
Hydraulic
System
Proportional relief valve (PRV) is energized by the TEC
controller with the engine running when the reel enable/
disable switch is in the ENABLE position, the cutting
units are down and the mow/transport slide is in the
MOW position. In the energized position, this valve directs gear pump oil flow toward the reel motors and also
functions as the relief valve for the front reel motors.
Maximum front reel motor pressure is 3000 PSI (207
bar). Front reel motor circuit pressure can be monitored
at the test fitting in mow control manifold port G.
When the mow circuit is engaged, oil flow from manifold
port P flows through the flow control valve (FC) used to
adjust reel speed. With the backlap valve (MV) in the
MOW position, oil flows through the backlap valve (MV),
out the manifold port (M1), and to the reel motors that
are connected in series. Any excess flow above the flow
control valve setting is by−passed to the reservoir
through the logic cartridge valve (LC). The logic cartridge valve (LC) reduces fluctuations in reel speed by
compensating for pressure variations across the flow
control valve (FC).
.73
REEL #4
Hydraulic System
Page 4 − 20
Reelmaster 3550−D
.73
.73
G
BACKLAP
SWITCH
(SW)
FC
M1
P
3000 PSI
OR1
.050”
CV1
MV
BREATHER
PRV
M2
REEL #4 REEL #1 REEL #5
.73
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
OIL COOLER
RV
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundmaster 3505−D
Lift Circuit: Lower
C8
RV1
OR1
.040”
7.0 GPM
LIFT CONTROL
MANIFOLD
OR8
.055”
OR6
C6 .046”
OR4
C4 .046”
C2
OR2
.046”
C1
Extend
To Lower
G1
P2
500 PSI
.33
P1
.58
S1
OR5
.040”
S3
T
OR7
.035”
3500 PSI
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
Extend
To Lower
2x
1.50” Bore
0.625” Rod
2.25” Stroke
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
P
S2
OR3
.040”
C3
1.50” Bore
0.625” Rod
2.25” Stroke
G1
G2
P
6.1
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
T
R
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
12.0
E
24.7
12.0
Lift Circuit: Lower
The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit
flow to by−pass the lift cylinders when de−energized
and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise
the cutting units when energized and lower them when
de−energized. When energized, solenoid valve S3 allows hydraulic flow to and from the front cutting unit lift
cylinders (#1, #4 and #5) and prevents oil passage to
and from these lift cylinders when de−energized. When
energized, solenoid valve S4 allows hydraulic flow to
and from the rear cutting unit lift cylinders (#2 and #3)
and prevents oil passage to and from these lift cylinder
when de−energized.
The console joystick is used to raise and lower the cutting units. The joystick acts as an input to the Toro Electronic Controller (TEC) to send electrical outputs to
appropriate lift control manifold solenoid coils in order to
raise or lower the cutting units.
Lift circuit pressure can be monitored at the test fitting in
lift control manifold port G1.
While operating the machine during conditions of not
raising or lowering the cutting units (joystick in the neutral (center) position), all of the lift manifold solenoid
valves (S1, S2, S3 and S4) are de−energized. Flow from
gear pump (P2) is directed through the steering control
valve, de−energized solenoid valve S1 in the lift control
manifold and then to the traction charge circuit. Flow in
excess of charge circuit needs then returns to the gear
pump inlet.
When the reel enable/disable switch is in the ENABLE
position, the cutting unit lift and lower operation is controlled by a program in the TEC controller (sequential
control) and the cutting units move fully up or fully down
when the joystick is bumped. When the reel enable/disable switch is in the DISABLE position, the cutting unit
lift and lower operation is under complete control of the
joystick (momentary control) and the cutting units move
up or down only as long as the joystick is held in position.
Reelmaster 3550−D
CUTTING UNIT LOCATIONS
1
1
2
#4
#5
#1
#2
FRONT 1
1
2
#3
2
1
Figure 22
1. Reel motor location
2. Weight location
Lower Cutting Units
The operator must be in the operator seat and the mow/
transport switch must be in the MOW position in order
to lower the cutting units. The cutting units will not lower
if the mow/transport switch is in the TRANSPORT position.
When the joystick is moved to the lower position by the
operator, solenoid valve S1, S3 and S4 are energized by
the TEC controller. To allow the front cutting units to be
lowered before the rear cutting units, the controller
slightly delays energizing solenoid S4 after the joystick
is moved. The energized solenoid valves direct gear
pump oil flow to the cap end of the lift cylinders. Flow
control orifices in the lift control manifold (OR2, OR4,
OR6 and OR8) are bypassed when lowering the cutting
units.
Hydraulic pressure along with cutting unit weight causes
the lift cylinder shafts to extend, and lower the cutting
units. Flow control orifices in the lift control manifold
(OR1, OR3, OR5 and OR7) control the cutting unit lowering speed by providing a restriction for the return flow
from the lift cylinders.
Because cutting unit weight assists in extending the lift
cylinders when lowering the cutting units, less hydraulic
pressure is necessary during the cutting unit lowering
operation. Lift circuit relief valve (RV) allows lift circuit
pressure to be limited to 500 PSI (34 bar) while lowering
the cutting units. The lift cylinders and cutting units stop
lowering when solenoid valves S1, S3 and S4 are de−
energized.
NOTE: Adjustment of the lift control manifold lift circuit
relief valve (RV) is not recommended.
Page 4 − 21
Hydraulic System
Hydraulic
System
The tandem gear pump is directly coupled to the variable displacement piston pump/hydrostat which is belt
driven by the engine. The rear section of the tandem
gear pump (P2) supplies hydraulic flow for the steering
circuit (priority flow), for raising and lowering the cutting
units and for the traction charge circuit. The gear pump
takes its suction from the hydraulic tank. Maximum
steering and lift circuit pressure of 1000 PSI (69 bar) is
limited by the relief valve located in the power steering
valve.
Hydraulic System
Page 4 − 22
Reelmaster 3550−D
.73
.73
G
BACKLAP
SWITCH
(SW)
FC
M1
P
3000 PSI
OR1
.050”
CV1
MV
BREATHER
PRV
M2
REEL #4 REEL #1 REEL #5
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
OIL COOLER
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
.73
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundmaster 3505−D
Lift Circuit: Raise
C8
RV1
OR1
.040”
7.0 GPM
LIFT CONTROL
MANIFOLD
OR8
.055”
OR6
C6 .046”
OR4
C4 .046”
C2
OR2
.046”
C1
Extend
To Lower
G1
P2
S2
500 PSI
P1
.58
S1
OR5
.040”
S3
T
OR7
.035”
3500 PSI
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
Extend
To Lower
2x
1.50” Bore
0.625” Rod
2.25” Stroke
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
P
.33
OR3
.040”
C3
1.50” Bore
0.625” Rod
2.25” Stroke
G1
G2
P
6.1
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
T
R
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
12.0
E
24.7
12.0
Lift Circuit: Raise
The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit
flow to by−pass the lift cylinders when de−energized
and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise
the cutting units when energized and lower them when
de−energized. When energized, solenoid valve S3 allows hydraulic flow to and from the front cutting unit lift
cylinders (#1, #4 and #5) and prevents oil passage to
and from these lift cylinders when de−energized. When
energized, solenoid valve S4 allows hydraulic flow to
and from the rear cutting unit lift cylinders (#2 and #3)
and prevents oil passage to and from these lift cylinder
when de−energized.
The console joystick is used to raise and lower the cutting units. The joystick acts as an input to the Toro Electronic Controller (TEC) to send electrical outputs to
appropriate lift control manifold solenoid coils in order to
raise or lower the cutting units.
Lift circuit pressure can be monitored at the test fitting in
lift control manifold port G1.
While operating the machine during conditions of not
raising or lowering the cutting units (joystick in the neutral (center) position), all of the lift manifold solenoid
valves (S1, S2, S3 and S4) are de−energized. Flow from
gear pump (P2) is directed through the steering control
valve, de−energized solenoid valve S1 in the lift control
manifold and then to the traction charge circuit. Flow in
excess of charge circuit needs then returns to the gear
pump inlet.
Reelmaster 3550−D
CUTTING UNIT LOCATIONS
1
1
2
#4
#5
#1
#2
FRONT 1
1
2
#3
2
1
Figure 23
1. Reel motor location
2. Weight location
Raise Cutting Units
NOTE: The operator must be in the operator seat in order to raise the cutting units.
When the joystick is moved to the raise position by the
operator, solenoid valve S1, S2, S3 and S4 are energized by the TEC controller. To allow the front cutting
units to be raised before the rear cutting units, the controller slightly delays energizing solenoid S4 after the
joystick is moved. The energized solenoid valves direct
gear pump oil flow to the rod end of the lift cylinders.
Flow control orifices in the lift control manifold (OR1,
OR3, OR5 and OR7) are bypassed when raising the cutting units.
Hydraulic pressure causes the lift cylinder shafts to retract, and raise the cutting units. Flow control orifices in
the lift control manifold (OR2, OR4, OR6 and OR8) control the cutting unit raising speed by providing a restriction for the return flow from the lift cylinders. The internal
relief valve in the steering control valve allows lift circuit
pressure to be limited to 1000 PSI (69 bar) while raising
the cutting units.
When the joystick is released, solenoid valves S1, S2,
S3 and S4 are de−energized so the lift cylinders and cutting units are held in position.
Page 4 − 23
Hydraulic System
Hydraulic
System
The tandem gear pump is directly coupled to the variable displacement piston pump/hydrostat which is belt
driven by the engine. The rear section of the tandem
gear pump (P2) supplies hydraulic flow for the steering
circuit (priority flow), for raising and lowering the cutting
units and for the traction charge circuit. The gear pump
takes its suction from the hydraulic tank. Maximum
steering and lift circuit pressure of 1000 PSI (69 bar) is
limited by the relief valve located in the power steering
valve.
Hydraulic System
Page 4 − 24
Reelmaster 3550−D
.73
.73
G
BACKLAP
SWITCH
(SW)
FC
M1
P
3000 PSI
OR1
.050”
CV1
MV
BREATHER
PRV
M2
REEL #4 REEL #1 REEL #5
.73
.73
LC
OR2
.020”
T
M3
SUCTION
STRAINER
25 PSI
OIL FILTER
OIL COOLER
1500 PSI
MOW CONTROL
MANIFOLD
REEL #2 REEL #3
.73
Working Pressure
Low Pressure (Charge)
Return or Suction
Flow
Groundmaster 3505−D
Steering Circuit (Right Turn Shown)
C8
RV1
OR1
.040”
7.0 GPM
LIFT CONTROL
MANIFOLD
OR8
.055”
OR6
C6 .046”
C2
OR4
C4 .046”
OR2
.046”
C1
Extend
To Lower
G1
P2
500 PSI
.33
P
P1
.58
S1
OR5
.040”
S3
T
OR7
.035”
3500 PSI
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
200−300 PSI
C2
4.0 GPM
S4
Extend
To Lower
2x
1.50” Bore
0.625” Rod
2.25” Stroke
C7
100−150 PSI
1.50” Bore
0.625” Rod
2.33” Stroke
1.44
C5
1.50” Bore
0.625” Rod
2.33” Stroke
S2
OR3
.040”
C3
1.50” Bore
0.625” Rod
2.25” Stroke
G1
G2
P
6.1
R
T
PUMP RPM = 0.96 x
ENGINE RPM
ENGINE IDLE
3200 / 1400
BYPASS
VALVE
STEERING
CONTROL
VALVE
1000 PSI
L
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
12.0
E
24.7
12.0
Steering Circuit
LEFT TURN
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
L
With the engine running and the steering control valve
in the centered position (steering wheel not being
turned), gear pump flow enters the steering control
valve at the P port and goes through the control valve,
by−passing the rotary meter and steering cylinder. Flow
leaves the control valve through the E port to be available for the lift circuit and then to the traction charge circuit.
R
6.1
Hydraulic
System
The tandem gear pump is directly coupled to the variable displacement piston pump/hydrostat which is belt
driven by the engine. The rear section of the tandem
gear pump (P2) supplies hydraulic flow for the steering
circuit (priority flow), for raising and lowering the cutting
units and for the traction charge circuit. The gear pump
takes its suction from the hydraulic tank. Maximum
steering and lift circuit pressure of 1000 PSI (69 bar) is
limited by the relief valve located in the power steering
valve.
1000 PSI
Right Turn
When a right turn is made with the engine running, the
turning of the steering wheel positions the control valve
so that flow goes through the bottom of the valve. Gear
pump flow entering the steering control valve at the P
port goes through the valve and is routed to two places.
First, most of the flow through the valve is by−passed out
the E port back through the lift control manifold and then
to the traction charge circuit. Second, the remainder of
the flow is drawn through the rotary meter in the steering
control valve and out port R to the steering cylinder. Flow
retracts the steering cylinder for a right turn. The rotary
meter ensures that the oil flow to the steering cylinder is
proportional to the amount of the steering wheel rotation. Fluid leaving the steering cylinder flows back
through the steering control valve then through the T
port and then to the traction charge circuit.
The steering control valve returns to the neutral position
when turning is complete.
P
FROM GEAR
PUMP
STEERING
CONTROL
VALVE
T
TO CHARGE
CIRCUIT
E
TO LIFT
MANIFOLD
Figure 24
Left Turn (Fig. 24)
When a left turn is made with the engine running, the
turning of the steering wheel positions the steering control valve so that flow goes through the top of the valve.
Gear pump flow entering the steering control valve at
the P port goes through the spool and is routed to two
places. As in a right turn, most of the flow through the
valve is by−passed out the E port back through the lift
control valve and then to the traction charge circuit. Also
like a right turn, the remainder of the flow is drawn
through the rotary meter in the steering control valve but
goes out port L to the steering cylinder. Flow extends the
steering cylinder for a left turn. The rotary meter ensures
that the oil flow to the cylinder is proportional to the
amount of the turning on the steering wheel. Fluid leaving the steering cylinder flows back through the steering
control valve then through the T port and then to the traction charge circuit.
The steering control valve returns to the neutral position
when turning is complete.
Reelmaster 3550−D
Page 4 − 25
Hydraulic System
Troubleshooting
The chart that follows contains information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures.
Review the hydraulic schematic and information on hydraulic system operation in the Hydraulic Flow Diagrams section of this Chapter. This information will be
useful during the hydraulic troubleshooting process.
General Hydraulic System Problems
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Problem
Possible Cause
Hydraulic oil leaks from system.
Hydraulic fitting(s), hose(s) or tube(s) are loose or damaged.
O−ring(s) or seal(s) are missing or damaged.
Hydraulic fluid foams.
Oil level in hydraulic tank is low.
Hydraulic system has wrong type of hydraulic oil.
The pump suction line has an air leak.
Incompatible hydraulic oils are mixed in the hydraulic system.
Water contamination is in the hydraulic system.
Hydraulic system operates hot
(above 200F (93C).
Traction pressure is high due to excessive load or brake applied.
Oil level in hydraulic tank is low, or inlet filter is loose or clogged
(NOTE: Other hydraulic systems are affected as well).
Hydraulic oil is contaminated or oil viscosity is too light.
Oil cooler is damaged or plugged.
Bypass valve in traction pump/hydrostat is open or defective.
Charge pressure is low.
Wheel motor(s) or cutting unit motor(s) are worn or damaged.
Traction pump/hydrostat is worn or damaged.
Hydraulic System
Page 4 − 26
Reelmaster 3550−D
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Traction Circuit Problems
Problem
Possible Cause
Neutral is difficult to find or machine
operates in one direction only.
External control linkage is misadjusted, disconnected, binding or
damaged.
Traction pump/hydrostat is worn or damaged.
Traction response is sluggish.
Bypass valve in traction pump/hydrostat is open or defective.
Brake is not released.
Hydraulic oil is very cold.
Traction charge pressure is low.
Traction pump/hydrostat or wheel motor(s) are worn or damaged.
Brake is not released.
Oil level in hydraulic tank is low
(NOTE: Other hydraulic systems are affected as well).
Bypass valve in traction pump/hydrostat is open or defective.
Traction pump/hydrostat drive belt is loose or broken.
Traction relief valve is damaged − open.
Traction charge pressure is low.
Traction pump/hydrostat or wheel motor(s) are worn or damaged.
Wheel will not turn.
Brakes are binding.
Key on wheel motor shaft is sheared or missing.
Internal parts in wheel motor are damaged.
Unit rolls when stopped on an incline
− Engine Running (up to 10% grade
and parking brake disengaged).
Make up fluid from charge pump is not available.
Unit rolls when stopped on an incline
− Engine Not Running (up to 10%
grade, wheels straight and parking
brake disengaged).
Wheel motor(s) are worn or damaged (see Testing in this Chapter).
Reelmaster 3550−D
Hydrostat check valves are damaged.
NOTE: If unit rolls away straight, both front wheel motors are worn.
If the unit turns to one side as it rolls away, the wheel motor on the
outside of the turn is worn.
Page 4 − 27
Hydraulic System
Hydraulic
System
No traction exists in either direction.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ
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Lift Circuit Problems
Problem
Possible Cause
Cutting units will not lift or lift slowly.
Engine speed is too low.
Hydraulic tank oil level is low
(NOTE: Other hydraulic systems are affected as well).
An electrical problem exists that prevent lift control manifold solenoids from being energized (see Chapter 5 − Electrical System in
this manual)
Lift arm bushings are binding.
Implement relief valve (in steering control valve) is stuck open.
Lift cylinders leak internally.
Gear pump (P2) is worn or damaged
(NOTE: Steering and traction charge systems are affected as well).
Cutting units raise, but will not stay
up as the traction units travels
between adjacent fairways or fields.
Lift circuit hydraulic lines or fittings are leaking.
NOTE: Lift circuit components cannot provide an absolutely perfect
seal. The lift arms will eventually
lower if left in the raised position during storage.
Lift cylinders leak internally.
Cutting units will not lower.
Lift arm pivots are binding.
NOTE: To lower the cutting units,
the seat must be occupied and the
mow/transport switch must be in the
MOW position.
An electrical problem exists that prevents the solenoid valve (S1) in
lift control manifold from being energized (See Chapter 5 − Electrical System in this manual).
Lift control manifold cartridge valve(s) has damaged seals or is faulty.
Solenoid valve (S1) in lift control manifold is faulty.
Lift cylinder(s) for affected cutting unit(s) is damaged.
Hydraulic System
Page 4 − 28
Reelmaster 3550−D
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Steering Circuit Problems
Problem
Possible Cause
Steering inoperative or sluggish
Oil level in hydraulic reservoir is low
(NOTE: Other hydraulic systems are affected as well).
Steering components (e.g. steering fork assembly, steering cylinder
ends) are worn or binding.
Relief valve in steering control valve is damaged − open.
Steering cylinder leaks internally.
Gear pump (P2) is worn or damaged
(NOTE: The lift/lower and traction charge circuits are affected as
well).
Turning steering wheel turns machine in the wrong direction.
Reelmaster 3550−D
Hoses to the steering cylinder are reversed.
Page 4 − 29
Hydraulic System
Hydraulic
System
Steering control valve is worn or damaged (see Troubleshooting
Guide in the Sauer/Danfoss Steering Unit Type OSPM Service
Manual.).
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Mow Circuit Problems
Problem
Possible Cause
Gear pump is noisy (cavitation).
Hydraulic tank oil level is low
(NOTE: Other hydraulic systems are affected as well).
Suction line is restricted.
Suction line has an air leak.
None of the cutting reels will turn.
Solenoid valve (PRV) is stuck open.
NOTE: To engage the mow circuit,
the seat must be occupied, the cutting units must be fully lowered, the
mow/transport switch must be in the
MOW position and the reel enable/
disable switch must be in the ENABLE position.
An electrical problem exists that prevents the PRV solenoid valve in
mow control manifold from being energized (See Chapter 5 − Electrical System in this manual).
Poor after−cut appearance (cutting
blades(s) turn too slowly).
All Cutting Units:
Gear pump is worn or damaged.
Flow control (FC) in mow control manifold requires adjustment.
NOTE: If possible, have another
person observe the machine while
mowing in dense turf prior to hydraulic testing. A bad reel motor
will run slower, produce fewer clippings, and may cause marcelling
(a washboard appearance) on the
turf.
Solenoid valve (PRV) is faulty.
Gear pump (P1) is inefficient (see Testing in this chapter).
One or more Cutting Units:
Cutting unit motor has internal leakage (see Testing in this
chapter).
Rear Cutting Units:
Relief valve (RV) is out of adjustment or faulty.
Single Cutting Unit:
Cutting unit reel bearing(s) is (are) damaged.
Hydraulic System
Page 4 − 30
Reelmaster 3550−D
Testing
Remember that pressure specifications that appear on
hydraulic schematics are the design specifications for
the specific component. Actual system pressure will
vary depending on oil temperature, the location of the
test port, and the specific components used in the hydraulic circuit.
IMPORTANT: The hydraulic test procedures listed
in this manual represent actual performance for this
machine. To correctly measure product or component performance, be sure to follow the test procedures provided.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to operate the machine, and the other should read and
record test results.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hydraulic equipment. Hydraulic fluid contamination will
cause excessive wear of components.
2. Put metal caps or plugs on any hydraulic lines left
open or exposed during testing or while hydraulic components are removed.
Before Performing Hydraulic Tests
All obvious areas such as fluid supply, filter, binding linkages, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem.
Precautions for Hydraulic Testing
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Do not use hands to search for
leaks; use paper or cardboard. Hydraulic fluid
escaping under pressure can have sufficient
force to penetrate the skin and cause serious
injury. If fluid is injected into the skin, it must
be surgically removed within a few hours by a
doctor familiar with this type of injury. Gangrene may result from such an injury.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in the General Information section.
3. The engine must be in good operating condition. Use
a phototach (non−contact tachometer) when performing
a hydraulic test. Engine speed can affect the accuracy
of the test readings. Monitor engine RPM during hydraulic testing. Use the information below when performing hydraulic system tests. If engine RPM is above
or below the specified speed during a test, you will need
to adjust the expected hydraulic performance parameters (aprox. 3% per 100 engine rpm at full throttle)
IMPORTANT: Hydraulic component output volume
relates directly to engine RPM. For every 100 engine
rpm the following component output volumes will
change by the volume listed.
CAUTION
Hydrostat: 100 engine RPM = 0.59 GPM or 76.6 oz.
(2265 cc) of hydraulic fluid displaced per minute
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to the gauge and possible
personal injury from leaking hot hydraulic fluid.
Gear Pump (P1): 100 engine RPM = 0.24 GPM or
30.8 oz. (912 cc) of hydraulic fluid displaced per
minute
Gear Pump (P2): 100 engine RPM = 0.14 GPM or
17.5 oz. (519 cc) of hydraulic fluid displaced per
minute
Reelmaster 3550−D
Page 4 − 31
Hydraulic System
Hydraulic
System
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the various
hydraulic circuits to perform various operational checks
(See the Special Tools section in this chapter).
NOTE: Engine−to−Pump ratio is 1:0.96. In other words,
1 engine RPM = 0.96 pump RPM.
10.All hydraulic tests should be made with the hydraulic
fluid at normal operating temperature.
4. The inlet and the outlet hoses must be properly connected and not reversed (hydraulic tester with pressure
and flow capabilities) to prevent damage to the hydraulic
tester or components.
Hydraulic Test Selection
5. When using a hydraulic tester with pressure and flow
capabilities, open load valve completely in the hydraulic
tester to minimize the possibility of damaging components.
6. Install fittings finger tight and far enough to make
sure that they are not cross−threaded before tightening
them with a wrench.
7. Position hydraulic tester hoses to prevent moving
machine parts from contacting and damaging the hoses
or tester.
8. Check fluid level in the hydraulic tank. After connecting test equipment, make sure tank is full.
9. Check control linkages for improper adjustment,
binding, or broken parts.
Hydraulic System
Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit
or steering and lift/sidewinder circuit. Once the faulty
system has been identified, perform tests that relate to
that circuit.
If a traction circuit problem exists, consider performing
one or more of the following tests: Charge Pressure
Test, Wheel Motor Efficiency Test, and/or Piston Pump/
Hydrostat Flow and Relief Valve Tests.
If a cutting (mow) circuit problem exists, consider performing one or more of the following tests: Circuit Pressure Test, Reel Motor Efficiency/Case Drain Test, Mow
Control Manifold Relief Pressure Test, and/or Gear
Pump (P1) Test.
If a steering or lift/sidewinder circuit problem exists, consider performing one or more of the following tests: Gear
Pump (P2) Flow Test, Relief Valve Pressure Test, and/or
Steering Control Valve and Steering Cylinder Test.
Page 4 − 32
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 33
Hydraulic System
Traction Circuit Testing − Charge Pressure Test
FRONT
FRONT
FORWARD
REAR
TRACTION WHEEL MOTORS
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
BYPASS
VALVE
LOWER
PORT
G2
UPPER
PORT
G1
3500 PSI
TEE CONNECTOR
AND
PRESSURE GUAGE
200−300
PSI
C2
FROM LIFT CONTROL
MANIFOLD (T) PORT
100−150 PSI
CHARGE RELIEF
HYDROSTAT
TO MOW CONTROL
MANIFOLD (P) PORT
P1
TO STEERING CONTROL
VALVE (P) PORT
P2
GEAR PUMP
SUCTION
STRAINER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 34
Reelmaster 3550−D
Traction Circuit Testing − Charge Pressure Test:
The charge pressure test is the first in a series of tests
recommended to determine traction circuit performance. A charge pressure drop of more than 20% indicates an internal leak in the piston pump/hydrostat.
Continued unit operation can generate excessive heat,
cause damage to seals and other components in the hydraulic system, and affect overall machine performance.
2
1
Special Equipment Required:
Figure 25
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
1.
Hydraulic tee fitting
2.
Piston pump
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and the reel engage/disengage switch is in the
disengage position. Make sure engine is off and the
parking brake is engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Make sure that traction pedal is adjusted to the neutral position.
4. Disconnect the upper hose at the tee fitting on the
piston pump/hydrostat. This hose comes from the steering control valve (T) port (Fig. 25).
5. Install a T−connector and pressure gauge between
the fitting and disconnected hose.
6. Disconnect hose from the lower hydraulic fitting on
the engine side of the hydrostat (Fig. 26).
7. Install tester in series with the pump and the disconnected hose. Make sure the tester flow control valve is
fully open.
8. Attach a heavy chain to the rear of the machine frame
and an immovable object to prevent the machine from
moving during testing.
9. Chock the wheels to prevent wheel rotation during
testing.
10.Start engine. Move throttle to full speed (3220 + 50
RPM).
11. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
12.Verify with a phototach that the pump speed is approximately 3090 RPM.
Reelmaster 3550−D
Hydraulic
System
2
1
Figure 26
1.
Lower hydraulic fitting
2.
Piston pump
13.Record reading on pressure gauge from the lift control manifold (T) port. Charge pressure (without load)
should read from 150 to 200 PSI (10.3 to13.8 Bar). If
charge relief pressure specification is not met, consider
the following:
A. Gear pump (P2) is faulty (steering/lift circuit performance will also be affected). Test gear pump (P2)
flow (see Gear Pump (P2) Flow Test in this chapter).
B. The piston pump charge relief valve is faulty. Repair or replace the piston pump charge relief valve
(see Piston Pump Service in this chapter).
14.Sit in the operator’s seat, release the parking brake,
and slowly depress the forward traction pedal until 1000
to 1500 PSI (68.9 to 103.4 Bar) is reached on the flow
meter pressure gauge.
15.Record reading on pressure gauge from lift control
manifold (T) port (under load). Charge pressure (under
load) should not drop more than 20% when compared
to charge pressure (without load) recorded in step 13.
If specifications are not met, perform Piston Pump/Hydrostat Flow and Traction Relief Pressure Test as outlined in this chapter.
16.Release traction pedal, move throttle to low speed
and turn the engine off.
Page 4 − 35
Hydraulic System
Traction Unit Testing − Wheel Motor Efficiency Tests
FRONT WHEEL MOTOR TEST
(together)
FRONT WHEEL MOTOR TEST
(individually)
FRONT
FRONT
FRONT
FRONT
REAR
FORWARD
FORWARD
REAR
TRACTION WHEEL MOTORS
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
BYPASS
VALVE
LOWER
PORT
G2
TRACTION WHEEL MOTORS
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
UPPER
PORT
G1
PISTON PUMP
(HYDROSTAT)
LOWER PORT
PISTON PUMP
(HYDROSTAT)
UPPER PORT
3500 PSI
REAR WHEEL MOTOR TEST
200−300
PSI
FRONT
C2
FRONT
FORWARD
REAR
100−150 PSI
CHARGE RELIEF
TRACTION WHEEL MOTORS
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
HYDROSTAT
FROM
LIFT
CONTROL
MANIFOLD
(T) PORT
TO GEAR PUMP
SUCTION
THROUGH
CASE DRAIN
PISTON PUMP
(HYDROSTAT)
LOWER PORT
PISTON PUMP
(HYDROSTAT)
UPPER PORT
High Pressure
Low Pressure
Return or Suction
Flow
Figure 27
Hydraulic System
Page 4 − 36
Reelmaster 3550−D
Traction Circuit Testing − Wheel Motor Efficiency
Test:
There are moments during wheel motor operation (geroller position) when fluid flow through the motor is less
restricted. If a wheel motor is tested in this position, the
test results will be higher should not be used to determine wheel motor efficiency. Test wheel motors in three
(3) different wheel positions to obtain accurate test results. Record test readings for all three (3) wheel positions.
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). In this configuration, the rear wheel motor can
mask front wheel motor performance issues, and the
front wheel motors can mask rear wheel motor performance issues. Start by testing both front wheel motors together, then individually if necessary. Finish by testing
the rear wheel motor.
Special Equipment Required:
S Pressure Gauge
2
1
Figure 28
1. Lower hydraulic fitting
2. Piston pump
Front Wheel Motor Test:s
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). To accurately test the front wheel motors, the
rear wheel motor must be removed from the traction circuit.
1. Disconnect hose from the lower hydraulic fitting on
the bottom of the hydrostat (Fig. 28).
NOTE: An alternate testing location would be at the hydraulic hose from the hydrostat and the hydraulic tube
supplying the front wheel motors under the left floor
plate.
2. Install flow tester between the hydrostat and the disconnected hose. Make sure the tester flow control valve
is fully open.
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity
3. Disconnect both hydraulic lines from the rear wheel
motor, then reconnect the lines to each other. Plug ports
in wheel motor to prevent contamination.
S Phototach (non−contact tachometer)
4. Chock front wheels to prevent wheel rotation.
1. Park machine on a level surface with the cutting units
lowered and the reel engage/disengage switch is in the
disengage position. The engine should be off and the
parking brake engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
5. Start engine. Move throttle to full speed (3220 + 50
RPM).
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
3. Make sure that traction pedal is adjusted to the neutral position.
4. Attach a heavy chain to the rear of the machine frame
and an immovable object to prevent the machine from
moving during testing.
Reelmaster 3550−D
Page 4 − 37
Hydraulic System
Hydraulic
System
Wheel motor efficiency is the second in a series of tests
recommended to determine traction circuit performance. Hydraulic fluid flow of 1.5 GPM (5.7 LPM) or more
through a stationary wheel motor under load indicates
an internal leak in the wheel motor. A worn wheel motor
is less efficient. Eventually, enough fluid by−pass will
cause the wheel motor to stall under heavy load conditions. Continued operation can generate excessive
heat, cause damage to seals and other components in
the hydraulic system, and affect overall machine performance.
7. Verify with a phototach that the pump speed is approximately 3090 RPM.
Flow meter should read less than 1.5 GPM (5.7
LPM).
17.Release traction pedal, shut engine off, and record
test results.
CAUTION
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
8. Sit in the operators seat, release the parking brake,
and set the Mow/Transport slide to the transport position.
18.Rotate front wheel 120 degrees and retest. Repeat
this procedure until wheel motor has been tested in
three (3) different positions.
19.Reconnect hydraulic lines to front wheel motor and
repeat procedure for remaining front wheel motor.
20.If specifications are not met, repair or replace worn
wheel motor.
9. Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
Flow meter should read less than 1.5 GPM (5.7
LPM).
10.Release traction pedal, shut engine off, and record
test results.
11. Rotate each front wheel 120 degrees and retest. Repeat this procedure until each wheel motor has been
tested in three (3) different positions.
Proceed to testing rear wheel motor If test results are
within specification. If specifications are not met, test
front wheel motors individually as follows:
12.Disconnect hydraulic lines from front wheel motor
that is not being tested. Cap disconnected hydraulic
lines and plug ports in wheel motor to prevent contamination.
13.Chock front wheel being tested to prevent wheel rotation.
14.Start engine. Move throttle to full speed.
CAUTION
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
15.Sit in the operators seat, release the parking brake,
and set the Mow/Transport slide to the transport position.
16.Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
Hydraulic System
Page 4 − 38
Reelmaster 3550−D
Rear Wheel Motor Test:
3. Raise off the floor and support both front wheels.
Hydraulic fluid flows through both front wheel motors (in
parallel) before passing through the rear wheel motor (in
series). To accurately test the rear wheel motor, the front
wheel motors must be allowed to rotate.
4. Chock rear wheel to prevent wheel rotation.
5. Start engine. Move throttle to full speed.
CAUTION
1. Disconnect hose from the upper hydraulic fitting of
the rear wheel motor (Fig. 29).
Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move
the machine forward.
RIGHT
FRONT
6. Sit in the operators seat, release the parking brake,
and set the Mow/Transport slide to the transport position.
7. Slowly depress forward traction pedal until 1000 to
1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge.
Flow meter should read less than 1.5 GPM (5.7
LPM).
1
8. Release traction pedal, shut engine off, and record
test results.
Figure 29
1. Rear wheel motor
2. Upper fitting
2. Install flow tester between the disconnected hydraulic hose and the rear wheel motor. Make sure the tester
flow control valve is fully open.
9. Rotate rear wheel 120 degrees and retest. Repeat
this procedure until wheel motor has been tested in
three (3) different positions.
10.If specifications are not met, repair or replace worn
wheel motor.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
Reelmaster 3550−D
Page 4 − 39
Hydraulic System
Hydraulic
System
2
Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test
FRONT
FRONT
FORWARD
REAR
TRACTION WHEEL MOTORS
TESTER WITH
PRESSURE GUAGE
AND FLOW METER
BYPASS
VALVE
LOWER
PORT
G2
UPPER
PORT
G1
3500 PSI
200−300
PSI
C2
FROM LIFT CONTROL
MANIFOLD (T) PORT
100−150 PSI
CHARGE RELIEF
HYDROSTAT
TO MOW CONTROL
MANIFOLD (P) PORT
P1
TO STEERING CONTROL
VALVE (P) PORT
P2
GEAR PUMP
SUCTION
STRAINER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 40
Reelmaster 3550−D
Traction Circuit Testing − Piston Pump/Hydrostat
Flow and Relief Pressure Test:
The hydrostat flow test is the third in a series of tests recommended to determine traction circuit performance.
The final traction circuit test is verifying the hydrostat relief valve operation. This test compares fluid flow at No
Load with fluid flow Under Load. A drop in flow under
load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat. A
worn hydrostat or malfunctioning relief valve is less efficient. Eventually, enough fluid by−pass will cause the
unit to stall under heavy load conditions. Continued operation can generate excessive heat, cause damage to
seals and other components in the hydraulic system,
and affect overall machine performance.
Special Equipment Required:
2
1
Figure 30
1.
Lower hydraulic fitting
2.
Piston pump
10.Sit in the operator’s seat, release the parking brake,
and set the Mow/Transport slide to the transport position.
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
1. Park machine on a level surface with the cutting units
lowered and the reel engage/disengage switch in the
disengage position. The engine should be off and the
parking brake engaged.
Use extreme caution when performing hydrostat
flow tests. The traction unit wheels will be rotating during the test.
11. Verify pump flow at No Load as follows:
2. Read Precautions for Hydraulic Testing in this
chapter.
A. Slowly depress forward traction pedal to full forward position.
3. Make sure that traction pedal is adjusted to the neutral position.
B. Record tester pressure and flow readings. Unrestricted pump output should be approximately 18
GPM (69 LPM) at 650 PSI (44.8 Bar).
WARNING
12. Verify pump flow Under Load as follows:
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
4. Raise off the floor and support both front wheels and
the rear wheel.
5. Disconnect hose from the lower hydraulic fitting on
the engine side of the hydrostat (Fig. 30).
6. Install tester in series with the pump and the disconnected hose. Make sure the tester flow control valve is
fully open.
7. Start engine. Move throttle to full speed (3220 + 50
RPM).
A. Slowly depress forward traction pedal to full forward position.
B. Apply an additional load of 1000 to 1500 PSI
(68.9 to 103.4 Bar) by slowly closing the flow meter.
The flow meter pressure gauge should read 1700 to
2100 PSI (117.2 to 144.8 Bar).
C. Record tester pressure and flow readings.
13.Verify traction relief valve operation as follows:
A. Return the traction pedal to neutral.
B. Fully close the flow meter flow control valve.
C. Slowly set traction pedal to full forward position.
8. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
9. Verify with a phototach that the pump speed is approximately 3090 RPM.
Reelmaster 3550−D
D. Record tester pressure reading.
System pressure should reach 3600 to 3650 PSI
(248 to 251 Bar) before the relief valve opens.
Page 4 − 41
Hydraulic System
Hydraulic
System
S Phototach (non−contact tachometer).
CAUTION
NOTE: The relief valve setting is 3500 PSI (241
Bar). An additional 100 to 200 PSI (6.9 to 10.3 Bar)
is necessary to overcome system charge pressure
before the relief valve opens.
E. Release traction pedal, open flow control valve
fully, move throttle to low speed and turn the engine
off.
14.If relief pressure can not be met or is greater than
specified, the traction relief valve is faulty and should be
replaced.
Hydraulic System
15.The Under Load test flow reading (step 12.) should
not drop more than 12% when compared to the No
Load test flow reading (step 11.). A difference of more
than 12% may indicate:
A. The traction belt is worn and/or slipping.
B. The piston pump/hydrostat is worn and should be
repaired or replaced.
16.Disconnect tester and reconnect hose to pump.
Page 4 − 42
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 43
Hydraulic System
Cutting Unit Circuit Testing − Pressure Test
REEL #4
REEL #1
M1
REEL #5
REEL #3
MOW CONTROL
MANIFOLD
M2
BACKLAP
REEL #2
MV
SWITCH
(SW)
CV1
OR2
.020”
OR1
.050”
FC
1500 PSI
RV
M3
LC
PRV
G
PRESSURE
GAUGE
3000 PSI
P
TO
HYDRAULIC
TANK
T
FROM
GEAR PUMP
(P1)
TO
OIL COOLER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 44
Reelmaster 3550−D
Cutting Unit Circuit Testing − Pressure Test:
Cutting unit circuit pressure is the first in a series of tests
recommended to check cutting unit circuit performance.
The results from this test will help determine which component(s) are the cause of cutting unit performance issues.
Special Equipment Required:
2
S Pressure Gauge with extension hose
S Phototach (non−contact tachometer).
1
1. Park machine on a level surface with the cutting units
lowered, the reel engage/disengage switch in the DISENGAGE position, and the mow/transport switch in the
MOW position. Make sure engine is off and the parking
brake is disengaged.
3. Read Precautions for Hydraulic Testing in this
chapter.
4. Remove cap from test fitting at mow control manifold
port (OR1/G) and install a pressure gauge with hydraulic
hose to the test fitting (Fig. 31).
CAUTION
Keep away from cutting units during test to prevent personal injury from the cutting blades.
5. Sit in the Operator’s seat, start the engine, and move
throttle to full speed (3220 + 50 RPM).
6. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
7. Verify with a phototach that the pump speed is approximately 3090 RPM.
8. Set the cutting unit speed control to #9 (maximum)
and engage the cutting units.
When engaged, the cutting circuit pressure may exceed
manifold relief valve pressure setting of 3000 PSI (207
Bar) momentarily opening the relief valve. Circuit pressure should then stabilize at approximately 1200 PSI
(83 Bar).
Reelmaster 3550−D
Figure 31
1.
Mow control manifold
2.
Test fitting (port OR1/G)
9. Safely secure the test pressure gauge and operate
the machine under your specific mowing conditions.
Monitor test gauge while mowing. Cutting unit circuit
pressure should be approximately: 1500 to 2000 PSI
(103 to 138 Bar) under low to normal load conditions.
10.Disengage cutting units, move throttle to low speed
and shut off engine.
11. If pressure readings are within specifications and
cutting unit performance is still in question, test cutting
unit motors individually (see Cutting Unit Circuit Testing
− Reel Motor Efficiency/Case Drain Test).
12.If pressure specifications are not met, consider the
following:
A. Proportional relief valve (PRV) is faulty (see Cutting Unit Circuit Testing − Proportional Relief Valve
(PRV) Pressure Test in this chapter).
B. Relief valve (RV) is faulty (see Cutting Unit Circuit
Testing − Relief Valve (RV) Pressure Test in this
chapter).
C. Logic Cartridge (LC) Is faulty (see Control Manifold Cartridge Valve Service in this chapter).
D. Gear pump (P1) is faulty (see Cutting Unit Circuit
Testing − Gear Pump (P1) Flow Under Load Test in
this chapter).
13.Disconnect test equipment from hydraulic manifold.
Page 4 − 45
Hydraulic System
Hydraulic
System
2. Make sure backlap knob on the hydraulic manifold is
in the MOW position. Make sure reel speed knob is set
for typical mowing conditions.
Cutting Unit Circuit Testing − Reel Motor Efficiency/Case Drain Test
REEL #4
REEL #1
REEL #5
REEL #2
REEL #3
TESTER
WITH
PRESSURE GAUGE
AND FLOW METER
TO
HYDRAULIC
TANK
TO
MOW CONTROL
MANIFOLD
PORT (M2)
FROM
MOW CONTROL
MANIFOLD
PORT (M1)
MEASURING
CONTAINER
TO
MOW CONTROL
MANIFOLD
PORT (M3)
NOTE: CONFIGURATION FOR TESTING REEL MOTOR #4 SHOWN
High Pressure
Low Pressure
Return or Suction
Flow
CUTTING UNIT LOCATIONS
1
1
2
Toro # TOR4077
#1
#4
#2
FRONT 1
1. Reel motor location
Hydraulic System
Page 4 − 46
1
2
#5
#3
2
1
2. Weight location
Reelmaster 3550−D
The reel motor efficiency/case drain test is the second
in a series of tests recommended to check cutting unit
circuit performance. Over a period of time, a reel motor
can wear internally. This test measures case drain
volume while restricting flow across the motor ports.
Case drain volume under load of more than 9% of total
motor flow indicates the gears and wear plates in the
motor have worn. A worn motor may by−pass hydraulic
fluid to its case drain causing the motor to be less efficient. Eventually, enough fluid loss will cause the reel
motor to stall under heavy cutting conditions. Continued
operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system, and affect quality of cut.
NOTE: One method to find a failing or malfunctioning
cutting unit motor is to have another person observe the
machine while mowing in dense turf. A bad motor will run
slower, produce fewer clippings and may cause a different appearance on the turf.
Special Equipment Required:
6. Install hydraulic tester between the motor and the
disconnected return hose. Make sure the tester flow
control valve is fully open.
7. Make sure backlap knob on the hydraulic manifold is
in the MOW position and reel speed is set to maximum.
8. Disconnect hose from reel motor case drain at the
hydraulic tube (#1 cutting unit), or from the bulkhead fitting (#2, 3, 4, & 5 cutting units). Cap the hydraulic tube
or bulkhead fitting to prevent system contamination.
9. Place open end of disconnected case drain hose into
a drain pan.
10.Two people are required to complete the following
steps. One person should sit in the operator’s seat and
operate the machine while another person reads the
tester and measures reel motor case drain volume.
11. Start the engine, and move throttle to full speed
(3220 + 50 RPM).
12.Verify with a phototach that the pump speed is approximately 3090 RPM.
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
CAUTION
S Phototach (non−contact tachometer).
1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes. Make sure the hydraulic tank is full.
Keep away from reels during test to prevent personal injury from the rotating reel blades.
2. Park the machine on a level surface with the cutting
units lowered and the reel enable/disable switch in the
disable position. Make sure engine is off and the parking
brake is disengaged.
13.Engage cutting units and slowly close tester flow
control valve until 1200 PSI (82.7 Bar) is obtained.
3. Read Precautions for Hydraulic Testing in this
chapter.
4. Make sure that traction pedal is adjusted to the neutral position.
NOTE: The cutting unit motors are connected in series.
If a faulty reel motor is not obvious (based on quality of
cut issues) you may have to test all the reel motors in the
circuit. If testing all reel motors, start with the first motor
in the series (#4 cutting unit).
5. Hydraulic oil passes through each reel motor from
the front to the rear. Disconnect the return hose from the
motor (hose at the rear of the reel motor).
14.Hold disconnected motor case drain hose into a container graduated in ounces or milliliters (e.g. Toro
#TOR4077) and collect hydraulic fluid for 30 seconds.
After 30 seconds, remove hose end from container.
15.Record amount of fluid collected in the container.
16.Disengage cutting units, set throttle to low speed,
and stop engine.
17.If volume is more than 43 oz (1265 milliliters), repair
or replace the tested reel motor.
18.Remove tester and reconnect hydraulic hoses.
19.Check hydraulic fluid level (see Traction Unit Operator’s Manual).
20.Repeat test for remaining reel motors as needed.
Reelmaster 3550−D
Page 4 − 47
Hydraulic System
Hydraulic
System
Cutting Unit Circuit Testing − Reel Motor Efficiency/
Case Drain Test
Cutting Unit Circuit Testing − Proportional Relief Valve (PRV) Pressure Test
REEL #4
REEL #1
REEL #5
REEL #2
REEL #3
TESTER
WITH
PRESSURE GAUGE
AND FLOW METER
M1
MOW CONTROL MANIFOLD
M2
BACKLAP
MV
SWITCH
(SW)
CV1
OR1
.050”
FC
OR2
.020”
1500 PSI
RV
M3
LC
PRV
G
3000 PSI
P
TO
HYDRAULIC
TANK
T
FROM
GEAR PUMP
(P1)
TO
OIL COOLER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 48
Reelmaster 3550−D
Cutting Unit Circuit Testing − Proportional Relief
Valve (PRV) Pressure Test:
2
Test the performance of the mow control manifold proportional relief valve (PRV) to make sure that the maximum amount of fluid is available to the cutting unit motors
up to the set relief pressure. This test also ensures that
pump (P1) is capable of generating enough pressure to
open a properly functioning proportional relief valve.
Special Equipment Required:
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
1
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered, reel engage/disengage switch in the disengage position, and the mow/transport switch in the
MOW position. Engine should be off and the parking
brake disengaged.
Figure 32
1.
Mow control manifold
2.
3. Disconnect the inlet hose from the front hydraulic fitting of the front left (#4) reel motor (Fig. 33).
1
2
4. Install tester between the hose and hydraulic fitting.
Make sure the flow control valve on tester is fully open.
Proportional relief valve
(PRV)
Hydraulic
System
2. Read Precautions for Hydraulic Testing in this
chapter.
#4
#1
#5
5. Make sure backlap knob on the hydraulic manifold is
in the MOW position, and the reel speed knob is set to
maximum.
6. Start the engine, and move throttle to full speed
(3220 + 50 RPM).
FRONT
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
#2
#3
8. Verify with a phototach that the pump speed is approximately 3090 RPM.
Figure 33
1. Reel motor #4
CAUTION
Keep away from reels during test to prevent personal injury from the rotating reel blades.
9. Engage cutting units.
2. Inlet hose
13.If specification is met, test pump (P1) flow (see Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test in
this chapter) If specification is not met, test relief valve
(PRV) solenoid, clean or replace valve (see Hydraulic
Manifold Service in this chapter) and retest.
14.Disconnect tester and reconnect hydraulic hose.
10.Watch pressure gauge carefully while slowly closing
the flow control valve.
11. System pressure should reach 3000 PSI (207 Bar)
before the relief valve opens.
12.Set throttle to low speed and shut off engine.
Reelmaster 3550−D
Page 4 − 49
Hydraulic System
Cutting Unit Circuit Testing − Mow Control Manifold Relief Valve (RV) Pressure Test
REEL #4
REEL #1
TESTER
REEL #2
WITH
PRESSURE GAUGE
AND FLOW METER
REEL #5
M1
MOW CONTROL MANIFOLD
M2
BACKLAP
REEL #3
MV
SWITCH
(SW)
CV1
OR2
.020”
OR1
.050”
FC
1500 PSI
RV
M3
LC
PRV
G
3000 PSI
P
TO
HYDRAULIC
TANK
T
FROM
GEAR PUMP
(P1)
TO
OIL COOLER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 50
Reelmaster 3550−D
Cutting Unit Circuit Testing − Mow Control Manifold
Relief Valve (RV) Pressure Test:
#4
If a rear cutting unit suddenly becomes obstructed during operation, mow control manifold relief valve (RV)
protects the obstructed cutting unit from additional damage by diverting the oil flow from the front cutting units.
Test the performance of the mow control manifold relief
valve (RV) to make sure that the relief valve opens at the
specified pressure.
#1
#5
Special Equipment Required:
#2
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
#3
1
S Phototach (non−contact tachometer).
FRONT
1. Park machine on a level surface with the cutting units
lowered, reel engage/disengage switch in the disengage position, and the mow/transport switch in the
MOW position. Engine should be off and the parking
brake disengaged.
2
Figure 34
1. Reel motor #2
inlet hose
2. Frame bulkhead fitting
Hydraulic
System
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect the inlet hose for the rear left (cutting unit
#2) reel motor at the frame bulkhead fitting (Fig. 34).
4. Install tester between the disconnected hydraulic
hose and the bulkhead fitting. Make sure the tester flow
direction is from the bulkhead fitting toward the reel motor, and that the tester flow control valve is fully open.
5. Make sure backlap knob on the hydraulic manifold is
in the MOW position, and the reel speed knob is set to
maximum.
1
6. Start the engine, and move throttle to full speed
(3220 + 50 RPM).
2
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
8. Verify with a phototach that the pump speed is approximately 3090 RPM.
CAUTION
Mow control manifold
2.
Relief valve (RV)
11. System pressure should reach 1500 PSI (103.4 Bar)
before the relief valve opens.
12.Set throttle to low speed and shut off engine.
Keep away from reels during test to prevent personal injury from the rotating reel blades.
9. Engage cutting units.
10.Watch pressure gauge carefully while slowly closing
the flow control valve.
Reelmaster 3550−D
Figure 35
1.
13.If specification is met, test pump (P1) flow (see Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test in
this chapter) If specification is not met, adjust relief valve
(RV) (see Adjustments in this chapter) and retest. If specification is still not met, clean or replace relief valve
(RV) (see Hydraulic Manifold Service in this chapter)
and retest.
14.Disconnect tester and reconnect hydraulic hoses.
Page 4 − 51
Hydraulic System
Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test
BYPASS
VALVE
G2
G1
3500 PSI
200−300
PSI
FROM LIFT CONTROL
MANIFOLD (T) PORT
C2
100−150 PSI
CHARGE RELIEF
HYDROSTAT
HYDROSTAT
TO MOW CONTROL
MANIFOLD (P) PORT
P1
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
TO STEERING CONTROL
VALVE (P) PORT
High Pressure
P2
SUCTION
STRAINER
GEAR PUMP
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 52
Reelmaster 3550−D
Cutting Unit Circuit Testing − Gear Pump (P1) Flow
Test:
2
The gear pump (P1) flow test is the last in a series of
tests recommended to determine cutting unit circuit performance. This test compares fluid flow at No Load with
fluid flow Under Load. A drop in flow under load of more
than 15% indicates the gears and wear plates in the
pump have worn. A worn pump will by−pass hydraulic
fluid and make the pump less efficient. Eventually,
enough fluid loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued
operation with a worn, inefficient pump can generate excessive heat and cause damage to the seals and other
components in the hydraulic system.
RIGHT
FRONT
1
P2
P1
Special Equipment Required:
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and reel enable/disable switch in the disengage
position. Make sure engine is off and the parking brake
is engaged.
Figure 36
1.
Gear pump assembly
2.
To mow control manifold
(P) port
10.Verify pump flow Under Load as follows:
CAUTION
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect hose connection on the gear pump (P1)
leading to port (P) on the mow control manifold (Fig. 36).
4. Install tester between the gear pump and the disconnected hose.
5. Make sure the flow control valve on the tester is fully
open.
6. Sit in the operator’s seat and start the engine. Move
the throttle to full speed (3220 + 50 RPM).
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
8. Verify with a phototach that the pump speed is approximately 3090 RPM.
9. Verify pump flow at No Load as follows:
Record tester pressure and flow reading at no load.
Unrestricted pump output should be approximately
7.3 GPM (29.3 LPM).
Do not close tester valve fully when performing this test. In this test, the hydraulic tester is
positioned before the manifold relief valve.
Pump damage can occur if the fluid flow is fully
restricted by fully closing the tester flow control valve.
A. Watch flow meter pressure gauge carefully while
slowly closing the flow control valve until 2000 PSI
(137.9 Bar) is obtained on gauge.
B. Record tester pressure and flow readings under
load.
11. Set throttle to low speed and shut off engine.
12.The under load test flow reading (step 10.B) should
not drop more than 15% when compared to no load test
flow reading (step 9.A). A difference in flow of more than
15%, or the inability to achieve specified pressure may
indicate:
A. A restriction in the pump intake line
B. A Worn and/or slipping traction belt
C. The gear pump (P1) is worn and should be repaired or replaced
13.Disconnect tester and reconnect hose to pump.
Reelmaster 3550−D
Page 4 − 53
Hydraulic System
Hydraulic
System
S Flow Meter with Pressure Gauge that has at least
a 12 GPM (45 LPM) capacity.
Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test
BYPASS
VALVE
G2
G1
3500 PSI
200−300
PSI
FROM LIFT CONTROL
MANIFOLD (T) PORT
C2
100−150 PSI
CHARGE RELIEF
HYDROSTAT
TO MOW CONTROL
MANIFOLD (P) PORT
P1
TO STEERING CONTROL
VALVE (P) PORT
P2
High Pressure
TESTER
WITH PRESSURE GAUGES
AND FLOW METER
SUCTION
STRAINER
GEAR PUMP
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 54
Reelmaster 3550−D
Steering/Lift Circuit Testing − Gear Pump (P2) Flow
Test:
2
Gear pump (P2) is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full
speed throttle). The Gear Pump (P2) Flow Test compares fluid flow at No Load with fluid flow Under Load.
A drop in flow under load of more than 15% indicates the
gears and wear plates in the pump have worn. Continued operation with a worn pump can generate excessive heat and cause damage to the seals and other
components in the hydraulic system.
RIGHT
FRONT
P2
P1
1
If unit steering is sluggish or otherwise performs poorly,
see Steering/Lift Circuit − Steering Control Valve and
Steering Cylinder Test in this chapter.
If both steering and lift operations perform poorly, perform the gear pump (P2) flow test and circuit relief valve
pressure test (see Steering/Lift Circuit − Relief Valve
Pressure Test in this chapter).
Figure 37
1.
Gear pump assembly
2.
To steering control valve
(P) port
9. Verify pump flow at No Load as follows:
Record tester pressure and flow readings at no load.
Unrestricted pump output should be approximately
4.2 GPM (15.8 LPM).
10.Verify pump flow Under Load as follows:
Special Equipment Required:
S Flow Meter with Pressure Gauge that has at least
a 5 GPM (16 LPM) capacity.
CAUTION
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and reel enable/disable switch in the disable
position. The engine should be off and the parking brake
engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect hose connection on the gear pump (P2)
leading to the steering control valve (P) port (Fig. 37).
4. Install tester between gear pump and the disconnected hose.
5. Make sure the flow control valve on the tester is fully
open.
6. Sit in the operator’s seat and start the engine. Move
the throttle to full speed (3220 + 50 RPM).
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
Do not close tester valve fully when performing this test. In this test, the hydraulic tester is
positioned before the manifold relief valve.
Pump damage can occur if the fluid flow is fully
restricted by fully closing the tester flow control valve.
A. Watch pressure gauge carefully while slowly
closing the flow control valve until 800 PSI (55.2 Bar)
is obtained on gauge.
B. Record tester pressure and flow readings under
load.
11. Set throttle to low speed and shut off engine.
12.The under load test flow reading (step 10.B) should
not drop more than 15% when compared to the no load
test flow reading (step 9.A). A difference in flow of more
than 15%, or the inability to achieve specified pressure
may indicate:
A. A restriction in the pump intake line
8. Verify with a phototach that the pump speed is approximately 3090 RPM.
B. A Worn and/or slipping drive belt
C. The gear pump (P1) is worn and should be repaired or replaced
Reelmaster 3550−D
Page 4 − 55
Hydraulic System
Hydraulic
System
If cutting unit lift operation is unsatisfactory, check lift
control manifold solenoid valves and/or lift cylinders.
Additional information on these components is available
in this chapter.
13.Disconnect tester and reconnect hose to pump.
NOTE: If necessary, circuit relief valve pressure test
can be conducted with tester in the same location as for
this test (see Steering/Lift Circuit − Relief Valve Pressure Test in this chapter).
Hydraulic System
Page 4 − 56
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 57
Hydraulic System
Steering/Lift Circuit Testing − Relief Valve Pressure Test
STEERING
CYLINDER
L
R
STEERING
CONTROL
VALVE
TEST
GAUGE
1000 PSI
P
T
FROM
LIFT CONTROL
MANIFOLD
(T) PORT
E
TO
LIFT CONTROL
MANIFOLD
(P) PORT
C2
TO
MOW CONTROL
MANIFOLD
(P) PORT
HYDROSTAT
100−150 PSI
CHARGE RELIEF
P2
P1
200−300
PSI
GEAR PUMP
SUCTION
STRAINER
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 58
Reelmaster 3550−D
Steering/Lift Circuit Testing − Relief Valve Pressure
Test:
2
The relief valve for the steering and lift circuits is integrated into the steering control valve. If both steering and
lift operations perform poorly, perform the relief valve
pressure test and gear pump (P2) flow test (see Steering/Lift Circuit − Gear Pump (P2) Flow Test in this
chapter).
RIGHT
FRONT
P2
P1
NOTE: If available, using a flow meter with pressure
gauge that has at least a 5 GPM (16 LPM) capacity instead of a pressure gauge (as described in this test) will
allow performing the relief valve test and the pump (P2)
flow test with the same test configuration (see Steering/
Lift Circuit − Gear Pump (P2) Flow Test in this chapter.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Disconnect hose connection on gear pump (P2)
leading to the steering control valve (Fig. 38).
4. Install T−connector with test gauge between the
gear pump and the disconnected hose.
Figure 38
1.
Gear pump assembly
2.
To steering control valve
9. System pressure should reach 940 to 1015 PSI (65
to 70 Bar) as the relief valve opens.
10.Return steering wheel to the center position and shut
off engine.
11. If specification is not met, repair or replace steering
control valve.
12.Disconnect T−connector with test gauge and reconnect hydraulic hose to gear pump.
5. Make sure steering wheel is positioned so the rear
wheel points directly ahead.
6. Start the engine, and move throttle to full speed
(3220 + 50 RPM).
7. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
8. Watch pressure gauge carefully while turning the
steering wheel completely in one direction and holding.
CAUTION
Do not allow pressure to exceed 1500 PSI. Hold
steering wheel at full lock only long enough to
get a system pressure reading. Holding the
steering wheel against the stop for an extended period may damage the steering control valve.
Reelmaster 3550−D
Page 4 − 59
Hydraulic System
Hydraulic
System
1. Park machine on a level surface with the cutting units
lowered and reel engage/disengage switch in the disengage position. Make sure engine is off and the parking
brake is engaged.
1
Steering/Lift Circuit Testing − Steering Control Valve and Steering Cylinder Test
STEERING
CYLINDER
OPEN FITTING
PLUG
L
R
STEERING
CONTROL
VALVE
1000 PSI
P
T
E
TO
LIFT CONTROL
MANIFOLD
(P) PORT
High Pressure
Low Pressure
Return or Suction
Flow
Hydraulic System
Page 4 − 60
Reelmaster 3550−D
Unit steering performance will be affected by incorrect
rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the
steering fork assembly. Make sure that these conditions
are checked and functioning properly before proceeding
with any steering system hydraulic testing.
1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10
minutes.
2. Drive machine slowly in a figure eight on a flat level
surface.
A. There should be no shaking or vibration in the
steering wheel or rear wheel.
B. Steering wheel movements should be followed
immediately by a corresponding rear wheel movement without the steering wheel continuing to turn.
3. Stop unit with the engine running. Turn steering
wheel with small quick movements in both directions.
Let go of the steering wheel after each movement. The
steering control valve should respond to each steering
wheel movement.
4. If either of these performance tests indicate a steering problem, determine if the steering cylinder is faulty
using the following procedure.
A. Park machine on a level surface with the cutting
units lowered, reel enable/disable switch in the disable position, and the parking brake engaged.
B. With the engine running, turn the steering wheel
to the left (counterclockwise) until the steering cylinder rod is fully extended and turn the engine off.
C. Read Precautions for Hydraulic Testing in this
chapter.
D. Remove hydraulic hose from the fitting on the rod
end of the steering cylinder. Plug the end of the hose
removed.
E. With the engine off, continue turning the steering
wheel to the left (counterclockwise) with the steering
cylinder fully extended. Observe the open fitting on
the steering cylinder as the wheel is turned. If hydraulic fluid comes out of the fitting while turning the
steering wheel to the left, the steering cylinder has internal leakage and must be repaired or replaced.
F. Remove plug from the hydraulic hose and reconnect the hose.
5. If steering problem exists and steering cylinder
passed test, perform the Gear Pump (P2) Flow Test and
Circuit Relief Valve Pressure Test (see specific test procedures in this chapter) to make sure the steering control valve and cylinder are receiving adequate fluid flow
and pressure. Based on the results of these tests, repair
or replace steering control valve as necessary (see
Steering Control Valve and Steering Control Valve Service in this chapter).
Reelmaster 3550−D
Page 4 − 61
Hydraulic System
Hydraulic
System
Steering/Lift Circuit Testing − Steering Control
Valve and Steering Cylinder Test:
Adjustments
Adjust Control Manifold Relief Valves
The hydraulic control manifolds on your Reelmaster include adjustable relief valves (RV & RV1). Mow control
manifold relief valve RV should be set to 1500 PSI (103
Bar) and lift control manifold relief valve RV1 should be
set to 500 PSI (34.5 Bar). Adjust the relief valves to the
recommended settings as necessary.
NOTE: Do not remove relief valve from the hydraulic
manifold for adjustment.
1
1. Locate relief valve on control manifold.
2. Remove cap on relief valve with an allen wrench.
3. To increase pressure setting, turn the adjustment
socket on the valve in a clockwise direction. A 1/8 turn
on the socket will make a measurable change in relief
pressure.
2
4. To decrease pressure setting, turn the adjustment
socket on the valve in a counterclockwise direction. A
1/8 turn on the socket will make a measurable change
in relief pressure.
Figure 39
5. Install and tighten cap on relief valve.
1. Relief valve cap
2.
Adjustment socket
6. Recheck relief pressure and readjust as needed.
Hydraulic System
Page 4 − 62
Reelmaster 3550−D
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Before Repair or Replacement of Hydraulic Components
After Repair or Replacement of Hydraulic Components
1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
1. Check oil level in the hydraulic tank and add correct
oil if necessary. Drain and refill hydraulic tank and
change oil filter if component failure was severe or system is contaminated (see Flush Hydraulic System in this
section of this chapter).
CAUTION
Operate all hydraulic controls to relieve system
pressure and avoid injury from pressurized hydraulic oil. Controls must be operated with the
ignition switch in RUN and the engine OFF. Make
sure all electrically operated control valves are
actuated. Return ignition switch to OFF when
pressure has been relieved. Remove key from
the ignition switch.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent
system contamination.
2. Lubricate O−rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
5. After repairs, check control linkages or cables for
proper adjustment, binding or broken parts.
6. After disconnecting or replacing any hydraulic components, operate machine functions slowly until air is
out of system (see Charge Hydraulic System in this section of this chapter).
7. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in hydraulic tank
and add correct oil if necessary.
4. Put labels on disconnected hydraulic lines and
hoses for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when installing hydraulic hoses and tubes.
Reelmaster 3550−D
Page 4 − 63
Hydraulic System
Hydraulic
System
2. Clean machine before disconnecting, removing or
disassembling any hydraulic components. Make sure
hydraulic components, hoses connections and fittings
are cleaned thoroughly. Always keep in mind the need
for cleanliness when working on hydraulic equipment.
Check Hydraulic Lines and Hoses
IMPORTANT: Check hydraulic lines and hoses daily
for leaks, kinked lines, loose mounting supports,
wear, loose fittings or deterioration. Make all necessary repairs before operating the machine.
WARNING
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Priming Hydraulic Pumps
Whenever the hydraulic system is flushed, the hydraulic
system is charged or hydraulic components are removed, it is important to properly prime the hydraulic
pumps. Hydraulic pump priming ensures that the gear
pump and piston (traction) pump have adequate oil during initial start−up and running. The pumps can be
primed by using a remote starter switch (see Special
Tools in this chapter) to crank engine which allows the
pumps to prime.
3
2
1
Use the following procedure to prime the hydraulic
pumps:
1. Make sure that ignition switch is in the OFF position
and key is removed from switch.
2. Check hydraulic reservoir oil level and adjust if necessary.
NOTE: It may not be necessary to remove the wire from
the starter solenoid B+ terminal when connecting a remote starter switch.
Figure 40
1. Starter motor
2. Starter solenoid
3. B+ terminal
3. Connect remote starter switch electrical leads to the
starter motor solenoid B+ terminal (Fig. 40) and the positive (+) terminal at the starter or battery.
4. Engage remote starter switch and crank starter for
thirty (30) seconds to prime hydraulic pumps. Wait thirty
(30) seconds to allow the starter motor and starter
solenoid to cool. Repeat cranking procedure a second
time.
5. Disconnect remote starter switch leads from starter
motor solenoid terminal and positive post of the battery.
Hydraulic System
Page 4 − 64
Reelmaster 3550−D
Flush Hydraulic System
IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid to a biodegradable fluid such as Toro Biodegradable
Hydraulic Fluid. Operate machine under normal operating conditions for at least four (4) hours before
draining.
IMPORTANT: If a component failure occurred in the
traction circuit, refer to Traction Circuit (Closed
Loop) Component Failure in this chapter for information regarding the importance of removing contamination from the traction circuit.
1. Park machine on a level surface. Lower cutting units,
disengage reel enable/disable switch. stop engine, and
engage parking brake. Remove key from the ignition
switch.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing hydraulic fluid and filters.
6. Reconnect all hydraulic hoses, lines, and components that were disconnected while draining system.
NOTE: Use only hydraulic fluids specified (see Traction
Unit Owner’s Manual). Other fluids may cause system
damage.
7. Fill hydraulic tank with new hydraulic fluid.
8. Prime hydraulic pumps (see Priming Hydraulic
Pumps in this chapter).
9. Start engine and let it idle at low speed for a minimum
of 2 minutes. Increase engine speed to high speed for
a minimum of 1 minute under no load.
10.Raise and lower cutting units several times. Turn
steering wheel fully left and right several times.
11. Move reel enable/disable switch to ENABLE to engage cutting units and let them run for several minutes.
Move reel enable/disable switch to DISABLE.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved. See Relieving Hydraulic System Pressure in this chapter.
IMPORTANT: Make sure to clean around any hydraulic connections that will be disassembled.
2. Drain hydraulic tank.
3. Drain hydraulic system. Drain all hoses, tubes, and
components while the system is warm.
4. Change and replace hydraulic fluid filter.
12.Shut off engine and check for hydraulic fluid leaks.
Check fluid level in hydraulic tank and add correct
amount of hydraulic fluid if necessary.
13.Operate the machine for 2 hours under normal operating conditions.
14.Check condition of hydraulic fluid. If the new fluid
shows any signs of contamination, repeat steps 1
through 14 again until fluid is clean. If changing to biodegradable fluid, repeat steps 1 through 14 again at least
once and until the fluid is clean.
15.Assume normal operation and follow recommended
maintenance intervals.
5. Inspect and clean hydraulic fluid tank (see Hydraulic
Tank Inspection in this chapter).
Reelmaster 3550−D
Page 4 − 65
Hydraulic System
Hydraulic
System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or if the system
is contaminated (fluid appears milky, black, or contains metal particles).
Filtering Closed−Loop Traction Circuit
Filtering of a closed−loop hydraulic system after a major
component failure (e.g. traction (piston) pump or wheel
motor) is a requirement to prevent debris from transmitting throughout the system. If a closed−loop hydraulic
system filtering tool is not used (to ensure system cleanliness) repeat failures and subsequent damage to other
hydraulic components in the system will occur. To effectively remove contamination from closed−loop traction
circuit, use of the Toro high flow hydraulic filter and hydraulic hose kit are recommended (see Special Tools in
this chapter).
1. Park machine on a level surface, stop engine and remove key from ignition switch.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Raise and support machine so all wheels are off the
ground.
NOTE: If a wheel motor was replaced, install high flow
filter to the inlet (when traveling forward) of new wheel
motor instead of to the inlet (when traveling forward) of
the traction pump. This will prevent system contamination from entering and damaging the new motor.
3. Thoroughly clean junction of hydraulic hose and
lower fitting on rear wheel motor (Fig. 41). Disconnect
hose from lower fitting on wheel motor.
4. Connect Toro high flow hydraulic filter in series between wheel motor fitting and disconnected hose. Use
hydraulic hose kit (see Special Tools in this chapter) to
connect filter to machine. Make sure that fitting and hose
connections are properly tightened.
7. With engine running at low idle speed, slowly depress the forward traction pedal to the full forward position to allow flow through the traction circuit and high
flow filter. Keep traction circuit engaged for five (5) minutes while gradually increasing both forward pressure
on traction pedal and engine speed. Monitor filter indicator to make sure that green color is showing during operation.
8. With engine running at high idle speed and traction
pedal moved to the forward direction, periodically apply
brakes to increase pressure in traction circuit. While
monitoring filter indicator, continue this process for an
additional five (5) minutes.
IMPORTANT: If using a filter that is not the bi−directional Toro high flow filter, do not press the traction
pedal in the reverse direction. If flow is reversed
when using a filter that is not bi−directional, debris
from the filter will re−enter the traction circuit.
9. With engine running at high idle speed, alternately
move traction pedal from forward to reverse. While monitoring filter indicator, continue this process for an additional five (5) minutes.
10.Shut engine off and remove key from ignition switch.
11. Remove high flow hydraulic filter and hydraulic hose
kit from machine. Reconnect hydraulic hose to rear
wheel motor fitting. Make sure to properly tighten hose
(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
12.Lower machine to ground.
13.Check oil level in hydraulic reservoir and add correct
oil if necessary.
IMPORTANT: Use only hydraulic fluids specified in
Operator’s Manual. Other fluids could cause system
damage.
1
5. After installing high flow filter to machine, check and
fill hydraulic reservoir with new hydraulic oil as required.
IMPORTANT: While engaging the traction circuit,
monitor the high flow hydraulic filter indicator. If the
indicator should show red, either reduce traction
pedal setting or reduce engine speed to decrease
hydraulic flow through the filter.
Hydraulic System
RIGHT
2
6. Start engine. Run engine at low idle speed and check
for any hydraulic leakage from filter and hose connections. Correct any leaks before proceeding.
FRONT
Figure 41
1. Rear wheel motor
Page 4 − 66
2. Lower fitting
Reelmaster 3550−D
Charge Hydraulic System
IMPORTANT: Change hydraulic fluid filter whenever hydraulic components are repaired or replaced.
1. Park machine on a level surface. Lower cutting units,
disengage reel enable/disable switch. stop engine, and
engage parking brake. Remove key from the ignition
switch.
2. Make sure all hydraulic connections, lines, and components are secured tightly.
3. If component failure was severe or the system is contaminated, flush and refill hydraulic system and tank
(see Flush Hydraulic System in this chapter).
4. Make sure hydraulic tank is full. Add correct hydraulic fluid if necessary.
5. Prime hydraulic pumps (see Priming Hydraulic
Pumps in this chapter).
A. Loose filter or suction lines.
B. Incorrect hydraulic hose routing.
C. Blocked suction line.
D. Faulty charge relief valve in traction pump.
E. Faulty gear pump.
9. Operate the traction pedal in the forward and reverse
directions. The wheels should rotate in the proper direction. If the wheels rotate in the wrong direction, stop engine, remove lines from rear of hydrostat pump, and
reverse the connections.
10.Make sure that traction pedal returns to the neutral
position when released from the forward or reverse direction.
11. Check operation of the traction interlock switches
(see Check Operation of Interlock Switches in Chapter
− 5, Electrical System in this manual).
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
6. Raise all 3 wheels off the floor and safely and support
the traction unit.
IMPORTANT: During initial operation, check hydraulic reservoir oil level frequently and add oil as
necessary.
7. Make sure traction pedal is in neutral. Sit in the operator’s seat and start engine and let it idle at low speed.
The hydraulic pumps should pick up hydraulic fluid and
fill the hydraulic system. If there is no indication of fill in
30 seconds, stop the engine and determine the cause.
Reelmaster 3550−D
8. After the hydraulic system starts to show signs of fill,
actuate lift control switch until the lift cylinders move in
and out several times. If the cylinders do not move after
15 seconds or the pump emits abnormal sounds, shut
the engine off immediately and determine cause or
problem. Inspect for the following:
12.Stop the engine and lower machine.
13.If the traction (traction) pump or a wheel motor was
replaced or rebuilt, run the traction unit so all wheels turn
slowly for 10 minutes.
14.Operate traction unit by gradually increasing its work
load to full over a 10 minute period.
15.Stop the machine. Check hydraulic tank and fill if
necessary. Check hydraulic components for leaks and
tighten any loose connections.
Page 4 − 67
Hydraulic System
Hydraulic
System
NOTE: When initially starting the hydraulic system with
new or rebuilt components such as motors, pumps, or
lift cylinders, it is important that the hydraulic system be
charged properly. Air must be purged from the system
and its components to reduce the chance of damage.
Hydraulic Tank
4
3
2
1
80 to 87 ft−lbs
(108.4 to 117.9 N−m)
5
6
7
8
TO HYDRAULIC PUMP
9
10
FROM
OIL
COOLER
12
13
11
18
19
20
14
Anti−seize
17
lubricant
30 to 60 in−lb
(3.4 to 6.8 N−m)
21
16
15
22
RIGHT
23
FRONT
24
Figure 42
1.
2.
3.
4.
5.
6.
7.
8.
Hydraulic tank
Dipstick
Tank cap
Shoulder screw
O−ring
Tank strainer
Hose clamp (2)
Suction hose
Hydraulic System
9.
10.
11.
12.
13.
14.
15.
16.
O−ring
Elbow fitting
Hydraulic tube
O−ring
Elbow fitting
Hydraulic tube
Elbow fitting
Filter head
Page 4 − 68
17.
18.
19.
20.
21.
22.
23.
24.
Filter element
Grommet (4)
Flat washer (4)
Flange head screw (4)
O−ring
Tee fitting
Hydraulic tube
Hydraulic tube
Reelmaster 3550−D
Hydraulic Tank Removal (Fig. 42)
Hydraulic Tank Installation (Fig. 42)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If fittings were removed from hydraulic tank, lubricate
and place new O−rings onto fittings. Install fittings into
tank openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).
3. To prevent contamination of hydraulic system during
hydraulic tank removal, thoroughly clean exterior of
tank.
4. To allow draining of hydraulic tank, disconnect the
suction hose from the tank strainer in the bottom of the
tank. Drain tank into a suitable container.
5. Disconnect hydraulic lines from tank and put caps or
plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper assembly.
6. Remove tank strainer from hydraulic tank. Discard
O−ring from strainer.
7. Remove four (4) flange head screws, flat washers
and grommets that secure hydraulic tank to machine.
Remove hydraulic tank from machine.
8. If fittings are to be removed from tank, mark fitting orientation to allow correct assembly. Remove fittings from
tank and discard O−rings from fittings.
2. Position hydraulic tank to machine. Apply anti−seize
lubricant or equivalent to the four (4) flange head screws
that secure the hydraulic tank. Secure tank to frame with
flange head screws, flat washers and grommets. Torque
screws from 30 to 60 in−lb (3.4 to 6.8 N−m).
3. Lubricate and install new O−ring on suction strainer.
4. Thread suction strainer into hydraulic tank. Torque
strainer into tank port from 80 to 87 ft−lb (109 to 117
N−m).
5. Remove caps and plugs from fittings and hydraulic
lines. Properly connect hydraulic lines to hydraulic tank
(see Hydraulic Hose and Tube Installation in the General Information section of this chapter).
6. Fill hydraulic tank with new hydraulic fluid.
7. Operate machine. Check hydraulic oil level and adjust if necessary. Check hydraulic components for leaks.
Tighten any loose connections.
Hydraulic Tank Inspection (Fig. 42)
1. Clean hydraulic tank and suction strainer with solvent.
2. Inspect hydraulic tank for leaks, cracks or other damage.
Reelmaster 3550−D
Page 4 − 69
Hydraulic System
Hydraulic
System
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of this section of this chapter.
Radiator and Oil Cooler Assembly
2
21
18
25
20
9
9
27
10
22
19
5
10
8
3
16
4
11
12
24
14
13
21
29
28
33
26
23
34
16
21
30
15
1
2
Thread
Sealant
RIGHT
33
31 2
7
FRONT
17
32
6
Figure 43
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Draincock valve
Flange head screw (8)
Flange nut (4)
Carriage bolt (4)
Radiator/oil cooler assembly
LH fan shroud
RH fan shroud
Flange head screw (4)
Hose clamp (2)
Flange head screw (6)
Overflow bottle bracket
Radiator lower shield
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Magnet
Radiator hose (upper)
Radiator hose (lower)
Hose clamp (2)
Straight hydraulic fitting
Hose
Coolant expansion tank
Radiator cap
Flange nut (6)
Foam seal (2)
Adapter
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
LH radiator bracket
RH radiator bracket
Bottom radiator bracket
Top radiator bracket
Plastic plug (2)
Flange nut (4)
Flange head screw (4)
Flat washer (4)
O−ring
O−ring
O−ring
NOTE: The hydraulic oil cooler on your Reelmaster is
combined with the radiator. See Radiator and Oil Cooler
Assembly in Chapter 3 − Kubota Diesel Engine for information on removal and installation of the radiator/oil
cooler assembly.
Hydraulic System
Page 4 − 70
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 71
Hydraulic System
Hydraulic Pump Assembly
10
26
27
25
28
58
25
45
50
7
44
49
48
43
47
42
8
5
29
12
54
1
24
45
53
40
32
9
13
77 to 93 ft−lb
(105 to 127 N−m)
27
3
33
30
40
38
55
6
56
34
40
51
4
46
1018
37
41
31
30
21 20
36
27 to 31 ft−lb
(37 to 42 N−m)
11
41
2
RIGHT
35
57
22
23
90 to 120 in−lb
(10.2 to 13.6 N−m)
52
17 16
39
FRONT
19
15
(tighten in 3 equal steps)
14
Blue Loctite
Figure 44
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Piston pump
Straight hydraulic fitting
Cap screw
Lock nut
90o hydraulic fitting
90o hydraulic fitting
Tee fitting
90o hydraulic fitting
90o hydraulic fitting
Washer
Hydraulic hose
Suction hose
Flange nut
Idler pivot pin
Grease fitting
Flange nut
Retaining ring
Cap screw
Thrust washer
Idler pulley
Hydraulic System
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Spacer
Torsion spring
Idler arm
Hose clamp
Flange nut
Cap screw
Flange head screw
Pump support
Spacer
Cap screw
Flat washer
Spacer
Pump mount plate
Pump mount spacer
Pulley
Cap screw
Lock washer
Taper lock bushing
V−belt
Page 4 − 72
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
O–ring
O–ring
O–ring
O–ring
O–ring
O–ring
Flat washer
O–ring
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Bushing
Gear pump
O–ring
Flat washer
Socket head screw
Idler arm spacer
Hydraulic hose
Reelmaster 3550−D
Drive Belt Removal (Fig. 44)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Raise and support hood.
CAUTION
CAUTION
Use caution when installing torsion spring end
onto the pump mount plate. Applying tension to
the spring may cause personal injury during installation.
4. Apply pump drive belt tension with torsion spring on
idler arm (Fig. 45).
3. Remove pump drive belt tension from torsion spring
on idler arm (Fig. 45).
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring that is secured on the pump
mount plate tab.
A. Insert nut driver or small piece of pipe onto the
end of the torsion spring.
B. Push down on the spring end and then hook the
spring under the tab on the pump mount plate.
5. Lubricate grease fitting on end of idler pivot shaft.
6. Lower and secure hood.
Hydraulic
System
The torsion spring that tensions the idler assembly is under tension and may cause personal
injury during removal. Use caution when removing spring end from the pump mount plate.
3
B. Push down and forward on the spring end to unhook the spring from the tab on the pump mount
plate.
5
4
4. Rotate idler pulley away from pump drive belt and remove drive belt from pulleys. Make sure that drive belt
is in good condition if it is to be re−installed. Replace
drive belt if worn or damaged.
2
5. Remove drive belt idler components as needed.
1
Drive Belt Installation (Fig. 44)
1. Install all removed drive belt idler components. Make
sure that idler pulley and idler arm rotate freely after assembly.
2. Install drive belt onto pulleys. Position idler pulley toward the pump drive belt.
3. Using a straight edge across the lower face of the
pump pulley, verify pump drive belt alignment across engine and pump pulleys. If pulleys are not in alignment,
adjust location of pump pulley on pump shaft so alignment is correct (see Piston Pump/Hydrostat in this chapter).
Reelmaster 3550−D
Figure 45
1. Pump drive belt
2. Idler pulley
3. Torsion spring end
Page 4 − 73
4. Spring end
5. Pump mount plate tab
Hydraulic System
Neutral Arm Assembly
1
4
23
24 7
22
18
21
19 20
6
5
7
9
12
8
9
10
14
12
3
2
11
32
33
29
16
17
15
16
31
13
26
25
27
30
28
Figure 46
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Pump assembly
Hose
Extension spring
Pump mount plate
Neutral bracket
Flange nut
Flange head screw
Neutral arm
Flange bushing
Thrust washer
90o grease fitting
Hydraulic System
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Lock nut
Spacer
Traction stud
Traction control cable
Flat washer
Ball joint
Lock nut
Cap screw
Flat washer
Hub assembly
Flange nut
Page 4 − 74
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Flange head screw
Cable support bracket
Ball bearing
Flat washer
Lock nut
Cap screw
Pump lever
Cap screw
Flat washer
Cap screw
Mount
Reelmaster 3550−D
Neutral Arm Removal (Fig. 46)
Neutral Arm Installation (Fig. 46)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. Install key into trunnion slot. Position neutral bracket
to the mount plate and the pump lever and hub assembly
to the pump trunnion.
2. Raise and support hood.
2. Secure pump lever and hub assembly to the piston
pump trunnion with flat washer and cap screw.
3. Secure neutral bracket to the pump mount plate with
flange head screw and flange nut. Secure neutral bracket to the piston pump with both flange head screws.
The extension spring is under tension and may
cause personal injury during removal. Use caution when removing spring from the pump lever.
4. Position three (3) flat washers to traction control
cable end. Secure traction control cable to the pump lever with cap screw and lock nut.
3. Remove extension spring from the cable support
bracket and neutral arm.
4. Disconnect traction control cable from the pump
lever. Locate and retrieve three (3) flat washers and note
their position for assembly purposes.
5. Remove both flange head screws securing the neutral bracket to the piston pump. Remove flange nut and
flange head screw securing the neutral bracket to the
pump mount plate.
6. Remove cap screw and flat washer that secure the
pump lever and hub assembly to the piston pump trunnion.
CAUTION
The extension spring is under tension and may
cause personal injury during installation. Use
caution when installing the spring to the pump
lever.
5. Install extension spring to the cable support bracket
and neutral arm.
6. Adjust traction drive for neutral.
7. Lower and secure hood.
7. Separate pump lever and hub assembly from pump
trunnion and neutral bracket from mount plate. Locate
and retrieve key from trunnion.
Reelmaster 3550−D
Page 4 − 75
Hydraulic System
Hydraulic
System
CAUTION
Piston Pump/Hydrostat
1
RIGHT
FRONT
2
3
4
5
6
10
9
8
7
Figure 47
1.
2.
3.
4.
Engine mount bracket
Flange nut
Flange screw
Pump mount plate
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
Piston Pump/Hydrostat Removal (Fig. 44 and 47)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Raise and support hood.
WARNING
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
3. Remove pump drive belt (see Drive Belt Removal in
this chapter).
4. Remove neutral arm assembly (see Neutral Arm Removal in this chapter).
5. Thoroughly clean hydraulic hose ends and fittings on
piston pump/hydrostat and gear pumps to prevent hydraulic system contamination.
6. Disconnect the suction hose from the barbed fitting
on the bottom of the gear pump and drain hydraulic tank
into a suitable container.
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
Hydraulic System
Page 4 − 76
Reelmaster 3550−D
7. Label all hydraulic hoses and fittings for assembly
purposes.
Remove plugs before installing
gear pump to piston pump
8. Disconnect all hydraulic hoses connected to the hydraulic fittings on the piston pump/hydrostat and gear
pump. Allow hoses to drain into a suitable container.
Plug hose and fitting openings to prevent contamination.
1
CAUTION
2
Support pump assembly during removal to prevent them from falling and causing personal injury or component damage.
9. Support hydraulic pump assembly to prevent it from
shifting.
11. Remove fasteners and spacers securing the pump
mount plate to the engine (Fig. 47). Note location of cap
screws, washers and spacers for assembly purposes.
12.Carefully remove pump mount plate with pumps,
pulley, pump support and idler assembly from the machine.
NOTE: A case drain exists in the piston pump/hydrostat
and a suction port is near the input shaft of the gear
pump (Fig. 48). When the gear pump is removed from
the piston pump/hydrostat, plug both case drain holes to
prevent draining the pumps.
13.Remove both cap screws and flat washers securing
gear pump to the piston pump. Separate gear pump
from the piston pump. Locate and retrieve O−ring. Plug
openings of gear pump to prevent contamination.
14.Remove pump pulley from the taper lock bushing on
the piston pump shaft:
A. Remove three (3) cap screws and lock washers
securing pulley to the taper lock bushing.
IMPORTANT: Excessive or unequal pressure on
the cap screws can break the bushing flange.
B. Insert cap screws into threaded removal holes of
the pulley. Tighten screws progressively and evenly
until the pulley is loose on the bushing. Remove
pulley from the bushing.
15.Loosen set screw that secures taper lock bushing to
piston pump shaft. Remove bushing from the pump
shaft. Locate and retrieve key from pump shaft.
Reelmaster 3550−D
2. Gear pump suction port
16.Remove both cap screws and washers that secure
piston pump to pump support. Locate and retrieve
spacers.
17.Remove lock nuts, flat washers and cap screws that
secure the piston pump to the pump mount plate. Remove pump from plate.
18.If hydraulic fittings are to be removed from piston
pump, mark fitting orientation to allow correct assembly.
Remove hydraulic fittings and O−rings from the piston
pump as needed. Discard removed O−rings.
Piston Pump Installation (Fig. 44 and 47)
1. Position and secure piston pump to the pump mount
plate with cap screws, flat washers and lock nuts.
2. Lubricate and place new O−rings onto all removed
pump fittings. Install fittings into pump openings using
marks made during the removal process to properly
orientate fittings. Tighten fittings (see Hydraulic Fitting
Installation in this chapter).
IMPORTANT: A case drain exists in the piston
pump/hydrostat and a suction port is near the input
shaft of the gear pump (Fig. 48). Before the gear
pump is installed to the piston pump, make sure that
plugs placed in either of these ports are removed.
Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before installing gear pump to piston pump, fill piston
pump housing with clean hydraulic oil through case
drain hole.
3. Install and secure gear pump to the piston pump (see
Gear Pump in this chapter).
Page 4 − 77
Hydraulic System
Hydraulic
System
10.Remove both flange head screws and flange nuts
that secure pump support to engine mount.
Figure 48
1. Piston pump/hydrostat
case drain
4. Place key into piston pump shaft slot. Slide taper lock
bushing onto the piston pump shaft with bushing flange
toward pump housing.
IMPORTANT: When tightening taper lock bushing
cap screws, tighten in three (3) equal steps and in a
circular pattern.
5. Make sure that tapered surfaces of pump pulley and
taper lock bushing are thoroughly clean (no oil, grease,
dirt, rust, etc.).
11. Secure taper lock bushing and pump pulley by tightening three (3) cap screws to a torque from 90 to 120
in−lb (10.2 to 13.6 N−m) in three (3) equal steps and in
a circular pattern.
6. Position pump pulley to taper lock bushing and align
non−threaded holes of pulley with threaded holes of
bushing. Loosely install three (3) cap screws with lock
washers to bushing and pulley.
CAUTION
Support pump assembly during installation to
prevent them from falling and causing personal
injury or component damage.
12.Check that pump drive belt alignment is still correct.
If needed, loosen and re−adjust pulley and taper lock
bushing location on pump shaft to allow for correct belt
alignment.
13.Remove caps and plugs from all fittings and hydraulic hoses. Using labels placed during pump removal,
properly connect hydraulic lines to pump assembly (see
Hydraulic Hose and Tube Installation in this chapter).
14.Install neutral arm assembly to the piston pump (see
Neutral Arm Installation in this chapter).
7. Position pump assembly to the machine. Install fasteners and spacers securing the pump mount plate to
the engine and pump support (Fig. 47). Tighten fasteners securely.
15.Fill hydraulic tank with new hydraulic fluid.
8. Position and secure pump support to pump mount
plate, piston pump and engine mount with removed fasteners and spacers.
17.Adjust traction drive for neutral (see Traction Unit
Operator’s Manual).
16.Properly charge hydraulic system (see Charge Hydraulic System in this chapter)
18.Lower and secure hood.
9. Install pump drive belt (see Drive Belt Installation in
this chapter).
10.Using a straight edge across the lower face of the
pump pulley, verify pump drive belt alignment across engine and pump pulleys. Slide pulley and taper lock bushing on pump shaft so that drive belt and straight edge are
aligned indicating correct position of pump pulley. Secure taper lock bushing in position with set screw.
Hydraulic System
Page 4 − 78
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 79
Hydraulic System
Piston Pump/Hydrostat Service
21
22
41
40
39
19
38
17
37
27
16
15
36
14
17
20
15
4
26
15
25
42
24
7
43
44
45
8
46
10
6 18
13
11
12
35
9
6
28
3
33
32
29
30
31
30
8
5
26
4
23
18
2
1
46
29
34
Figure 49
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Key
Drive shaft
Bearing
Cap screw (3 used per plate)
Cover plate
O–ring
Shim kit
Bearing cone
Key
Swashplate
Rotating kit
Gasket
Valve plate
Bearing
Dowel pin
Back plate
Hydraulic System
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
O–ring
Plug
Relief valve asm.
Check valve asm.
Bypass valve asm.
Cap screw
O–ring
Shaft seal
Cover plate
Washer (3 per plate)
Coupler
Housing
Retaining ring
Thrust washer
Thrust bearing
Page 4 − 80
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Washer
Shaft seal
Retaining ring
Cam plate insert
Retaining ring
Washer
Charge relief spring
Charge relief poppet
Charge relief housing
O–ring
Cartridge
O–ring
Bleed−off spring
Bleed−off valve poppet
Bearing cup
Reelmaster 3550−D
IMPORTANT: If a piston pump failure occurred, refer to Traction Circuit (Closed Loop) Component
Failure in this chapter for information regarding the
importance of removing contamination from the
traction circuit.
CHARGE RELIEF
VALVE
4
NOTE: The traction circuit charge relief valve and the
bleed off valve for traction circuit cooling are attached to
the piston pump back plate assembly (Fig. 50). The
back plate assembly must be removed from the piston
pump/hydrostat to service either the relief valve or the
bleed off valve.
5
7
6
8
1
9
2
IMPORTANT: The shim kit is used to replace the
original crush ring (not shown) in the cover plate. If
the swash plate, cover plate or housing is replaced
during servicing, the old crush ring must be replaced. See Piston Pump Crush Ring Replacement
in this chapter in conjunction with the Eaton service
manual at the end of this chapter for additional information.
BLEED OFF
VALVE
10
11
12
NOTE: For repair of the piston pump, see the Eaton
Medium Duty Piston Pump Repair Information Model
70160 Variable Displacement Piston Pump at the end of
this chapter.
Reelmaster 3550−D
Figure 50
1.
2.
3.
4.
5.
6.
7.
Page 4 − 81
Back plate assembly
Charge relief valve
Bleed off valve
O−ring
Housing
Poppet
Spring
8.
9.
10.
11.
12.
13.
Washer
Retaining ring
Bleed off valve
Spring
O−ring
Cartridge
Hydraulic System
Hydraulic
System
3
13
4
5
29 ft−lb
(39 N−m)
8
7
2
3
v
9
10
6
1
Figure 51
1.
2.
3.
4.
Crush ring
Shims
Cover plate
Housing
5. Camplate (control shaft)
6. Bearing cone
7. Bearing cup
8. O−ring
9. Washer (3)
10. Cap screw (3)
Piston Pump/Hydrostat Crush Ring Replacement
(Fig. 51)
5. Install washers and cap screws to the cover plate
and housing. Torque cap screws to 29 ft−lbs (39 N−m).
NOTE: The shims replace the crush ring in the cover
plate. If the camplate, cover plate or housing is replaced
during servicing of the pump, the old crush ring can not
be used to make sure of proper preload.
6. Check torque required to rotate control shaft. Torque
should be from 15 to 25 in−lbs (1.7 to 2.8 N−m).
1. Remove crush ring from the cover plate. Measure
thickness of crush ring.
B. If torque is too high, remove shims and repeat
steps 3 through 6 until the specified torque is
achieved.
2. Stack shims to the thickness of the crush ring.
3. Insert shims into the cover plate in the same location
that the crush ring was removed from.
4. Assemble housing sub assembly consisting of the
housing, camplate, bearing cone, bearing cup and cover plate (see Eaton, Medium Duty Piston Pump, Repair
Information, Model 70160 Variable Displacement Piston
Pump at the end of this chapter).
Hydraulic System
A. If torque is too low, add additional shims and repeat steps 3 through 6 until the specified torque is
achieved.
7. Complete assembly of the pump (see Eaton, Medium Duty Piston Pump, Repair Information, Model
70160 Variable Displacement Piston Pump at the end of
this chapter).
Page 4 − 82
Reelmaster 3550−D
Gear Pump
9
5
10
4
12
11
13
14
2
1
RIGHT
15
FRONT
17
16
Hydraulic
System
8
7
3
6
Figure 52
1.
2.
3.
4.
5.
6.
Piston pump
Gear pump
Hydraulic hose (tank suction)
Hydraulic hose (hydraulic manifold)
Hydraulic hose (steering valve)
Hose clamp
7.
8.
9.
10.
11.
12.
Hydraulic barb fitting
O–ring
O–ring
90o hydraulic fitting
O–ring
O–ring
13.
14.
15.
16.
17.
90o hydraulic fitting
O–ring
Cap screw
Flat washer
O–ring
5. Label hydraulic hoses and fittings on gear pump for
assembly purposes.
Removal (Fig. 52)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch. Raise and support hood.
2. Remove muffler from the engine to gain access to
the gear pump (see Exhaust System in Chapter 3 − Kubota Diesel Engine in this manual).
WARNING
6. Disconnect hydraulic hoses connected to the hydraulic fittings on the gear pump. Allow hoses to drain
into a suitable container. Plug hose openings to prevent
contamination.
NOTE: A case drain exists in the piston pump/hydrostat
and a suction port is near the input shaft of the gear
pump (Fig. 53). When the gear pump is removed from
the piston pump, plug piston pump case drain hole to
prevent draining the piston pump.
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in this chapter.
7. Remove both cap screws and flat washers securing
gear pump to the piston pump. Separate gear pump
from the piston pump. Locate and retrieve O−ring. Plug
openings of gear pump to prevent contamination.
3. Thoroughly clean hydraulic hose ends and fittings on
gear pump to prevent hydraulic system contamination.
8. If hydraulic fittings are to be removed from gear
pump, mark fitting orientation to allow correct assembly.
Remove hydraulic fittings and O−rings from the gear
pump as needed. Discard removed O−rings.
4. Drain hydraulic oil from hydraulic tank by disconnecting the suction hose from the barbed fitting in the bottom
of the gear pump. Drain tank into a suitable container.
Reelmaster 3550−D
Page 4 − 83
Hydraulic System
Installation (Fig. 52)
Remove plugs before installing
gear pump to piston pump
1. If fittings were removed from gear pump, lubricate
and place new O−rings onto fittings. Install fittings into
pump openings using marks made during the removal
process to properly orientate fittings. Tighten fittings
(see Hydraulic Fitting Installation in the General Information section of this chapter).
1
2. Make sure mounting and O−ring sealing surfaces on
the gear pump and piston pump are clean.
2
3. Apply clean hydraulic oil to gear pump flange O−ring.
Place O−ring on the gear pump.
IMPORTANT: A case drain exists in the piston
pump/hydrostat and a suction port is near the input
shaft of the gear pump (Fig. 53). Before the gear
pump is installed to the piston pump, make sure that
plugs placed in either of these ports are removed.
Failure to remove plugs will cause excessive pressure in the piston pump and damage seals. Also, before installing gear pump to piston pump, fill piston
pump housing with clean hydraulic oil through case
drain hole.
4. Remove plugs that were placed in piston pump case
drain and gear pump suction port. Fill piston pump housing with clean hydraulic oil through case drain hole.
Figure 53
1. Piston pump/hydrostat
case drain
2. Gear pump suction port
6. Remove caps and plugs from gear pump fittings and
hoses. Using labels placed during gear pump removal,
properly connect hydraulic lines to pump (see Hydraulic
Hose and Tube Installation in this chapter).
7. Fill hydraulic tank with new hydraulic fluid.
IMPORTANT: The gear pump suction fitting must be
on the same side as the trunnion of the piston pump.
8. Install muffler to the engine (see Exhaust System in
Chapter 3 − Kubota Diesel Engine in this manual).
5. Align gear teeth and slide gear pump input shaft into
piston pump coupler. Secure gear pump to piston pump
with two (2) cap screws and flat washers.
9. Properly fill hydraulic system (see Charge Hydraulic
System in this chapter).
Hydraulic System
10.Lower and secure hood.
Page 4 − 84
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 85
Hydraulic System
Gear Pump Service
19
14
18
17
11
10
12
2
8
3
6
1
3
2
20
16
21
13
15
13
14
33 ft−lb
(45 N−m)
9
8
7
5
4
Figure 54
1.
2.
3.
4.
5.
6.
7.
Front cover
Pressure seal
Back−up gasket
Front thrust plate
Idler gear
Drive shaft
Rear thrust plate
8.
9.
10.
11.
12.
13.
14.
Dowel pin
Seal
Body
Seal
Splined connecting shaft
Pressure seal
Back−up gasket
15.
16.
17.
18.
19.
20.
21.
Front thrust plate
Idler gear
Drive gear
Rear thrust plate
Rear cover
Washer (4 used)
Cap screw (4 used)
Disassembly (Fig. 54)
NOTE: The gear pump must be replaced as a complete
assembly. Individual gears, housings and thrust plates
are not available separately. Disassemble gear pump
for cleaning, inspection and seal replacement only.
DIAGONAL LINE
1. Plug pump ports and thoroughly clean exterior of
pump with cleaning solvent. Make sure work area is
clean.
2. Use a marker to make a diagonal line across the
gear pump for assembly purposes (Fig. 55).
Figure 55
Hydraulic System
Page 4 − 86
Reelmaster 3550−D
IMPORTANT: Use caution when clamping gear
pump in a vise to avoid distorting any pump components.
3. Secure the front cover of the pump in a vise with the
drive shaft pointing down.
8. Clean all pump parts. Check all components for
burrs, scoring, nicks and other damage.
9. Replace the entire pump assembly if parts are excessively worn or scored.
Assembly (Fig. 54)
4. Loosen the four (4) cap screws that secure pump assembly.
1. Apply clean hydraulic fluid to all parts before assembling.
5. Remove pump from vise and remove fasteners.
IMPORTANT: Mark the relative positions of the gear
teeth and the thrust plates so they can be reassembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear
finish.
7. Remove the thrust plates and seals from each pump
section. Before removing each gear set, apply marking
dye to mating teeth to retain ”timing”. Pump efficiency
may be affected if the teeth are not installed in the same
position during assembly. Keep the parts for each pump
section together; do not mix parts between sections.
Reelmaster 3550−D
NOTE: Pressure seals and back−up gaskets fit in
grooves machined into thrust plates. Body seals fit in
grooves machined in body faces.
2. Assemble pump sections starting at front cover end.
Apply grease or petroleum jelly to new section seals to
hold them in position during gear pump assembly.
3. After pump has been assembled, tighten cap screws
by hand. Rotate the drive shaft to check for binding. Protect the shaft if using a pliers to rotate shaft.
4. Tighten the four (4) cap screws evenly in a crossing
pattern to a torque of 33 ft−lb (45 N−m).
Page 4 − 87
Hydraulic System
Hydraulic
System
6. Support the pump assembly and gently tap the pump
case with a soft face hammer to loosen the pump sections. Be careful to not drop parts or disengage gear
mesh.
Front Wheel Motors
5
7
6
8
8
9
9
10
10
4
1
RIGHT
2
FRONT
11
3
1.
2.
3.
4.
Lock nut
Spacer
Socket head screw
Hydraulic wheel motor
5.
6.
7.
8.
Figure 56
Frame
Hydraulic tube
Hydraulic tube
O–ring
9. Hydraulic fitting
10. O–ring
11. Brake bracket
NOTE: The left front wheel motor has a yellow dot on
the body to distinguish it from the right front wheel motor.
Hydraulic System
Page 4 − 88
Reelmaster 3550−D
Removal (Fig. 56)
Installation (Fig. 56)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If adapters were removed from wheel motor, lubricate and place new O−rings onto fittings. Install adapters into motor openings and tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of this chapter).
WARNING
2. Install wheel motor and brake bracket to frame using
four (4) socket head screws, spacers and lock nuts.
2. Jack up front of machine enough to allow the removal
of the front wheel. Support machine with appropriate
jackstands.
IMPORTANT: DO NOT hit wheel hub, wheel hub
puller or wheel motor with a hammer during removal
or installation. Hammering may cause damage to
the wheel motor.
3. Remove wheel assembly, wheel hub and brake drum
from the hydraulic motor. Remove brake assembly from
the brake bracket (see Front Wheel and Brake Removal
in Chapter 6 − Chassis in this manual).
4. Thoroughly clean hydraulic line ends and wheel motor fittings to prevent hydraulic system contamination.
3. Remove caps and plugs from wheel motor fittings
and hoses. Using labels placed during motor removal,
properly connect hydraulic lines to motor (see Hydraulic
Hose and Tube Installation in this chapter).
4. Install brake assembly to the brake bracket. Install
brake drum, wheel hub and wheel assembly to the hydraulic motor (see Front Wheel and Brake Installation in
the Chapter 6 − Chassis in this manual).
5. Lower the machine to the ground.
6. Make sure that lock nut is torqued from 250 to 275
ft−lb (339 to 372 N−m). Also, make sure that wheel lug
nuts are torqued from 45 to 65 ft−lb (61 to 88 N−m).
7. Make sure hydraulic tank is full. Add correct oil if necessary.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
5. Disconnect hydraulic tubes from adapters on wheel
motors. Plug hose openings to prevent contamination.
6. Remove four (4) socket head screws and lock nuts
that secure brake bracket and wheel motor to frame.
Located and retrieve spacers. Remove brake bracket
and wheel motor from machine.
7. If necessary, remove hydraulic adapters and
O−rings from the wheel motor. Discard removed
O−rings.
Reelmaster 3550−D
Page 4 − 89
Hydraulic System
Hydraulic
System
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
Rear Wheel Motor
250 to 275 ft−lb
(339 to 372 N−m)
2
3
1
14
11
12
13
15
45 to 65 ft−lb
(61 to 88 N−m)
4
5
10
6
7
RIGHT
FRONT
9
8
Figure 57
1.
2.
3.
4.
5.
Lug nuts (4)
Rear wheel assembly
Lock nut
Wheel hub
Wheel stud (4)
Hydraulic System
6.
7.
8.
9.
10.
Lock nut (4)
Rear wheel motor
Socket head screw (4)
Rear fork
Woodruff key
Page 4 − 90
11.
12.
13.
14.
15.
O−ring (2)
Elbow fitting (2)
O−ring (2)
Hydraulic hose
Hydraulic hose
Reelmaster 3550−D
8. Using hub puller (see Special Tools in this chapter),
loosen wheel hub from wheel motor.
Removal (Fig. 57)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
10.If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly.
Discard O−rings from removed fittings.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Jack up rear of equipment enough to allow the removal of the rear wheel.
3. Remove rear wheel assembly from machine.
4. Thoroughly clean hydraulic hose ends and rear
wheel motor fittings to prevent hydraulic system contamination.
Installation (Fig. 57)
1. If fittings were removed from rear wheel motor, lubricate and place new O−rings onto fittings. Install fittings
into motor openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter).
2. Thoroughly clean wheel motor shaft and wheel hub
taper.
3. Lock wheel hub in a vise. Install woodruff key into the
wheel motor shaft. Slide motor shaft into hub and secure
with lock nut. Torque lock nut from 250 to 275 ft−lb (339
to 372 N−m). Remove wheel motor and hub from vise.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
5. Disconnect hydraulic hoses from fittings on wheel
motor. Plug hose openings to prevent contamination.
6. Remove four (4) socket head screws and lock nuts
that secure rear wheel motor to rear fork. Remove wheel
motor with wheel hub attached from the rear fork.
7. Secure wheel hub in a vise. Loosen but do not remove lock nut that secures wheel hub to wheel motor.
IMPORTANT: DO NOT hit wheel hub, wheel hub
puller or wheel motor with a hammer during wheel
hub removal or installation. Hammering may cause
damage to the wheel motor.
4. Position wheel motor with wheel hub attached to the
rear fork. Secure rear wheel motor to rear fork with four
(4) socket head screws and lock nuts.
5. Remove caps and plugs from wheel motor fittings
and hoses. Using labels placed during motor removal,
properly connect hydraulic lines to motor (see Hydraulic
Hose and Tube Installation in this chapter).
6. Install wheel assembly to machine and secure with
four (4) lug nuts.
7. Lower the machine to the ground.
8. Make sure that lock nut is torqued from 250 to 275
ft−lb (339 to 372 N−m). Also, make sure that wheel lug
nuts are torqued from 45 to 65 ft−lb (61 to 88 N−m).
9. Make sure hydraulic tank is full. Add correct oil if necessary.
Page 4 − 91
Hydraulic System
Hydraulic
System
WARNING
Reelmaster 3550−D
9. Remove wheel hub and motor from vise. Remove
lock nut and wheel hub from motor shaft. Locate and retrieve woodruff key.
Wheel Motor Service
45 to 55 ft−lb
(60 to 76 N−m)
13
12
11
10
3
4
5
6
7
8
9 8
14
2
15
16
1
17
24
5
23
5
22
5
21
20
19
5
18
Figure 58
1.
2.
3.
4.
5.
6.
7.
8.
Dirt seal
Bearing
Housing
Back−up washer
Seal ring
Back−up washer
Inner seal
Thrust washer
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Thrust bearing
Bearing
Coupling shaft
Thrust bearing
Drive link
Cap screw
Commutator seal
Commutator
NOTE: The wheel motors used on the Reelmaster
3550−D have the same basic construction. The left front
wheel motor has a yellow sticker on the motor housing
for identification purposes. The right front and rear
wheel motors have reverse timed manifolds. The rear
wheel motor includes a check valve in the end cover.
Woodruff key
Wear plate
Rotor
Vane
Stator
Manifold
Commutator ring
End cover
IMPORTANT: If a wheel motor failure occurred, refer
to Traction Circuit (Closed Loop) Component Failure in the General Information section for information regarding the importance of removing
contamination from the traction circuit.
NOTE: For repair of the wheel motors, see the Parker
TorqmotorTM Service Procedure (TC, TB, TE, TJ, TF,
TG, TH and TL Series) at the end of this chapter.
Hydraulic System
Page 4 − 92
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 93
Hydraulic System
Cutting Unit Reel Motor
5
11
5
11
6
10
8
7
4
2
4
6
1
11
10
8
7
#3
1
4
2
2
5
6
4
6
10
8
7
4
2
1
4
10
1
#5
2
9
11
1
2
7
#2
1
4
2
1
11
#1
1
3
4
RIGHT
5
5
FRONT
6
10
8
7
4
2
4
10
1
2
1
#4
Figure 59
1.
2.
3.
4.
O−ring
Elbow fitting
Straight fitting
O−ring
Hydraulic System
5.
6.
7.
8.
Hydraulic hose (Inlet)
Hydraulic hose (return)
O−ring
Straight fitting
Page 4 − 94
9. Elbow fitting
10. O−ring
11. Hydraulic hose (case drain)
Reelmaster 3550−D
Removal
1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components in this chapter.
3. Label all hydraulic connections for assembly purposes (Fig. 59). Thoroughly clean hydraulic connections prior to loosening hydraulic lines from reel motor to
prevent hydraulic system contamination.
2
1
Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the General Information section of this chapter.
4. Disconnect hydraulic hoses from fittings in reel motor. Allow lines to drain into a suitable container. Remove
and discard O−rings.
5. Put caps or plugs on disconnected hoses and fittings
to prevent contamination.
Figure 60
1. Hydraulic reel motor
2. Flange nut or flange
head screw (2)
2. Coat spline shaft of the reel motor with No. 2 multipurpose lithium base grease. Lubricate the O−ring on
the motor flange with clean oil.
3. Rotate the motor clockwise so the motor flanges
clear the flange nuts in the cutting unit side plates. Align
reel motor shaft splines with cutting reel insert splines.
Slide motor shaft into reel insert.
6. Loosen two (2) flange nuts or flange head screws
that secure the hydraulic reel motor to the cutting unit
side plate (Fig. 60). Rotate motor clockwise and remove
motor from cutting unit.
4. Rotate the motor counter−clockwise until the motor
flanges are encircling the cap screws in the side plates.
While holding motor, tighten two (2) flange nuts or flange
head screws to secure reel motor to cutting unit
(Fig. 60).
7. Inspect the O−ring on the reel motor flange and replace O−ring if damaged.
5. Remove caps or plugs from fittings and hoses.
8. If hydraulic fittings are to be removed from motor,
mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O−rings.
Installation
1. If hydraulic fittings were removed from motor, lubricate new O−rings, position O−rings to fittings and install
fittings into motor ports (see Hydraulic Fitting Installation
in this chapter). Make sure that fittings are orientated
correctly.
Reelmaster 3550−D
IMPORTANT: When installing the hydraulic hoses,
make sure that hydraulic hoses are straight (not twisted)
before tightening the hoses to the motor fittings.
6. Lubricate and install new O−rings on motor fittings.
Correctly connect hydraulic hoses to the motor using labels placed during removal procedure (Fig. 59).
7. Check oil level in hydraulic reservoir and add correct
oil if necessary.
8. Follow Hydraulic System Start−up procedures (see
Hydraulic System Start−up in this section).
Page 4 − 95
Hydraulic System
Hydraulic
System
CAUTION
Cutting Unit Reel Motor Service
18 ft−lb
(25 N−m)
18
17
16
12
5
13
14
15
11
10
6
1
2
3
7
8
9
4
Figure 61
1.
2.
3.
4.
5.
6.
Dust seal
Retaining ring
Backup washer
Shaft seal
Front flange
Dowel pin (2)
7.
8.
9.
10.
11.
12.
O–ring
Pressure seal (outer)
Backup gasket (outer)
Wear plate (outer)
Drive gear
Idler gear
13.
14.
15.
16.
17.
18.
Wear plate (inner)
Backup gasket (inner)
Pressure seal (inner)
Body
Cap screw (4)
Washer (4)
Disassembly (Fig. 61)
1. Plug motor ports and clean the outside of the motor
thoroughly. After cleaning, remove plugs and drain any
fluid out of the motor.
2. Use a marker to make a diagonal line across the
front flange and body for assembly purposes (Fig. 62).
IMPORTANT: Prevent damage when clamping the
motor into a vise; use a vise with soft jaws and
clamp on the front flange only.
MARKER
LINE
3. Clamp front flange of motor in a vise with soft jaws
with the shaft end down.
Figure 62
4. Loosen cap screws from the rear cover.
5. Remove motor from the vise. Turn motor so that the
shaft end is facing down and remove cap screws.
Hydraulic System
6. Carefully remove body. Lift body straight up to remove. Make sure the rear wear plate remains on the
drive and idler gear shafts. Remove and discard O–ring
from the body. Locate and retrieve dowel pins.
Page 4 − 96
Reelmaster 3550−D
IMPORTANT: Note position of the open and closed
side of the wear plates before removing. Identify
wear plates (inner and outer, drive gear and idler
gear) with a marker for proper assembly.
1
2
3
4
IMPORTANT: Mark the relative positions of the gear
teeth so they can be reassembled in the same
(mated) position. Do not touch the gear surfaces as
residue on hands may be corrosive to gear finish.
7. Carefully disassemble the inner wear plate, idler
gear, drive gear and outer wear plate.
8. Remove and discard back−up gaskets and pressure
seals from wear plates.
9. Turn front flange over, with seal side up.
Figure 63
1. Dust seal
2. Retaining ring
3. Backup washer
4. Shaft seal
2
10.Carefully remove dust seal, retaining ring, backup
washer and shaft seal from the front flange (Fig. 63).
Discard removed seals.
Hydraulic
System
IMPORTANT: Make sure to not damage the front
flange counter bore when removing the seals from
the front flange.
3
2
1
Inspection
4
1. Remove any nicks and burrs from all parts with
emery cloth.
4
CAUTION
2
3
Use goggles or other appropriate eye protection
when using compressed air for drying parts.
2. Clean all parts with solvent. Dry all parts with compressed air.
3. Inspect drive gears and idler gears for the following
(Fig. 64):
A. Gear shafts should be free of rough surfaces and
excessive wear at bushing points and sealing areas.
Scoring, rough surfaces or wear on gear shafts indicates need for replacement.
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
2
Figure 64
1. Gear shaft spline
2. Gear shaft
3. Gear teeth
4. Gear face edge
4. Inspect wear plates for the following:
A. Bearing areas should not have excessive wear or
scoring.
B. Face of wear plates that are in contact with gears
should be free of wear, roughness or scoring.
C. Thickness of wear plates should be equal.
5. Inspect front flange and rear cover for damage or
wear.
C. Inspect gear face edge for sharpness. Sharp
edges of gears will damage wear plates and should
be replaced.
Reelmaster 3550−D
Page 4 − 97
Hydraulic System
Assembly (Fig. 61)
1. Lubricate O–rings, pressure seals, back−up gaskets
and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic fluid.
9. Install inner wear plate with pressure seal side up
and open side of the pressure seal pointing to the inlet
side of the motor.
10.Apply a light coating of petroleum jelly to new O–ring
and O–ring grooves in the body. Install new O–ring to the
body.
2. Install new seals into front flange (Fig. 63):
A. Press new shaft seal into front flange until it
reaches the bottom of the bore.
NOTE: When assembling the motor, check the marker
line on each part to make sure the parts are properly
aligned during assembly.
B. Install backup washer into front flange and then
install retaining ring into the groove of the front
flange.
11. Install locating dowels in body. Align marker line on
the body and front flange.
C. Install new dust seal into front flange.
IMPORTANT: Do not dislodge seals during installation.
3. Place front flange, seal side down, on a flat surface.
4. Install the outer pressure seal, flat side outward, into
the grooves in the outer wear plate. Follow by carefully
placing the outer backup gasket, flat side outward, between the pressure seal and the grooves in the outer
wear plate.
12.Gently slide the body onto the assembly. Firm hand
pressure should be sufficient to engage the dowels.
13.Check to make sure that the surface of the body contacts the front flange. If the body does not contact the
front flange, check assembly for a shifted pressure seal,
backup gasket or O–ring. Correct before proceeding.
5. Apply a light coating of petroleum jelly to the exposed
side of the front flange.
14.Install the four (4) cap screws with washers and hand
tighten screws.
6. Lubricate the drive gear shaft with clean hydraulic
fluid. Insert the drive end of the drive shaft through the
outer wear plate with the pressure seal side down and
the open side of the pressure seal pointing to the inlet
side of the motor. Carefully install shaft into front flange.
IMPORTANT: Prevent damage when clamping the
motor into a vise; use a vise with soft jaws and
clamp on the front flange only.
7. Lubricate the idler gear shaft with clean hydraulic fluid. Install idler gear shaft into the remaining position in
the outer wear plate with gear teeth in the mated position
noted during dis−assembly. Apply a light coating of
clean hydraulic fluid to gear faces.
8. Install the inner pressure seal, flat side outward, into
the grooves in the inner wear plate. Follow by carefully
placing the inner backup gasket, flat side outward, between the pressure seal and the grooves in the inner
wear plate.
Hydraulic System
15.Place front flange of the motor into a vise with soft
jaws and alternately torque the cap screws 18 ft−lb (25
N−m).
16.Remove motor from vise.
17.Place a small amount of clean hydraulic fluid in the
inlet of the motor and rotate the drive shaft away from the
inlet one revolution. If any binding is noted, disassemble
the motor and check for assembly problems.
Page 4 − 98
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 99
Hydraulic System
Mow Control Manifold
4
5
10
8
18
9
10
17
6
16
10
14
12
11
15
3
13
9
1
8
10
7
2
10
20
8
9
19
RIGHT
FRONT
Figure 65
1.
2.
3.
4.
5.
6.
7.
Mow control manifold
Hydraulic tube
Hydraulic tube
Hydraulic tube
Hydraulic hose
Hydraulic tube
Hydraulic tube
Hydraulic System
8.
9.
10.
11.
12.
13.
14.
Straight hydraulic fitting (3)
O−ring
O−ring
90o hydraulic fitting
O−ring
O−ring
Hydraulic tee fitting
Page 4 − 100
15.
16.
17.
18.
19.
20.
O−ring
Test fitting
O−ring
Dust cap
Flange head screw (2)
Front axle
Reelmaster 3550−D
Removal (Fig. 65)
Installation (Fig. 65)
The ports on the mow control manifold are marked for
easy identification of components. Example: PRV is the
proportional relief valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic
lines and cartridge valves at each port location).
1. If fittings were removed from mow control manifold,
lubricate and place new O−rings onto fittings. Install fittings into manifold openings using marks made during
the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter).
The mow control manifold is located on the left side of
the traction unit frame. Access the manifold from above
through the hinged floor plate in front of the operator’s
seat, or from behind (below the traction unit frame).
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2. Install mow control manifold to the frame.
3. Remove caps and plugs from fittings and hoses. Using labels placed during manifold removal, properly connect hydraulic lines to manifold (see Hydraulic Hose and
Tube Installation in the this chapter).
4. Connect wire harness connector to the proportional
relief valve coil (PRV) on the mow control manifold.
5. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
Hydraulic
System
3. To prevent contamination of hydraulic system during
manifold removal, thoroughly clean exterior of mow control manifold and fittings.
4. Disconnect wire harness connector from the proportional relief valve coil (PRV) and the backlap switch
(SW) on the mow control manifold.
5. Disconnect hydraulic lines from manifold and put
caps or plugs on open hydraulic lines and fittings. Label
disconnected hydraulic lines for proper installation.
6. Remove the two (2) flange head screws from under
the manifold that secure the manifold to the frame.
7. If hydraulic fittings are to be removed from manifold,
mark fitting orientation to allow correct assembly. Remove fittings from manifold and discard O−rings.
NOTE: Refer to Mow Control Manifold Service in this
chapter for information on cartridge valve removal and
installation.
Reelmaster 3550−D
Page 4 − 101
Hydraulic System
Mow Control Manifold Service
VIEW FROM
ABOVE
VIEW FROM
BELOW
FRONT
60 in−lb
(6.7 N−m)
FRONT
17
22
19
2
20 ft−lb
(27 N−m)
18
8
15
17
12
3
21
16
40 ft−lb
(54 N−m)
3
20
25 ft−lb
(33 N−m)
1
13
11
3
25 ft−lb
(33 N−m)
10
5
1
9
4
7
3
3
23
3
3
4
4
25
24
3
20 ft−lb
(27 N−m)
14
6
20 ft−lb
(27 N−m) 50 ft−lb
(67 N−m)
25 ft−lb
(33 N−m)
20 ft−lb
(27 N−m)
Figure 66
1.
2.
3.
4.
5.
6.
7.
8.
9.
Mow control manifold
Coil nut
SAE #4 plug with O−ring (17)
SAE #6 plug with O−ring (4)
Orifice plug (0.020) (port OR2)
Orifice (0.050) (port OR1)
Zero leak #4 plug with O−ring
Spring pin (2)
Check valve (CV port)
Hydraulic System
10.
11.
12.
13.
14.
15.
16.
17.
Logic spool cartridge (LC port)
Flow control valve (FC port)
Rotary handle assembly
Proportional relief valve (PRV port)
Relief valve (RV port)
Solenoid coil
Backlap spool
Retaining ring (2)
Page 4 − 102
18.
19.
20.
21.
22.
23.
24.
25.
O−ring (2)
Back−up ring
O−ring
Back−up ring
Spool handle
Ball
Ball switch (normally open)
O−ring
Reelmaster 3550−D
2. To install rotary handle:
IMPORTANT: Make sure that flow control cartridge
valve is properly secured in manifold before installing rotary handle to valve.
A. Place handle base on flow control valve and position alignment mark on base with number 1 on manifold. Secure base with two (2) set screws. Apply a
light coating of grease to chamfer on top of base to
ease seal installation.
NOTE: The hydraulic manifold shown uses several
zero leak plugs. These plugs have a tapered sealing
surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also
have an O−ring to provide a secondary seal. If zero leak
plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench
to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
When installing plugs into the manifold, torque plugs to
the values shown.
B. Make sure that sleeve bearing is in handle cap. If
necessary, press sleeve bearing into cap. Install lip
seal on cap with seal lip facing down.
C. While pressing on the cap to keep the lip seal in
place, rotate cap in a clockwise direction until the arrow on the cap aligns with number 1 on the manifold.
By rotating the cap clockwise, the valve will remain
closed. Install screw to retain cap.
NOTE: The mow control manifold includes two (2) orifice fittings. The 0.020” orifice threads into manifold port
OR2 under a hex plug. The 0.050” orifice threads into
manifold port OR1 under the diagnostic test fitting.
D. Make sure that alignment marks on cap and base
are in line and that arrow on cap is pointing to number
1 on manifold. Tighten two (2) set screws to secure
handle cap.
Cartridge Valve Service
The mow control manifold includes an adjustable relief
valve (RV). Mow control manifold relief valve (RV)
should be set to 1500 PSI (103 Bar). Adjust the relief
valve to the recommended setting as necessary (see
Adjustments in this chapter).
8
6
For cartridge valve service procedures, see Cartridge
Valve Service in this chapter. When installing cartridge
valves into the manifold, torque cartridge valves to the
values shown.
2
9
Rotary Handle Assembly (Fig. 67)
10
1. To remove rotary handle from valve:
4
11
3
A. Loosen two (2) set screws that secure handle
cap.
5
7
B. Remove screw and then lift handle cap from
valve.
1
C. Locate and retrieve detent pin, compression
spring, bushing and lip seal. The sleeve bearing
should stay in the cap.
D. Loosen two (2) set screws that secure handle
base to flow control valve and remove base.
Reelmaster 3550−D
Figure 67
1.
2.
3.
4.
5.
6.
Page 4 − 103
Handle base
Handle cap
Detent pin
Compression spring
Bushing
Set screw (2)
7.
8.
9.
10.
11.
Set screw (2)
Screw
Lip seal
Sleeve bearing
Flow control valve
Hydraulic System
Hydraulic
System
NOTE: The ports on the mow control manifold are
marked for easy identification of components. Example:
PRV is the proportional relief valve and T is the return
port (see Hydraulic Schematic to identify the function of
the hydraulic lines and cartridge valves at each port
location).
VIEW FROM
ABOVE
7
10
11
10
VIEW FROM
BELOW
FRONT
12
10 ft−lb
(13.5 N−m)
FRONT
6
8
5
9
1
1
20 ft−lb
(27 N−m)
2
3
4
Figure 68
1.
2.
3.
4.
Mow control manifold
Ball switch (normally open)
O−ring
Ball
Hydraulic System
5.
6.
7.
8.
Backlap spool
Retaining ring (lower)
Retaining ring (upper)
Back−up ring
Page 4 − 104
9.
10.
11.
12.
O−ring
O−ring (2)
Back−up ring
Spool handle
Reelmaster 3550−D
Backlap Spool (Fig. 68)
3. To install backlap spool into manifold:
1. To remove backlap spool from manifold:
A. Remove backlap switch from manifold before removing backlap spool. Remove ball from manifold
port after switch is removed. Remove and discard
O−ring from switch.
B. Remove lower retaining ring from backlap spool.
Raise backlap spool to allow access to retaining ring
on upper end of spool. Remove upper retaining ring.
A. Install O−rings and back−up ring to upper
grooves on spool. Apply a light coating of grease to
O−rings.
B. Carefully push spool down into manifold port until
lower O−ring and back−up ring groove is exposed on
bottom of manifold. Install lower O−ring and back−up
ring to spool. Apply a light coating of grease to O−
ring.
C. Install lower retaining ring to spool.
D. Pull spool up and out of manifold. Remove O−
rings and back−up ring from spool.
E. Discard all removed O−rings and back−up rings.
2. Visually inspect the spool and manifold port for damage to the sealing surfaces and contamination.
D. Carefully raise backlap spool until upper retaining
ring groove on spool is exposed on top of manifold.
Install upper retaining ring.
E. If handle was removed from spool, position spool
so handle location of spool is between spring pins in
manifold. Apply Loctite 603 Retaining Compound (or
equivalent) to threads on handle and install handle
into spool. Torque handle 10 ft−lb (13.5 N−m).
F. Place ball in manifold port SW (backlap switch).
Install new O−ring onto backlap switch. Thread
backlap switch into port and torque 20 ft−lb (27
N−m).
Reelmaster 3550−D
Page 4 − 105
Hydraulic System
Hydraulic
System
C. Push spool down until lower O−ring and back−up
ring are exposed on bottom of manifold. Remove
lower O−ring and back−up ring from spool.
Lift Control Manifold
4
3
RIGHT
FRONT
13
5
6
7
9
1
8
12
10
2
11
O−Rings Between Fittings and Hoses/Tubes Not Shown
Figure 69
1.
2.
3.
4.
5.
Mow control manifold
Flange head screw (2 used)
Hydraulic hose
Hydraulic hose
Hydraulic tube (to rear bulkhead)
Hydraulic System
6.
7.
8.
9.
Hydraulic tube (to rear bulkhead)
Hydraulic hose (RH lift cylinder)
Hydraulic hose (RH lift cylinder)
Hydraulic hose (center lift cylinder)
Page 4 − 106
10.
11.
12.
13.
Hydraulic hose (center lift cylinder)
Hydraulic hose (LH lift cylinder)
Hydraulic hose (LH lift cylinder)
Front axle
Reelmaster 3550−D
The ports on the lift control manifold are marked for easy
identification of components. Example: S1 is the solenoid valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic lines and
cartridge valves at each port location).
The lift control manifold is located on the right side of the
traction unit frame. Access the manifold from above
through the hinged floor plate in front of the operator’s
seat, or from behind (below the traction unit frame).
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
3. To prevent contamination of hydraulic system during
lift control manifold removal, thoroughly clean exterior of
manifold.
5. Disconnect hydraulic lines from lift control manifold
and put caps or plugs on open hydraulic lines and fittings. Label disconnected hydraulic lines for proper assembly.
6. Remove the two (2) flange head screws from under
the manifold that secure the manifold to the frame.
NOTE: Refer to Lift Control Manifold Service in this
chapter for information on hydraulic fitting and cartridge
valve removal and installation.
IMPORTANT: A flow control orifice is located beneath many of the fittings in the lift control manifold
ports. If any of the fittings is removed from the manifold, make sure to remove orifice and label its position for assembly purposes. When installing the
orifice in the manifold, make sure that the orifice is
flat in the base of the port. Manifold damage is possible if the orifice is cocked in the port.
Installation (Fig. 69)
1. Install lift control manifold to the frame.
2. Remove caps and plugs from fittings and hoses.
Properly connect hydraulic lines to lift control manifold
(see Hydraulic Hose and Tube Installation in this chapter).
WARNING
Make sure that cutting units are fully lowered before loosening hydraulic lines from lift manifold.
If cutting units are raised as hydraulic lines are
loosened, cutting units may drop unexpectedly.
3. Connect wire harness electrical connectors to the
solenoid valve coils on the lift control manifold.
4. Make sure hydraulic tank is full. Add correct oil if necessary before returning machine to service.
4. Label wire harness electrical connectors that attach
to manifold solenoid coils. Disconnect wire harness
electrical connectors from the solenoid valve coils.
Reelmaster 3550−D
Page 4 − 107
Hydraulic System
Hydraulic
System
Removal (Fig. 69)
Lift Control Manifold Service
VIEW FROM
ABOVE
VIEW FROM
ABOVE
60 in−lb
(6.7 N−m)
60 in−lb
(6.7 N−m)
16
17
FRONT
9
FRONT
16
8
8
9
16
20 ft−lb
(27 N−m)
8
20 ft−lb
(27 N−m)
20 ft−lb
(27 N−m)
5
8
7
7
1
12
6
4
13
20 ft−lb
(27 N−m)
1
19
10
12
13
20 ft−lb
(27 N−m)
14
3
15
20 ft−lb
(27 N−m)
20 ft−lb
(27 N−m)
2
18
11
25 ft−lb
(33 N−m)
3
Figure 70
1.
2.
3.
4.
5.
6.
7.
Lift control manifold
Dust cover
SAE #4 plug with O−ring (2)
Relief valve (RV1)
Solenoid valve (S1)
Solenoid valve (S2)
Solenoid valve (S3 and S4)
Hydraulic System
8.
9.
10.
11.
12.
13.
Solenoid coil (4)
Coil spacer (2)
Orifice (0.035) (port C7)
Orifice (0.055) (port C8)
Orifice (0.040) (ports C1, C3 & C5)
Orifice (0.046) (ports C2, C4 & C6)
Page 4 − 108
14.
15.
16.
17.
18.
19.
Straight fitting (6)
Straight fitting (2)
Coil nut (3)
Tall coil nut
Straight fitting (2)
Diagnostic fitting
Reelmaster 3550−D
CAUTION
Before continuing further, read and become familiar with General Precautions for Removing
and Installing Hydraulic System Components in
this section of this chapter.
WARNING
If lift manifold is attached to machine, make sure
that cutting units are fully lowered before loosening hydraulic lines or cartridge valves from lift
manifold. If cutting units are raised as components are loosened in manifold, cutting units
may drop unexpectedly.
IMPORTANT: A flow control orifice is located beneath many of the fittings in the lift control manifold
ports. If any of the fittings is removed from the manifold, make sure to remove orifice and label its position for assembly purposes. When installing the
orifice in the manifold, make sure that the orifice is
flat in the base of the port. Manifold damage is possible if the orifice is cocked in the port.
NOTE: The hydraulic manifold shown uses several
zero leak plugs. These plugs have a tapered sealing
surface on the plug head that is designed to resist vibration induced plug loosening. The zero leak plugs also
have an O−ring to provide a secondary seal. If zero leak
plug removal is necessary, lightly rap the plug head using a punch and hammer before using an allen wrench
to remove the plug: the impact will allow plug removal with less chance of damage to the socket head of the plug.
When installing plugs into the manifold, torque plugs to
the values shown.
The lift control manifold includes an adjustable relief
valve (RV1). Lift control manifold relief valve (RV1)
should be set to 500 PSI (34.5 Bar). Adjust the relief
valve to the recommended setting as necessary (see
Adjustments in this chapter).
For cartridge valve service procedures, see Cartridge
Valve Service in this chapter. When installing cartridge
valves into the manifold, torque cartridge valves to the
values shown.
Reelmaster 3550−D
Page 4 − 109
Hydraulic System
Hydraulic
System
NOTE: The ports on the lift control manifold are marked
for easy identification of components. Example: S1 is
the solenoid valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic
lines and cartridge valves at each port location).
Control Manifold Cartridge Valve Service
1. Make sure the control manifold is clean before removing the cartridge valve from the control manifold.
2. If cartridge valve is solenoid operated, remove nut
securing solenoid coil to the cartridge valve. Carefully
slide coil off the valve.
IMPORTANT: Use care when handling the cartridge
valve. Slight bending or distortion of the stem tube
can cause binding and malfunction. When removing cartridge valve from manifold, make sure that
deep well socket fully engages the valve base.
3. Remove cartridge valve from manifold using a deep
socket wrench. Note correct location for O−rings, sealing rings and back−up rings. Remove seal kit from cartridge valve and discard removed seals.
4. Visually inspect the port in the manifold for damage
to the sealing surfaces, damaged threads and contamination.
7. Install the cartridge valve into the manifold:
A. Lubricate new seal kit components with clean hydraulic oil and install on valve. The O−rings, sealing
rings and back−up rings must be arranged properly
on the cartridge valve for proper operation and sealing.
B. Dip assembled cartridge into clean hydraulic oil.
IMPORTANT: Use care when handling the valve
cartridge. Slight bending or distortion of the
stem tube can cause binding and malfunction.
When installing cartridge valve into manifold,
make sure that deep well socket fully engages
the valve base.
C. Thread cartridge valve carefully into manifold
port by hand until the top O−ring is met. The valve
should go into manifold port easily without binding.
5. Visually inspect cartridge valve for damaged sealing
surfaces and contamination.
D. Torque cartridge valve using a deep socket
wrench to value identified in control manifold illustration.
A. Contamination may cause valves to stick or hang
up. Contamination can become lodged in small valve
orifices or seal areas causing malfunction.
8. If cartridge valve is solenoid operated, carefully
install solenoid coil to the cartridge valve. Secure coil to
valve with nut and torque nut to 60 in−lb (6.8 N−m).
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or
there may be water in the system.
9. If problems still exist after assembly, remove valve
and clean again or replace valve.
CAUTION
Use eye protection such as goggles when using
compressed air.
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push
the internal spool in and out 20 to 30 times to flush out
contamination. Be extremely careful not to damage cartridge. Use compressed air for cleaning.
Hydraulic System
Page 4 − 110
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 111
Hydraulic System
Steering Control Valve
26
10
18
17
19
RIGHT
20 to 26 ft−lb
(28 to 35 N−m)
14
FRONT
27
4
9
11
24
7
Blue
Loctite 242
5
2
6
8
12
8
20
25
29
2
30
21
1
22
23
13
15
16
28
3
31
32
3
Figure 71
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Steering arm
Flange nut (4)
Flange head screw (4)
Steering valve bracket
Cap screw (2)
Pivot hub (2)
Steering valve cover
Washer head screw (5)
Tilt steering boss
Ball knob
Steering tilt lever
Hydraulic System
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Steering control valve
Tilt bracket
Cap screw
Flat washer
Flange nut
Steering wheel
Steering wheel nut
Flat washer
Friction disc
Friction disc
Flat washer
Page 4 − 112
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Jam nut
Flange head screw (4)
Steering shield
Steering wheel cap
Screw
Flange nut (2)
Bag holder
Washer head screw (2)
Lock nut (2)
Flat washer (2)
Reelmaster 3550−D
Removal (Fig. 71)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
2. Thoroughly clean hydraulic hose ends and fittings on
steering control valve to prevent hydraulic system contamination.
1
2
5
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
3
4
Hydraulic
System
3. Label all hydraulic hoses and fittings for assembly
purposes. Note port identification on steering control
valve.
4. Remove steering control valve from the steering
column.
Figure 72
Installation (Fig. 71)
1. Install steering control valve to the steering column.
Use labels placed during the removal process to properly install hydraulic hoses to control valve.
1. Tilt bracket
2. Jam nut
3. Flat washer
4. Friction disc
5. Steering tilt lever
2
2. Adjust location of steering shield so that it just contacts hydraulic hoses when the steering wheel is tilted
to its lowest position.
3
3. Make sure hydraulic tank is full. Add correct oil if necessary.
1
4
5
Figure 73
1. Hose from gear pump
2. Hose to charge circuit
3. Hose to lift manifold
Reelmaster 3550−D
Page 4 − 113
4. Hose to steer cylinder
5. Hose to steer cylinder
Hydraulic System
Steering Control Valve Service
8
9
7
6
10
5
4
3
2
11
1
12
22
13
14
15
21
13
16
20
13
17
18
20 to 24 ft−lb
(27 to 33 N−m)
19
Figure 74
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Cross pin
Ring
Spool
Bearing assembly
Shaft seal
Ball stop
Ball
9.
10.
11.
12.
13.
14.
15.
Dust seal ring
Housing
Cardan shaft
Spacer
O–ring
Distribution plate
Inner gearwheel
16.
17.
18.
19.
20.
21.
22.
Outer gearwheel
End cover
O–ring (5 used)
Screw/fitting (ports L, R, T)
Screw/fitting (ports P and E)
P port check ball
Spring set
NOTE: For service of the steering control valve, see the
Sauer/Danfoss Steering Unit Type OSPM Service
Manual at the end of this chapter.
Hydraulic System
Page 4 − 114
Reelmaster 3550−D
Hydraulic
System
This page is intentionally blank.
Reelmaster 3550−D
Page 4 − 115
Hydraulic System
Steering Cylinder
8
7
6
No. 2 General
Purpose Grease
No. 2 General
Purpose Grease
8
5
7
1
4
9
65 to 85 ft−lb
(88 to 115 N−m)
3
2
10
12
9
RIGHT
FRONT
65 to 85 ft−lb
(88 to 115 N−m)
11
Figure 75
1.
2.
3.
4.
Hydraulic hose
Hydraulic hose
O−ring (2)
Hydraulic fitting (2)
Hydraulic System
5.
6.
7.
8.
O−ring (2)
Steering cylinder
Ball joint
Retaining ring
Page 4 − 116
9.
10.
11.
12.
Jam nut (4)
Frame
Rear fork
Rear casting
Reelmaster 3550−D
Removal (Fig. 75)
Installation (Fig. 75)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If removed, install ball joints into steering cylinder.
NOTE: The rear tire must be removed to allow sufficient
clearance to remove the steering cylinder from the machine.
2. Lubricate and place new O−rings onto removed
steering cylinder fittings. Install fittings into cylinder
openings using marks made during the removal process
to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter).
3. Install steering cylinder to the frame and rear. When
securing cylinder ball joints to machine, tighten the first
jam nut from 65 to 85 ft−lb (88 to 115 N−m), then tighten
the second jam nut to the same specification.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
2. Jack or lift rear wheel off the ground.
3. Remove rear wheel from the machine.
4. Thoroughly clean hydraulic hose ends and fittings on
steering cylinder to prevent hydraulic system contamination.
4. Remove caps and plugs from steering cylinder fittings and hoses. Using labels placed during cylinder removal, properly connect hydraulic lines to steering
cylinder (see Hydraulic Hose and Tube Installation in
this chapter).
5. Secure rear wheel to the machine with four (4) lug
nuts. Lower machine to the ground. Torque wheel lug
nuts in a crossing pattern from 45 to 65 ft−lb (61 to 88
N−m).
6. Make sure hydraulic tank is full. Add correct oil if necessary.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System Pressure in the General Information section
of this chapter.
7. After assembly is completed, operate steering cylinder to verify that hydraulic hoses and fittings are not contacted by anything.
5. Label the hydraulic hoses to show their correct position on the steering cylinder. Remove hydraulic hoses
from steering cylinder.
6. Remove two (2) jam nuts from both steering cylinder
ball joints. Remove steering cylinder with ball joints from
machine.
7. If hydraulic fittings are to be removed from steering
cylinder, mark fitting orientation to allow correct assembly. Discard O−rings from removed fittings.
8. If needed, remove ball joints from steering cylinder.
Reelmaster 3550−D
Page 4 − 117
Hydraulic System
Hydraulic
System
WARNING
Steering Cylinder Service
1
3
4
7
8
11
12
2
5
6
40 ft−lb
(54 N−m)
9
10
8
5
1
2
3
9
6
4
7
10
12
11
Figure 76
1.
2.
3.
4.
Barrel with clevis
Lock nut
Piston seal
Piston
Hydraulic System
5.
6.
7.
8.
O−ring
O−ring
Back−up ring
Head
Page 4 − 118
9.
10.
11.
12.
Head seal
Dust seal
Internal collar
Rod
Reelmaster 3550−D
Disassembly (Fig. 76)
Assembly (Fig. 76)
1. Remove oil from the steering cylinder into a drain pan
by slowly pumping the cylinder rod. Plug both ports and
clean the outside of the cylinder.
1. Make sure all steering cylinder components are
clean before assembly.
2. Coat new O−rings, seals and back−up ring with
clean hydraulic oil.
A. Install piston seal and O−ring to the piston.
2. Mount barrel end of steering cylinder in a vise. Use
a spanner wrench to remove internal collar from barrel.
B. Install O−ring, back−up ring, head seal and dust
seal to the head.
3. Remove plugs from ports. Extract rod, head and piston assembly from barrel by carefully twisting and pulling on the rod.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Clamp on the clevis ONLY.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Clamp on the clevis ONLY.
4. Mount rod securely in a vise by clamping on the clevis of the rod. Remove lock nut from the rod. Slide piston
and head off the rod.
5. Remove seals, back−up rings and O−rings from the
piston and head. Discard removed seals.
3. Mount rod securely in a vise by clamping on the clevis of the rod.
A. Place internal collar onto rod.
B. Coat rod with a light coat of clean hydraulic oil.
C. Carefully slide head assembly and then piston
assembly onto the rod. Install lock nut onto the rod
and torque nut 40 ft−lb (54 N−m).
D. Remove rod assembly from the vise.
IMPORTANT: Prevent damage when clamping the
steering cylinder into a vise; clamp on the barrel
clevis ONLY.
4. Mount clevis of the barrel in a vise.
5. Coat all internal cylinder parts with a light coat of
clean hydraulic oil. Slide piston, rod and head assembly
into the barrel being careful to not damage the seals.
6. Thread the internal collar into the barrel and secure
with spanner wrench.
Reelmaster 3550−D
Page 4 − 119
Hydraulic System
Hydraulic
System
IMPORTANT: Prevent damage when clamping the
steering cylinder into a vise; clamp on the clevis
ONLY.
Front Lift Cylinders
RIGHT
FRONT
6
14
13
14
13
19
17
16
19
18
16
15
7
2
13
4
15
8
5
7
19
Blue
Loctite 242
13
13
14
14
6
14
3
12
13
14
16
17
4
5
8
11
1
10
9
Blue
Loctite 242
4
5
Figure 77
1.
2.
3.
4.
5.
6.
7.
#1 lift arm
#5 lift arm
#4 lift arm
Recessed bumper (3)
Flange head screws (3)
Cylinder pin (2)
Pivot pin (2)
Hydraulic System
8.
9.
10.
11.
12.
13.
Washer head screw (2)
Lift cylinder
Thrust washer
Lynch pin
Cylinder pin
Thrust washer (6)
Page 4 − 120
14.
15.
16.
17.
18.
19.
Retaining ring (6)
Lift cylinder (2)
O−ring (6)
Elbow fitting (4)
Straight fitting (2)
O−ring (6)
Reelmaster 3550−D
Removal (Fig. 77)
Installation (Fig. 77)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If fittings were removed from lift cylinder, lubricate
and place new O−rings onto fittings. Install fittings into
cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter).
2. Read the General Precautions for Removing and
Installing Hydraulic System Components in this chapter.
2. Secure cylinder barrel clevis to frame.
WARNING
Make sure that the cutting units are fully lowered
before loosening hydraulic lines from lift cylinders. If cutting units are not fully lowered as hydraulic lines are loosened, cutting units may
drop unexpectedly.
NOTE: To ease installation, label the hydraulic hoses to
show their correct position on the lift cylinder.
4. Disconnect hydraulic hoses from lift cylinder being
removed and plug hydraulic hoses to prevent contamination.
5. Remove retaining ring and flat washer from one end
of the cylinder pin that secures rod end of lift cylinder to
lift arm. Pull pin from lift arm and cylinder rod.
A. Slide pivot pin into frame and cylinder barrel clevis. Secure pivot pin to frame with washer head
screw.
B. For inner lift cylinder, make sure that roll pin is in
good condition and is installed in pin. Slide pin into
frame and cylinder barrel clevis. Secure pin to frame
with thrust washer and lynch pin.
3. Make sure that flat washer and retaining ring are installed on one end of the cylinder pin.
4. Position cylinder rod end to lift arm and insert pin
through lift arm and cylinder rod end. Secure pin to lift
arm with second flat washer and retaining ring.
5. Attach hydraulic hoses to lift cylinder (see Hydraulic
Hose and Tube Installation in this chapter).
6. Fill reservoir with hydraulic fluid as required.
7. After installation is completed, operate lift cylinder to
verify that lift cylinder, hydraulic hoses and fittings are
not contacted by anything.
6. Remove pin from frame and cylinder barrel clevis.
A. For outer lift cylinders, remove washer head
screw that secures the pivot pin to the frame. Slide
pivot pin from frame and cylinder barrel clevis.
B. For inner lift cylinder, remove lynch pin and thrust
washer that retains pin in frame. Slide pin from frame
and cylinder barrel clevis.
7. Remove lift cylinder from machine.
8. If hydraulic fittings are to be removed from lift cylinder, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O−rings.
Reelmaster 3550−D
Page 4 − 121
Hydraulic System
Hydraulic
System
3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
Rear Lift Cylinders
4
3
11
4
3
12
6
8
4
9
7
9
8
10
6
13
4
14
15
5
8
5
9
7
9
8
2
1
RIGHT
FRONT
Figure 78
1.
2.
3.
4.
5.
#2 lift arm
#3 lift arm
Pin (2)
Washer head screw (4)
Rear lift cylinder (2)
Hydraulic System
6.
7.
8.
9.
10.
Pin (2)
Cylinder pin (2)
Thrust washer (4)
Retaining ring (4)
Grease fitting (2)
Page 4 − 122
11.
12.
13.
14.
15.
RH torsion spring
LH torsion spring
O−ring (4)
Straight fitting (4)
O−ring (4)
Reelmaster 3550−D
Removal (Fig. 78)
Installation (Fig. 78)
1. Park machine on a level surface. Lower cutting units,
stop engine and engage parking brake. Remove key
from the ignition switch.
1. If fittings were removed from lift cylinder, lubricate
and place new O- rings onto fittings. Install fittings into
cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter).
3. To prevent contamination of hydraulic system during
lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
WARNING
Make sure that the cutting units are fully lowered
before loosening hydraulic lines from lift cylinders. If cutting units are not fully lowered as hydraulic lines are loosened, cutting units may
drop unexpectedly.
NOTE: To ease installation, label the hydraulic hoses to
show their correct position on the lift cylinder.
IMPORTANT: Before
disconnecting
hydraulic
hoses from lift cylinder, note orientation of hoses to
allow correct assembly (Fig. 79).
4. Disconnect hydraulic hoses from lift cylinder that is
to be removed.
2. Position cylinder barrel clevis to frame and insert cylinder pin through the frame and cylinder barrel clevis.
Secure pin with washer head screw.
3. Make sure that flat washer and retaining ring are installed on one end of the cylinder pin.
4. Position cylinder rod end to lift arm and insert cylinder pin through lift arm and cylinder rod end. Secure pin
to lift arm with second flat washer and retaining ring.
5. Attach hydraulic hoses to lift cylinder (see Hydraulic
Hose and Tube Installation in this chapter). Make sure
that hoses are orientated as noted during cylinder removal.
6. Fill reservoir with hydraulic fluid as required.
7. After installation is completed, operate lift cylinder to
verify that lift cylinder, hydraulic hoses and fittings are
not contacted by anything. Make sure that hoses do not
contact square tube of frame (Fig. 79) during lift cylinder
operation.
2
5. Remove retaining ring and flat washer from one end
of the cylinder pin that secures rod end of lift cylinder to
lift arm. Pull pin from lift arm and cylinder rod.
3
1
6. Remove washer head screw that secures the pin to
the frame. Remove pin from frame and cylinder barrel
clevis.
7. Remove lift cylinder from machine.
8. If necessary, remove hydraulic fittings from lift cylinder and discard O- rings.
Figure 79
1. RH lift cylinder
2. LH lift cylinder
Reelmaster 3550- D
Page 4 - 123
3. Square tube
Hydraulic System
Hydraulic
System
2. Read the General Precautions for Removing and
Installing Hydraulic System Components in this chapter.
Lift Cylinder Service
3
5
7
1
9
11
2
12
4
13
6
40 ft−lb
(54 N−m)
8
10
14
4
2
1
6
3
5
11
10
8
9
12
13
7
Figure 79
1.
2.
3.
4.
5.
Barrel
Lock nut
Wear ring
Piston
Seal
6.
7.
8.
9.
10.
O−ring
Head
O−ring
Back−up ring
Seal
11.
12.
13.
14.
Dust seal
Retaining ring
Rod (cutting units #1, #2 and #3)
Rod (cutting units #4 and #5)
NOTE: All of the lift cylinders used on the Reelmaster
3550−D have the same basic construction. The cylinders for cutting units #1, #2 and #3 are the same and use
one style of cylinder rod, while the lift cylinders for cutting
units #4 and #5 are the same but have a different style
cylinder rod. Service procedures for all lift cylinders are
the same.
Hydraulic System
Page 4 − 124
Reelmaster 3550−D
Disassembly (Fig. 79)
Assembly (Fig. 79)
1. Remove oil from the lift cylinder into a drain pan by
slowly pumping the cylinder rod. Plug both ports and
clean the outside of the cylinder.
1. Make sure all lift cylinder components are clean before assembly.
IMPORTANT: Prevent damage when clamping the
cylinder in a vise; clamp on the clevis only.
2. Coat new O−rings, seals and back−up ring with
clean hydraulic oil.
A. Install Uni−ring and O−ring to the piston.
2. Mount lift cylinder securely in a vise by clamping on
the clevis end of the barrel. Use of a vise with soft jaws
is recommended.
B. Install O−rings, back−up ring and rod seal to the
cylinder gland.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Clamp on the clevis ONLY.
A. Use a spanner wrench to rotate head clockwise
until the edge of the retaining ring appears in the barrel opening.
B. Insert a screwdriver under the beveled edge of
the retaining ring to start the retaining ring through
the opening.
C. Rotate the head counter−clockwise to remove retaining ring from barrel and head.
4. Remove plugs from ports. Extract rod, head and piston assembly from barrel by carefully twisting and pulling on the rod.
IMPORTANT: Do not clamp vise jaws against the
rod surface. Clamp on the clevis ONLY.
5. Mount rod securely in a vise by clamping on the clevis of the rod. Remove lock nut from the rod. Slide piston
and head off the rod.
6. Remove seals, back−up rings and O−rings from the
piston and head.
3. Mount rod securely in a vise by clamping on the clevis of the rod.
A. Coat rod with a light coat of clean hydraulic oil.
B. Carefully slide head assembly and then piston
assembly onto the rod. Install lock nut onto the rod
and torque nut 40 ft−lb (54 N−m).
C. Remove rod assembly from the vise.
4. Coat all internal parts with a light coat of clean hydraulic oil. Slide piston, rod and head assembly into the
barrel being careful to not damage the seals.
IMPORTANT: Prevent damage when clamping the
cylinder’s barrel into a vise; clamp on the clevis
only.
5. Mount lift cylinder in a vise with soft jaws. Secure
head in barrel:
A. Align retaining ring hole in the head with the access slot in the barrel.
B. Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is completely pulled into the barrel and the ring ends are
covered.
C. Apply silicone sealer to barrel access slot.
Reelmaster 3550−D
Page 4 − 125
Hydraulic System
Hydraulic
System
3. Loosen head from barrel:
This page is intentionally blank.
Hydraulic System
Page 4 − 126
Reelmaster 3550−D
Chapter 5
Electrical System
Table of Contents
Reelmaster 3550−D
Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower/Raise Joystick Switches . . . . . . . . . . . . .
Reel Enable/Disable Switch . . . . . . . . . . . . . . . .
Mow/Transport Switch . . . . . . . . . . . . . . . . . . . . .
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Temperature Sender . . . . . . . . . . . . . . .
TEC Outputs
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Solenoid Valve Coils . . . . . . . . . . . . .
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAN−bus Termination Resistors . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . .
Worklight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . .
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cartridge Valve Coil Replacement . . . . . . . . . . . .
Worklight Bulb Replacement . . . . . . . . . . . . . . . . .
Page 5 − 1
27
28
29
30
31
32
33
35
37
38
39
41
43
44
44
45
46
47
47
47
48
51
52
Electrical System
Electrical
System
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Toro Electronic Controllers (TEC) . . . . . . . . . . . . . 2
CAN−bus Communications . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostic Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Run and Transport Problems . . . . . . . . . 16
Cutting Unit Operating Problems . . . . . . . . . . . . . 17
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 18
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . 18
Charging System Test . . . . . . . . . . . . . . . . . . . . . . 18
Glow Plug System Test . . . . . . . . . . . . . . . . . . . . . 18
Check Operation of Interlock Switches . . . . . . . . 19
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 20
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Toro Electronic Controller (TEC) . . . . . . . . . . . . . 24
TEC Inputs
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . 26
General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine.
Toro Electronic Controller (TEC)
Reelmaster 3550−D machines use a single Toro Electronic Controller (TEC) to manage machine electrical
functions. The TEC controller is attached to the control
panel.
The controller is a microprocessor that senses the
condition of various machine switches (inputs) and directs electrical power to control appropriate machine
functions (outputs) based on the state of the inputs. The
status of inputs to the controller as well as outputs from
the controller can be checked with the Diagnostic Display (see Special Tools in this chapter).
Because of the solid state circuitry built into the Toro
Electronic Controller (TEC), there is no method to test
it directly. The TEC may be damaged if an attempt is
made to test it with an electrical test device, such as a
digital multimeter.
IMPORTANT: Before performing any welding on the
machine, disconnect the battery cables from the
battery, disconnect the wire harness connectors
from the Toro Electronic Controller and disconnect
the terminal connector from the alternator to prevent damage to the machine electrical system.
CAN−bus Communications
The TEC controller used on the Reelmaster 3550−D can
communicate with other electrical components on a
CAN−bus communication system. The CAN−bus system reduces the number of electrical components and
connections used on the machine and allows the number of wires in the wire harness to be reduced.
CAN identifies the Controller Area Network that is used
on the Reelmaster. Two (2) specially designed, twisted
cables form the bus. These wires provide the data pathways between machine components. The engineering
term for these two (2) cables are CAN−high and CAN−
low. At the ends of the twisted pair of bus cables are 120
ohm termination resistors.
Electrical System
Each of the components that is controlled by the CAN−
bus link only needs four (4) wires to operate and communicate to the system: CAN−high, CAN−low, B+ (power)
and ground.
IMPORTANT: The termination resistors at the ends
of the bus cables are required for proper electrical
system operation.
Page 5 − 2
Reelmaster 3550−D
Electrical Schematic
Electrical
System
The electrical schematic and wiring diagrams for the Reelmaster 3550−D are located in Chapter 9 − Foldout
Drawings in this manual.
Reelmaster 3550−D
Page 5 − 3
Electrical System
Special Tools
Order special tools from your Toro distributor. Some
tools may also be available from a local supplier.
Multimeter
The multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage.
Obtain this tool locally.
NOTE: Toro recommends the use of a DIGITAL Volt−
Ohm−Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Dielectric Gel
Dielectric gel should be used to prevent corrosion of unsealed connection terminals. To ensure complete coating of terminals, liberally apply gel to both component
and wire harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and
reconnect harness connector to component. Connectors should be thoroughly packed with gel for effective
results.
Do not use dielectric gel on sealed connection terminals
as the gel can unseat connector seals during assembly.
Figure 2
Toro Part Number: 107−0342
Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.
Figure 3
Electrical System
Page 5 − 4
Reelmaster 3550−D
Terminal Protector
Aerosol spray that should be used on battery terminals,
ring terminals, and fork terminals to reduce corrosion
problems. Apply battery terminal protector to the connection after the battery cable, ring terminal, or fork terminal has been secured.
Toro Part Number: 107−0392
Figure 4
Diagnostic Display
The Diagnostic Display (Fig. 5) can be connected to the
wiring harness connector located under the control panel to verify correct electrical functions of the machine.
Toro Electronic Controllers (TEC) inputs and outputs
can be checked using the Diagnostic Display.
Electrical
System
Toro Part Number for Diagnostic Display: 85−4750
Toro Part Number for Overlay (English): 121−7886
IMPORTANT: The Diagnostic Display must not be
left connected to the machine. It is not designed to
withstand the environment of the machine’s every
day use. When use of Diagnostic Display is completed, disconnect it from the machine and reconnect loop−back connector to harness connector.
Machine will not operate without loop−back connector installed on harness. Store Diagnostic Display in a dry, secure, indoor location and not on
machine.
Figure 5
TEC
OVERLAY
Figure 6
Reelmaster 3550−D
Page 5 − 5
Electrical System
Troubleshooting
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and components used on this machine (see Chapter 8 − Foldout
Drawings in this manual).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the machine has any interlock switches by−passed,
reconnect the switches for proper safety and troubleshooting.
NOTE: Use the Diagnostic Display (see Special Tools
in this chapter) to test Electronic Control Module inputs
and outputs when troubleshooting an electrical problem
on your Reelmaster.
Diagnostic Light
Reelmaster 3550−D machines are equipped with a
diagnostic light that indicates if the machine electrical
system is functioning correctly. The diagnostic light is located on the control panel (Fig. 7).
1
When the ignition switch is moved to the RUN position
and the machine electrical system is functioning properly, the diagnostic light will be illuminated for approximately three (3) seconds and then will turn off. The light
should remain off during normal machine operation.
If the machine TEC controller detects an electrical system malfunction (fault) during machine operation, the
diagnostic light will flash rapidly. The light will stop flashing and will automatically reset when the ignition switch
is turned to the OFF position. The fault, however, will be
retained in controller memory and can be retrieved at a
future time (see Retrieving Fault Codes below).
2
Figure 7
1. Control panel
If the diagnostic light does not illuminate when the ignition switch is turned to the RUN position, possible
causes are:
2. Diagnostic light
1
The loopback connector located below the control panel is not connected to the wire harness
(Fig. 8).
The diagnostic light (or circuit wiring) is faulty.
2
TEC controller fuses are faulty (see Fuses in this
chapter).
3
The TEC controller is faulty.
Test electrical connections, controller fuses and the
diagnostic light to determine malfunction. Make sure
that the loopback connector is secured to the wire harness connector.
Electrical System
Figure 8
1. Control panel
2. Loopback connector
Page 5 − 6
3. Harness connector
Reelmaster 3550−D
Retrieving Fault Codes
All machine fault codes are retained in the TEC controller memory. The three (3) most recent fault codes that
have occurred within the last forty (40) hours of operation can be retrieved using the diagnostic light. To retrieve these fault codes from the controller memory,
perform the following switch sequence:
1. Operator seat should be UNOCCUPIED, the traction
pedal should be in neutral, the mow/transport slide
should be placed in the transport position and the machine should not be in backlap position.
2. Move and hold joystick in the RAISE position.
3. Turn ignition switch to the RUN position.
4. Monitor the diagnostic light for fault code(s).
NOTE: Once the diagnostic light begins to display fault
codes, the joystick can be released.
If there are no faults that have occurred within the last
forty (40) hours of operation, the diagnostic light will
flash continuously after performing the above switch sequence.
If a fault code is not retrieved from the controller memory
within forty (40) hours of machine operating time, the
fault cannot be retrieved from controller memory using
this procedure. If necessary, contact your Toro distributor to retrieve older fault codes.
Fault Description
1−3
Controller master board is faulty
1−5
Circuit current to high temperature warning light is excessive
1−6
High engine temp warning occurred (PTO was shutdown by controller)
1−7
High engine temp shutdown occurred (engine was shutdown by controller)
1−8
Low engine oil pressure occurred
1−9
Engine alternator fault occurred
2−1
Excessive charging voltage was detected by controller (check charging system)
2−2
Low charging voltage was detected by controller (check charging system)
2−3
Upper fuse 2 (7.5 amp) is faulty
2−4
Upper fuse 3 (7.5 amp) is faulty
2−5
Upper fuse 4 (7.5 amp) is faulty
2−6
Main power relay fault occurred (check main power relay)
3−1
Circuit current to start relay is excessive (check start relay circuit)
3−3
Circuit current to fuel stop solenoid is excessive (check solenoid circuit)
3−5
Circuit current to glow plug relay is excessive (check glow plug circuit)
4−1
Circuit current to energize the lift/lower S1 solenoid is excessive
5−1
Circuit current to energize the PRV solenoid (mow) is excessive
5−3
Circuit current to energize the lift/lower S2 solenoid is excessive
5−5
Circuit current to energize the lift/lower S3 solenoid is excessive
5−7
Circuit current to energize the lift/lower S4 solenoid is excessive
Table 1: Diagnostic Fault Codes
Reelmaster 3550−D
Page 5 − 7
Electrical System
Electrical
System
Fault Code (Lamp Flashes)
Fault codes are listed in the chart below. There will be
a one (1) second pause between the first and second
digit of a code. Up to three (3) fault codes retained in
controller memory will be displayed by the diagnostic
light in order from the most recent fault to the oldest fault.
If there are multiple faults in controller memory, there will
be a three (3) second pause between codes. The fault
codes will continually repeat after a five (5) second
pause until the ignition key is turned off.
Clearing Fault Codes
2. Operator seat should remain UNOCCUPIED.
After fault codes have been retrieved, clearing of those
faults can be completed using the following switch sequence:
3. Move mow/backlap lever on the hydraulic mow control manifold to the BACKLAP position.
4. Move joystick to the RAISE position.
1. Place machine switches in fault retrieval (see Retrieving Fault Codes in this chapter). The diagnostic light
should be displaying the fault codes.
Electrical System
5. Monitor the diagnostic light for continuous flashing
indicating that all faults have been cleared from the controller memory.
Page 5 − 8
Reelmaster 3550−D
Diagnostic Display
Reelmaster 3550−D machines are equipped with a Toro
Electronic Controller (TEC) which controls machine
electrical functions. The controller monitors various input switches (e.g. ignition switch, seat switch, neutral
switch) and energizes outputs to actuate solenoids or
relays for the requested machine function.
3
For the TEC to control the machine as desired, each of
the inputs (switches and sensors) and outputs (solenoids and relays) must be connected and functioning
properly.
2
1
The Diagnostic Display (see Special Tools in this chapter) is a tool to help the technician verify correct electrical
functions of the machine.
Figure 9
1. Wire harness connector
2. Loop−back connector
3. Control panel
TEC
OVERLAY
Electrical
System
IMPORTANT: The Diagnostic Display must not be
left connected to the machine. It is not designed to
withstand the environment of the machine’s every
day use. When use of the Diagnostic Display is completed, disconnect it from the machine and reconnect loop−back connector to harness connector.
The machine will not operate without the loop−back
connector installed on the harness. Store the Diagnostic Display in a dry, secure, indoor location and
not on machine.
CAUTION
The interlock switches are for the protection of
the operator and bystanders and to ensure correct operation of the machine. Do not bypass or
disconnect switches. Check the operation of the
interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine.
Verify Diagnostic Display Input Functions
1. Park machine on a level surface, lower the cutting
units, stop the engine and apply the parking brake.
2. Remove cover from control panel to allow access to
wire harness loop−back connector. Locate wire harness
and loop−back connector (Fig. 9). Carefully unplug
loop−back connector from wire harness connector.
Figure 10
3. Connect the Diagnostic Display connector to the
wire harness connector. Make sure correct overlay decal is positioned on the Diagnostic Display (Fig. 10).
NOTE: When the ignition switch is in the OFF position,
all Diagnostic Display LED’s should be OFF.
Reelmaster 3550−D
Page 5 − 9
Electrical System
4. Turn the ignition switch to the ON position, but do not
start machine.
NOTE: The red text on the Diagnostic Display overlay
decal refers to TEC inputs and the green text refers to
TEC outputs.
5. The “inputs displayed” LED, on lower right column of
the Diagnostic Display, should be illuminated. If “outputs
displayed” LED is illuminated, press the toggle button on
the Diagnostic Display to change to “inputs displayed”
LED.
6. The Diagnostic Display will illuminate the LED
associated with each of the inputs when that input switch
is closed. Individually, change each of the switches from
open to closed (i.e., sit on seat, press traction pedal,
etc.), and note that the appropriate LED on the Diagnostic Display will illuminate when the corresponding switch
is closed. Repeat on each switch that is possible to be
changed by hand (see Table 2: Diagnostic Display Inputs).
Diagnostic Display Inputs
ENGINE TEMP (A)
P BRAKE OFF
NEUTRAL
LOWER REEL
RAISE REEL
NOTE: When the Diagnostic Display is attached to the
wire harness connector and the ignition switch is in the
ON position, the input LED for alternator, engine temp
and engine oil pressure should be illuminated. To test
these inputs, disconnect the wire harness connector
from the specific sensor and the appropriate LED should
go off after a few second delay. When the harness connector is reattached to the sensor, the input LED should
again illuminate after a few seconds.
7. If appropriate LED does not toggle on and off when
switch state is changed, check all wiring and connections to that switch and/or test switch (see Component
Testing in this chapter). Replace any defective switches
and repair any damaged wiring.
8. After input functions testing is complete, disconnect
the Diagnostic Display connector from the wire harness
connector and plug loop−back connector into wire harness. Install cover onto control panel.
Diagnostic Display LED Operation
Engine coolant temperature high, sensor and circuit wiring OK: LED ON
Coolant temperature low, sensor or circuit wiring faulty: LED OFF
Parking brake disengaged: LED ON
Parking brake engaged: LED OFF
Traction pedal in neutral: LED ON
Traction pedal in forward or reverse: LED OFF
Lower/raise control lever in LOWER position: LED ON
Lower/raise control lever NOT in LOWER position: LED OFF
Lower/raise control lever in RAISE position: LED ON
Lower/raise control lever NOT in RAISE position: LED OFF
PTO
Enable/disable switch in ON position (pulled out): LED ON
Enable/disable switch in OFF position (pushed in): LED OFF
MOW
Mow/transport slide in the MOW position: LED ON
Mow/transport slide in the TRANSPORT position: LED OFF
ALT. L
Engine not running OR alternator faulty: LED ON
Alternator OK: LED OFF
ENGINE OIL PRESSURE
SEAT
BACKLAP
Engine not running OR low engine oil pressure: LED ON
Engine oil pressure OK: LED OFF
Operator seat occupied: LED ON
Operator seat empty: LED OFF
Cutting reels in backlap position: LED ON
Cutting reels NOT in backlap position: LED OFF
Table 2: Diagnostic Display Inputs
Electrical System
Page 5 − 10
Reelmaster 3550−D
Verify Diagnostic Display Output Functions
3
The Diagnostic Display also has the ability to detect
which outputs (solenoids, relays and indicator lights) are
energized by the TEC controller. This is a quick way to
determine if a machine malfunction is electrical or hydraulic.
NOTE: An open output (e.g. an unplugged connector or
a broken wire) cannot be detected with the Diagnostic
Display. The diagnostic display confirms the signal is being sent from the TEC controller, not that the solenoid,
relay or indicator light is receiving the signal.
2
1
1. Park machine on a level surface, lower the cutting
units, stop the engine and engage the parking brake.
2. Remove cover from control panel to allow access to
wire harness loop−back connector. Locate wire harness
and loop−back connector (Fig. 11). Carefully unplug
loop−back connector from wire harness connector.
Figure 11
1. Wire harness connector
2. Loop−back connector
3. Control panel
3. Connect the Diagnostic Display connector to the
wire harness connector. Make sure correct overlay decal is positioned on the Diagnostic Display (Fig. 12).
TEC
OVERLAY
Electrical
System
NOTE: The red text on the Diagnostic Display overlay
decal refers to TEC inputs and the green text refers to
TEC outputs.
4. The “outputs displayed” LED, on lower right column
of the Diagnostic Display, should be illuminated. If “inputs displayed” LED is illuminated, press the toggle button on the Diagnostic Display to change the LED to
“outputs displayed”.
NOTE: It may be necessary to toggle between “inputs
displayed” and “outputs displayed” several times to perform the following step. To change from inputs to outputs, press toggle button once. This may be done as
often as required. Do not press and hold toggle button.
5. Attempt to operate the desired function of the machine. Use the following information to position the necessary input(s) and illuminate the desired output LED
indicating that the TEC controller is energizing that function.
Figure 12
CAUTION
Keep away from cutting units during test to prevent personal injury from the cutting blades.
Reelmaster 3550−D
Page 5 − 11
Electrical System
Output
No.
Output Name
1
START
Key Switch − START
Traction Pedal − NEUTRAL
Seat Switch − OCCUPIED or Parking Brake − ENGAGED
Reel Enable/Disable Switch − DISABLE
Joystick − NEUTRAL
2
ETR
Key Switch − RUN or START
Traction Pedal − NEUTRAL
Seat Switch − OCCUPIED or Parking Brake − ENGAGED
Engine Coolant Temperature − BELOW 240°F (116°C)
3
GLOW
Key Switch − RUN or START
LED illuminates for 6 seconds when key switch is in RUN position.
LED illuminates when key switch is in START position.
4
DIAGNOSTIC
LIGHT
Key Switch − RUN
LED illuminates for 3 seconds when key switch is in RUN position.
5
SV1 (LIFT/
LOWER)
6
(unused)
7
FRONT MOW
(SP)
8
SV2 (LIFT)
Engine − RUNNING
Mow/Transport Switch − MOW
Reel Enable/Disable Switch − DISABLE
Seat Switch − OCCUPIED
Joystick − RAISE
Backlap Switch − MOW
9
SV3 (FRONT EN)
Engine − RUNNING
Mow/Transport Switch − MOW
Reel Enable/Disable Switch − DISABLE
Seat Switch − OCCUPIED
Joystick − LOWER or RAISE
10
SV4 (REAR EN)
Engine − RUNNING
Mow/Transport Switch − MOW
Reel Enable/Disable Switch − DISABLE
Seat Switch − OCCUPIED
Joystick − LOWER or RAISE
11
ALTERNATOR
Key Switch − RUN
12
OVER TEMP
Key Switch − RUN
Input Conditions Required to Illuminate Output LED
Engine − RUNNING
Mow/Transport Switch − MOW
Reel Enable/Disable Switch − DISABLE
Seat Switch − OCCUPIED
Joystick − LOWER or RAISE
Not used for this product
Engine − RUNNING
Engine Coolant Temperature − BELOW 220°F (105°C)
Mow/Transport Switch − MOW
Reel Enable/Disable Switch − ENABLE
Seat Switch − OCCUPIED
Cutting Units − FULLY LOWERED
Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs
Electrical System
Page 5 − 12
Reelmaster 3550−D
6. The automatic cutting unit Lower Sequence or Raise
Sequence (programed into the TEC controller) energizes and de−energizes outputs 5 thru 10 in a predetermined order. Operation of the program sequence can be
checked using the diagnostic display by meeting the input conditions required for these outputs, setting the reel
enable/disable switch to the ENABLE position, and momentarily moving the joystick to RAISE or LOWER. The
output LEDs will illuminate during the sequence and extinguish when the sequence is completed, with one exception. The LED for output 7 (Front Mow (SP)) will
remain illuminated after the Lower Sequence has completed.
START
ETR
GLOW
DIAGNOSTIC LIGHT
SV1 (LIFT/LOWER)
REAR MOW (SV)
FRONT MOW (SP)
8. If each input is in the correct position and functioning
correctly, and the output LED is not illuminating, a TEC
controller problem may exist. If this occurs, contact your
Toro Distributor for assistance.
9. After output functions testing is complete, disconnect the Diagnostic Display connector from the wire harness connector and plug loop−back connector into wire
harness. Install cover onto control panel.
Diagnostic Display LED Operation
Start Relay energized: LED ON
Start Relay de−energized: LED OFF
Fuel Pump and Fuel Stop solenoid (HOLD) energized: LED ON
Fuel Pump and Fuel Stop solenoid (HOLD) de−energized: LED OFF
Glow Relay, Glow Plugs, and Glow Plug Indicator Light energized: LED ON
Glow Relay, Glow Plugs, and Glow Plug Indicator Light de−energized: LED OFF
Diagnostic Light energized: LED ON
Diagnostic Light de−energized: LED OFF
Solenoid S1 energized: LED ON
Solenoid S1 de−energized: LED OFF
Not used for this product
Proportional Relief Valve (PRV) energized: LED ON
Proportional Relief Valve (PRV) de−energized: LED OFF
SV2 (LIFT)
Solenoid S2 energized: LED ON
Solenoid S2 de−energized: LED OFF
SV3 (FRONT EN)
Solenoid S3 energized: LED ON
Solenoid S3 de−energized: LED OFF
SV4 (REAR EN)
Solenoid S4 energized: LED ON
Solenoid S3 de−energized: LED OFF
ALTERNATOR
OVER TEMP
Electrical
System
Output Name
7. If the output LED illuminates as specified, but the machine does not function properly, suspect a failed electrical component, an open condition in the tested circuit or
a non-electrical problem (e.g. hydraulic component
problem). Repair as necessary.
Charge Indicator Light energized: LED ON
Charge Indicator Light de−energized: LED OFF
High Temperature Warning Light energized: LED ON
High Temperature Warning Light de−energized: LED OFF
Table 4: Diagnostic Display Outputs
Reelmaster 3550−D
Page 5 − 13
Electrical System
Starting Problems
Problem
Possible Causes
Nothing happens when start attempt is made.
The traction pedal is not in the neutral position.
NOTE: If high engine coolant temperature (above
240°F (116°C)) causes the engine to stop, the engine
can be restarted for ten (10) seconds to allow the
machine to be moved. After ten seconds in this
condition, the engine will again shutdown.
The traction neutral sensor is out of adjustment or is
faulty.
The parking brake is disengaged and the operator seat
is unoccupied.
The reel enable/disable switch is in the ENABLE (up)
position or is faulty.
The engine coolant temperature is excessive or the
engine high temperature shutdown switch is faulty.
The battery is discharged or is faulty.
The battery cables are loose or corroded.
The ground connection is loose or corroded.
Fuse(s) is (are) faulty.
The fusible link harness at the engine starter motor is
faulty.
Wiring in the engine crank circuit is loose, corroded or
damaged (see electrical schematic in Chapter 9 −
Foldout Drawings in this manual).
The ignition switch is faulty.
Wiring at the starter solenoid is loose, corroded or
damaged.
Main power relay or circuit wiring is faulty.
The starter solenoid is faulty.
The TEC controller is faulty.
Starter solenoid clicks, but starter will not crank.
The battery is discharged or is faulty.
NOTE: If the starter solenoid clicks, the problem is not The battery cables are loose or corroded.
in the interlock system.
The ground connection is loose or corroded.
The wiring at the starter is faulty.
The starter solenoid is faulty.
The starter motor is faulty.
Electrical System
Page 5 − 14
Reelmaster 3550−D
Starting Problems (continued)
Problem
Possible Causes
The engine cranks, but does not start.
The fuel tank is empty.
Wiring in the engine crank circuit is loose, corroded or
damaged (see electrical schematic in Chapter 9 −
Foldout Drawings in this manual).
The fuel filter is plugged.
The engine and/or fuel may be too cold.
The fusible link to the engine run solenoid pull coil is
faulty.
The engine run solenoid or circuit wiring is faulty.
The engine fuel pump or circuit wiring is faulty.
The engine glow plug circuit does not operate properly
(see below).
The engine or fuel system is malfunctioning (see
Chapter 3 − Kubota Diesel Engine).
One (or more) of the engine glow plugs is faulty.
Fuse(s) is (are) faulty.
The fusible link harness at the engine starter motor is
faulty.
The glow relay is faulty.
The TEC Controller is faulty.
The engine cranks (but should not):
with the traction pedal in FORWARD or
REVERSE.
The neutral switch is out of adjustment or faulty.
The neutral switch circuit wiring is faulty.
with the operator’s seat UNOCCUPIED and
the parking brake DISENGAGED.
The seat switch or seat switch circuit wiring is faulty.
The brake switch is out of adjustment or faulty.
The brake switch circuit wiring is faulty.
with the reel enable/disable switch in the
ENABLE (up) position.
The reel enable/disable switch or reel enable/disable
switch circuit wiring is faulty.
with the joystick in the RAISE or LOWER
position.
The joystick raise or lower switch is faulty.
The joystick raise or lower switch circuit wiring is faulty.
The TEC Controller is faulty.
The engine starts, but stops when the ignition switch is
released from the START position.
The engine fuel stop solenoid hold coil circuit wiring is
faulty.
The ignition switch is faulty.
Reelmaster 3550−D
Page 5 − 15
Electrical System
Electrical
System
The engine glow plug circuit does not operate properly. Wiring in the engine glow circuit is loose, corroded or
damaged (see electrical schematic in Chapter 9 −
Foldout Drawings in this manual).
General Run and Transport Problems
Problem
Possible Causes
Engine stops during operation (operator sitting on
seat).
Operator not in center of seat (seat switch is not
depressed).
Fuel tank is empty.
Machine is being operated on a slope with a low fuel
level.
The parking brake was engaged or the parking brake
sensor is faulty.
Fuse(s) is (are) faulty (other electrical components
most likely affected as well).
The engine temperature is high (above 240oF / 115oC).
Engine temperature sender or circuit wiring is faulty.
The seat switch is faulty.
The engine run solenoid or fuel pump failed.
Wiring in the run circuit is faulty or disconnected (see
electrical schematic in Chapter 9 − Foldout Drawings).
Engine stops when the traction pedal is moved to the
FORWARD or REVERSE position with the operator in
the seat.
Operator is sitting too far forward on the seat (seat
switch not depressed).
Seat switch is faulty.
Seat switch wiring is loose, corroded or damaged.
Parking brake is engaged.
Parking brake switch is out of adjustment or is faulty.
Parking brake switch wiring is loose, corroded or
damaged.
Battery does not charge.
NOTE: If the alternator warning lamp is faulty, or the
alternator warning lamp wiring is loose, corroded or
damaged, the alternator warning lamp will not
illuminate when a charging system failure occurs.
Wiring to the charge circuit components is loose,
corroded or damaged (see electrical schematic in
Chapter 9 − Foldout Drawings in this manual).
The engine alternator belt is loose or damaged.
The fusible link connecting the engine starter motor to
the alternator is faulty.
The battery is faulty.
The alternator/voltage regulator is faulty.
Electrical System
Page 5 − 16
Reelmaster 3550−D
Cutting Unit Operating Problems
Problem
Possible Causes
Cutting units run (but should not) when raised.
The mow control manifold proportional relief valve
(PRV) solenoid coil or circuit wiring is faulty.
A hydraulic problem exists (see Chapter 5 − Hydraulic
System in this manual).
The TEC Controller is faulty.
Cutting units do not run when lowered with the
mow/transport switch in the MOW position.
Fuse(s) is (are) faulty (other electrical components
most likely affected as well).
Engine temperature is high (above 220°F (105°C).
Engine temperature sender or circuit wiring is faulty.
The transport/mow switch is out of adjustment.
The transport/mow switch or circuit wiring is faulty.
The mow control manifold proportional relief valve
(PRV) solenoid coil or circuit wiring is faulty.
The TEC Controller is faulty.
Cutting units will not raise.
Fuse(s) is (are) faulty (other electrical components
most likely affected as well).
Raise switch in joystick assembly is faulty.
Raise switch circuit wiring is faulty.
Lift control manifold solenoid valve coil(s) (S1, S3
and/or S4) or circuit wiring is faulty.
A hydraulic problem exists (see Chapter 5 − Hydraulic
System in this manual).
The TEC Controller is faulty.
Cutting units will not lower.
Fuse(s) is (are) faulty (other electrical components
most likely affected as well).
Lower switch in joystick assembly is faulty.
Lower switch circuit wiring is faulty.
Lift control manifold solenoid valve coil(s) (S1, S2, S3
and/or S4) or circuit wiring is faulty.
A hydraulic problem exists (see Chapter 5 − Hydraulic
System in this manual).
The TEC Controller is faulty.
Reelmaster 3550−D
Page 5 − 17
Electrical System
Electrical
System
A hydraulic problem exists (see Chapter 5 − Hydraulic
System in this manual).
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Set multimeter to the DC volts setting. The battery
should be at a temperature of 60° to 100°F (16° to 38°C).
The ignition key should be off and all accessories turned
off. Connect the positive (+) meter lead to the positive
battery post and the negative (−) meter lead to the negative battery post.
Voltage Measured
Battery Charge Level
12.68 V (or higher)
Fully charged (100%)
12.45 V
75% charged
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
the Service and Repairs section of this chapter).
Charging System Test
This is a simple test used to determine if a charging system is functioning. It will tell you if the charging system
has an output, but not its capacity.
After running the engine for at least three (3) minutes,
battery voltage should be at least 0.50 volt higher than
initial battery voltage.
Use a digital multimeter set to DC volts. Connect the
positive (+) multimeter lead to the positive battery post
and the negative (−) multimeter lead to the negative battery post. Keep the test leads connected to the battery
posts and record the battery voltage.
Test the battery (see Battery Service in this manual) and/
or the alternator/voltage regulator assembly (see
Kubota Workshop Manual) if necessary.
NOTE: Upon starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will
increase at different rates as the battery charges.
An example of a charging system that is functioning:
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
= 12.30 v
Battery Voltage after 3 Minute Charge
= 12.85 v
Difference
= +0.55 v
Start the engine and run at high idle (3200 RPM). Allow
the battery to charge for at least three (3) minutes. Record the battery voltage.
Glow Plug System Test
This is a fast, simple test that can help to determine the
integrity and operation of your Reelmaster glow plug
system. The test should be run anytime hard starting
(cold engine) is encountered on a diesel engine
equipped with a glow plug system.
ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow
plug system. Adjust the meter to read zero (if applicable). Activate the glow plug system by turning the ignition switch to ON and record the multimeter results.
The Reelmaster glow plug system should have a readUse a digital multimeter and/or inductive Ammeter (AC/
ing of approximately nine (9) amps per glow plug (27
DC Current Transducer). Properly connect the ammeter
amps total). If low current reading is observed, one (or
to the digital multimeter (refer to manufacturers’ instrucmore) of the glow plugs is faulty.
tions) and set the multimeter to the correct scale. With
the ignition switch in the OFF position, place the
Electrical System
Page 5 − 18
Reelmaster 3550−D
Check Operation of Interlock Switches
CAUTION
Electrical
System
Do not disconnect safety switches. They are for
the operator’s protection. Check the operation of
the interlock switches daily for proper operation.
Replace any malfunctioning switches before operating the machine.
Interlock switch operation is described in the Traction
Unit Operator’s Manual. Your Reelmaster is equipped
with an Toro Electronic Controller (TEC) which monitors
interlock switch operation. Use the Diagnostic Display
(see Special Tools in this chapter) to test Toro Electronic
Controller inputs and outputs before further troubleshooting of an electrical problem on your Reelmaster
(see Diagnostic Display in this chapter).Information for
testing individual interlock switches and relays is included in the this Chapter.
Reelmaster 3550−D
Page 5 − 19
Electrical System
Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
checking continuity on the switch terminals).
NOTE: For engine component testing information
(starter solenoid and motor, alternator, glow plugs) see
the Kubota Workshop Manual: 05 Series Diesel Engine.
CAUTION
When testing electrical components for continuity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
Ignition Switch
The ignition (key) switch is located on the control panel
and has three (3) positions: STOP, RUN and START
(Fig. 13). The Toro Electronic Controller (TEC) monitors
the operation of the ignition switch and reacts to the various ignition switch positions.
STOP
RUN
START
Testing
6
5
4
1. Park machine on a level surface, lower cutting units,
engage parking brake and stop engine. Remove key
from ignition switch.
2. Remove cover from control panel to access ignition
switch.
1
2
3
REAR VIEW
FRONT VIEW
Figure 13
3. Make sure ignition switch is in the OFF position. Disconnect wire harness connector from ignition switch.
SWITCH
POSITION
4. The ignition switch terminals are identified in Figure
13 and the circuitry of the switch is shown in the chart in
Figure 14. With the use of a multimeter (ohms setting),
the switch functions can be tested to determine whether
continuity exists between the various terminals for each
switch position. Verify continuity between switch terminals.
5. Replace ignition switch if testing determines that it is
faulty.
6. If the ignition switch tests correctly and a circuit problem still exists, check wire harness.
CIRCUITS
STOP
1+6
RUN
1+3+4+5+6
START
1+2+4+5+6
Figure 14
NOTE: Ignition switch terminals 1 and 6 are connected
internally. Terminals 4 and 5 are also connected internally. These terminals should have continuity regardless of
switch position.
7. After testing is complete, connect machine wire harness connector to ignition switch. Install cover onto control panel.
Electrical System
Page 5 − 20
Reelmaster 3550−D
Main Power Relay
The main power relay is secured to the control panel assembly next to the operator seat (Fig. 15). This relay is
attached to the wire harness with a four (4) wire connector (Fig. 16). The relay can be accessed by removing the
control panel cover.
1
6
The main power relay is used to provide current to the
TEC controller and most of the fuse protected circuits
(worklights, power point, console indicators and other
electric equipment). When the ignition switch is in the
RUN or START position, the main power relay is energized.
4
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
5
3
Figure 15
1. Lock nut
2. Start relay
3. Main power relay
4. Glow relay
5. Screw
6. Mounting bracket
3. Remove cover from control panel and locate main
power relay (Fig. 15).
86
87
4. Disconnect wire harness connector from relay. Remove relay from mounting bracket for testing.
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from from the measured value of the component you
are testing.
5. Using a multimeter, verify that coil resistance between terminals 86 and 85 is approximately 72 ohms.
6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
Reelmaster 3550−D
30
85
85
30
86
87
Figure 16
7. Disconnect voltage and test leads from the relay terminals.
8. After testing is completed, secure relay to mounting
bracket and connect wire harness connector to relay.
Install cover to control panel.
9. Connect positive (+) cable to battery and then connect negative (−) cable to battery (see Battery Service
in the Service and Repairs section of this chapter).
Page 5 − 21
Electrical System
Electrical
System
2. To make sure that machine operation does not occur
unexpectedly, disconnect negative (−) cable from battery and then disconnect positive (+) cable from battery
(see Battery Service in the Service and Repairs section
of this chapter).
2
Fuses
The fuse blocks are located under the control panel cover on the right side of the machine.
Fuse Identification and Function
Use the fuse decal (Fig.17) and fuse block (Fig. 18) to
identify each individual fuse and its correct amperage.
The fuses have the following function:
Upper, rear fuse 1 (2 amp) protects logic power circuit
to the TEC controller.
Upper fuse 2 (7.5 amp) protects TEC output power
supply for start relay, fuel stop solenoid, fuel pump, glow
relay, glow plug indicator light and console diagnostic
light. If this fuse is faulty, a fault should be displayed by
the diagnostic light on the control panel (see Diagnostic
Light in this chapter).
Fuse Testing
Remove cover from control panel to access fuse blocks.
Turn ignition switch to the ON position (do not start engine). With the fuse installed in the fuse block, use a
multimeter to verify that 12 VDC exists at both of the terminal test points on the fuse. If 12 VDC exists at one of
the fuse test points but not at the other, the fuse is faulty.
If necessary, make sure that ignition switch is OFF and
key is removed from switch. Remove fuse from fuse
block and check that fuse has continuity across the fuse
terminals.
Upper fuse 3 (7.5 amp) protects TEC output power
supply for cutting unit proportional relief valve (PRV), lift/
lower enable solenoid (S1) and lift/lower solenoid (S2).
If this fuse is faulty, a fault should be displayed by the
diagnostic light on the control panel (see Diagnostic
Light in this chapter).
Upper, front fuse 4 (7.5 amp) protects TEC output
power supply for front cutting unit lift solenoid (S3), rear
cutting unit lift solenoid (S4), alternator indicator light
and over temperature indicator light. If this fuse is faulty,
a fault should be displayed by the diagnostic light on the
control panel (see Diagnostic Light in this chapter).
Lower, rear fuse 1 (15 amp) protects parking brake
switch, hour meter, alternator, low oil pressure light.
Figure 17
FRONT
REAR
Lower fuse 2 (10 amp) protects engine starter circuit.
7.5A
7.5A
7.5A
10A
10A
10A
1
2
3
4
2A
Lower, front fuse 4 (10 amp) protects worklight circuit.
15A
Lower fuse 3 (10 amp) protects power point circuit.
Figure 18
Electrical System
Page 5 − 22
Reelmaster 3550−D
Fusible Links
The Reelmaster 3550−D uses four (4) fusible links for
circuit protection. Three (3) of the fusible links are located in a single harness that connects the starter B+
terminal to the main wire harness (Fig. 19). The fusible
links in this harness protect the glow plug, alternator,
and main power relay circuits.
FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK
An additional fusible link is integrated into the main wire
wire harness between the starter G terminal and the fuel
stop solenoid pull coil.
Figure 19
If any of these links should fail, current to the protected
circuit will be interrupted. Refer to electrical schematic
in Chapter 8 − Foldout Drawings in this manual for additional information.
1
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, and engage parking brake. Unlatch and
raise hood.
2
Figure 20
3. For fusible link harness (Fig. 19):
1. Fuel stop solenoid
2. Harness connector
A. Locate and unplug fusible link connector from
machine wire harness.
2
B. Use a multimeter to make sure that continuity exists between the fusible link terminal on the starter
B+ terminal (terminal J1 on fusible link harness) and
each of the terminals in the link harness connector
P1. If any of the fusible links are open, replace the
fusible link harness.
1
4. For fusible link integrated into wire harness:
A. Locate and unplug machine wire harness connector from the fuel stop solenoid (Fig. 20).
Figure 21
1. Fuel stop solenoid
B. Use a multimeter to make sure that continuity exists between the wire harness connector at the starter and the engine fuel stop solenoid connector for the
solenoid pull coil (Fig. 21 − yellow wire).
C. If this fusible link should fail, make sure that the
wire harness is repaired with the correct fusible link.
Do not replace a failed harness fusible link with a regular section of wire.
Reelmaster 3550−D
2. Pull coil terminal
5. When testing is completed, make sure to connect all
disconnected wire harness components. Connect positive (+) battery cable and then negative (−) cable (see
Battery Service in the Service and Repairs section of
this chapter).
Page 5 − 23
Electrical System
Electrical
System
2. Disconnect negative (−) battery cable from battery
terminal and then disconnect positive (+) cable from battery (see Battery Service in the Service and Repairs section of this chapter).
Toro Electronic Controller (TEC)
The Reelmaster 3550−D uses a Toro Electronic Controller (TEC) to monitor the condition of various switches
(inputs) and directs power to a variety or outputs to control certain machine functions. The controller is located
under the control panel (Fig. 22). The handheld Diagnostic Display with the correct overlay should be used
to check inputs and outputs of the controller (see Diagnostic Display in this chapter).
Logic power is provided to the controller as long as the
battery cables are connected to a charged battery. A two
(2) amp fuse (upper, rear fuse 1) provides circuit protection for the logic power to the controller.
1
3
2
The TEC controller monitors the states of the following
components as inputs: ignition switch, parking brake
switch, neutral switch, reel lower/raise joystick switches,
reel enable/disable switch, mow/transport switch, seat
switch, backlap switch, engine temperature sender.
Current output to the indicator lights, mow circuit hydraulic solenoid valve coil, lift circuit hydraulic solenoid
valve coils and engine components (glow plug relay,
start relay, fuel pump and fuel stop solenoid) are controlled based on the inputs received by the controller.
Circuit protection for the TEC outputs is provided by
three (3) 7.5 Amp fuses (upper, rear fuse 2, 3 and 4).
The machine electrical schematic and wire harness
drawings in Chapter 10 − Foldout Drawings can be used
to identify possible circuit problems between the controllers and the input or output devices (e.g. switches and
solenoid coils).
4
Figure 22
1. Control panel
2. TEC controller
WIRE HARNESS CONNECTOR FOR
TEC CONTROLLER
41
IMPORTANT: When testing for wire harness continuity at the connector for the TEC controller, take
care to not damage the connector pins with multimeter test leads. If connector pins are enlarged or
damaged during testing, connector repair will be
necessary for proper machine operation.
Electrical System
50
40
31
21
30
11
20
Because of the solid state circuitry built into the controller, there is no method to test the controller directly. The
controller may be damaged if an attempt is made to test
it with an electrical test device, such as a digital multimeter.
Electrical power for the controller outputs is provided
through three (3) connectors (PWR2, PWR3 and
PWR4) each protected with a 7.5 amp fuse. A fifty (50)
pin wire harness connector attaches to the controller.
The layout of the wire harness connector that plugs into
the TEC controller is provided (Fig. 23). The TEC controller connection terminal functions and the connector
pins are shown for reference (Fig. 24).
3. Cap screw (4)
4. Flange nut (4)
1
NOTE TAB
POSITION
10
Figure 23
NOTE: The TEC controller used on the Reelmaster
3550−D is specifically programed for correct machine
operation. If the controller is replaced for any reason, the
controller needs to be reprogrammed by your Toro Distributor.
IMPORTANT: Before performing any welding on the
machine, disconnect both positive and negative
battery cables from the battery, disconnect the wire
harness connector from the TEC controller and disconnect the terminal connector from the alternator.
This will prevent damage to the electrical system of
your Reelmaster.
Page 5 − 24
Reelmaster 3550−D
12V POWER
(7.5A FUSES)
OUTPUTS
(PWR 2)
12V LOGIC
POWER
(2 AMP FUSE)
VOLTAGE
OUT
OUTPUTS
(PWR 3)
IGNITION
SWITCH
INPUTS
OUTPUTS
(PWR 4)
COMM
PORT
DIGITAL
INPUTS
(OPEN/
CLOSED)
CAN BUS
Electrical
System
GROUND
ANALOG
INPUTS
(VARIABLE)
Figure 24
Reelmaster 3550−D
Page 5 − 25
Electrical System
Parking Brake Switch
The parking brake switch is a normally closed proximity
switch that is located on the control console (Fig. 25).
The sensing plate that opens the switch is the parking
brake lever.
1
When the parking brake is applied, the parking brake
lever is positioned near the target end of the parking
brake switch so the switch is opened. The parking brake
lever is moved away from the switch when the parking
brake is released causing the switch to close.
The TEC controller monitors the position of the parking
brake switch (open or closed). Using inputs from the
parking brake switch and other switches in the interlock
system, the TEC controller controls the energizing of the
fuel stop solenoid and fuel pump (see Table 3: Input
Conditions Required to Illuminate Diagnostic Display
Outputs in this chapter).
2
Testing
5
5
4
3
4
13 to 17 ft−lb
(18 to 23 N−m)
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Before disconnecting the parking brake switch for
testing, the switch and its circuit wiring should be tested
as a TEC electrical input using the Diagnostic Display
(see Diagnostic Display in this chapter). If input testing
verifies that the parking brake switch and circuit wiring
are functioning correctly, no further switch testing is necessary. If, however, input testing determines that the
parking brake switch and circuit wiring are not functioning correctly, proceed with the following switch testing
procedure.
3. Remove cover from control panel to gain access to
parking brake switch.
4. Make sure that when the parking brake is applied,
the clearance between the brake lever and the end of
the parking brake switch switch is 0.250” (6.3 mm). If
necessary, adjust switch and return to step 4 in this procedure.
Figure 25
1. Control panel cover
2. Parking brake lever
3. Brake switch
4. Jam nut (2)
5. Lock washer (2)
5. Make sure ignition switch is OFF and disconnect the
parking brake switch connector from machine wire harness.
6. Verify that the machine wire harness connector terminal for black wire is closed (continuity) to ground.
7. Turn ignition switch to the ON position (do not start
engine) and verify with a multimeter that machine wire
harness connector terminal for pink wire has system
voltage (12 VDC) present.
8. If black wire is closed to ground, and the pink wire
has system voltage present, replace parking brake
switch.
9. Make sure that there is 0.250” (6.3 mm) clearance
between the brake lever and the end of the parking
brake switch after switch installation is complete. Tighten brake switch jam nuts from 13 to 17 ft−lb (18 to 23
N−m).
10.Install cover to control panel.
Electrical System
Page 5 − 26
Reelmaster 3550−D
Neutral Switch
The neutral switch is a normally open proximity switch
that closes when the traction pedal is in the neutral position. The neutral switch is located under the floor plate
(Fig. 26).
The TEC controller monitors the position of the neutral
switch (open or closed). Using inputs from the neutral
switch and other switches in the interlock system, the
TEC controller controls the energizing of the engine
start relay, and the fuel stop solenoid and fuel pump (see
Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
2
Testing
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Before disconnecting the neutral switch for testing,
the switch and its circuit wiring should be tested as a
TEC electrical input using the Diagnostic Display (see
Diagnostic Display in this chapter). If input testing verifies that the neutral switch and circuit wiring are functioning correctly, no further switch testing is necessary. If,
however, input testing determines that the neutral
switch and circuit wiring are not functioning correctly,
proceed with the following switch testing procedure.
1
Electrical
System
3
3. Make sure ignition switch is in the OFF position. Disconnect electrical connector from the neutral switch.
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
Figure 26
1. Neutral switch
2. Floor plate
3. Switch bracket
5. With the traction pedal in the neutral position, there
should be continuity between the two (2) switch leads.
6. Slowly depress the traction pedal. The continuity tester should show no continuity as the pedal is moved in
either the forward or reverse direction.
7. Reconnect switch after testing.
Adjustment
The neutral switch should be installed so that the pin on
the traction pedal (neutral position) is centered with the
switch when the pedal is in the neutral position. The
switch must open with forward or reverse movement of
0.25” to 1.00” (6.3mm to 25.4mm) when measured at
the top of the traction pedal.
Reelmaster 3550−D
Page 5 − 27
Electrical System
Lower/Raise Joystick Switches
The cutting unit raise and lower switches are located on
the joystick assembly that is attached to the control panel. The rear switch is used to lower the cutting units and
the front switch to raise them (Fig. 27). The switches are
identical (Fig. 28).
1
The TEC controller monitors the position of the lower/
raise switches (open or closed). Using inputs from the
lower/raise switches and other switches in the interlock
system, the TEC controller controls the energizing of the
solenoid valves (S1, S2, S3, S4) used to lower and raise
the cutting units (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this
chapter).
3
FRONT
2
Testing
Figure 27
1. Park machine on level surface, lower cutting units if
possible, stop engine, apply parking brake and remove
key from ignition switch.
2. Before disconnecting the raise and lower switches
for testing, the switches and their circuit wiring should be
tested as TEC electrical inputs using the Diagnostic Display (see Diagnostic Display this chapter). If input testing verifies that the raise and lower switches and circuit
wiring are functioning correctly, no further switch testing
is necessary. If, however, input testing determines that
the raise and lower switches and circuit wiring are not
functioning correctly, proceed with the following switch
testing procedure.
3. Remove cover from control panel to gain access to
raise and lower switches on joystick assembly.
4. Make sure ignition switch is in the OFF position. Disconnect wire harness connectors from raise and lower
switches on joystick assembly.
5. Check the continuity of the raise switch by connecting a multimeter (ohms setting) across the switch connector terminals as follows:
A. With the joystick in the neutral position, continuity
should only exist between the common and NC terminals.
B. With the joystick in the raise position, continuity
should only exist between the common and NO terminals.
Electrical System
1. Joystick assembly
2. Raise switch
3. Lower switch
1
2
4
3
Figure 28
1. Common terminal
2. NO terminal
3. NC terminal
4. Switch lever
6. Check the continuity of the lower switch by connecting a multimeter (ohms setting) across the switch connector terminals as follows:
A. With the joystick in the neutral position, continuity
should only exist between the common and NC terminals.
B. With the joystick in the lower position, continuity
should only exist between the common and NO terminals.
7. Replace raise and lower switch if testing identifies
that switch is faulty.
8. After switch testing is completed, connect the harness connectors to the raise and lower switches on joystick assembly. Install control panel cover.
Page 5 − 28
Reelmaster 3550−D
Reel Enable/Disable Switch
The enable/disable switch is located on the control
panel (Fig. 29). This switch is pulled out to engage the
cutting units and pushed in to disengage the cutting
units.
1
The TEC controller monitors the position of the enable/
disable switch (pulled out or pushed in). Using inputs
from the enable/disable switch and other switches in the
interlock system, the TEC controller controls the energizing of the proportional relief valve (PRV) used to drive
the cutting unit motors (see Table 3: Input Conditions
Required to Illuminate Diagnostic Display Outputs in
this chapter).
2
Testing
Figure 29
1. Control panel
2. Before disconnecting the enable/disable switch for
testing, the switch and its circuit wiring should be tested
as a TEC electrical input using the Diagnostic Display
(see Diagnostic Display in this chapter). If input testing
verifies that the enable/disable switch and circuit wiring
are functioning correctly, no further switch testing is necessary. If, however, input testing determines that the enable/disable switch and circuit wiring are not functioning
correctly, proceed with the following switch testing procedure.
3. Remove cover from control panel to gain access to
enable/disable switch.
4. Disconnect wire harness electrical connector from
the enable/disable switch.
5. The enable/disable switch terminals are marked
(Fig. 30). The circuit logic of the enable/disable switch
is shown in the chart (Fig. 31). With the use of a multimeter (ohms setting), the switch functions can be tested to
determine whether continuity exists between the various terminals for each switch position. Verify continuity
between switch terminals. Replace enable/disable
switch if testing identifies that switch is faulty.
6. If the enable/disable switch tests correctly and circuit
problem still exists, check other circuit components (see
Electrical Schematic in Chapter 8 − Foldout Drawings in
this manual).
Reelmaster 3550−D
2. Enable/disable switch
4
1
2
5
6
3
Figure 30
1. COM B terminal
2. NO B terminal
3. NC B terminal
4. COM C terminal
5. NO C terminal
6. NC C terminal
SWITCH
POSITION
CLOSED
CIRCUITS
OPEN
CIRCUITS
OFF (DOWN)
COM B + NC B
COM C + NC C
COM B + NO B
COM C + NO C
ON (UP)
COM B + NO B
COM C + NO C
COM B + NC B
COM C + NC C
Figure 31
7. After testing is completed, connect the wire harness
connector to the enable/disable switch. Install control
panel cover.
Page 5 − 29
Electrical System
Electrical
System
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
Mow/Transport Switch
The switch used for the mow/transport slide is a normally closed switch. The switch opens when the mow/
transport slide is in the transport position. The switch is
located under the floor plate (Fig 32).
The TEC controller monitors the position of the mow/
transport switch (open or closed). Using inputs from the
mow/transport switch and other switches in the interlock
system, the TEC controller controls the energizing of the
proportional relief valve (PRV) used to drive the cutting
unit motors,and solenoid valves (S1, S2, S3, and S4)
used to lower and raise the cutting units (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
Testing
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
2. Before disconnecting the mow/transport switch for
testing, the switch and its circuit wiring should be tested
as a TEC electrical input using the Diagnostic Display
(see Diagnostic Display in this chapter). If input testing
verifies that the mow/transport switch and circuit wiring
are functioning correctly, no further switch testing is necessary. If, however, input testing determines that the
mow/transport switch and circuit wiring are not functioning correctly, proceed with the following switch testing
procedure.
3. Locate switch and disconnect electrical connector
from the switch.
1
Figure 32
1. Mow/Transport switch
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector terminals.
5. When the switch plunger is extended (mow/transport
slide in MOW position) there should be continuity
between the switch terminals.
6. When the switch plunger is depressed (mow/transport slide in TRANSPORT position) there should be no
continuity between the switch terminals.
7. Replace switch if testing determines that it is faulty.
8. When switch testing is completed, reconnect switch
to wire harness.
Electrical System
Page 5 − 30
Reelmaster 3550−D
Seat Switch
The seat switch is normally open and closes when the
operator seat is occupied. The seat switch is located directly under the seat.
2
The TEC controller monitors the position of the seat
switch (open or closed). Using inputs from the seat
switch and other switches in the interlock system, the
TEC controller controls the energizing of the engine
start relay, the fuel stop solenoid and fuel pump, the proportional relief valve (PRV) used to drive the cutting unit
motors,and solenoid valves (S1, S2, S3, and S4) used
to lower and raise the cutting units (see Table 3: Input
Conditions Required to Illuminate Diagnostic Display
Outputs in this chapter).
3
1
Testing
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
3. A short wire harness is used to connect the seat
switch to the main wire harness. Disconnect the seat
switch harness from the main wire harness. The seat
switch harness connector is located under the seat assembly between the operator’s control panel and the
seat.
4. Check the continuity of the seat switch by connecting
a multimeter (ohms setting) across the seat switch harness connector terminals. With no pressure on the seat,
there should be no continuity through the switch.
5. Press directly onto the seat switch through the seat
cushion. There should be continuity through the switch
as the seat cushion approaches the bottom of its travel.
6. If the continuity test determines that the seat switch
is not operating correctly,remove the seat cushion from
the seat chassis (Fig. 33):
A. Remove two (2) flange head screws under the
front of the seat cushion.
B. Lift front of seat cushion up then slide forward and
out of seat chassis.
Reelmaster 3550−D
6
5
4
Figure 33
1. Seat chassis
2. Seat back
3. Seat cushion
4. Flange head screw (2)
5. Seat switch harness
6. Seat switch
WARNING
If seat switch service is necessary, remove
seat cushion from seat chassis to access
switch. DO NOT attempt to reach switch
through openings in seat chassis as edges of
openings may be sharp.
7. Check seat switch and/or seat switch harness for
continuity. Repair or replace components as needed.
8. If the seat switch and seat switch harness tests correctly and a circuit problem still exists, check machine
wire harness (see Electrical Schematics and Wire Harness Drawings in Chapter 9 - Foldout Drawings in this
manual).
9. After testing is complete, install seat cushion, connect seat switch wire harness to seat switch and install
operator seat. Connect seat switch wire harness to main
wire harness and check seat switch operation.
Page 5 − 31
Electrical System
Electrical
System
2. Before disconnecting the seat switch for testing, the
switch and its circuit wiring should be tested as a TEC
electrical input using the Diagnostic Display (see Diagnostic Display in this chapter). If input testing verifies
that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however,
input testing determines that the seat switch and circuit
wiring are not functioning correctly, proceed with the following switch testing procedure.
Backlap Switch
The backlap switch is a normally open ball switch that is
in the normal, open state when the backlap lever is in the
mow position. When the backlap lever is in the backlap
position, the switch closes. The backlap switch is attached to the hydraulic mow control manifold located on
the left side of the machine under the hinged access
panel in front of the operator’s seat (Fig. 34).
1
5
The TEC controller monitors the position of the backlap
switch (open or closed). Using inputs from the backlap
switch and other switches in the interlock system, the
TEC controller controls the energizing of solenoid valve
(MV) used to reverse the direction of the cutting unit reel
motors (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
Testing
2
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
2. Before disconnecting the seat switch for testing, the
switch and its circuit wiring should be tested as a TEC
electrical input using the Diagnostic Display (see Diagnostic Display in this chapter). If input testing verifies
that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary. If, however,
input testing determines that the seat switch and circuit
wiring are not functioning correctly, proceed with the following switch testing procedure.
3. Raise the hinged access panel and locate the backlap switch on the front of the mow control manifold (left
side). Disconnect the harness electrical connector from
the backlap switch.
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the switch connector
terminals.
5. With the ignition switch in the OFF position, turn the
backlap lever to the backlap position while watching the
multimeter. Continuity should be made as the switch
closes.
Electrical System
3
4
20 ft−lb (27 N−m)
Figure 34
1. Mow control manifold
2. Backlap switch
3. O−ring
4. Ball
5. Backlap lever
6. Turn the backlap lever to the mow position while
watching the multimeter. Continuity should be broken as
the switch opens.
7. If backlap switch is faulty, replace switch. Make sure
that dowel and ball are placed in the manifold port before
installing new switch in manifold. Torque switch to 20 ftlb (27 N- m).
8. If the backlap switch tests correctly and a circuit
problem still exists, check wire harness (see Electrical
Schematic and Wire Harness Drawings in Chapter 9 Foldout Drawings in this manual).
9. After testing is completed, connect harness electrical connector to the backlap switch and close access
panel.
Page 5 − 32
Reelmaster 3550−D
Engine Temperature Sender
The engine temperature sender is located above the alternator, in the thermostat housing (Fig. 35). The resistance of the temperature sender reduces as the engine
coolant temperature increases.
The TEC controller uses input from the temperature
sender to control the high temperature warning light on
the operator’s control panel (on or off). Using inputs from
the temperature sender and other switches in the interlock system, the TEC controller controls the energizing
of the engine start relay, the fuel stop solenoid and fuel
pump, and the proportional relief valve (PRV) used to
drive the cutting unit motors (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs
in this chapter).
1
2
3
Figure 35
1. Engine temp. sender
2. Alternator
3. Oil pressure switch
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Locate temperature sender on engine and disconnect wire harness connector from sender.
Make sure engine is cool before removing the
temperature sender from engine.
3. Lower coolant level in the engine and remove the
temperature sender from the thermostat housing.
4. Put sender in a container of oil with a thermometer
and slowly heat the oil (Fig. 36).
Electrical
System
CAUTION
Figure 36
5. Check resistance of the sender with a multimeter
(ohms setting) as the oil temperature increases.
A. The meter should indicate from 11.4 to 13.6
K- ohms at 68F (20C).
B. The meter should indicate from 2.3 to 2.6
K- ohms at 140F (60C).
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
C. The meter should indicate from 0.6 to 0.7
K- ohms at 212F (100C).
NOTE: Prior to taking resistance readings with a digital
multi meter, short the meter test leads together. The meter will display a small resistance value (usually 0.5
ohms or less) due to the internal resistance of the meter
and test leads. Subtract this value from from the measured value of the component you are testing.
Reelmaster 3550- D
Page 5 - 33
Electrical System
6. Replace temperature sender if specifications are not
met.
7. Install temperature sender to the thermostat housing.
A. Clean threads of water flange and temperature
sender thoroughly. Apply thread sealant to the
threads of the sender.
Electrical System
B. Screw sender into the water flange until it is finger
tight. Then, tighten sender an additional 2 to 3 full
turns.
C. Connect wire harness connector to sender.
8. Fill engine cooling system.
Page 5 − 34
Reelmaster 3550−D
Start Relay
The start relay is secured to the control panel assembly
next to the operator seat (Fig. 37). This relay is attached
to the wire harness with a five (5) wire connector
(Fig. 38). The relay can be accessed by removing the
control panel cover.
The start relay is used to provide current to the engine
starter motor. The TEC controller energizes and monitors the operation of the start relay when specific input
conditions are met. The start relay should remain energized while the ignition switch is set to the START position for a maximum of thirty (30) seconds.
1
3. Test the circuit wiring:
A. Remove cover from control panel and locate relay that is to be tested.
B. Disconnect wire harness connector from the
relay.
C. Position the necessary input(s) to illuminate the
START output LED indicating that the TEC controller
is energizing that function (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
D. Connect multimeter (DC voltage setting) across
the terminals of the wire harness connector. 12VDC
should be present at the connector when the START
LED is illuminated.
6
E. Repair damaged wiring as necessary.
3
1
4
86
2
85
3
1
4. Glow relay
5. Screw
6. Mounting bracket
30
2
Figure 38
1. Coil terminal
2. Common terminal
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Test the start relay circuit as a TEC electrical output
using the Diagnostic Display (see Diagnostic Display in
this chapter). If output testing verifies that the TEC is energizing the start relay circuit under the appropriate conditions, leave the diagnostic display connected and test
the circuit wiring between the TEC and the start relay.
Reelmaster 3550−D
87
5
Figure 37
1. Lock nut
2. Start relay
3. Main power relay
87A
3. Normally closed term.
4. Normally open terminal
4. If the circuit wiring is functioning correctly, use the following procedure to test the relay.
A. To make sure that machine operation does not
occur unexpectedly, disconnect negative (−) cable
from battery and then disconnect positive (+) cable
from battery (see Battery Service in the Service and
Repairs section of this chapter).
B. Remove relay from control panel for testing.
Page 5 − 35
Electrical System
Electrical
System
4
NOTE: Prior to taking small resistance readings
with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due
to the internal resistance of the meter and test leads.
Subtract this value from from the measured value of
the component you are testing.
C. Using a multimeter, verify that coil resistance between terminals 85 and 86 is from 71 to 88 ohms.
D. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply
+12 VDC to terminal 85. The relay should make and
break continuity between terminals 30 and 87 as +12
VDC is applied and removed from terminal 85.
F. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87A. Apply +12 VDC to terminal 85.
The relay should make and break continuity between
terminals 30 and 87A as +12 VDC is applied and removed from terminal 85.
G. Disconnect voltage and multimeter test leads
from the relay terminals.
5. After testing is completed, secure relay to mounting
bracket and connect wire harness connector to relay.
Install cover to control panel.
6. Connect positive (+) cable to battery and then connect negative (−) cable to battery (see Battery Service
in this chapter).
E. Disconnect voltage from terminal 85 and multimeter lead from terminal 87.
Electrical System
Page 5 − 36
Reelmaster 3550−D
Fuel Stop Solenoid
The fuel stop solenoid includes two coils for operation:
the pull coil and the hold coil. The TEC controller energizes and monitors the operation of the fuel stop solenoid when specific input conditions are met. When the
ignition switch is set to RUN or START, the fuel stop solenoid is energized and the pull coil retracts the solenoid
plunger. Once the plunger is retracted, the hold coil will
keep it retracted for continued engine operation. When
the solenoid is de−energized, the plunger extends to
shut off fuel supply to the engine causing the engine to
stop running. The fuel stop solenoid is grounded
through the solenoid housing.
NOTE: The TEC output circuit that controls the fuel
stop solenoid also controls the electric fuel pump. This
circuit is known as the Energize To Run (ETR) circuit.
Refer to the Electrical Schematics and Wire Harness
Drawings in Chapter 8 − Foldout Drawings in this manual for additional information.
Testing
4. If the circuit wiring is functioning correctly, use the following procedure to test the fuel stop solenoid.
NOTE: Prior to taking small resistance readings
with a digital multimeter, short the test leads together. The meter will display a small resistance value
(usually 0.5 ohms or less). This resistance is due to
the internal resistance of the meter and test leads.
Subtract this value from the measured value of the
component you are testing.
A. Using a digital multimeter, touch one test lead to
the pull coil terminal and the other test lead to the fuel
stop solenoid frame (ground) (Fig. 40). The resistance of the pull coil should be less than 1 ohm (but
not zero).
B. Using a digital multimeter, touch one test lead to
the hold coil terminal and the other test lead to the
fuel stop solenoid frame (ground) (Fig. 40). The resistance of the hold coil should be approximately 15
ohms.
5. Replace solenoid if necessary and reconnect the
wiring harness.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch. Unlatch and raise hood.
Electrical
System
The fuel stop solenoid must be energized for the diesel
engine to run. The solenoid is mounted to the injection
pump on the engine (Fig. 39).
1
2. Test the ETR circuit as a TEC electrical output using
the Diagnostic Display (see Diagnostic Display in this
chapter). If output testing verifies that the TEC is energizing the ETR circuit under the appropriate conditions,
leave the diagnostic display connected and test the circuit wiring.
2
3. Test the circuit wiring:
A. Disconnect wire harness connector from the fuel
stop solenoid.
Figure 39
1. Fuel stop solenoid
B. Position the necessary input(s) to illuminate the
ETR output LED indicating that the TEC controller is
energizing that function (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
2. Harness connector
2
1
C. Connect multimeter (DC voltage setting) across
the terminals of the wire harness connector. 12VDC
should be present at the connector when the ETR
LED is illuminated.
3
D. Repair damaged wiring as necessary.
Figure 40
1. Fuel stop solenoid
2. Pull coil terminal
Reelmaster 3550−D
Page 5 − 37
3. Hold coil terminal
Electrical System
Fuel Pump
The fuel pump is attached to the left side of the engine
near the fuel/water separator (Fig. 41).
C. Make sure fuel hoses to and from the fuel pump
are not kinked, damaged, and free of obstructions.
The TEC controller energizes and monitors the operation of the fuel pump when specific input conditions are
met. The fuel pump is energized when the ignition switch
is set to RUN or START. The fuel pump includes an internal pressure switch that energizes and de−energizes
the pump to maintain fuel line pressure.
D. Place disconnected fuel hose into a graduated
cylinder with at least a 1 quart (0.95 liter) capacity.
NOTE: The TEC output circuit that controls the electric
fuel pump also controls the fuel stop solenoid. This circuit is known as the Energize To Run (ETR) circuit. Refer
to the Electrical Schematics and Wire Harness Drawings in Chapter 8 − Foldout Drawings in this manual for
additional information.
IMPORTANT: When testing the fuel pump, DO
NOT turn ignition switch to START.
E. Collect fuel in the graduated cylinder by turning
ignition switch to the RUN position. Allow pump to
run for time listed below, then return switch to OFF.
The amount of fuel collected in the graduated cylinder should be approximately 21 to 37 fl oz (0.62 to
1.1 Ltr) after thirty (30) seconds.
2
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, and engage parking brake. Unlatch and
raise hood.
2. Test the ETR circuit as a TEC electrical output using
the Diagnostic Display (see Diagnostic Display in this
chapter). If output testing verifies that the TEC is energizing the ETR circuit under the appropriate conditions,
leave the diagnostic display connected test the circuit
wiring.
3
1
3. Test the circuit wiring:
A. Disconnect wire harness connector from the fuel
pump.
B. Position the necessary input(s) to illuminate the
ETR output LED indicating that the TEC controller is
energizing that function (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
C. Connect multimeter (DC voltage setting) across
the terminals of the wire harness connector. 12VDC
should be present at the connector when the ETR
LED is illuminated.
Figure 41
1. Fuel pump
2. Fuel hose (discharge)
3. Fuel filter
5. Replace fuel pump as necessary. Reconnect fuel
hose to the fuel filter/separator.
6. Reconnect electrical connector to the fuel stop solenoid.
7. Bleed fuel system.
Fuel Pump Specifications
Pump Capacity
D. Repair damaged wiring as necessary.
4. If the circuit wiring is functioning correctly, use the following procedure to test the pump.
42 to 74 fl oz/min
(1.2 to 2.2 Ltr/min)
Pressure
2.3 psi (15.8 kPa)
Max. Current Draw
1.8 amp
A. Disconnect electrical connector from the fuel stop
solenoid to prevent the engine from starting.
B. Disconnect the fuel hose between the pump and
the filter/separator (pump discharge) at the filter separator.
Electrical System
Page 5 − 38
Reelmaster 3550−D
Glow Relay
The glow relay is secured to the control panel assembly
next to the operator seat (Fig. 42). This relay is attached
to the wire harness with a four (4) wire connector
(Fig. 43). The relay can be accessed by removing the
control panel cover.
The glow relay is used to provide current to the engine
glow plugs. The TEC controller energizes and monitors
the operation of the glow relay when specific input conditions are met. The glow relay should remain energized
for six (6) seconds after the ignition switch is set to the
RUN position. The glow relay should also remain energized as long as the ignition switch is in the START position.
86
87
30
85
85
30
86
87
Figure 43
3. Test the circuit wiring:
A. Remove cover from control panel and locate relay that is to be tested.
1
B. Disconnect wire harness connector from the relay.
6
4
D. Connect multimeter (DC voltage setting) across
the terminals of the wire harness connector. 12VDC
should be present at the connector when the GLOW
LED is illuminated.
E. Repair damaged wiring as necessary.
2
3
5
Figure 42
1. Lock nut
2. Start relay
3. Main power relay
4. Glow relay
5. Screw
6. Mounting bracket
A. To make sure that machine operation does not
occur unexpectedly, disconnect negative (−) cable
from battery and then disconnect positive (+) cable
from battery (see Battery Service in the Service and
Repairs section of this chapter).
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
2. Test the glow relay circuit as a TEC electrical output
using the Diagnostic Display (see Diagnostic Display in
this chapter). If output testing verifies that the TEC is energizing the glow relay circuit under the appropriate conditions, use the following procedure to test the circuit
wiring between the TEC and the glow relay.
Reelmaster 3550−D
4. If the circuit wiring is functioning correctly, use the following procedure to test the relay.
B. Remove cover from control panel and locate
relay to be tested.
C. Disconnect wire harness connector from relay.
Remove relay from mounting bracket for testing.
Page 5 − 39
Electrical System
Electrical
System
C. Position the necessary input(s) to illuminate the
GLOW output LED indicating that the TEC controller
is energizing that function (see Table 3: Input Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
NOTE: Prior to taking small resistance readings
with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due
to the internal resistance of the meter and test leads.
Subtract this value from from the measured value of
the component you are testing.
D. Using a multimeter, verify that coil resistance between terminals 86 and 85 is approximately 72
ohms.
E. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply
Electrical System
+12 VDC to terminal 85. The relay should make and
break continuity between terminals 30 and 87 as +12
VDC is applied and removed from terminal 85.
F. Disconnect voltage and test leads from the relay
terminals.
5. After testing is completed, secure relay to mounting
bracket and connect wire harness connector to relay.
Install cover to control panel.
6. Connect positive (+) cable to battery and then connect negative (−) cable to battery (see Battery Service
in this chapter).
Page 5 − 40
Reelmaster 3550−D
Hydraulic Solenoid Valve Coils
The Reelmaster 3550−D hydraulic control manifolds
use several hydraulic solenoid valve coils for system
control. The lift manifold includes four (4) solenoid
valves (S1, S2, S3, and S4). The mow manifold includes
a single solenoid valve (PRV).
1
2
The TEC controller energizes and monitors the operation of the solenoid coils when specific input conditions
are met. When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic circuit flow.
Testing of the coils can be done with the coil installed on
the hydraulic valve.
Testing
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
Figure 44
1. Mow control manifold
3
2. PRV solenoid valve
4
5
Electrical
System
2. Before disconnecting and testing solenoid valve
coils, test the TEC controller outputs with the Diagnostic
Display (see Diagnostic Display in this chapter). If output testing verifies that the TEC is energizing the solenoid coil circuit under the appropriate conditions, leave
the diagnostic display connected and test the specific
circuit wiring.
2
3. Test the circuit wiring:
A. Lift hinged access cover in front of operator’s seat
and locate valve coil that is to be tested.
B. Disconnect wire harness connector from the coil.
C. Position the necessary input(s) to illuminate the
appropriate output LED indicating that the TEC controller is energizing that function (see Table 3: Input
Conditions Required to Illuminate Diagnostic Display Outputs in this chapter).
D. Connect multimeter (DC voltage setting) across
the terminals of the disconnected wire harness connector. 12VDC should be present at the connector
when the appropriate LED is illuminated.
E. Repair damaged wiring as necessary.
4. If the circuit wiring is functioning correctly, use the following procedure to test the solenoid coil(s).
A. Determine solenoid coil(s) that is to be tested and
locate coil on correct hydraulic manifold. Access the
manifolds through the hinged access panel in front of
the operator’s seat. The lift control manifold is on the
right side of the machine and the mow control manifold is on the right side of the machine.
Reelmaster 3550−D
1
Figure 45
1. Lift control manifold
2. S1 solenoid valve
3. S2 solenoid valve
4. S3 solenoid valve
5. S4 solenoid valve
B. Disconnect wire harness connector from the hydraulic solenoid valve coil that is to be tested (Figs.
44 or 45).
NOTE: Prior to taking small resistance readings
with a digital multimeter, short the meter test leads together. The meter may display a small resistance
value (usually 0.5 ohms or less). This resistance is
due to the internal resistance of the meter and test
leads. Subtract this value from the measured value
of the solenoid coil being testing.
Page 5 − 41
Electrical System
C. Solenoid coil resistance should be measured
with solenoid at approximately 68°F (20°C). Resistance may be slightly different than listed at different
temperatures. Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open
(infinite resistance). Use a multimeter (ohms setting)
and measure resistance between the two (2) connector terminals on the solenoid valve coil. The resistance for the solenoid coils is identified below:
Solenoid Valve Coil
Resistance
PRV (mow)
7.1 ohms
S1, S2, S3 and S4 (lift)
8.8 ohms
Electrical System
NOTE: To assist in troubleshooting, identical solenoid valve coils can be exchanged. If the problem follows the exchanged coil, an electrical problem likely
exists with the coil. If the problem remains unchanged, something other than the solenoid coil is
the problem source (e.g. switch, circuit wiring, hydraulic problem). The lift manifold S1, S2, S3 and S4
coils are identical.
D. If solenoid coil resistance is incorrect, replace solenoid (see the Service and Repairs section of Chapter 4 − Hydraulic System in this manual).
5. After coil testing is completed, connect wire harness
connector to the solenoid valve coil(s).
Page 5 − 42
Reelmaster 3550−D
Indicator Lights
4
To test the high temperature shutdown light and circuit
wiring, start the engine and ground the blue wire attached to the temperature sender at the engine thermostat housing. Warning light should illuminate.
3
The high temperature warning light is controlled by the
TEC controller (see Engine Temperature Sensor in this
chapter for additional information).
1
2
5
5
3
2
1B
1A (+)
2B
2A (+)
Figure 46
4. Engine oil pressure
5. Charge indicator
4
1
Diagnostic Light
Figure 47
When the ignition switch is moved to the RUN position
and the machine electrical system is functioning properly, the diagnostic light will be illuminated for approximately three (3) seconds and then will turn off. The light
should remain off during normal machine operation.
If the machine TEC controller detects an electrical system malfunction (fault) during machine operation, the
diagnostic light will flash rapidly (see Diagnostic Light in
the chapter for additional information).
Glow Plug Indicator Light
1. Glow plug indicator
2. High temp warning
3. Engine oil pressure
4. Charge indicator
5. Warning light back
Engine Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
The oil pressure light should come on with the engine
running if the engine oil pressure drops to an unsafe
level. The engine oil pressure light is controlled by the
oil pressure switch (see Oil Pressure Switch in this
chapter for additional information).
The glow plug light should come on when the ignition
switch is placed in RUN prior to placing the ignition
switch in START. The light should stay lit for approximately six (6) seconds while the ignition switch is left in
ON.
IMPORTANT: If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.
The glow plug indicator light is controlled by the TEC
controller (see Glow Relay in this chapter for additional
information).
The charge indicator light should come on when the ignition switch is in ON with the engine not running or with
an improperly operating charging system while the engine is running. The charge indicator light is controlled
by the TEC controller. Test the charging system if necessary (see Charging System Test in this chapter).
High Temperature Warning Light
If the engine coolant temperature rises to approximately
220°F (105°C), the high temperature light should come
on and the cutting units will disengage. The high temperature light will remain on and the cutting units will remain
inactive until the engine temperature drops below 220°F
(105°C).
If the engine temperature rises above 240°F (116°C) for
more than 10 seconds the engine will shutdown.
Reelmaster 3550−D
Charge Indicator Light
Testing Indicator Lights
1. Apply 12 VDC to terminals 1A and 2A.
2. Ground terminals 1B and 2B.
3. Both indicator lights should light.
Page 5 − 43
Electrical System
Electrical
System
1. Diagnostic light
2. Glow plug indicator
3. High temp warning
CAN- bus Termination Resistors
System communication between electrical components
on Reelmaster 3550- D machines is accomplished on a
CAN- bus communication system. Two (2) specially designed, twisted cables form the bus for the network used
on the machine. These wires provide the data pathways
between machine components. At the ends of the twisted pair of bus cables are two (2) 120 ohm termination
resistors.
Termination
Resistor
A
B
Keyway
The resistors plug into the wire harness under the control panel. The resistors can be accessed by removing
the cover from the control panel (see Electrical Schematics and Wire Harness Drawings in Chapter 8 - Foldout
Drawings in this manual for additional information). The
termination resistor and the wire harness connector
have blue inserts to identify the proper location for the
termination resistor. The resistor also has a center keyway to prevent it from plugging into the wrong wire harness connector.
C
Figure 48
IMPORTANT: The termination resistors are required for proper electrical system operation.
Testing
The termination resistors (Fig. 48) can be tested using
a digital multimeter (ohms setting). There should be 120
ohms resistance between terminals A and B of the termination resistor. Terminal C is not used on Reelmaster
3550- D machines.
Hour Meter
The hour meter is located on the control panel. The hour
meter (Fig. 49) indicates the total hours of machine operation. The hour meter starts to function whenever the
key switch is in the ON position.
1. Connect the positive (+) terminal of a 12 VDC source
to the positive terminal of the hour meter.
2. Connect the negative (- ) terminal of the voltage
source to the other terminal of the hour meter.
Hobbs
QUARTZ
00001
HOURS
1
10
+
3. The hour meter should move 1/10 of an hour in six
minutes.
4. Disconnect the voltage source from the hour meter.
BACK
Figure 49
Electrical System
Page 5 - 44
Reelmaster 3550- D
Oil Pressure Switch
The engine oil pressure switch is located on the engine
below the alternator (Fig. 50). The oil pressure switch is
a normally closed switch that opens with pressure. The
oil pressure switch should open at approximately 8 PSI
(0.56 kg/cm2).
1
If low engine oil pressure allows the oil pressure switch
to close during engine operation, the engine oil pressure
light should illuminate.
2
Testing
3
NOTE: Refer to the Kubota Workshop Manual: 05
Series Diesel Engine for information regarding engine
lubrication system and testing.
1. Set the ignition switch to the RUN position. The oil
pressure indicator light on the control panel should be
illuminated.
2. If the indicator light is not illuminated, open hood to
gain access to engine.
3. Locate oil pressure switch on engine and disconnect
the harness wire from the switch.
Figure 50
1. Engine temp. sender
2. Alternator
3. Oil pressure switch
5. If the light comes on, the oil pressure switch is faulty.
6. If the light does not come on after step 4, check the
oil pressure light circuit wiring and indicator light (see Indicator Lights in this section).
7. After testing is completed, connect the harness wire
to the switch. Lower and secure hood.
Reelmaster 3550−D
Page 5 − 45
Electrical
System
4. With the ignition switch in the RUN position, ground
the disconnected wire to the engine block.
Electrical System
Worklight Switch
The worklight switch is located on the control panel
(Fig. 51). This rocker switch allows the worklights
(headlights) to be turned on and off.
Testing
2
1. Park machine on level surface, lower cutting units,
stop engine, apply parking brake and remove key from
ignition switch.
2. Remove cover from control panel to gain access to
worklight switch.
1
3. Disconnect wire harness electrical connector from
the worklight switch.
4. With the use of a multimeter (ohms setting), the
worklight switch functions may be tested to determine
whether continuity exists between the various terminals
for each position. The switch terminals are marked as
shown in Figure 52. The circuitry of the worklight switch
is shown in the chart below. Verify continuity between
switch terminals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
2+1
5+4
Figure 51
1. Control panel
2. Worklight switch
BACK OF SWITCH
5. Replace worklight switch if testing identifies that
switch is faulty.
6. After testing is completed, connect the wire harness
connector to the worklight switch. Install control panel
cover.
Electrical System
Figure 52
NOTE: Worklight switch terminals 1, 4, 5 and 6 are not
used on Reelmaster 3550−D machines.
Page 5 − 46
Reelmaster 3550−D
Service and Repairs
NOTE: For engine component repair information, see
the Kubota Workshop Manual: 05 Series Diesel Engine.
Battery Storage
If the machine will be stored for more than 30 days:
1. Remove the battery and charge it fully (see Battery
Service in this section).
4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge.
5. To help prevent the battery from freezing, make sure
it is fully charged (see Battery Service in this section).
2. Either store battery on a shelf or on the machine.
3. Leave cables disconnected if the battery is stored on
the machine.
Battery Care
3. Battery cables must be tight on battery terminals to
provide good electrical contact.
WARNING
Connecting cables to the wrong post could result in personal injury and/or damage to the electrical system.
WARNING
Wear safety goggles and rubber gloves when
working with electrolyte. Charge battery in a
well ventilated place so gasses produced while
charging can dissipate. Since the gases are explosive, keep open flames and electrical sparks
away from the battery; do not smoke. Nausea
may result if the gases are inhaled. Unplug charger from electrical outlet before connecting or
disconnecting charger leads to or from battery
posts.
IMPORTANT: Do not remove fill caps while cleaning.
4. If corrosion occurs at battery terminals, disconnect
cables. Always disconnect negative (−) cable first.
Clean clamps and terminals separately. Reconnect
cables with positive (+) cable first. Coat battery posts
and cable connectors with battery terminal protector
(see Special Tools in this chapter) or petroleum jelly to
prevent corrosion.
5. Check electrolyte level every 25 operating hours and
every 30 days if machine is in storage.
6. Maintain battery cell level with distilled or demineralized water. Do not fill cells above the fill line.
2. Check battery condition weekly or after every 50
hours of operation. Keep terminals and entire battery
case clean because a dirty battery will discharge slowly.
A. Clean battery by washing entire case with a solution of baking soda and water. Rinse with clear water.
B. Coat battery posts and cable connectors with battery terminal protector (see Special Tools in this
chapter) or petroleum jelly to prevent corrosion.
Reelmaster 3550−D
Page 5 − 47
Electrical System
Electrical
System
1. Battery electrolyte level must be properly maintained. The top of the battery must be kept clean. lf the
machine is stored in a location where temperatures are
extremely high, the battery will discharge more rapidly
than if the machine is stored in a location where temperatures are cool.
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented (see Battery Storage and Battery
Care in this chapter).
2
CAUTION
1
3
4
Use extreme caution to avoid splashing or spilling battery electrolyte. Electrolyte can destroy
clothing and burn skin or eyes. Always wear
safety goggles and a face shield when working
with batteries.
5
10
6
Battery Specifications
7
BCI Group 55 Battery
570 Amp Cranking Performance at 0oF (−18oC)
90 minute Reserve Capacity at 80oF (27oC)
Electrolyte Specific Gravity (fully charged): from 1.250
to 1.280
Electrolyte Specific Gravity (discharged): 1.240
11
9
8
Figure 53
Battery Removal and Installation (Fig. 53)
1. Remove battery cover from the frame. Loosen battery retainer securing the back of the battery to the battery support.
2. Note battery cable routing and loosen nut on ground
cable (−) post and remove cable from battery. This
should prevent short circuiting the battery, other components, or the operators hands.
1.
2.
3.
4.
5.
6.
Knob (2)
Battery cover
Negative cable
Positive cable
Lock nut
Flat washer
7.
8.
9.
10.
11.
Battery retainer
Carriage screw
Battery support
Battery
Battery tray
Battery Inspection and Maintenance
1. Replace battery if case is cracked or leaking.
3. Note battery cable routing and loosen nut on positive
(+) cable post and remove cable from battery.
2. Check battery terminal posts for corrosion. Use wire
brush to clean corrosion from posts.
4. Carefully remove battery from machine.
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
5. Install battery in reverse order making sure to connect and tighten positive cable to battery before connecting the negative cable. Route battery cables as
noted during removal.
NOTE: Before connecting the negative (ground) cable,
connect a digital multimeter (set to amps) between the
negative battery post and the negative (ground) cable
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the machine’s electrical
system should be tested for short circuits or faulty components and repaired.
6. Make sure that rubber boot is properly placed over
positive cable end and positive battery post.
7. Secure battery cover after installing battery.
Electrical System
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse
it with clean water.
4. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.
5. Check the electrolyte level in each cell. If the level is
below the tops of the plates in any cell, fill all cells with
distilled water between the minimum and maximum fill
lines. Charge at 15 to 25 amps for fifteen (15) minutes
to allow sufficient mixing of the electrolyte.
Page 5 − 48
Reelmaster 3550−D
Battery Testing
C. Make sure battery terminals are free of corrosion.
1. Conduct a hydrometer test of the battery electrolyte.
D. Measure the temperature of the center battery
cell.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm−
up the hydrometer. At the same time take the temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (6oC) above 80oF (27oC) add 0.004 to the specific gravity reading. For each 10oF (6oC) below 80oF
(27oC) subtract 0.004 from the specific gravity reading.
E. Connect a battery load tester to the battery terminals following the load tester manufacturer’s instructions. Connect a digital multimeter to the
battery terminals.
F. Apply a test load of 285 amps (one half the Cranking Performance rating of the battery) for fifteen (15)
seconds.
G. Take a battery voltage reading after the load has
been applied to the battery for fifteen (15) seconds,
then remove the load. Record the voltage reading.
H. Using the table below, determine the minimum
voltage for the cell temperature reading:
Minimum
Voltage
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given in Battery Charging or until all cells specific
gravity is 1.225 or greater with the difference in specific gravity between the highest and lowest cell less
than 0.050. If these charging conditions can not be
met, replace the battery.
2. Perform a high−discharge test with an adjustable
load tester.
Battery Electrolyte
Temperature
9.6
70oF (and up)
21oC (and up)
9.5
60oF
16oC
9.4
50oF
10oC
9.3
40oF
4oC
9.1
30oF
−1oC
8.9
20oF
−7oC
8.7
10oF
−12oC
8.5
0oF
−18oC
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
This is one of the most reliable means of testing a battery
as it simulates the cold−cranking test. A commercial battery load tester is required to perform this test.
CAUTION
Follow the battery load tester manufacturer’s
instructions when using a load tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for fifteen (15) seconds to remove the surface
charge. Use a battery load tester following the
manufacturer’s instructions.
Reelmaster 3550−D
Page 5 − 49
Electrical System
Electrical
System
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(38oC minus 27oC equals 11oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/6oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (27oC)
1.253
Battery Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger
which is available in most locations.
CAUTION
Follow the battery charger manufacturer’s
instructions when using a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
1. Determine the battery charge level from either its
specific gravity or open circuit voltage.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60oF (16oC) before connecting to a charger.
Charge the battery in a well−ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
3. Following the battery charger manufacturer’s
instructions, connect the charger cables to the battery.
Make sure a good connection is made.
4. Charge the battery following the battery charger
manufacturer’s instructions.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125oF (52oC) or
the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
2. Determine the charging time and rate using the battery charger manufacturer’s instructions or the following table.
Battery
Reserve
Capacity
(Minutes)
CAUTION
6. Three (3) hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three (3) consecutive readings.
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs 15.8 hrs
@
@
4 amps 4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
Electrical System
Page 5 − 50
Reelmaster 3550−D
Cartridge Valve Coil Replacement
The solenoid valve coil on the hydraulic control manifold
(Fig. 54) can be replaced without opening the hydraulic
system.
60 in−lb
(6.8 N−m)
5
Removal
4
1. Park machine on a level surface, lower cutting
decks, engage parking brake, stop engine and remove
key from the ignition switch.
3
2. Disconnect the wire harness electrical connector
from the solenoid valve coil.
2
3. Remove the nut from the spool assembly.
4. Slide the coil assembly from the solenoid valve stem.
Discard the coil.
5. Clean any corrosion or dirt from the valve stem.
Installation
1. Slide new coil assembly onto the solenoid valve
stem.
2. Install the nut onto the spool assembly and torque
nut 60 in−lb (6.8 N−m) (do not over tighten).
3. Connect the wire harness electrical connector to the
solenoid valve coil.
Reelmaster 3550−D
Figure 54
1. Lift control manifold
2. Solenoid valve (S3)
3. Solenoid valve coil
Page 5 − 51
4. Spacer
5. Nut
Electrical System
Electrical
System
1
Worklight Bulb Replacement
The worklights are adjustable left and right, and up and
down as necessary. The worklights use a replaceable
halogen bulb.
5
3
4
CAUTION
1
The worklights use a halogen bulb that becomes
extremely hot when in operation. Handling a hot
bulb can cause severe burns and personal injury.
Allow enough time for bulb to cool before handling.
2
Bulb Replacement (Fig. 55)
Figure 55
1. Park machine on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
2. Remove screw securing bezel to worklight body and
remove bezel.
3. Disconnect worklight from wire harness at bulb and
remove worklight.
1. Body
2. Screw
3. Bezel
4. Worklight
5. Bulb
6. Connect worklight to wire harness at bulb.
7. Install worklight, bezel, and screw.
8. Adjust/aim worklight as needed.
4. Loosen the bulb from the worklight by rotating it 1/4
turn counter−clockwise. Then, grasp bulb base and remove bulb from the worklight.
CAUTION
Any surface contamination can damage the
halogen bulb and lead to its failure or explosion
creating a serious safety hazard.
Halogen bulbs should be handled without touching the clear bulb surface. Handle the bulb by
holding onto the base.
5. Align tabs on bulb with notches in headlight opening.
Insert bulb into back of headlight without touching the
glass bulb surface. Secure bulb to worklight by rotating
it 1/4 turn clockwise.
Electrical System
Page 5 − 52
Reelmaster 3550−D
Chapter 6
Chassis
Table of Contents
Chassis
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjust Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 6
Rear Fork and Wheel . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Lever Linkages . . . . . . . . . . . . . . . . . . . . . . 12
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reelmaster 3550−D
Page 6 − 1
Chassis
Specifications
Item
Description
Tire pressure
12 PSI (96 kPa)
Wheel lug nut torque
70 to 90 ft−lb (95 to 122 N−m)
Special Tools
Order special tools from your Toro Distributor.
Wheel Hub Puller
Part Number: TOR4097
The wheel hub puller allows safe removal of the wheel
hub from the shaft of wheel motors.
Figure 1
Chassis
Page 6 − 2
Reelmaster 3550−D
Adjustments
Adjust Brakes
C. If brakes can not be adjusted properly, repair or
replace brake components as necessary.
CAUTION
D. After adjustment is complete, install both front
wheel assemblies to the machine (see Front Brake
and Wheel Installation in the Service and Repairs
section).
Before and after adjusting the brakes, always
check the brakes in a wide open area that is flat
and free of other persons and obstructions.
E. Lower front wheels to the ground.
1. Check brake adjustment as follows:
F. Before starting engine, close by−pass valve on
pump by rotating it 90 degrees (Fig. 2).
A. Park machine on a level surface, lower cutting
units, stop engine and remove key from the ignition
switch.
B. Rotate by−pass valve on the piston pump 90 degrees to allow front wheels to turn freely (Fig. 2).
1
CAUTION
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
Figure 2
1. Piston pump
2. By−pass valve
D. Apply the parking brake. The force to actuate the
brake lever should be from 30 to 40 lbs (133 to 178
N).
1
5
4
E. With the parking brake applied, use a torque
wrench on the wheel hub lock nut to identify the
break away torque at each front wheel. The minimum break away torque with the parking applied
should be 300 ft−lb (407 N−m).
2
6
2. If adjustment is necessary, adjust brakes as follows:
A. Remove both front wheel assemblies from the
machine (see Front Brake and Wheel Removal in the
Service and Repairs section).
B. Adjust brakes by turning clevis to increase or decrease shoe pressure on the brake drum (Fig. 3).
Make sure that brake shoes do not drag against
drums with the parking brake lever released.
Reelmaster 3550−D
Chassis
C. Chock rear wheel. Jack up both front wheels and
support the machine with jackstands or hardwood
blocks.
2
3
Figure 3
1. Clevis
2. Adjustment rod
3. Brake lever
Page 6 − 3
4. Wheel hub
5. Cotter pin
6. Jam nut
Chassis
Service and Repairs
Operator Seat
8
9
8
2
6
5
3
4
4
3
19
5 6
20
20
1
18
10
7
23
22
12
11
16
15
13
23
17
14
21
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
Bottom cushion
Back cushion
Seat belt
Flat washer
Flat washer
Cap screw
Bottom cover
Armrest kit
9.
10.
11.
12.
13.
14.
15.
16.
Back cover
Seat switch
Adjusting track − RH
Track − LH
Support strap
Flange nut
Knob kit
Weight indicator
17.
18.
19.
20.
21.
22.
23.
Weight adjust kit
Spring and saddle kit
Shock absorber kit
Knob kit
Chassis assembly
Heat shield
Flange head screw (4)
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Install any new seat parts (Fig. 4) as a guide.
2. Position seat with support straps attached to the fuel
tank and frame.
2. Remove heat shield and seat support straps with
seat attached from the frame.
3. Attach electrical connector to the seat switch.
3. Disconnect electrical connector from the seat switch
and remove seat assembly.
4. Secure seat support straps to the frame with four hex
flange head screws.
4. Remove seat parts as necessary to make repairs
(Fig. 4).
Chassis
Page 6 − 4
Reelmaster 3550−D
Chassis
This page is intentionally blank.
Reelmaster 3550−D
Page 6 − 5
Chassis
Front Wheels and Brakes
24
21
25
22
30
27
18
11
20
12
23
29
13
28
5
10
14
1
8
16
4
3
26
17
14
15
19
2
Antiseize
Lubricant
6
RIGHT
FRONT
70 to 90 ft−lb
(95 to 122 N−m)
9
7
250 to 275 ft−lb
(339 to 372 N−m)
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hydraulic wheel motor (LH shown)
Brake drum
Socket head screw (4 per motor)
Brake bracket
Lock nut (4 per motor)
Wheel hub
Lock nut
Front wheel assembly
Lug nut (4 used per wheel)
Cap screw (4 per brake assembly)
Chassis
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Lock nut (4 per brake assembly)
Brake plate
Spring (2 per wheel)
Brake shoe (2 per wheel)
Cam shaft
Spacer (4 per motor)
Brake lever
Clevis pin
Wheel stud (4 per wheel)
Cotter pin
Page 6 − 6
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Brake pivot shaft
Brake pivot bracket
Flange head screw (2 per bracket)
Flange nut (2 per bracket)
Flange bushing
E−ring
Cotter pin
Brake rod
Jam nut
Yoke
Reelmaster 3550−D
Removal (Fig. 5)
Installation (Fig. 5)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake and remove key
from the ignition switch.
1. If removed, insert four socket head screws through
the frame, hydraulic motor, spacers, and brake bracket.
Secure with lock nuts, but do not fully tighten.
2. Assemble brake assembly as follows (Fig. 6):
WARNING
A. If removed, secure backing plate to the brake
bracket with four cap screws and lock washers.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
B. Apply antiseize lubricant to cam shaft splines. Insert cam shaft through the backing plate.
2. Jack up front wheel and use jack stands or blocking
to keep the front tire off the floor.
C. Attach brake lever to the cam shaft. Make sure
matchmarks are aligned properly. Secure lever to
shaft with E−ring.
3. Remove lug nuts from drive studs. Pull wheel from
drive studs and wheel hub.
D. Lubricate brake shoe pivot points with a light
coating of grease. Position both brake shoes on the
backing plate so that the concave heels attach to the
anchor pin.
NOTE: The installation torque of the lock nut is from
250 to 350 ft−lb (339 to 474 N−m). Use impact wrench
to remove lock nut from the hydraulic motor shaft.
E. Insert both return springs into the holes of both
brake shoes. Make sure shoes fit snuggly against
the anchor pin and cam shaft.
4. Remove lock nut from the hydraulic motor shaft. Release parking brake.
5. Use wheel hub puller to remove wheel hub and brake
drum from the hydraulic motor shaft (see Special Tools
in this chapter). Remove woodruff key from the shaft.
6. Remove cotter pin that retains adjustment rod to
brake lever. Separate adjustment rod from brake lever.
NOTE: The brake lever, backing plate, retainer clip, return springs, brake shoes and cam shaft can be removed as a complete brake assembly.
7. Remove the brake assembly from the brake bracket,
remove four cap screws and lock nuts securing the assembly to the bracket.
8. Disassemble brake assembly as follows (Fig. 6):
A. Remove return springs from the brake shoes. Remove brake shoes from the backing plate.
3. If the complete brake assembly was removed, secure brake assembly to the brake bracket with four cap
screws and lock nuts. Tighten fasteners.
4. Attach adjustment rod to the brake lever and secure
with cotter pin.
5. Make sure that wheel hub and hydraulic motor shafts
are thoroughly clean. Install key to the slot on the hydraulic motor shaft. Slide wheel hub and brake drum assembly onto the shaft.
6. Secure wheel hub and brake drum to the hydraulic
motor shaft with lock nut.
NOTE: For proper brake operation, the brake shoes
and backing plate must be concentrically aligned with
the brake drum.
7. To align brake shoes and drum, apply parking brake.
Then tighten four socket head screws (item 3) and lock
nuts that secure the brake bracket and wheel motor to
the frame.
B. Matchmark brake cam and brake lever to assure
proper alignment during assembly. Remove E−ring
from the brake cam. Pull brake lever from the cam.
Remove cam from backing plate.
9. Remove lock nuts, spacers and socket head screws
securing the brake bracket and hydraulic motor to the
frame if necessary.
WARNING
Failure to maintain proper wheel lug nut and
wheel hub lock nut torque could result in failure
or loss of wheel and may result in personal injury.
8. Secure wheel to machine with four (4) lug nuts.
Reelmaster 3550−D
Page 6 − 7
Chassis
Chassis
IMPORTANT: Do not hit wheel hub or puller with a
hammer during removal or installation. Hammering
may cause damage to the hydraulic wheel motor.
9. Lower wheel to ground. Torque wheel lug nuts from
70 to 90 ft−lb (95 to 122 N−m) in a crossing pattern.
10.Torque lock nut from 250 to 350 ft−lb (339 to 474
N−m). Release parking brake.
11. Check brake adjustment and and adjust if necessary
(see Adjust Brakes in the Adjustments section).
7
3
4
1
5
2
6
Figure 6
1.
2.
3.
4.
Return spring
Brake shoe (toe end)
Brake shoe (heel end)
Backing plate
Chassis
5. Retaining clip
6. Cam shaft
7. Anchor pin
Page 6 − 8
Reelmaster 3550−D
Chassis
This page is intentionally blank.
Reelmaster 3550−D
Page 6 − 9
Chassis
Rear Fork and Wheel
11
10
12
9
10
8
9
1
2
3
4
70 to 90 ft−lb
(95 to 122 N−m)
250 to 275 ft−lb
(339 to 372 N−m)
20
60 to 80 ft−lb
(81 to 108 N−m)
19
4
21
5
21
65 to 85 ft−lb
(88 to 115 N−m)
6
17
16
18
15
14
RIGHT
13
FRONT
7
Figure 7
1.
2.
3.
4.
5.
6.
7.
Cap screw
Thrust washer
Lock washer
Flange bushing (2)
Rear casting
Rear fork
Socket head screw (4)
Chassis
8.
9.
10.
11.
12.
13.
14.
Plug
Ball joint (2)
Retaining ring (2)
Grease fitting
Hydraulic steering cylinder
Wheel motor
Lock nut (4)
Page 6 − 10
15.
16.
17.
18.
19.
20.
21.
Key
Drive stud (4)
Hub
Wheel and tire assembly
Lock nut
Lug nut (4)
Jam nut (4)
Reelmaster 3550−D
Removal (Fig. 7)
Installation (Fig. 7)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. Position rear fork through the frame.
2. Remove hood from the machine.
2. Install lock washer, thrust washer, and cap screw to
the rear fork shaft. Torque cap screw from 60 to 80 ft−lb
(81 to 108 N−m). Make sure fork turns freely.
3. Install hydraulic motor to the rear fork. Secure motor
to the fork with four hex socket head screws and lock
nuts.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 − Safety.
4. Secure hydraulic cylinder to the rear fork as follows:
A. Swing cylinder to the rear fork.
3. Raise and safely support rear of machine enough to
allow the removal of the rear wheel.
4. Remove lug nuts and remove tire and wheel assembly from hub.
5. Separate hydraulic cylinder from the rear fork as follows:
A. Remove both jam nuts securing the ball joint to
the rear fork.
B. Install ball joint to rear fork.
C. Secure ball joint to the rear fork with both jam
nuts. Tighten the first jam nut from 65 to 85 ft−lb (88
to 115 N−m), then tighten the second jam nut to the
same specification.
5. Lower wheel to ground. Torque wheel lug nuts from
70 to 90 ft−lb (95 to 122 N−m) in a crossing pattern.
B. Separate ball joint from the rear fork.
C. Swing cylinder clear of the rear fork.
6. Remove four lock nuts and hex socket head screws
securing the hydraulic motor to the rear fork. Remove
motor from the fork and position it away from the fork.
CAUTION
Support rear fork to prevent its falling during removal and installation. Personal injury or damage to the fork may result from improper handling.
Chassis
7. Remove cap screw, thrust washer, and lock washer
from the rear fork shaft.
8. Lower rear fork from machine.
9. Check bushings for wear and damage. Replace if
necessary.
Reelmaster 3550−D
Page 6 − 11
Chassis
Brake Lever Linkages
2
1
3
3
4
4
9
10
5
6
6
5
7
8
14
11
15
13
12
31
31
16
30
32
30
13 to 17 ft−lb
(18 to 23 N−m)
17
18
19
20
29
21
28
RIGHT
22
27
FRONT
23
26
25
24
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Pop rivet (4)
Control panel cover
Cover bracket (2)
Magnetic catch (2)
Hex washer head screw (4)
Strike bracket (2)
Lever assembly
Lock nut
Parking brake spacer
Cap screw
Flat washer
Chassis
12. Cotter pin
13. Clevis pin
14. Parking brake link
15. Clevis pin
16. Cotter pin
17. Brake pivot shaft
18. Cotter pin
19. Clevis pin
20. Flange bushing
21. Brake pivot bracket
22. Hex flange head screw (2)
Page 6 − 12
23. Cotter pin
24. Brake cam
25. Brake lever
26. E−ring
27. Adjustment rod
28. Jam nut
29. Adjustable clevis
30. Nut (2)
31. Lock washer (2)
32. Proximity switch
Reelmaster 3550−D
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove control panel cover from the machine.
IMPORTANT: When removing the adjustable clevis,
adjustment rod, or the brake lever, make sure to
mark both parts. Marking both parts will make reassembly and brake adjustment easier.
3. Remove and replace parts as necessary to repair
brake linkages.
4. Install control panel cover to the machine.
Chassis
IMPORTANT: Always check and adjust brakes anytime brake linkages are disassembled or repaired.
Reelmaster 3550−D
Page 6 − 13
Chassis
Steering Column
20 to 26 ft−lb
(28 to 35 N−m)
8
10
26
13
19
20
RIGHT
7
FRONT
35
36
9
16
27
11
Blue
Loctite 242
33
18
2
17
4
23
6
21
5
24
38
8
34
32
25
24
31
37
39
15
12
2
14
30
29
28
1
3
Figure 9
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Steering arm
Flange nut
Flange head screw (2)
Steering valve bracket
Cap screw (2)
Pivot hub (2)
Steering cover
Cap screw (5)
Ball knob
Steering tilt lever
Steering control valve
Tilt bracket
Cap screw
Chassis
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Flat washer
Flange nut
Steering wheel
Hydraulic fitting (2)
Hydraulic fitting (3)
Steering wheel nut
Toro decal
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Hydraulic hose
Tilt steering boss
Page 6 − 14
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Friction disc
Friction disc
Flat washer
Jam nut
Flange screw (2)
Bag holder
Flange screw (4)
Steering shield
Philips head screw
Steering wheel cap
Flat washer (2)
Flange nut (2)
Lock nut (2)
Reelmaster 3550−D
Disassembly
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2
2. Remove philips head screws and steering wheel cap
from the steering wheel.
1
3. Remove steering wheel nut from the steering control
valve. Pull steering wheel from the control valve.
6
4. Remove cover from the steering control valve bracket.
3
5. Remove four flange screws securing the steering
control valve to the steering control valve bracket.
6. Remove both hex flange nuts, cap screws, and pivot
hubs securing the steering control valve bracket to the
steering arm. Slide bracket from the steering control
valve and steering arm.
8
7. Remove and replace parts as necessary to repair
steering column (Fig. 9 and 10).
4
5
Assembly
1. Make sure lever and friction discs are properly assembled to the steering control valve bracket (Fig. 9 and
10).
2. Position steering control bracket to the steering control valve and steering arm. Secure bracket to the steering arm with pivot hubs, cap screws, and hex flange
nuts.
3. Apply blue Loctite 242 to flange hd. screws and install steering control valve to the steering valve bracket
7
Figure 10
1.
2.
3.
4.
Tilt bracket
Steering valve bracket
Jam nut
Flat washer
5.
6.
7.
8.
Friction disc
Tilt steering lever
Steering arm
Friction disc
4. Secure cover to the steering control valve bracket
with cap screws.
Chassis
5. Install steering wheel to the steering control valve.
Torque steering wheel nut from 20 to 26 ft−lb (28 to 35
N−m).
6. Secure steering wheel cap to the steering wheel with
six philips head screws.
Reelmaster 3550−D
Page 6 − 15
Chassis
Front Lift Arms
RIGHT
FRONT
3
2
2
4
5
3
6
6
7
13
5
1
12
10
Blue
Loctite 242
11
10
8
3
2
4
5
2
6
5
9
6
7
6
5
7
6
5
13
Blue
Loctite 242
12
10
3
10
1
10
8
9
2
3
2
14
Blue
Loctite 242
10
8
9
16
1
17
18
4
3
15
19
20
Figure 11
1.
2.
3.
4.
5.
6.
7.
Pivot yoke (3)
Thrust washer (2 per yoke)
Flange bushing (2 per lift arm)
Lynch pin (3)
Retaining ring (2 per pin)
Thrust washer (2 per pin)
Pin (3)
Chassis
8.
9.
10.
11.
12.
13.
14.
Flange head screw (3)
Recessed bumper (3)
Flange bushing (2 per lift arm)
Lift arm #5
Lift arm pin (3)
Hex head screw
Lift arm #1
Page 6 − 16
15.
16.
17.
18.
19.
20.
Lift arm #4
Cap screw (2 per lift arm)
Washer (2 per lift arm)
Flange nut (2 per lift arm
Chain hoop (3)
Chain (3)
Reelmaster 3550−D
Removal (Fig. 11)
Installation (Fig. 11)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
1. If the lift arm pin was removed from frame, install lift
arm pin in frame and secure with cap screw.
2. Slide lift arm onto the lift arm pivot pin.
2. Remove cutting units (see Chapter 7 − Cutting Units
in this manual).
3. Remove lynch pin and thrust washer securing pivot
yoke to lift arm and remove pivot yoke.
4. Remove retaining ring and flat washer from one end
of the cylinder pin that secures rod end of lift cylinder to
lift arm. Pull pin from lift arm and cylinder rod. Support
lift cylinder away from lift arm. DO NOT allow the lift cylinder to hang by the hydraulic hoses.
5. Remove flange head screw and recessed bumper
securing lift arm to lift arm pin. Slide lift arm assembly
from pin.
3. Apply Loctite to flange head screw and secure lift
arm and recessed bumper to lift arm pin.
4. Slide pivot yoke into lift arm and secure with thrust
washer and lynch pin.
5. Secure hydraulic cylinder to the lift arm with pins,
washers, and retaining rings.
6. Install cutting unit to the front lift arm pivot yoke (see
Chapter 7 − Cutting Units in this manual).
7. Grease front lift arm and pivot yoke.
6. Remove hex head screw and drive lift arm pin from
frame if necessary.
Chassis
7. Repair lift arm as necessary.
Reelmaster 3550−D
Page 6 − 17
Chassis
Rear Lift Arms
14
13
11
13
12
10
8
9
9
8
10
4
3
2
8
9
8
20
9
21
22
5
3
23
6
2
5
1
7
4
3
2
2
3
1
17
16
15
RIGHT
FRONT
18
19
Figure 12
1.
2.
3.
4.
5.
6.
7.
8.
Pivot yoke (2)
Thrust washer (2 per pivot yoke)
Flange bushing (2 per lift arm)
Lynch pin (2)
Flange bushing (2 per lift arm)
#3 lift arm
#2 lift arm
Retaining ring (2 per pin)
Chassis
9.
10.
11.
12.
13.
14.
15.
16.
Thrust washer (2 per pin)
Pin (2)
Counterbalance spring (RH)
Counterbalance spring (LH)
Lift arm pin (2)
Flange head screw (2)
Cap screw (2 per lift arm)
Washer (2 per lift arm)
Page 6 − 18
17.
18.
19.
20.
21.
22.
23.
Flange nut (2 per lift arm)
Chain hoop (2)
Chain (2)
Cap screw (2)
Spacer (2)
Washer (2)
Lock nut (2)
Reelmaster 3550−D
Removal (Fig. 12)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove cutting units (see Chapter 7 − Cutting Units
in this manual).
3. Remove lynch pin and thrust washer securing pivot
yoke to lift arm and remove pivot yoke.
1
4. Remove retaining ring and flat washer from one end
of the cylinder pin that secures rod end of lift cylinder to
lift arm. Pull pin from lift arm and cylinder rod. Support
lift cylinder away from lift arm. DO NOT allow the lift cylinder to hang by the hydraulic hoses.
5. Note the position of the spring actuator prior to removal for proper assembly. Insert a tube or similar object
onto the straight end of the counterbalance spring. Lift
the spring end up and remove the spring actuator (cap
screw, spacer, washer, and lock nut) (Fig. 13). Relieve
all tension from the counterbalance spring.
6. Remove flange head screw from lift arm pin.
7. Support lift arm assembly and slide lift arm pin from
frame. Remove lift arm assembly and counterbalance
spring.
2
Figure 13
1. Counterbalance spring
2. Spring actuator
Installation (Fig. 12)
1. If the lift arm pin was removed from frame, install lift
arm pin in frame and secure with cap screw.
2. Position counterbalance spring over lift arm as
shown.
8. Remove hex head screw and drive lift arm pin from
frame if necessary.
3. Support lift arm and slide lift arm pin into frame. Secure lift arm pin to frame with flange head screw.
9. Repair lift arm as necessary.
4. Insert a tube or similar object onto the straight end of
the counterbalance spring. Lift the spring end up and install the spring actuator (cap screw, spacer, washer, and
lock nut) (Fig. 13). Rest end of counterbalance spring on
spring actuator.
6. Secure hydraulic cylinder to the lift arm with pins,
washers, and retaining rings.
7. Install cutting unit to the rear lift arm pivot yoke (see
Chapter 7 − Cutting Units in this manual).
8. Grease rear lift arm and pivot yoke.
Reelmaster 3550−D
Page 6 − 19
Chassis
Chassis
5. Slide pivot yoke into lift arm and secure with thrust
washer and lynch pin.
This page is intentionally blank.
Chassis
Page 6 − 20
Reelmaster 3550−D
Chapter 7
Cutting Units
Table of Contents
DPA Cutting
Units
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Cutting Unit Operator’s Manual . . . . . . . . . . . . . . . 3
Cutting Unit Removal and Installation . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FACTORS THAT CAN AFFECT CUTTING
PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SET UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . 13
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Leveling Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 15
Cutting Unit Reel Motor . . . . . . . . . . . . . . . . . . . . . 15
Backlapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bedbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bedbar Adjuster Service . . . . . . . . . . . . . . . . . . . . 20
Bedknife Replacement and Grinding . . . . . . . . . . 22
Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reel Assembly Service . . . . . . . . . . . . . . . . . . . . . 28
Preparing Reel for Grinding . . . . . . . . . . . . . . . . . 30
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rear Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Roller Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Roller Brush (Optional) . . . . . . . . . . . . . . . . . 36
Reelmaster 3550−D
Page 7 − 1
Cutting Units
Specifications
Figure 1
Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt−on cast aluminum side plates.
Bedknife Adjustment: Dual screw adjustment to the
reel; detents corresponding to 0.0007 inch (0.018 mm)
bedknife movement for each indexed position.
Reel Construction: Reels are 18 inches (45.7 cm) in
length and 5 inch (12.7 cm) in diameter. High strength,
low alloy steel blades are thru hardened and impact resistant. Reels are available in 8 and 11 blade configurations. Optional 22 inch (55.9 cm), 8 and 11 blade reels
are available for the rear cutting unit positions.
Front and Rear Rollers: Greaseable through−shaft
front and rear rollers are used with these cutting units.
Both rollers use the same heavy duty ball bearings.
Reel Bearings: Two sealed, stainless steel ball bearings support the reel shaft.
Reel Drive: The reel weldment shaft is a 1 5/16 inch
(33.3 mm) diameter tube with drive inserts threaded into
both ends. The reel drive inserts have an eight (8) tooth
internal spline.
Height−of−Cut (HOC): Cutting height is adjusted on
the front roller by two (2) vertical screws. Effective HOC
may vary depending on turf conditions, type of bedknife,
roller type and installed attachments.
Counterbalance Weight: A 7 lb. (3.2 kg) cast iron
weight mounted opposite to the hydraulic drive motor
balances the cutting unit.
Cutting Unit Weight (without counterbalance weight):
18” Reel, 8 Blade
78 lb. (35 kg)
with Rear Roller Brush (+16 lb.) 94 lb. (43 kg)
18” Reel, 11 Blade
80 lb. (36 kg)
with Rear Roller Brush (+16 lb.) 96 lb. (44 kg)
with Groomer +(30 lb.)
110 lb. (50 kg)
22” Reel, 8 Blade (optional)
87 lb. (39 kg)
22” Reel, 11 Blade (optional)
91 lb. (41 kg)
Options:
Refer to Cutting Unit Operator’s Manual for available options for your Reelmaster cutting unit.
Bedknife: A replaceable, single edged bedknife is fastened to a machined cast iron bedbar with screws. A
variety of bedknives are available for specific cutting applications.
Cutting Units
Page 7 − 2
Reelmaster 3550−D
General Information
Cutting Unit Operator’s Manual
The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the cutting units on your Reelmaster machine. Additionally, if optional kits have been
installed on the cutting units (e.g. rear roller brush), the
installation instructions for the kit includes set−up and
operation information. Refer to those publications for
additional information when servicing the cutting units.
Cutting Unit Removal and Installation
Cutting Unit Removal
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
2
2. Remove hydraulic reel motor from cutting unit that is
to be removed (see Hydraulic Reel Motor in this section). Position motor away from cutting unit.
1
3
3. For assembly purposes, note location of snapper pin
in lift arm chain (Fig. 2). Remove snapper pin from cutting unit chain bracket and lift arm chain.
4. Move hair pin from rear hole of turf compensator rod
to the hole closest to the rod bracket (Fig. 3). This will
lock the turf compensator spring in position.
Figure 2
1. Lift arm chain
2. Chain bracket
3. Snapper pin
1
5. Remove cutting unit from pivot yoke (Fig. 4):
3
A. Remove snapper pin and cap that retain cutting
unit carrier frame to pivot yoke in lift arm.
4
2
B. Remove carrier frame shaft from pivot yoke on lift
arm.
6. For rear cutting units when the height of cut is above
3/4 inch (1.2 cm) use the following procedure:
B. Slide the pivot yoke shaft out of the lift arm. Make
sure that second thrust washer remains on the pivot
yoke shaft.
Figure 3
C. Move cutting unit away from machine.
D. Remove the cutting unit from the pivot yoke as
described in step 5.
Reelmaster 3550−D
1. Compensator rod assy
2. Unlocked pin position
Page 7 − 3
3. Locked pin position
4. Rod bracket
Cutting Units
DPA Cutting
Units
A. Remove the lynch pin and washer securing the
lift arm pivot yoke shaft to the rear lift arm (Fig. 5).
Cutting Unit Installation
3
IMPORTANT: When installing cutting unit to machine, make sure that turf compensator spring is
mounted on the same side of the cutting unit as the
hydraulic reel drive motor. Also, make sure that cutting unit is installed on machine with motor and
weight properly orientated to machine (Fig. 6).
2
1
1. Lower all the lift arms completely. Make sure the
snapper pin and cap are removed from the lift arm pivot
yoke (Fig. 4).
4
2. Position cutting unit to machine. Coat the cutting unit
carrier frame shaft with clean grease.
3. Install cutting unit to lift arm pivot yoke:
A. Slide cutting unit under the lift arm while inserting
the carrier frame shaft up into the pivot yoke on lift
arm.
B. Place the cap over the carrier frame shaft and
pivot yoke.
C. Secure the cap and the carrier frame shaft to the
pivot yoke with the snapper pin. Use the pivot yoke
slot if a steering cutting unit is desired or use the yoke
hole if the cutting unit is to be locked in position.
Figure 4
1. Pivot yoke
2. Cap
4. For rear cutting units when the height of cut is above
3/4 inch (1.2 cm) use the following procedure:
3. Snapper pin
4. Carrier frame shaft
1
A. Slide the pivot yoke onto the cutting unit carrier
frame shaft and secure with cap and snapper pin as
described in step 3.
B. Make sure that thrust washer is positioned on the
pivot yoke shaft. Insert the yoke arm shaft into the lift
arm and secure it with the washer and lynch pin
(Fig. 5).
2
3
5. Secure the lift arm chain to the cutting unit chain
bracket with the snapper pin (Fig. 2). Use the number of
chain links described in the cutting unit Operator’s
Manual.
1. Rear lift arm
2. Lynch pin and washer
6. Move hair pin to the rear hole of turf compensator rod
to unlock the turf compensator spring (Fig. 3).
1
Figure 5
3. Pivot yoke shaft
1
2
1
2
FRONT
7. Install reel motor to cutting unit (see Hydraulic Reel
Motor in this section).
1
4
IMPORTANT: After installing cutting reel motor,
make sure that the reel motor hoses are not twisted,
kinked or in the risk of being pinched.
5
3
2
1
2
1
Figure 6
1. Reel motor location
Cutting Units
Page 7 − 4
2. Weight location
Reelmaster 3550−D
Special Tools
Special tools are available from your Toro Distributor.
Some tools may have been supplied with your machine
or are available as TORO parts.
Gauge Bar Assembly
Toro Part Number: 108−6715
Use gauge bar to verify height−of−cut adjustment.
Used for groomer
adjustment
Used for Height−of−
Cut adjustment
Figure 7
Cutting Reel Shim
Toro Part Number: 125−5611
The cutting reel shim (0.002”) is used to ensure that the
bedknife is parallel to the cutting reel.
Figure 8
Cutting Performance Paper
Toro Part Number: 125−5610
DPA Cutting
Units
Cutting performance paper is used to test the cutting
reel performance after adjusting the reel to bedknife
clearance. 300 strips of cutting performance paper are
included in this part number.
Figure 9
Reelmaster 3550−D
Page 7 − 5
Cutting Units
Bedknife Screw Tool
Toro Part Number: TOR510880
This screwdriver−type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar.
IMPORTANT: To prevent damage to the bedbar, DO
NOT use an air or manual impact wrench with this
tool.
Figure 10
Handle Assembly
Toro Part Number: 29−9100
For applying lapping compound to cutting units while
keeping hands a safe distance from the rotating reel.
Components for the handle assembly are available individually as follows:
Brush
36−4310
Handle
29−9080
Handle cap 2410−18
Figure 11
Cutting Unit Kickstand
Toro Part Number: 119−8010−03
The cutting unit kickstand is used to prop up the rear of
the cutting unit during service. Use of this tool prevents
the bedbar adjusting screws from resting on the work
surface.
KICKSTAND
Figure 12
Cutting Units
Page 7 − 6
Reelmaster 3550−D
Spline Insert Tool
Toro Part Number: TOR4112 (8 tooth)
Use the spline insert tool for rotating the cutting reel
when hydraulic motor is removed. Also, use this tool for
installation of threaded inserts into the cutting reel shaft.
Figure 13
Roller Rebuild Kit
Toro Part Number: 115−0803
Bearing Installation
Washer
This tool kit is used to assemble the cutting unit rollers.
Tools in this kit are also available individually as follows:
115−0852 Inner Seal Tool
115−0853 Bearing/Outer Seal Tool
107−8133 Bearing Installation Washer
Bearing/Outer Seal
Tool
Inner Seal
Tool
Figure 14
Diameter/Circumference Measuring Tape
Spring steel measuring tape for accurately measuring
the circumference and outside diameter of cutting reel
and other spherical components. Tape calibration is in
fixed inch readings (no adjustments).
Toro Part Number: TOR6023
DPA Cutting
Units
Figure 15
Reelmaster 3550−D
Page 7 − 7
Cutting Units
Turf Evaluator Tool
Toro Model Number: 04399
Many turf discrepancies are subtle and require closer
examination. In these instances, the Turf Evaluator
grass viewing tool is helpful. It can assist turf managers
and service technicians in determining causes for poor
reel mower performance and in comparing the effective
height−of−cut of one mowed surface to another. This
tool should be used with the Toro Guide to Evaluation
Reel Mower Performance and Using the TurfEvaluator
(Toro part no. 97931SL).
Figure 16
Cutting Units
Page 7 − 8
Reelmaster 3550−D
Factors That Can Affect Cutting Performance
There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess” or attempting to cut off too much grass
height may not always be overcome by adjusting the
cutting unit. It is important to remember that the lower
the height−of−cut, the more critical these factors are.
Refer to the Cutting Unit’s Operator’s Manual for detailed cutting unit adjustment procedures. For cutting
unit repair information, refer to the Service and Repairs
section of this chapter.
NOTE: For additional information regarding cutting unit
troubleshooting, see Aftercut Appearance Troubleshooting Aid (Toro part no. 00076SL).
Factor
Possible Problem/Correction
Tire pressure
Check tire pressure of all traction unit tires. Adjust tire
pressure as necessary (see Traction Unit Operator’s
Manual).
Governed engine speed
For best cutting performance and appearance, engine
should be run at maximum governed speed during
machine operation. Check maximum governed engine
speed. Adjust engine to specifications if necessary
(see Chapter 3 Kubota Diesel Engine in this manual).
Reel speed
All cutting reels must rotate at the same speed (within
100 rpm).
All cutting units must have equal bedknife to reel and
height−of−cut adjustments.
Make sure that reel speed selection is correct (see Clip
Chart in Traction Unit Operator’s Manual).
Check reel bearings for wear and replace if necessary.
Bedknife to reel adjustment
Check bedknife to reel contact daily. The bedknife
must have light contact across the entire reel. No
contact will dull the cutting edges. Excessive contact
accelerates wear of both edges. Quality of cut is
adversely affected by both conditions (see Bedknife to
Reel Adjustment in the Cutting Unit Operator’s
Manual).
DPA Cutting
Units
Reel bearing condition
Reelmaster 3550−D
Page 7 − 9
Cutting Units
Factor
Possible Problem/Correction
Reel and bedknife sharpness
A reel and/or bedknife that has rounded cutting edges
or “rifling” (grooved or wavy appearance) cannot be
corrected by tightening the bedknife to reel contact.
Grind cutting reel to remove taper and/or rifling. Grind
bedknife to sharpen and/or remove rifling.
The most common cause of rifling is bedknife to reel
contact that is too tight.
Dull cutting edges must be corrected by grinding the
bedknife and cutting reel (see Bedknife Replacement
and Grinding and Preparing Reel for Grinding in the
Service and Repairs section of this chapter).
A new bedknife must be ground flat (within 0.002”)
after installation to the bedbar. Backlapping may
be required to properly mate the reel and bedknife
after installation into the cutting unit.
NOTE: On cutting units equipped with optional
bedknives, slightly dull cutting edges may be corrected
by backlapping (see Backlapping in the Traction Unit
Operator’s Manual).
Rear roller adjustment
Adjust the rear roller brackets to correct position
depending on the height−of−cut range desired.
See Rear Roller Adjustment in the Operator’s Manual.
Height−of−cut
“Effective” or actual height−of−cut depends on the
cutting unit weight and turf conditions. Effective
height−of−cut will be different from the bench set
height−of−cut.
See Height−of−Cut Adjustment in the Cutting Unit
Operator’s Manual.
Proper bedknife selection for height−of−cut desired
If the bedknife is incorrect for effective height−of−cut,
poor quality of cut will result.
See Cutting Unit Operator’s Manual for bedknife
options.
Stability of bedbar
Make sure bedbar pivot bolts are seated securely.
Check condition of the bushings in the side plates.
See Bedbar Removal and Installation in the Cutting
Unit Operator’s Manual.
Number of reel blades
Use correct number of reel blades for clip frequency
and optimum height−of−cut range.
Cutting unit alignment and carrier frame ground
following
Check carrier frames and lift arms for damage, binding
conditions or bushing wear. Repair if necessary.
Cutting Units
Page 7 − 10
Reelmaster 3550−D
Factor
Possible Problem/Correction
Roller condition and roller type
Make sure that front and rear rollers rotate freely.
Repair roller bearings as necessary.
See Roller Service in the Service and Repairs section
of this chapter.
Refer to Cutting Unit Operator’s Manual for roller
options.
Refer to Traction Unit Operator’s Manual for
adjustment procedures.
Turf compensation spring adjustment
Refer to Traction Unit Operator’s Manual for
adjustment procedures.
Cutting unit accessories
A variety of cutting unit accessories are available that
can be used to enhance aftercut appearance. Refer to
Operator’s Manual for a listing of available
accessories.
DPA Cutting
Units
Rear lift arm counterbalance spring adjustment
Reelmaster 3550−D
Page 7 − 11
Cutting Units
This page is intentionally blank.
Cutting Units
Page 7 − 12
Reelmaster 3550−D
Set Up and Adjustments
Characteristics
If a cutting unit is determined to be out of adjustment,
complete the following procedures in the specified order
to adjust the cutting unit properly.
CAUTION
Never install or work on the cutting units or lift
arms with the engine running. Always stop engine and remove key first.
The dual knob bedknife−to−reel adjustment system incorporated in this cutting unit simplifies the adjustment
procedure needed to deliver optimum mowing performance. The precise adjustment possible with this design gives the necessary control to provide a continual
self−sharpening action. This feature maintains sharp
cutting edges, assures good quality of cut and greatly
reduces the need for routine backlapping.
NOTE: See Cutting Unit Operator’s Manual for complete cutting unit adjustment procedures for your Reelmaster.
1. Adjust the bedknife parallel to the reel.
2. Determine desired height−of−cut range and install
rear roller mounting shim(s) accordingly.
3. Adjust the height−of−cut.
DPA Cutting
Units
In addition, the rear roller positioning system allows for
various height-of-cut ranges and aggressiveness of cut
selections.
Reelmaster 3550−D
Page 7 − 13
Cutting Units
Leveling Rear Roller
The precision machined components of the cutting unit
frame keep the rear roller and cutting reel in alignment
(parallel). If the side plates are disassembled or as the
cutting reel wears, a limited amount of side plate adjustment is possible to make sure that the cutting unit is
properly aligned.
2
1. Place the assembled cutting unit on a surface plate.
2. Make sure that bedknife is properly adjusted to cutting reel.
3. Using the surface plate, check if rear roller is level to
cutting reel by using a 0.005” (0.13 mm) shim at each
end of rear roller. If the shim will pass under the roller at
one end but not the other, a frame adjustment should be
made.
4. Loosen, but do not remove, shoulder bolts that secure the side plate to the frame opposite the side that is
not level (Fig. 17).
1
3
1
Figure 17
1. Shoulder bolt
2. Side plate
3. Rear roller
5. Adjust the position of the side plate to parallel the
rear roller and cutting reel. Then, tighten the shoulder
bolts to a torque from 27 to 33 ft−lb (37 to 44 N−m).
15 to 19 ft−lb
(20 to 26 N−m)
4
5
1
6. After tightening the side plate, recheck the rear roller.
If necessary, loosen and adjust second side plate.
6
7. If rear roller is still not level after adjusting both side
plates, check to see if cutting reel is tapered (see Preparing Reel for Grinding in this chapter). If cutting reel is
not tapered and rear roller is not level, a 0.010” shim
(part number 107−4001) is available to allow additional
rear roller adjustment. The shim would be used on one
side of the rear roller and should be installed between
the rear roller bracket and roller shim (Fig. 18). Tighten
the flange nuts to a torque from 15 to 19 ft−lb (20 to 26
N−m)
7
8
2
8. After leveling rear roller, complete cutting unit set−up
and adjustment sequence.
3
Figure 18
1.
2.
3.
4.
5.
Cutting Units
Page 7 − 14
Rear roller assembly
Rear roller bracket
Carriage screw (4)
Flange nut (4)
Flat washer (4)
6. Roller shims (in storage
above side plate)
7. Roller shims (in use
below side plate)
8. 0.010” shim (if needed)
Reelmaster 3550−D
Service and Repairs
Cutting Unit Reel Motor
1. Park the machine on a level surface, engage parking
brake, lower cutting units and stop engine. Remove key
from the ignition switch.
1
1
2
1
2
FRONT
2. Read the General Precautions for Removing and
Installing Hydraulic System Components in this chapter.
1
4
3. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to
loosening hydraulic lines from reel motor to prevent hydraulic system contamination.
5
3
2
1
CAUTION
2
1
Figure 19
Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and
avoid injury from pressurized hydraulic oil. See
Relieving Hydraulic System Pressure in the General Information section of this chapter.
1. Reel motor location
2. Weight location
4. Disconnect hydraulic hoses from fittings in reel motor. Allow lines to drain into a suitable container. Remove
and discard O−rings.
5. Put caps or plugs on disconnected hoses and fittings
to prevent contamination.
7. Inspect the O−ring on the reel motor flange and replace O−ring if damaged.
8. If hydraulic fittings are to be removed from motor,
mark fitting orientation to allow correct assembly. Remove fittings from motor and discard O−rings.
NOTE: See Cutting Unit Reel Motor Service in Chapter
4 − Hydraulic System in this manual for additional reel
motor service information.
Installation
1. If hydraulic fittings were removed from motor, lubricate new O−rings, position O−rings to fittings and install
fittings into motor ports (see Hydraulic Fitting Installation
in this chapter). Make sure that fittings are orientated
correctly.
Reelmaster 3550−D
2
1
Figure 20
1. Hydraulic reel motor
2. Flange nut or flange
head screw (2)
2. Coat spline shaft of the reel motor with No. 2 multipurpose lithium base grease. Lubricate the O−ring on
the motor flange with clean oil.
3. Rotate the motor clockwise so the motor flanges
clear the flange nuts in the cutting unit side plates. Align
reel motor shaft splines with cutting reel insert splines.
Slide motor shaft into reel insert.
4. Rotate the motor counter−clockwise until the motor
flanges are encircling the cap screws in the side plates.
While holding motor, tighten two (2) flange nuts or flange
head screws to secure reel motor to cutting unit
(Fig. 20).
Page 7 − 15
Cutting Units
DPA Cutting
Units
6. Loosen two (2) flange nuts or flange head screws
that secure the hydraulic reel motor to the cutting unit
side plate (Fig. 20). Rotate motor clockwise and remove
motor from cutting unit.
5. Remove caps or plugs from fittings and hoses.
7. Check oil level in hydraulic reservoir and add correct
oil if necessary.
IMPORTANT: When installing the hydraulic hoses,
make sure that hydraulic hoses are straight (not twisted)
before tightening the hoses to the motor fittings.
8. Follow Hydraulic System Start−up procedures (see
Hydraulic System Start−up in this section).
6. Lubricate and install new O−rings on motor fittings.
Correctly connect hydraulic hoses to the motor using labels placed during removal procedure.
Cutting Units
Page 7 − 16
Reelmaster 3550−D
Backlapping
DANGER
3
TO AVOID PERSONAL INJURY OR DEATH:
D Never place hands or feet in the reel area
while the engine is running. Stay away from the
cutting reels when backlapping.
D When backlapping, run engine at idle speed
only.
D While backlapping, the reels may stall and
then restart.
D Do not attempt to restart reels by hand or foot.
1
D Do not adjust reels while the engine is running.
D If a reel stalls, stop engine before attempting
to clear the reel.
D Reel motors are connected in series: rotating
one motor causes rotation in other motors.
2
Figure 21
1. Mow manifold
2. Backlap lever
3. Reel speed knob
NOTE: Instructions and procedures on backlapping
are available in the Traction Unit Operator’s Manual and
the Toro General Service Training Book, Reel Mower
Basics (part no. 09168SL).
1
Figure 22
DPA Cutting
Units
1. Long Handle Brush
Reelmaster 3550−D
Page 7 − 17
Cutting Units
Bedbar Assembly
Serial No. 315000001 & Up
18” Cutting Unit Components Shown
20
19
17
18
16
14
15
10
14
13
12
11
9
8
3
27 to 33 ft−lb
(37 to 44 N−m)
2
RIGHT
3
FRONT
4
5
6
7
1
Antiseize
Lubricant
Figure 23
1.
2.
3.
4.
5.
6.
7.
Side plate
Rubber bushing (2)
Flange bushing (2)
Plastic washer (4)
Metal washer (2)
Bedbar pivot bolt (2)
Lock nut (2)
Cutting Units
8.
9.
10.
11.
12.
13.
14.
Screw (8)
Bedknife
Bedbar
Frame
Bedbar adjuster shaft (2)
Wave washer (2)
Flange bushing (4)
Page 7 − 18
15.
16.
17.
18.
19.
20.
Washer (2)
Lock nut (2)
Bedbar adjuster screw (2)
Washer (2)
Compression spring (2)
Lock nut (2)
Reelmaster 3550−D
Bedbar Removal (Fig. 23)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.
2. Remove the cutting unit from the machine. Use the
cutting unit kickstand to support the cutting unit (see
Special Tools).
3. Loosen the lock nuts on the end of each bedbar adjuster assembly until washers are loose.
4. Loosen the lock nuts on each bedbar pivot bolt.
5. Remove two (2) bedbar pivot bolts, two (2) metal
washers and four (4) plastic washers from the cutting
unit side plates.
5. Position bedbar into cutting unit. Make sure that the
top of each bedbar arm is between washer and adjuster
screw flange.
6. Position a plastic washer between bedbar and each
cutting unit side plate (Fig. 24).
7. Install the bedbar pivot bolt assemblies. Make sure
that plastic washers are not caught on the threads of the
pivot bolts. Tighten each bedbar pivot bolt from 27 to 33
ft−lbs (37 to 44 N−m).
8. Tighten the pivot bolt lock nuts equally, on each side,
until the outer steel washers cannot be rotated by hand.
Then, loosen the lock nuts slightly so the outer steel
washers just rotate by hand, yet no bedbar end play is
present. The plastic washer between the bedbar and
side plate may be loose.
9. Tighten the lock nut on each bedbar adjuster assembly until the adjuster spring is fully compressed, then
loosen lock nut 1/2 turn.
CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when handling the bedbar.
10.Adjust cutting unit (see Cutting Unit Operator’s
Manual).
11. Install cutting unit to machine.
6. Remove bedbar assembly from cutting unit.
Antiseize
Lubricant
ÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇ
7. Inspect flange bushings and rubber bushings in side
plates for wear or damage. Remove bushings and replace if necessary.
Bedbar Installation (Fig. 23)
1. If rubber bushing was removed from either cutting
unit side plate, apply antiseize lubricant to the side plate
bore and install a new bushing. The bushing should be
installed flush with the inside of the side plate.
8
ÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇ
2. If removed, install the flange bushings with flange
facing outward. Apply antiseize lubricant to inside of
flange bushing.
6
3. Apply antiseize lubricant to the bedbar threads and
the shoulder area of each bedbar pivot bolt.
4
2
4
7
3
5
Figure 24
1.
2.
3.
4.
Cutting unit side plate
Rubber bushing
Flange bushing
Washer (plastic)
5.
6.
7.
8.
Washer (metal)
Bedbar
Bedbar pivot bolt
Lock nut
DPA Cutting
Units
4. Slide one metal washer and one plastic washer onto
each bedbar pivot bolt.
1
CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when handling the bedbar.
Reelmaster 3550−D
Page 7 − 19
Cutting Units
Bedbar Adjuster Service
Antiseize
Lubricant
Loctite #242
14 to 16 ft−lb
(19 to 21 N−m)
9
7
Antiseize
Lubricant
11 12
10
8
6
5
1
4
13
4
3
2
RIGHT
FRONT
Figure 25
1.
2.
3.
4.
5.
Bedbar assembly
Bedbar adjuster shaft
Wave washer
Flange bushing (2)
Flat washer
Cutting Units
6.
7.
8.
9.
Lock nut
Bedbar adjuster screw
Washer
Compression spring
Page 7 − 20
10.
11.
12.
13.
Lock nut
Cap screw
Detent
Frame
Reelmaster 3550−D
Removal (Fig. 25)
1. Remove lock nut, compression spring and washer
from bedbar adjuster screw.
2. Remove bedbar (see Bedbar Removal in this
chapter.
NOTE: Bedbar adjuster shaft has left−hand internal
threads.
3. Unscrew bedbar adjuster screw from the bedbar adjuster shaft.
4. Remove lock nut and flat washer from adjuster shaft.
Slide adjuster shaft and wave washer from cutting unit
frame.
5. Inspect flange bushings in cutting unit frame and remove if necessary.
6. If detent is damaged, remove it from cutting unit side
plate by removing the cap screw.
Installation (Fig. 25)
3. Slide wave washer onto adjuster shaft and then slide
adjuster shaft into flange bushings in cutting unit frame.
Secure adjuster shaft with flat washer and lock nut.
Tighten lock nut to shoulder of adjuster shaft and then
torque lock nut from 15 to 20 ft−lb (21 to 27 N−m).
NOTE: Bedbar adjuster shaft has left−hand internal
threads.
4. Apply antiseize lubricant to threads of bedbar adjuster screw that fit into adjuster shaft. Thread bedbar adjuster screw into adjuster shaft.
5. Install bedbar (see Bedbar Installation in this
chapter).
6. Install washer, compression spring and lock nut onto
adjuster screw. Tighten the lock nut on each bedbar adjuster assembly until the compression spring is fully
compressed, then loosen lock nut 1/2 turn.
7. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
DPA Cutting
Units
1. If detent was removed, apply Loctite #242 (or equivalent) to threads of cap screw and secure detent to cutting unit side plate with cap screw. Torque cap screw
from 14 to 16 ft−lb (19 to 21 N−m).
2. If flange bushings were removed, apply antiseize lubricant to bore of cutting unit frame. Align key on bushing
to slot in frame and install bushings into frame.
Reelmaster 3550−D
Page 7 − 21
Cutting Units
Bedknife Replacement and Grinding
Bedknife Removal
1. Remove bedbar from cutting unit (see Bedbar Removal in this chapter.
18” Cutting Unit Components Shown
NOTE: 18” cutting units use 6 screws to secure bedknife to bedbar. 22” cutting units use 8 screws to secure
bedknife to bedbar.
2
2. Remove screws from bedbar using a socket wrench
and bedknife screw tool (see Special Tools in this
chapter). Discard screws. Remove bedknife from the
bedbar (Fig. 26).
Bedknife Installation
3
1. Use scraper to remove all rust, scale and corrosion
from bedbar surface. Lightly oil bedbar surface before
installing bedknife.
Antiseize
Lubricant
1
2. Make sure that screw threads in bedbar
(5/16−18UNC−2A) are clean. Apply antiseize lubricant
to the threads of new screws. Take care to keep antiseize lubricant from taper on screw heads.
IMPORTANT: Do not use an impact wrench to tighten screws into the bedbar.
Lightly Oil
Bedbar
Surface
250 to 300 in−lb
(29 to 33 N−m)
Figure 26
1.
2.
Screw
Bedbar
3.
Bedknife
3. Use new screws to secure bedknife to bedbar. Install
all screws but do not tighten fully. Then, using a torque
wrench and bedknife screw tool, torque screws from
200 to 250 in−lb (23 to 29 N−m) for 18” cutting units, or
from 250 to 300 in−lb (29 to 33 N−m) for 22” cutting
units. Use a torquing pattern working from the center toward each end of the bedknife (Fig. 27).
4. After installing bedknife to bedbar, grind bedknife.
# TOR510880
5
3
1
2
4
6
Figure 27
Cutting Units
Page 7 − 22
Reelmaster 3550−D
Bedknife Grinding
Since there can be variations in the mounting surface of
the bedbar, a new bedknife will not be perfectly flat after
it is installed to the bedbar. Because of this, it is necessary to grind a new bedknife after installing it to the bedbar. Follow the bedknife grinding specifications
provided and grind only enough to make sure the top
surface of the bedknife is true (Fig. 28 and 29).
IMPORTANT: Do Not grind the bedknife below it’s
service limit (Fig. 28 and 30). Operating the cutting
unit with the bedknife below the service limit may
result in poor after−cut appearance and reduce the
structural integrity of the bedknife for impacts.
NOTE: When grinding the bedknife, be careful to not
overheat the bedknife. Remove small amounts of material with each pass of the grinder. Also, clean and dress
grinding stone often during the grinding process.
NOTE: Some bedknives were produced with a 5_ top
angle. Use a 10_ top angle when regrinding bedknives.
Top
Surface
Remove
Burr
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
Top
Angle
Front Angle
Figure 29
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉ
1. Use Toro General Service Training Book, Reel Mower Basics (part no. 09168SL) and grinder manufacturer’s instructions for bedknife grinding information.
Lip
Height
Service
Limit
Figure 30
1.
Bedknife
2. After grinding bedknife, check lead−in chamfer on
bedknife (Fig. 31). Regrind bedknife lead−in chamfer if
necessary.
3. After bedknife grinding is complete, install bedbar to
cutting unit.
Bedknife Grinding Specifications
Top
Angle
2
EdgeMaxR
Low HOC
Premium
Low HOC
Extended
Low HOC
0.06”
(1.5 mm)
5_
Figure 31
Standard
Low HOC
Extended EdgeMaxR
Low HOC
0.25” (6.4 mm)
1
Front
Angle
1.
0.19”
(4.8 mm)
10_
Bedknife
2.
Lead −in Chamfer
10_
DPA Cutting
Units
Bedknife
Lip Height
Service
Limit
EdgeMaxR
Standard HOC
Standard
Standard HOC
5_
Heavy Duty
Standard HOC
Figure 28
Reelmaster 3550−D
Page 7 − 23
Cutting Units
Reel Assembly
18” Cutting Unit Components Shown
27 to 33 ft−lb
(37 to 44 N−m)
14
8*
6
3
2
12
Loctite #242
10*
11
Loctite #242
4
13
10*
14*
16
1
RIGHT
7
9
13
FRONT
8*
5
11
15
6
12
27 to 33 ft−lb
(37 to 44 N−m)
Figure 32
7.
1. Cutting reel
8.
2. Frame
9.
3. Bedbar assembly
10.
4. RH side plate
11.
5. LH side plate
6. O−ring (2)
*Used on cutting units prior to serial no. 315000001.
Weight
Flange nut (4)*
Wire Spring
Cap screw (4)*
Threaded insert (4)
12.
13.
14.
15.
16.
Flange head screw (4)
O−Ring (2)
Relief valve (2)
Plug
Grease fitting (reel motor side only)
NOTE: Removal of the cutting reel requires removal of
the left side plate from the cutting unit frame. The right
side plate does not have to be removed from the frame.
Cutting Units
Page 7 − 24
Reelmaster 3550−D
27 to 33 ft−lb
(37 to 44 N−m)
15 to 19 ft−lb
(20 to 25 N−m)
13
4
1
11
10
12
3
2
16*
9
15 to 19 ft−lb
(20 to 25 N−m)
8
12
10*
14
9
15
16
7
4
11
5
27 to 33 ft−lb
(37 to 44 N−m)
7
27 to 33 ft−lb
(37 to 44 N−m)
6
Figure 33
Removal (Fig. 32 & 33)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.
2. Remove the cutting unit from the machine and place
on a flat work area.
3. If cutting unit is equipped with a counterweight on LH
side plate, remove the two (2) flange nuts securing the
counter weight to the side plate and remove counter
weight from the cutting unit. Remove and discard O−ring
from counter weight.
Reelmaster 3550−D
12.
13.
14.
15.
16.
Flange bushing (2)
Rear grass shield
Spacer (2)
Shim (as required)*
Flange nut (2)
Flange nut (4)
Special screw
Flat washer
Cap screw
Shim (as required)
4. If cutting unit is equipped with an optional groomer or
rear roller brush, remove components for those options
from left hand side plate of cutting unit. See Chapter 8
− Groomer in this manual for additional groomer information. See Rear Roller Brush in this chapter for information on rear roller brush.
5. Remove bedbar assembly (see bedbar removal in
this chapter).
6. Remove front and rear rollers (see Front Roller Removal and Rear Roller Removal in this chapter).
Page 7 − 25
Cutting Units
DPA Cutting
Units
7.
1. Frame
8.
2. LH side plate
9.
3. RH side plate
10.
4. Shoulder bolt (4)
11.
5. Carrier frame
6. Flange head screw (2)
*Used on cutting units prior to serial no. 315000001.
7. Remove cap screw and flat washer that secure rear
grass shield to LH side plate.
8. Remove flange head screw and flange nut that secures frame spacer and carrier frame to LH side plate.
NOTE: The reel bearings and grease seals are press fit
on the cutting reel shaft and should remain on the reel
when removing the LH side plate.
1
2
Antiseize
Lubricant
9. Remove two (2) shoulder bolts and flange nuts that
secure the LH side plate to the cutting unit frame. Remove the LH side plate from the reel shaft and cutting
unit frame.
CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when removing the cutting reel.
10.Carefully slide the cutting reel assembly from the RH
side plate.
11. Inspect and service cutting reel assembly as required (see Reel Assembly Service in this chapter).
Figure 34
1.
Side plate − RH
2.
Side plate − LH
Installation (Fig. 32 & 33)
6. Slide the LH side plate onto the cutting reel assembly.
1. Thoroughly clean side plates and other cutting unit
components. Inspect side plates for wear or damage
and replace if needed.
7. Install shoulder bolts and flange nuts that secure the
LH side plate to the cutting unit frame. Torque the shoulder bolts from 27 to 33 ft-lbs (37 to 44 N−m).
2. Make sure that grease seals and bearings are properly installed on cutting reel (see Reel Assembly Service
in this Chapter).
8. Apply Loctite #242 (or equivalent) to threads of
flange head screw that secures frame spacer and carrier frame to LH side plate. Install screw and torque from
27 to 33 ft-lbs (37 to 44 N−m). After tightening screw,
check the clearance between the carrier frame and side
plate. If clearance is more than 0.065” (1.6 mm), remove flange head screw and position shim(s) between
carrier frame and side plate so that clearance is less
than 0.065” (1.6 mm). Make sure that the carrier frame
pivots freely after assembly.
3. Cutting unit serial nos. 315000001 & Up have
O−rings in the reel bearing bore of each side plate. Make
sure the O−rings are in good condition and properly installed in the side plates.
4. Apply a thin coat of antiseize lubricant to the reel
bearing bore of each side plate (Fig. 34).
9. Install cap screw and flat washer that secure rear
grass shield to LH side plate. Torque screw from 15 to
19 ft-lbs (20 to 25 N−m).
CAUTION
Contact with the reel, bedknife or other cutting
unit parts can result in personal injury. Use
heavy gloves when installing the cutting reel.
5. Carefully slide the RH end of the cutting reel assembly (no groove in reel shaft or on face of threaded
insert) into the RH side plate. Make sure that bearing is
fully seated into side plate.
Cutting Units
10.Install the bedbar assembly (see Bedbar Installation
in this section).
11. Install front and rear rollers (see Front Roller Installation and Rear Roller Installation in this section).
12.Adjust cutting unit (see Cutting Unit Operator’s
Manual).
Page 7 − 26
Reelmaster 3550−D
NOTE: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame
and side plates of the cutting unit. If necessary, the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the
cutting reel (see Leveling Rear Roller in this Chapter).
14.If counterweight was removed from cutting unit,
install new O−ring on counter weight. Secure counter
weight to cutting unit side plate with two (2) flange nuts.
Torque screws from 27 to 33 ft-lbs (37 to 44 N−m).
15.Install cutting unit to the machine.
DPA Cutting
Units
13.If cutting unit is equipped with optional groomer or
rear roller brush, install components for those options to
left hand side plate of cutting unit. See Chapter 8 −
Groomer for information on groomer. See Rear Roller
Brush in this chapter for information on rear roller brush.
Reelmaster 3550−D
Page 7 − 27
Cutting Units
Reel Assembly Service
Loctite #242
9
10
11
1
12
2
7
6
5
4
85 to 95 ft−lb
(115 to 128 N−m)
(Right Hand Threads)
3
Loctite #242
10
3
4
5
RIGHT
6
7
FRONT
8
85 to 95 ft−lb
(115 to 128 N−m)
(Left Hand Threads − Groove in Face)
Figure 35
1.
2.
3.
4.
Cutting reel
Threaded insert (RH thread)
Plastic plug
Retaining ring
5.
6.
7.
8.
Special washer
Flocked seal
Sealed bearing
Threaded insert (LH thread)
Cutting Reel Inspection
1. Inspect reel bearings to insure that they spin freely
and have minimal axial play.
9.
10.
11.
12.
Groove indicating LH threads
Reel spider
Retaining ring groove
Bearing shoulder
3. Check the threaded inserts in the reel shaft for excessive wear or distortion. Replace inserts if damage is
evident.
2. Inspect the reel shaft as follows. If reel damage is detected, replace reel.
A. Check the reel shaft for bending and distortion by
placing the shaft ends in V−blocks.
B. Check the reel blades for bending or cracking.
A. One insert has LH threads and the other insert
has RH threads. The insert with LH threads has a
groove on the insert face. A groove is cut 2.2” (5.6
cm) from the end of the reel shaft to identify the reel
end that has LH threads.
B. Use correct spline insert tool to remove threaded
inserts (see Special Tools in this chapter).
C. Check the service limit of the reel diameter (see
Preparing a Reel for Grinding in this section).
Cutting Units
Page 7 − 28
Reelmaster 3550−D
Assembly of Cutting Reel (Fig. 35)
1. If flocked seals and/or bearings were removed from
reel shaft, discard removed components and replace.
Flocked
Surface
Toward
Bearing
2. Make sure that the retaining ring is fully seated into
the groove on the cutting reel shaft.
3. Install special washer with recessed slots toward
bearing. Drive special washer onto reel shaft until it
squarely contacts retaining ring.
Loctite #242
85 to 95 ft−lb
(115 to 129 N−m)
7
2
3
4. Slide flocked seal and bearing onto reel shaft with
flocked side of seal against bearing.
4
5
6
5. Install threaded insert.
Mobil XHP−222
Grease
or equivalent
A. One insert has LH threads and the other insert
has RH threads. The insert with LH threads has a
groove on the insert face. A groove is cut 2.2” (5.6
cm) from the end of the reel shaft to identify the reel
end that has LH threads.
B. For cutting unit serial no. prior to 315000001,
make sure plastic plug is pressed flush into end of
threaded insert. For cutting unit serial no.
315000001 & Up, make sure plastic plug is pressed
unto reel shaft 1.5” (38 mm) below the end of the
shaft (Fig. 37).
8
1
Figure 36
1.
2.
3.
4.
Side plate
Retaining ring (2)
Special washer (2)
Flocked seal (2)
5.
6.
7.
8.
Bearing (2)
Plug (2)
Threaded insert LH
Wire spring
C. Use correct spline insert tool to install threaded
inserts (see Special Tools in this chapter).
D. Apply thread locking compound (Loctite #242 or
equivalent) to threaded portion of insert. Tighten
threaded insert from 85 to 95 ft-lb (115 to 128 N−m).
E. Fill threaded insert splines with high temp Mobil
XHP−222 grease or equivalent.
6. Repeat procedure for other end of reel if necessary.
Figure 37
1.
Reelmaster 3550−D
Page 7 − 29
Reel shaft
2.
Plastic plug (2)
Cutting Units
DPA Cutting
Units
1.5” (38 mm)
Preparing Reel for Grinding
Presently, the Reelmaster 3550- D machines use scalloped radial reels (Fig. 38). The radial reel design has
blades that are placed in line with the center of the reel
shaft. The rear of the blade has a scalloped relief.
SCALLOPED RADIAL REEL
2
1
Before grinding a cutting reel, make sure that all cutting
unit components are in good condition. Depending on
type of grinder used, faulty cutting unit components can
affect grinding results.
When grinding, be careful to not overheat the cutting
reel blades. Remove small amounts of material with
each pass of the grinder.
Follow reel grinder manufacturer’s instructions to grind
cutting reel to Toro specifications (see Reel Grinding
Specifications chart below). Additional reel grinding information can be found in the Toro General Service
Training Book, Reel Mower Basics (part no. 09168SL).
Figure 38
1. Blade land width
2. Blade relief angle
After completing the reel grinding process, adjust cutting unit (see Cutting Unit Operator’s Manual).
Reel Diameter (New)
5.060 in (128.5 mm)
Service Limit Reel Diameter
4.500 in (114 mm)
Reel Shaft Diameter (OD)
1.313 in (33.3 mm)
Service Limit Reel Diameter Taper
D2
D1
Reel Grinding Specifications
Reel Diameter Taper = D1 - D2
Figure 39
0.010 in (0.25 mm) (Fig. 39)
Blade Land Width
0.060 in +/- 0.010 in
(1.5 mm +/- .25 mm)
Blade Relief Angle
30o +/- 5o
Relief grind of cutting reel blades is necessary when
blade land width exceeds 0.120” (3 mm).
NOTE: After grinding the reel and/or bedknife, check
the reel to bedknife contact again after cutting two (2)
fairways. During this initial use, any burrs will be removed from reel and bedknife which may create improper reel to bedknife clearance and thus accelerate wear.
This practice of re- checking the reel to bedknife contact
after grinding will extend the longevity of the sharpness
of the edge of the reel and the bedknife.
Cutting Units
Page 7 - 30
Reelmaster 3550- D
Front Roller
Removal (Fig. 40)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.
1
Loctite #242
Antiseize
Lubricant
2. Remove the cutting unit from the machine and place
on a level working surface. Use cutting unit kickstand
(see Special Tools) to raise front roller from work surface.
2
15 to 19 ft−lb
(20 to 26 N−m)
3
3. Loosen flange nuts and cap screws securing the
front roller shaft to each front height−of−cut brackets.
5
6
4. Remove flange lock nut and carriage screw that secures one of the height−of−cut brackets to the cutting
unit side plate. Remove the height−of−cut bracket from
the cutting unit.
Loctite #242
7
4
8
5. Slide the front roller assembly from the remaining
height−of−cut bracket on the cutting unit.
Installation (Fig. 40)
1. Place cutting unit on a level working surface and use
cutting unit kickstand (see Special Tools) to support cutting unit.
2. Inspect condition of cap screws in both height−of−
cut brackets. Replace cap screw(s) if necessary:
A. Place two (2) flat washers on cap screw.
B. Apply Loctite #242 (or equivalent) to threads of
cap screw at 0.750” (19 mm) below screw head.
Thread flange lock nut (flange toward screw head)
onto cap screw over applied Loctite.
C. Apply antiseize lubricant to cap screw threads
that will extend into height−of−cut bracket.
D. Thread cap screw into bracket.
NOTE: When assembling height−of−cut brackets to
side plate, make sure that cap screw head and one flat
washer are above adjustment flange on side plate and
second flat washer and flange lock nut are below adjustment flange.
Figure 40
1.
2.
3.
4.
Cap screw
Flat washer
Flange lock nut
Height−of−cut bracket
5.
6.
7.
8.
Carriage screw
Cap screw
Flange nut
Front roller assembly
4. Slide front roller shaft into bracket attached to the
cutting unit. Slide second height−of−cut bracket onto the
other end of roller shaft. Secure second bracket to cutting unit side plate with carriage screw and flange nut.
5. Tighten flange lock nut on cap screw and then loosen
nut 1/4 to 1/2 turn. Cap screw should rotate freely with
little (if any) end play after lock nut installation.
6. Apply Loctite #242 (or equivalent) to threads of two
(2) remaining cap screws. Center front roller to the cutting reel and secure in place with cap screws. Torque
cap screws from 15 to 19 ft−lb (20 to 26 N−m). Secure
cap screws with flange nuts.
7. Lubricate front roller.
8. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
DPA Cutting
Units
6. If necessary, remove the second height−of−cut
bracket from the cutting unit.
3. If both front height−of−cut brackets were removed
from cutting unit side plate, position one of the brackets
to side plate. Secure bracket to side plate with carriage
screw and flange lock nut.
Reelmaster 3550−D
Page 7 − 31
Cutting Units
Rear Roller
Removal (Fig. 41)
15 to 19 ft−lb
(20 to 26 N−m)
4
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.
5
1
6
2. Remove the cutting unit from the machine and place
on a level working surface. Place support blocks under
bedbar to raise rear roller from work surface.
3. Loosen flange nuts that secure the rear roller shaft
to the rear roller brackets.
7
4. Remove flange nuts and carriage screws that secure
rear roller bracket and roller shims to one of the cutting
unit side plates.
8
2
NOTE: On cutting units equipped with optional High
Height of Cut Kit, there will be additional roller shims
installed between rear roller bracket and cutting unit
side plate.
5. Remove the roller bracket and roller shims from the
rear roller and cutting unit.
6. Slide the rear roller assembly from the remaining
rear roller bracket on the cutting unit.
3
Figure 41
1.
2.
3.
4.
5.
Rear roller assembly
Rear roller bracket
Carriage screw (4)
Flange nut (4)
Flat washer (4)
6. Roller shims (in storage
above side plate)
7. Roller shims (in use
below side plate)
8. 0.010” shim (if needed)
7. If necessary, remove the second rear roller bracket
and roller shims from the cutting unit.
3. Slide rear roller shaft into the rear roller bracket attached to the cutting unit.
Installation (Fig. 41)
4. Slide second rear roller bracket onto the other end of
roller shaft. Secure second roller bracket and shims to
cutting unit side plate with two (2) carriage screws and
flange nuts. Install slotted roller shims as shown
(Fig. 41). Do not fully tighten flange nuts.
1. Place cutting unit on a level working surface.
NOTE: Refer to Cutting Unit Operator’s Manual for
number of roller shims required for various height of cut
settings.
NOTE: A 0.010” shim (part number 107−4001) is available to allow for leveling of the rear roller (see Leveling
Rear Roller in the Set−up and Adjustments section of
this chapter). If necessary, this shim would be used on
one side of the rear roller and should be installed between the rear roller bracket and roller shim.
5. Center rear roller to the cutting reel and secure in
place by tightening flange nuts. Torque flange nuts from
15 to 19 ft−lb (20 to 26 N−m).
6. Lubricate rear roller.
7. Adjust cutting unit (see Cutting Unit Operator’s
Manual).
2. If both rear roller brackets were removed from cutting
unit side plate, position brackets and roller shims to one
of the side plates, and install two (2) carriage screws and
flange nuts to retain bracket in position. Install slotted
roller shims as shown (Fig. 41). Do not fully tighten
flange nuts.
Cutting Units
Page 7 − 32
Reelmaster 3550−D
Roller Service
Disassembly (Fig. 42)
50 to 60 ft−lb
(68 to 81 N−m)
2
1. Remove bearing lock nut from each end of roller
shaft.
3
4
2. Loosely secure roller assembly in bench vise and
lightly tap one end of roller shaft until outer seals and
bearing are removed from opposite end of roller tube.
Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove
shaft from roller tube.
5
6
7
1
2
3
3. Carefully remove inner seal from both ends of roller
tube taking care to not damage tube surfaces.
4
5
6
4. Discard removed seals and bearings.
5. Clean roller shaft and all surfaces on the inside of the
roller tube. Inspect components for wear or damage.
Also, carefully inspect seating surface and threads of
bearing lock nuts. Replace all damaged components.
Assembly (Fig. 42)
1
1. Install both inner seals into roller tube making sure
that seal lip (and garter spring) faces end of tube. Use
inner seal tool (see Special Tools in this chapter) and
soft face hammer to fully seat seals against roller shoulder (Fig. 43). Apply a small amount of grease around the
lip of both inner seals after installation.
7
Figure 42
1.
2.
3.
4.
Roller tube
Roller shaft
Inner seal
Bearing
5. Outer seal
6. Bearing lock nut
7. Grease fitting
1
IMPORTANT: During assembly process, frequently
check that bearings rotate freely and do not bind. If
any binding is detected, consider component removal and reinstallation.
2
3
2. Install new bearing and outer seals into one end of
roller tube:
A. Position a new bearing into one end of roller tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) with a soft face hammer to fully seat bearing
against roller shoulder (Fig. 44). After bearing installation, make sure that it rotates freely with no binding.
Figure 43
1. Roller tube
2. Inner seal
B. Apply a small amount of grease around the lip of
both outer seals.
3. Inner seal tool
1
2
3
4
D. Using the same process, install second outer
seal making sure to not crush the previously installed
installed outer seal. Again, make sure that bearing
still freely rotates.
Reelmaster 3550−D
DPA Cutting
Units
C. Install first outer seal into roller tube making sure
that seal lip (and garter spring) faces end of tube.
Use bearing/outer seal tool (see Special Tools in this
chapter) and soft face hammer to lightly seat seal
against roller shoulder (Fig. 45). Make sure that
bearing still freely rotates after seal installation.
Figure 44
1. Roller tube
2. Inner seal
Page 7 − 33
3. Bearing
4. Bearing/outer seal tool
Cutting Units
3. From the roller tube end with only the inner seal
installed, carefully install the roller shaft into the roller
tube. Make sure that seals are not damaged as shaft is
installed.
1
3
2
4
5
4. Install new bearing and outer seals into second end
of roller tube:
A. Position a second new bearing to roller shaft and
tube. Position washer (see Special Tools in this
chapter) on bearing to allow pressing on both inner
and outer bearing races simultaneously.
B. Use washer and bearing/outer seal tool (see
Special Tools in this chapter) with a soft face hammer
to fully seat bearing (Fig. 46). After bearing installation, make sure that shaft freely rotates and that no
binding is detected. If necessary, lightly tap bearing
and/or shaft ends to align shaft and bearings. Remove washer from roller.
Figure 45
1. Roller tube
2. Inner seal
3. Bearing
1
4. Outer seal
5. Bearing/outer seal tool
2
4
3
5
6
C. Apply a small amount of grease around the lip of
both outer seals.
D. Carefully install first outer seal into roller tube
making sure that seal lip (and garter spring) faces
end of tube. Use bearing/outer seal tool (see Special
Tools in this chapter) and soft face hammer to lightly
seat seal (Fig. 47). Make sure that shaft and bearings still freely rotate after seal installation.
E. Using the same process, install second outer
seal making sure to not crush the previously installed
outer seal. Again, make sure that shaft and bearings
still freely rotate.
Figure 46
1. Roller tube
2. Roller shaft
3. Inner seal
1
4. Bearing
5. Washer
6. Bearing/outer seal tool
2
3
4
5
6
IMPORTANT: Make sure that all grease is removed
from shaft threads to prevent bearing lock nut loosening.
5. Thoroughly clean threads on both ends of roller
shaft.
NOTE: If original bearing lock nut(s) are being re−used,
apply Loctite #242 (or equivalent) to threads of lock
nut(s).
6. Install bearing lock nut onto each end of the roller
shaft. Make sure that outer seals are not damaged during nut installation. Torque bearing lock nuts from 50 to
60 ft−lb (68 to 81 N−m).
Figure 47
1. Roller tube
2. Roller shaft
3. Inner seal
4. Bearing
5. Outer seal
6. Bearing/outer seal tool
7. If grease fittings were removed from end of roller
shaft, install fittings in shaft.
NOTE: After roller is installed to cutting unit, lubricate
roller grease fittings, rotate roller to properly distribute
grease in bearings and clean excess grease from roller
ends. A properly assembled roller should rotate with
less than 5 in−lb (0.68 N−m) resistance.
Cutting Units
Page 7 − 34
Reelmaster 3550−D
DPA Cutting
Units
This page is intentionally blank.
Reelmaster 3550−D
Page 7 − 35
Cutting Units
Rear Roller Brush (Optional)
2
4
5
LEFT SIDE DRIVEN REAR ROLLER BRUSH ASSEMBLY SHOWN
6
9
19
20 to 25 in- lb
(2.3 to 2.8 N- m)
1
18
10
9
7
25
8
27 to 33 ft- lb
(36 to 45 N- m)
11
20
25
18
5
7
21
22
6
5
23
24
26
4
12
13
14
15
16
3
41
17
42
30
Loctite #242
85 to 95 ft- lb
(115 to 129 N- m)
RIGHT
FRONT
29
43
44
45
46
27
28
31
Grease
Grommet ID
32
33
34
35
35 to 40 ft- lb
(47 to 54 N- m)
36
37
38
15 to 19 ft- lb
(20 to 25 N- m)
39
40
Figure 48
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Roller brush
Bearing housing (non- driven)
Bearing housing (driven)
Bearing (2)
Seal (3)
Excluder seal (2)
J- bolt (2)
Roller brush shaft
Lock nut (2)
O- ring
Carriage bolt (2)
Spacer
Hardened washer (as required)
Driven pulley
Flange nut
Cover
Cutting Units
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Flange nut (3)
Flat washer (4)
Cap screw (2)
Bracket - RH
Bracket - LH
Spacer
Cap screw (2)
Grease fitting
Flange nut (4)
Cap screw (2)
Bearing housing
Grommet
O- ring
Drive shaft
Brush plate
Page 7 - 36
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
Flange head screw
Spacer
Drive pulley
Flange head screw
Drive belt
Idler pulley
Bearing
Retaining ring
Lock nut
Carriage bolt (4)
Idler arm
Spacer
Torsion spring
Washer
Lock nut
Reelmaster 3550- D
NOTE: Drive components for the rear roller brush are
located on the opposite side of the cutting unit from the
cutting reel hydraulic motor. Figure 48 shows components used when the brush drive is on the left side of the
cutting unit.
2
1
3
NOTE: The Installation Instructions for the rear roller
brush kit has detailed information regarding assembly
and adjustment. Use those Instructions along with this
Service Manual when servicing the rear roller brush.
4
20 to 25 in−lb
(2.3 to 2.8 N−m)
Figure 49
Disassembly (Fig. 48)
1. Position machine on a clean and level surface, lower
cutting units, stop engine, engage parking brake and remove key from the ignition switch.
1. Roller brush shaft
2. J−bolt
3. Roller brush
4. Lock nut
2. To remove roller brush from brush shaft:
A. Remove the non−driven brush bearing assembly
from cutting unit.
1
2
4
4
4
B. Slide excluder seal from roller brush shaft.
C. Remove lock nut and J−bolt from both ends of the
brush (Fig. 49).
D. While rotating brush, slide brush from the shaft.
3
CAUTION
3
Figure 50
3. To remove roller brush drive belt, rotate the cutting
reel and carefully pry the belt off the drive pulley.
4. Disassemble roller brush components as necessary.
Assembly (Fig. 48)
1. If brush was removed from shaft, slide brush onto
shaft while rotating brush. Secure brush to shaft with two
(2) J−bolts and lock nuts. Make sure that the J−bolts are
installed with the threaded portion on the outside of the
brush (Fig. 49). Torque lock nuts from 20 to 25 in−lb (2.3
to 2.8 N−m).
3. Bearing
4. Grease seal
2. If seals or bearings were removed from brush bearing housings, install new components.
A. Pack bearings with grease before installation.
B. Press bearing into bearing housing so that bearing contacts shoulder in housing bore.
C. Install grease seals as shown (Fig 50). Press
seals into housing so that seals contact bore
shoulders.
3. Assemble roller brush components (Fig. 48).
A. Apply a light coating of grease to inner diameter
of the grommet in drive bearing housing.
B. Tighten flange head screw that secures drive
pulley to drive shaft from 35 to 40 ft−lb (47 to 54
N−m).
C. Apply a light coating of grease to inner diameter
of the seals in roller brush bearing housings.
D. Inspect O−ring on non−driven end of roller brush
shaft and replace if necessary.
Reelmaster 3550−D
Page 7 − 37
Cutting Units
DPA Cutting
Units
Contact with the reel or other cutting unit parts
can result in personal injury. Use heavy gloves
when handling the cutting reel.
1. Housing (non−driven)
2. Housing (driven)
E. Apply antiseize lubricant to splines of roller brush
shaft before sliding hardened washer(s) and driven
pulley onto shaft. Torque flange nut that secures driven pulley to roller brush shaft from 27 to 33 ft−lb (36
to 45 N−m).
4
1
F. Position excluder seals on brush shaft so that
seals just touch bearing housings.
2
CAUTION
3
Contact with the reel or other cutting unit parts
can result in personal injury. Use heavy gloves
when handling the cutting reel.
G. To install drive belt, loop belt around driven pulley
and over the top of the idler pulley. While rotating the
cutting reel, carefully guide belt onto drive pulley
(Fig. 51). After belt installation, make sure that belt
and pulley grooves are aligned and that belt is centered in idler pulley.
Figure 51
1. Drive pulley
2. Driven pulley
CHECK
ALIGNMENT
2
1
4. Check alignment of pulleys with a straight edge
placed along the outer face of the driven pulley (Fig. 52).
The outer faces of the driven and drive pulleys (not the
idler pulley) should be in line within 0.030” (0.76 mm).
If necessary to align pulleys, remove driven pulley from
brush shaft and add or remove hardened washer(s) until
drive and driven pulleys are aligned within 0.030” (0.76
mm).
5. Check that roller brush is parallel to rear roller with
0.060” (1.5 mm) clearance to light contact with roller
(Fig. 53). If contact is incorrect, brush operation will be
adversely affected.
3. Idler pulley
4. Drive belt
3
Figure 52
1. Drive pulley
2. Driven pulley
3. Straight edge
6. Lubricate grease fittings on brush bearing housings
until grease purges past inboard seals. Wipe excess
grease from seals and fittings.
1
3
2
Figure 53
1. Rear roller brush
2. Rear roller
Cutting Units
Page 7 − 38
3. Light contact
Reelmaster 3550−D
Chapter 8
Groomer (Optional)
Table of Contents
Groomer
GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
Groomer Reel Mechanical Problems . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Groomer Drive Belt Replacement . . . . . . . . . . . . . 4
Groomer Plate Assembly . . . . . . . . . . . . . . . . . . . . . 6
Groomer Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Groomer Reel Service . . . . . . . . . . . . . . . . . . . . . . 12
Height Adjuster Assembly . . . . . . . . . . . . . . . . . . . 14
Reelmaster 3550−D
Page 8 − 1
Groomer
Grooming Performance
There are a number of factors that can affect the performance of grooming. These factors vary for different
golf courses and from fairway to fairway. It is important
to inspect the turf frequently and vary the grooming
practice with turf needs.
IMPORTANT: Improper or overaggressive use of the
groomer (e.g. too deep or too frequent grooming) may
cause unnecessary stress on the turf leading to severe
turf damage. Use the groomer carefully. READ AND
UNDERSTAND THE GROOMER OPERATION INSTRUCTIONS BEFORE OPERATING OR TESTING
GROOMER PERFORMANCE.
It is important to remember that factors affecting quality
of cut also affect grooming performance.
Variables That Affect the Use and Performance of
Groomers:
1. The growing season and weather conditions.
2. General turf conditions.
3. The frequency of grooming/cutting − number of cuttings per week and how many passes per cutting.
4. The height−of−cut.
5. The grooming depth.
6. The type of grass.
7. The amount of time that a groomer reel has been in
use on a particular turf area.
8. The amount of traffic on the turf.
9. The overall turf management program − irrigation,
fertilizing, weed control, coring, over−seeding, sand
dressing, disease control and pest control.
10.Stress periods for turf − high temperatures, high humidity, unusually high traffic.
Groomer
Page 8 − 2
Reelmaster 3550−D
Troubleshooting
Groomer Reel Mechanical Problems
Problem
Possible Causes
Correction
No rotation of the groomer reel.
The groomer drive belt needs to be
adjusted.
Adjust groomer drive belt.
Seized groomer reel or idler bearing(s) in groomer side plate(s).
Identify and replace faulty bearing(s).
Broken or damaged idler spring.
Replace spring.
The groomer drive belt is worn, bro- If the drive belt slips, it probably is
ken or damaged.
out of adjustment or worn.
Repair or replace drive belt if necessary. A broken or worn belt could
be the result of improper belt routing or seized bearings in groomer
assembly.
Change grooming depth.
The groomer reel blades are bent,
damaged or missing.
Repair or replace blades if necessary.
The groomer reel shaft is bent or
damaged.
Replace groomer reel shaft.
Grooming depth is not equal on
both ends of groomer reel.
Adjust depth if necessary. Check
and adjust cutting unit set up (level
bedknife to reel, level rear roller to
reel, set height−of−cut, etc.).
Groomer
The turf is damaged or has uneven
grooming.
Grooming depth is too deep.
Reelmaster 3550−D
Page 8 − 3
Groomer
Service and Repairs
CAUTION
Never work on the groomer with the engine
running. Always stop the engine, remove the
key from the ignition switch and wait for all
machine movement to stop before working on
the groomer.
NOTE: The Groomer Operator’s Manual provides information regarding the installation, set−up and operation of the optional groomer on your Reelmaster
machine. Refer to these instructions for additional information when servicing the groomer.
Groomer Drive Belt Replacement
The groomer drive belt should be inspected/replaced
annually or after 750 hours of operation.
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
3
4
NOTE: If cutting unit is equipped with powered rear
roller brush, removal of roller brush components will be
necessary to replace groomer drive belt (see Roller
Brush (Optional) in Chapter 7 − Cutting Units in this
manual).
1
NOTE: When removing groomer cover, groomer
weights do not have to be removed from cover.
2. Remove the access cover from the groomer cover
assembly (Fig. 1).
2
Figure 1
1. Access cover
2. Lock nut (2)
3. Groomer cover
4. Flange nut (2)
3. Remove two (2) flange nuts that secure groomer
cover, then remove cover (Fig. 1).
4. Remove groomer belt tension by pivoting idler plate
and pulley using a wrench on pulley nut. Slip groomer
drive belt off pulleys (Fig. 2). Carefully release idler plate
and pulley.
5. Install new drive belt to drive pulley, idler pulley and
driven pulley observing correct belt routing (Fig. 2).
Make sure that groomer drive belt is above idler pulley
after belt installation.
6. Install groomer cover and secure with two (2) flange
nuts.
1
4
7. Install access cover to groomer cover assembly.
2
3
Figure 2
1. Drive pulley
2. Idler pulley
Groomer
Page 8 − 4
3. Driven pulley
4. Groomer drive belt
Reelmaster 3550−D
Groomer
This page is intentionally left blank.
Reelmaster 3550−D
Page 8 − 5
Groomer
Groomer Plate Assembly
Loctite #242
7
19
25
Left Side Driven Groomer Assembly Shown
26
21
20
16
22
1
23
Antiseize
Lubricant
Loctite #242
27 to 33 ft−lb
(37 to 44 N−m)
24
Antiseize
Lubricant
18
25
19
16
26
27
7 4
14
13
23
Loctite #242
85 to 98 ft−lb
(115 to 129 N−m)
17
12
2
Antiseize
Lubricant
RIGHT
11
3
5
27 to 33 ft−lb
(37 to 44 N−m)
Antiseize
Lubricant
FRONT
6
15
7
8
Loctite #242
9
10
75 to 90 in−lb
(8 to 10 N−m)
Figure 3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Groomer reel
Pulley spacer
Washer (as required)
Square key
Driven pulley
Flange nut
Socket head screw (4)
Idler plate
Idler pulley assembly
Lock nut
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flange head screw
Drive pulley
Retaining ring
Extension spring
Pivot hub (drive)
O−ring
Groomer plate assembly (drive)
Groomer shim
Shoulder bolt (2)
20. Pivot hub assembly (non−drive)
21. Flange nut (2)
22. Groomer plate assembly
(non−drive)
23. Excluder seal (2)
24. O−ring
25. Ball joint rod (2)
26. Spacer (2)
27. Drive shaft
NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting unit hydraulic
motor.
Groomer
Page 8 − 6
Reelmaster 3550−D
Removal (Fig. 3)
B. Remove shoulder bolt and spacer that secures
quick−up ball joint rod to groomer plate.
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
C. Remove two (2) socket head screws that secure
groomer components to cutting unit side plate.
D. Remove pivot hub from cutting unit.
NOTE: If cutting unit is equipped with powered rear
roller brush, removal of roller brush components will be
necessary to service groomer plate assemblies (see
Roller Brush (Optional) in Chapter 7 − Cutting Units in
this manual).
2. To remove groomer plate assembly from groomer
drive side of cutting unit:
E. Support groomer shaft to prevent it from falling.
Carefully slide non−drive side groomer plate from
groomer shaft and cutting unit.
4. Inspect seals, bearings and bushing in groomer
plates. Remove and discard damaged or worn components.
A. Remove groomer belt cover and groomer drive
belt from groomer drive (see Groomer Belt Replacement in this section).
Installation (Fig. 3)
NOTE: To prevent cutting reel from turning when removing drive pulley, block reel with piece of wood.
2
1
B. Remove flange head screw that retains drive pulley. Pull drive pulley from drive shaft. Locate and retrieve square key from drive shaft.
NOTE: To prevent groomer shaft from turning when
removing driven pulley, use wrench on shaft flats to
hold groomer shaft.
C. Remove the flange nut that secures driven pulley
to groomer shaft. Remove driven pulley from shaft.
3
4
4
3
4
D. Slide washer(s) and pulley spacer from groomer
shaft.
E. Remove shoulder bolt and spacer that secures
quick−up ball joint rod to groomer plate.
G. Remove two (2) socket head screws that secure
groomer components to cutting unit side plate.
1. If seals, bearings or bushing was removed from
groomer plates, install new components noting proper
orientation (Fig. 4).
H. Remove pivot hub and idler plate assembly from
cutting unit.
I. Support groomer shaft to prevent it from falling.
Carefully slide drive side groomer plate from
groomer shaft and cutting unit. Remove groomer
shim.
3. To remove groomer plate assembly from groomer
non−drive side of cutting unit:
A. Remove hydraulic reel motor from cutting unit
(see Hydraulic Reel Motor Removal in Chapter 7 −
Cutting Units in this manual).
Reelmaster 3550−D
3. Bearing
4. Grease seal
Page 8 − 7
A. Pack bearings with grease before installation.
B. Press bearings into groomer plate so that bearings contact shoulder in groomer plate bore.
C. Install grease seals so that seal lips are positioned toward the groomer blade location. Seals
should be flush with surface of groomer plate.
D. Press bushings into groomer plate until the bushing contacts the shoulder in the groomer plate bore.
E. If groomer studs (not shown) were removed from
groomer plate, install new studs into groomer plate
and torque from 14 to 18 ft−lb (19 to 24 N−m).
Groomer
Groomer
F. Disconnect extension spring from stud on
groomer plate.
Figure 4
1. Drive side groomer plate
2. Non−drive groomer plate
2. Install groomer plate assembly to groomer non−
drive side of cutting unit:
A. Apply a thin layer of grease to inner lip of seal and
carefully position non−drive side groomer plate onto
groomer shaft and slide to cutting unit.
B. Apply antisieze lubricant to the outside diameter
of the pivot hub and position pivot hub to cutting unit
(Fig. 6).
1
C. Apply Loctite to two (2) socket head screws and
secure pivot hub to cutting unit side plate.
D. Install shoulder bolt and spacer that secures
quick−up ball joint rod to groomer plate. Torque
Shoulder bolt from 17 to 21 ft−lb (23 to 28 N−m).
E. Install hydraulic reel motor to cutting unit (see Hydraulic Reel Motor Installation in Chapter 7 − Cutting
Units in this manual).
3
2
Figure 5
1. Drive pulley
2. Driven pulley
3. Install groomer plate assembly to groomer drive side
of cutting unit:
3. Straight edge
2
1
A. Position groomer shim to cutting unit side plate.
B. Apply a thin layer of grease to inner lip of seals
and carefully position drive side groomer plate onto
groomer shaft and slide to cutting unit.
C. Apply antisieze lubricant to the outside diameter
of the pivot hub and position pivot hub to cutting unit
(Fig. 6). Apply Loctite to two (2) socket head screws
and secure pivot hub to cutting unit side plate.
Antiseize
Lubricant
D. Apply antisieze lubricant to the outside diameter
of the pivot hub and position idler plate assembly to
pivot hub.
E. Connect extension spring to stud on groomer
plate. Make sure that spring is in the stud groove and
that spring hook is positioned toward the drive pulley.
Figure 6
1. Pivot hub
(non−drive side)
F. Secure quick−up ball joint rod to drive side
groomer plate with shoulder bolt and spacer. Torque
shoulder bolt from 17 to 21 ft−lb (23 to 28 N−m).
G. Slide pulley spacer and washer(s) onto groomer
shaft.
H. Apply antiseize lubricant to square key that locates drive pulley. Position key into shaft slot.
NOTE: To prevent cutting reel from turning when installing drive pulley, block cutting reel with piece of
wood.
Groomer
Antiseize
Lubricant
Page 8 − 8
2. Pivot hub
(drive side)
I. Apply Loctite #242 to threads of flange head
screw that secures drive pulley to pivot hub shaft.
Slide drive pulley onto shaft and secure with flange
head screw. Torque screw from 27 to 33 ft−lb (37 to
44 N−m).
NOTE: To prevent groomer shaft from turning when
installing driven pulley, use wrench on groomer shaft
flats.
J. Apply antiseize lubricant to splines of driven pulley and slide driven pulley onto groomer shaft. Secure driven pulley with flange nut and torque flange
nut from 27 to 33 ft−lb (37 to 44 N−m).
Reelmaster 3550−D
K. Check pulley alignment by laying a straight edge
along the outer face of the drive pulley (Fig. 5). Drive
and driven pulleys should be in line within 0.030”
(0.70 mm). If necessary, align pulleys by removing
driven pulley and installing or removing washer(s)
between pulley and pulley spacer.
L. After pulleys are aligned, install groomer drive
belt and groomer belt cover (see Groomer Belt Replacement in this section).
4. Check that excluder seals just touch groomer plate
assembly. Reposition excluder seals on groomer shaft
if necessary.
5. Check groomer reel height and mower height−of−cut
settings. Adjust as needed.
6. Lubricate groomer bearings.
Groomer
NOTE: After greasing groomer bearings, operate
groomer for 30 seconds, stop machine and wipe excess
grease from groomer shaft and seals.
Reelmaster 3550−D
Page 8 − 9
Groomer
Groomer Reel
Loctite #242
7
19
25
Left Side Driven Groomer Assembly Shown
26
21
20
16
22
1
23
Antiseize
Lubricant
Loctite #242
27 to 33 ft−lb
(37 to 44 N−m)
24
Antiseize
Lubricant
18
25
19
16
26
27
7 4
14
13
23
Loctite #242
85 to 98 ft−lb
(115 to 129 N−m)
17
12
2
Antiseize
Lubricant
RIGHT
11
3
5
27 to 33 ft−lb
(37 to 44 N−m)
Antiseize
Lubricant
FRONT
6
15
7
8
Loctite #242
9
10
75 to 90 in−lb
(8 to 10 N−m)
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Groomer reel
Pulley spacer
Washer (as required)
Square key
Driven pulley
Flange nut
Socket head screw (4)
Idler plate
Idler pulley assembly
Lock nut
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flange head screw
Drive pulley
Retaining ring
Extension spring
Pivot hub (drive)
O−ring
Groomer plate assembly (drive)
Groomer shim
Shoulder bolt (2)
20. Pivot hub assembly (non−drive)
21. Flange nut (2)
22. Groomer plate assembly
(non−drive)
23. Excluder seal (2)
24. O−ring
25. Ball joint rod (2)
26. Spacer (2)
27. Drive shaft
Remove the groomer reel to replace individual groomer
blades or replace the shaft. The groomer blades can be
reversed on the shaft to provide additional blade life.
NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting unit hydraulic
motor.
Groomer
Page 8 − 10
Reelmaster 3550−D
Removal (Fig. 7)
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch. If desired, remove cutting unit from machine
(see Traction Unit Operator’s Manual).
NOTE: If cutting unit is equipped with powered rear
roller brush, removal of roller brush components will be
necessary to remove groomer reel (see Roller Brush
(Optional) in Chapter 7 − Cutting Units in this manual).
2
1
2. Remove groomer plate assembly from groomer
drive side of cutting unit (see Groomer Plate Assembly
Removal in this section).
Figure 8
3. Carefully pull the groomer reel from the non−drive
side groomer plate assembly.
4. Inspect all seals, bushings and bearings in groomer
plate assemblies for wear or damage. Replace components as needed (see Groomer Plate Assembly in this
section).
Installation (Fig. 7)
1. Groomer plate
2. Excluder seal
5. Carefully install groomer plate assembly to groomer
reel and groomer drive side of cutting unit (see Groomer
Plate Assembly Installation in this section).
6. Check that excluder seals just touch groomer plate
assembly (Fig. 8). Reposition excluder seals on
groomer shaft if necessary.
1. Position cutting unit on a level surface. If cutting unit
is attached to traction unit, make sure to stop engine, engage parking brake and remove key from the ignition
switch.
7. Check groomer reel height and mower height−of−cut
settings. Adjust as needed.
2. Apply a light coating of grease to seal lips in groomer
plate assemblies.
NOTE: After greasing groomer bearings, operate
groomer for 30 seconds, stop machine and wipe excess
grease from groomer shaft and seals.
3. Make sure that O−ring and excluder seals are installed on groomer shaft. The excluder seal outer lips
should be toward the groomer plate assemblies. Apply
a film of grease on seal outer lip.
8. Lubricate groomer bearings.
Groomer
4. Carefully slide the groomer reel into the non−drive
side groomer plate assembly taking care not to damage
seals in groomer plate assembly.
Reelmaster 3550−D
Page 8 − 11
Groomer
Groomer Reel Service
Inspect groomer reel blades frequently for damage and
wear. Straighten bent blades. Either replace worn
blades or reverse the blades to put the sharpest blade
edge forward (Fig. 9). Blades that are rounded to the
midpoint of the blade tip must be reversed or replaced
for best groomer performance.
3
MIDPOINT
1
2
Disassembly (Fig. 10)
4
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
2. Remove groomer reel from cutting unit (see
Groomer Reel Removal in this section).
GROOMER
ROTATION
3. Remove excluder seals from groomer reel.
4. If groomer reel is equipped with broomer kit (Fig. 11),
remove straps and broomer brushes from reel.
Figure 9
1. Groomer blade
2. Location hole
3. Sharp edge
4. Dull (rounded) edge
5. Remove lock nut from either end of the shaft
(Fig. 10).
2
6. Remove spacers and blades from groomer shaft. If
needed, remove second lock nut from shaft.
Assembly (Fig. 10)
200 to 250 in−lb
(23 to 28 N−m)
3
4
1
3
5
1. Install lock nut on drive end of groomer shaft. Place
a 1-1/4” (31.7 mm) spacer, a1/4” (6.3 mm) spacer, and
then the first blade on the groomer shaft.
2. Alternately install remaining 1−1/4” (31.7 mm)
spacers and blades making sure that all blades are separated by a spacer. Additionally, rotate location hole on
each installed blade one flat of the shaft, in a counterclockwise direction.
6
CENTERED ON SHAFT
3. When all blades have been installed, place remaining 1/4” (6.3 mm) spacer against blade then final 1−1/4”
(31.7 mm) spacer on shaft. Thread second lock nut onto
the shaft. Center blades on shaft by adjusting lock nuts.
4. Using wrench on shaft flats to prevent shaft from
turning, torque second lock nut from 200 to 250 in−lb
(23 to 28 N−m). After torquing lock nut, spacers should
not be free to rotate and groomer blades should be
centered on shaft.
Groomer
5
3
4
3
2
3 4 3 5
6
1
Figure 10
1. Groomer reel shaft
2. Groomer blade (32)
3. 1−1/4” (31.7 mm) Spacer
(33)
Page 8 − 12
4. 1/4” (6.3 mm) Spacer (2)
5. Lock nut (2)
6. Excluder seal
Reelmaster 3550−D
5. If groomer reel is equipped with broomer kit:
A. Slide a brush into each groove around the full
length of the groomer reel (Fig. 11). Make sure
brushes are seated in groomer blade slots (Fig. 12)
1
B. Loosely wrap the straps around the groomer reel
shaft and brushes as shown (Fig. 11). Straps should
be positioned between blades 1−2, 11−12, 21−22
and 31−32.
2
IMPORTANT: The straps must be wrapped
around the groomer blade and brush assembly
in the correct direction.
C. Pull straps tight and cut off strap extension approximately 1/4” (6 mm) beyond retainer.
FORWARD
2
Figure 11
1. Groomer reel
2. Broomer strap (4)
6. Place excluder seals on groomer shaft.
2
7. Install O−ring on non−drive end of groomer shaft.
8. Install groomer reel back on cutting unit (see
Groomer Reel Installation in this section).
1
ROTATION
Figure 12
2. Blade
Groomer
1. Brush
Reelmaster 3550−D
Page 8 − 13
Groomer
Height Adjuster Assembly
11
12
Left Side Driven Groomer Assembly Shown
10
9
30 to 40 in−lb
(3.4 to 4.5 N−m)
Antiseize
Lubricant
8
7
13
14
6
5
4
Antiseize
Lubricant
3
Loctite #242
17 to 21 ft−lb
(23 to 28 N−m)
2
Antiseize
Lubricant
1
Figure 13
1.
2.
3.
4.
5.
Groomer plate (LH drive shown)
Shoulder bolt
Ball joint rod
Jam nut
Compression spring
6.
7.
8.
9.
10.
Flange head screw
Lower ramp
External snap ring
Upper ramp
Bushing
NOTE: The groomer reel drive is located on the opposite side of the cutting unit from the cutting reel hydraulic
motor.
11.
12.
13.
14.
Flat washer
Groomer adjuster
Detent spring
Washer head screw
B. If jam nuts were removed from ball joint rod, apply
antiseize lubricant to threads of rod where jam nuts
will be positioned (close to rod eye). Install jam nuts
and thread all the way to rod eye end of ball joint rod.
Disassembly (Fig. 13)
1. Park machine on a clean and level surface, lower
cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition
switch.
C. Apply antiseize lubricant to shoulder of groomer
adjuster before installing it on ball joint rod.
D. If detent spring was removed, secure detent
spring to upper ramp with washer head screw.
Torque screw from 30 to 40 in−lb (3.4 to 4.5 N−m).
2. Disassemble height adjuster.
3. Clean all components and inspect for wear or damage. Replace all worn or damaged components.
Assembly (Fig. 13)
3. Check groomer reel height and adjust as needed.
1. Assemble height adjuster:
A. If bushing was removed from upper ramp, press
new bushing into housing fully to the shoulder in the
bore.
Groomer
2. Apply antiseize lubricant to shoulder of shoulder bolt.
Apply Loctite to shoulder bolt threads and secure ball
joint rod to groomer plate with shoulder bolt. Torque
shoulder bolt from 17 to 21 ft−lb (23 to 28 N−m).
4. After groomer height has been adjusted, adjust location of jam nuts so compression spring length is 1.38”
(3.5 cm) when the groomer handle is in the disengaged
position (handle toward rear of cutting unit).
Page 8 − 14
Reelmaster 3550−D
Chapter 9
Foldout Drawings
Table of Contents
Reelmaster 3550- D
2
3
4
5
6
Page 9 - 1
Foldout Drawings
Foldout
Drawings
ELECTRICAL DRAWING DESIGNATIONS . . . . . . .
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . .
WIRE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . .
WIRE HARNESS DRAWING . . . . . . . . . . . . . . . . . . .
Electrical Drawing Designations
The following abbreviations are used for wire harness
colors on the electrical schematics and wire harness
drawings in this chapter.
ABBREVIATION
COLOR
BK
BLACK
BR or BN
BROWN
BU
BLUE
GN
GREEN
GY
GRAY
OR
ORANGE
PK
PINK
R or RD
RED
T
TAN
VIO
VIOLET
W or WH
WHITE
Y or YE
YELLOW
Numerous harness wires used on Reelmaster machines include a line with an alternate color. These wires
are identified with the wire color and line color with either
a / or _ separating the color abbreviations listed above
(e.g. R/BK is a red wire with a black line, OR_BK is an
orange wire with a black line).
NOTE: A splice used in a wire harness will be identified
on the wire harness diagram by SP. The manufacturing
number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1).
Foldout Drawings
Page 9 - 2
Reelmaster 3550- D
1.50” Bore
0.625” Rod
2.33” Stroke
1.50” Bore
0.625” Rod
2.25” Stroke
.73
.73
REEL #4
.73
REEL #1
REEL #5
.73
REEL #2
2x
1.50” Bore
0.625” Rod
2.25” Stroke
1.50” Bore
0.625” Rod
2.33” Stroke
Extend
To Lower
.73
REEL #3
STEERING CYLINDER
2.00” Bore
0.625” Rod
3.79” Stroke
Extend
To Lower
R
L
C3
C1
OR2
.046”
OR3
.040”
OR1
.040”
C7
C5
OR5
.040”
OR7
.035”
C2
OR4
.046”
C4
M1
M2
S3
OR6
C6 .046”
MV
C8
BACKLAP
SWITCH
(SW)
S4
6.1
MOW CONTROL
MANIFOLD
RV1
OR8
.055”
500 PSI
1000 PSI
S2
CV1
P
OR2
.020”
FC
S1
1500 PSI
OR1
.050”
T
E
RV
M3
LC
G
STEERING
CONTROL
VALVE
LIFT CONTROL
MANIFOLD
PRV
P
G1
T
4.0 GPM
3000 PSI
P
T
7.0 GPM
C2
G2
MOW = 10 GPM (6 MPH)
TRANSPORT = 18 GPM (11 MPH)
OIL COOLER
BYPASS
3000 PSI
OIL FILTER
P2
.58
12.0
ENGINE IDLE
3200 / 1400
P1
.33
12.0
VALVE
100−150 PSI
1.44
PUMP RPM = 0.96 x
ENGINE RPM
200−300 PSI
25 PSI
24.7
G1
BREATHER
SUCTION
STRAINER
Reelmaster 3550−D
Hydraulic Schematic
Page 8 − 3
Reelmaster 3550−D
Electrical Schematic
All relays and solenoids
are shown as de−energized.
All ground wires are black.
Page 8 − 4
BLACK/WHITE
RED/WHITE
BLACK/WHITE
RED/WHITE
PINK
BLACK
RED/WHITE
BLACK/WHITE
GRAY
RED/WHITE
BLACK/WHITE
RED/WHITE
BLACK/WHITE
BLUE
GRAY
TAN
WHITE
BLUE
ORANGE
GRAY
VIOLET
GREEN
BLACK
ORANGE
BLUE
BLACK
BROWN
GREEN
YELLOW
BLACK
GRAY
GREEN
ORANGE
BLACK
RED
WHITE
BLUE
WHITE
RED
GREEN
YELLOW
BLACK
YELLOW
BROWN
BROWN
BLACK
BLACK
WHITE
BLACK
BLACK
ORANGE
BLACK
BROWN
PINK
ORANGE
RED
BLACK
BLUE
YELLOW
WHITE
BLACK
BLACK
BLACK
PINK
YELLOW
ORANGE
BLACK
BLACK
YELLOW
GREEN
PINK
YELLOW
TAN
VIOLET
GRAY
RED
BLACK
GRAY
BLACK
PINK
BLACK
BLACK
BROWN
BLACK
BLACK
BLACK
PINK
BLACK
RED
BLACK
BLACK
VIOLET
BLACK
BLACK
BLACK
BROWN
BLACK
YELLOW
BLACK
BLACK
BLACK
WHITE
BLACK
BLACK
BLACK
Reelmaster 3550−D
Harness Diagram
Page 8 − 5
Reelmaster 3550−D
Harness Drawing
Page 8 − 6
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