Service Manual

ManualsBrandsToro ManualsRiding ProductsReelmaster 3575 Traction Unit

Form No. 15213SL Rev H

Reelmaster

3550−D/3555−D/3575−D

Original Instructions (EN)

Summary of content (338 pages)

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Form No.
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Revision History Revision Date Description -- 2015 Initial Issue. A 2015 Updated Hydraulic chapter. B 2016 Updated Electrical System chapter. C 2016 Updated Universal Groomer chapter. D 02/2018 Added revision history. E 04/2018 Revised bedknife installation procedure. F 11/2018 Updated Hydraulic and Chassis chapter. G 03/2019 Updated Engine and Chassis chapter. H 06/2020 Updated Electrical Systems, Cutting Unit, Universal Groomer chapters and Foldout Drawings.
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Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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NOTES _
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Part No. 15213SL Rev. H Service Manual ReelmasterR 3550--D/3555--D/3575--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/3555--D/3375--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.
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General Safety Instructions . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 4 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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General Safety Instructions The Reelmaster 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.
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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.
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Jacking Instructions CAUTION 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.
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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 . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.
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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.
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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
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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.
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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.
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Chapter 3 Kubota Diesel Engine Table of Contents Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 4 Air Cleaner and Muffler . . . . . . . . . . . . . . . . . . . . . . 4 Fuel System . . . . . . . .
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Specifications Item Description Make / Designation Kubota Model D1105−E3B 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 Firing Order 1 (fan end) − 2 − 3 (flywheel end) Compression Ratio 22.0:1 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.
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General Information 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.
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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 (3) Air cleaner body Filter cover Page 3 − 4 15. 16. 17. 18. 19. 20. 21.
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Check Air Filter, Filter Cover, & Burp Valve The air cleaner body, air filter, filter cover, 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.
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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) 39 RIGHT 11 7 40 FRONT 16 41 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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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.
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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. 13.
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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. 2. If hydraulic fittings were removed from oil cooler, lubricate and place new O−rings onto fittings.
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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.
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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 4. Support bracket 5. Speed control lever 6.
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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.
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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.
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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 . . . . . . . . . .
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
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Hydraulic System G BA CK LAP SW ITCH (SW ) FC M1 REEL MOTOR #4 .73 CID .73 CID P PRV OR1 .050” CV1 MV LC OR2 .020” Page 4 − 14 BREATHER OIL COOLER 25 psi OIL FILTER RV 1500 psi M3 .73 CID REEL REEL MOTOR #2 MOTOR #3 .73 CID MOW ER CONTROL MANIFOLDT M2 REEL REEL MOTOR #1 MOTOR #5 .73 CID RV1 1.44 CID 200−300 psi S1 .040” C5 T LIFT CYLINDER #5 BORE: 1 .50” STROKE: 2.33” ROD: 0.625” EXTEND TO RAISE 3500 PSI S3 G1 C7 P1 .33 CID P 1000 psi E 12.
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Reelmaster 3550−D/3555−D/3575−D Page 4 − 15 Hydraulic System M1 REEL MOTOR #5 REEL MOTOR #2 REEL MOTOR #3 REEL MOTOR #1 M2 REEL MOTOR #5 REEL MOTOR #2 M3 BAC KLAP SW ITCH (SW ) FC M1 OR1 .050” CV1 MV LC OR2 .020” BREATHER OIL COOLER P MOWER CONTROL MANIFOLD T PR V 3000 PSI M2 25 psi OIL FILTER RV 1500 psi M3 REEL MOTOR #3 3 /REV RM 3555−D REEL MOTOR DISPLACEMENT = 0.73 IN REEL MOTOR #4 G REEL MOTOR #1 3 /REV RM 3575−D REEL MOTOR DISPLACEMENT = 0.97 IN REEL MOTOR #4 .
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Hydraulic System G BA CK LAP SW ITCH (SW ) FC M1 REEL MOTOR #4 .73 CID .73 CID P PRV 3000 PSI OR1 .050” CV1 MV LC OR2 .020” Page 4 − 16 BREATHER OIL COOLER 25 psi OIL FILTER RV 1500 psi M3 .73 CID REEL REEL MOTOR #2 MOTOR #3 .73 CID MOW ER CONTROL MANIFOLDT M2 REEL REEL MOTOR #1 MOTOR #5 .73 CID RV1 1: 0.96 C2 P 1.44 CID 100−150 psi 17.1 GPM S2 .040” .040” 500 psi C3 LIFT CONTROLMANIFOLDE G .055” .046” .046” .
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Reelmaster 3550−D/3555−D/3575−D Page 4 − 17 Hydraulic System FC OR1 .050” PR V LC OR2 .020” BREATHER T REEL MOTOR #3 25 psi OIL FILTER RV 1500 psi REEL MOTOR #2 OIL COOLER REEL MOTOR #5 CV1 MV 3000 PSI M2 REEL MOTOR #1 P MOWER CONTROL MANIFOLD G BAC KLAP SW ITCH (SW ) M1 REEL MOTOR #4 RM 3555−D REEL MOTOR DISPLACEMENT = 0.733IN /REV /REV RM 3575−D REEL MOTOR DISPLACEMENT = 0.973IN M3 500 psi 1: 0.96 C2 P 1.44 CID 100−150 psi 17.1 GPM G .040” .
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Traction Circuit The traction circuit of the hydraulic system consists of a hydrostat connected in a closed loop circuit to three orbital geroller wheel motors. 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. The mow/transport slide control on the machines has positions for mow and transport.
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Hydraulic System Page 4 − 20 Reelmaster 3550−D/3555−D/3575−D G BA CK LAP SW ITCH (SW ) FC M1 REEL MOTOR #4 P PRV 3000 psi OR1 .050” CV1 MV REEL MOTOR #5 LC OR2 .020” BREATHER OIL FILTER OIL COOLER T REEL MOTOR #2 MOWER CONTROL MANIFOLD M2 REEL MOTOR #1 RV M3 1: 0.96 ENGINE RATED SPEED 3 000 RPM 25 psi 1500 psi REEL MOTOR #3 1.44 CID 100−150 psi 17.1 GPM C2 CHARGE PRESSURE 200−300 psi 3500 PSI G1 6. 9 GPM TOW V ALVE G2 P1 .58 CID REVERSE TO WHEEL MOTORS P2 .
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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. .
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Hydraulic System Page 4 − 22 Reelmaster 3550−D/3555−D/3575−D LIFT CONTROL MANIFOLD OR8 .055” OR6 .046” OR4 .046” RV1 OR1 .040” C1 G1 P S2 C3 OR3 .040” 500 PSI Working Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3550−D Lift Circuit: Lower C8 C6 C4 C2 OR2 .046” Extend To Lower 1.50” Bore 0.625” Rod 2.25” Stroke S1 OR5 .040” C5 1.50” Bore 0.625” Rod 2.33” Stroke S3 T 1.50” Bore 0.625” Rod 2.33” Stroke OR7 .035” C2 OR2 .046” Extend To Lower C3 P 1.
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Lift Circuit: Lower 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, for raising and lowering the cutting units and for the traction charge circuit. The gear pump takes its suction from the hydraulic tank.
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Hydraulic System Page 4 − 24 Reelmaster 3550−D/3555−D/3575−D LIFT CONTROL MANIFOLD OR8 .055” OR6 .046” OR4 .046” RV1 OR1 .040” Working Pressure Low Pressure (Charge) Return or Suction Flow G1 S2 500 PSI OR3 .040” P S1 OR5 .040” C5 OR7 S3 T .035” S4 C7 C2 OR2 .046” C3 LIFT CONTROL MANIFOLD OR8 .055” OR6 .046” OR4 .046” RV1 G Working Pressure Low Pressure (Charge) Return or Suction Flow S2 500 PSI OR3 .040” Groundmaster 3555−D/3575−D Lift Circuit: Raise C8 C6 C4 OR1 .
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Lift Circuit: Raise The maximum steering circuit pressure of 1000 PSI (69 bar) is limited by the relief valve located in the power steering valve. On Reelmaster 3550−D machines, the maximum lift circuit pressure is also controlled by the relief valve located in the power steering valve.
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Hydraulic System Page 4 − 26 STEERING UNIT 1000 PSI 6.1 CID E T T P STEERING CYLINDER BORE: 2 .00” STROKE: 3.76” ROD: 0.625” EXTEND TO TURN LEFT P 1000 PSI 6.1 R 1000 PSI 6.1 CID R STEERING UNIT L STEERING UNIT E L T T P P 1000 PSI 6.1 R 1000 PSI 6.1 CID R STEERING UNIT L STEERING UNIT E L LEFT TURN T T STEERING CYLINDER BORE: 2 .00” STROKE: 3.76” ROD: 0.625” EXTEND TO TURN LEFT STEERING CYLINDER BORE: 2 .00” STROKE: 3.76” ROD: 0.
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Steering Circuit With the engine running and the steering control valve in the centered position (steering wheel not being turned), hydraulic flow enters the steering control valve at the P port and goes through the control valve, by− passing the rotary meter and steering cylinder. On Reelmaster 3550−D machine, the steering circuit comes before the lift circuit. Flow leaves the steering control valve through the E port to supply the lift circuit and then the traction charge circuit.
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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.
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
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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.
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NOTE: Engine−to−Pump ratio is 1:0.96. In other words, 1 engine RPM = 0.96 pump RPM. Hydraulic Test Selection 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. Before beginning any hydraulic test, identify if the problem is related to the traction circuit, cutting (mow) circuit or steering and lift/sidewinder circuit.
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Traction Circuit Testing − Charge Pressure Test FRONT FRONT FORWARD REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER TOW VALVE LOWER PORT G2 UPPER PORT G1 3500 PSI TEE CONNECTOR AND PRESSURE GUAGE 200−300 PSI C2 CHARGE CIRCUIT PRESSURE 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TO STEERING/LIFT/CHARGE CIRCUIT P2 GEAR PUMP SUCTION STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 36 Reelmaster 3550−D/3555−D
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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.
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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 TOW 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 100−1
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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.
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9. Slowly depress forward traction pedal until 1000 to 1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge. Rear Wheel Motor Test: Flow meter should read less than 1.5 GPM (5.7 LPM). 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. 10.Release traction pedal, shut engine off, and record test results. 1.
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7. Slowly depress forward traction pedal until 1000 to 1500 PSI (68.9 to 103.4 Bar) is displayed on the pressure gauge. 9. Rotate rear wheel 120 degrees and retest. Repeat this procedure until wheel motor has been tested in three (3) different positions. Flow meter should read less than 1.5 GPM (5.7 LPM). 10.If specifications are not met, repair or replace worn wheel motor. Hydraulic System 8. Release traction pedal, shut engine off, and record test results.
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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 TOW VALVE LOWER PORT G2 UPPER PORT G1 3500 PSI 200−300 PSI C2 CHARGE CIRCUIT PRESSURE 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 − 42 Reelmaster 3550−D/3555
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Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test: Special Equipment Required: 2 1 Figure 27 1. Lower hydraulic fitting CAUTION 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. Piston pump 10.
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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. 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: D. Record tester pressure reading. A. The traction belt is worn and/or slipping. E.
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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 .
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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.
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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 MEASURING CONTAINER TO MOW CONTROL MANIFOLD PORT (M3) TO MOW CONTROL MANIFOLD PORT (M2) FROM MOW CONTROL MANIFOLD PORT (M1) 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 2 1.
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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.
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Cutting Unit Circuit Testing − Reel Motor Cross−Over Relief Pressure Test (Reelmaster 3575−D) USE A TEE FITTING TO INSTALL PRESSURE GAUGE IN BOTH INLET AND OUTLET LINES OF MOTOR BEING TESTED. NOTE: INLET IS FRONT HOSE. OUTLET IS REAR HOSE.
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Cutting Unit Circuit Testing − Reel Motor Cross− Over Relief Pressure Test (Reelmaster 3575−D) 3 1. Determine which cutting reel motor needs to be tested by observing the machine during mowing. 2 2. Park machine on a level surface with the cutting units lowered and reel engage switch OFF. Make sure engine is off and mow/transport lever is in mow. Apply the parking brake. OUT 3. Read Precautions For Hydraulic Testing in this section.
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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 .
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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.
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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 .
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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.
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Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test TOW VALVE G2 G1 3500 PSI 200−300 PSI CHARGE CIRCUIT PRESSURE C2 100−150 PSI CHARGE RELIEF HYDROSTAT HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TESTER WITH PRESSURE GAUGES AND FLOW METER P2 High Pressure SUCTION STRAINER GEAR PUMP Low Pressure Return or Suction Flow Hydraulic System Page 4 − 56 Reelmaster 3550−D/3555−D/3575−D
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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.
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Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test TOW VALVE G2 G1 3500 PSI 200−300 PSI CHARGE CIRCUIT PRESSURE C2 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 REELMASTER 3550−D TO STEERING CONTROL VALVE (P) PORT REELMASTER 3555−D/3575−D TO LIFT CONTROL MANIFOLD (P) PORT High Pressure P2 TESTER WITH PRESSURE GAUGES AND FLOW METER SUCTION STRAINER GEAR PUMP Low Pressure Return or Suction Flow Hydraulic System Page 4 − 58 Reelmaster 3550−D/3555−D/3575−D
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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.
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Steering/Lift Circuit Testing − Lift Relief Valve (RV1) Pressure Test (Reelmaster 3555−D and 3575−D) LIFT CYLINDER #1 BOR E: 1.50” STROKE: 2.25” ROD: 0.625” EXTEND TO LOW ER LIFT CYLINDER #4 BOR E: 1.50” STROKE: 2.33” ROD: 0.625” EXTEND TO LOW ER LIFT CYLINDER #5 BORE: 1.50” STROKE: 2.33” ROD: 0.625” EXTEND TO LOW ER C3 C5 .040” .040” C1 .040” C2 LIFT CYLINDER #3 BOR E: 1.50” STROKE: 2.25” ROD: 0.625” EXTEND TO LOW ER LIFT CYLINDER #2 BOR E: 1.50” STROKE: 2.25” ROD: 0.625” EXTEND TO LOW ER C7 .
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Steering/Lift Circuit Testing − Lift Relief Valve (RV1) Pressure Test (Reelmaster 3555−D and 3575−D) 1. Park machine on a level surface with the cutting units lowered and reel engage switch OFF. Make sure engine is OFF and apply the parking brake. 2. Read Precautions For Hydraulic Testing in this section. CAUTION 3. Gain access to hydraulic lift control manifold from below front of machine. 4. Thoroughly clean test port (G) on the right side of the lift control manifold (Fig. 38).
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Steering/Lift Circuit Testing − Steering Relief Valve Pressure Test STEERING CYLINDER L R STEERING CONTROL VALVE (REELMASTER 3550−D CIRCUIT SHOWN) 1000 PSI REELMASTER 3550−D FROM GEAR PUMP (P2) P T E REELMASTER 3555−D/3575−D FROM LIFT CONTROL MANIFOLD (T) PORT TEST GAUGE TO MOW CONTROL MANIFOLD (P) PORT REELMASTER 3550−D TO STEERING CONTROL VALVE (P) PORT REELMASTER 3555−D/3575−D TO LIFT CONTROL MANIFOLD (P) PORT P2 HYDROSTAT P1 GEAR PUMP SUCTION STRAINER High Pressure Low Pressure Return or
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Steering/Lift Circuit Testing − Steering Relief Valve Pressure Test: 2 The relief valve for the steering and lift circuits (RM 3550−D), or for the steering circuit only (RM 3555−D/3575−D) is integrated into the steering control valve. If both steering and lift operations (RM 3550−D), or just the steering circuit (RM 3555−D/3575−D) 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).
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Steering/Lift Circuit Testing − Steering Control Valve and Steering Cylinder Test STEERING CYLINDER OPEN FITTING PLUG L R STEERING CONTROL VALVE (REELMASTER 3550−D VALVE SHOWN) 1000 PSI P T E High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 64 Reelmaster 3550−D/3555−D/3575−D
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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.
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Adjustments Adjust Control Manifold Relief Valves The hydraulic control manifolds on your Reelmaster include the following adjustable relief valves: All machines − Mow control manifold relief valve RV should be set to 1500 PSI (103 Bar). Reelmaster 3550−D − Lift control manifold relief valve RV1 should be set to 500 PSI (34.5 Bar). 1 Reelmaster 3555−D and 3575−D − Lift control manifold relief valve RV1 should be set to 2000 PSI (138 Bar).
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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.
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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.
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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.
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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.
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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.
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Hydraulic Tank 4 TO HYDRAULIC TANK 3 FROM OIL COOLER 12 13 2 1 14 17 80 to 87 ft−lbs (108.4 to 117.9 N−m) 16 15 5 6 REELMASTER 3550−D 7 8 TO HYDRAULIC PUMP 9 10 FROM HYDRAULIC OIL FILTER 11 18 19 20 Anti−seize lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) 21 FROM OIL COOLER 22 26 25 RIGHT 23 27 12 16 FRONT 17 TO HYDRAULIC TANK 24 REELMASTER 3555−D/3575−D Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9.
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Hydraulic Tank Removal (Fig. 43) Hydraulic Tank Installation (Fig. 43) 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.
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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 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 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 Magnet 14. 15.
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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 11 41 2 35 57 52 17 16 39 RIGHT FRONT 22 23 90 to 120 in−lb (10.2 to 13.6 N−m) 27 to 31 ft−lb (37 to 42 N−m) 19 15 (tighten in 3 equal steps) 14 Blue Loctite Figure 45 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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Drive Belt Removal (Fig. 45) 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. 46). 3. Remove pump drive belt tension from torsion spring on idler arm (Fig.
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Neutral Arm Assembly 1 4 23 24 7 22 18 19 21 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 47 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.
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Neutral Arm Removal (Fig. 47) Neutral Arm Installation (Fig. 47) 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.
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Piston Pump/Hydrostat 1 RIGHT FRONT 2 3 4 5 6 10 9 8 7 Figure 48 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. 45 and 48) 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.
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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.
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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.
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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 12 11 35 9 6 28 3 33 32 29 30 31 30 8 5 26 4 23 18 2 1 46 29 34 Figure 50 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.
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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. 51).
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4 5 29 ft−lb (39 N−m) 8 7 2 3 v 9 10 6 1 Figure 52 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. 52) 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.
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Gear Pump 9 5 10 4 12 11 13 14 2 1 RIGHT 15 FRONT 17 16 Hydraulic System 8 7 3 6 Figure 53 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.
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Installation (Fig. 53) 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.
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Gear Pump Service 19 14 18 17 12 11 10 2 8 3 6 2 21 3 20 13 1 16 15 14 13 33 ft−lb (45 N−m) 9 8 7 5 4 Figure 55 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.
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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. 55) 4. Loosen the four (4) cap screws that secure pump assembly. 1. Apply clean hydraulic fluid to all parts before assembling. 5.
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Front Wheel Motors 5 7 6 8 8 9 9 10 10 4 1 RIGHT FRONT 2 11 3 Figure 57 1. 2. 3. 4. Lock nut Spacer Socket head screw Hydraulic wheel motor 5. 6. 7. 8. Frame Hydraulic tube Hydraulic tube O–ring 9. Hydraulic fitting (2) 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.
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Removal (Fig. 57) Installation (Fig. 57) 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.
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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 58 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 − 94 11. 12. 13. 14. 15.
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8. Using hub puller (see Special Tools in this chapter), loosen wheel hub from wheel motor. Removal (Fig. 58) 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.
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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 59 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.
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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 1 4 #2 2 1 11 #1 1 3 4 RIGHT 5 5 6 10 8 7 4 2 4 FRONT 1 2 1 #4 Figure 60 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 − 98 9. Elbow fitting 10. O−ring 11.
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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. 60). Thoroughly clean hydraulic connections prior to loosening hydraulic lines from reel motor to prevent hydraulic system contamination.
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Cutting Unit Reel Motor Service (Reelmaster 3550−D and 3555−D) 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 62 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) Idler gear Drive gear 13. 14. 15. 16. 17. 18. Wear plate (inner) Backup gasket (inner) Pressure seal (inner) Body Cap screw (4) Washer (4) Disassembly (Fig. 62) 1.
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IMPORTANT: Record 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.
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Assembly (Fig. 62) 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. 64): A.
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Cutting Unit Reel Motor Service (Reelmaster 3575−D) 33 ft−lb (45 N−m) 19 8 7 20 18 1 9 4 5 3 11 2 20 17 12 9 15 18 18 ft−lb (25 N−m) 10 6 14 13 16 Figure 66 1. 2. 3. 4. 5. 6. 7. Body Front flange Front thrust plate Rear thrust plate Drive gear Idler gear Socket head screw (4) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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IMPORTANT: Record 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. 8. Carefully disassemble the inner wear plate, idler gear, drive gear and outer wear plate. 9.
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Assembly (Fig. 62) 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. 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. NOTE: When assembling the motor, check the marker line on each part to make sure the parts are properly aligned during assembly. 2. Install new seals into front flange (Fig. 68): A.
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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 70 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 − 108 15. 16. 17. 18. 19. 20.
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Removal (Fig. 70) Installation (Fig. 70) 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.
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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 OR 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 71 1. 2. 3. 4. 5. 6. 7. 8. 9.
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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.
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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 4 3 Figure 73 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 − 112 9. 10. 11. 12.
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3. To install backlap spool into manifold: Backlap Spool (Fig. 73) 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.
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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 74 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 − 114 10. 11. 12. 13.
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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 the front axle (below the traction unit frame). 1.
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Lift Control Manifold Service (Reelmaster 3550−D) 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 75 1. 2. 3. 4. 5. 6. 7.
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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.
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Lift Control Manifold Service (Reelmaster 3555−D and 3575−D) VIEW FROM ABOVE VIEW FROM ABOVE 60 in−lb (6.7 N−m) 16 60 in−lb (6.7 N−m) 17 FRONT 9 FRONT 16 8 8 9 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 16 8 20 ft−lb (27 N−m) 5 8 7 7 20 4 1 12 6 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 76 1. 2. 3. 4. 5. 6. 7.
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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.
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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.
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Steering Control Valve 26 10 18 17 27 19 RIGHT FRONT 20 to 26 ft−lb (28 to 35 N−m) 14 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 77 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.
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Removal (Fig. 77) 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.
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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 80 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.
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Steering Cylinder No. 2 General Purpose Grease 14 8 6 7 OR 14 No. 2 General Purpose Grease 8 7 OR 5 1 4 85 to 115 ft−lb (115 to 156 N−m) 13 OR 3 9 65 to 85 ft−lb (88 to 115 N−m) 2 10 12 9 13 OR 65 to 85 ft−lb (88 to 115 N−m) 85 to 115 ft−lb (115 to 156 N−m) 11 RIGHT FRONT Figure 81 1. 2. 3. 4. 5. Hydraulic hose Hydraulic hose O−ring (2) Hydraulic fitting (2) O−ring (2) Hydraulic System 6. 7. 8. 9. 10.
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Removal (Fig. 81) Installation (Fig. 81) 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.
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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 82 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 − 128 9. 10. 11. 12.
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Disassembly (Fig. 82) Assembly (Fig. 82) 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.
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Front Lift Cylinders REELMASTER 3550−D SHOWN 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 12 13 13 14 14 6 14 3 13 14 16 17 4 5 8 11 1 10 9 Blue Loctite 242 4 5 Figure 83 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.
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Removal (Fig. 83) REELMASTER 3555−D/3575−D SHOWN 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1 4 3 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 2 3. To prevent contamination of hydraulic system during lift cylinder removal, thoroughly clean exterior of cylinder and fittings.
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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 REELMASTER 3550−D SHOWN Figure 85 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 − 132 11. 12. 13. 14. 15.
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Removal (Fig. 85) Installation (Fig. 85) 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.
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Lift Cylinder Service 3 5 7 1 9 11 2 12 4 13 6 40 ft−lb (54 N−m) 14 8 10 4 2 1 6 3 11 10 5 8 9 13 OR 14 7 12 Figure 86 1. 2. 3. 4. 5. Barrel Lock nut Wear ring Piston Seal 6. 7. 8. 9. 10. Two different styles of lift cylinders as used on the Reelmaster machines. The most common style uses a thick retaining ring between the cylinder head and barrel to hold the cylinder head in place.
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Disassembly − Retaining Ring Style (Fig. 86) Assembly − Retaining Ring Style (Fig. 86) 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. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel.
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15 1 40 ft−lb (54 N−m) 2 3 5 4 6 3 10 8 9 7 11 12 13 14 4 2 1. 2. 3. 4. 5. Barrel Lock nut Wear ring (2) Piston Seal 6 3 5 1 10 8 3 6. 7. 8. 9. 10. 11 7 9 Figure 87 O−ring Head O−ring Back−up ring Seal 12 13 11. 12. 13. 14. 15. Dust seal Internal collar Rod Grease fitting Grease fitting The threaded collar style lift cylinder uses a threaded internal collar to hold the cylinder head in place.
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Disassembly − Threaded Collar Style (Fig. 86) Assembly − Threaded Collar Style (Fig. 86) 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 wear rings, O−rings, seals and back−up ring with clean hydraulic oil. A.
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Chapter 5 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 . . . . . . . . . . . . . . . . . . . . . . . . .
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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) The Reelmaster machines use a single Toro Electronic Controller (TEC) to manage machine electrical functions. The TEC controller is attached to the control panel.
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Electrical Schematic Electrical System The electrical schematic and wiring diagrams for the Reelmaster machines are located in Chapter 10 − Foldout Drawings in this manual.
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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.
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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 Electrical System 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.
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Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 10 − 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.
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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.
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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.
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Diagnostic Display Reelmaster 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.
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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.
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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.
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Output No. Output Name Input Conditions Required to Illuminate Output LED 1 START 2 ETR 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.
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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.
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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.
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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 10 − 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.
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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).
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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). Turn around switch or circuit wiring is faulty. (RM 3555−D/3575−D). The TEC Controller is faulty. Cutting units do not run when lowered with the mow/transport switch in the MOW position.
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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 100F (16 to 38C). 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.
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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.
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Adjustments 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 near the traction pedal. 2 Adjusting 1. Before adjusting the traction neutral switch, check and adjust traction system neutral position (refer to Traction Unit Operator’s Manual).
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Parking Brake Switch The parking brake switch is a normally closed proximity switch that is located on the control console (Fig. 32). 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.
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Turn Around Switch (Reelmaster 3555−D and 3575−D) The cutting unit turn around switch is a normally open proximity switch that closes when the front right cutting unit (cutting unit #5) is in the turn−around position. The turn around switch is attached to a bracket outside the front right lift arm pivot pin. A plate on the front right lift arm acts as the sensing plate for the turn around switch (Fig. 17). 162 to 198 in−lb (18.4 to 22.
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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 18). Adjusting 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. 2.
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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.
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Main Power Relay The main power relay is secured to the control panel assembly next to the operator seat (Fig. 22). This relay is attached to the wire harness with a four (4) wire connector (Fig. 23). 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).
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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.24) and fuse block (Fig. 25) to identify each individual fuse and its correct amperage. The fuses have the following function: F1−1 (2 amp) protects logic power circuit to the TEC controller. F1−2 (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.
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Fusible Links The Reelmaster machines use 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. 26). 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.
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Toro Electronic Controller (TEC) The Reelmaster machines use 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. 29). 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).
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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 3. Socket head screw If the wire harness connector is removed from the TEC controller for any reason, tighten the harness connector screw from 25 to 28 in--lb (2.8 to 3.2 N·m). Electrical System GROUND Figure 32 1. TEC controller 2.
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Parking Brake Switch The parking brake switch is a normally closed proximity switch that is located on the control console (Fig. 32). 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.
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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. 33). The TEC controller monitors the position of the neutral switch (open or closed).
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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. 34). The switches are identical (Fig. 35). 1 The TEC controller monitors the position of the lower/ raise switches (open or closed).
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Reel Enable/Disable Switch The enable/disable switch is located on the control panel (Fig. 36). 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).
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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 39). The TEC controller monitors the position of the mow/ transport switch (open or closed).
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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).
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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. 41). 1 5 The TEC controller monitors the position of the backlap switch (open or closed).
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Turn Around Switch (Reelmaster 3555−D and 3575−D) The cutting unit turn around switch is a normally open proximity switch that closes when the front right cutting unit (cutting unit #5) is in the turn−around position. The turn around switch is attached to a bracket outside the front right lift arm pivot pin. A plate on the front right lift arm acts as the sensing plate for the turn around switch (Fig. 42). The TEC controller monitors the position of the turn around switch (open or closed).
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Engine Temperature Sender The engine temperature sender is located above the alternator, in the thermostat housing (Fig. 43). 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).
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Start Relay The start relay is secured to the control panel assembly next to the operator seat (Fig. 45). This relay is attached to the wire harness with a five (5) wire connector (Fig. 46). 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.
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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.
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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.
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Fuel Pump The fuel pump is attached to the left side of the engine near the fuel/water separator (Fig. 49). 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.
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Glow Relay The glow relay is secured to the control panel assembly next to the operator seat (Fig. 50). This relay is attached to the wire harness with a four (4) wire connector (Fig. 51). 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.
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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.
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Hydraulic Solenoid Valve Coils The Reelmaster 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.
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C. Solenoid coil resistance should be measured with solenoid at approximately 68F (20C). 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.
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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 54 4. Engine oil pressure 5.
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CAN−bus Termination Resistors System communication between electrical components on Reelmaster 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 The resistors plug into the wire harness under the control panel.
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Oil Pressure Switch The engine oil pressure switch is located on the engine below the alternator (Fig. 58). 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 1. Set the ignition switch to the RUN position.
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Worklight Switch The worklight switch is located on the control panel (Fig. 59). 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.
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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.
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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 1 Battery Specifications Maintenance free wet lead acid BCI Group 26 Battery 525−540 Cold Cranking Amps (CCA) at 0F (−18C) 80 minute Reserve Capacity at 80F (27C) 3 4 Battery Removal and Installation (Fig. 61) 5 10 1.
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Battery Testing 1. Perform a high−discharge test with an adjustable load tester. Minimum Voltage 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. Battery Temperature 9.6 70F (and up) 21C (and up) 9.5 60F 16C 9.4 50F 10C 9.3 40F 4C CAUTION Follow the battery load tester manufacturer’s instructions when using a load tester. A.
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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. WARNING 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.
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Cartridge Valve Coil Replacement The solenoid valve coils on the hydraulic control manifolds (Fig. 62) 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.
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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. 63) Figure 63 1. Park machine on a level surface, stop engine, apply parking brake and remove key from ignition switch.
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Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Tire pressure (22 x 12 − 12 4 ply) Reelmaster 3550−D = 12 PSI (96 kPa) Reelmaster 3555−D/3575−D = 20 PSI (138 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.
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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.
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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 − LH Track − RH Support strap (2) Flange nut (4) Knob kit Weight indicator 17. 18. 19. 20. 21. 22. 23.
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Front Wheels and Brakes 24 21 25 22 30 27 18 11 23 20 29 Antiseize Lubricant 12 28 14 13 5 15 1 8 16 26 4 17 3 10 13 14 19 2 6 RIGHT FRONT 70 to 90 ft−lb (95 to 122 N−m) (REELMASTER 3550−D SHOWN) 9 7 250 to 275 ft−lb (339 to 372 N−m) Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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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): A. If removed, secure backing plate to the brake bracket with four cap screws and lock washers.
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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 275 ft- lb (339 to 372 N- m). Release parking brake. 11. Check brake adjustment and adjust if necessary (see Adjust Brakes in the Adjustments section). 7 3 4 Burnish Brake Pads After brake pad replacement, burnish (break- in) the brakes before use. 1.
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Rear Fork and Wheel 9 12 OR 8 10 11 11 10 8 OR 9 60 to 80 ft−lb (81 to 108 N−m) 1 2 3 4 70 to 90 ft−lb (95 to 122 N−m) 20 22 OR 21 4 85 to 115 ft−lb (115 to 156 N−m) 5 22 OR 21 65 to 85 ft−lb (88 to 115 N−m) 65 to 85 ft−lb (88 to 115 N−m) 19 6 17 16 18 RIGHT 250 to 275 ft−lb (339 to 372 N−m) 15 14 13 FRONT 7 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. Cap screw Thrust washer Lock washer Flange bushing (2) Rear casting Rear fork Socket head screw (4) Ball joint − greasable (2) Chassis 9.
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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.
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Brake Lever Linkages 3 2 4 4 9 1 10 5 3 6 6 5 7 8 14 11 15 12 13 31 31 16 30 32 30 13 to 17 ft−lb (18 to 23 N−m) 17 18 19 20 29 21 22 RIGHT FRONT 28 28 OR 27 33 29 19 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.
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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.
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Steering Column 20 to 26 ft−lb (28 to 35 N−m) 8 10 26 13 19 20 RIGHT FRONT 7 35 36 9 16 27 11 Blue Loctite 242 33 18 2 17 4 23 6 21 5 22 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.
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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.
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Front Lift Arms (Reelmaster 3550−D and 3555−D) 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 (REELMASTER 3550−D SHOWN) 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.
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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.
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Front Lift Arms (Reelmaster 3575−D) 1 4 2 3 5 6 7 5 6 12 10 3 2 18 19 20 16 11 17 10 3 2 4 24 13 23 8 Blue Loctite 242 9 12 22 21 2 6 7 80 to 100 ft−lb (108 to 135 N−m) 1 16 10 5 3 5 18 19 20 17 6 24 14 10 9 13 15 10 8 12 25 10 7 6 5 Blue Loctite 242 21 RIGHT FRONT 80 to 100 ft−lb (108 to 135 N−m) 22 9 8 2 3 3 2 4 1 18 Blue Loctite 242 16 17 19 20 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9.
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Removal (Fig. 12) Installation (Fig. 12) 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.
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Rear Lift Arms (Reelmaster 3550−D) 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 13 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.
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Removal (Fig. 13) 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.
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Rear Lift Arms (Reelmaster 3555−D and 3575−D) 9 10 9 8 8 3 2 4 1 6 2 23 3 16 17 5 15 20 22 21 13 14 24 8 18 9 5 11 19 8 10 13 5 14 24 23 21 12 20 4 22 2 25 26 7 3 2 3 15 16 18 17 RIGHT FRONT 19 1 (REELMASTER 3555−D SHOWN) Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9.
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Removal (Fig. 15) 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. 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.
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Chapter 7 DPA 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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt--on cast aluminum side plates. Cutting Unit/Reel Size Reelmaster 3550--D: 18 in. (45.7 cm) in length with 5 in. (12.7 cm) diameter 8 or 11 blade reel. Optional 22 in. (55.9 cm) 8 and 11 blade reels are available for the rear cutting unit positions. Reelmaster 3555--D: 22 in. (55.9 cm) in length with 5 in. (12.7 cm) diameter 8 or 11 blade reel. Reelmaster 3575--D: 22 in. (55.
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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.
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Installation 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). 3 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.
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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.
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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.
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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.
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Pulley Alignment Tool Toro Part Number: 114--5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush drive and driven pulleys. Figure 16 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).
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Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131--6828 and 131--6829 1 Because the top grind angle on bedknives is critical for edge retention, and therefore after-- cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives. 2 3 Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar. 1.
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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.
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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. NOTE: After grinding the reel and/or bedknife, check the reel to bedknife contact again after cutting two (2) fairways.
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Factor Possible Problem/Correction Cutting unit alignment and carrier frame ground following Check carrier frames and lift arms for damage, binding conditions or bushing wear. Repair if necessary. 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.
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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.
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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.
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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.
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5. Remove caps or plugs from fittings and hoses. IMPORTANT: When installing the hydraulic hoses, make sure that hydraulic hoses are straight (not twisted) before tightening the hoses to the motor fittings. 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). 6. Lubricate and install new O--rings on motor fittings.
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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. D Do not adjust reels while the engine is running. D If a reel stalls, stop engine before attempting to clear the reel.
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Bedbar Assembly Serial No. 315000001 & Up 18” Cutting Unit Components Shown 2 3 4 1 27 to 33 ft--lb (37 to 44 N--m) 6 7 5 5 8 9 10 RIGHT Antiseize Lubricant Figure 27 1. 2. 3. 4. Bedbar assembly Lock nut (2 used) Compression spring (2 used) Washer (2 used) 5. Plastic washer (4 used) 6. Rubber bushing (2 used) 7. Flange bushing (2 used) Bedbar Removal (Fig. 27) 1.
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CAUTION Contact with the reel, bedknife or other cutting unit parts can result in personal injury. Use heavy gloves when handling the bedbar. 6. Remove bedbar assembly from cutting unit. 7. Inspect flange bushings and rubber bushings in side plates for wear or damage. Remove bushings and replace if necessary. Bedbar Installation (Fig. 27) 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.
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Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Removal in this chapter). 22” Cuting Unit 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. 29). 3. See bedknife grinding information on the following pages.
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Bedknife Grinding Top Surface Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the 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. 31 and 32). Remove Burr (without dulling sharp corner) Top Angle IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 31 and 33).
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Bedbar Adjuster Service Antiseize Lubricant Loctite #242 14 to 16 ft--lb (19 to 21 N--m) 7 Antiseize Lubricant 11 12 3 4 5 8 9 10 6 1 13 4 2 RIGHT FRONT Figure 35 1. 2. 3. 4. 5. Bedbar assembly Bedbar adjuster shaft Wave washer Flange bushing (2) Flat washer DPA Cutting Units 6. 7. 8. 9. Lock nut Bedbar adjuster screw Washer Compression spring Page 7 -- 22 10. 11. 12. 13.
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Removal (Fig. 35) 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.
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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 13 Antiseize Lubricant Antiseize Lubricant Loctite #242 4 10* 16 14* 1 RIGHT 7 9 13 FRONT 8* 5 11 15 6 12 27 to 33 ft--lb (37 to 44 N--m) Figure 36 1. 2. 3. 4. 5. 6. Cutting reel Frame Bedbar assembly RH side plate LH side plate O--ring (2) 7. 8. 9. 10. 11. Weight Flange nut (4)* Wire Spring Cap screw (4)* Threaded insert (4) 12. 13. 14. 15. 16.
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27 to 33 ft--lb (37 to 44 N--m) 15 to 19 ft--lb (20 to 25 N--m) 13 4 1 11 12 3 2 16 9 15 to 19 ft--lb (20 to 25 N--m) 8 12 14 9 15 10 16 7 4 11 5 27 to 33 ft--lb (37 to 44 N--m) 27 to 33 ft--lb (37 to 44 N--m) 7 6 1. Frame 7. Flange bushing (2) 2. LH side plate 8. Rear grass shield 3. RH side plate 9. Spacer (2) 10. Shim (as required)* 4. Shoulder bolt (4) 11. Flange nut (2) 5. Carrier frame 6. Flange head screw (2) *Used on 18” cutting units prior to serial no. 315000001. Removal (Fig.
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IMPORTANT: If the reel bearings or seals are being replaced, the reel spline inserts must be removed. Use the following procedure to restrain the reel and loosen the spline insert before removing the rollers. 5. Loosen the spline inserts (Fig. 38): 3 A. Tip the cutting unit to access the bottom of the reel. 85 to 95 ft---lb (115 to 128 Nm) 1 B. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit.
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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. 6. Slide the LH side plate onto the cutting reel assembly. 1 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 Antiseize Lubricant 8.
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IMPORTANT: To avoid grinding the reel, do not contact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the spline insert being tightened. IMPORTANT: The spline insert on the left end of the cutting reel has left hand threads and the spline insert on the right end of the cutting reel has right hand threads. C.
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Reel Assembly Service Loctite #242 9 10 11 1 12 2 7 6 5 85 to 95 ft--lb (115 to 128 N--m) (Right Hand Threads) 4 3 Loctite #242 Loctite #242 RIGHT 13* 15* 10 3 14* 4 5 6 7 FRONT 8 85 to 95 ft--lb (115 to 128 N--m) (Left Hand Threads -- Groove in Face) Figure 41 1. 2. 3. 4. 5. Cutting reel Threaded insert (RH thread) Plastic plug (2) Retaining ring Special washer 6. 7. 8. 9. 10. Flocked seal Sealed bearing Threaded insert (LH thread) Groove indicating LH threads Reel spider 11. 12. 13.
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Assembly of Cutting Reel (Fig. 41) 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. 6 2 3 4.
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Preparing Reel for Grinding Three (3) types of reel designs are used in Reelmaster cutting units: scalloped radial reel, tapered radial reel and tapered forward swept reel (Fig. 44). The radial reel designs have blades that are placed in line with the center of the reel shaft. The rear of the blades either have a scalloped relief or a tapered relief. The forward swept reel have blades that have a slight forward slant. The rear of the forward swept reel blades have a tapered relief.
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Front Roller Removal (Fig. 46) 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.
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Rear Roller Removal (Fig. 47) 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.
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Roller Service Disassembly (Fig. 48) 2 1. Remove bearing lock nut from each end of roller shaft. 50 to 60 ft--lb (68 to 81 N--m) 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 1 2 3.
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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 2 3 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.
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Rear Roller Brush (Optional) 2 4 5 6 REAR ROLLER BRUSH ASSEMBLY FOR 18 IN. CUTTING UNIT WITH LEFT HAND DRIVE AND NO GROOMER SHOWN 9 19 1 20 to 25 in--lb (2.3 to 2.
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Rear roller brush drive components are located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Figure 54 shows components used when the brush drive is on the left side of the cutting unit. 1 2 3 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 Disassembly (Fig. 54) 1.
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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. 4 1 E. Apply antiseize lubricant to splines of roller brush shaft before sliding hardened washer(s) and driven pulley onto shaft.
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Chapter 8 Belt Driven Groomer (Optional) Table of Contents Belt Driven 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 . . . . . . . . . . . . . . . . . . . . .
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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.
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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.
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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.
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Groomer Plate Assembly Special Instructions (see text) 17 to 21 ft−lb (23 to 28 N−m) Loctite #242 19 25 7 21 Left Side Driven Groomer Assembly Shown 26 Special Instructions (see text) 17 to 21 ft−lb (23 to 28 N−m) 20 16 Antiseize Lubricant 22 1 23 Loctite #242 27 to 33 ft−lb (37 to 44 N−m) 24 18 25 19 26 Antiseize Lubricant 7 4 27 16 14 13 23 Loctite #242 85 to 98 ft−lb (115 to 129 N−m) 17 12 2 RIGHT FRONT 11 3 5 Antiseize Lubricant 6 15 7 8 27 to 33 ft−lb (37 to 44 N−m) Loct
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B. Remove shoulder bolt and spacer that secures quick−up ball joint rod to groomer plate. Removal (Fig. 3) 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.
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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). C. Apply Loctite to two (2) socket head screws and secure pivot hub to cutting unit side plate. 1 IMPORTANT: The shoulder bolts that secure the quick−up ball joint rod to the groomer plate have a patch−lock feature.
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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). 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).
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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 15 7 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant FRONT 6 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.
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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.
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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.
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5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 1 16 to 21 ft−lb (23 to 28 N−m) B. 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) 2 IMPORTANT: The straps must be wrapped around the groomer blade and brush assembly in the correct direction. C. Loosely wrap the straps around the groomer reel shaft and brushes as shown (Fig. 11).
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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 14 1. 2. 3. 4. 5. Groomer plate (LH drive shown) Shoulder bolt Ball joint rod Jam nut Compression spring 6. 7. 8. 9. 10. 11. 12. 13. 14.
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Chapter 9 Universal Groomer (Optional) Table of Contents Universal Groomer GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Groomer Reel . . . . . . . . . . . . .
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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.
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Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive gears. Repair groomer drive. 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.
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Service and Repairs 5 2 6 3 1 4 RIGHT 4 FRONT Figure 1 1. Gear box assembly 2. Idler assembly 3. Groomer reel 4. Height adjuster assembly (2) 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. Universal Groomer 5. Weight 6.
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Gear Box Assembly 90 to 100 ft--lb (122 to 135 N--m) 6 RIGHT FRONT 2 4 3 1 5 Figure 2 1. Gear box assembly 2. Rear roller brush drive shield 3. Button head screw 4. Cotter pin NOTE: The groomer gear box assembly is located on the opposite side of the cutting unit from the cutting unit hydraulic motor. Removal (Fig. 2) 5. Clevis pin 6.
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4. If installed, remove the rear roller brush drive shield from the gear box. 3 6 5. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1--803022) in the end of the drive shaft and tighten to 13 N·m (120 in--lb); refer to Fig. 3. 2 5 6. Remove the cotter pin and clevis pin from the height adjustment rod at the front of the groomer gear box. Discard cotter pin. 7. Tip up the cutting unit to access the bottom of the reel to remove the drive shaft assembly. Figure 3 1. Square head set screw 2.
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H. Insert a long--handled pry bar (3/8 x 12 inch with screwdriver handle recommended) through the bottom of the cutting unit. The pry bar should pass between the top of the reel shaft and the backs of the reel blades so that the reel will not move. I. Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. 5 J. Use the drive shaft removal tool (Toro p/n 137--0920) on the large flats of the drive shaft assembly; refer to Fig. 5. K.
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Disassembly (Fig. 6) 1 115 to 125 ft--lb (156 to 169 N--m) 2 3 4 13 5 12 6 7 11 8 10 9 14 40 16 15 39 38 18 37 33 36 35 32 26 31 34 41 30 19 29 42 25 17 28 20 27 43 44 18 45 44 21 43 18 46 7 in. Reel Cutting Units Only 85 to 95 in--lb (9 to 11 N--m) 24 23 22 Tighten to Specified Torque (see text) 32 to 42 in--lb (4 to 5 N--m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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The gear box assemblies for cutting units with 5 in. reels and 7 in. reels are very similar. The gear box for cutting units with 7 in. reels have two (2) additional idler gear assemblies (Fig. 4). 1 CAUTION Use the 1--3/8” flats on the input shaft to prevent the input shaft from rotating during adapter removal. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter removal or input shaft damage may occur. 2 3 1. Remove input shaft adapter (item 1) if necessary. 2.
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CAUTION Use the 1--3/8” flats on the input shaft to prevent the input shaft from rotating during adapter installation. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter installation or input shaft damage may occur. 10.If removed, install the threaded adapter in the input shaft. If reusing a previously installed threaded adapter, apply medium strength thread locker to the smaller (5/8--11) threads only. Tighten threaded adapter from 115--125 ft--lb (156--196 N--m). 5 6 11.
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Idler Assembly Loctite #242 85 to 95 ft−lb (115 to 129 N−m) 5 Antiseize Lubricant 4 3 2 1 6 27 to 33 ft−lb (37 to 45 N−m) 8 9 7 12 10 9 13 24 to 30 ft−lb (33 to 41 N−m) 11 Figure 5 1. 2. 3. 4. 5. Socket head screw (2) Pivot hub Idler arm Bushing Threaded insert 6. 7. 8. 9. Cotter pin Clevis pin Stub shaft and shield Bearing shield (2) NOTE: The groomer idler assembly is located on the same side of the cutting unit as the cutting unit hydraulic motor. 10. 11. 12. 13.
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Installation (Fig. 5) 1. If shields, bearing or bushing was removed from idler arm, install new components. 1 A. Press bushing into groomer plate until the bushing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing contact shoulder in idler arm bore and install bearing retaining ring. C. Install bearing shields with flocked side of shield toward bearing. D. Verify idler arm orientation (LH or RH cutting unit) and insert stub shaft through shields and bearing.
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Groomer Reel 3 4 45 to 60 in−lb (5 to 7 N−m) 2 1 2 4 3 45 to 60 in−lb (5 to 7 N−m) Figure 7 1. Groomer reel 2. Shaft clamp (4) 3. Cap screw (4) Remove the groomer reel to replace individual groomer blades or replace the shaft. The groomer reel can be reversed to provide additional blade life. 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.
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Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 8). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance. 2 MIDPOINT 1 Disassembly (Fig. 9) 3 1.
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5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 1 31 to 35 ft−lb (42 to 48 N−m) B. Slide a brush into each groove around the full length of the groomer reel (Fig. 10). Make sure brushes are seated in groomer blade slots (Fig. 11) 2 IMPORTANT: The straps must be wrapped around the groomer blade and brush assembly in the correct direction. C. Loosely wrap the straps around the groomer reel shaft and brushes as shown (Fig. 10).
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Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). 3 The grooming brush element or shaft can be serviced separately (Fig. 13). 1 3 2 Figure 13 3. Roll pin (2) Universal Groomer 1. Brush element 2.
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Height Adjuster Assembly Antiseize Lubricant 9 10 2 3 4 11 5 12 13 6 14 15 7 1 8 16 Antiseize Lubricant 17 18 16 19 Figure 14 1. 2. 3. 4. 5. 6. 7. Height of cut bracket Height adjustment bolt Washer (2) Lock nut Carriage bolt Flange nut Cotter pin 8. 9. 10. 11. 12. 13. Clevis pin Button head screw Detent spring Groomer height adjuster knob Quick up cover Quick up lever Disassembly (Fig. 14) 1.
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Assembly (Fig. 14) 1. Apply antiseize lubricant to upper threads of adjustment rod and lower threads of height adjusters. Assemble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and secure with carriage bolt and flange nut. Do Not tighten the flange nut at this time. Ensure the height adjustment bolt and one (1) washer is above slot in side plate and one (1) washer and lock nut is below slot in side plate. 3.
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Chapter 10 Foldout Drawings Table of Contents Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 3 Reelmaster 3550--D . . . . . . . . . . . . . . . . . . . . . . . . . 3 Reelmaster 3555--D/3575--D . . . . . . . . . . . . . . . . . 4 ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . 5 Reelmaster 3550--D (machines below serial number 316000300) . .
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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.
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.73 CID .73 CID .73 CID .73 CID REEL REEL REEL MOTOR #4 MOTOR #1 MOTOR #5 LIFT CYLINDER #1 BORE: 1.50” STROKE: 2.2 5” ROD: 0.625” EXTEND TO RAISE .73 CID REEL REEL MOTOR #2 MOTOR #3 C1 .040” C2 M1 M2 C3 C5 .040” .040” LIFT CYLINDER #3 BORE: 1 .50” STROKE: 2.2 5” ROD: 0.625” EXTEND TO RAISE C7 .046” S3 S4 .046” C6 6.1 CID 500 psi .046” CV1 RV1 C8 OR1 .050” FC R L .035” C4 MV BA CK LAP SW ITCH (SW ) LIFT CYLINDER #2 BORE: 1.50” STROKE: 2.25” ROD: 0.
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LIFT CYLINDER #1 BOR E: 1.50” STROKE: 2.25” ROD: 0.625” EXTEND TO LOW ER REEL REEL REEL REEL REEL MOTOR #4 MOTOR #1 MOTOR #5 MOTOR #2 MOTOR #3 RM 3575--D REEL MOTOR DISPLACEMENT = 0.97 3IN/REV M1 M2 LIFT CYLINDER #4 BOR E: 1.50” STROKE: 2.33” ROD: 0.625” EXTEND TO LOW ER LIFT CYLINDER #5 BORE: 1.50” STROKE: 2.33” ROD: 0.625” EXTEND TO LOW ER C3 C5 .040” .040” C1 .040” M3 C2 LIFT CYLINDER #2 BOR E: 1.50” STROKE: 2.25” ROD: 0.625” EXTEND TO LOW ER LIFT CYLINDER #3 BOR E: 1.50” STROKE: 2.
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121--7824 REV. B Reelmaster 3550--D (machine serial numbers below 316000300) Electrical Schematic All relays and solenoids are shown as de-- energized. All ground wires are black.
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122--0417 REV. B All relays and solenoids are shown as de-- energized. All ground wires are black.
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All relays and solenoids are shown as de energized. All ground wires are black.
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120--3959 REV.
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BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE PINK BLACK RED/WHITE BLACK/WHITE GRAY RED/WHITE BLACK/WHITE BROWN VIOLET BROWN BLACK BLACK 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 BLACK BLACK WHITE BLACK BLACK GRAY RED ORANGE BLACK BROWN PINK ORANGE RED BLACK BLUE YELLOW WHITE BLACK BLACK BLACK PINK YELLOW ORANGE BLACK
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122--0416 REV.
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122--0416 REV.
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122--1526 Rev C Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing (Serial Numbers 403446001 to 405999999) Page 10 -- 12
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122--1526 Rev C Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing (Serial Numbers 403446001 to 405999999) Page 10 -- 13
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122--1731 Rev A Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing (Serial Numbers Above 406000000) CV Page 10 -- 14
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122--1731 Rev A Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing (Serial Numbers Above 406000000) Page 10 -- 15
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