Part No. 15213SL Service Manual ReelmasterR 3550- D Preface The purpose of this publication is to provide the service technician with service information for service and repair of major systems and components on the Reelmaster 3550- D. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Copies of the Operator’s Manuals and Parts Catalog are available on the internet at www.Toro.com.
This page is intentionally blank.
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Electrical System Quick Checks . . . . . . . . . . . . . 5 - 18 Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
General Safety Instructions The Reelmaster 3550−D has been tested and certified by Toro for compliance with existing safety standards and specifications. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine.
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.
Jacking Instructions Jacking the Rear End CAUTION 1. Chock both front wheels. When changing attachments, tires or performing other service, use correct jacks and supports. Make sure machine is parked on a solid, level surface such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use jack stands to support the raised machine.
Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Reelmaster 3550−D. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.
This page is intentionally blank.
Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . .
Equivalents and Conversions 0.
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.
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
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.
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.
Chapter 3 Kubota Diesel Engine Table of Contents Reelmaster 3550- D Page 3 - 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Kubota Workshop Manual . . . . . . . . . . . . . . . . . . . . 4 Kubota Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
Specifications Description Item Make / Designation Kubota D1105- E3B or D1105- E4B 4- Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) 68.5 in3 (1123 cc) Total Displacement 1 (fan end) - 2 - 3 (flywheel end) Direction of Rotation Counterclockwise (viewed from flywheel) Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low Sulfur Content Fuel Capacity 7.5 U.S. gallons (28.
General Information This Chapter gives information about specifications and repair of the diesel engine used in the Reelmaster 3550- D. General maintenance procedures are described in your Traction Unit Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Kubota Workshop Manual: 05 Series Diesel Engine. Most repairs and adjustments require tools which are commonly available in many service shops.
Kubota Diesel Engine This page is intentionally left blank.
Service and Repairs Air Cleaner and Muffler 10 11 12 14 19 16 21 15 4 13 18 3 12 17 20 12 7 8 1 5 9 2 6 4 5 Figure 2 1. 2. 3. 4. 5. 6. 7. Exhaust guard Cap screw Muffler Flange head screw Flange nut Muffler bracket Hex nut Kubota Diesel Engine 8. 9. 10. 11. 12. 13. 14. Lock washer Exhaust gasket Hose clamp Air inlet hose (upper) Hose clamp Air cleaner body Filter cover Page 3 − 6 15. 16. 17. 18. 19. 20. 21.
Check Air Filter, Dust Cup, & Burp Valve The air cleaner body, air filter, dust cup, and burp valve should be checked daily, prior to operation. IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation. 4 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 1 3.
Fuel System 6 5 TO PUMP 4 6 12 7 10 8 16 17 11 18 Thread Sealant (typical) 9 8 3 13 14 2 20 19 15 11 21 22 11 38 11 27 28 1 30 31 32 29 33 37 23 24 25 34 27 35 36 26 TO TANK Thread Sealant (typical) 11 7 39 RIGHT 40 FRONT 16 41 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
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.
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.
Removal (Fig. 7) Installation (Fig. 7) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. Inspect seals around radiator location for wear or damage. Replace seals if necessary. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene- glycol antifreeze is poisonous.
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.
Removal (Fig. 8) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 4 3 5 2. Open and remove engine hood from the machine. Slide seat all the way forward. 3. Disconnect air hose from the air cleaner and radiator. Remove air cleaner assembly from the engine. 5. Remove muffler from the exhaust manifold and muffler bracket (see Muffler Removal in this Chapter). 1 Figure 9 1. Battery ground cable 2. Wire harness ground 3.
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.
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.
This page is intentionally blank.
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 . . . . . . . . . .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
.73 .73 .73 Hydraulic System G BACKLAP SWITCH (SW) FC M1 Page 4 − 14 P 3000 PSI OR1 .050” CV1 MV BREATHER PRV M2 REEL #4 REEL #1 REEL #5 .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER OIL COOLER RV 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 7.0 GPM LIFT CONTROL MANIFOLD RV1 OR1 .040” G1 P2 500 PSI .33 P S2 OR3 .040” C3 .58 P1 S1 OR5 .040” S3 T OR7 .035” Extend To Lower 3500 PSI G1 G2 P 6.1 R T PUMP RPM = 0.
Hydraulic System This page is intentionally blank.
Hydraulic System .73 .73 Page 4 − 16 G BACKLAP SWITCH (SW) FC M1 P .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER RV 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 OIL COOLER 3000 PSI OR1 .050” CV1 MV BREATHER PRV M2 REEL #4 REEL #1 REEL #5 .73 Working Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3550−D Traction Circuit (Forward) C8 RV1 OR1 .040” 7.0 GPM LIFT CONTROL MANIFOLD OR8 .055” OR6 C6 .046” OR4 C4 .046” C2 OR2 .
Traction Circuit The mow/transport slide control on Reelmaster 3550−D machines has positions for mow and transport. The mow position allows traction pedal inputs that are appropriate for mow speeds by limiting the movement of the traction pedal and the piston pump swash plate. The transport position allows full movement of the traction pedal so complete pump swash rotation is possible. Forward The engine drives traction pump (P3) indirectly through pulleys and a V−belt.
Hydraulic System Page 4 − 18 Reelmaster 3550−D .73 .73 G BACKLAP SWITCH (SW) FC M1 P BREATHER 3000 PSI OR1 .050” CV1 MV PRV M2 REEL #4 REEL #1 REEL #5 .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER OIL COOLER RV 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 .73 High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3550−D Cutting Unit Circuit − Mow C8 7.0 GPM RV1 OR1 .040” LIFT CONTROL MANIFOLD OR8 .055” OR6 C6 .046” OR4 C4 .
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. .
Hydraulic System Page 4 − 20 Reelmaster 3550−D .73 .73 G BACKLAP SWITCH (SW) FC M1 P 3000 PSI OR1 .050” CV1 MV BREATHER PRV M2 REEL #4 REEL #1 REEL #5 .73 .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER OIL COOLER RV 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3505−D Lift Circuit: Lower C8 RV1 OR1 .040” 7.0 GPM LIFT CONTROL MANIFOLD OR8 .055” OR6 C6 .046” OR4 C4 .046” C2 OR2 .
Lift Circuit: Lower The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit flow to by−pass the lift cylinders when de−energized and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise the cutting units when energized and lower them when de−energized.
Hydraulic System Page 4 − 22 Reelmaster 3550−D .73 .73 G BACKLAP SWITCH (SW) FC M1 P 3000 PSI OR1 .050” CV1 MV BREATHER PRV M2 REEL #4 REEL #1 REEL #5 .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER OIL COOLER 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 .73 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3505−D Lift Circuit: Raise C8 RV1 OR1 .040” 7.0 GPM LIFT CONTROL MANIFOLD OR8 .055” OR6 C6 .046” OR4 C4 .046” C2 OR2 .
Lift Circuit: Raise The lift control manifold includes four (4) electrically operated solenoid valves. Solenoid valve S1 causes circuit flow to by−pass the lift cylinders when de−energized and directs flow to the cylinders when energized. Directional solenoid valve S2 is used to direct oil flow to raise the cutting units when energized and lower them when de−energized.
Hydraulic System Page 4 − 24 Reelmaster 3550−D .73 .73 G BACKLAP SWITCH (SW) FC M1 P 3000 PSI OR1 .050” CV1 MV BREATHER PRV M2 REEL #4 REEL #1 REEL #5 .73 .73 LC OR2 .020” T M3 SUCTION STRAINER 25 PSI OIL FILTER OIL COOLER 1500 PSI MOW CONTROL MANIFOLD REEL #2 REEL #3 .73 Working Pressure Low Pressure (Charge) Return or Suction Flow Groundmaster 3505−D Steering Circuit (Right Turn Shown) C8 RV1 OR1 .040” 7.0 GPM LIFT CONTROL MANIFOLD OR8 .055” OR6 C6 .046” C2 OR4 C4 .
Steering Circuit LEFT TURN STEERING CYLINDER 2.00” Bore 0.625” Rod 3.79” Stroke L With the engine running and the steering control valve in the centered position (steering wheel not being turned), gear pump flow enters the steering control valve at the P port and goes through the control valve, by−passing the rotary meter and steering cylinder. Flow leaves the control valve through the E port to be available for the lift circuit and then to the traction charge circuit. R 6.
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.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
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.
NOTE: Engine−to−Pump ratio is 1:0.96. In other words, 1 engine RPM = 0.96 pump RPM. 10.All hydraulic tests should be made with the hydraulic fluid at normal operating temperature. 4. The inlet and the outlet hoses must be properly connected and not reversed (hydraulic tester with pressure and flow capabilities) to prevent damage to the hydraulic tester or components. Hydraulic Test Selection 5.
Hydraulic System This page is intentionally blank.
Traction Circuit Testing − Charge Pressure Test FRONT FRONT FORWARD REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER BYPASS VALVE LOWER PORT G2 UPPER PORT G1 3500 PSI TEE CONNECTOR AND PRESSURE GUAGE 200−300 PSI C2 FROM LIFT CONTROL MANIFOLD (T) PORT 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TO STEERING CONTROL VALVE (P) PORT P2 GEAR PUMP SUCTION STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 34 Reelma
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.
Traction Unit Testing − Wheel Motor Efficiency Tests FRONT WHEEL MOTOR TEST (together) FRONT WHEEL MOTOR TEST (individually) FRONT FRONT FRONT FRONT REAR FORWARD FORWARD REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER BYPASS VALVE LOWER PORT G2 TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER UPPER PORT G1 PISTON PUMP (HYDROSTAT) LOWER PORT PISTON PUMP (HYDROSTAT) UPPER PORT 3500 PSI REAR WHEEL MOTOR TEST 200−300 PSI FRONT C2 FRONT FORWARD REAR 1
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.
7. Verify with a phototach that the pump speed is approximately 3090 RPM. Flow meter should read less than 1.5 GPM (5.7 LPM). 17.Release traction pedal, shut engine off, and record test results. CAUTION Use extreme caution when performing wheel motor tests. The wheel motors will be trying to move the machine forward. 8. Sit in the operators seat, release the parking brake, and set the Mow/Transport slide to the transport position. 18.Rotate front wheel 120 degrees and retest.
Rear Wheel Motor Test: 3. Raise off the floor and support both front wheels. Hydraulic fluid flows through both front wheel motors (in parallel) before passing through the rear wheel motor (in series). To accurately test the rear wheel motor, the front wheel motors must be allowed to rotate. 4. Chock rear wheel to prevent wheel rotation. 5. Start engine. Move throttle to full speed. CAUTION 1. Disconnect hose from the upper hydraulic fitting of the rear wheel motor (Fig. 29).
Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test FRONT FRONT FORWARD REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER BYPASS VALVE LOWER PORT G2 UPPER PORT G1 3500 PSI 200−300 PSI C2 FROM LIFT CONTROL MANIFOLD (T) PORT 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TO STEERING CONTROL VALVE (P) PORT P2 GEAR PUMP SUCTION STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 40 Reelma
Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test: The hydrostat flow test is the third in a series of tests recommended to determine traction circuit performance. The final traction circuit test is verifying the hydrostat relief valve operation. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 12% indicates an internal leak or malfunctioning relief valve in the piston pump/hydrostat.
NOTE: The relief valve setting is 3500 PSI (241 Bar). An additional 100 to 200 PSI (6.9 to 10.3 Bar) is necessary to overcome system charge pressure before the relief valve opens. E. Release traction pedal, open flow control valve fully, move throttle to low speed and turn the engine off. 14.If relief pressure can not be met or is greater than specified, the traction relief valve is faulty and should be replaced. Hydraulic System 15.The Under Load test flow reading (step 12.
Hydraulic System This page is intentionally blank.
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 .
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.
Cutting Unit Circuit Testing − Reel Motor Efficiency/Case Drain Test REEL #4 REEL #1 REEL #5 REEL #2 REEL #3 TESTER WITH PRESSURE GAUGE AND FLOW METER TO HYDRAULIC TANK TO MOW CONTROL MANIFOLD PORT (M2) FROM MOW CONTROL MANIFOLD PORT (M1) MEASURING CONTAINER TO MOW CONTROL MANIFOLD PORT (M3) NOTE: CONFIGURATION FOR TESTING REEL MOTOR #4 SHOWN High Pressure Low Pressure Return or Suction Flow CUTTING UNIT LOCATIONS 1 1 2 Toro # TOR4077 #1 #4 #2 FRONT 1 1.
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.
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 .
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.
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 .
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.
Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test BYPASS VALVE G2 G1 3500 PSI 200−300 PSI FROM LIFT CONTROL MANIFOLD (T) PORT C2 100−150 PSI CHARGE RELIEF HYDROSTAT HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TESTER WITH PRESSURE GAUGES AND FLOW METER TO STEERING CONTROL VALVE (P) PORT High Pressure P2 SUCTION STRAINER GEAR PUMP Low Pressure Return or Suction Flow Hydraulic System Page 4 − 52 Reelmaster 3550−D
Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test: 2 The gear pump (P1) flow test is the last in a series of tests recommended to determine cutting unit circuit performance. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn. A worn pump will by−pass hydraulic fluid and make the pump less efficient.
Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test BYPASS VALVE G2 G1 3500 PSI 200−300 PSI FROM LIFT CONTROL MANIFOLD (T) PORT C2 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT P1 TO STEERING CONTROL VALVE (P) PORT P2 High Pressure TESTER WITH PRESSURE GAUGES AND FLOW METER SUCTION STRAINER GEAR PUMP Low Pressure Return or Suction Flow Hydraulic System Page 4 − 54 Reelmaster 3550−D
Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test: 2 Gear pump (P2) is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). The Gear Pump (P2) Flow Test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
13.Disconnect tester and reconnect hose to pump. NOTE: If necessary, circuit relief valve pressure test can be conducted with tester in the same location as for this test (see Steering/Lift Circuit − Relief Valve Pressure Test in this chapter).
Hydraulic System This page is intentionally blank.
Steering/Lift Circuit Testing − Relief Valve Pressure Test STEERING CYLINDER L R STEERING CONTROL VALVE TEST GAUGE 1000 PSI P T FROM LIFT CONTROL MANIFOLD (T) PORT E TO LIFT CONTROL MANIFOLD (P) PORT C2 TO MOW CONTROL MANIFOLD (P) PORT HYDROSTAT 100−150 PSI CHARGE RELIEF P2 P1 200−300 PSI GEAR PUMP SUCTION STRAINER High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 58 Reelmaster 3550−D
Steering/Lift Circuit Testing − Relief Valve Pressure Test: 2 The relief valve for the steering and lift circuits is integrated into the steering control valve. If both steering and lift operations perform poorly, perform the relief valve pressure test and gear pump (P2) flow test (see Steering/Lift Circuit − Gear Pump (P2) Flow Test in this chapter).
Steering/Lift Circuit Testing − Steering Control Valve and Steering Cylinder Test STEERING CYLINDER OPEN FITTING PLUG L R STEERING CONTROL VALVE 1000 PSI P T E TO LIFT CONTROL MANIFOLD (P) PORT High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 60 Reelmaster 3550−D
Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylinder, extra weight on the vehicle, and/or binding of the steering fork assembly. Make sure that these conditions are checked and functioning properly before proceeding with any steering system hydraulic testing. 1. Make sure hydraulic fluid is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Drive machine slowly in a figure eight on a flat level surface.
Adjustments Adjust Control Manifold Relief Valves The hydraulic control manifolds on your Reelmaster include adjustable relief valves (RV & RV1). Mow control manifold relief valve RV should be set to 1500 PSI (103 Bar) and lift control manifold relief valve RV1 should be set to 500 PSI (34.5 Bar). Adjust the relief valves to the recommended settings as necessary. NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1 1. Locate relief valve on control manifold. 2.
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.
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.
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.
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.
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.
Hydraulic Tank 4 3 2 1 80 to 87 ft−lbs (108.4 to 117.9 N−m) 5 6 7 8 TO HYDRAULIC PUMP 9 10 FROM OIL COOLER 12 13 11 18 19 20 14 Anti−seize 17 lubricant 30 to 60 in−lb (3.4 to 6.8 N−m) 21 16 15 22 RIGHT 23 FRONT 24 Figure 42 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic tank Dipstick Tank cap Shoulder screw O−ring Tank strainer Hose clamp (2) Suction hose Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16.
Hydraulic Tank Removal (Fig. 42) Hydraulic Tank Installation (Fig. 42) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If fittings were removed from hydraulic tank, lubricate and place new O−rings onto fittings. Install fittings into tank openings using marks made during the removal process to properly orientate fittings.
Radiator and Oil Cooler Assembly 2 21 18 25 20 9 9 27 10 22 19 5 10 8 3 16 4 11 12 24 14 13 21 29 28 33 26 23 34 16 21 30 15 1 2 Thread Sealant RIGHT 33 31 2 7 FRONT 17 32 6 Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Draincock valve Flange head screw (8) Flange nut (4) Carriage bolt (4) Radiator/oil cooler assembly LH fan shroud RH fan shroud Flange head screw (4) Hose clamp (2) Flange head screw (6) Overflow bottle bracket Radiator lower shield 13. 14. 15. 16. 17.
Hydraulic System This page is intentionally blank.
Hydraulic Pump Assembly 10 26 27 25 28 58 25 45 50 7 44 49 48 43 47 42 8 5 29 12 54 1 24 45 53 40 32 9 13 77 to 93 ft−lb (105 to 127 N−m) 27 3 33 30 40 38 55 6 56 34 40 51 4 46 1018 37 41 31 30 21 20 36 27 to 31 ft−lb (37 to 42 N−m) 11 41 2 RIGHT 35 57 22 23 90 to 120 in−lb (10.2 to 13.6 N−m) 52 17 16 39 FRONT 19 15 (tighten in 3 equal steps) 14 Blue Loctite Figure 44 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Drive Belt Removal (Fig. 44) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Raise and support hood. CAUTION CAUTION Use caution when installing torsion spring end onto the pump mount plate. Applying tension to the spring may cause personal injury during installation. 4. Apply pump drive belt tension with torsion spring on idler arm (Fig. 45). 3. Remove pump drive belt tension from torsion spring on idler arm (Fig.
Neutral Arm Assembly 1 4 23 24 7 22 18 21 19 20 6 5 7 9 12 8 9 10 14 12 3 2 11 32 33 29 16 17 15 16 31 13 26 25 27 30 28 Figure 46 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Pump assembly Hose Extension spring Pump mount plate Neutral bracket Flange nut Flange head screw Neutral arm Flange bushing Thrust washer 90o grease fitting Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Neutral Arm Removal (Fig. 46) Neutral Arm Installation (Fig. 46) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. Install key into trunnion slot. Position neutral bracket to the mount plate and the pump lever and hub assembly to the pump trunnion. 2. Raise and support hood. 2. Secure pump lever and hub assembly to the piston pump trunnion with flat washer and cap screw. 3.
Piston Pump/Hydrostat 1 RIGHT FRONT 2 3 4 5 6 10 9 8 7 Figure 47 1. 2. 3. 4. Engine mount bracket Flange nut Flange screw Pump mount plate 5. Hardened washer 6. 10 mm cap screw (4) 7. 8 mm cap screw (1) Piston Pump/Hydrostat Removal (Fig. 44 and 47) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Raise and support hood. WARNING 8. Hardened washer 9. Long spacer (4) 10. Short spacer (1) 3.
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.
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.
Hydraulic System This page is intentionally blank.
Piston Pump/Hydrostat Service 21 22 41 40 39 19 38 17 37 27 16 15 36 14 17 20 15 4 26 15 25 42 24 7 43 44 45 8 46 10 6 18 13 11 12 35 9 6 28 3 33 32 29 30 31 30 8 5 26 4 23 18 2 1 46 29 34 Figure 49 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Key Drive shaft Bearing Cap screw (3 used per plate) Cover plate O–ring Shim kit Bearing cone Key Swashplate Rotating kit Gasket Valve plate Bearing Dowel pin Back plate Hydraulic System 17. 18. 19. 20. 21. 22.
IMPORTANT: If a piston pump failure occurred, refer to Traction Circuit (Closed Loop) Component Failure in this chapter for information regarding the importance of removing contamination from the traction circuit. CHARGE RELIEF VALVE 4 NOTE: The traction circuit charge relief valve and the bleed off valve for traction circuit cooling are attached to the piston pump back plate assembly (Fig. 50).
4 5 29 ft−lb (39 N−m) 8 7 2 3 v 9 10 6 1 Figure 51 1. 2. 3. 4. Crush ring Shims Cover plate Housing 5. Camplate (control shaft) 6. Bearing cone 7. Bearing cup 8. O−ring 9. Washer (3) 10. Cap screw (3) Piston Pump/Hydrostat Crush Ring Replacement (Fig. 51) 5. Install washers and cap screws to the cover plate and housing. Torque cap screws to 29 ft−lbs (39 N−m). NOTE: The shims replace the crush ring in the cover plate.
Gear Pump 9 5 10 4 12 11 13 14 2 1 RIGHT 15 FRONT 17 16 Hydraulic System 8 7 3 6 Figure 52 1. 2. 3. 4. 5. 6. Piston pump Gear pump Hydraulic hose (tank suction) Hydraulic hose (hydraulic manifold) Hydraulic hose (steering valve) Hose clamp 7. 8. 9. 10. 11. 12. Hydraulic barb fitting O–ring O–ring 90o hydraulic fitting O–ring O–ring 13. 14. 15. 16. 17. 90o hydraulic fitting O–ring Cap screw Flat washer O–ring 5. Label hydraulic hoses and fittings on gear pump for assembly purposes.
Installation (Fig. 52) Remove plugs before installing gear pump to piston pump 1. If fittings were removed from gear pump, lubricate and place new O−rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 1 2. Make sure mounting and O−ring sealing surfaces on the gear pump and piston pump are clean. 2 3.
Hydraulic System This page is intentionally blank.
Gear Pump Service 19 14 18 17 11 10 12 2 8 3 6 1 3 2 20 16 21 13 15 13 14 33 ft−lb (45 N−m) 9 8 7 5 4 Figure 54 1. 2. 3. 4. 5. 6. 7. Front cover Pressure seal Back−up gasket Front thrust plate Idler gear Drive shaft Rear thrust plate 8. 9. 10. 11. 12. 13. 14. Dowel pin Seal Body Seal Splined connecting shaft Pressure seal Back−up gasket 15. 16. 17. 18. 19. 20. 21. Front thrust plate Idler gear Drive gear Rear thrust plate Rear cover Washer (4 used) Cap screw (4 used) Disassembly (Fig.
IMPORTANT: Use caution when clamping gear pump in a vise to avoid distorting any pump components. 3. Secure the front cover of the pump in a vise with the drive shaft pointing down. 8. Clean all pump parts. Check all components for burrs, scoring, nicks and other damage. 9. Replace the entire pump assembly if parts are excessively worn or scored. Assembly (Fig. 54) 4. Loosen the four (4) cap screws that secure pump assembly. 1. Apply clean hydraulic fluid to all parts before assembling. 5.
Front Wheel Motors 5 7 6 8 8 9 9 10 10 4 1 RIGHT 2 FRONT 11 3 1. 2. 3. 4. Lock nut Spacer Socket head screw Hydraulic wheel motor 5. 6. 7. 8. Figure 56 Frame Hydraulic tube Hydraulic tube O–ring 9. Hydraulic fitting 10. O–ring 11. Brake bracket NOTE: The left front wheel motor has a yellow dot on the body to distinguish it from the right front wheel motor.
Removal (Fig. 56) Installation (Fig. 56) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If adapters were removed from wheel motor, lubricate and place new O−rings onto fittings. Install adapters into motor openings and tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). WARNING 2.
Rear Wheel Motor 250 to 275 ft−lb (339 to 372 N−m) 2 3 1 14 11 12 13 15 45 to 65 ft−lb (61 to 88 N−m) 4 5 10 6 7 RIGHT FRONT 9 8 Figure 57 1. 2. 3. 4. 5. Lug nuts (4) Rear wheel assembly Lock nut Wheel hub Wheel stud (4) Hydraulic System 6. 7. 8. 9. 10. Lock nut (4) Rear wheel motor Socket head screw (4) Rear fork Woodruff key Page 4 − 90 11. 12. 13. 14. 15.
8. Using hub puller (see Special Tools in this chapter), loosen wheel hub from wheel motor. Removal (Fig. 57) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 10.If hydraulic fittings are to be removed from wheel motor, mark fitting orientation to allow correct assembly. Discard O−rings from removed fittings. Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 2.
Wheel Motor Service 45 to 55 ft−lb (60 to 76 N−m) 13 12 11 10 3 4 5 6 7 8 9 8 14 2 15 16 1 17 24 5 23 5 22 5 21 20 19 5 18 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. Dirt seal Bearing Housing Back−up washer Seal ring Back−up washer Inner seal Thrust washer 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Hydraulic System This page is intentionally blank.
Cutting Unit Reel Motor 5 11 5 11 6 10 8 7 4 2 4 6 1 11 10 8 7 #3 1 4 2 2 5 6 4 6 10 8 7 4 2 1 4 10 1 #5 2 9 11 1 2 7 #2 1 4 2 1 11 #1 1 3 4 RIGHT 5 5 FRONT 6 10 8 7 4 2 4 10 1 2 1 #4 Figure 59 1. 2. 3. 4. O−ring Elbow fitting Straight fitting O−ring Hydraulic System 5. 6. 7. 8. Hydraulic hose (Inlet) Hydraulic hose (return) O−ring Straight fitting Page 4 − 94 9. Elbow fitting 10. O−ring 11.
Removal 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 3. Label all hydraulic connections for assembly purposes (Fig. 59). Thoroughly clean hydraulic connections prior to loosening hydraulic lines from reel motor to prevent hydraulic system contamination.
Cutting Unit Reel Motor Service 18 ft−lb (25 N−m) 18 17 16 12 5 13 14 15 11 10 6 1 2 3 7 8 9 4 Figure 61 1. 2. 3. 4. 5. 6. Dust seal Retaining ring Backup washer Shaft seal Front flange Dowel pin (2) 7. 8. 9. 10. 11. 12. O–ring Pressure seal (outer) Backup gasket (outer) Wear plate (outer) Drive gear Idler gear 13. 14. 15. 16. 17. 18. Wear plate (inner) Backup gasket (inner) Pressure seal (inner) Body Cap screw (4) Washer (4) Disassembly (Fig. 61) 1.
IMPORTANT: Note position of the open and closed side of the wear plates before removing. Identify wear plates (inner and outer, drive gear and idler gear) with a marker for proper assembly. 1 2 3 4 IMPORTANT: Mark the relative positions of the gear teeth so they can be reassembled in the same (mated) position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. 7. Carefully disassemble the inner wear plate, idler gear, drive gear and outer wear plate. 8.
Assembly (Fig. 61) 1. Lubricate O–rings, pressure seals, back−up gaskets and wear plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean hydraulic fluid. 9. Install inner wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet side of the motor. 10.Apply a light coating of petroleum jelly to new O–ring and O–ring grooves in the body. Install new O–ring to the body. 2. Install new seals into front flange (Fig. 63): A.
Hydraulic System This page is intentionally blank.
Mow Control Manifold 4 5 10 8 18 9 10 17 6 16 10 14 12 11 15 3 13 9 1 8 10 7 2 10 20 8 9 19 RIGHT FRONT Figure 65 1. 2. 3. 4. 5. 6. 7. Mow control manifold Hydraulic tube Hydraulic tube Hydraulic tube Hydraulic hose Hydraulic tube Hydraulic tube Hydraulic System 8. 9. 10. 11. 12. 13. 14. Straight hydraulic fitting (3) O−ring O−ring 90o hydraulic fitting O−ring O−ring Hydraulic tee fitting Page 4 − 100 15. 16. 17. 18. 19. 20.
Removal (Fig. 65) Installation (Fig. 65) The ports on the mow control manifold are marked for easy identification of components. Example: PRV is the proportional relief valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location). 1. If fittings were removed from mow control manifold, lubricate and place new O−rings onto fittings.
Mow Control Manifold Service VIEW FROM ABOVE VIEW FROM BELOW FRONT 60 in−lb (6.7 N−m) FRONT 17 22 19 2 20 ft−lb (27 N−m) 18 8 15 17 12 3 21 16 40 ft−lb (54 N−m) 3 20 25 ft−lb (33 N−m) 1 13 11 3 25 ft−lb (33 N−m) 10 5 1 9 4 7 3 3 23 3 3 4 4 25 24 3 20 ft−lb (27 N−m) 14 6 20 ft−lb (27 N−m) 50 ft−lb (67 N−m) 25 ft−lb (33 N−m) 20 ft−lb (27 N−m) Figure 66 1. 2. 3. 4. 5. 6. 7. 8. 9.
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.
VIEW FROM ABOVE 7 10 11 10 VIEW FROM BELOW FRONT 12 10 ft−lb (13.5 N−m) FRONT 6 8 5 9 1 1 20 ft−lb (27 N−m) 2 3 4 Figure 68 1. 2. 3. 4. Mow control manifold Ball switch (normally open) O−ring Ball Hydraulic System 5. 6. 7. 8. Backlap spool Retaining ring (lower) Retaining ring (upper) Back−up ring Page 4 − 104 9. 10. 11. 12.
Backlap Spool (Fig. 68) 3. To install backlap spool into manifold: 1. To remove backlap spool from manifold: A. Remove backlap switch from manifold before removing backlap spool. Remove ball from manifold port after switch is removed. Remove and discard O−ring from switch. B. Remove lower retaining ring from backlap spool. Raise backlap spool to allow access to retaining ring on upper end of spool. Remove upper retaining ring. A. Install O−rings and back−up ring to upper grooves on spool.
Lift Control Manifold 4 3 RIGHT FRONT 13 5 6 7 9 1 8 12 10 2 11 O−Rings Between Fittings and Hoses/Tubes Not Shown Figure 69 1. 2. 3. 4. 5. Mow control manifold Flange head screw (2 used) Hydraulic hose Hydraulic hose Hydraulic tube (to rear bulkhead) Hydraulic System 6. 7. 8. 9. Hydraulic tube (to rear bulkhead) Hydraulic hose (RH lift cylinder) Hydraulic hose (RH lift cylinder) Hydraulic hose (center lift cylinder) Page 4 − 106 10. 11. 12. 13.
The ports on the lift control manifold are marked for easy identification of components. Example: S1 is the solenoid valve and P is the supply port (see Hydraulic Schematic to identify the function of the hydraulic lines and cartridge valves at each port location). The lift control manifold is located on the right side of the traction unit frame. Access the manifold from above through the hinged floor plate in front of the operator’s seat, or from behind (below the traction unit frame). 1.
Lift Control Manifold Service VIEW FROM ABOVE VIEW FROM ABOVE 60 in−lb (6.7 N−m) 60 in−lb (6.7 N−m) 16 17 FRONT 9 FRONT 16 8 8 9 16 20 ft−lb (27 N−m) 8 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 5 8 7 7 1 12 6 4 13 20 ft−lb (27 N−m) 1 19 10 12 13 20 ft−lb (27 N−m) 14 3 15 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 2 18 11 25 ft−lb (33 N−m) 3 Figure 70 1. 2. 3. 4. 5. 6. 7.
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.
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.
Hydraulic System This page is intentionally blank.
Steering Control Valve 26 10 18 17 19 RIGHT 20 to 26 ft−lb (28 to 35 N−m) 14 FRONT 27 4 9 11 24 7 Blue Loctite 242 5 2 6 8 12 8 20 25 29 2 30 21 1 22 23 13 15 16 28 3 31 32 3 Figure 71 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Steering arm Flange nut (4) Flange head screw (4) Steering valve bracket Cap screw (2) Pivot hub (2) Steering valve cover Washer head screw (5) Tilt steering boss Ball knob Steering tilt lever Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 71) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on steering control valve to prevent hydraulic system contamination. 1 2 5 WARNING Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved. See Relieving Hydraulic System Pressure in the General Information section of this chapter.
Steering Control Valve Service 8 9 7 6 10 5 4 3 2 11 1 12 22 13 14 15 21 13 16 20 13 17 18 20 to 24 ft−lb (27 to 33 N−m) 19 Figure 74 1. 2. 3. 4. 5. 6. 7. 8. Sleeve Cross pin Ring Spool Bearing assembly Shaft seal Ball stop Ball 9. 10. 11. 12. 13. 14. 15. Dust seal ring Housing Cardan shaft Spacer O–ring Distribution plate Inner gearwheel 16. 17. 18. 19. 20. 21. 22.
Hydraulic System This page is intentionally blank.
Steering Cylinder 8 7 6 No. 2 General Purpose Grease No. 2 General Purpose Grease 8 5 7 1 4 9 65 to 85 ft−lb (88 to 115 N−m) 3 2 10 12 9 RIGHT FRONT 65 to 85 ft−lb (88 to 115 N−m) 11 Figure 75 1. 2. 3. 4. Hydraulic hose Hydraulic hose O−ring (2) Hydraulic fitting (2) Hydraulic System 5. 6. 7. 8. O−ring (2) Steering cylinder Ball joint Retaining ring Page 4 − 116 9. 10. 11. 12.
Removal (Fig. 75) Installation (Fig. 75) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If removed, install ball joints into steering cylinder. NOTE: The rear tire must be removed to allow sufficient clearance to remove the steering cylinder from the machine. 2. Lubricate and place new O−rings onto removed steering cylinder fittings.
Steering Cylinder Service 1 3 4 7 8 11 12 2 5 6 40 ft−lb (54 N−m) 9 10 8 5 1 2 3 9 6 4 7 10 12 11 Figure 76 1. 2. 3. 4. Barrel with clevis Lock nut Piston seal Piston Hydraulic System 5. 6. 7. 8. O−ring O−ring Back−up ring Head Page 4 − 118 9. 10. 11. 12.
Disassembly (Fig. 76) Assembly (Fig. 76) 1. Remove oil from the steering cylinder into a drain pan by slowly pumping the cylinder rod. Plug both ports and clean the outside of the cylinder. 1. Make sure all steering cylinder components are clean before assembly. 2. Coat new O−rings, seals and back−up ring with clean hydraulic oil. A. Install piston seal and O−ring to the piston. 2. Mount barrel end of steering cylinder in a vise. Use a spanner wrench to remove internal collar from barrel. B.
Front Lift Cylinders RIGHT FRONT 6 14 13 14 13 19 17 16 19 18 16 15 7 2 13 4 15 8 5 7 19 Blue Loctite 242 13 13 14 14 6 14 3 12 13 14 16 17 4 5 8 11 1 10 9 Blue Loctite 242 4 5 Figure 77 1. 2. 3. 4. 5. 6. 7. #1 lift arm #5 lift arm #4 lift arm Recessed bumper (3) Flange head screws (3) Cylinder pin (2) Pivot pin (2) Hydraulic System 8. 9. 10. 11. 12. 13. Washer head screw (2) Lift cylinder Thrust washer Lynch pin Cylinder pin Thrust washer (6) Page 4 − 120 14. 15. 16. 17.
Removal (Fig. 77) Installation (Fig. 77) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O−rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter). 2.
Rear Lift Cylinders 4 3 11 4 3 12 6 8 4 9 7 9 8 10 6 13 4 14 15 5 8 5 9 7 9 8 2 1 RIGHT FRONT Figure 78 1. 2. 3. 4. 5. #2 lift arm #3 lift arm Pin (2) Washer head screw (4) Rear lift cylinder (2) Hydraulic System 6. 7. 8. 9. 10. Pin (2) Cylinder pin (2) Thrust washer (4) Retaining ring (4) Grease fitting (2) Page 4 − 122 11. 12. 13. 14. 15.
Removal (Fig. 78) Installation (Fig. 78) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O- rings onto fittings. Install fittings into cylinder port openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in this chapter). 3.
Lift Cylinder Service 3 5 7 1 9 11 2 12 4 13 6 40 ft−lb (54 N−m) 8 10 14 4 2 1 6 3 5 11 10 8 9 12 13 7 Figure 79 1. 2. 3. 4. 5. Barrel Lock nut Wear ring Piston Seal 6. 7. 8. 9. 10. O−ring Head O−ring Back−up ring Seal 11. 12. 13. 14. Dust seal Retaining ring Rod (cutting units #1, #2 and #3) Rod (cutting units #4 and #5) NOTE: All of the lift cylinders used on the Reelmaster 3550−D have the same basic construction.
Disassembly (Fig. 79) Assembly (Fig. 79) 1. Remove oil from the lift cylinder into a drain pan by slowly pumping the cylinder rod. Plug both ports and clean the outside of the cylinder. 1. Make sure all lift cylinder components are clean before assembly. IMPORTANT: Prevent damage when clamping the cylinder in a vise; clamp on the clevis only. 2. Coat new O−rings, seals and back−up ring with clean hydraulic oil. A. Install Uni−ring and O−ring to the piston. 2.
This page is intentionally blank.
Chapter 5 Electrical System Table of Contents Reelmaster 3550−D Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower/Raise Joystick Switches . . . . . . . . . . . . . Reel Enable/Disable Switch . . . . . . . . . . . . . . . . Mow/Transport Switch . . . . . . . . . . . . . . . . . . . . . Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Temperature Sender . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Reelmaster machine. Refer to the Operator’s Manual for additional information when servicing the machine. Toro Electronic Controller (TEC) Reelmaster 3550−D machines use a single Toro Electronic Controller (TEC) to manage machine electrical functions. The TEC controller is attached to the control panel.
Electrical Schematic Electrical System The electrical schematic and wiring diagrams for the Reelmaster 3550−D are located in Chapter 9 − Foldout Drawings in this manual.
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.
Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply battery terminal protector to the connection after the battery cable, ring terminal, or fork terminal has been secured. Toro Part Number: 107−0392 Figure 4 Diagnostic Display The Diagnostic Display (Fig. 5) can be connected to the wiring harness connector located under the control panel to verify correct electrical functions of the machine.
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this machine (see Chapter 8 − Foldout Drawings in this manual). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. If the machine has any interlock switches by−passed, reconnect the switches for proper safety and troubleshooting.
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.
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.
Diagnostic Display Reelmaster 3550−D machines are equipped with a Toro Electronic Controller (TEC) which controls machine electrical functions. The controller monitors various input switches (e.g. ignition switch, seat switch, neutral switch) and energizes outputs to actuate solenoids or relays for the requested machine function. 3 For the TEC to control the machine as desired, each of the inputs (switches and sensors) and outputs (solenoids and relays) must be connected and functioning properly.
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.
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.
Output No. Output Name 1 START Key Switch − START Traction Pedal − NEUTRAL Seat Switch − OCCUPIED or Parking Brake − ENGAGED Reel Enable/Disable Switch − DISABLE Joystick − NEUTRAL 2 ETR Key Switch − RUN or START Traction Pedal − NEUTRAL Seat Switch − OCCUPIED or Parking Brake − ENGAGED Engine Coolant Temperature − BELOW 240°F (116°C) 3 GLOW Key Switch − RUN or START LED illuminates for 6 seconds when key switch is in RUN position. LED illuminates when key switch is in START position.
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.
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.
Starting Problems (continued) Problem Possible Causes The engine cranks, but does not start. The fuel tank is empty. Wiring in the engine crank circuit is loose, corroded or damaged (see electrical schematic in Chapter 9 − Foldout Drawings in this manual). The fuel filter is plugged. The engine and/or fuel may be too cold. The fusible link to the engine run solenoid pull coil is faulty. The engine run solenoid or circuit wiring is faulty. The engine fuel pump or circuit wiring is faulty.
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).
Cutting Unit Operating Problems Problem Possible Causes Cutting units run (but should not) when raised. The mow control manifold proportional relief valve (PRV) solenoid coil or circuit wiring is faulty. A hydraulic problem exists (see Chapter 5 − Hydraulic System in this manual). The TEC Controller is faulty. Cutting units do not run when lowered with the mow/transport switch in the MOW position. Fuse(s) is (are) faulty (other electrical components most likely affected as well).
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set multimeter to the DC volts setting. The battery should be at a temperature of 60° to 100°F (16° to 38°C). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (−) meter lead to the negative battery post. Voltage Measured Battery Charge Level 12.
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.
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.
Main Power Relay The main power relay is secured to the control panel assembly next to the operator seat (Fig. 15). This relay is attached to the wire harness with a four (4) wire connector (Fig. 16). The relay can be accessed by removing the control panel cover. 1 6 The main power relay is used to provide current to the TEC controller and most of the fuse protected circuits (worklights, power point, console indicators and other electric equipment).
Fuses The fuse blocks are located under the control panel cover on the right side of the machine. Fuse Identification and Function Use the fuse decal (Fig.17) and fuse block (Fig. 18) to identify each individual fuse and its correct amperage. The fuses have the following function: Upper, rear fuse 1 (2 amp) protects logic power circuit to the TEC controller. Upper fuse 2 (7.
Fusible Links The Reelmaster 3550−D uses four (4) fusible links for circuit protection. Three (3) of the fusible links are located in a single harness that connects the starter B+ terminal to the main wire harness (Fig. 19). The fusible links in this harness protect the glow plug, alternator, and main power relay circuits. FUSIBLE LINK FUSIBLE LINK FUSIBLE LINK An additional fusible link is integrated into the main wire wire harness between the starter G terminal and the fuel stop solenoid pull coil.
Toro Electronic Controller (TEC) The Reelmaster 3550−D uses a Toro Electronic Controller (TEC) to monitor the condition of various switches (inputs) and directs power to a variety or outputs to control certain machine functions. The controller is located under the control panel (Fig. 22). The handheld Diagnostic Display with the correct overlay should be used to check inputs and outputs of the controller (see Diagnostic Display in this chapter).
12V POWER (7.
Parking Brake Switch The parking brake switch is a normally closed proximity switch that is located on the control console (Fig. 25). The sensing plate that opens the switch is the parking brake lever. 1 When the parking brake is applied, the parking brake lever is positioned near the target end of the parking brake switch so the switch is opened. The parking brake lever is moved away from the switch when the parking brake is released causing the switch to close.
Neutral Switch The neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral position. The neutral switch is located under the floor plate (Fig. 26). The TEC controller monitors the position of the neutral switch (open or closed).
Lower/Raise Joystick Switches The cutting unit raise and lower switches are located on the joystick assembly that is attached to the control panel. The rear switch is used to lower the cutting units and the front switch to raise them (Fig. 27). The switches are identical (Fig. 28). 1 The TEC controller monitors the position of the lower/ raise switches (open or closed).
Reel Enable/Disable Switch The enable/disable switch is located on the control panel (Fig. 29). This switch is pulled out to engage the cutting units and pushed in to disengage the cutting units. 1 The TEC controller monitors the position of the enable/ disable switch (pulled out or pushed in).
Mow/Transport Switch The switch used for the mow/transport slide is a normally closed switch. The switch opens when the mow/ transport slide is in the transport position. The switch is located under the floor plate (Fig 32). The TEC controller monitors the position of the mow/ transport switch (open or closed).
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).
Backlap Switch The backlap switch is a normally open ball switch that is in the normal, open state when the backlap lever is in the mow position. When the backlap lever is in the backlap position, the switch closes. The backlap switch is attached to the hydraulic mow control manifold located on the left side of the machine under the hinged access panel in front of the operator’s seat (Fig. 34). 1 5 The TEC controller monitors the position of the backlap switch (open or closed).
Engine Temperature Sender The engine temperature sender is located above the alternator, in the thermostat housing (Fig. 35). The resistance of the temperature sender reduces as the engine coolant temperature increases. The TEC controller uses input from the temperature sender to control the high temperature warning light on the operator’s control panel (on or off).
6. Replace temperature sender if specifications are not met. 7. Install temperature sender to the thermostat housing. A. Clean threads of water flange and temperature sender thoroughly. Apply thread sealant to the threads of the sender. Electrical System B. Screw sender into the water flange until it is finger tight. Then, tighten sender an additional 2 to 3 full turns. C. Connect wire harness connector to sender. 8. Fill engine cooling system.
Start Relay The start relay is secured to the control panel assembly next to the operator seat (Fig. 37). This relay is attached to the wire harness with a five (5) wire connector (Fig. 38). The relay can be accessed by removing the control panel cover. The start relay is used to provide current to the engine starter motor. The TEC controller energizes and monitors the operation of the start relay when specific input conditions are met.
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.
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.
Fuel Pump The fuel pump is attached to the left side of the engine near the fuel/water separator (Fig. 41). C. Make sure fuel hoses to and from the fuel pump are not kinked, damaged, and free of obstructions. The TEC controller energizes and monitors the operation of the fuel pump when specific input conditions are met. The fuel pump is energized when the ignition switch is set to RUN or START.
Glow Relay The glow relay is secured to the control panel assembly next to the operator seat (Fig. 42). This relay is attached to the wire harness with a four (4) wire connector (Fig. 43). The relay can be accessed by removing the control panel cover. The glow relay is used to provide current to the engine glow plugs. The TEC controller energizes and monitors the operation of the glow relay when specific input conditions are met.
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.
Hydraulic Solenoid Valve Coils The Reelmaster 3550−D hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The lift manifold includes four (4) solenoid valves (S1, S2, S3, and S4). The mow manifold includes a single solenoid valve (PRV). 1 2 The TEC controller energizes and monitors the operation of the solenoid coils when specific input conditions are met. When the solenoid coils are energized, hydraulic valve shift occurs to control hydraulic circuit flow.
C. Solenoid coil resistance should be measured with solenoid at approximately 68°F (20°C). Resistance may be slightly different than listed at different temperatures. Typically, a failed solenoid coil will either be shorted (very low or no resistance) or open (infinite resistance). Use a multimeter (ohms setting) and measure resistance between the two (2) connector terminals on the solenoid valve coil. The resistance for the solenoid coils is identified below: Solenoid Valve Coil Resistance PRV (mow) 7.
Indicator Lights 4 To test the high temperature shutdown light and circuit wiring, start the engine and ground the blue wire attached to the temperature sender at the engine thermostat housing. Warning light should illuminate. 3 The high temperature warning light is controlled by the TEC controller (see Engine Temperature Sensor in this chapter for additional information). 1 2 5 5 3 2 1B 1A (+) 2B 2A (+) Figure 46 4. Engine oil pressure 5.
CAN- bus Termination Resistors System communication between electrical components on Reelmaster 3550- D machines is accomplished on a CAN- bus communication system. Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components. At the ends of the twisted pair of bus cables are two (2) 120 ohm termination resistors.
Oil Pressure Switch The engine oil pressure switch is located on the engine below the alternator (Fig. 50). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 1 If low engine oil pressure allows the oil pressure switch to close during engine operation, the engine oil pressure light should illuminate.
Worklight Switch The worklight switch is located on the control panel (Fig. 51). This rocker switch allows the worklights (headlights) to be turned on and off. Testing 2 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch. 2. Remove cover from control panel to gain access to worklight switch. 1 3. Disconnect wire harness electrical connector from the worklight switch. 4.
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.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented (see Battery Storage and Battery Care in this chapter). 2 CAUTION 1 3 4 Use extreme caution to avoid splashing or spilling battery electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries.
Battery Testing C. Make sure battery terminals are free of corrosion. 1. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center battery cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm− up the hydrometer. At the same time take the temperature of the cell. B.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most locations. CAUTION Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
Cartridge Valve Coil Replacement The solenoid valve coil on the hydraulic control manifold (Fig. 54) can be replaced without opening the hydraulic system. 60 in−lb (6.8 N−m) 5 Removal 4 1. Park machine on a level surface, lower cutting decks, engage parking brake, stop engine and remove key from the ignition switch. 3 2. Disconnect the wire harness electrical connector from the solenoid valve coil. 2 3. Remove the nut from the spool assembly. 4. Slide the coil assembly from the solenoid valve stem.
Worklight Bulb Replacement The worklights are adjustable left and right, and up and down as necessary. The worklights use a replaceable halogen bulb. 5 3 4 CAUTION 1 The worklights use a halogen bulb that becomes extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury. Allow enough time for bulb to cool before handling. 2 Bulb Replacement (Fig. 55) Figure 55 1. Park machine on a level surface, stop engine, apply parking brake and remove key from ignition switch.
Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Tire pressure 12 PSI (96 kPa) Wheel lug nut torque 70 to 90 ft−lb (95 to 122 N−m) Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
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.
Service and Repairs Operator Seat 8 9 8 2 6 5 3 4 4 3 19 5 6 20 20 1 18 10 7 23 22 12 11 16 15 13 23 17 14 21 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Bottom cushion Back cushion Seat belt Flat washer Flat washer Cap screw Bottom cover Armrest kit 9. 10. 11. 12. 13. 14. 15. 16. Back cover Seat switch Adjusting track − RH Track − LH Support strap Flange nut Knob kit Weight indicator 17. 18. 19. 20. 21. 22. 23.
Chassis This page is intentionally blank.
Front Wheels and Brakes 24 21 25 22 30 27 18 11 20 12 23 29 13 28 5 10 14 1 8 16 4 3 26 17 14 15 19 2 Antiseize Lubricant 6 RIGHT FRONT 70 to 90 ft−lb (95 to 122 N−m) 9 7 250 to 275 ft−lb (339 to 372 N−m) Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hydraulic wheel motor (LH shown) Brake drum Socket head screw (4 per motor) Brake bracket Lock nut (4 per motor) Wheel hub Lock nut Front wheel assembly Lug nut (4 used per wheel) Cap screw (4 per brake assembly) Chassis 11. 12. 13. 14. 15. 16. 17.
Removal (Fig. 5) Installation (Fig. 5) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1. If removed, insert four socket head screws through the frame, hydraulic motor, spacers, and brake bracket. Secure with lock nuts, but do not fully tighten. 2. Assemble brake assembly as follows (Fig. 6): WARNING A. If removed, secure backing plate to the brake bracket with four cap screws and lock washers.
9. Lower wheel to ground. Torque wheel lug nuts from 70 to 90 ft−lb (95 to 122 N−m) in a crossing pattern. 10.Torque lock nut from 250 to 350 ft−lb (339 to 474 N−m). Release parking brake. 11. Check brake adjustment and and adjust if necessary (see Adjust Brakes in the Adjustments section). 7 3 4 1 5 2 6 Figure 6 1. 2. 3. 4. Return spring Brake shoe (toe end) Brake shoe (heel end) Backing plate Chassis 5. Retaining clip 6. Cam shaft 7.
Chassis This page is intentionally blank.
Rear Fork and Wheel 11 10 12 9 10 8 9 1 2 3 4 70 to 90 ft−lb (95 to 122 N−m) 250 to 275 ft−lb (339 to 372 N−m) 20 60 to 80 ft−lb (81 to 108 N−m) 19 4 21 5 21 65 to 85 ft−lb (88 to 115 N−m) 6 17 16 18 15 14 RIGHT 13 FRONT 7 Figure 7 1. 2. 3. 4. 5. 6. 7. Cap screw Thrust washer Lock washer Flange bushing (2) Rear casting Rear fork Socket head screw (4) Chassis 8. 9. 10. 11. 12. 13. 14.
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.
Brake Lever Linkages 2 1 3 3 4 4 9 10 5 6 6 5 7 8 14 11 15 13 12 31 31 16 30 32 30 13 to 17 ft−lb (18 to 23 N−m) 17 18 19 20 29 21 28 RIGHT 22 27 FRONT 23 26 25 24 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Pop rivet (4) Control panel cover Cover bracket (2) Magnetic catch (2) Hex washer head screw (4) Strike bracket (2) Lever assembly Lock nut Parking brake spacer Cap screw Flat washer Chassis 12. Cotter pin 13. Clevis pin 14. Parking brake link 15. Clevis pin 16.
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.
Steering Column 20 to 26 ft−lb (28 to 35 N−m) 8 10 26 13 19 20 RIGHT 7 FRONT 35 36 9 16 27 11 Blue Loctite 242 33 18 2 17 4 23 6 21 5 24 38 8 34 32 25 24 31 37 39 15 12 2 14 30 29 28 1 3 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Steering arm Flange nut Flange head screw (2) Steering valve bracket Cap screw (2) Pivot hub (2) Steering cover Cap screw (5) Ball knob Steering tilt lever Steering control valve Tilt bracket Cap screw Chassis 14. 15. 16. 17. 18. 19. 20. 21.
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.
Front Lift Arms RIGHT FRONT 3 2 2 4 5 3 6 6 7 13 5 1 12 10 Blue Loctite 242 11 10 8 3 2 4 5 2 6 5 9 6 7 6 5 7 6 5 13 Blue Loctite 242 12 10 3 10 1 10 8 9 2 3 2 14 Blue Loctite 242 10 8 9 16 1 17 18 4 3 15 19 20 Figure 11 1. 2. 3. 4. 5. 6. 7. Pivot yoke (3) Thrust washer (2 per yoke) Flange bushing (2 per lift arm) Lynch pin (3) Retaining ring (2 per pin) Thrust washer (2 per pin) Pin (3) Chassis 8. 9. 10. 11. 12. 13. 14.
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.
Rear Lift Arms 14 13 11 13 12 10 8 9 9 8 10 4 3 2 8 9 8 20 9 21 22 5 3 23 6 2 5 1 7 4 3 2 2 3 1 17 16 15 RIGHT FRONT 18 19 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. Pivot yoke (2) Thrust washer (2 per pivot yoke) Flange bushing (2 per lift arm) Lynch pin (2) Flange bushing (2 per lift arm) #3 lift arm #2 lift arm Retaining ring (2 per pin) Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting units (see Chapter 7 − Cutting Units in this manual). 3. Remove lynch pin and thrust washer securing pivot yoke to lift arm and remove pivot yoke. 1 4. Remove retaining ring and flat washer from one end of the cylinder pin that secures rod end of lift cylinder to lift arm. Pull pin from lift arm and cylinder rod.
This page is intentionally blank.
Chapter 7 Cutting Units Table of Contents DPA Cutting Units SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Cutting Unit Operator’s Manual . . . . . . . . . . . . . . . 3 Cutting Unit Removal and Installation . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Figure 1 Frame Construction: Precision machined die cast aluminum cross member with two (2) bolt−on cast aluminum side plates. Bedknife Adjustment: Dual screw adjustment to the reel; detents corresponding to 0.0007 inch (0.018 mm) bedknife movement for each indexed position. Reel Construction: Reels are 18 inches (45.7 cm) in length and 5 inch (12.7 cm) in diameter. High strength, low alloy steel blades are thru hardened and impact resistant.
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting units on your Reelmaster machine. Additionally, if optional kits have been installed on the cutting units (e.g. rear roller brush), the installation instructions for the kit includes set−up and operation information. Refer to those publications for additional information when servicing the cutting units.
Cutting Unit Installation 3 IMPORTANT: When installing cutting unit to machine, make sure that turf compensator spring is mounted on the same side of the cutting unit as the hydraulic reel drive motor. Also, make sure that cutting unit is installed on machine with motor and weight properly orientated to machine (Fig. 6). 2 1 1. Lower all the lift arms completely. Make sure the snapper pin and cap are removed from the lift arm pivot yoke (Fig. 4). 4 2. Position cutting unit to machine.
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.
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.
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.
Turf Evaluator Tool Toro Model Number: 04399 Many turf discrepancies are subtle and require closer examination. In these instances, the Turf Evaluator grass viewing tool is helpful. It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height−of−cut of one mowed surface to another. This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL).
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.
Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be corrected by tightening the bedknife to reel contact. Grind cutting reel to remove taper and/or rifling. Grind bedknife to sharpen and/or remove rifling. The most common cause of rifling is bedknife to reel contact that is too tight.
Factor Possible Problem/Correction Roller condition and roller type Make sure that front and rear rollers rotate freely. Repair roller bearings as necessary. See Roller Service in the Service and Repairs section of this chapter. Refer to Cutting Unit Operator’s Manual for roller options. Refer to Traction Unit Operator’s Manual for adjustment procedures. Turf compensation spring adjustment Refer to Traction Unit Operator’s Manual for adjustment procedures.
This page is intentionally blank.
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.
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.
Service and Repairs Cutting Unit Reel Motor 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 1 1 2 1 2 FRONT 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 1 4 3. Label all hydraulic connections for assembly purposes. Thoroughly clean hydraulic connections prior to loosening hydraulic lines from reel motor to prevent hydraulic system contamination.
5. Remove caps or plugs from fittings and hoses. 7. Check oil level in hydraulic reservoir and add correct oil if necessary. IMPORTANT: When installing the hydraulic hoses, make sure that hydraulic hoses are straight (not twisted) before tightening the hoses to the motor fittings. 8. Follow Hydraulic System Start−up procedures (see Hydraulic System Start−up in this section). 6. Lubricate and install new O−rings on motor fittings.
Backlapping DANGER 3 TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. Stay away from the cutting reels when backlapping. D When backlapping, run engine at idle speed only. D While backlapping, the reels may stall and then restart. D Do not attempt to restart reels by hand or foot. 1 D Do not adjust reels while the engine is running. D If a reel stalls, stop engine before attempting to clear the reel.
Bedbar Assembly Serial No. 315000001 & Up 18” Cutting Unit Components Shown 20 19 17 18 16 14 15 10 14 13 12 11 9 8 3 27 to 33 ft−lb (37 to 44 N−m) 2 RIGHT 3 FRONT 4 5 6 7 1 Antiseize Lubricant Figure 23 1. 2. 3. 4. 5. 6. 7. Side plate Rubber bushing (2) Flange bushing (2) Plastic washer (4) Metal washer (2) Bedbar pivot bolt (2) Lock nut (2) Cutting Units 8. 9. 10. 11. 12. 13. 14.
Bedbar Removal (Fig. 23) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove the cutting unit from the machine. Use the cutting unit kickstand to support the cutting unit (see Special Tools). 3. Loosen the lock nuts on the end of each bedbar adjuster assembly until washers are loose. 4. Loosen the lock nuts on each bedbar pivot bolt. 5.
Bedbar Adjuster Service Antiseize Lubricant Loctite #242 14 to 16 ft−lb (19 to 21 N−m) 9 7 Antiseize Lubricant 11 12 10 8 6 5 1 4 13 4 3 2 RIGHT FRONT Figure 25 1. 2. 3. 4. 5. Bedbar assembly Bedbar adjuster shaft Wave washer Flange bushing (2) Flat washer Cutting Units 6. 7. 8. 9. Lock nut Bedbar adjuster screw Washer Compression spring Page 7 − 20 10. 11. 12. 13.
Removal (Fig. 25) 1. Remove lock nut, compression spring and washer from bedbar adjuster screw. 2. Remove bedbar (see Bedbar Removal in this chapter. NOTE: Bedbar adjuster shaft has left−hand internal threads. 3. Unscrew bedbar adjuster screw from the bedbar adjuster shaft. 4. Remove lock nut and flat washer from adjuster shaft. Slide adjuster shaft and wave washer from cutting unit frame. 5. Inspect flange bushings in cutting unit frame and remove if necessary. 6.
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Removal in this chapter. 18” Cutting Unit Components Shown NOTE: 18” cutting units use 6 screws to secure bedknife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar. 2 2. Remove screws from bedbar using a socket wrench and bedknife screw tool (see Special Tools in this chapter). Discard screws. Remove bedknife from the bedbar (Fig. 26). Bedknife Installation 3 1.
Bedknife Grinding Since there can be variations in the mounting surface of the bedbar, a new bedknife will not be perfectly flat after it is installed to the bedbar. Because of this, it is necessary to grind a new bedknife after installing it to the bedbar. Follow the bedknife grinding specifications provided and grind only enough to make sure the top surface of the bedknife is true (Fig. 28 and 29). IMPORTANT: Do Not grind the bedknife below it’s service limit (Fig. 28 and 30).
Reel Assembly 18” Cutting Unit Components Shown 27 to 33 ft−lb (37 to 44 N−m) 14 8* 6 3 2 12 Loctite #242 10* 11 Loctite #242 4 13 10* 14* 16 1 RIGHT 7 9 13 FRONT 8* 5 11 15 6 12 27 to 33 ft−lb (37 to 44 N−m) Figure 32 7. 1. Cutting reel 8. 2. Frame 9. 3. Bedbar assembly 10. 4. RH side plate 11. 5. LH side plate 6. O−ring (2) *Used on cutting units prior to serial no. 315000001. Weight Flange nut (4)* Wire Spring Cap screw (4)* Threaded insert (4) 12. 13. 14. 15. 16.
27 to 33 ft−lb (37 to 44 N−m) 15 to 19 ft−lb (20 to 25 N−m) 13 4 1 11 10 12 3 2 16* 9 15 to 19 ft−lb (20 to 25 N−m) 8 12 10* 14 9 15 16 7 4 11 5 27 to 33 ft−lb (37 to 44 N−m) 7 27 to 33 ft−lb (37 to 44 N−m) 6 Figure 33 Removal (Fig. 32 & 33) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove the cutting unit from the machine and place on a flat work area. 3.
7. Remove cap screw and flat washer that secure rear grass shield to LH side plate. 8. Remove flange head screw and flange nut that secures frame spacer and carrier frame to LH side plate. NOTE: The reel bearings and grease seals are press fit on the cutting reel shaft and should remain on the reel when removing the LH side plate. 1 2 Antiseize Lubricant 9. Remove two (2) shoulder bolts and flange nuts that secure the LH side plate to the cutting unit frame.
NOTE: The parallel position of the rear roller to the cutting reel is controlled by the precision machined frame and side plates of the cutting unit. If necessary, the cutting unit side plates can be loosened and a slight adjustment can be made to parallel the rear roller with the cutting reel (see Leveling Rear Roller in this Chapter). 14.If counterweight was removed from cutting unit, install new O−ring on counter weight. Secure counter weight to cutting unit side plate with two (2) flange nuts.
Reel Assembly Service Loctite #242 9 10 11 1 12 2 7 6 5 4 85 to 95 ft−lb (115 to 128 N−m) (Right Hand Threads) 3 Loctite #242 10 3 4 5 RIGHT 6 7 FRONT 8 85 to 95 ft−lb (115 to 128 N−m) (Left Hand Threads − Groove in Face) Figure 35 1. 2. 3. 4. Cutting reel Threaded insert (RH thread) Plastic plug Retaining ring 5. 6. 7. 8. Special washer Flocked seal Sealed bearing Threaded insert (LH thread) Cutting Reel Inspection 1.
Assembly of Cutting Reel (Fig. 35) 1. If flocked seals and/or bearings were removed from reel shaft, discard removed components and replace. Flocked Surface Toward Bearing 2. Make sure that the retaining ring is fully seated into the groove on the cutting reel shaft. 3. Install special washer with recessed slots toward bearing. Drive special washer onto reel shaft until it squarely contacts retaining ring. Loctite #242 85 to 95 ft−lb (115 to 129 N−m) 7 2 3 4.
Preparing Reel for Grinding Presently, the Reelmaster 3550- D machines use scalloped radial reels (Fig. 38). The radial reel design has blades that are placed in line with the center of the reel shaft. The rear of the blade has a scalloped relief. SCALLOPED RADIAL REEL 2 1 Before grinding a cutting reel, make sure that all cutting unit components are in good condition. Depending on type of grinder used, faulty cutting unit components can affect grinding results.
Front Roller Removal (Fig. 40) 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 1 Loctite #242 Antiseize Lubricant 2. Remove the cutting unit from the machine and place on a level working surface. Use cutting unit kickstand (see Special Tools) to raise front roller from work surface. 2 15 to 19 ft−lb (20 to 26 N−m) 3 3.
Rear Roller Removal (Fig. 41) 15 to 19 ft−lb (20 to 26 N−m) 4 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and remove key from the ignition switch. 5 1 6 2. Remove the cutting unit from the machine and place on a level working surface. Place support blocks under bedbar to raise rear roller from work surface. 3. Loosen flange nuts that secure the rear roller shaft to the rear roller brackets. 7 4.
Roller Service Disassembly (Fig. 42) 50 to 60 ft−lb (68 to 81 N−m) 2 1. Remove bearing lock nut from each end of roller shaft. 3 4 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube. Remove second set of outer seals and bearing from roller tube by tapping on opposite end of shaft. Remove shaft from roller tube. 5 6 7 1 2 3 3.
3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 1 3 2 4 5 4. Install new bearing and outer seals into second end of roller tube: A. Position a second new bearing to roller shaft and tube. Position washer (see Special Tools in this chapter) on bearing to allow pressing on both inner and outer bearing races simultaneously. B.
DPA Cutting Units This page is intentionally blank.
Rear Roller Brush (Optional) 2 4 5 LEFT SIDE DRIVEN REAR ROLLER BRUSH ASSEMBLY SHOWN 6 9 19 20 to 25 in- lb (2.3 to 2.8 N- m) 1 18 10 9 7 25 8 27 to 33 ft- lb (36 to 45 N- m) 11 20 25 18 5 7 21 22 6 5 23 24 26 4 12 13 14 15 16 3 41 17 42 30 Loctite #242 85 to 95 ft- lb (115 to 129 N- m) RIGHT FRONT 29 43 44 45 46 27 28 31 Grease Grommet ID 32 33 34 35 35 to 40 ft- lb (47 to 54 N- m) 36 37 38 15 to 19 ft- lb (20 to 25 N- m) 39 40 Figure 48 1. 2. 3. 4. 5. 6. 7.
NOTE: Drive components for the rear roller brush are located on the opposite side of the cutting unit from the cutting reel hydraulic motor. Figure 48 shows components used when the brush drive is on the left side of the cutting unit. 2 1 3 NOTE: The Installation Instructions for the rear roller brush kit has detailed information regarding assembly and adjustment. Use those Instructions along with this Service Manual when servicing the rear roller brush. 4 20 to 25 in−lb (2.3 to 2.
E. Apply antiseize lubricant to splines of roller brush shaft before sliding hardened washer(s) and driven pulley onto shaft. Torque flange nut that secures driven pulley to roller brush shaft from 27 to 33 ft−lb (36 to 45 N−m). 4 1 F. Position excluder seals on brush shaft so that seals just touch bearing housings. 2 CAUTION 3 Contact with the reel or other cutting unit parts can result in personal injury. Use heavy gloves when handling the cutting reel. G.
Chapter 8 Groomer (Optional) Table of Contents Groomer GROOMING PERFORMANCE . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Groomer Reel Mechanical Problems . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Groomer Drive Belt Replacement . . . . . . . . . . . . . 4 Groomer Plate Assembly . . . . . . . . . . . . . . . . . . . . . 6 Groomer Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
Service and Repairs CAUTION Never work on the groomer with the engine running. Always stop the engine, remove the key from the ignition switch and wait for all machine movement to stop before working on the groomer. NOTE: The Groomer Operator’s Manual provides information regarding the installation, set−up and operation of the optional groomer on your Reelmaster machine. Refer to these instructions for additional information when servicing the groomer.
Groomer This page is intentionally left blank.
Groomer Plate Assembly Loctite #242 7 19 25 Left Side Driven Groomer Assembly Shown 26 21 20 16 22 1 23 Antiseize Lubricant Loctite #242 27 to 33 ft−lb (37 to 44 N−m) 24 Antiseize Lubricant 18 25 19 16 26 27 7 4 14 13 23 Loctite #242 85 to 98 ft−lb (115 to 129 N−m) 17 12 2 Antiseize Lubricant RIGHT 11 3 5 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant FRONT 6 15 7 8 Loctite #242 9 10 75 to 90 in−lb (8 to 10 N−m) Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Removal (Fig. 3) B. Remove shoulder bolt and spacer that secures quick−up ball joint rod to groomer plate. 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, engage parking brake and remove key from the ignition switch. C. Remove two (2) socket head screws that secure groomer components to cutting unit side plate. D. Remove pivot hub from cutting unit.
2. Install groomer plate assembly to groomer non− drive side of cutting unit: A. Apply a thin layer of grease to inner lip of seal and carefully position non−drive side groomer plate onto groomer shaft and slide to cutting unit. B. Apply antisieze lubricant to the outside diameter of the pivot hub and position pivot hub to cutting unit (Fig. 6). 1 C. Apply Loctite to two (2) socket head screws and secure pivot hub to cutting unit side plate. D.
K. Check pulley alignment by laying a straight edge along the outer face of the drive pulley (Fig. 5). Drive and driven pulleys should be in line within 0.030” (0.70 mm). If necessary, align pulleys by removing driven pulley and installing or removing washer(s) between pulley and pulley spacer. L. After pulleys are aligned, install groomer drive belt and groomer belt cover (see Groomer Belt Replacement in this section). 4. Check that excluder seals just touch groomer plate assembly.
Groomer Reel Loctite #242 7 19 25 Left Side Driven Groomer Assembly Shown 26 21 20 16 22 1 23 Antiseize Lubricant Loctite #242 27 to 33 ft−lb (37 to 44 N−m) 24 Antiseize Lubricant 18 25 19 16 26 27 7 4 14 13 23 Loctite #242 85 to 98 ft−lb (115 to 129 N−m) 17 12 2 Antiseize Lubricant RIGHT 11 3 5 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant FRONT 6 15 7 8 Loctite #242 9 10 75 to 90 in−lb (8 to 10 N−m) Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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.
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.
5. If groomer reel is equipped with broomer kit: A. Slide a brush into each groove around the full length of the groomer reel (Fig. 11). Make sure brushes are seated in groomer blade slots (Fig. 12) 1 B. Loosely wrap the straps around the groomer reel shaft and brushes as shown (Fig. 11). Straps should be positioned between blades 1−2, 11−12, 21−22 and 31−32. 2 IMPORTANT: The straps must be wrapped around the groomer blade and brush assembly in the correct direction. C.
Height Adjuster Assembly 11 12 Left Side Driven Groomer Assembly Shown 10 9 30 to 40 in−lb (3.4 to 4.5 N−m) Antiseize Lubricant 8 7 13 14 6 5 4 Antiseize Lubricant 3 Loctite #242 17 to 21 ft−lb (23 to 28 N−m) 2 Antiseize Lubricant 1 Figure 13 1. 2. 3. 4. 5. Groomer plate (LH drive shown) Shoulder bolt Ball joint rod Jam nut Compression spring 6. 7. 8. 9. 10.
Chapter 9 Foldout Drawings Table of Contents Reelmaster 3550- D 2 3 4 5 6 Page 9 - 1 Foldout Drawings Foldout Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DRAWING . . . . . . . . . . . . . . . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Reelmaster machines include a line with an alternate color.
1.50” Bore 0.625” Rod 2.33” Stroke 1.50” Bore 0.625” Rod 2.25” Stroke .73 .73 REEL #4 .73 REEL #1 REEL #5 .73 REEL #2 2x 1.50” Bore 0.625” Rod 2.25” Stroke 1.50” Bore 0.625” Rod 2.33” Stroke Extend To Lower .73 REEL #3 STEERING CYLINDER 2.00” Bore 0.625” Rod 3.79” Stroke Extend To Lower R L C3 C1 OR2 .046” OR3 .040” OR1 .040” C7 C5 OR5 .040” OR7 .035” C2 OR4 .046” C4 M1 M2 S3 OR6 C6 .046” MV C8 BACKLAP SWITCH (SW) S4 6.1 MOW CONTROL MANIFOLD RV1 OR8 .
Reelmaster 3550−D Electrical Schematic All relays and solenoids are shown as de−energized. All ground wires are black.
BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE PINK BLACK RED/WHITE BLACK/WHITE GRAY RED/WHITE BLACK/WHITE RED/WHITE BLACK/WHITE BLUE GRAY TAN WHITE BLUE ORANGE GRAY VIOLET GREEN BLACK ORANGE BLUE BLACK BROWN GREEN YELLOW BLACK GRAY GREEN ORANGE BLACK RED WHITE BLUE WHITE RED GREEN YELLOW BLACK YELLOW BROWN BROWN BLACK BLACK WHITE BLACK BLACK ORANGE BLACK BROWN PINK ORANGE RED BLACK BLUE YELLOW WHITE BLACK BLACK BLACK PINK YELLOW ORANGE BLACK BLACK YELLOW GREEN PINK YEL
Reelmaster 3550−D Harness Drawing Page 8 − 6