Toro Reelmaster 3550-D Preliminary Service Manual Download Page 12

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Reelmaster 3550--D

Page 2 -- 4

Product Records and Maintenance

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)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

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

in--lb

N--cm

# 6 -- 32 UNC

10 + 2

13 + 2

147 + 23

15 + 2

169 + 23

23 + 3

262 + 34

# 6 -- 40 UNF

17 + 2

192 + 23

25 + 3

282 + 34

# 8 -- 32 UNC

13 + 2

25 + 5

282 + 30

29 + 3

328 + 34

41 + 5

463 + 56

# 8 -- 36 UNF

31 + 4

350 + 45

43 + 5

486 + 56

# 10 -- 24 UNC

18 + 2

30 + 5

339 + 56

42 + 5

475 + 56

60 + 6

678 + 68

# 10 -- 32 UNF

48 + 5

542 + 56

68 + 7

768 + 79

1/4 -- 20 UNC

48 + 7

53 + 7

599 + 79

100 + 10

1130 + 113

140 + 15

1582 + 169

1/4 -- 28 UNF

53 + 7

65 + 10

734 + 113

115 + 12

1299 + 136

160 + 17

1808 + 192

5/16 -- 18 UNC

115 + 15

105 + 15

1186 + 169

200 + 25

2260 + 282

300 + 30

3390 + 339

5/16 -- 24 UNF

138 + 17

128 + 17

1446 + 192

225 + 25

2542 + 282

325 + 33

3672 + 373

ft--lb

N--m

ft--lb

N--m

ft--lb

N--m

3/8 -- 16 UNC

16 + 2

22 + 3

30 + 3

41 + 4

43 + 5

58 + 7

3/8 -- 24 UNF

17 + 2

18 + 2

24 + 3

35 + 4

47 + 5

50 + 6

68 + 8

7/16 -- 14 UNC

27 + 3

37 + 4

50 + 5

68 + 7

70 + 7

95 + 9

7/16 -- 20 UNF

29 + 3

39 + 4

55 + 6

75 + 8

77 + 8

104 + 11

1/2 -- 13 UNC

30 + 3

48 + 7

65 + 9

75 + 8

102 + 11

105 + 11

142 + 15

1/2 -- 20 UNF

32 + 4

53 + 7

72 + 9

85 + 9

115 + 12

120 + 12

163 + 16

5/8 -- 11 UNC

65 + 10

88 + 12

119 + 16

150 + 15

203 + 20

210 + 21

285 + 28

5/8 -- 18 UNF

75 + 10

95 + 15

129 + 20

170 + 18

230 + 24

240 + 24

325 + 33

3/4 -- 10 UNC

93 + 12

140 + 20

190 + 27

265 + 27

359 + 37

375 + 38

508 + 52

3/4 -- 16 UNF

115 + 15

165 + 25

224 + 34

300 + 30

407 + 41

420 + 43

569 + 58

7/8 -- 9 UNC

140 + 20

225 + 25

305 + 34

430 + 45

583 + 61

600 + 60

813 + 81

7/8 -- 14 UNF

155 + 25

260 + 30

353 + 41

475 + 48

644 + 65

667 + 66

904 + 89

NOTE:

Reduce torque values listed in the table above

by 25% for lubricated fasteners. Lubricated fasteners

are defined as threads coated with a lubricant such as

engine oil or thread sealant such as Loctite.

NOTE:

Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc.

NOTE:

The nominal torque values listed above for

Grade 5 and 8 fasteners are based on 75% of the mini-

mum proof load specified in SAE J429. The tolerance is

approxi 10% of the nominal torque value. Thin

height nuts include jam nuts.

Summary of Contents for Reelmaster 3550-D

Page 1: ...lable on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information abou...

Page 2: ...Reelmaster 3550 D This page is intentionally blank ...

Page 3: ...BLE DISPLACEMENT PISTON PUMP PARKER TORQMOTORTM SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Chapter 5 Electrical System General Information 5 2 Electrical Drawings 5 3 Special Tools 5 4 Troubleshooting 5 7 Electrical System Quick Checks 5 14 Component Testing 5 16 Service and Repairs 5 27 Chapter 6 Chassis Specifications 6 2 General Inf...

Page 4: ...Reelmaster 3550 D This page is intentionally blank ...

Page 5: ...Reelmaster 3550 D Page 1 1 Safety Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 Safety ...

Page 6: ...d cutting units are DISENGAGED 4 Since diesel fuel is flammable handle it carefully A Use an approved fuel container B Do not remove fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Wipe up any spilled fuel While Operating 1 Sit on the seat when starting ...

Page 7: ...from cutting units and other mov ing parts Keep bystanders away 11 To assure safety and accuracy check maximum en gine speed 12 Shut engine off before checking or adding oil to the engine crankcase 13 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily conn...

Page 8: ... 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 ...

Page 9: ...s 6 Product Records Insert Operator s Manuals and Parts Catalog for your Reelmaster at the end of this chapter Additionally insert Installation Instructions Operator s Manuals and Parts Catalogs for any accessories that have been installed on your Reelmaster at the end of this section Maintenance Maintenance procedures and recommended service in tervals for your Reelmaster are covered in the Tract...

Page 10: ...0 09375 Reelmaster 3550 D Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 11: ... the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torq...

Page 12: ... 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 10 UNC 93 12 140 20 190 27 265 ...

Page 13: ... 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced when installin...

Page 14: ... in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Type A Type B No 6 18 20 20 5 in lb...

Page 15: ...50 D Page 3 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 E3B SERIES Kubota Diesel Engine ...

Page 16: ...l or Biodiesel up to B20 Fuel with Low or Ultra Low Sulfur Content Fuel Capacity 7 5 U S gallons 28 4 liters Fuel Injection Pump Bosch MD Type Mini Injection Nozzle Mini Nozzle DNOPD Governor Centrifugal Mechanical Low Idle no load 1400 50 RPM High Idle no load 3220 50 RPM Engine Oil API CH 4 CI 4 or higher Engine Oil Viscosity See Operator s Manual Crankcase Oil Capacity 3 5 U S Quarts 3 3 Liters...

Page 17: ...n the Kubota Workshop Manual 05 Series Diesel Engine The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair fa cility Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepared to p...

Page 18: ...Reelmaster 3550 D Page 3 4 Kubota Diesel Engine This page is intentionally blank ...

Page 19: ...IC SCHEMATIC 10 SPECIAL TOOLS 12 TESTING 16 ADJUSTMENTS 17 Adjust Control Manifold Relief Valves 17 SERVICE AND REPAIRS 18 General Precautions for Removing and Installing Hydraulic System Components 18 Check Hydraulic Lines and Hoses 19 Flush Hydraulic System 20 Filtering Closed Loop Traction Circuit 21 Charge Hydraulic System 22 EATON MEDIUM DUTY PISTON PUMP REPAIR INFORMATION MODEL 70160 VARIABL...

Page 20: ...Reelmaster 3550 D Hydraulic System Page 4 2 This page is intentionally blank ...

Page 21: ...section positive displacement gear type pump Front Section mow circuit Displacement per revolution 0 58 in3 9 45 cc Rear Section steering lift Displacement per revolution 0 33 in3 5 34 cc Steering Control Valve Sauer Danfoss steering unit Series OSPM Displacement per revolution 6 1 in3 100 cc Steering and Lift Lower Circuit Relief Pressure 1000 PSI 6 9 bar Cutting Unit Motors Casappa gear motor Di...

Page 22: ...on only at a speed below 3 mph 4 8 kph and for a very short distance The piston traction pump is equipped with a bypass valve that needs to be turned 90o for towing Fig 1 Do not turn bypass valve when engine is running See Traction Unit Operator s Manual for additional tow ing procedures 1 Bypass valve location Figure 1 1 Check Hydraulic Fluid The Reelmaster 3550 D hydraulic systems are de signed ...

Page 23: ...hap ter into the circuit This filter should be used when con necting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction cir cuit component e g traction piston pump or wheel motor The filter will ensure that contaminates are re moved from the closed loop and thus do not cause addi tional component damage Once the Toro high flow hydraulic filter k...

Page 24: ...he hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book...

Page 25: ...set Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 3...

Page 26: ...ecords and Maintenance to determine necessary con version information 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T ...

Page 27: ...position with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 7 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench wi...

Page 28: ... ENGINE RPM BACKLAP SWITCH SW REEL 4 LC FC PRV MV T M1 C1 P C4 G G1 M2 T C5 RV S2 S4 S3 S1 P L 4 0 GPM 7 0 GPM BREATHER G2 G1 C2 MOW CONTROL VALVE LIFT CONTROL VALVE 200 300 psi 73 73 73 73 CV1 25 psi 2 33 Stroke C2 C3 C7 C6 C8 1500 psi M3 E T R P OR2 046 OR4 046 OR6 046 OR6 055 BYPASS VALVE MOW 10 GPM 6 MPH TRANSPORT 18 GPM 11 MPH REEL 1 REEL 5 REEL 2 REEL 3 OR1 040 OR3 040 OR5 040 OR7 035 3 79 S...

Page 29: ...Reelmaster 3550 D Hydraulic System Page 4 11 This page is intentionally blank ...

Page 30: ...st hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter This tester includes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 ...

Page 31: ... GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 3 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM 20 to 150 LPM Toro Part Number AT40002 NOTE This tester does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 below Figure 12 Hydraulic Hose Kit This kit includes hydraulic fittings and hoses needed...

Page 32: ...or after replacing a failed traction circuit component e g piston traction pump or wheel motor the high flow hy draulic filter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional compo nent damage Toro Part Number TOR6011 NOTE This kit does not include hydraulic hoses see Hydraulic Hose Kit TOR6007 abov...

Page 33: ...m the case drain line while the motor is pressurized by the hydraulic system The table in Figure 17 provides gallons per minute GPM conversion for measured milliliter or ounce motor case drain leakage Toro Part Number TOR4077 Figure 16 Figure 17 O ring Kit The kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections It is recommended that O rings be replaced whe...

Page 34: ...ew hours by a doctor famil iar with this type of injury Gangrene may result from such an injury WARNING Precautions for Hydraulic Testing 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Hydraulic system contamination will cause excessive wear of hydraulic components 2 Put met...

Page 35: ...ol manifold 2 Remove cap on relief valve with an allen wrench 3 To increase pressure setting turn the adjustment socket on the valve in a clockwise direction A 1 8 turn on the socket will make a measurable change in relief pressure 4 To decrease pressure setting turn the adjustment socket on the valve in a counterclockwise direction A 1 8 turn on the socket will make a measurable change in relief ...

Page 36: ...hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when installing hydraulic hoses and tubes After Repair or Replacement of Hydraulic Compo nents 1 Check oil level in the hydraulic reservoir and add cor rect oil if nec...

Page 37: ... escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury IMPORTANT Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings or deterioratio...

Page 38: ...s that were disconnected while draining system NOTE Use only hydraulic fluids specified in the Trac tion Unit Operator s Manual Other fluids may cause system damage 7 Fill hydraulic reservoir with new hydraulic fluid 8 Disconnect wire harness connector from engine run solenoid to prevent the engine from starting 9 Turn ignition key switch to start and engage starter for ten 10 seconds to prime pum...

Page 39: ...AUTION All wheels will be off the ground and rotating dur ing this procedure Make sure machine is well supported so it will not move and accidentally fall to prevent injuring anyone around machine IMPORTANT While engaging the traction circuit monitor the indicator on the high flow hydraulic fil ter If the indicator should show red either reduce pressure on the traction pedal or reduce engine speed...

Page 40: ...10 Make sure traction pedal is in neutral Start engine and run it at low idle 1400 RPM The pumps should pick up oil and fill the hydraulic system If there is no in dication of fill in thirty 30 seconds stop the engine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control until the lift cylinder rods move in and out several times If the cylinder rod...

Page 41: ...EM QUICK CHECKS 14 Battery Test Open Circuit 14 Charging System Test 14 Glow Plug System Test 14 Check Operation of Interlock Switches 15 COMPONENT TESTING 16 Ignition Switch 16 Fuses 17 Indicator Lights 18 Lower Raise Control Lever Switches 19 Enable Disable Switch 20 Light Switch 21 Main Power and Glow Relays 22 Start Relay 23 Parking Brake Switch 24 Toro Electronic Controller TEC 25 Fusible Lin...

Page 42: ...al test device such as a digital multimeter IMPORTANT Before performing any welding on the machine disconnect the battery cables from the battery disconnect the wire harness connectors from the Toro Electronic Controller and disconnect the terminal connector from the alternator to pre vent damage to the machine electrical system CAN bus Communications The TEC controller used on the Reelmaster 3550...

Page 43: ...Reelmaster 3550 D Page 5 3 Electrical System Electrical Schematic The electrical schematic for the Reelmaster 3550 D is located in Chapter 8 Foldout Drawings ...

Page 44: ...ent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number TOR50547 Figure 2 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure complete ...

Page 45: ...fic gravity of battery electrolyte Obtain this tool locally Figure 4 Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply battery terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 Figure 5 ...

Page 46: ... NOTE Diagnostic Display overlays are available in several languages for your Reelmaster Refer to your Parts Catalog for overlay language options and part numbers IMPORTANT The Diagnostic Display must not be left connected to the machine It is not designed to withstand the environment of the machine s every day use When use of Diagnostic Display is com pleted disconnect it from the machine and rec...

Page 47: ...e diagnostic light will be illuminated for approxi mately three 3 seconds and then will turn off The light should remain off during normal machine operation If the machine TEC controller detects an electrical sys tem malfunction fault during machine operation the diagnostic light will flash rapidly The light will stop flash ing and will automatically reset when the ignition switch is turned to the...

Page 48: ...ight will flash continuously after performing the above switch se quence If a fault code is not retrieved from the controller memory within forty 40 hours of machine operating time the fault cannot be retrieved from controller memory using this procedure If necessary contact your Toro distribu tor to retrieve older fault codes Fault Code Lamp Flashes Fault Description 1 3 Controller master board i...

Page 49: ...s in fault retrieval see Re trieving Fault Codes above The diagnostic light should be displaying the fault codes 2 Operator seat should remain UNOCCUPIED 3 Move mow backlap lever on the hydraulic mow con trol manifold to the BACKLAP position 4 Move joystick to the RAISE position 5 Monitor the diagnostic light for continuous flashing indicating that all faults have been cleared from the con troller...

Page 50: ...connector The machine will not operate without the loop back connector installed on the harness Store the Diag nostic Display in a dry secure indoor location and not on machine CAUTION The interlock switches are for the protection of the operator and bystanders and to ensure cor rect operation of the machine Do not bypass or disconnect switches Check the operation of the interlock switches daily f...

Page 51: ...and see Diagnostic Display Inputs and LED Operation chart on following page NOTE When the Diagnostic Display is attached to the wire harness connector and the ignition switch is in the ON position the input LED for alternator and engine temp should be illuminated If the machine wire harness connector is disconnected from the sensor for either of these inputs the appropriate LED should go off after...

Page 52: ...l lever in RAISE position LED ON Lower raise control lever NOT in RAISE position LED OFF PTO Enable disable switch in ON position pulled out LED ON Enable disable switch in OFF position pushed in LED OFF MOW Mow transport slide in the MOW position LED ON Mow transport slide in the TRANSPORT position LED OFF ALTERNATOR L Engine not running OR alternator faulty LED ON Alternator OK LED OFF ENGINE OI...

Page 53: ...splayed and outputs displayed several times to per form the following step To change from inputs to out puts press toggle button once This may be done as often as required Do not press and hold toggle but ton 6 Sit on seat and attempt to operate the desired func tion of the machine The appropriate output LED s should illuminate on the Diagnostic Display to indicate that the TEC controller is turni...

Page 54: ...n the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Start the engine and run at high idle 3200 RPM Allow the battery to charge for at least three 3 minutes Re cord the battery voltage After running the engine for at least three 3 minutes battery voltage should be at least 0 50 volt higher than initial battery vol...

Page 55: ...ine 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 Testing of individual interlock switches and relays is included in the Component Test ing section of this Chapter NOTE Use the Diagnostic Display see Special Tools in this chapter to test Toro Electronic Cont...

Page 56: ...ring are functioning correctly no further ignition switch testing is necessary If however input testing determines that the ignition switch and circuit wiring are not functioning correctly proceed with the fol lowing ignition switch testing procedure 3 Remove cover from control panel to access ignition switch 4 Make sure ignition switch is in the OFF position Dis connect wire harness connector fro...

Page 57: ...ubleshooting section of this chapter Upper front fuse 4 7 5 amp protects TEC output power supply for lift solenoid S3 front cutting units lift solenoid S4 rear cutting units alternator indicator light and over temperature indicator light NOTE If this fuse is faulty a fault should be displayed by the diagnostic light on the control panel see Diagnostic Light in the Troubleshooting section of this c...

Page 58: ...sition with the engine not running Also it should light with the engine running if the engine oil pressure drops below 7 PSI 0 5 kg cm2 To test the oil pressure light and circuit wiring ground the gray wire attached to oil pressure switch located on right side of engine near the starter motor Turn ignition switch to ON the oil pressure light should illuminate indi cating correct operation of the e...

Page 59: ...ocedure 3 Remove cover from control panel to gain access to raise and lower switches on joystick assembly 4 Make sure ignition switch is in the OFF position Dis connect wire harness connectors from raise and lower switches on joystick assembly 5 Check the continuity of the raise switch by connect ing a multimeter ohms setting across the switch con nector terminals as follows A With the joystick in...

Page 60: ...cessary If however input testing determines that the enable disable switch and circuit wiring are not functioning correctly proceed with the following switch testing procedure 3 Remove cover from control panel to gain access to enable disable switch 4 Disconnect wire harness electrical connector from the enable disable switch 5 The enable disable switch terminals are marked as shown in Figure 22 T...

Page 61: ... the light switch functions may be tested to determine whether continuity exists between the various terminals for each position The switch terminals are marked as shown in Figure 25 The circuitry of the light switch is shown in the chart below Verify continuity between switch terminals SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS ON 2 3 5 6 OFF 2 1 5 4 5 Replace light switch if testing identifi...

Page 62: ... 3 Remove cover from control panel and locate relay to be tested 4 Disconnect wire harness connector from relay Re move relay from mounting bracket for testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the m...

Page 63: ...his resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 5 Using a multimeter verify that coil resistance be tween terminals 85 and 86 is from 71 to 88 ohms 6 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should ma...

Page 64: ...o gain access to parking brake switch 4 Turn ignition switch to the ON position and check LED on cable end of parking brake switch LED should be illuminated when the parking brake is applied The LED should not be illuminated when the parking brake is released 5 If the brake switch LED did not function correctly A Make sure that when the parking brake is applied the clearance between the brake leve...

Page 65: ...rrent output to the indicator lights mow circuit hy draulic valve solenoid coil lift circuit hydraulic valve so lenoid coils and engine components glow plug relay start relay fuel pump and engine run solenoid are con trolled based on the inputs received by the controller Because of the solid state circuitry built into the control ler there is no method to test the controller directly The controlle...

Page 66: ...ry cable from battery terminal Then dis connect positive cable from battery see Battery Service in the Service and Repairs section of this chapter Lo cate and unplug fusible link connector P1 from ma chine wire harness Use a multimeter to make sure that continuity exists between each terminal pin in connector P1 and connector J1 at the starter Fig 32 If any of the fusible links are open replace th...

Page 67: ...m the battery do not smoke Nausea may result if the gases are inhaled Unplug char ger from electrical outlet before connecting or disconnecting charger leads to or from battery posts IMPORTANT Do not remove fill caps while clean ing 2 Check battery condition weekly or after every 50 hours of operation Keep terminals and entire battery case clean because a dirty battery will discharge slowly A Clea...

Page 68: ...he negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty com ponents and repaired 6 Make sure that rubber boot is properly placed over positive cable end and positive battery post 7 Install and secure battery cover after installing bat tery...

Page 69: ...rge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less t...

Page 70: ...mps 171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60oF 16oC before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explos...

Page 71: ...Reelmaster 3550 D Page 6 1 Chassis Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manuals 3 Parts Catalogs 3 Cutting Unit Identification 3 Chassis ...

Page 72: ...Reelmaster 3550 D Page 6 2 Chassis Specifications Item Description Tire pressure 12 PSI 96 kPa Wheel lug nut torque 45 to 65 ft lb 61 to 88 N m ...

Page 73: ...nformation when servicing the machine Parts Catalogs The Traction Unit and Cutting Unit Parts Catalogs can be used to provide disassembly and assembly informa tion for the chassis on your Reelmaster machine Refer to these publications for additional information when servicing the machine Cutting Unit Identification Cutting units on the Reelmaster 3550 are identified as shown in Figure 1 1 Reel mot...

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Page 75: ... Unit Operator s Manual 3 SPECIAL TOOLS 4 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE 8 SET UP AND ADJUSTMENTS 12 Characteristics 12 SERVICE AND REPAIRS 13 Hydraulic Reel Motor 13 Cutting Unit Removal and Installation 14 Backlapping 16 Bedknife Replacement and Grinding 18 Preparing Reel for Grinding 20 Roller Service 22 DPA Cutting Units ...

Page 76: ...ut HOC Cutting height is adjusted on the front roller by two 2 vertical screws Effective HOC may vary depending on turf conditions type of bedknife roller type and installed attachments Bedknife Replaceable single edged EdgeMaxTM bedknife is fastened to a machined cast iron bedbar with screws Optional bedknifes are available Bedknife Adjustment Dual screw adjustment to the reel detents correspondi...

Page 77: ...eration general maintenance and maintenance intervals for the DPA 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 ...

Page 78: ...adjustment Figure 2 Used for Height of Cut adjustment Used for groomer adjustment Cutting Reel Shim Toro Part Number 125 5611 The cutting reel shim 0 002 is used to ensure that the bedknife is parallel to the cutting reel Figure 3 Cutting Performance Paper Toro Part Number 125 5610 Cutting performance paper is used to test the cutting reel performance after adjusting the reel to bedknife clearance...

Page 79: ...l Figure 5 Handle Assembly Toro Part Number 29 9100 For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel Components for the handle assembly are available indi vidually as follows Brush 36 4310 Handle 29 9080 Handle cap 2410 18 Figure 6 Cutting Unit Kickstand Toro Part Number 119 8010 03 The cutting unit kickstand is used to prop up the rear of t...

Page 80: ...sed to assemble the cutting unit rollers Tools in this kit are also available individually as follows 115 0852 Inner Seal Tool 115 0853 Bearing Outer Seal Tool 107 8133 Bearing Installation Washer Figure 9 Inner Seal Tool Bearing Outer Seal Bearing Installation Washer Tool Diameter Circumference Measuring Tape Spring steel measuring tape for accurately measuring the circumference and outside diame...

Page 81: ...s the Turf Evaluator grass viewing tool is helpful It can assist turf managers and service technicians in determining causes for poor reel mower performance and in comparing the effective height of cut of one mowed surface to another This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator Toro part no 97931SL Figure 11 ...

Page 82: ...le Problem Correction Tire pressure Check tire pressure of all traction unit tires Adjust tire pressure as necessary Governed engine speed For best cutting performance and appearance engine should be run at maximum governed speed during machine operation Check maximum governed engine speed Adjust engine to specifications if necessary Reel speed All cutting reels must rotate at the same speed withi...

Page 83: ...klapping see Backlapping in the Traction Unit Operator s Manual Rear roller adjustment Adjust the rear roller brackets to correct position depending on the height of cut range desired See Rear Roller Adjustment in the Operator s Manual Height of cut Effective or actual height of cut depends on the cutting unit weight and turf conditions Effective height of cut will be different from the bench set ...

Page 84: ...reely 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 Cutting unit accessories A variety of cutting unit accessories are available that can be used to enhance aftercut appearance Refer to Operator s Manual for a listing of available accessories ...

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Page 86: ... self sharpening action This feature maintains sharp cutting edges assures good quality of cut and greatly reduces the need for routine backlapping In addition the rear roller positioning system allows for various height of cut ranges and aggressiveness of cut selections If a cutting unit is determined to be out of adjustment complete the following procedures in the specified order to adjust the c...

Page 87: ...ive plastic cap see Special Tools into the hole in the cutting unit side plate to prevent debris entry into reel bearing area Installation NOTE Refer to Figure 12 for correct placement of cut ting unit reel motors and weights 1 Coat spline shaft of the reel motor with No 2 multi purpose lithium base grease Lubricate the O ring on the motor flange with clean oil 2 Rotate the motor clockwise so the ...

Page 88: ...height of cut is above 3 4 inch 1 2 cm use the following procedure A Remove the lynch pin and washer securing the lift arm pivot yoke shaft to the rear lift arm Fig 18 B Slide the pivot yoke shaft out of the lift arm Make sure that second thrust washer remains on the pivot yoke shaft C Remove the pivot yoke from the cutting unit car rier frame as described in step 4 above 7 Move cutting unit away ...

Page 89: ...described in step 3 above B Make sure that thrust washer is positioned on the pivot yoke shaft Insert the yoke arm shaft into the lift arm and secure it with the washer and lynch pin Fig 18 5 Secure the lift arm chain to the cutting unit chain bracket with the snapper pin Fig 14 Use the number of chain links described in the cutting unit Operator s Manual 6 Move hair pin to the rear hole of turf c...

Page 90: ...D Do not attempt to restart reels by hand or foot D Do not adjust reels while the engine is running D If a reel stalls stop engine before attempting to clear the reel D Reel motors are connected in series rotating one motor causes rotation in other motors NOTE Instructions and procedures on backlapping are available in the Traction Unit Operator s Manual and the Toro General Service Training Book ...

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Page 92: ...move bedknife from the bedbar Fig 22 Bedknife Installation 1 Use scraper to remove all rust scale and corrosion from bedbar surface Lightly oil bedbar surface before installing bedknife 2 Make sure that screw threads in bedbar 5 16 18UNC 2A are clean Apply antiseize lubricant to the threads of new screws Take care to keep anti seize lubricant from taper on screw heads IMPORTANT Do not use an impac...

Page 93: ...lean and dress grinding stone often during the grinding process 1 Use Toro General Service Training Book Reel Mow er Basics part no 09168SL and grinder manufactur er s instructions for bedknife grinding information Bedknife Grinding Specifications see Fig 24 Front Angle all bedknife types 5o Relief Angle most bedknife types 5o Relief Angle 22 Low cut EdgeMax 15o Minimum bedknife lip height all bed...

Page 94: ... Grind ing Specifications chart to the right Additional reel grinding information can be found in Toro General Ser vice Training Book Reel Mower Basics part no 09168SL 2 After completing the reel grinding process adjust cutting unit see Cutting Unit Operator s Manual Reel Grinding Specifications Reel Diameter New 5 060 in 128 5 mm Service Limit Reel Diameter 4 500 in 114 3 mm Reel Shaft Diameter O...

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Page 96: ...ng assembly process frequently check that bearings rotate freely and do not bind If any binding is detected consider component re moval and reinstallation 2 Install new bearing and outer seals into one end of roller tube A Position a new bearing into one end of roller tube Use bearing outer seal tool see Special Tools in this chapter with a soft face hammer to fully seat bearing against roller sho...

Page 97: ...ear ings still freely rotate after seal installation E Using the same process install second outer seal making sure to not crush the installed outer seal Again make sure that shaft and bearings still freely rotate IMPORTANT Make sure that all grease is removed from shaft threads to prevent bearing lock nut loos ening 5 Thoroughly clean threads on both ends of roller shaft NOTE If original bearing ...

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Page 99: ...Reelmaster 3550 D Foldout Drawings Page 8 1 Chapter 8 Foldout Drawings Table of Contents HYDRAULIC SCHEMATIC 3 ELECTRICAL SCHEMATIC 4 Foldout Drawings ...

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Page 101: ...4 G G1 M2 T C5 RV S2 S4 S3 S1 P L 4 0 GPM 7 0 GPM BREATHER G2 G1 C2 MOW CONTROL VALVE LIFT CONTROL VALVE 200 300 psi 73 73 73 73 CV1 25 psi 2 33 Stroke C2 C3 C7 C6 C8 2 33 Stroke 1500 psi M3 E T R P OR2 046 OR4 046 OR6 046 OR6 055 BYPASS VALVE MOW 10 GPM 6 MPH TRANSPORT 18 GPM 11 MPH REEL 1 REEL 5 REEL 2 REEL 3 OR1 040 OR3 040 OR5 040 OR7 035 1 50 Bore 1 50 Bore 1 50 Bore 1 50 Bore 0 625 Rod 0 625...

Page 102: ...Page 8 4 Electrical Schematic Reelmaster 3550 D All relays and solenoids are shown as de energized All ground wires are black ...

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Toro Reelmaster 3550-D, Preliminary Service Manual

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