Toro 3550-D - Manuals

Reelmaster 3550−D Page 1 − 2 Safety General Safety Instructions The Reelmaster 3550−D has been tested and certifiedby Toro for compliance with existing safety standardsand specifications. Although hazard control and acci-dent prevention partially are dependent upon the designand configuration of the...

Reelmaster 3550−D Page 1 − 3 Safety Maintenance and Service 1. The Traction Unit and Cutting Unit Operator’s Manu-als provide information regarding the operation, generalmaintenance and maintenance intervals for your Reel-master machine. Refer to these publications for addi-tional information when s...

Reelmaster 3550−D Page 1 − 4 Safety Jacking Instructions CAUTION When changing attachments, tires or perform-ing other service, use correct jacks and sup-ports. Make sure machine is parked on a solid,level surface such as a concrete floor. Prior toraising machine, remove any attachments thatmay inte...

Reelmaster 3550−D Page 1 − 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed tothe Reelmaster 3550−D. If any decal becomes illegibleor damaged, install a new decal. Decal part numbers arelisted in your Parts Catalog. Safety

Reelmaster 3550−D Page 2 − 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . ....

0.09375 Reelmaster 3550−D Page 2 − 2 Product Records and Maintenance Equivalents and Conversions

Reelmaster 3550−D Page 2 − 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in thefollowing tables. For critical applications, as determinedby Toro, either the recommended torque or a torque thatis unique to the application is clearly identified a...

Reelmaster 3550−D Page 2 − 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque 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/...

Reelmaster 3550- D Page 3 - 1 Kubota Diesel Engine Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 4 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 4 . . . . . . . . . . . . . . . . . . . . . ....

Reelmaster 3550- D Page 3 - 3 Kubota Diesel Engine Specifications Item Description 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) Total Displacement 68.5 in 3 (1123 cc) Firing Order 1 (fan end) - 2 -...

Reelmaster 3550- D Page 3 - 4 Kubota Diesel Engine 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 troub...

Reelmaster 3550−D Page 3 − 5 Kubota Diesel Engine This page is intentionally left blank. Kubota Diesel Engine

Reelmaster 3550−D Page 3 − 6 Kubota Diesel Engine Service and Repairs Air Cleaner and Muffler Figure 2 1. Exhaust guard 2. Cap screw 3. Muffler4. Flange head screw5. Flange nut 6. Muffler bracket 7. Hex nut 8. Lock washer 9. Exhaust gasket 10. Hose clamp11. Air inlet hose (upper)12. Hose clamp13. Ai...

Reelmaster 3550−D Page 3 − 7 Kubota Diesel Engine Check Air Filter, Dust Cup, & Burp Valve The air cleaner body, air filter, dust cup, and burp valveshould be checked daily, prior to operation. IMPORTANT: Any leaks in the air cleaner systemwill cause serious engine damage. Make sure thatall air ...

Reelmaster 3550−D Page 3 − 8 Kubota Diesel Engine Fuel System Figure 5 1. Fuel tank 2. Grommet3. Fuel gauge 4. Seat support strap (2)5. Heat shield 6. Washer head screw (4)7. Fuel hose (tank to pump)8. Bushing (2) 9. Elbow fitting 10. Stand pipe11. Hose clamp (7)12. Fuel hose (tee to tank)13. Cap sc...

Reelmaster 3550−D Page 3 − 9 Kubota Diesel Engine DANGER Because diesel fuel is flammable, use cautionwhen storing or handling it. Do not smoke whilefilling the fuel tank. Do not fill fuel tank while en-gine is running, hot or when machine is in an en-closed area. Always fill fuel tank outside andwi...

Reelmaster 3550−D Page 3 − 10 Kubota Diesel Engine Radiator and Oil Cooler Assembly Figure 7 1. Draincock valve 2. Flange head screw (8)3. Flange nut (4)4. Carriage bolt (4)5. Radiator/oil cooler assembly6. LH fan shroud7. RH fan shroud8. Flange head screw (4)9. Hose clamp (2)10. Flange head screw (...

Reelmaster 3550−D Page 3 − 12 Kubota Diesel Engine Engine Figure 8 1. Engine mount bracket − RH2. Cap screw 3. Hardened washer 4. Engine mount 5. Lower radiator hose6. Hose clamp 7. Exhaust flange gasket8. Coolant temperature switch9. Upper radiator hose10. Wire Harness − fusible link11. Flat washer...

Reelmaster 3550−D Page 3 − 13 Kubota Diesel Engine Removal (Fig. 8) 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Open and remove engine hood from the machine.Slide seat all the way forward. 3. Disconnect air hos...

Reelmaster 3550−D Page 3 − 14 Kubota Diesel Engine CAUTION Make sure lift or hoist can support the totalweight of the engine before removing the capscrews from the engine and engine brackets. 13. Remove hex nuts, cap screws, and washers from thecenter of the three engine mounts. CAUTION One person s...

Reelmaster 3550−D Page 3 − 15 Kubota Diesel Engine 15. Separate hydrostat and pump assembly from the en-gine as follows (Fig. 12): A. Remove traction belt from the engine flywheeland hydrostat pulleys. B. Remove five cap screws, washers, and spacerssecuring the pump mount plate to the engine. C. Rem...

Reelmaster 3550- D Hydraulic System Page 4 - 1 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 3 . . . . . . . . . . . . . . . . . . . . . . . . . ....

Reelmaster 3550−D Hydraulic System Page 4 − 3 General Information Operator ’s Manual The Traction Unit and Cutting Unit Operator’s Manualsprovide information regarding the operation, generalmaintenance and maintenance intervals for your Reel-master machine. Refer to these publications for addi-tiona...

Reelmaster 3550−D Hydraulic System Page 4 − 4 Hydraulic Hoses Hydraulic hoses are subject to extreme conditions suchas pressure differentials during operation and exposureto weather, sun, chemicals, very warm storage condi-tions or mishandling during operation and maintenance.These conditions can ca...

Reelmaster 3550−D Hydraulic System Page 4 − 5 Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/tube and the fitting are free of burrs, nicks, scratches orany foreign material. 2. As a preventative measure against leakage, it is rec...

Reelmaster 3550−D Hydraulic System Page 4 − 8 Special Tools Order the following special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostictests. Quick disconnect fittings provided attach directlyto mating fittings on machine test ports ...

Reelmaster 3550−D Hydraulic System Page 4 − 9 40 GPM Hydraulic Tester (Pressure and Flow) Use to test hydraulic circuits and components for flowand pressure capacities as recommended in the Testingsection of this chapter. This tester includes the following: 1. LOAD VALVE: A simulated working load is...

Reelmaster 3550−D Hydraulic System Page 4 − 10 High Flow Hydraulic Filter Kit The high flow hydraulic filter kit is designed with largeflow (40 GPM/150 LPM) and high pressure (5000PSI/345 bar) capabilities. This kit provides for bi−direc-tional filtration which prevents filtered debris from beingall...

Reelmaster 3550−D Hydraulic System Page 4 − 11 Measuring Container Use this container for doing hydraulic motor efficiencytesting (motors with case drain lines only). Measure effi-ciency of a hydraulic motor by restricting the outlet flowfrom the motor and measuring leakage from the casedrain line w...

Reelmaster 3550−D Hydraulic System Page 4 − 12 Remote Starter Switch After flushing the hydraulic system or replacing a hy-draulic component (e.g. gear pump, piston pump, wheelmotor), it is necessary to prime the hydraulic pumps. Aremote starter switch (Fig. 17) can be used for this pur-pose. Obtain...

Reelmaster 3550−D Hydraulic System Page 4 − 13 Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheelhub from the shaft of wheel motors. Figure 20 Hydraulic System

Reelmaster 3550−D Hydraulic System Page 4 − 14 Hydraulic Schematic Hydraulic Schematic Reelmaster 3550−D All solenoids are shown as de−energized NOTE: A larger hydraulic schematic is included in Chapter 8 − Foldout Drawings. .73 .33 .58 500 PSI 3500 PSI 100−150 PSI 12.0 12.0 24.7 1.44 6.1 1000 PSI S...

Reelmaster 3550−D Hydraulic System Page 4 − 16 Hydraulic Flow Diagrams STEERING CYLINDER STEERING CONTROL VA LV E Extend T o Lower Extend T o Lower T raction Circuit (Forward) W orking Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 3550−D .73 .33 .58 500 PSI 3500 PSI 100−150 PSI 12...

Reelmaster 3550−D Hydraulic System Page 4 − 17 Traction Circuit The traction circuit of the hydraulic system consists of ahydrostat connected in a closed loop circuit to three or-bital geroller wheel motors. The mow/transport slide control on Reelmaster 3550−Dmachines has positions for mow and trans...

Reelmaster 3550−D Hydraulic System Page 4 − 19 Cutting Unit Circuit Mow The tandem gear pump is directly coupled to the pistonpump/hydrostat which is belt driven by the engine. Thefront section of the gear pump (P1) supplies hydraulicflow for the cutting unit circuit. The gear pump takes itssuction ...

Reelmaster 3550−D Hydraulic System Page 4 − 21 Lift Circuit: Lower The tandem gear pump is directly coupled to the vari-able displacement piston pump/hydrostat which is beltdriven by the engine. The rear section of the tandemgear pump (P2) supplies hydraulic flow for the steeringcircuit (priority fl...

Reelmaster 3550−D Hydraulic System Page 4 − 25 Steering Circuit The tandem gear pump is directly coupled to the vari-able displacement piston pump/hydrostat which is beltdriven by the engine. The rear section of the tandemgear pump (P2) supplies hydraulic flow for the steeringcircuit (priority flow)...

Reelmaster 3550−D Hydraulic System Page 4 − 26 Troubleshooting The chart that follows contains information to assist introubleshooting. There may possibly be more than onecause for a machine malfunction. Review the hydraulic schematic and information on hy-draulic system operation in the Hydraulic F...

Reelmaster 3550−D Hydraulic System Page 4 − 27 Traction Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Neutral is difficult to find or machi...

Reelmaster 3550−D Hydraulic System Page 4 − 28 Lift Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ...

Reelmaster 3550−D Hydraulic System Page 4 − 29 Steering Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ...

Reelmaster 3550−D Hydraulic System Page 4 − 30 Mow Circuit Problems ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Gear pump is n...

Reelmaster 3550−D Hydraulic System Page 4 − 31 Testing The most effective method for isolating problems in thehydraulic system is by using hydraulic test equipmentsuch as pressure gauges and flow meters in the varioushydraulic circuits to perform various operational checks(See the Special Tools sect...

Reelmaster 3550−D Hydraulic System Page 4 − 34 Traction Circuit Testing − Charge Pressure Test High Pressure Low Pressure Return or Suction Flow TO STEERING CONTROL VALVE (P) PORT 3500 PSI 100−150 PSI G2 G1 C2 200−300 BYPASS VALVE SUCTIONSTRAINER P1 P2 TRACTION WHEEL MOTORS FRONT REAR FRONT PSI GEAR...

Reelmaster 3550−D Hydraulic System Page 4 − 35 Traction Circuit Testing − Charge Pressure Test: The charge pressure test is the first in a series of testsrecommended to determine traction circuit perform-ance. A charge pressure drop of more than 20% indic-ates an internal leak in the piston pump/hyd...

Reelmaster 3550−D Hydraulic System Page 4 − 36 Traction Unit Testing − Wheel Motor Efficiency Tests Figure 27 3500 PSI 100−150 PSI G2 G1 C2 200−300 BYPASS VALVE TRACTION WHEEL MOTORS FRONT REAR FRONT PSI HYDROSTAT FROM CHARGE RELIEF FOR W ARD TESTER WITH PRESSURE GUAGE AND FLOW METER LOWER PORT UPPE...

Reelmaster 3550−D Hydraulic System Page 4 − 37 Traction Circuit Testing − Wheel Motor EfficiencyTest: Wheel motor efficiency is the second in a series of testsrecommended to determine traction circuit perform-ance. Hydraulic fluid flow of 1.5 GPM (5.7 LPM) or morethrough a stationary wheel motor und...

Reelmaster 3550−D Hydraulic System Page 4 − 39 Rear Wheel Motor Test: Hydraulic fluid flows through both front wheel motors (inparallel) before passing through the rear wheel motor (inseries). To accurately test the rear wheel motor, the frontwheel motors must be allowed to rotate. 1. Disconnect hos...

Reelmaster 3550−D Hydraulic System Page 4 − 42 NOTE: The relief valve setting is 3500 PSI (241Bar). An additional 100 to 200 PSI (6.9 to 10.3 Bar)is necessary to overcome system charge pressurebefore the relief valve opens. E. Release traction pedal, open flow control valvefully, move throttle to lo...

Reelmaster 3550−D Hydraulic System Page 4 − 44 Cutting Unit Circuit Testing − Pressure Test High Pressure Low Pressure Return or Suction Flow BACKLAP SWITCH (SW) REEL #4 LC FC PRV MV T M1 P G M2 MOW CONTROL MANIFOLD CV1 1500 PSI M3 REEL #1 REEL #5 REEL #2 REEL #3 OR1 .050” OR2.020” RV PRESSURE GAUGE...

Reelmaster 3550−D Hydraulic System Page 4 − 45 Cutting Unit Circuit Testing − Pressure Test: Cutting unit circuit pressure is the first in a series of testsrecommended to check cutting unit circuit performance.The results from this test will help determine which com-ponent(s) are the cause of cuttin...

Reelmaster 3550−D Hydraulic System Page 4 − 47 Cutting Unit Circuit Testing − Reel Motor Efficiency/Case Drain Test The reel motor efficiency/case drain test is the secondin a series of tests recommended to check cutting unitcircuit performance. Over a period of time, a reel motorcan wear internally...

Reelmaster 3550−D Hydraulic System Page 4 − 49 Cutting Unit Circuit Testing − Proportional ReliefValve (PRV) Pressure Test: Test the performance of the mow control manifold pro-portional relief valve (PRV) to make sure that the maxim-um amount of fluid is available to the cutting unit motorsup to th...

Reelmaster 3550−D Hydraulic System Page 4 − 52 Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test High Pressure Low Pressure Return or Suction Flow TESTER WITH PRESSURE GAUGES AND FLOW METER TO STEERING CONTROL VALVE (P) PORT SUCTIONSTRAINER P1 P2 GEAR PUMP TO MOW CONTROL MANIFOLD (P) PORT HYDR...

Reelmaster 3550−D Hydraulic System Page 4 − 56 13. Disconnect tester and reconnect hose to pump. NOTE: If necessary, circuit relief valve pressure testcan be conducted with tester in the same location as forthis test (see Steering/Lift Circuit − Relief Valve Pres-sure Test in this chapter).

Reelmaster 3550−D Hydraulic System Page 4 − 58 Steering/Lift Circuit Testing − Relief Valve Pressure Test High Pressure Low Pressure Return or Suction Flow TEST GAUGE SUCTION STRAINER P1 P2 GEAR PUMP TO HYDROSTAT MOW CONTROL MANIFOLD (P) PORT 1000 PSI P L E T R TO LIFT CONTROL MANIFOLD (P) PORT 100−...

Reelmaster 3550−D Hydraulic System Page 4 − 62 Adjustments Adjust Control Manifold Relief Valves The hydraulic control manifolds on your Reelmaster in-clude adjustable relief valves (RV & RV1). Mow controlmanifold relief valve RV should be set to 1500 PSI (103Bar) and lift control manifold relie...

Reelmaster 3550−D Hydraulic System Page 4 − 64 Check Hydraulic Lines and Hoses WARNING Keep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, tosearch for leaks. Hydraulic fluid escaping underpressure can have sufficie...

Reelmaster 3550−D Hydraulic System Page 4 − 65 Flush Hydraulic System IMPORTANT: Flush the hydraulic system any timethere is a severe component failure or if the systemis contaminated (fluid appears milky, black, or con-tains metal particles). IMPORTANT: Flush hydraulic system when chang-Ing from pe...

Reelmaster 3550−D Hydraulic System Page 4 − 66 Filtering Closed−Loop Traction Circuit Filtering of a closed−loop hydraulic system after a majorcomponent failure (e.g. traction (piston) pump or wheelmotor) is a requirement to prevent debris from transmit-ting throughout the system. If a closed−loop h...

Reelmaster 3550−D Hydraulic System Page 4 − 67 Charge Hydraulic System NOTE: When initially starting the hydraulic system withnew or rebuilt components such as motors, pumps, orlift cylinders, it is important that the hydraulic system becharged properly. Air must be purged from the systemand its com...

Reelmaster 3550−D Hydraulic System Page 4 − 68 Hydraulic Tank 1. Hydraulic tank 2. Dipstick3. Tank cap 4. Shoulder screw 5. O−ring6. Tank strainer 7. Hose clamp (2)8. Suction hose 9. O−ring10. Elbow fitting11. Hydraulic tube12. O−ring13. Elbow fitting14. Hydraulic tube15. Elbow fitting16. Filter hea...

Reelmaster 3550−D Hydraulic System Page 4 − 69 Hydraulic Tank Removal (Fig. 42) 1. Park machine on a level surface. Lower cutting units,stop engine and engage parking brake. Remove keyfrom the ignition switch. 2. Read the General Precautions for Removing andInstalling Hydraulic System Components at ...

Reelmaster 3550−D Hydraulic System Page 4 − 72 Hydraulic Pump Assembly 1. Piston pump 2. Straight hydraulic fitting3. Cap screw 4. Lock nut 5. 90 o hydraulic fitting 6. 90 o hydraulic fitting 7. Tee fitting 8. 90 o hydraulic fitting 9. 90 o hydraulic fitting 10. Washer11. Hydraulic hose12. Suction h...

Reelmaster 3550−D Hydraulic System Page 4 − 73 Drive Belt Removal (Fig. 44) 1. Park machine on a level surface. Lower cutting units,stop engine and engage parking brake. Remove keyfrom the ignition switch. 2. Raise and support hood. CAUTION The torsion spring that tensions the idler as-sembly is und...

Reelmaster 3550−D Hydraulic System Page 4 − 76 Piston Pump/Hydrostat Figure 47 1. Engine mount bracket2. Flange nut 3. Flange screw 4. Pump mount plate 5. Hardened washer 6. 10 mm cap screw (4)7. 8 mm cap screw (1) 8. Hardened washer 9. Long spacer (4)10. Short spacer (1) 1 2 3 4 5 6 7 8 9 10 FRONT ...

Reelmaster 3550−D Hydraulic System Page 4 − 77 7. Label all hydraulic hoses and fittings for assemblypurposes. 8. Disconnect all hydraulic hoses connected to the hy-draulic fittings on the piston pump/hydrostat and gearpump. Allow hoses to drain into a suitable container.Plug hose and fitting openin...

Reelmaster 3550−D Hydraulic System Page 4 − 78 4. Place key into piston pump shaft slot. Slide taper lockbushing onto the piston pump shaft with bushing flangetoward pump housing. 5. Make sure that tapered surfaces of pump pulley andtaper lock bushing are thoroughly clean (no oil, grease,dirt, rust,...

Reelmaster 3550−D Hydraulic System Page 4 − 80 Piston Pump/Hydrostat Service 1. Key2. Drive shaft 3. Bearing4. Cap screw (3 used per plate)5. Cover plate 6. O–ring7. Shim kit 8. Bearing cone 9. Key10. Swashplate11. Rotating kit12. Gasket13. Valve plate14. Bearing15. Dowel pin16. Back plate 17. O–rin...

Reelmaster 3550−D Hydraulic System Page 4 − 82 1. Crush ring 2. Shims3. Cover plate 4. Housing 5. Camplate (control shaft)6. Bearing cone 7. Bearing cup 8. O−ring9. Washer (3) 10. Cap screw (3) Figure 51 v 29 ft−lb (39 N−m) 6 4 5 8 7 2 3 9 10 1 Piston Pump/Hydrostat Crush Ring Replacement(Fig. 51) N...

Reelmaster 3550−D Hydraulic System Page 4 − 83 Gear Pump 1. Piston pump 2. Gear pump 3. Hydraulic hose (tank suction)4. Hydraulic hose (hydraulic manifold)5. Hydraulic hose (steering valve)6. Hose clamp 7. Hydraulic barb fitting8. O–ring9. O–ring10. 90 o hydraulic fitting 11. O–ring12. O–ring 13. 90...

Reelmaster 3550−D Hydraulic System Page 4 − 84 Installation (Fig. 52) 1. If fittings were removed from gear pump, lubricateand place new O−rings onto fittings. Install fittings intopump openings using marks made during the removalprocess to properly orientate fittings. Tighten fittings(see Hydraulic...

Reelmaster 3550−D Hydraulic System Page 4 − 86 Gear Pump Service 1. Front cover 2. Pressure seal 3. Back−up gasket 4. Front thrust plate5. Idler gear 6. Drive shaft 7. Rear thrust plate 8. Dowel pin 9. Seal10. Body11. Seal12. Splined connecting shaft13. Pressure seal14. Back−up gasket 15. Front thru...

Reelmaster 3550−D Hydraulic System Page 4 − 87 IMPORTANT: Use caution when clamping gearpump in a vise to avoid distorting any pump compo-nents. 3. Secure the front cover of the pump in a vise with thedrive shaft pointing down. 4. Loosen the four (4) cap screws that secure pump as-sembly. 5. Remove ...

Reelmaster 3550−D Hydraulic System Page 4 − 88 Front Wheel Motors 1. Lock nut 2. Spacer3. Socket head screw4. Hydraulic wheel motor 5. Frame6. Hydraulic tube 7. Hydraulic tube 8. O–ring 9. Hydraulic fitting 10. O–ring11. Brake bracket Figure 56 FRONT RIGHT 5 1 68 9 10 7 8 9 4 2 11 10 3 NOTE: The lef...

Reelmaster 3550−D Hydraulic System Page 4 − 90 Rear Wheel Motor 1. Lug nuts (4)2. Rear wheel assembly3. Lock nut 4. Wheel hub 5. Wheel stud (4) 6. Lock nut (4)7. Rear wheel motor8. Socket head screw (4)9. Rear fork 10. Woodruff key 11. O−ring (2)12. Elbow fitting (2)13. O−ring (2)14. Hydraulic hose1...

Reelmaster 3550−D Hydraulic System Page 4 − 91 Removal (Fig. 57) 1. Park machine on a level surface. Lower cutting units,stop engine and engage parking brake. Remove keyfrom the ignition switch. WARNING Before jacking up the machine, review and followJacking Instructions in Chapter 1 − Safety. 2. Ja...

Reelmaster 3550−D Hydraulic System Page 4 − 92 Wheel Motor Service 1. Dirt seal 2. Bearing3. Housing4. Back−up washer 5. Seal ring 6. Back−up washer 7. Inner seal 8. Thrust washer 9. Thrust bearing 10. Bearing11. Coupling shaft12. Thrust bearing13. Drive link14. Cap screw15. Commutator seal16. Commu...

Reelmaster 3550−D Hydraulic System Page 4 − 94 Cutting Unit Reel Motor 1. O−ring2. Elbow fitting 3. Straight fitting 4. O−ring 5. Hydraulic hose (Inlet)6. Hydraulic hose (return)7. O−ring8. Straight fitting 9. Elbow fitting 10. O−ring11. Hydraulic hose (case drain) Figure 59 FRONT RIGHT 10 4 2 #1 #5...

Reelmaster 3550−D Hydraulic System Page 4 − 95 Removal 1. Park the machine on a level surface, engage parkingbrake, lower cutting units and stop engine. Remove keyfrom the ignition switch. 2. Read the General Precautions for Removing andInstalling Hydraulic System Components in this chapter. 3. Labe...

Reelmaster 3550−D Hydraulic System Page 4 − 96 Cutting Unit Reel Motor Service 1. Dust seal 2. Retaining ring 3. Backup washer 4. Shaft seal 5. Front flange 6. Dowel pin (2) 7. O–ring8. Pressure seal (outer)9. Backup gasket (outer)10. Wear plate (outer)11. Drive gear12. Idler gear 13. Wear plate (in...

Reelmaster 3550−D Hydraulic System Page 4 − 97 IMPORTANT: Note position of the open and closedside of the wear plates before removing. Identifywear plates (inner and outer, drive gear and idlergear) with a marker for proper assembly. IMPORTANT: Mark the relative positions of the gearteeth so they ca...

Reelmaster 3550−D Hydraulic System Page 4 − 98 Assembly (Fig. 61) 1. Lubricate O–rings, pressure seals, back−up gasketsand wear plate grooves with a thin coat of petroleum jel-ly. Lubricate all other internal parts freely with clean hy-draulic fluid. 2. Install new seals into front flange (Fig. 63):...

Reelmaster 3550−D Hydraulic System Page 4 − 100 Mow Control Manifold 1. Mow control manifold2. Hydraulic tube 3. Hydraulic tube 4. Hydraulic tube 5. Hydraulic hose 6. Hydraulic tube 7. Hydraulic tube 8. Straight hydraulic fitting (3)9. O−ring10. O−ring11. 90 o hydraulic fitting 12. O−ring13. O−ring1...

Reelmaster 3550−D Hydraulic System Page 4 − 101 Removal (Fig. 65) The ports on the mow control manifold are marked foreasy identification of components. Example: PRV is theproportional relief valve and P is the supply port (see Hy-draulic Schematic to identify the function of the hydrauliclines and ...

Reelmaster 3550−D Hydraulic System Page 4 − 102 Mow Control Manifold Service 1. Mow control manifold2. Coil nut 3. SAE #4 plug with O−ring (17)4. SAE #6 plug with O−ring (4)5. Orifice plug (0.020) (port OR2)6. Orifice (0.050) (port OR1)7. Zero leak #4 plug with O−ring8. Spring pin (2)9. Check valve ...

Reelmaster 3550−D Hydraulic System Page 4 − 105 Backlap Spool (Fig. 68) 1. To remove backlap spool from manifold: A. Remove backlap switch from manifold before re-moving backlap spool. Remove ball from manifoldport after switch is removed. Remove and discardO−ring from switch. B. Remove lower retain...

Reelmaster 3550−D Hydraulic System Page 4 − 106 Lift Control Manifold 1. Mow control manifold2. Flange head screw (2 used)3. Hydraulic hose 4. Hydraulic hose 5. Hydraulic tube (to rear bulkhead) 6. Hydraulic tube (to rear bulkhead)7. Hydraulic hose (RH lift cylinder)8. Hydraulic hose (RH lift cylind...

Reelmaster 3550−D Hydraulic System Page 4 − 107 Removal (Fig. 69) The ports on the lift control manifold are marked for easyidentification of components. Example: S1 is the sole-noid valve and P is the supply port (see Hydraulic Sche-matic to identify the function of the hydraulic lines andcartridge...

Reelmaster 3550−D Hydraulic System Page 4 − 108 Lift Control Manifold Service 1. Lift control manifold2. Dust cover 3. SAE #4 plug with O−ring (2)4. Relief valve (RV1)5. Solenoid valve (S1)6. Solenoid valve (S2)7. Solenoid valve (S3 and S4) 8. Solenoid coil (4)9. Coil spacer (2)10. Orifice (0.035) (...

Reelmaster 3550−D Hydraulic System Page 4 − 110 Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re-moving the cartridge valve from the control manifold. 2. If cartridge valve is solenoid operated, remove nutsecuring solenoid coil to the cartridge valve. Car...

Reelmaster 3550−D Hydraulic System Page 4 − 112 Steering Control Valve 1. Steering arm 2. Flange nut (4)3. Flange head screw (4)4. Steering valve bracket5. Cap screw (2)6. Pivot hub (2)7. Steering valve cover8. Washer head screw (5)9. Tilt steering boss10. Ball knob11. Steering tilt lever 12. Steeri...

Reelmaster 3550−D Hydraulic System Page 4 − 114 Steering Control Valve Service 1. Sleeve2. Cross pin 3. Ring4. Spool5. Bearing assembly 6. Shaft seal 7. Ball stop 8. Ball 9. Dust seal ring10. Housing11. Cardan shaft12. Spacer13. O–ring14. Distribution plate15. Inner gearwheel 16. Outer gearwheel17. ...

Reelmaster 3550−D Hydraulic System Page 4 − 116 Steering Cylinder Figure 75 FRONT RIGHT 1. Hydraulic hose 2. Hydraulic hose 3. O−ring (2) 4. Hydraulic fitting (2) 5. O−ring (2) 6. Steering cylinder 7. Ball joint 8. Retaining ring 9. Jam nut (4)10. Frame11. Rear fork12. Rear casting 8 9 12 11 9 1 8 7...

Reelmaster 3550−D Hydraulic System Page 4 − 117 Removal (Fig. 75) 1. Park machine on a level surface. Lower cutting units,stop engine and engage parking brake. Remove keyfrom the ignition switch. NOTE: The rear tire must be removed to allow sufficientclearance to remove the steering cylinder from th...

Reelmaster 3550−D Hydraulic System Page 4 − 118 Steering Cylinder Service 1. Barrel with clevis2. Lock nut 3. Piston seal 4. Piston 5. O−ring6. O−ring7. Back−up ring 8. Head 9. Head seal 10. Dust seal11. Internal collar12. Rod Figure 76 40 ft−lb (54 N−m) 2 3 4 5 8 9 10 11 1 6 7 12 2 3 4 5 8 9 10 11 ...

Reelmaster 3550−D Hydraulic System Page 4 − 119 Disassembly (Fig. 76) 1. Remove oil from the steering cylinder into a drain panby slowly pumping the cylinder rod. Plug both ports andclean the outside of the cylinder. IMPORTANT: Prevent damage when clamping thesteering cylinder into a vise; clamp on ...

Reelmaster 3550−D Hydraulic System Page 4 − 120 Front Lift Cylinders 1. #1 lift arm2. #5 lift arm3. #4 lift arm4. Recessed bumper (3)5. Flange head screws (3)6. Cylinder pin (2)7. Pivot pin (2) 8. Washer head screw (2)9. Lift cylinder 10. Thrust washer11. Lynch pin12. Cylinder pin13. Thrust washer (...

Reelmaster 3550−D Hydraulic System Page 4 − 121 Removal (Fig. 77) 1. Park machine on a level surface. Lower cutting units,stop engine and engage parking brake. Remove keyfrom the ignition switch. 2. Read the General Precautions for Removing andInstalling Hydraulic System Components in this chapter. ...

Reelmaster 3550−D Hydraulic System Page 4 − 122 Rear Lift Cylinders 1. #2 lift arm2. #3 lift arm3. Pin (2) 4. Washer head screw (4)5. Rear lift cylinder (2) 6. Pin (2) 7. Cylinder pin (2)8. Thrust washer (4)9. Retaining ring (4)10. Grease fitting (2) 11. RH torsion spring12. LH torsion spring13. O−r...

Reelmaster 3550−D Hydraulic System Page 4 − 124 Lift Cylinder Service 1. Barrel2. Lock nut 3. Wear ring 4. Piston5. Seal 6. O−ring7. Head8. O−ring9. Back−up ring 10. Seal 11. Dust seal12. Retaining ring13. Rod (cutting units #1, #2 and #3)14. Rod (cutting units #4 and #5) Figure 79 2 3 6 8 9 10 11 1...

Reelmaster 3550−D Hydraulic System Page 4 − 125 Disassembly (Fig. 79) 1. Remove oil from the lift cylinder into a drain pan byslowly pumping the cylinder rod. Plug both ports andclean the outside of the cylinder. IMPORTANT: Prevent damage when clamping thecylinder in a vise; clamp on the clevis only...

Reelmaster 3550−D Page 5 − 1 Electrical System Chapter 5 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Toro Electronic Controllers (TEC) 2 . . . . . . . . . . . . . CAN−bus C...

Reelmaster 3550−D Page 5 − 3 Electrical System Electrical Schematic The electrical schematic and wiring diagrams for the Re-elmaster 3550−D are located in Chapter 9 − FoldoutDrawings in this manual. Electrical System

Reelmaster 3550−D Page 5 − 4 Electrical System Special Tools Order special tools from your Toro distributor. Sometools may also be available from a local supplier. Multimeter The multimeter can test electrical components and cir-cuits for current (amps), resistance (ohms) or voltage.Obtain this tool...

Reelmaster 3550−D Page 5 − 5 Electrical System Terminal Protector Aerosol spray that should be used on battery terminals,ring terminals, and fork terminals to reduce corrosionproblems. Apply battery terminal protector to the con-nection after the battery cable, ring terminal, or fork ter-minal has b...

Reelmaster 3550−D Page 5 − 6 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings andwatches, before doing any electrical trouble-shooting or testing. Disconnect the batterycables unless the test requires battery voltage. For effective troubleshooting and repairs, there mus...

Reelmaster 3550−D Page 5 − 8 Electrical System Clearing Fault Codes After fault codes have been retrieved, clearing of thosefaults can be completed using the following switch se-quence: 1. Place machine switches in fault retrieval (see Re-trieving Fault Codes in this chapter). The diagnostic lightsh...

Reelmaster 3550−D Page 5 − 9 Electrical System Diagnostic Display Reelmaster 3550−D machines are equipped with a ToroElectronic Controller (TEC) which controls machineelectrical functions. The controller monitors various in-put switches (e.g. ignition switch, seat switch, neutralswitch) and energize...

Reelmaster 3550−D Page 5 − 14 Electrical System Starting Problems Problem Possible Causes Nothing happens when start attempt is made. NOTE: If high engine coolant temperature (above240 ° F (116 ° C)) causes the engine to stop, the engine can be restarted for ten (10) seconds to allow themachine to b...

Reelmaster 3550−D Page 5 − 16 Electrical System General Run and Transport Problems Problem Possible Causes Engine stops during operation (operator sitting onseat). Operator not in center of seat (seat switch is notdepressed). Fuel tank is empty. Machine is being operated on a slope with a low fuelle...

Reelmaster 3550−D Page 5 − 17 Electrical System 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 − Hydra...

Reelmaster 3550−D Page 5 − 18 Electrical System Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between thebattery terminals. Set multimeter to the DC volts setting. The batteryshould be at a temperature of 60 ° to 100 ° F (16 ° to 38 ° C). The...

Reelmaster 3550−D Page 5 − 19 Electrical System Check Operation of Interlock Switches CAUTION Do not disconnect safety switches. They are forthe operator’s protection. Check the operation ofthe interlock switches daily for proper operation.Replace any malfunctioning switches before op-erating the ma...

Reelmaster 3550−D Page 5 − 20 Electrical System Component Testing For accurate resistance and/or continuity checks, elec-trically disconnect the component being tested from thecircuit (e.g. unplug the ignition switch connector beforechecking continuity on the switch terminals). NOTE: For engine comp...

Reelmaster 3550−D Page 5 − 21 Electrical System Main Power Relay The main power relay is secured to the control panel as-sembly next to the operator seat (Fig. 15). This relay isattached to the wire harness with a four (4) wire connec-tor (Fig. 16). The relay can be accessed by removing thecontrol p...

Reelmaster 3550−D Page 5 − 22 Electrical System Fuses The fuse blocks are located under the control panel cov-er on the right side of the machine. Fuse Identification and Function Use the fuse decal (Fig.17) and fuse block (Fig. 18) toidentify each individual fuse and its correct amperage.The fuses ...

Reelmaster 3550−D Page 5 − 23 Electrical System Fusible Links The Reelmaster 3550−D uses four (4) fusible links forcircuit protection. Three (3) of the fusible links are lo-cated in a single harness that connects the starter B+terminal to the main wire harness (Fig. 19). The fusiblelinks in this har...

Reelmaster 3550−D Page 5 − 24 Electrical System Toro Electronic Controller (TEC) The Reelmaster 3550−D uses a Toro Electronic Control-ler (TEC) to monitor the condition of various switches(inputs) and directs power to a variety or outputs to con-trol certain machine functions. The controller is loca...

Reelmaster 3550−D Page 5 − 26 Electrical System Parking Brake Switch The parking brake switch is a normally closed proximityswitch that is located on the control console (Fig. 25).The sensing plate that opens the switch is the parkingbrake lever. When the parking brake is applied, the parking brakel...

Reelmaster 3550−D Page 5 − 27 Electrical System Neutral Switch The neutral switch is a normally open proximity switchthat closes when the traction pedal is in the neutral posi-tion. The neutral switch is located under the floor plate(Fig. 26). The TEC controller monitors the position of the neutrals...

Reelmaster 3550−D Page 5 − 28 Electrical System Lower/Raise Joystick Switches The cutting unit raise and lower switches are located onthe joystick assembly that is attached to the control pan-el. The rear switch is used to lower the cutting units andthe front switch to raise them (Fig. 27). The swit...

Reelmaster 3550−D Page 5 − 29 Electrical System Reel Enable/Disable Switch The enable/disable switch is located on the controlpanel (Fig. 29). This switch is pulled out to engage thecutting units and pushed in to disengage the cuttingunits. The TEC controller monitors the position of the enable/disa...

Reelmaster 3550−D Page 5 − 30 Electrical System Mow/Transport Switch The switch used for the mow/transport slide is a nor-mally closed switch. The switch opens when the mow/transport slide is in the transport position. The switch islocated under the floor plate (Fig 32). The TEC controller monitors ...

Reelmaster 3550−D Page 5 − 31 Electrical System Seat Switch The seat switch is normally open and closes when theoperator seat is occupied. The seat switch is located dir-ectly under the seat. The TEC controller monitors the position of the seatswitch (open or closed). Using inputs from the seatswitc...

Reelmaster 3550−D Page 5 − 32 Electrical System Backlap Switch The backlap switch is a normally open ball switch that isin the normal, open state when the backlap lever is in themow position. When the backlap lever is in the backlapposition, the switch closes. The backlap switch is at-tached to the ...

Reelmaster 3550−D Page 5 − 33 Electrical System Engine Temperature Sender The engine temperature sender is located above the al-ternator, in the thermostat housing (Fig. 35). The resist-ance of the temperature sender reduces as the enginecoolant temperature increases. The TEC controller uses input f...

Reelmaster 3550−D Page 5 − 34 Electrical System 6. Replace temperature sender if specifications are notmet. 7. Install temperature sender to the thermostat hous-ing. A. Clean threads of water flange and temperaturesender thoroughly. Apply thread sealant to thethreads of the sender. B. Screw sender i...

Reelmaster 3550−D Page 5 − 35 Electrical System Start Relay The start relay is secured to the control panel assemblynext to the operator seat (Fig. 37). This relay is attachedto the wire harness with a five (5) wire connector(Fig. 38). The relay can be accessed by removing thecontrol panel cover. Th...

Reelmaster 3550−D Page 5 − 37 Electrical System Fuel Stop Solenoid The fuel stop solenoid must be energized for the dieselengine to run. The solenoid is mounted to the injectionpump on the engine (Fig. 39). The fuel stop solenoid includes two coils for operation:the pull coil and the hold coil. The ...

Reelmaster 3550−D Page 5 − 38 Electrical System Fuel Pump The fuel pump is attached to the left side of the enginenear the fuel/water separator (Fig. 41). The TEC controller energizes and monitors the opera-tion of the fuel pump when specific input conditions aremet. The fuel pump is energized when ...

Reelmaster 3550−D Page 5 − 39 Electrical System Glow Relay The glow relay is secured to the control panel assemblynext to the operator seat (Fig. 42). This relay is attachedto the wire harness with a four (4) wire connector(Fig. 43). The relay can be accessed by removing thecontrol panel cover. The ...

Reelmaster 3550−D Page 5 − 41 Electrical System Hydraulic Solenoid Valve Coils The Reelmaster 3550−D hydraulic control manifoldsuse several hydraulic solenoid valve coils for systemcontrol. The lift manifold includes four (4) solenoidvalves (S1, S2, S3, and S4). The mow manifold includesa single sol...

Reelmaster 3550−D Page 5 − 43 Electrical System Indicator Lights 1. Diagnostic light 2. Glow plug indicator3. High temp warning 4. Engine oil pressure5. Charge indicator Figure 46 5 2 3 4 1 Diagnostic Light When the ignition switch is moved to the RUN positionand the machine electrical system is fun...

Reelmaster 3550- D Page 5 - 44 Electrical System 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 de- signed, twisted cables form the bus for the network used on the ...

Reelmaster 3550−D Page 5 − 45 Electrical System Oil Pressure Switch The engine oil pressure switch is located on the enginebelow the alternator (Fig. 50). The oil pressure switch isa normally closed switch that opens with pressure. Theoil pressure switch should open at approximately 8 PSI(0.56 kg/cm...

Reelmaster 3550−D Page 5 − 46 Electrical System Worklight Switch The worklight switch is located on the control panel(Fig. 51). This rocker switch allows the worklights(headlights) to be turned on and off. Testing 1. Park machine on level surface, lower cutting units,stop engine, apply parking brake...

Reelmaster 3550−D Page 5 − 47 Electrical System Service and Repairs NOTE: For engine component repair information, seethe 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 BatteryServic...

Reelmaster 3550−D Page 5 − 48 Electrical System Battery Service The battery is the heart of the electrical system. Withregular and proper service, battery life can be extended.Additionally, battery and electrical component failurecan be prevented (see Battery Storage and BatteryCare in this chapter)...

Reelmaster 3550−D Page 5 − 49 Electrical System Battery Testing 1. Conduct a hydrometer test of the battery electrolyte. IMPORTANT: Make sure the area around the cells isclean before opening the battery caps. A. Measure the specific gravity of each cell with ahydrometer. Draw electrolyte in and out ...

Reelmaster 3550−D Page 5 − 50 Electrical System Battery Charging To minimize possible damage to the battery and allowthe battery to be fully charged, the slow charging meth-od is presented here. This charging method can be ac-complished with a constant current battery chargerwhich is available in mo...

Reelmaster 3550−D Page 5 − 51 Electrical System Cartridge Valve Coil Replacement The solenoid valve coil on the hydraulic control manifold(Fig. 54) can be replaced without opening the hydraulicsystem. Removal 1. Park machine on a level surface, lower cuttingdecks, engage parking brake, stop engine a...

Reelmaster 3550−D Page 5 − 52 Electrical System Worklight Bulb Replacement The worklights are adjustable left and right, and up anddown as necessary. The worklights use a replaceablehalogen bulb. CAUTION The worklights use a halogen bulb that becomesextremely hot when in operation. Handling a hotbul...

Reelmaster 3550−D Page 6 − 1 Chassis Chapter 6 Chassis Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust...

Reelmaster 3550−D Page 6 − 2 Chassis Specifications Item Description Tire pressure 12 PSI (96 kPa) Wheel lug nut torque 70 to 90 ft−lb (95 to 122 N−m) Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the w...

Reelmaster 3550−D Page 6 − 3 Chassis Adjustments Adjust Brakes CAUTION Before and after adjusting the brakes, alwayscheck the brakes in a wide open area that is flatand free of other persons and obstructions. 1. Check brake adjustment as follows: A. Park machine on a level surface, lower cuttingunit...

Reelmaster 3550−D Page 6 − 4 Chassis Service and Repairs Operator Seat 1. Bottom cushion 2. Back cushion 3. Seat belt 4. Flat washer 5. Flat washer 6. Cap screw 7. Bottom cover 8. Armrest kit 9. Back cover 10. Seat switch11. Adjusting track − RH12. Track − LH13. Support strap14. Flange nut15. Knob k...

Reelmaster 3550−D Page 6 − 6 Chassis Front Wheels and Brakes Figure 5 FRONT RIGHT Antiseize Lubricant 70 to 90 ft−lb (95 to 122 N−m) 250 to 275 ft−lb (339 to 372 N−m) 1. Hydraulic wheel motor (LH shown)2. Brake drum 3. Socket head screw (4 per motor)4. Brake bracket 5. Lock nut (4 per motor)6. Wheel...

Reelmaster 3550−D Page 6 − 10 Chassis Rear Fork and Wheel 1. Cap screw 2. Thrust washer 3. Lock washer 4. Flange bushing (2)5. Rear casting 6. Rear fork 7. Socket head screw (4) 8. Plug9. Ball joint (2)10. Retaining ring (2)11. Grease fitting12. Hydraulic steering cylinder13. Wheel motor14. Lock nut...

Reelmaster 3550−D Page 6 − 11 Chassis Removal (Fig. 7) 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove hood from the machine. WARNING Before jacking up the machine, review and followJacking Instructions in C...

Reelmaster 3550−D Page 6 − 12 Chassis Brake Lever Linkages 1. Pop rivet (4)2. Control panel cover3. Cover bracket (2)4. Magnetic catch (2)5. Hex washer head screw (4)6. Strike bracket (2)7. Lever assembly 8. Lock nut 9. Parking brake spacer10. Cap screw11. Flat washer 12. Cotter pin13. Clevis pin14....

Reelmaster 3550−D Page 6 − 13 Chassis 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove control panel cover from the machine. IMPORTANT: When removing the adjustable clevis,adjustment rod, or the brake lever, ...

Reelmaster 3550−D Page 6 − 14 Chassis Steering Column 1. Steering arm 2. Flange nut 3. Flange head screw (2)4. Steering valve bracket5. Cap screw (2)6. Pivot hub (2)7. Steering cover 8. Cap screw (5)9. Ball knob 10. Steering tilt lever11. Steering control valve12. Tilt bracket13. Cap screw 14. Flat ...

Reelmaster 3550−D Page 6 − 16 Chassis Front Lift Arms 1. Pivot yoke (3)2. Thrust washer (2 per yoke)3. Flange bushing (2 per lift arm)4. Lynch pin (3)5. Retaining ring (2 per pin)6. Thrust washer (2 per pin)7. Pin (3) 8. Flange head screw (3)9. Recessed bumper (3)10. Flange bushing (2 per lift arm)1...

Reelmaster 3550−D Page 6 − 17 Chassis Removal (Fig. 11) 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove cutting units (see Chapter 7 − Cutting Unitsin this manual). 3. Remove lynch pin and thrust washer secu...

Reelmaster 3550−D Page 6 − 18 Chassis Rear Lift Arms 1. Pivot yoke (2)2. Thrust washer (2 per pivot yoke)3. Flange bushing (2 per lift arm)4. Lynch pin (2)5. Flange bushing (2 per lift arm)6. #3 lift arm7. #2 lift arm8. Retaining ring (2 per pin) 9. Thrust washer (2 per pin)10. Pin (2)11. Counterbal...

Reelmaster 3550−D Page 6 − 19 Chassis Removal (Fig. 12) 1. Park machine on a level surface, lower cutting units,stop engine, engage parking brake, and remove keyfrom the ignition switch. 2. Remove cutting units (see Chapter 7 − Cutting Unitsin this manual). 3. Remove lynch pin and thrust washer secu...

Reelmaster 3550−D Cutting Units Page 7 − 1 Chapter 7 Cutting Units Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Cutting Unit Operator’s Manual 3 . . . . . . . . . . . . . . . Cutting Unit Re...

Reelmaster 3550−D Cutting Units Page 7 − 3 General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa-tion regarding the operation, general maintenance andmaintenance intervals for the cutting units on your Reel-master machine. Additionally, if optional ki...

Reelmaster 3550−D Cutting Units Page 7 − 4 Cutting Unit Installation IMPORTANT: When installing cutting unit to ma-chine, make sure that turf compensator spring ismounted on the same side of the cutting unit as thehydraulic reel drive motor. Also, make sure that cut-ting unit is installed on machine...

Reelmaster 3550−D Cutting Units Page 7 − 5 Special Tools Special tools are available from your Toro Distributor.Some tools may have been supplied with your machineor are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108−6715 Use gauge bar to verify height−of−cut adjustment. Figure 7 ...

Reelmaster 3550−D Cutting Units Page 7 − 6 Bedknife Screw Tool Toro Part Number: TOR510880 This screwdriver−type bit is made to fit Toro bedknife at-taching screws. Use this bit with a torque wrench to se-cure the bedknife to the bedbar. IMPORTANT: To prevent damage to the bedbar, DONOT use an air o...

Reelmaster 3550−D Cutting Units Page 7 − 7 Spline Insert Tool Toro Part Number: TOR4112 (8 tooth) Use the spline insert tool for rotating the cutting reelwhen hydraulic motor is removed. Also, use this tool forinstallation of threaded inserts into the cutting reel shaft. Figure 13 Roller Rebuild Kit...

Reelmaster 3550−D Cutting Units Page 7 − 8 Turf Evaluator Tool Toro Model Number: 04399 Many turf discrepancies are subtle and require closerexamination. In these instances, the Turf Evaluatorgrass viewing tool is helpful. It can assist turf managersand service technicians in determining causes for ...

Reelmaster 3550−D Cutting Units Page 7 − 9 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un-satisfactory quality of cut, some of which may be turfconditions. Turf conditions such as excessive thatch,“sponginess” or attempting to cut off too much gra...

Reelmaster 3550−D Cutting Units Page 7 − 11 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 sectionof this chapter. Refer to Cutting Unit Operato...

Reelmaster 3550−D Cutting Units Page 7 − 13 Set Up and Adjustments Characteristics CAUTION Never install or work on the cutting units or liftarms with the engine running. Always stop en-gine and remove key first. The dual knob bedknife−to−reel adjustment system in-corporated in this cutting unit sim...

Reelmaster 3550−D Cutting Units Page 7 − 14 Leveling Rear Roller The precision machined components of the cutting unitframe keep the rear roller and cutting reel in alignment(parallel). If the side plates are disassembled or as thecutting reel wears, a limited amount of side plate adjust-ment is pos...

Reelmaster 3550−D Cutting Units Page 7 − 17 Backlapping DANGER TO AVOID PERSONAL INJURY OR DEATH: D Never place hands or feet in the reel area while the engine is running. Stay away from thecutting reels when backlapping. D When backlapping, run engine at idle speed only. D While backlapping, the re...

Reelmaster 3550−D Cutting Units Page 7 − 18 Bedbar Assembly 1. Side plate 2. Rubber bushing (2)3. Flange bushing (2)4. Plastic washer (4)5. Metal washer (2)6. Bedbar pivot bolt (2)7. Lock nut (2) 8. Screw (8) 9. Bedknife10. Bedbar11. Frame12. Bedbar adjuster shaft (2)13. Wave washer (2)14. Flange bu...

Reelmaster 3550−D Cutting Units Page 7 − 19 Bedbar Removal (Fig. 23) 1. Position machine on a clean and level surface, lowercutting units, stop engine, engage parking brake and re-move key from the ignition switch. 2. Remove the cutting unit from the machine. Use thecutting unit kickstand to support...

Reelmaster 3550−D Cutting Units Page 7 − 20 Bedbar Adjuster Service Figure 25 1. Bedbar assembly 2. Bedbar adjuster shaft3. Wave washer 4. Flange bushing (2)5. Flat washer 6. Lock nut 7. Bedbar adjuster screw8. Washer9. Compression spring 10. Lock nut11. Cap screw12. Detent13. Frame FRONT RIGHT 14 t...

Reelmaster 3550−D Cutting Units Page 7 − 22 Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re-moval in this chapter. NOTE: 18” cutting units use 6 screws to secure bed-knife to bedbar. 22” cutting units use 8 screws to securebedknife to bedbar. 2. R...

Reelmaster 3550−D Cutting Units Page 7 − 23 Bedknife Grinding Since there can be variations in the mounting surface ofthe bedbar, a new bedknife will not be perfectly flat afterit is installed to the bedbar. Because of this, it is neces-sary to grind a new bedknife after installing it to the bed-bar...

Reelmaster 3550−D Cutting Units Page 7 − 24 Reel Assembly 1. Cutting reel 2. Frame3. Bedbar assembly 4. RH side plate5. LH side plate6. O−ring (2) 7. Weight8. Flange nut (4)*9. Wire Spring 10. Cap screw (4)*11. Threaded insert (4) 12. Flange head screw (4)13. O−Ring (2)14. Relief valve (2)15. Plug16...

Reelmaster 3550−D Cutting Units Page 7 − 25 1. Frame2. LH side plate3. RH side plate4. Shoulder bolt (4)5. Carrier frame 6. Flange head screw (2) 7. Flange bushing (2)8. Rear grass shield9. Spacer (2) 10. Shim (as required)*11. Flange nut (2) 12. Flange nut (4)13. Special screw14. Flat washer15. Cap...

Reelmaster 3550−D Cutting Units Page 7 − 28 Reel Assembly Service 1. Cutting reel 2. Threaded insert (RH thread)3. Plastic plug 4. Retaining ring 5. Special washer 6. Flocked seal 7. Sealed bearing 8. Threaded insert (LH thread) 9. Groove indicating LH threads10. Reel spider11. Retaining ring groove...

Reelmaster 3550−D Cutting Units Page 7 − 29 Assembly of Cutting Reel (Fig. 35) 1. If flocked seals and/or bearings were removed fromreel shaft, discard removed components and replace. 2. Make sure that the retaining ring is fully seated intothe groove on the cutting reel shaft. 3. Install special wa...

Reelmaster 3550- D Cutting Units Page 7 - 30 Preparing Reel for Grinding Presently, the Reelmaster 3550- D machines use scal- loped 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. Befor...

Reelmaster 3550−D Cutting Units Page 7 − 31 Front Roller Removal (Fig. 40) 1. Position machine on a clean and level surface, lowercutting units, stop engine, engage parking brake and re-move key from the ignition switch. 2. Remove the cutting unit from the machine and placeon a level working surface...

Reelmaster 3550−D Cutting Units Page 7 − 32 Rear Roller Removal (Fig. 41) 1. Position machine on a clean and level surface, lowercutting units, stop engine, engage parking brake and re-move key from the ignition switch. 2. Remove the cutting unit from the machine and placeon a level working surface....

Reelmaster 3550−D Cutting Units Page 7 − 33 Roller Service Disassembly (Fig. 42) 1. Remove bearing lock nut from each end of rollershaft. 2. Loosely secure roller assembly in bench vise andlightly tap one end of roller shaft until outer seals andbearing are removed from opposite end of roller tube.R...

Reelmaster 3550−D Cutting Units Page 7 − 37 NOTE: Drive components for the rear roller brush arelocated on the opposite side of the cutting unit from thecutting reel hydraulic motor. Figure 48 shows compo-nents used when the brush drive is on the left side of thecutting unit. NOTE: The Installation ...

Reelmaster 3550−D Groomer Page 8 − 1 Chapter 8 Groomer (Optional) Table of Contents GROOMING PERFORMANCE 2 . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Groomer Reel Mechanical Problems 3 . . . . . . . . . . . SERVICE AND REPAIRS 4 . . . . . ...

Reelmaster 3550−D Groomer Page 8 − 2 Grooming Performance There are a number of factors that can affect the per-formance of grooming. These factors vary for differentgolf courses and from fairway to fairway. It is importantto inspect the turf frequently and vary the groomingpractice with turf needs....

Reelmaster 3550−D Groomer Page 8 − 3 Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to beadjusted. Seized groomer reel or idler bear-ing(s) in groomer side plate(s). Broken or damaged idler spring. The...

Reelmaster 3550−D Groomer Page 8 − 4 Service and Repairs CAUTION Never work on the groomer with the enginerunning. Always stop the engine, remove thekey from the ignition switch and wait for allmachine movement to stop before working onthe groomer. NOTE: The Groomer Operator’s Manual provides in-for...

Reelmaster 3550−D Groomer Page 8 − 6 Groomer Plate Assembly Figure 3 1. Groomer reel 2. Pulley spacer 3. Washer (as required)4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw (4)8. Idler plate 9. Idler pulley assembly10. Lock nut 11. Flange head screw12. Drive pulley13. Retaining rin...

Reelmaster 3550−D Groomer Page 8 − 8 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 andcarefully position non−drive side groomer plate ontogroomer shaft and slide to cutting unit. B. Apply antisieze lubricant to the o...

Reelmaster 3550−D Groomer Page 8 − 10 Groomer Reel 1. Groomer reel 2. Pulley spacer 3. Washer (as required)4. Square key 5. Driven pulley 6. Flange nut 7. Socket head screw (4)8. Idler plate 9. Idler pulley assembly10. Lock nut 11. Flange head screw12. Drive pulley13. Retaining ring14. Extension spr...

Reelmaster 3550−D Groomer Page 8 − 12 Groomer Reel Service Inspect groomer reel blades frequently for damage andwear. Straighten bent blades. Either replace wornblades or reverse the blades to put the sharpest bladeedge forward (Fig. 9). Blades that are rounded to themidpoint of the blade tip must b...

Reelmaster 3550−D Groomer Page 8 − 13 5. If groomer reel is equipped with broomer kit: A. Slide a brush into each groove around the fulllength of the groomer reel (Fig. 11). Make surebrushes are seated in groomer blade slots (Fig. 12) B. Loosely wrap the straps around the groomer reelshaft and brush...

Reelmaster 3550−D Groomer Page 8 − 14 Height Adjuster Assembly Figure 13 1. Groomer plate (LH drive shown)2. Shoulder bolt 3. Ball joint rod 4. Jam nut 5. Compression spring 6. Flange head screw7. Lower ramp 8. External snap ring9. Upper ramp 10. Bushing 11. Flat washer12. Groomer adjuster13. Detent...

Reelmaster 3550- D Foldout Drawings Page 9 - 1 Chapter 9 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS 2 . . . . . . . HYDRAULIC SCHEMATIC 3 . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATIC 4 . . . . . . . . . . . . . . . . . . . . WIRE HARNESS DIAGRAM 5 . . . . . ...

Reelmaster 3550- D Foldout Drawings Page 9 - 2 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 ...

Page 8 − 5 Harness Diagram Reelmaster 3550−D BLACK BLACK BLACK BLACK RED BLACK BLACK BLACK BLACK BLACK BROWN BROWN BLACK BLACK PINK GRA Y BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE BLACK/WHITE RED/WHITE BLACK BROWN GREEN YELLOW BLACK BLUE BLACK ORANGE BLUE ORANGE GRA Y VIOLET GREEN GRA Y TA N WHITE...