Page 1 Form No. 15213SL Rev H Reelmaster ® 3550−D/3555−D/3575−D Original Instructions (EN)
Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
Page 4 NOTES...
Page 5 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. EThe Toro Company - - 2015, 2016, 2018, 2019, 2020...
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Page 7: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System General Safety Instructions ....1 -- 2 General Information .
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Page 9 Chapter 1 Safety Table of Contents GENERAL SAFETY INSTRUCTIONS ... . Before Operating ......While Operating .
Page 10: General Safety Instructions
General Safety Instructions The Reelmaster has been tested and certified by Toro for compliance with existing safety standards and speci- WARNING fications. Although hazard control and accident preven- tion partially are dependent upon the design and To reduce the potential for injury or death, configuration of the machine, these factors are also de- comply with the following safety instructions.
Page 11: Maintenance And Service
Toro replacement parts and sult. accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance 7.
Page 12: Jacking Instructions
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 to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine.
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Reelmaster 3550−D/3555−D/3575−D...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm...
Page 18: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
Page 19 Chapter 3 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Kubota Workshop Manual .
Page 20: Specifications
Specifications Item Description Make / Designation Kubota Model D1105−E3B 4−Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.5 in (1123 cc) Firing Order 1 (fan end) − 2 − 3 (flywheel end) Compression Ratio 22.0:1 Direction of Rotation...
Page 21: General Information
Most repairs and adjustments require tools which are Distributor. If no parts list is available, be prepared to commonly available in many service shops. Special provide your distributor with the Toro model and serial tools are described in the Kubota Workshop Manual: 05 number.
Page 22: Service And Repairs
Service and Repairs Air Cleaner and Muffler Figure 2 1. Exhaust guard 8. Lock washer 15. Burp (Actuator) valve 9. Exhaust gasket 16. Mounting band assembly 2. Cap screw 3. Muffler 10. Hose clamp 17. Shoulder bolt 4. Flange head screw 11.
Page 23 Check Air Filter, Filter Cover, & Burp Valve The air cleaner body, air filter, filter cover, and burp valve should be checked daily, prior to operation. IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation.
Page 24: Fuel System
Fuel System PUMP Thread Sealant (typical) Thread TANK Sealant (typical) RIGHT FRONT Figure 5 1. Fuel tank 15. Fuel cap 29. Barbed fitting 2. Grommet 16. Hose clamp (2) 30. Barbed fitting 17. Flange nut (2) 31. Tee fitting 3. Fuel gauge 4.
Page 25 DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while en- gine is running, hot or when machine is in an en- closed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Page 26: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly Thread Sealant RIGHT FRONT Figure 7 1. Draincock valve 14. Radiator hose (upper) 23. Straight hydraulic fitting 2. Flange head screw (8) 15. Radiator hose (lower) 24. LH radiator bracket 3. Flange nut (4) 16. Hose clamp (2) 25.
Page 27 Removal (Fig. 7) Installation (Fig. 7) 1. Park machine on a level surface, lower cutting units, 1. Inspect seals around radiator location for wear or stop engine, engage parking brake and remove key damage. Replace seals if necessary. from the ignition switch. 2.
Page 28: Engine
Engine Thread Sealant Figure 8 17. Engine ground wire 33. Lock washer 1. Engine mount bracket − RH 2. Cap screw 18. Flat washer 34. Flange nut 3. Hardened washer 19. Cap screw 35. Engine mount bracket − front 4. Engine mount (2) 20.
Page 29 Removal (Fig. 8) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Open and remove engine hood from the machine. Slide seat all the way forward. 3.
Page 30 CAUTION CAUTION Make sure lift or hoist can support the total One person should operate lift or hoist while the weight of the engine before removing the cap other person guides the engine out of the ma- screws from the engine and engine brackets. chine.
Page 31 15.Separate hydrostat and pump assembly from the en- tion in Chapter 4− Hydraulic System). gine as follows (Fig. 12): 8. Connect fuel hose to the fuel pump (Fig. 9) and front A. Remove traction belt from the engine flywheel injector nozzle. and hydrostat pulleys.
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Page 33 Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS ..... GENERAL INFORMATION .
Page 34: Specifications
Specifications Item Description Piston Pump (Hydrostat) Variable displacement piston pump Charge Pressure Specification:100 to 150 PSI (6.9 to 10.3 bar) Tested: 150 to 200 PSI (10.3 to 13.8 bar) Maximum Displacement 1.44 in /rev (23.6 cc/rev) Traction Circuit Relief Pressure (Forward Only) 3500 PSI (241 bar) Tandem Gear Pump 2 section positive displacement gear type pump...
Page 35: General Information
(2) front wheel motors and the rear wheel motor. If a during operation. Because the Toro high flow filter is bi− component in the traction circuit should fail, debris and directional, the traction circuit can be operated in both contamination from the failed component will circulate the forward and reverse direction.
Page 36: Hydraulic Hoses
For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 37: Hydraulic Hose And Tube Installation
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 38: Hydraulic Fitting Installation
Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 4) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1. Make sure all threads and sealing surfaces of fitting od of assembly is the Flats From Finger Tight (F.F.F.T.) and component port are free of burrs, nicks, scratches method.
Page 39 Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O−ring be replaced any time the connection is opened.
Page 40: Special Tools
Special Tools Order the following special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 41 3. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated from 4 to 40 GPM (20 to 150 LPM). Toro Part Number: AT40002 Figure 10 NOTE: This tester does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 below).
Page 42 Toro Part Number: TOR6011 NOTE: This kit does not include hydraulic hoses (see Hydraulic Hose Kit TOR6007 above). NOTE: Replacement filter element is Toro part number TOR6012. Filter element canister tightening torque is 25 ft−lb (34 N−m). Hydraulic Test Fitting Kit This kit includes a variety of O−ring Face Seal fittings to...
Page 43 The table in Figure 15 provides gallons per minute (GPM) conversion for measured milliliter or ounce motor case drain leakage. Toro Part Number: TOR4077 Figure 14 Figure 15 O−ring Kit The kit includes O−rings in a variety of sizes for face seal and port seal hydraulic connections.
Page 44 Figure 17 A remote stater switch can also be constructed using Toro switch #106−2027, a length of 14 gauge wire, a 20 amp in−line fuse, two (2) alligator clips and necessary MACHINE connectors. Connecting the wire to switch terminals 1...
Page 45 Wheel Hub Puller Toro Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors. Figure 20 Reelmaster 3550−D/3555−D/3575−D Page 4 − 13 Hydraulic System...
Page 46: Hydraulic Schematics
Hydraulic Schematics Hydraulic System Page 4 − 14 Reelmaster 3550−D/3555−D/3575−D...
Page 47 Reelmaster 3550−D/3555−D/3575−D Page 4 − 15 Hydraulic System...
Page 48: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 − 16 Reelmaster 3550−D/3555−D/3575−D...
Page 49 Reelmaster 3550−D/3555−D/3575−D Page 4 − 17 Hydraulic System...
Page 50: Traction Circuit
Traction Circuit The traction circuit of the hydraulic system consists of a them in the reverse direction. Fluid flow out of the front hydrostat connected in a closed loop circuit to three or- wheel motors returns to the lower port of the hydrostat bital geroller wheel motors.
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Page 52 Hydraulic System Page 4 − 20 Reelmaster 3550−D/3555−D/3575−D...
Page 53: Cutting Unit Circuit
Cutting Unit Circuit The tandem gear pump is directly coupled to the piston pump/hydrostat which is belt driven by the engine. The front section of the gear pump (P1) supplies hydraulic REEL #4 REEL #1 REEL #5 REEL #2 REEL #3 flow for the cutting unit circuit.
Page 54 Hydraulic System Page 4 − 22 Reelmaster 3550−D/3555−D/3575−D...
Page 55: Lift Circuit
3555−D/375−D = RV2) is not recommended. The console joystick is used to raise and lower the cut- ting units. The joystick acts as an input to the Toro Elec- tronic Controller (TEC) which sends electrical outputs to the appropriate lift control manifold solenoid coils in or- der to raise or lower the cutting units.
Page 56 Hydraulic System Page 4 − 24 Reelmaster 3550−D/3555−D/3575−D...
Page 57 The console joystick is used to raise and lower the cut- able displacement piston pump/hydrostat which is belt ting units. The joystick acts as an input to the Toro Elec- driven by the engine. The rear section of the tandem...
Page 58: Steering Circuit
Return or Suction Working Pressure Steering Circuit Flow Low Pressure (Charge) REELMASTER 3550−D REELMASTER 3555−D/3575−D Hydraulic System Page 4 − 26 Reelmaster 3550−D/3555−D/3575−D...
Page 59 Steering Circuit The tandem gear pump is directly coupled to the vari- Left Turn able displacement piston pump/hydrostat which is belt When a left turn is made with the engine running, the driven by the engine. The rear section of the tandem turning of the steering wheel positions the steering con- gear pump (P2) supplies hydraulic flow for the steering trol valve so that flow goes through the top of the valve.
Page 60: Troubleshooting
Troubleshooting The chart that follows contains information to assist in Refer to the Testing section of this Chapter for precau- troubleshooting. There may possibly be more than one tions and specific hydraulic test procedures. cause for a machine malfunction. Review the hydraulic schematic and information on hy- draulic system operation in the Hydraulic Flow Dia- grams section of this Chapter.
Page 61: Traction Circuit Problems
Traction Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 62: Lift Circuit Problems
Lift Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 63: Steering Circuit Problems
Steering Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 64: Mow Circuit Problems
Mow Circuit Problems Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á...
Page 65: Testing
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment CAUTION such as pressure gauges and flow meters in the various hydraulic circuits to perform various operational checks (See the Special Tools section in this chapter). All testing should be performed by two (2) people.
Page 66 NOTE: Engine−to−Pump ratio is 1:0.96. In other words, Hydraulic Test Selection 1 engine RPM = 0.96 pump RPM. Before beginning any hydraulic test, identify if the prob- 4. The inlet and the outlet hoses must be properly con- lem is related to the traction circuit, cutting (mow) circuit nected and not reversed (hydraulic tester with pressure or steering and lift/sidewinder circuit.
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Page 68: Traction Circuit Testing Charge Pressure Test
Traction Circuit Testing − Charge Pressure Test FRONT FRONT REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER LOWER UPPER VALVE PORT PORT 3500 PSI TEE CONNECTOR PRESSURE GUAGE 200−300 CHARGE CIRCUIT PRESSURE 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT TO STEERING/LIFT/CHARGE...
Page 69 Traction Circuit Testing − Charge Pressure Test: The charge pressure test is the first in a series of tests recommended to determine traction circuit perform- ance. A charge pressure drop of more than 20% indic- ates an internal leak in the piston pump/hydrostat. Continued unit operation can generate excessive heat, cause damage to seals and other components in the hy- draulic system, and affect overall machine perform-...
Page 70: Wheel Motor Efficiency Tests
Traction Unit Testing − Wheel Motor Efficiency Tests FRONT WHEEL MOTOR TEST FRONT WHEEL MOTOR TEST (together) (individually) FRONT FRONT FRONT FRONT REAR REAR TRACTION WHEEL MOTORS TRACTION WHEEL MOTORS TESTER WITH TESTER WITH PRESSURE GUAGE PRESSURE GUAGE AND FLOW METER AND FLOW METER LOWER VALVE...
Page 71 Traction Circuit Testing − Wheel Motor Efficiency Test: Wheel motor efficiency is the second in a series of tests recommended to determine traction circuit perform- ance. Hydraulic fluid flow of 1.5 GPM (5.7 LPM) or more through a stationary wheel motor under load indicates an internal leak in the wheel motor.
Page 72 9. Slowly depress forward traction pedal until 1000 to Rear Wheel Motor Test: 1500 PSI (68.9 to 103.4 Bar) is displayed on the pres- Hydraulic fluid flows through both front wheel motors (in sure gauge. parallel) before passing through the rear wheel motor (in Flow meter should read less than 1.5 GPM (5.7 series).
Page 73 7. Slowly depress forward traction pedal until 1000 to 9. Rotate rear wheel 120 degrees and retest. Repeat 1500 PSI (68.9 to 103.4 Bar) is displayed on the pres- this procedure until wheel motor has been tested in sure gauge. three (3) different positions.
Page 74: Piston Pump/Hydrostat Flow And Relief Pressure Test
Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test FRONT FRONT REAR TRACTION WHEEL MOTORS TESTER WITH PRESSURE GUAGE AND FLOW METER LOWER UPPER VALVE PORT PORT 3500 PSI 200−300 CHARGE CIRCUIT PRESSURE 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT TO STEERING CONTROL...
Page 75 Traction Circuit Testing − Piston Pump/Hydrostat Flow and Relief Pressure Test: The hydrostat flow test is the third in a series of tests re- commended to determine traction circuit performance. The final traction circuit test is verifying the hydrostat re- lief valve operation.
Page 76 NOTE: The relief valve setting is 3500 PSI (241 15.The Under Load test flow reading (step 12.) should Bar). An additional 100 to 200 PSI (6.9 to 10.3 not drop more than 12% when compared to the No Bar) is necessary to overcome system charge Load test flow reading (step 11.).
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Page 78 Cutting Unit Circuit Testing − Pressure Test REEL #4 REEL #1 REEL #5 REEL #2 REEL #3 MOW CONTROL MANIFOLD BACKLAP SWITCH (SW) .020” 1500 PSI .050” PRESSURE 3000 PSI GAUGE FROM HYDRAULIC GEAR PUMP OIL COOLER TANK (P1) High Pressure Low Pressure Return or Suction Flow...
Page 79: Cutting Unit Circuit Testing Pressure Test
Cutting Unit Circuit Testing − Pressure Test: Cutting unit circuit pressure is the first in a series of tests recommended to check cutting unit circuit performance. The results from this test will help determine which com- ponent(s) are the cause of cutting unit performance is- sues.
Page 80 NOTE: CONFIGURATION FOR TESTING REEL MOTOR #4 SHOWN MEASURING CONTAINER High Pressure Low Pressure Return or Suction Flow CUTTING UNIT LOCATIONS Toro # TOR4077 FRONT 1. Reel motor location 2. Weight location Hydraulic System Page 4 − 48 Reelmaster 3550−D/3555−D/3575−D...
Page 81 Make sure engine is off and the parking 14.Hold disconnected motor case drain hose into a con- brake is disengaged. tainer graduated in ounces or milliliters (e.g. Toro #TOR4077) and collect hydraulic fluid for 30 seconds. 3. Read Precautions for Hydraulic Testing in this After 30 seconds, remove hose end from container.
Page 82 Cutting Unit Circuit Testing − Reel Motor Cross−Over Relief Pressure Test (Reelmaster 3575−D) USE A TEE FITTING TO INSTALL PRESSURE GAUGE IN BOTH INLET AND OUTLET LINES OF MOTOR BEING TESTED. NOTE: INLET IS FRONT HOSE. OUTLET IS REAR HOSE. TESTING FRONT LEFT REEL MOTOR SHOWN FRONT REAR...
Page 83 Cutting Unit Circuit Testing − Reel Motor Cross− Over Relief Pressure Test (Reelmaster 3575−D) 1. Determine which cutting reel motor needs to be test- ed by observing the machine during mowing. 2. Park machine on a level surface with the cutting units lowered and reel engage switch OFF.
Page 84 Cutting Unit Circuit Testing − Proportional Relief Valve (PRV) Pressure Test REEL #4 REEL #1 REEL #5 REEL #2 REEL #3 TESTER WITH PRESSURE GAUGE AND FLOW METER MOW CONTROL MANIFOLD BACKLAP SWITCH (SW) .020” 1500 PSI .050” 3000 PSI FROM HYDRAULIC GEAR PUMP...
Page 85: Proportional Relief Valve (Prv)
Cutting Unit Circuit Testing − Proportional Relief Valve (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 motors up to the set relief pressure.
Page 86 Cutting Unit Circuit Testing − Mow Control Manifold Relief Valve (RV) Pressure Test TESTER REEL #4 REEL #1 REEL #5 REEL #2 REEL #3 WITH PRESSURE GAUGE AND FLOW METER MOW CONTROL MANIFOLD BACKLAP SWITCH (SW) .020” 1500 PSI .050” 3000 PSI FROM HYDRAULIC...
Page 87 Cutting Unit Circuit Testing − Mow Control Manifold Relief Valve (RV) Pressure Test: If a rear cutting unit suddenly becomes obstructed dur- ing operation, mow control manifold relief valve (RV) protects the obstructed cutting unit from additional dam- age by diverting the oil flow from the front cutting units. Test the performance of the mow control manifold relief valve (RV) to make sure that the relief valve opens at the specified pressure.
Page 88 Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test VALVE 3500 PSI 200−300 CHARGE CIRCUIT PRESSURE 100−150 PSI CHARGE RELIEF HYDROSTAT HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT TESTER WITH PRESSURE GAUGES AND FLOW METER SUCTION STRAINER GEAR PUMP High Pressure Low Pressure Return or Suction...
Page 89 Cutting Unit Circuit Testing − Gear Pump (P1) Flow Test: The gear pump (P1) flow test is the last in a series of tests recommended to determine cutting unit circuit per- RIGHT formance. This test compares fluid flow at No Load with FRONT fluid flow Under Load.
Page 90 Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test VALVE 3500 PSI 200−300 CHARGE CIRCUIT PRESSURE 100−150 PSI CHARGE RELIEF HYDROSTAT TO MOW CONTROL MANIFOLD (P) PORT REELMASTER 3550−D TO STEERING CONTROL VALVE (P) PORT REELMASTER 3555−D/3575−D SUCTION TO LIFT CONTROL MANIFOLD STRAINER TESTER (P) PORT...
Page 91: Pressure Test
Steering/Lift Circuit Testing − Gear Pump (P2) Flow Test: Gear pump (P2) is designed to satisfy both steering cyl- inder and lift cylinder needs simultaneously (at full RIGHT speed throttle). The Gear Pump (P2) Flow Test com- FRONT pares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
Page 92 Steering/Lift Circuit Testing − Lift Relief Valve (RV1) Pressure Test (Reelmaster 3555−D and 3575−D) LIFT CYLINDER #1 LIFT CYLINDER #4 LIFT CYLINDER #5 LIFT CYLINDER #2 LIFT CYLINDER #3 BOR E: 1.50” BOR E: 1.50” BORE: 1.50” BOR E: 1.50” BOR E: 1.50”...
Page 93 Steering/Lift Circuit Testing − Lift Relief Valve (RV1) Pressure Test (Reelmaster 3555−D and 3575−D) 1. Park machine on a level surface with the cutting units lowered and reel engage switch OFF. Make sure engine is OFF and apply the parking brake. 2.
Page 94: Steering Relief Valve Pressure Test
Steering/Lift Circuit Testing − Steering Relief Valve Pressure Test STEERING CYLINDER STEERING CONTROL VALVE (REELMASTER 3550−D CIRCUIT SHOWN) 1000 PSI REELMASTER 3550−D FROM GEAR PUMP (P2) REELMASTER 3555−D/3575−D FROM LIFT CONTROL MANIFOLD (T) PORT TEST GAUGE REELMASTER 3550−D MOW CONTROL TO STEERING CONTROL HYDROSTAT MANIFOLD...
Page 95 Steering/Lift Circuit Testing − Steering Relief Valve Pressure Test: The relief valve for the steering and lift circuits (RM 3550−D), or for the steering circuit only (RM RIGHT 3555−D/3575−D) is integrated into the steering control FRONT valve. If both steering and lift operations (RM 3550−D), or just the steering circuit (RM 3555−D/3575−D) per- form poorly, perform the relief valve pressure test and gear pump (P2) flow test (see Steering/Lift Circuit −...
Page 96: Steering Control Valve And Steering Cylinder Test
Steering/Lift Circuit Testing − Steering Control Valve and Steering Cylinder Test STEERING CYLINDER OPEN FITTING PLUG STEERING CONTROL VALVE (REELMASTER 3550−D VALVE SHOWN) 1000 PSI High Pressure Low Pressure Return or Suction Flow Hydraulic System Page 4 − 64 Reelmaster 3550−D/3555−D/3575−D...
Page 97 Steering/Lift Circuit Testing − Steering Control 4. If either of these performance tests indicate a steer- Valve and Steering Cylinder Test: ing problem, determine if the steering cylinder is faulty using the following procedure. Unit steering performance will be affected by incorrect rear tire pressure, binding in the hydraulic steering cylin- A.
Page 98: Adjustments
Adjustments Adjust Control Manifold Relief Valves The hydraulic control manifolds on your Reelmaster in- clude the following adjustable relief valves: All machines − Mow control manifold relief valve RV should be set to 1500 PSI (103 Bar). Reelmaster 3550−D − Lift control manifold relief valve RV1 should be set to 500 PSI (34.5 Bar).
Page 99: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Hydraulic Compo- After Repair or Replacement of Hydraulic Compo- nents nents 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic tank and add correct tem, park machine on a level surface, engage parking oil if necessary.
Page 100: Check Hydraulic Lines And Hoses
Check Hydraulic Lines and Hoses IMPORTANT: Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, WARNING wear, loose fittings or deterioration. Make all neces- sary repairs before operating the machine. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure.
Page 101: Flush Hydraulic System
Ing from petroleum base hydraulic fluid to a biode- NOTE: Use only hydraulic fluids specified (see Traction gradable fluid such as Toro Biodegradable Unit Owner’s Manual). Other fluids may cause system Hydraulic Fluid. Operate machine under normal op- damage.
Page 102: Filtering Closed−Loop Traction Circuit
Toro high flow hydraulic filter and hy- 8. With engine running at high idle speed and traction draulic hose kit are recommended (see Special Tools in pedal moved to the forward direction, periodically apply this chapter).
Page 103: Charge Hydraulic System
Charge Hydraulic System NOTE: When initially starting the hydraulic system with 8. After the hydraulic system starts to show signs of fill, new or rebuilt components such as motors, pumps, or actuate lift control switch until the lift cylinders move in lift cylinders, it is important that the hydraulic system be and out several times.
Page 104: Hydraulic Tank
Hydraulic Tank FROM TO HYDRAULIC TANK COOLER 80 to 87 ft−lbs (108.4 to 117.9 N−m) REELMASTER 3550−D TO HYDRAULIC PUMP FROM HYDRAULIC OIL FILTER Anti−seize FROM lubricant 30 to 60 in−lb COOLER (3.4 to 6.8 N−m) RIGHT FRONT TO HYDRAULIC TANK REELMASTER 3555−D/3575−D Figure 43...
Page 105 Hydraulic Tank Removal (Fig. 43) Hydraulic Tank Installation (Fig. 43) 1. Park machine on a level surface. Lower cutting units, 1. If fittings were removed from hydraulic tank, lubricate stop engine and engage parking brake. Remove key and place new O−rings onto fittings. Install fittings into from the ignition switch.
Page 106: Radiator And Oil Cooler Assembly
Radiator and Oil Cooler Assembly Thread Sealant RIGHT FRONT Figure 44 1. Draincock valve 14. Radiator hose (upper) 23. Straight hydraulic fitting 2. Flange head screw (8) 15. Radiator hose (lower) 24. LH radiator bracket 3. Flange nut (4) 16. Hose clamp (2) 25.
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Page 108: Hydraulic Pump Assembly
Hydraulic Pump Assembly 77 to 93 ft−lb (105 to 127 N−m) 27 to 31 ft−lb (37 to 42 N−m) RIGHT FRONT 90 to 120 in−lb (10.2 to 13.6 N−m) Blue Loctite (tighten in 3 equal steps) Figure 45 Piston pump 21.
Page 109 Drive Belt Removal (Fig. 45) CAUTION 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. Use caution when installing torsion spring end onto the pump mount plate. Applying tension to 2.
Page 110 Neutral Arm Assembly Figure 47 Pump assembly 12. Lock nut 23. Flange head screw Hose 13. Spacer 24. Cable support bracket Extension spring 14. Traction stud 25. Ball bearing Pump mount plate 15. Traction control cable 26. Flat washer Neutral bracket 16.
Page 111 Neutral Arm Removal (Fig. 47) Neutral Arm Installation (Fig. 47) 1. Park machine on a level surface. Lower cutting units, 1. Install key into trunnion slot. Position neutral bracket stop engine and engage parking brake. Remove key to the mount plate and the pump lever and hub assembly from the ignition switch.
Page 112: Piston Pump/Hydrostat
Piston Pump/Hydrostat RIGHT FRONT Figure 48 1. Engine mount bracket 5. Hardened washer 8. Hardened washer 2. Flange nut 6. 10 mm cap screw (4) 9. Long spacer (4) 3. Flange screw 7. 8 mm cap screw (1) 10. Short spacer (1) 4.
Page 113 7. Label all hydraulic hoses and fittings for assembly purposes. Remove plugs before installing gear pump to piston pump 8. Disconnect all hydraulic hoses connected to the hy- draulic fittings on the piston pump/hydrostat and gear pump. Allow hoses to drain into a suitable container. Plug hose and fitting openings to prevent contamina- tion.
Page 114 4. Place key into piston pump shaft slot. Slide taper lock IMPORTANT: When tightening taper lock bushing bushing onto the piston pump shaft with bushing flange cap screws, tighten in three (3) equal steps and in a toward pump housing. circular pattern.
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Page 116: Piston Pump/Hydrostat Service
Piston Pump/Hydrostat Service Figure 50 17. O–ring 32. Washer 1. Key 2. Drive shaft 18. Plug 33. Shaft seal 3. Bearing 19. Relief valve asm. 34. Retaining ring 4. Cap screw (3 used per plate) 20. Check valve asm. 35. Cam plate insert 5.
Page 117 IMPORTANT: If a piston pump failure occurred, re- fer to Traction Circuit (Closed Loop) Component CHARGE RELIEF Failure in this chapter for information regarding the VALVE importance of removing contamination from the traction circuit. NOTE: The traction circuit charge relief valve and the bleed off valve for traction circuit cooling are attached to the piston pump back plate assembly (Fig.
Page 118 29 ft−lb (39 N−m) Figure 52 8. O−ring 1. Crush ring 5. Camplate (control shaft) 2. Shims 6. Bearing cone 9. Washer (3) 3. Cover plate 7. Bearing cup 10. Cap screw (3) 4. Housing Piston Pump/Hydrostat Crush Ring Replacement 5.
Page 119: Gear Pump
Gear Pump RIGHT FRONT Figure 53 Piston pump Hydraulic barb fitting 13. 90 hydraulic fitting Gear pump O–ring 14. O–ring Hydraulic hose (tank suction) O–ring 15. Cap screw Hydraulic hose (hydraulic manifold) 10. 90 hydraulic fitting 16. Flat washer Hydraulic hose (steering valve) 11.
Page 120 Installation (Fig. 53) Remove plugs before installing 1. If fittings were removed from gear pump, lubricate gear pump to piston pump and place new O−rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Infor- mation section of this chapter).
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Page 122: Gear Pump Service
Gear Pump Service 33 ft−lb (45 N−m) Figure 55 Front cover Dowel pin 15. Front thrust plate Pressure seal Seal 16. Idler gear Back−up gasket 10. Body 17. Drive gear Front thrust plate 11. Seal 18. Rear thrust plate Idler gear 12.
Page 123 IMPORTANT: Use caution when clamping gear 8. Clean all pump parts. Check all components for pump in a vise to avoid distorting any pump compo- burrs, scoring, nicks and other damage. nents. 9. Replace the entire pump assembly if parts are ex- 3.
Page 124: Front Wheel Motors
Front Wheel Motors RIGHT FRONT Figure 57 Lock nut Frame Hydraulic fitting (2) Spacer Hydraulic tube 10. O–ring Socket head screw Hydraulic tube 11. Brake bracket Hydraulic wheel motor O–ring NOTE: The left front wheel motor has a yellow dot on the body to distinguish it from the right front wheel motor.
Page 125 Removal (Fig. 57) Installation (Fig. 57) 1. Park machine on a level surface. Lower cutting units, 1. If adapters were removed from wheel motor, lubri- stop engine and engage parking brake. Remove key cate and place new O−rings onto fittings. Install ad- from the ignition switch.
Page 126: Rear Wheel Motor
Rear Wheel Motor 250 to 275 ft−lb (339 to 372 N−m) 45 to 65 ft−lb (61 to 88 N−m) RIGHT FRONT Figure 58 1. Lug nuts (4) 6. Lock nut (4) 11. O−ring (2) 2. Rear wheel assembly 7. Rear wheel motor 12.
Page 127 Removal (Fig. 58) 8. Using hub puller (see Special Tools in this chapter), loosen wheel hub from wheel motor. 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key 9. Remove wheel hub and motor from vise. Remove from the ignition switch.
Page 128: Wheel Motor Service
Wheel Motor Service 45 to 55 ft−lb (60 to 76 N−m) Figure 59 1. Dirt seal 9. Thrust bearing 17. Woodruff key 2. Bearing 10. Bearing 18. Wear plate 3. Housing 11. Coupling shaft 19. Rotor 4. Back−up washer 12. Thrust bearing 20.
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Page 130: Cutting Unit Reel Motor
Cutting Unit Reel Motor RIGHT FRONT Figure 60 1. O−ring 5. Hydraulic hose (Inlet) 9. Elbow fitting 2. Elbow fitting 6. Hydraulic hose (return) 10. O−ring 3. Straight fitting 7. O−ring 11. Hydraulic hose (case drain) 4. O−ring 8. Straight fitting Hydraulic System Page 4 −...
Page 131 Removal 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 3. Label all hydraulic connections for assembly pur- poses (Fig.
Page 132: Cutting Unit Reel Motor Service
Cutting Unit Reel Motor Service (Reelmaster 3550−D and 3555−D) 18 ft−lb (25 N−m) Figure 62 1. Dust seal 7. O–ring 13. Wear plate (inner) 8. Pressure seal (outer) 14. Backup gasket (inner) 2. Retaining ring 3. Backup washer 9. Backup gasket (outer) 15.
Page 133 IMPORTANT: Record position of the open and closed side of the wear plates before removing. Identify wear plates (inner and outer, drive gear and idler gear) with a marker for proper assembly. IMPORTANT: Mark the relative positions of the gear teeth so they can be reassembled in the same (mated) position.
Page 134 Assembly (Fig. 62) 9. Install inner wear plate with pressure seal side up and open side of the pressure seal pointing to the inlet 1. Lubricate O–rings, pressure seals, back−up gaskets side of the motor. and wear plate grooves with a thin coat of petroleum jel- ly.
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Page 136: Cutting Unit Reel Motor Service (Reelmaster 3575−D)
Cutting Unit Reel Motor Service (Reelmaster 3575−D) 33 ft−lb (45 N−m) 18 ft−lb (25 N−m) Figure 66 1. Body 8. Flat washer (4) 15. Back−up seal 2. Front flange 9. O−ring (2) 16. Back−up seal 3. Front thrust plate 10. Pressure seal 17.
Page 137 IMPORTANT: Record position of the open and closed side of the wear plates before removing. Identify wear plates (inner and outer, drive gear and idler gear) with a marker for proper assembly. IMPORTANT: Mark the relative positions of the gear teeth so they can be reassembled in the same (mated) position.
Page 138 Assembly (Fig. 62) 10.Apply a light coating of petroleum jelly to new O–ring and O–ring grooves in the body. Install new O–ring to the 1. Lubricate O–rings, pressure seals, back−up gaskets body. and wear plate grooves with a thin coat of petroleum jel- ly.
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Page 140: Mow Control Manifold
Mow Control Manifold RIGHT FRONT Figure 70 1. Mow control manifold 8. Straight hydraulic fitting (3) 15. O−ring 2. Hydraulic tube 9. O−ring 16. Test fitting 3. Hydraulic tube 10. O−ring 17. O−ring 4. Hydraulic tube 11. 90 hydraulic fitting 18.
Page 141 Removal (Fig. 70) Installation (Fig. 70) The ports on the mow control manifold are marked for 1. If fittings were removed from mow control manifold, lubricate and place new O−rings onto fittings. Install fit- easy identification of components. Example: PRV is the proportional relief valve and P is the supply port (see Hy- tings into manifold openings using marks made during draulic Schematic to identify the function of the hydraulic...
Page 142: Mow Control Manifold Service
Mow Control Manifold Service VIEW FROM ABOVE VIEW FROM FRONT BELOW 60 in−lb (6.7 N−m) FRONT 20 ft−lb (27 N−m) 40 ft−lb (54 N−m) 25 ft−lb (33 N−m) 25 ft−lb (33 N−m) 20 ft−lb (27 N−m) 25 ft−lb (33 N−m) 20 ft−lb 20 ft−lb (27 N−m)
Page 143 NOTE: The ports on the mow control manifold are 2. To install rotary handle: marked for easy identification of components. Example: IMPORTANT: Make sure that flow control cartridge PRV is the proportional relief valve and T is the return valve is properly secured in manifold before instal- port (see Hydraulic Schematic to identify the function of ling rotary handle to valve.
Page 144 VIEW FROM ABOVE VIEW FROM FRONT BELOW FRONT 10 ft−lb (13.5 N−m) 20 ft−lb (27 N−m) Figure 73 1. Mow control manifold 5. Backlap spool 9. O−ring 2. Ball switch (normally open) 6. Retaining ring (lower) 10. O−ring (2) 3. O−ring 7.
Page 145 Backlap Spool (Fig. 73) 3. To install backlap spool into manifold: 1. To remove backlap spool from manifold: A. Install O−rings and back−up ring to upper grooves on spool. Apply a light coating of grease to A. Remove backlap switch from manifold before re- O−rings.
Page 146: Lift Control Manifold
Lift Control Manifold RIGHT FRONT O−Rings Between Fittings and Hoses/Tubes Not Shown Figure 74 1. Mow control manifold 6. Hydraulic tube (to rear bulkhead) 10. Hydraulic hose (center lift cylinder) 7. Hydraulic hose (RH lift cylinder) 2. Flange head screw (2 used) 11.
Page 147 Removal (Fig. 74) 5. Disconnect hydraulic lines from lift control manifold and put caps or plugs on open hydraulic lines and fit- The ports on the lift control manifold are marked for easy tings. Label disconnected hydraulic lines for proper as- identification of components.
Page 148: Lift Control Manifold Service (Reelmaster 3550−D)
Lift Control Manifold Service (Reelmaster 3550−D) VIEW FROM VIEW FROM ABOVE ABOVE 60 in−lb (6.7 N−m) 60 in−lb (6.7 N−m) FRONT FRONT 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m)
Page 149 NOTE: The ports on the lift control manifold are marked IMPORTANT: A flow control orifice is located be- for easy identification of components. Example: S1 is neath many of the fittings in the lift control manifold the solenoid valve and P is the supply port (see Hydrau- ports.
Page 150: Lift Control Manifold Service
Lift Control Manifold Service (Reelmaster 3555−D and 3575−D) VIEW FROM VIEW FROM ABOVE ABOVE 60 in−lb (6.7 N−m) 60 in−lb (6.7 N−m) FRONT FRONT 20 ft−lb 20 ft−lb (27 N−m) (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb (27 N−m) 20 ft−lb...
Page 151 NOTE: The ports on the lift control manifold are marked NOTE: The hydraulic manifold shown uses several for easy identification of components. Example: S1 is zero leak plugs. These plugs have a tapered sealing the solenoid valve and P is the supply port (see Hydrau- surface on the plug head that is designed to resist vibra- lic Schematic to identify the function of the hydraulic tion induced plug loosening.
Page 152: Control Manifold Cartridge Valve Service
Control Manifold Cartridge Valve Service 1. Make sure the control manifold is clean before re- 7. Install the cartridge valve into the manifold: moving the cartridge valve from the control manifold. A. Lubricate new seal kit components with clean hy- 2.
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Page 154: Steering Control Valve
Steering Control Valve RIGHT FRONT 20 to 26 ft−lb (28 to 35 N−m) Blue Loctite 242 Figure 77 1. Steering arm 12. Steering control valve 23. Jam nut 24. Flange head screw (4) 2. Flange nut (4) 13. Tilt bracket 3.
Page 155 Removal (Fig. 77) 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on steering control valve to prevent hydraulic system con- tamination.
Page 156: Steering Control Valve Service
Steering Control Valve Service 20 to 24 ft−lb (27 to 33 N−m) Figure 80 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 18. O–ring (5 used) 3. Ring 11. Cardan shaft 4.
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Page 158: Steering Cylinder
Steering Cylinder No. 2 General Purpose Grease No. 2 General Purpose Grease 85 to 115 ft−lb (115 to 156 N−m) 65 to 85 ft−lb (88 to 115 N−m) 65 to 85 ft−lb (88 to 115 N−m) 85 to 115 ft−lb (115 to 156 N−m) RIGHT FRONT...
Page 159 Removal (Fig. 81) Installation (Fig. 81) 1. Park machine on a level surface. Lower cutting units, 1. If removed, install ball joints into steering cylinder. stop engine and engage parking brake. Remove key 2. Lubricate and place new O−rings onto removed from the ignition switch.
Page 160: Steering Cylinder Service
Steering Cylinder Service 40 ft−lb (54 N−m) Figure 82 9. Head seal 1. Barrel with clevis 5. O−ring 2. Lock nut 6. O−ring 10. Dust seal 3. Piston seal 7. Back−up ring 11. Internal collar 4. Piston 8. Head 12. Rod Hydraulic System Page 4 −...
Page 161 Disassembly (Fig. 82) Assembly (Fig. 82) 1. Remove oil from the steering cylinder into a drain pan 1. Make sure all steering cylinder components are by slowly pumping the cylinder rod. Plug both ports and clean before assembly. clean the outside of the cylinder. 2.
Page 162: Front Lift Cylinders
Front Lift Cylinders REELMASTER 3550−D SHOWN RIGHT FRONT Blue Loctite 242 Blue Loctite 242 Figure 83 1. #1 lift arm 8. Washer head screw (2) 14. Retaining ring (6) 2. #5 lift arm 9. #1 Lift cylinder 15. #4 & 5 Lift cylinder (2) 3.
Page 163 Removal (Fig. 83) REELMASTER 3555−D/3575−D SHOWN 1. Park machine on a level surface. Lower cutting units, stop engine and engage parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 3.
Page 164: Rear Lift Cylinders
Rear Lift Cylinders RIGHT FRONT REELMASTER 3550−D SHOWN Figure 85 1. #2 lift arm 6. Pin (2) 11. RH torsion spring 2. #3 lift arm 7. Cylinder pin (2) 12. LH torsion spring 3. Pin (2) 8. Thrust washer (4) 13.
Page 165 Removal (Fig. 85) Installation (Fig. 85) 1. Park machine on a level surface. Lower cutting units, 1. If fittings were removed from lift cylinder, lubricate stop engine and engage parking brake. Remove key and place new O−rings onto fittings. Install fittings into from the ignition switch.
Page 166: Lift Cylinder Service
Lift Cylinder Service 40 ft−lb (54 N−m) 13 OR 14 Figure 86 6. O−ring 11. Dust seal 1. Barrel 2. Lock nut 7. Head 12. Retaining ring 3. Wear ring 8. O−ring 13. Rod (cutting units #1, #2 and #3) 4.
Page 167 Disassembly − Retaining Ring Style (Fig. 86) Assembly − Retaining Ring Style (Fig. 86) 1. Remove oil from the lift cylinder into a drain pan by 1. Make sure all lift cylinder components are clean be- slowly pumping the cylinder rod. Plug both ports and fore assembly.
Page 168 40 ft−lb (54 N−m) Figure 87 1. Barrel 6. O−ring 11. Dust seal 2. Lock nut 7. Head 12. Internal collar 3. Wear ring (2) 8. O−ring 13. Rod 4. Piston 9. Back−up ring 14. Grease fitting 5. Seal 10. Seal 15.
Page 169 Disassembly − Threaded Collar Style (Fig. 86) Assembly − Threaded Collar Style (Fig. 86) 1. Remove oil from the lift cylinder into a drain pan by 1. Make sure all lift cylinder components are clean be- slowly pumping the cylinder rod. Plug both ports and fore assembly.
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Page 171 GENERAL INFORMATION ..... Toro Electronic Controller (TEC) ... . .
Page 172: General Information
Toro Electronic Controller (TEC) The Reelmaster machines use a single Toro Electronic Because of the solid state circuitry built into the Toro Controller (TEC) to manage machine electrical func- Electronic Controller (TEC), there is no method to test tions.
Page 173: Electrical Schematic
Electrical Schematic The electrical schematic and wiring diagrams for the Re- elmaster machines are located in Chapter 10 − Foldout Drawings in this manual. Reelmaster 3550−D/3555−D/3575−D Page 5 − 3 Electrical System...
Page 174: Special Tools
The multimeter can test electrical components and cir- cuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 175 The Diagnostic Display (Fig. 5) can be connected to the wiring harness connector located under the control pan- el to verify correct electrical functions of the machine. Toro Electronic Controllers (TEC) inputs and outputs can be checked using the Diagnostic Display. Diagnostic Display: Part No. 85−4750 RM 3550−D/3555−D/3575−D Overlay (English):...
Page 176: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- CAUTION ponents used on this machine (see Chapter 10 − Fold- out Drawings in this manual). Remove all jewelry, especially rings and If the machine has any interlock switches by−passed, watches, before doing any electrical trouble- shooting or testing.
Page 177 (40) hours of machine operating time, the fault cannot be retrieved from controller memory using 4. Monitor the diagnostic light for fault code(s). this procedure. If necessary, contact your Toro distribu- tor to retrieve older fault codes. NOTE: Once the diagnostic light begins to display fault codes, the joystick can be released.
Page 178 Clearing Fault Codes 2. Operator seat should remain UNOCCUPIED. After fault codes have been retrieved, clearing of those 3. Move mow/backlap lever on the hydraulic mow con- faults can be completed using the following switch se- trol manifold to the BACKLAP position. quence: 4.
Page 179: Diagnostic Display
Diagnostic Display Reelmaster machines are equipped with a Toro Elec- tronic Controller (TEC) which controls machine electri- cal functions. The controller monitors various input switches (e.g. ignition switch, seat switch, neutral switch) and energizes outputs to actuate solenoids or relays for the requested machine function.
Page 180 4. Turn the ignition switch to the ON position, but do not NOTE: When the Diagnostic Display is attached to the start machine. wire harness connector and the ignition switch is in the ON position, the input LED for alternator, engine temp NOTE: The red text on the Diagnostic Display overlay and engine oil pressure should be illuminated.
Page 181 Verify Diagnostic Display Output Functions The Diagnostic Display also has the ability to detect which outputs (solenoids, relays and indicator lights) are energized by the TEC controller. This is a quick way to determine if a machine malfunction is electrical or hy- draulic.
Page 182 Output Output Name Input Conditions Required to Illuminate Output LED START Key Switch − START Traction Pedal − NEUTRAL Seat Switch − OCCUPIED or Parking Brake − ENGAGED Reel Enable/Disable Switch − DISABLE Joystick − NEUTRAL Key Switch − RUN or START Seat Switch −...
Page 183 If this occurs, contact your output LEDs will illuminate during the sequence and ex- Toro Distributor for assistance. tinguish when the sequence is completed, with one ex- ception. The LED for output 7 (Front Mow (SP)) will 9.
Page 184: Starting Problems
Starting Problems Problem Possible Causes Nothing happens when start attempt is made. The traction pedal is not in the neutral position. NOTE: If high engine coolant temperature (above The traction neutral sensor is out of adjustment or is 240°F (116°C)) causes the engine to stop, the engine faulty.
Page 185 Starting Problems (continued) Problem Possible Causes The engine cranks, but does not start. The fuel tank is empty. Wiring in the engine crank circuit is loose, corroded or damaged (see electrical schematic in Chapter 10 − Foldout Drawings in this manual). The fuel filter is plugged.
Page 186: General Run And Transport Problems
General Run and Transport Problems Problem Possible Causes Engine stops during operation (operator sitting on Operator not in center of seat (seat switch is not seat). depressed). Fuel tank is empty. Machine is being operated on a slope with a low fuel level.
Page 187: Cutting Unit Operating Problems
Cutting Unit Operating Problems Problem Possible Causes Cutting units run (but should not) when raised. The mow control manifold proportional relief valve (PRV) solenoid coil or circuit wiring is faulty. A hydraulic problem exists (see Chapter 5 − Hydraulic System in this manual). Turn around switch or circuit wiring is faulty.
Page 188: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100F (16 to 38C).
Page 189: Check Operation Of Interlock Switches
Toro Electronic Controller (TEC) which monitors interlock switch operation. Use the Diagnostic Display Do not disconnect safety switches. They are for (see Special Tools in this chapter) to test Toro Electronic the operator’s protection. Check the operation of Controller inputs and outputs before further trouble- the interlock switches daily for proper operation.
Page 190: Adjustments
Adjustments Neutral Switch The neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral posi- tion. The neutral switch is located under the floor plate near the traction pedal. Adjusting 1. Before adjusting the traction neutral switch, check and adjust traction system neutral position (refer to Traction Unit Operator’s Manual).
Page 191: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally closed proximity switch that is located on the control console (Fig. 32). The sensing plate that opens the switch is the parking brake lever. When the parking brake is applied, the parking brake lever is positioned near the target end of the parking brake switch so the switch is opened.
Page 192: Turn Around Switch (Rm 3555−D/3575−D)
Turn Around Switch (Reelmaster 3555−D and 3575−D) The cutting unit turn around switch is a normally open proximity switch that closes when the front right cutting 162 to 198 in−lb (18.4 to 22.4 N−m) unit (cutting unit #5) is in the turn−around position. The turn around switch is attached to a bracket outside the front right lift arm pivot pin.
Page 193: Mow/Transport Switch
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 is located under the floor plate (Fig 18). Adjusting 1. Park the machine on a level surface, engage the parking brake, lower the cutting units and stop the en- gine.
Page 194: Component Testing
The ignition (key) switch is located on the control panel and has three (3) positions: STOP, RUN and START STOP (Fig. 20). The Toro Electronic Controller (TEC) monitors the operation of the ignition switch and reacts to the vari- START ous ignition switch positions.
Page 195: Main Power Relay
Main Power Relay The main power relay is secured to the control panel as- sembly next to the operator seat (Fig. 22). This relay is attached to the wire harness with a four (4) wire connec- tor (Fig. 23). The relay can be accessed by removing the control panel cover.
Page 196: Fuses
Fuses The fuse blocks are located under the control panel cov- Fuse Testing er on the right side of the machine. Remove cover from control panel to access fuse blocks. Fuse Identification and Function Turn ignition switch to the ON position (do not start en- gine).
Page 197: Fusible Links
Fusible Links The Reelmaster machines use four (4) fusible links for circuit 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. 26). The fusible links in this harness protect the glow plug, alternator, and main power relay circuits.
Page 198 (3) connectors (PWR2, PWR3 and operation. If the controller is replaced for any reason, the PWR4) each protected with a 7.5 amp fuse. A fifty (50) controller needs to be reprogrammed by your Toro Dis- pin wire harness connector attaches to the controller. tributor.
Page 199 12V POWER (7.5A FUSES) OUTPUTS (PWR 2) 12V LOGIC POWER (2 AMP FUSE) VOLTAGE OUTPUTS IGNITION (PWR 3) SWITCH INPUTS OUTPUTS (PWR 4) COMM PORT Figure 32 DIGITAL INPUTS 1. TEC controller 3. Socket head screw (OPEN/ CLOSED) 2. Harness connector CAN BUS If the wire harness connector is removed from the TEC controller for any reason, tighten the harness connector...
Page 200: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally closed proximity switch that is located on the control console (Fig. 32). The sensing plate that opens the switch is the parking brake lever. When the parking brake is applied, the parking brake lever is positioned near the target end of the parking brake switch so the switch is opened.
Page 201: Neutral Switch
Neutral Switch The neutral switch is a normally open proximity switch that closes when the traction pedal is in the neutral posi- tion. The neutral switch is located under the floor plate (Fig. 33). The TEC controller monitors the position of the neutral switch (open or closed).
Page 202: Lower/Raise Joystick Switches
Lower/Raise Joystick Switches The cutting unit raise and lower switches are located on the joystick assembly that is attached to the control pan- el. The rear switch is used to lower the cutting units and the front switch to raise them (Fig. 34). The switches are identical (Fig.
Page 203: Reel Enable/Disable Switch
Reel Enable/Disable Switch The enable/disable switch is located on the control panel (Fig. 36). This switch is pulled out to engage the cutting units and pushed in to disengage the cutting units. The TEC controller monitors the position of the enable/ disable switch (pulled out or pushed in).
Page 204: Mow/Transport Switch
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 is located under the floor plate (Fig 39). The TEC controller monitors the position of the mow/ transport switch (open or closed).
Page 205: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator seat is occupied. The seat switch is located dir- ectly under the seat. The TEC controller monitors the position of the seat switch (open or closed). Using inputs from the seat switch and other switches in the interlock system, the TEC controller controls the energizing of the engine start relay, the fuel stop solenoid and fuel pump, the pro-...
Page 206: Backlap Switch
Backlap Switch The backlap switch is a normally open ball switch that is in the normal, open state when the backlap lever is in the mow position. When the backlap lever is in the backlap position, the switch closes. The backlap switch is at- tached to the hydraulic mow control manifold located on the left side of the machine under the hinged access panel in front of the operator’s seat (Fig.
Page 207: Turn Around Switch (Rm 3555−D/3575−D)
Turn Around Switch (Reelmaster 3555−D and 3575−D) The cutting unit turn around switch is a normally open proximity switch that closes when the front right cutting unit (cutting unit #5) is in the turn−around position. The turn around switch is attached to a bracket outside the front right lift arm pivot pin.
Page 208: Engine Temperature Sender
Engine Temperature Sender The engine temperature sender is located above the al- ternator, in the thermostat housing (Fig. 43). The resist- ance of the temperature sender reduces as the engine coolant temperature increases. The TEC controller uses input from the temperature sender to control the high temperature warning light on the operator’s control panel (on or off).
Page 209: Start Relay
Start Relay The start relay is secured to the control panel assembly 3. Test the circuit wiring: next to the operator seat (Fig. 45). This relay is attached A. Remove cover from control panel and locate re- to the wire harness with a five (5) wire connector lay that is to be tested.
Page 210 NOTE: Prior to taking small resistance readings F. Connect multimeter (ohms setting) leads to relay with a digital multimeter, short the meter test leads to- terminals 30 and 87A. Apply +12 VDC to terminal 85. gether. The meter will display a small resistance val- The relay should make and break continuity between ue (usually 0.5 ohms or less).
Page 211: Fuel Stop Solenoid
Fuel Stop Solenoid The fuel stop solenoid must be energized for the diesel 4. If the circuit wiring is functioning correctly, use the fol- engine to run. The solenoid is mounted to the injection lowing procedure to test the fuel stop solenoid. pump on the engine (Fig.
Page 212: Fuel Pump
Fuel Pump C. Make sure fuel hoses to and from the fuel pump The fuel pump is attached to the left side of the engine near the fuel/water separator (Fig. 49). are not kinked, damaged, and free of obstructions. The TEC controller energizes and monitors the opera- D.
Page 213: Glow Relay
Glow Relay The glow relay is secured to the control panel assembly next to the operator seat (Fig. 50). This relay is attached to the wire harness with a four (4) wire connector (Fig. 51). The relay can be accessed by removing the control panel cover.
Page 214 NOTE: Prior to taking small resistance readings +12 VDC to terminal 85. The relay should make and with a digital multimeter, short the meter test leads to- break continuity between terminals 30 and 87 as +12 gether. The meter will display a small resistance val- VDC is applied and removed from terminal 85.
Page 215: Hydraulic Solenoid Valve Coils
Hydraulic Solenoid Valve Coils The Reelmaster hydraulic control manifolds use several hydraulic solenoid valve coils for system control. The lift manifold includes four (4) solenoid valves (S1, S2, S3, and S4). The mow manifold includes a single solenoid valve (PRV). The TEC controller energizes and monitors the opera- tion of the solenoid coils when specific input conditions are met.
Page 216 C. Solenoid coil resistance should be measured NOTE: To assist in troubleshooting, identical sole- with solenoid at approximately 68F (20C). Resist- noid valve coils can be exchanged. If the problem fol- ance may be slightly different than listed at different lows the exchanged coil, an electrical problem likely temperatures.
Page 217: Indicator Lights
Indicator Lights To test the high temperature shutdown light and circuit wiring, start the engine and ground the blue wire at- tached to the temperature sender at the engine thermo- stat housing. Warning light should illuminate. The high temperature warning light is controlled by the TEC controller (see Engine Temperature Sensor in this chapter for additional information).
Page 218: Can−Bus Termination Resistors
CAN−bus Termination Resistors System communication between electrical components Termination on Reelmaster machines is accomplished on a CAN− Resistor bus communication system. Two (2) specially designed, twisted cables form the bus for the network used on the machine. These wires provide the data pathways between machine components.
Page 219: Oil Pressure Switch
Oil Pressure Switch The engine oil pressure switch is located on the engine below the alternator (Fig. 58). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm If low engine oil pressure allows the oil pressure switch to close during engine operation, the engine oil pressure...
Page 220: Worklight Switch
Worklight Switch The worklight switch is located on the control panel (Fig. 59). This rocker switch allows the worklights (headlights) to be turned on and off. Testing 1. Park machine on level surface, lower cutting units, stop engine, apply parking brake and remove key from ignition switch.
Page 221: Service And Repairs
Service and Repairs NOTE: For engine component repair information, see the Kubota Workshop Manual: 05 Series Diesel Engine. Battery Storage If the machine will be stored for more than 30 days: 4. Store battery in a cool atmosphere to avoid quick de- terioration of the battery charge.
Page 222: Battery Service
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented (see Battery Storage and Battery Care in this chapter). Battery Specifications Maintenance free wet lead acid BCI Group 26 Battery 525−540 Cold Cranking Amps (CCA) at 0F (−18C)
Page 223 Battery Testing Minimum Battery Temperature Voltage 1. Perform a high−discharge test with an adjustable 70F (and up) 21C (and up) 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.
Page 224 Battery Charging Battery Battery Charge Level Reserve (Percent of Fully Charged) To minimize possible damage to the battery and allow Capacity the battery to be fully charged, the slow charging meth- (Minutes) od is presented here. This charging method can be ac- 80 or less 3.8 hrs 7.5 hrs...
Page 225: Cartridge Valve Coil Replacement
Cartridge Valve Coil Replacement The solenoid valve coils on the hydraulic control mani- folds (Fig. 62) can be replaced without opening the hy- 60 in−lb draulic system. (6.8 N−m) Removal 1. Park machine on a level surface, lower cutting decks, engage parking brake, stop engine and remove key from the ignition switch.
Page 226: Worklight Bulb Replacement
Worklight Bulb Replacement The worklights are adjustable left and right, and up and down as necessary. The worklights use a replaceable halogen bulb. CAUTION The worklights use a halogen bulb that becomes extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury.
Page 227 Chapter 6 Chassis Table of Contents SPECIFICATIONS ......SPECIAL TOOLS ......ADJUSTMENTS .
Page 228: Specifications
Reelmaster 3555−D/3575−D = 20 PSI (138 kPa) Wheel lug nut torque 70 to 90 ft−lb (95 to 122 N−m) Special Tools Order special tools from your Toro Distributor. Wheel Hub Puller Part Number: TOR4097 The wheel hub puller allows safe removal of the wheel hub from the shaft of wheel motors.
Page 229: Adjustments
Adjustments Adjust Brakes C. If brakes can not be adjusted properly, repair or replace brake components as necessary. CAUTION D. After adjustment is complete, install both front wheel assemblies to the machine (see Front Brake Before and after adjusting the brakes, always and Wheel Installation in the Service and Repairs check the brakes in a wide open area that is flat section).
Page 230: Service And Repairs
Service and Repairs Operator Seat Figure 4 1. Bottom cushion 9. Back cover 17. Weight adjust kit 10. Seat switch 18. Spring and saddle kit 2. Back cushion 3. Seat belt 11. Adjusting track − LH 19. Shock absorber kit 4.
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Page 232: Front Wheels And Brakes
Front Wheels and Brakes Antiseize Lubricant RIGHT FRONT 70 to 90 ft−lb (95 to 122 N−m) (REELMASTER 3550−D SHOWN) 250 to 275 ft−lb (339 to 372 N−m) Figure 5 1. Hydraulic wheel motor (LH shown) 11. Lock nut (4 per brake assembly) 21.
Page 233 Removal (Fig. 5) Installation (Fig. 5) 1. Park machine on a level surface, lower cutting units, 1. If removed, insert four socket head screws through stop engine, engage parking brake and remove key the frame, hydraulic motor, spacers, and brake bracket. from the ignition switch.
Page 234 9. Lower wheel to ground. Torque wheel lug nuts from Burnish Brake Pads 70 to 90 ft- lb (95 to 122 N- m) in a crossing pattern. After brake pad replacement, burnish (break- in) the 10.Torque lock nut from 250 to 275 ft- lb (339 to 372 brakes before use.
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Page 236: Rear Fork And Wheel
Rear Fork and Wheel 60 to 80 ft−lb (81 to 108 N−m) 70 to 90 ft−lb (95 to 122 N−m) 85 to 115 ft−lb (115 to 156 N−m) 65 to 85 ft−lb (88 to 115 N−m) 65 to 85 ft−lb (88 to 115 N−m) 250 to 275 ft−lb (339 to 372 N−m)
Page 237 Removal (Fig. 7) Installation (Fig. 7) 1. Park machine on a level surface, lower cutting units, 1. Position rear fork through the frame. stop engine, engage parking brake, and remove key 2. Install lock washer, thrust washer, and cap screw to from the ignition switch.
Page 238: Brake Lever Linkages
Brake Lever Linkages 13 to 17 ft−lb (18 to 23 N−m) RIGHT FRONT Figure 8 1. Pop rivet (4) 12. Cotter pin 23. Cotter pin 2. Control panel cover 13. Clevis pin 24. Brake cam 3. Cover bracket (2) 14. Parking brake link 25.
Page 239 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove control panel cover from the machine. IMPORTANT: When removing the adjustable clevis, adjustment rod, or the brake lever, make sure to mark both parts.
Page 240: Steering Column
18. Hydraulic fitting (3) 31. Flange screw (2) Pivot hub (2) 19. Steering wheel nut 32. Bag holder Steering cover 20. Toro decal 33. Flange screw (4) Cap screw (5) 21. Hydraulic hose 34. Steering shield Ball knob 22. Hydraulic hose 35.
Page 241 Disassembly 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove philips head screws and steering wheel cap from the steering wheel. 3. Remove steering wheel nut from the steering control valve.
Page 242 Front Lift Arms (Reelmaster 3550−D and 3555−D) RIGHT FRONT Blue Loctite 242 Blue Loctite 242 Blue Loctite 242 (REELMASTER 3550−D SHOWN) Figure 11 Pivot yoke (3) Flange head screw (3) 15. Lift arm #4 Recessed bumper (3) 16. Cap screw (2 per lift arm) Thrust washer (2 per yoke) Flange bushing (2 per lift arm) 10.
Page 243 Removal (Fig. 11) Installation (Fig. 11) 1. Park machine on a level surface, lower cutting units, 1. If the lift arm pin was removed from frame, install lift stop engine, engage parking brake, and remove key arm pin in frame and secure with cap screw. from the ignition switch.
Page 244 Front Lift Arms (Reelmaster 3575−D) Blue Loctite 242 80 to 100 ft−lb (108 to 135 N−m) Blue Loctite 242 RIGHT 80 to 100 ft−lb FRONT (108 to 135 N−m) Blue Loctite 242 Figure 12 Pivot yoke (3) 10. Flange bushing (2 per lift arm) 18.
Page 245 Removal (Fig. 12) Installation (Fig. 12) 1. Park machine on a level surface, lower cutting units, 1. If the lift arm pin was removed from frame, install lift stop engine, engage parking brake, and remove key arm pin in frame and secure with cap screw. from the ignition switch.
Page 246 Rear Lift Arms (Reelmaster 3550−D) RIGHT FRONT Figure 13 1. Pivot yoke (2) 9. Thrust washer (2 per pin) 17. Flange nut (2 per lift arm) 2. Thrust washer (2 per pivot yoke) 10. Pin (2) 18. Chain hoop (2) 3.
Page 247 Removal (Fig. 13) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting units (see Chapter 7 − Cutting Units in this manual). 3. Remove lynch pin and thrust washer securing pivot yoke to lift arm and remove pivot yoke.
Page 248 Rear Lift Arms (Reelmaster 3555−D and 3575−D) RIGHT FRONT (REELMASTER 3555−D SHOWN) Figure 15 1. Pivot yoke (2) 10. Pin (2) 19. Chain (2) 2. Thrust washer (2 per pivot yoke) 11. Counterbalance spring (RH) 20. Cap screw − spring actuator (2) 3.
Page 249 Removal (Fig. 15) 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cutting units (see Chapter 7 − Cutting Units in this manual). 3. Remove lynch pin and thrust washer securing pivot yoke to lift arm and remove pivot yoke.
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Page 251 Chapter 7 DPA Cutting Units Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Cutting Unit Operator’s Manual .
Page 252: Specifications
Specifications Figure 1 Frame Construction: Precision machined die cast alu- Bedknife: A replaceable, single edged bedknife is fas- minum cross member with two (2) bolt--on cast alumin- tened to a machined cast iron bedbar with screws. A um side plates. variety of bedknives are available for specific cutting ap- plications.
Page 253: General Information
General Information Cutting Unit Operator’s Manual The Cutting Unit Operator’s Manual provides informa- tion regarding the operation, general maintenance and maintenance intervals for the cutting units on your Reel- master 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.
Page 254 Installation IMPORTANT: When installing cutting unit to ma- chine, make sure that turf compensator spring is mounted on the same side of the cutting unit as the hydraulic reel drive motor. Also, make sure that cut- ting unit is installed on machine with motor and weight properly orientated to machine (Fig.
Page 255: Special Tools
Special Tools Special tools are available from your Toro Distributor. Some tools may have been supplied with your machine or are available as TORO parts. Gauge Bar Assembly Toro Part Number: 108- -6715 Use gauge bar to verify height--of--cut adjustment.
Page 256 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, DO NOT use an air or manual impact wrench with this tool.
Page 257 Tool Figure 14 Plastic Plug Toro Part Number: 2410- -30 (for 5 inch reels) 94- -2703 (for 7 inch reels) This cap is used for placement into the cutting unit side plate when the cutting reel motor is removed. It prevents dirt and debris from entering the cutting reel bearing area.
Page 258 Pulley Alignment Tool Toro Part Number: 114- -5446 Use pulley alignment tool to verify alignment of groomer and/or rear roller brush drive and driven pulleys. Figure 16 Diameter/Circumference Measuring Tape Spring steel measuring tape for accurately measuring the circumference and outside diameter of cutting reel and other spherical components.
Page 259 Bedknife Top Angle Indicator and Mount Toro Part Numbers: 131- -6828 and 131- -6829 Because the top grind angle on bedknives is critical for edge retention, and therefore after-- cut appearance, Toro has developed these service tools for accurately measuring the top grind angle on all bedknives.
Page 260: Factors That Can Affect Cutting Performance
NOTE: For additional information regarding cutting unit cutting unit. It is important to remember that the lower troubleshooting, see Aftercut Appearance Trouble- the height--of--cut, the more critical these factors are. shooting Aid (Toro part no. 00076SL) Factor Possible Problem/Correction Tire pressure Check tire pressure of all traction unit tires.
Page 261 Factor Possible Problem/Correction Reel and bedknife sharpness A reel and/or bedknife that has rounded cutting edges or “rifling” (grooved or wavy appearance) cannot be NOTE: After grinding the reel and/or bedknife, check corrected by tightening the bedknife to reel contact. the reel to bedknife contact again after cutting two (2) Grind cutting reel to remove taper and/or rifling.
Page 262 Factor Possible Problem/Correction Cutting unit alignment and carrier frame ground Check carrier frames and lift arms for damage, binding following conditions or bushing wear. Repair if necessary. Roller condition and roller type Make sure that front and rear rollers rotate freely. Repair roller bearings as necessary.
Page 263: Set Up And Adjustments
Set Up and Adjustments Characteristics If a cutting unit is determined to be out of adjustment, CAUTION complete the following procedures in the specified order to adjust the cutting unit properly. NOTE: See Cutting Unit Operator’s Manual for com- Never install or work on the cutting units or lift plete cutting unit adjustment procedures for your Reel- arms with the engine running.
Page 264: Leveling Rear Roller
Leveling Rear Roller The precision machined components of the cutting unit frame keep the rear roller and cutting reel in alignment (parallel). If the side plates are disassembled or as the cutting reel wears, a limited amount of side plate adjust- ment is possible to make sure that the cutting unit is properly aligned.
Page 265: Service And Repairs
Service and Repairs Cutting Unit Reel Motor 1. Park the machine on a level surface, engage parking brake, lower cutting units and stop engine. Remove key from the ignition switch. FRONT 2. Read the General Precautions for Removing and Installing Hydraulic System Components in this chapter. 3.
Page 266 5. Remove caps or plugs from fittings and hoses. 7. Check oil level in hydraulic reservoir and add correct oil if necessary. IMPORTANT: When installing the hydraulic hoses, make sure that hydraulic hoses are straight (not twisted) 8. Follow Hydraulic System Start--up procedures (see before tightening the hoses to the motor fittings.
Page 267: Backlapping
NOTE: Additional instructions and procedures on result in personal injury. backlapping are available in the Toro General Service Training Book, Reel Mower Basics (part no. 7. To make a cutting unit adjustment while backlapping, 09168SL).
Page 268: Bedbar Assembly
Bedbar Assembly Serial No. 315000001 & Up 18” Cutting Unit Components Shown 27 to 33 ft- -lb (37 to 44 N- -m) RIGHT FRONT Antiseize Lubricant Figure 27 1. Bedbar assembly 5. Plastic washer (4 used) 8. Metal washer (2 used) 2.
Page 269 7. Install the bedbar pivot bolt assemblies. Make sure CAUTION that plastic washers are not caught on the threads of the pivot bolts. Tighten each bedbar pivot bolt from 27 to 33 ft- -lbs (37 to 44 N- -m). Contact with the reel, bedknife or other cutting 8.
Page 270: Bedknife Replacement And Grinding
Bedknife Replacement and Grinding Bedknife Removal 1. Remove bedbar from cutting unit (see Bedbar Re- 22” Cuting Unit Shown moval in this chapter). NOTE: 18” cutting units use 6 screws to secure bed- knife to bedbar. 22” cutting units use 8 screws to secure bedknife to bedbar.
Page 271 Low HOC Figure 34 Standard Bedknife Lead - -in Chamfer Low HOC 1. Use Toro General Service Training Book, Reel Mow- Extended EdgeMax er Basics (part no. 09168SL) and grinder manufactur- Low HOC 0.19” er’s instructions for bedknife grinding information.
Page 272: Bedbar Adjuster Service
Bedbar Adjuster Service Antiseize Loctite #242 Lubricant 14 to 16 ft- -lb (19 to 21 N- -m) Antiseize Lubricant RIGHT FRONT Figure 35 1. Bedbar assembly 6. Lock nut 10. Lock nut 2. Bedbar adjuster shaft 7. Bedbar adjuster screw 11.
Page 273 Removal (Fig. 35) 2. If flange bushings were removed, apply antiseize lu- bricant to bore of cutting unit frame. Align key on bushing 1. Remove lock nut, compression spring and washer to slot in frame and install bushings into frame. from bedbar adjuster screw.
Page 274: Reel Assembly
Reel Assembly 18” Cutting Unit Components Shown 27 to 33 ft- -lb (37 to 44 N- -m) Loctite #242 Antiseize Loctite #242 Lubricant Antiseize Lubricant RIGHT FRONT 27 to 33 ft- -lb (37 to 44 N- -m) Figure 36 1. Cutting reel 7.
Page 275 27 to 33 ft- -lb 15 to 19 ft- -lb (37 to 44 N- -m) (20 to 25 N- -m) 15 to 19 ft- -lb (20 to 25 N- -m) 27 to 33 ft- -lb (37 to 44 N- -m) 27 to 33 ft- -lb (37 to 44 N- -m) Figure 37...
Page 276 IMPORTANT: If the reel bearings or seals are being replaced, the reel spline inserts must be removed. Use the following procedure to restrain the reel and loosen the spline insert before removing the rollers. 5. Loosen the spline inserts (Fig. 38): 85 to 95 ft- - - -lb A.
Page 277 5. Carefully slide the RH end of the cutting reel as- sembly (no groove in reel shaft or on face of threaded insert) into the RH side plate. Make sure that bearing is fully seated into side plate. 6. Slide the LH side plate onto the cutting reel as- sembly.
Page 278 IMPORTANT: To avoid grinding the reel, do not con- tact the cutting edge of any blade with the pry bar as this may damage the cutting edge and/or cause a high blade. B. Move the pry bar against the weld side of the reel support plate closest to the spline insert being tightened.
Page 279: Reel Assembly Service
Reel Assembly Service Loctite #242 85 to 95 ft- -lb (115 to 128 N- -m) (Right Hand Threads) Loctite #242 Loctite #242 RIGHT FRONT 85 to 95 ft- -lb (115 to 128 N- -m) (Left Hand Threads - - Groove in Face) Figure 41 1.
Page 280 Assembly of Cutting Reel (Fig. 41) 1. If flocked seals and/or bearings were removed from Flocked reel shaft, discard removed components and replace. Surface Toward Bearing 2. Make sure that the retaining ring is fully seated into Loctite #242 the groove on the cutting reel shaft. 85 to 95 ft- -lb (115 to 129 N- -m) 3.
Page 281: Preparing Reel For Grinding
Specifications chart below). Additional reel grinding in- formation can be found in your Cutting Unit Operator’s Manual. An additional resource is the Toro Basics Se- ries Training Book, Reel Mower Basics (part no. 09168SL) found on the Service Reference Set available from your Authorized Toro Distributor.
Page 282: Front Roller
Front Roller Removal (Fig. 46) Loctite #242 1. Position machine on a clean and level surface, lower cutting units, stop engine, engage parking brake and re- Antiseize move key from the ignition switch. Lubricant 2. Remove the cutting unit from the machine and place on a level working surface.
Page 283: Rear Roller
Rear Roller Removal (Fig. 47) 15 to 19 ft- -lb 1. Position machine on a clean and level surface, lower (20 to 26 N- -m) cutting units, stop engine, engage parking brake and re- move key from the ignition switch. 2.
Page 284: Roller Service
Roller Service Disassembly (Fig. 48) 50 to 60 ft- -lb 1. Remove bearing lock nut from each end of roller (68 to 81 N- -m) shaft. 2. Loosely secure roller assembly in bench vise and lightly tap one end of roller shaft until outer seals and bearing are removed from opposite end of roller tube.
Page 285 3. From the roller tube end with only the inner seal installed, carefully install the roller shaft into the roller tube. Make sure that seals are not damaged as shaft is installed. 4. Install new bearing and outer seals into second end of roller tube: A.
Page 286: Rear Roller Brush (Optional)
Rear Roller Brush (Optional) REAR ROLLER BRUSH ASSEMBLY FOR 18 IN. CUTTING UNIT WITH LEFT HAND DRIVE AND NO GROOMER SHOWN 20 to 25 in- -lb (2.3 to 2.8 N- -m) Tighten to Specified Torque (see text) 15 to 19 ft- -lb (20 to 25 N- -m) Loctite #242 85 to 95 ft- -lb...
Page 287 Rear roller brush drive components are located on the opposite side of the cutting unit from the cutting unit hy- draulic motor. Figure 54 shows components used when the brush drive is on the left side of the cutting unit. The Installation Instructions for the rear roller brush kit has detailed information regarding assembly and ad- justment.
Page 288 C. Apply a light coating of grease to inner diameter of the seals in roller brush bearing housings. D. Inspect O--ring on non--driven end of roller brush shaft and replace if necessary. E. Apply antiseize lubricant to splines of roller brush shaft before sliding hardened washer(s) and driven pulley onto shaft.
Page 289 Chapter 8 Belt Driven Groomer (Optional) Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .
Page 290: Grooming Performance
Grooming Performance There are a number of factors that can affect the per- formance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs.
Page 291: Troubleshooting
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive belt needs to be Adjust groomer drive belt. adjusted. Seized groomer reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s). ing(s).
Page 292: Service And Repairs
Service and Repairs NOTE: The Groomer Operator’s Manual provides in- formation regarding the installation, set−up and opera- CAUTION tion of the optional groomer on your Reelmaster machine. Refer to these instructions for additional in- Never work on the groomer with the engine formation when servicing the groomer.
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Page 294: Groomer Plate Assembly
Groomer Plate Assembly Special Instructions (see text) Loctite 17 to 21 ft−lb (23 to 28 N−m) Left Side Driven Groomer Assembly Shown #242 Special Instructions (see text) 17 to 21 ft−lb (23 to 28 N−m) Loctite #242 Antiseize 27 to 33 ft−lb Lubricant (37 to 44 N−m) Antiseize...
Page 295 Removal (Fig. 3) B. Remove shoulder bolt and spacer that secures quick−up ball joint rod to groomer plate. 1. Park machine on a clean and level surface, lower C. Remove two (2) socket head screws that secure cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition groomer components to cutting unit side plate.
Page 296 A. Apply a thin layer of grease to inner lip of seal and carefully position non−drive side groomer plate onto groomer shaft and slide to cutting unit. B. Apply antisieze lubricant to the outside diameter of the pivot hub and position pivot hub to cutting unit (Fig.
Page 297 NOTE: To prevent groomer shaft from turning when installing driven pulley, use wrench on groomer shaft flats. J. Apply antiseize lubricant to splines of driven pul- ley and slide driven pulley onto groomer shaft. Se- cure driven pulley with flange nut and torque flange nut from 27 to 33 ft−lb (37 to 44 N−m).
Page 298: Groomer Reel
Groomer Reel Loctite #242 Left Side Driven Groomer Assembly Shown Loctite #242 27 to 33 ft−lb (37 to 44 N−m) Antiseize Lubricant Antiseize Lubricant Loctite #242 85 to 98 ft−lb (115 to 129 N−m) Antiseize RIGHT Lubricant 27 to 33 ft−lb FRONT (37 to 44 N−m) Antiseize...
Page 299 Removal (Fig. 7) 1. Park machine on a clean and level surface, lower cutting units completely to the ground, stop engine, en- gage parking brake and remove key from the ignition switch. If desired, remove cutting unit from machine (see Traction Unit Operator’s Manual). NOTE: If cutting unit is equipped with powered rear roller brush, removal of roller brush components will be necessary to remove groomer reel (see Roller Brush...
Page 300: Groomer Reel Service
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn MIDPOINT blades or reverse the blades to put the sharpest blade edge forward (Fig. 9). Blades that are rounded to the midpoint of the blade tip must be reversed or replaced for best groomer performance.
Page 301 5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 16 to 21 ft−lb (23 to 28 N−m) B. Slide a brush into each groove around the full length of the groomer reel (Fig.
Page 302: Height Adjuster Assembly
Height Adjuster Assembly Left Side Driven Groomer Assembly Shown Antiseize Lubricant 30 to 40 in−lb (3.4 to 4.5 N−m) Antiseize Lubricant Loctite #242 17 to 21 ft−lb (23 to 28 N−m) Antiseize Lubricant Figure 14 1. Groomer plate (LH drive shown) 6.
Page 303 Chapter 9 Universal Groomer (Optional) Table of Contents GROOMING PERFORMANCE ....TROUBLESHOOTING ......Groomer Reel Mechanical Problems .
Page 304: Grooming Performance
Grooming Performance There are a number of factors that can affect the per- formance of grooming. These factors vary for different golf courses and from fairway to fairway. It is important to inspect the turf frequently and vary the grooming practice with turf needs.
Page 305: Troubleshooting
Troubleshooting Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. The groomer drive is in Neutral. Engage groomer drive to Forward or Reverse. Damaged or seized groomer drive Repair groomer drive. gears. The turf is damaged or has uneven The groomer reel blades are bent, Repair or replace blades if neces- grooming.
Page 306: Service And Repairs
Service and Repairs RIGHT FRONT Figure 1 1. Gear box assembly 3. Groomer reel 5. Weight 2. Idler assembly 4. Height adjuster assembly (2) 6. Button head screw (2) NOTE: The Groomer Operator’s Manual provides in- formation regarding the installation, set−up, operation CAUTION and maintenance of the universal groomer on your Reelmaster machine.
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Page 308: Gear Box Assembly
Gear Box Assembly 90 to 100 ft- -lb (122 to 135 N- -m) RIGHT FRONT Figure 2 1. Gear box assembly 3. Button head screw 5. Clevis pin 2. Rear roller brush drive shield 4. Cotter pin 6. Input shaft NOTE: The groomer gear box assembly is located on NOTE: If cutting unit is equipped with an optional pow- the opposite side of the cutting unit from the cutting unit...
Page 309 5. Install a 5/16–18 X 5/8 inch square head set screw (Toro p/n 1--803022) in the end of the drive shaft and tighten to 13 N·m (120 in--lb); refer to Fig. 3. 120 in- -lb 6.
Page 310 I. Move the pry bar against the weld side of the reel support plate closest to the drive shaft assembly. J. Use the drive shaft removal tool (Toro p/n 137--0920) on the large flats of the drive shaft as- sembly; refer to Fig. 5.
Page 311 Disassembly (Fig. 6) 115 to 125 ft- -lb (156 to 169 N- -m) 85 to 95 in- -lb (9 to 11 N- -m) 7 in. Reel Cutting Units Only 32 to 42 in- -lb Tighten to Specified Torque (see text) (4 to 5 N- -m) Figure 6 1.
Page 312 The gear box assemblies for cutting units with 5 in. reels and 7 in. reels are very similar. The gear box for cutting units with 7 in. reels have two (2) additional idler gear as- semblies (Fig. 4). CAUTION Use the 1- -3/8” flats on the input shaft to prevent the input shaft from rotating during adapter re- moval.
Page 313 CAUTION Use the 1- -3/8” flats on the input shaft to prevent the input shaft from rotating during adapter in- stallation. DO NOT use the 1/2” hex on the input shaft to secure the shaft during adapter installa- tion or input shaft damage may occur. 10.If removed, install the threaded adapter in the input shaft.
Page 314: Idler Assembly
Idler Assembly Loctite #242 85 to 95 ft−lb (115 to 129 N−m) Antiseize Lubricant 27 to 33 ft−lb (37 to 45 N−m) 24 to 30 ft−lb (33 to 41 N−m) Figure 5 1. Socket head screw (2) 6. Cotter pin 10.
Page 315 Installation (Fig. 5) 1. If shields, bearing or bushing was removed from idler arm, install new components. A. Press bushing into groomer plate until the bush- ing is centered in the idler arm bore. B. Press bearing into idler arm so that bearing con- tact shoulder in idler arm bore and install bearing re- taining ring.
Page 316: Groomer Reel
Groomer Reel 45 to 60 in−lb (5 to 7 N−m) 45 to 60 in−lb (5 to 7 N−m) Figure 7 1. Groomer reel 3. Cap screw (4) 4. Jam nut (4) 2. Shaft clamp (4) Remove the groomer reel to replace individual groomer 3.
Page 317: Groomer Reel Service
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades. Either replace worn MIDPOINT blades or reverse the individual blades to put the sharpest blade edge forward (Fig. 8). Blades that are rounded to the midpoint of the blade tip must be re- versed or replaced for best groomer performance.
Page 318 5. If groomer reel is equipped with broomer kit: A. Loosen the groomer blade retaining nuts on each end of the groomer shaft. 31 to 35 ft−lb (42 to 48 N−m) B. Slide a brush into each groove around the full length of the groomer reel (Fig.
Page 319: Grooming Brush (Optional)
Grooming Brush (Optional) Service The optional grooming brush is removed and installed from the groomer in the same manner as the groomer reel (see Groomer Reel in this chapter). The grooming brush element or shaft can be serviced separately (Fig. 13). Figure 13 1.
Page 320: Height Adjuster Assembly
Height Adjuster Assembly Antiseize Lubricant Antiseize Lubricant Figure 14 1. Height of cut bracket 8. Clevis pin 14. Pinch bolt (front roller) 2. Height adjustment bolt 9. Button head screw 15. Lock nut 3. Washer (2) 10. Detent spring 16. Washer (2) 4.
Page 321 Assembly (Fig. 14) 1. Apply antiseize lubricant to upper threads of adjust- ment rod and lower threads of height adjusters. Assem- ble height adjuster assembly as shown. 2. If both height adjusters were removed, fit one height adjuster assembly to the cutting unit side plate and se- cure with carriage bolt and flange nut.
Page 322 This page is intentionally left blank. Universal Groomer Page 9 − 20 Reelmaster 3550−D/3555−D/3575−D...
Page 323: Hydraulic Schematics
Chapter 10 Foldout Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS ..HYDRAULIC SCHEMATICS ....Reelmaster 3550--D .
Page 324: Foldout Drawings
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 BLACK BR or BN BROWN BLUE GREEN GRAY ORANGE PINK R or RD VIOLET W or WH WHITE Y or YE YELLOW...
Page 325: Reelmaster 3550--D
121- -7825 REV. C STEERING CYLINDER BORE: 2 .00” STROKE: 3.76” ROD: 0.625” LIFT CYLINDER #1 LIFT CYLINDER #4 LIFT CYLINDER #5 LIFT CYLINDER #2 LIFT CYLINDER #3 EXTEND TO TURN LEFT BORE: 1.50” BORE: 1.50” BORE: 1 .50” BORE: 1.50” BORE: 1 .50”...
Page 326: Reelmaster 3555--D/3575--D
133- -0907 REV. A 133- -0908 REV. A STEERING CYLINDER BORE: 2.00” STROKE: 3.76” ROD: 0.625” LIFT CYLINDER #5 LIFT CYLINDER #1 LIFT CYLINDER #4 LIFT CYLINDER #2 LIFT CYLINDER #3 EXTEND TO TURN LEFT BORE: 1.50” BOR E: 1.50” BOR E: 1.50”...
Page 327: Reelmaster 3550--D (Machines Below Serial Number 316000300)
121- -7824 REV. B Reelmaster 3550--D (machine serial numbers below 316000300) Electrical Schematic All relays and solenoids are shown as de- - energized. All ground wires are black. Page 10 - - 5...
Page 328: Reelmaster 3550--D/3555--D/3575--D
122- -0417 REV. B Reelmaster 3550--D/3555--D/3575--D (machine serial numbers All relays and solenoids 316000301 to 403446000) are shown as de- - energized. Electrical Schematic All ground wires are black. Page 10 - - 6...
Page 329 122- -1525 Rev A Reelmaster 3550- -D/3555- -D/3575- -D All relays and solenoids Electrical Schematic are shown as de energized. (Serial Numbers Above 403446001) All ground wires are black. Page 10 - - 7...
Page 330 120- -3959 REV. F Reelmaster 3550--D (machine serial numbers below 316000300) Wire Harness Drawing Page 10 - - 8...
Page 331 120- -3959 REV. F GRAY BLACK PINK BLACK BLACK BLACK BROWN BLACK PINK BLACK BLACK BLACK BLACK VIOLET BLACK BLACK BROWN BLACK BLACK BLACK BLACK YELLOW BLACK BLACK WHITE BLACK BLACK BLACK BLACK BLACK/WHITE BLACK/WHITE RED/WHITE RED/WHITE Reelmaster 3550--D (machine serial numbers below 316000300) Wire Harness Diagram Page 10 - - 9...
Page 332 122- -0416 REV. C Reelmaster 3550--D/3555--D/3575--D (Machine serial number 316000301 to 403446000) Wire Harness Drawing Page 10 - - 10...
Page 333 122- -0416 REV. C Reelmaster 3550--D/3555--D/3575--D (Machine serial number 316000301 to 403446000) Wire Harness Drawing Page 10 - - 11...
Page 334 122- -1526 Rev C Reelmaster 3550- -D/3555- -D/3575- -D Wire Harness Drawing (Serial Numbers 403446001 to 405999999) Page 10 - - 12...
Page 335 122- -1526 Rev C Reelmaster 3550- -D/3555- -D/3575- -D Wire Harness Drawing (Serial Numbers 403446001 to 405999999) Page 10 - - 13...
Page 336 122- -1731 Rev A Reelmaster 3550- -D/3555- -D/3575- -D Wire Harness Drawing (Serial Numbers Above 406000000) Page 10 - - 14...
Page 337 122- -1731 Rev A Reelmaster 3550- -D/3555- -D/3575- -D Wire Harness Drawing (Serial Numbers Above 406000000) Page 10 - - 15...
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This manual is also suitable for:

Reelmaster 3555-d Reelmaster 3575-d

Toro Reelmaster 3550-D Service Manual

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Chapter 2 Product Records and Maintenance

Chapter 3 Kubota Diesel Engine

Chapter 4 Hydraulic System

Chapter 5 Electrical System

Chapter 6 Chassis

Chapter 7 Dpa Cutting Units

Chapter 8 Belt Driven Groomer (Optional)

Chapter 9 Universal Groomer (Optional)

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