Page 1 Bloomington, MN 55420–1196 vent damage to systems or components on the machine. The Toro Company reserves the right to change product specifications or this publication without notice. E The Toro Company – 2000, 2002, 2003, 2004, 2007...
Page 2 Reelmaster 5500-D...
Page 3: Table Of Contents
......4 – 37 Service and Repairs ..... . . 4 – 41 Reelmaster 5500-D Rev. D...
Page 4 Reelmaster 5500-D...
Page 5 ..... . 10 – 3 Electrical Harness Drawings ....10 − 5 Reelmaster 5500-D Rev. C...
Page 6 Reelmaster 5500-D...
Page 7: General Safety Instructions
....General Safety Instructions The REELMASTER 5500-D was tested and certified by duce the potential for injury or death, comply with the TORO for compliance with the B71.4-1990 specifica-...
Page 8 D. Stop engine and remove key from switch. C. Watch for holes or other hidden hazards. E. Toro recommends that anytime the machine is D. Look behind machine before backing up. parked (short or long term) the cutting units should be lowered to the ground.
Page 9 Toro replacement parts and sult. accessories. Replacement parts and accessories made 26.Before disconnecting or performing any work on the...
Page 10: Jacking Instructions
C. Chock both front tires. Jack rear of machine off E. On 4WD models, use jack stands or blocks under the ground. the axle tube as close to the gear box housings as possible to secure the machine. Safety Reelmaster 5500-D Page 1 - 4...
Page 11: Product Records
....Product Records Insert Operator’s Manual and Parts Catalog for your Reelmaster 5500-D at the end of this chapter. Addition- ally, if any optional equipment or accessories have been installed to your machine, insert the Installation Instruc- tions, Operator’s Manuals and Parts Catalogs for those...
Page 12: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Reelmaster 5500-D Page 2 - 2 Rev. D...
Page 13: 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 14: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
SAE J429. The tolerance is installing fasteners into threaded aluminum or brass. approximately + 10% of the nominal torque value. Thin The specific torque value should be determined based height nuts include jam nuts. Product Records and Maintenance Reelmaster 5500-D Page 2 - 4...
Page 15: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Note: Torque values may have to be reduced when SAE J1199. The tolerance is approximately + 10% of the installing fasteners into threaded aluminum or brass. nominal torque value. The specific torque value should be determined based Reelmaster 5500-D Product Records and Maintenance Page 2 - 5...
Page 16: Other Torque Specifications
All torque values are based on non–lubricated fasteners. Conversion Factors in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb Product Records and Maintenance Reelmaster 5500-D Page 2 - 6...
Page 17 ......KUBOTA WORKSHOP MANUAL 05 SERIES DIESEL ENGINE Rev. C Reelmaster 5500-D Page 3 - 1 Kubota Diesel Engine...
Page 18: Introduction
Reelmaster 5500-D. pair facility. Most repairs and adjustments require tools which are Service and repair parts for Kubota engines are sup- commonly available in many service shops.
Page 19: Specifications
3.8 (4.0) with Filter Starter 12 VDC, 1.4 KW Alternator/Regulator 12 VDC 40 AMP Coolant Capacity liters (U.S. qt.) 9.1 (9.6) with 0.9 (1.0) Reservoir Dry Weight kilograms (U.S. lbs) 98.0 (215.0) Reelmaster 5500-D Page 3 - 3 Kubota Diesel Engine...
Page 20: General Information
(not the filler neck). Do not overfill. Install cap to stop engine, engage parking brake, and remove key the neck from the ignition switch. 2. Clean area around the fuel tank cap. Remove cap from the tank. Kubota Diesel Engine Reelmaster 5500-D Page 3 - 4...
Page 21: Check Cooling System
3. If coolant level is low, remove expansion tank cap and cause burns. Open radiator cap only when and replenish the system. Do not overfill. the radiator and engine are cold. 4. Install expansion tank cap. Reelmaster 5500-D Page 3 - 5 Kubota Diesel Engine...
Page 22: Adjustments
20 lb (89 N). Figure 5 1. Throttle cable connector 3. High idle stop screw 2. Control lever arm 4. Fuel injection pump Kubota Diesel Engine Reelmaster 5500-D Page 3 - 6...
Page 23: Adjust Alternator/Fan Belt
8. Tighten both lock nuts to secure the adjustment. Figure 7 1. Upper lock nut 3. Cooling fan belt 2. Belt tensioner lever Reelmaster 5500-D Page 3 - 7 Kubota Diesel Engine...
Page 24: Service And Repairs
However, if the engine does not start, air may be trapped between injection pump and injectors (see Bleed Air from Fuel Injectors). Figure 10 1. Bleed screw 2. Fuel injection pump Kubota Diesel Engine Reelmaster 5500-D Page 3 - 8...
Page 25: Bleed Air From Fuel Injectors
Do not over- Figure 12 tighten filter. 1. Drain plug 4. Add oil to the crankcase (see Check Engine Oil). Figure 13 1. Oil filter 2. Radiator hose Reelmaster 5500-D Page 3 - 9 Kubota Diesel Engine...
Page 26: Clean Radiator And Oil Coolers
Figure 16 1. Fuel filter assembly 4. Filter element 5. Install filter bowl by hand until O-ring contacts mount- 2. Filter bowl 5. Filter head ing surface. 3. O-ring Kubota Diesel Engine Reelmaster 5500-D Page 3 - 10...
Page 27: Muffler Removal And Installation
1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove muffler and/or muffler bracket from the en- gine as necessary using Figure 17 as a guide. Reelmaster 5500-D Page 3 - 11 Kubota Diesel Engine...
Page 28: Fuel System
Use die- loose connections. Replace hoses, clamps, and con- sel fuel for the engine only; not for any other pur- nections as necessary. pose. Kubota Diesel Engine Reelmaster 5500-D Page 3 - 12...
Page 29: Fuel Tank Removal
2. Flush fuel tank out with clean diesel fuel and com- pletely drain. Make sure tank is free of contaminates and debris. 3. Install fuel tank to the machine (see Fuel Tank Instal- lation). Reelmaster 5500-D Page 3 - 13 Kubota Diesel Engine...
Page 30: Air Filtering System
1. Filter element 2. Body conditions, raising the precleaner bowl above the hood with an optional extension tube (Toro Part No. 43-3810) C. Dry filter element using warm, flowing air (160_F is recommended. max.), or allow element to air-dry. Do not use a light bulb to dry the filter element as damage may result.
Page 31: Water/Fuel Separator
Rotate element an additional 1/2 turn. 7. Screw filter element and base onto filter head by hand until the gasket contacts the mounting surface. Rotate element and base an additional 1/2 turn. Reelmaster 5500-D Page 3 - 15 Kubota Diesel Engine...
Page 32: Radiator
33. Radiator shield 51. O-ring 16. Hose clamp 34. Grommet 52. Straight Hydraulic fitting 17. Expansion tank hose 35. Grommet 53. Hydraulic oil cooler 18. Hose clamp 36. Starter relay 54. Lock nut Kubota Diesel Engine Reelmaster 5500-D Page 3 - 16...
Page 33: Removal And Installation
10.Close engine hood to the machine. DANGER Because diesel fuel is highly flammable, use cau- tion when storing or handling it. Do not smoke while servicing fuel lines. Reelmaster 5500-D Page 3 - 17 Kubota Diesel Engine...
Page 34: Engine
43. Lock washer 66. Retaining clamp 21. Lock washer 44. V-belt 67. Flange nut 22. Hex nut 45. Cap screw 68. Washer plate 23. Lock washer 46. Idler pulley Kubota Diesel Engine Reelmaster 5500-D Rev. C Page 3 - 18...
Page 35: Removal
12.Connect hoist or lift to the front and rear lift tabs. from the water/fuel separator at the injector and fuel pumps. Disconnect fuel hose from the fuel tank at the fuel pump (Fig. 31). Reelmaster 5500-D Page 3 - 19 Kubota Diesel Engine...
Page 36: Installation
Connect both fuel hoses from the water/fuel separator to the injector and fuel pumps. Connect fuel hose from the fuel tank to the fuel pump (Fig. 31). Kubota Diesel Engine Reelmaster 5500-D Rev. C Page 3 - 20...
Page 37 13.Connect both battery cables to the battery (see Bat- tery Service in Chapter 5 - Electrical System). 14.Adjust throttle cable (see Adjust Throttle Cable). 15.Bleed fuel system (see Bleed Fuel System). 16.Close engine hood. Rev. C Reelmaster 5500-D Page 3 - 21 Kubota Diesel Engine...
Page 38: Fan Drive Hub
5. Apply Loctite #242 (or equivalent) to threads of shaft screw. Install flat washer and shaft screw. Torque screw from 156 to 204 in−lbs (17.6 to 23.1 N−m). Kubota Diesel Engine Reelmaster 5500-D Rev. C Page 3 - 22...
Page 39: Service And Repairs
....Heat Exchanger ......Reelmaster 5500-D Page 4 - 1 Hydraulic System (Rev. C)
Page 40: Specifications
Hydraulic Reservoir (Reels, Lift, and Steering Circuits) 8.5 gal. U.S. (32.2 L) Hydraulic Oil See Check Hydraulic System Fluid in General Information section Hydraulic Reservoir in Differential Housing (Transmission) 5.0 qts. U.S. (4.7 L) Hydraulic System (Rev. C) Page 4 - 2 Reelmaster 5500-D...
Page 41: Hydraulic Hoses
8 (1/2 in.) 0.75 + 0.25 Finger Tight After Proper Tightening 10 (5/8 in.) 1.00 + 0.25 12 (3/4 in.) 0.75 + 0.25 16 (1 in.) 0.75 + 0.25 Figure 2 Reelmaster 5500-D Page 4 - 3 Hydraulic System (Rev. C)
Page 42 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Figure 5 Hydraulic System (Rev. C) Page 4 - 4 Reelmaster 5500-D...
Page 43: Towing Traction Unit
5. When towing is completed, reinstall driveshaft. The Figure 7 splines are designed to allow assembly only when the 1. Front frame member two halves of the shaft are properly oriented (Fig. 6). Reelmaster 5500-D Page 4 - 5 Hydraulic System (Rev. C)
Page 44: Check Transmission Fluid
Mobil DTE 26 type fluids. Hydraulic System (Rev. C) Page 4 - 6 Reelmaster 5500-D...
Page 45 4 to 6 gal. (15 to 23 L) of hydraulic fluid. Order Phillips HG Fluid Part No. 44-2500 from your Authorized Toro Distributor Note: The fluids in this group are interchangeable. Group 2 Hydraulic Fluid (Recommended for ambi- ent temperatures consistently above 70_ F.):...
Page 46: Hydraulic Schematics
Hydraulic Schematics Hydraulic System (Rev. C) Page 4 - 8 Reelmaster 5500-D...
Page 47 Reelmaster 5500-D Page 4 - 9 Hydraulic System (Rev. C)
Page 48 Hydraulic System (Rev. C) Page 4 - 10 Reelmaster 5500-D...
Page 49 This page is intentionally blank. Reelmaster 5500-D Page 4 - 11 Hydraulic System (Rev. C)
Page 50 Hydraulic Flow Diagrams Hydraulic System (Rev. C) Page 4 - 12 Reelmaster 5500-D...
Page 51: Traction Circuit
If pressure exceeds the relief setting, oil flows through the relief valve to the low pressure side of the closed loop circuit. Reelmaster 5500-D Page 4 - 13 Hydraulic System (Rev. C)
Page 52 Hydraulic System (Rev. C) Page 4 - 14 Reelmaster 5500-D...
Page 53: Lower Cutting Units
#1, 4, and 5 are located on the main lift manifold below the operator’s platform. The remaining flow control valve that regulates lift cylinders #2 & 3 is lo- cated in the rear of the traction unit. Reelmaster 5500-D Page 4 - 15 Hydraulic System (Rev. C)
Page 54 Hydraulic System (Rev. C) Page 4 - 16 Reelmaster 5500-D...
Page 55: Raise Cutting Units
(#4 and #5). the hydraulic reservoir. Pressure to the lift manifold can be monitored at port (G3). Reelmaster 5500-D Page 4 - 17 Hydraulic System (Rev. C)
Page 56 Hydraulic System (Rev. C) Page 4 - 18 Reelmaster 5500-D...
Page 57: Mow And Backlap
(MD1). the front or rear reel motors. System pressure on the (P1) side can be measured at Port (G1). Reelmaster 5500-D Page 4 - 19 Hydraulic System (Rev. C)
Page 58 Hydraulic System (Rev. C) Page 4 - 20 Reelmaster 5500-D...
Page 59: Right And Left Turns
The rotary meter ensures that the oil flow to the reservoir. cylinder is proportional to the amount of steering wheel Reelmaster 5500-D Page 4 - 21 Hydraulic System (Rev. C)
Page 60: Special Tools
Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit - TOR47009 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 61 Figure 13 Reelmaster 5500-D Page 4 - 23 Hydraulic System (Rev. C)
Page 62: Troubleshooting
No cutting units will operate. Lower-mow/raise lever was improperly used. Electrical problem exists (see Chapter 5 - Electrical System). Gear pump or its coupler is damaged (Steering and lift circuits are also affected). Hydraulic System (Rev. C) Page 4 - 24 Reelmaster 5500-D...
Page 63 Solenoid valve SV1 is not shifting. Flow control(s) valve is(are) not adjusted properly (closed). Solenoid valve SV2 is shifted (See Chapter 5 - Electrical System). Relief valve R3 is by-passing. Reelmaster 5500-D Page 4 - 25 Hydraulic System (Rev. C)
Page 64 This page is intentionally blank. Hydraulic System (Rev. C) Page 4 - 26 Reelmaster 5500-D...
Page 65: Testing
Stop engine; 9. Check control linkages for improper adjustment, lower or support attachments. binding,or broken parts. 10.All hydraulic tests should be made with the hydraulic oil at normal operating temperature. Reelmaster 5500-D Page 4 - 27 Hydraulic System (Rev. C)
Page 66: Test No. 1: Traction Circuit Charge Pressure
When the pump and/or motor is worn or damaged the charge pump is not able to keep up with the internal leak- age. Hydraulic System (Rev. C) Page 4 - 28 Reelmaster 5500-D...
Page 67: Test No. 2: Traction Circuit System Relief Pressure
Note: Clean or replace valves as necessary. These cartridge type valves are factory set, and are not adjust- able. If check/relief valves are in good condition, replace or overhaul transmission. Reelmaster 5500-D Page 4 - 29 Hydraulic System (Rev. C)
Page 68: Test No. 3: Relief Valve (R1) And (R2) Pressure
7. Have another person occupy seat, move ”Enable/ Disable” switch to ENABLE. Move ”Lower− Mow/Raise” lever forward to engage cutting units, then monitor the tester pressure gauge. Hydraulic System (Rev. C) Page 4 - 30 Reelmaster 5500-D...
Page 69: Test No. 4: Gear Pump Section (P1 & P2) Flow
4. Make sure the parking brake is engaged. Start the engine and move throttle to full speed (3200 RPM). DO NOT engage the cutting units. Reelmaster 5500-D Page 4 - 31 Hydraulic System (Rev. C)
Page 70: Test No. 5: Reel Drive Motor Cross-Over Relief Pressure
Keep away from reels during tests to prevent personal injury from rotating blades. Do not 1. Make sure hydraulic oil is at normal operating temper- stand in front of the machine. ature before doing test. Hydraulic System (Rev. C) Page 4 - 32 Reelmaster 5500-D...
Page 71 6. With cutting units in lowered position and engine OFF, insert a block of wood between cutting unit reel blades and front cross tube of cutting unit to prevent reel from turning (Fig. 20). Reelmaster 5500-D Page 4 - 33 Hydraulic System (Rev. C)
Page 72: Test No. 6: Reel Drive Motor Efficiency
Hydraulic System (Rev. C) Page 4 - 34 Reelmaster 5500-D...
Page 73 Reconnect case drain hose to Keep away from cutting units during test to pre- the reel motor. vent personal injury from rotating reel blades. Do not stand in front of the machine. Reelmaster 5500-D Page 4 - 35 Hydraulic System (Rev. C)
Page 74: Test No. 7: Gear Pump Section (P3) Flow And Relief Valve Pressure
7. While watching pressure gauges, slowly close flow control valve further until 1450 PSI (100 bar) is main- tained as the relief valve lifts. TESTER READING: Relief valve setting of 1450 PSI (100 bar). Hydraulic System (Rev. C) Page 4 - 36 Reelmaster 5500-D...
Page 75: Adjustments
3. To decrease pressure setting, turn the adjustment socket inside the valve 1/8 of a turn counterclockwise. 4. Install and tighten cap to valve. Retest pressure set- ting (see Testing). Reelmaster 5500-D Page 4 - 37 Hydraulic System (Rev. C)
Page 76: Adjust Traction Drive For Neutral
Hydraulic System (Rev. C) Page 4 - 38 Reelmaster 5500-D...
Page 77: Adjust Cutting Unit Drop Rates
1/2 turn clockwise. 3. Verify drop rate adjustment by raising and lowering cutting units several times. Readjust as required. 4. After desired drop rate is attained, tighten locking ring to lock adjustment. Reelmaster 5500-D Page 4 - 39 Hydraulic System (Rev. C)
Page 78: Adjust Traction Control Linkage
(70 mm) (Fig. 28). Tighten outer locknut. 2.75” (70 mm) 4. Operate the machine and check for safe stopping distance. Figure 28 1. Spring anchor plate 3. Inner lock nut 2. Eye bolt 4. Outer locknut Hydraulic System (Rev. C) Page 4 - 40 Reelmaster 5500-D...
Page 79: Service And Repairs
5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes. Reelmaster 5500-D Page 4 - 41 Hydraulic System (Rev. C)
Page 80: Check Hydraulic Lines And Hoses
1 through 15 again at least once and until the oil is clean. 5. Inspect and clean hydraulic reservoir (see Hydraulic Reservoir Inspection). 16.Assume normal operation and follow recommended maintenance intervals. Hydraulic System (Rev. C) Page 4 - 42 Reelmaster 5500-D...
Page 81: Charge Hydraulic System
Check hydraulic components for leaks and tighten any loose connections. 9. Raise one front and rear wheel off the floor, and place support blocks under the frame. Chock remaining wheel to prevent movement of the machine. Reelmaster 5500-D Page 4 - 43 Hydraulic System (Rev. C)
Page 82: Change Hydraulic Fluid
Change Hydraulic Fluid Change hydraulic fluid after every 800 operating hours, in normal conditions. If fluid becomes contaminated, contact your local TORO distributor because the system must be flushed. Contaminated fluid looks milky or black when compared to clean oil.
Page 83: Replace Hydraulic Oil Filter
GREEN zone. When the in- dicator is in the RED zone, the filter element should be changed. IMPORTANT: Use only the Toro replacement filter recommended for this product (see parts catalog or service reference decal on unit). Use of any other fil- ter may void the warranty on some components.
Page 84: Replace Transmission Fluid
3. Lubricate new filter gasket and fill the filter with hy- operation and every 800 hours, thereafter. draulic oil. IMPORTANT: Only the Toro replacement filter (Part 4. Assure filter mounting area is clean. Screw filter on No.75-1330) can be used in the hydraulic system.
Page 85: Transmission Control Linkage
5. Loosen cap screw and lock nut securing pump con- 5. Adjust traction control neutral (see Adjust Traction trol to swashplate control shaft. Drive for Neutral). Reelmaster 5500-D Page 4 - 47 Hydraulic System (Rev. C)
Page 86: Transmission
15. Transmission pilot sleeve 33. Lock washer 51. O-ring 16. Lock nut 34. Transmission 52. Rim 17. Bolt decal 35. Lock nut 53. Tire 18. O-ring 36. O-ring 54. Flat washer Hydraulic System (Rev. C) Page 4 - 48 Reelmaster 5500-D...
Page 87 6. Connect drive shaft to the transmission (Fig. 35). 4. Uncover hole in support plate if necessary. 7. Remove plugs or caps from disconnected hydraulic hoses and open ports of the transmission. Reelmaster 5500-D Page 4 - 49 Hydraulic System (Rev. C)
Page 88 Operate machine slowly in forward and re- verse. Stop engine and check differential oil level. 11. Install a new filter and fill differential with correct oil. Check transmission for leaks. Hydraulic System (Rev. C) Page 4 - 50 Reelmaster 5500-D...
Page 89 This page is intentionally blank. Reelmaster 5500-D Page 4 - 51 Hydraulic System (Rev. C)
Page 90: Transmission Service
Cleanliness is a primary means of assuring satisfactory Protect all sealing surfaces and open cavities from dam- transmission life, on either new or repair units. Cleaning age and foreign material. Hydraulic System (Rev. C) Page 4 - 52 Reelmaster 5500-D...
Page 91: Disassembly
5. Carefully remove valve plates from center section. It may be necessary to pry valve plates off with a small screwdriver (Fig. 41). Figure 41 6. Remove valve plate pins from the center section (Fig. 42). Figure 42 Reelmaster 5500-D Page 4 - 53 Hydraulic System (Rev. C)
Page 92 9. Use O-ring pick or wire to remove thrust plates from swashplate and housing (Fig. 45). Figure 45 10.Use an internal hex wrench to remove pipe plug over motor shaft bearing retaining pin (Fig. 46). Figure 46 Hydraulic System (Rev. C) Page 4 - 54 Reelmaster 5500-D...
Page 93 13.Press motor shaft out of the bearings and spacer (Fig. 49). Figure 49 14.Remove spiral retaining ring and remove PTO seal guide (with O-ring) from the housing (Fig. 50). Figure 50 Reelmaster 5500-D Page 4 - 55 Hydraulic System (Rev. C)
Page 94 O-ring and trunnion bearing on the side oppo- site the control. Remove these parts from the housing (Fig. 52). Figure 52 17.Tilt and lift swashplate from housing (Fig. 53). Figure 53 Hydraulic System (Rev. C) Page 4 - 56 Reelmaster 5500-D...
Page 95: Inspection
2. Install swashplate into housing. Make sure swash- plate control shaft is located on correct side of housing (note marks made during disassembly) (Fig. 55). Figure 55 Reelmaster 5500-D Page 4 - 57 Hydraulic System (Rev. C)
Page 96 6 to 9 ft.-lb (8 to 12 N-m) (Fig. 58). Figure 58 7. Press ball bearing onto pump shaft. Install pump shaft and bearing assembly into housing (Fig. 59). Figure 59 Hydraulic System (Rev. C) Page 4 - 58 Reelmaster 5500-D...
Page 97 9. Press inner bearing, spacer and outer bearing onto motor shaft (Fig. 61). Figure 61 10.Install motor shaft assembly into housing (Fig. 62). Figure 62 11. Install motor shaft bearing retaining pin into housing (Fig. 63). Figure 63 Reelmaster 5500-D Page 4 - 59 Hydraulic System (Rev. C)
Page 98 15.Lay the transmission on its side and install cylinder block kits into the housing (Fig. 67). 16.Put the transmission housing on a work surface with the center section opening facing up. Figure 67 Hydraulic System (Rev. C) Page 4 - 60 Reelmaster 5500-D...
Page 99 (Fig. 70). Figure 70 19.Install the two (2) alignment pins and install a new center section gasket onto the housing (Fig. 71). Figure 71 Reelmaster 5500-D Page 4 - 61 Hydraulic System (Rev. C)
Page 100 In-Line Filter Check Valve Replacement Filter By-Pass Valve Replacement Figure 73 Heat Exchanger By-Pass Valve Replacement Charge Pressure Relief Valve Replacement Check/High Pressure Relief Valve Replacement Trunnion Seal Replacement Shaft Seal Replacement Hydraulic System (Rev. C) Page 4 - 62 Reelmaster 5500-D...
Page 101: Shaft Seal Replacement
0.056 to 0.096 inch (1.42 to 2.44 mm) below the outer surface of the charge pump cover. Install the retaining ring. Figure 75 1. Shaft seal 4. Transmission 2. Charge pump cover 5. Retaining ring 3. Shaft Reelmaster 5500-D Page 4 - 63 Hydraulic System (Rev. C)
Page 102: Trunnion Seal Replacement
11. Install pump control onto transmission swashplate control shaft. Check machine for ”creeping” when en- gine is running with foot pedal in neutral position (see Adjust Traction Drive for Neutral). Hydraulic System (Rev. C) Page 4 - 64 Reelmaster 5500-D...
Page 103: High Pressure Relief/Check Valve Replacement
Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check transmission for leaks. Reelmaster 5500-D Page 4 - 65 Hydraulic System (Rev. C)
Page 104: Charge Pressure Relief Valve Replacement
Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check the transmission for leaks. Hydraulic System (Rev. C) Page 4 - 66 Reelmaster 5500-D...
Page 105: Heat Exchanger By-Pass Valve Replacement
4. Relief valve Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check the transmission for leaks. Reelmaster 5500-D Page 4 - 67 Hydraulic System (Rev. C)
Page 106: Filter By-Pass Valve Replacement
4. Relief valve Start the engine and let it run for one to two minutes, then turn the engine off and check the oil level again. Check the transmission for leaks. Hydraulic System (Rev. C) Page 4 - 68 Reelmaster 5500-D...
Page 107: Charge Pump Replacement
Make sure the ger- oter engages the drive pin in the shaft. 11. Tighten the charge pump cover cap screws to a torque of 27 to 37 ft.-lb (37 to 50 N-m). Reelmaster 5500-D Page 4 - 69 Hydraulic System (Rev. C)
Page 108: Gear Pump
6. Connect fuel stop solenoid electrical connector, start the engine and check for proper operation. 7. Stop engine and check for hydraulic oil leaks. Check hydraulic reservoir oil level. Hydraulic System (Rev. C) Page 4 - 70 Reelmaster 5500-D...
Page 109 This page is intentionally blank. Reelmaster 5500-D Page 4 - 71 Hydraulic System (Rev. C)
Page 110: Gear Pump Service
15. Anti extrusion seal (SNP2) 23. Relief valve 7. Dowel pin 16. Pressure loading seal (SNP2) 24. Valve block 8. Housing 17. Housing 25. Bolt 9. O-ring − 2.675” (68 mm) dia. Hydraulic System (Rev. C) Page 4 - 72 Reelmaster 5500-D...
Page 111: Section Seal Replacement
4. Remove the four (4) pump housing bolts. 5. Put your hand on the pump case and gently tap the pump case with a soft face hammer to loosen the pump Reelmaster 5500-D Page 4 - 73 Hydraulic System (Rev. C)
Page 112: Reel Motor Service
2. Tighten motor mounting nuts 3. Remove caps or plugs from fittings and hoses. Con- nect hydraulic lines lines to the motor. Hydraulic System (Rev. C) Page 4 - 74 Reelmaster 5500-D...
Page 113: Adjusting Valve (Cross-Over Relief Valve) Service
O-ring grooves in gear housing and install new O-rings in each groove. 8. Remove rear bearing block from drive and idler gear shafts. Reelmaster 5500-D Page 4 - 75 Hydraulic System (Rev. C)
Page 114: Reassembly
Protect the shaft if 6. Install the two front dowel pins in the flange. using a pliers. If drive shaft binds, disassemble motor and repeat assembly process. Hydraulic System (Rev. C) Page 4 - 76 Reelmaster 5500-D...
Page 115 This page is intentionally blank. Reelmaster 5500-D Page 4 - 77 Hydraulic System (Rev. C)
Page 116: Hydraulic Control Manifolds
Service and Repairs section of this chap- ter. 1. Disconnect all electrical connectors from solenoid valves and switches. 2. Disconnect all hydraulic tubes and hoses. 3. Remove hydraulic manifold from the frame (Fig. 89). Hydraulic System (Rev. C) Page 4 - 78 Reelmaster 5500-D...
Page 117 Service and Repairs section of this chap- ter. 1. Disconnect all electrical connectors from solenoid valves. 2. Disconnect all hydraulic tubes and hoses. 3. Remove hydraulic manifold from the frame (Fig. 90). Reelmaster 5500-D Page 4 - 79 Hydraulic System (Rev. C)
Page 118: Hydraulic Control Manifold Service
P1 is the gear pump connec- tion port. (See Hydraulic Schematics to identify the func- tion of the hydraulic lines and cartridge valves at each port location). Hydraulic System (Rev. C) Page 4 - 80 Reelmaster 5500-D...
Page 119 P1 is the gear pump connec- tion port. (See Hydraulic Schematics to identify the func- tion of the hydraulic lines and cartridge valves at each port location). Reelmaster 5500-D Page 4 - 81 Hydraulic System (Rev. C)
Page 120: Solenoid Operated Cartridge Valves
Submerge valve in clean mineral spirits to flush out valves. Remove solenoid. contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. Use compressed air for cleaning. Hydraulic System (Rev. C) Page 4 - 82 Reelmaster 5500-D...
Page 121: Rotary Cartridge Valves
Clean and dry with compressed air. tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45 to the right in line with the indicator plate. Reelmaster 5500-D Page 4 - 83 Hydraulic System (Rev. C)
Page 122: Logic Cartridge
Torque the B. If sealing surfaces appear pitted or damaged, the valve 45 ft-lb (61 N-m). hydraulic system may be overheating or there may be water in the system. Hydraulic System (Rev. C) Page 4 - 84 Reelmaster 5500-D...
Page 123: Flow Divider
(5.6 to 6.2 N−m) 30 to 35 ft−lb (41 to 47 N−m) 20 to 25 ft−lb (27 to 34 N−m) Figure 94 Manifold 3. Flow regulator cartridge Solenoid cartridge valve Reelmaster 5500-D Page 4 - 85 Hydraulic System (Rev. C)
Page 124: Lift Cylinders
Secure thrust washer and retaining ring to the 1. Self tapping screw 5. Cylinder rod end pin 2. Cylinder pin (short) 6. Thrust washer cylinder rod end pin. 3. Carrier frame 7. Lift arm 4. Retaining ring Hydraulic System (Rev. C) Page 4 - 86 Reelmaster 5500-D...
Page 125 7. Lift arm 4. Retaining ring and thrust washer through the lift arm and cylinder clevis. Secure thrust washer and retaining ring to the cylinder rod end pin (Fig. 96 and 95). Reelmaster 5500-D Page 4 - 87 Hydraulic System (Rev. C)
Page 126: Lift Cylinder Service
7. Wear ring 12. Lock nut 3. O−ring 8. Shaft with clevis 13. Barrel with clevis 4. Wiper 9. Retaining ring 14. Grease fitting 5. Rod seal 10. Head Hydraulic System (Rev. C) Page 4 - 88 Reelmaster 5500-D Rev. D...
Page 127 Inspect shaft, head, are covered. and piston for evidence of excessive scoring, pitting, or wear. Replace any damaged parts. Reelmaster 5500-D Page 4 - 89 Hydraulic System (Rev. C) Rev. D...
Page 128: Hydraulic Reservoir
21. Formed hydraulic hose 33. Grommet 10. Screw cap 22. O-ring 34. Flat washer 11. 90 hydraulic fitting 23. Plug 35. Lock washer 12. O-ring 24. O-ring 36. Hydraulic hose Hydraulic System (Rev. C) Page 4 - 90 Reelmaster 5500-D...
Page 129 5. Fill reservoir with hydraulic fluid (see Change Hy- draulic Fluid). 1. Clean hydraulic reservoir and suction strainer with solvent. 2. Inspect hydraulic reservoir for leaks, cracks, or other damage. Reelmaster 5500-D Page 4 - 91 Hydraulic System (Rev. C) Rev. D...
Page 130: Heat Exchanger
(Fig. 102). Figure 103 Oil cooler Heat exchanger Hydraulic hose (IN) Hydraulic hose (IN) 3. Hydraulic hose (OUT) 8. Hydraulic hose (OUT) Hydraulic straight fitting Hydraulic straight fitting O-ring 10. O-ring Hydraulic System (Rev. C) Page 4 - 92 Reelmaster 5500-D...
Page 131 ..Warning Light Cluster ..... . . Reelmaster 5500-D Page 5 - 1 Electrical System (Rev. C)
Page 132: Harness And Connectors Drawings
Electrical Schematic, and Electrical Harness and Connec- tors Drawings The electrical schematic and other electrical drawings for the Reelmaster 5500-D are located in Chapter 10 - Electrical Diagrams. Electrical System (Rev. C) Page 5 - 2 Reelmaster 5500-D...
Page 133: Special Tools
Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. 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 134 Toro Automated Control Electronicst Diagnostic Tool Diagnostic ACEt Display The diagnostic display is connected to the wiring Overlay harness connector located inside the control console to Diagnostic help the user verfiy correct electrical functions of the ma- ACE Display chine (Fig. 3 and 4).
Page 135: Troubleshooting
(i.e. seat sensor, key switch, etc.) and turns on the outputs to actuate solenoids or relays for the re- quested machine function. Reelmaster 5500-D Page 5 - 5 Electrical System (Rev. C)
Page 136: Check Interlock Switches
7. If switch is closed and appropriate LED does not turn on, check all wiring and connections to switch and/or check switches with an ohm meter. Replace any defec- tive switches and repair any defective wiring. Electrical System (Rev. C) Page 5 - 6 Reelmaster 5500-D...
Page 137: Retrieving Stored Faults
6. Release RAISE lever and turn Ignition switch to illuminated, this indicates an ECU problem. If this oc- OFF. Return the Mow/Backlap valve to MOW and the curs, contact your Toro Distributor for assistance. Enable/Disable switch to DISABLE. Fault memory is now cleared.
Page 138: Starting Problems
The problem is not electrical (see Chapter 3 - Kubota Engines). Start cranks, but should not when the traction is The traction neutral switch is out of adjustment. depressed. The traction neutral switch or circuit wiring is faulty. Electrical System (Rev. C) Page 5 - 8 Reelmaster 5500-D...
Page 139: General Run & Transport Problems
The front reels down sensor or circuit wiring is faulty. Ground circuit wiring to solenoids may be open. A hydraulic problem exists (see Troubleshooting section of Chapter 4 - Hydraulic System). Reelmaster 5500-D Page 5 - 9 Electrical System (Rev. C)
Page 140 The rear backlap switch or circuit wiring is faulty. The rear cutting units do not backlap, but all cutting The rear backlap switch or circuit wiring is faulty. units run in the forward direction. Electrical System (Rev. C) Page 5 - 10 Reelmaster 5500-D...
Page 141 Any time the machine gives a series of 4 short D Alarm short circuit (LED blinking): Check TurfDe- beeps. fender alarm or wires. Replace if necessary. c. False alarms are observed. Reelmaster 5500-D Page 5 - 11 Electrical System (Rev. C)
Page 142 Note: Only large air leaks can be detected by Turf- Defender. 5. Your Authorized Toro Distributor has equipment to analyze system problems. 2. When toggling “output” a LED should display (Fig. 10) any of the following problems diagnosed by the...
Page 143 “Self Diagnostic” LED lit steadily c. “DATA LINE” LED lit steadily d. “Alarm ON” LED lit temporarily Problem Diagnosed: The appropriate LED will blink to identify the problem Figure 10 Reelmaster 5500-D Page 5 - 13 Electrical System (Rev. C)
Page 144: Turfdefender Tm Leak Detector
TurfDefender Leak Detector 94−6345 BLK/BU OR/BLK Electrical System (Rev. C) Page 5 - 14 Reelmaster 5500-D...
Page 145: Electrical System Quick Check
11.89 V 0% charged tive battery post. NOTE: This test provides a relative condition of the bat- tery. Load testing of the battery will provide additional and more accurate information. Reelmaster 5500-D Page 5 - 15 Electrical System (Rev. C)
Page 146: Component Testing
POSITION CIRCUIT NONE B + I + A, X + Y START B + I + S Figure 11 1. Key 3. Lock washer 2. Hex nut 4. Ignition switch Electrical System (Rev. C) Page 5 - 16 Reelmaster 5500-D...
Page 147: Glow And Start Relays
30 and 87 should read as an open circuit. Start Relay B. For the start relay, resistance between terminals Figure 14 30 and 87A should be 1 ohm or less. 4. Disconnect voltage and leads from all terminals. Reelmaster 5500-D Page 5 - 17 Electrical System (Rev. C)
Page 148: Fuses
(optional), and Turf Defender Leak Detector (option- al). B. Has two orange wires. Fuse B3 (When Optional Lighting is Installed) A. Supplies power to light relay terminal 1. B. Has two red wires. Electrical System (Rev. C) Page 5 - 18 Reelmaster 5500-D...
Page 149: Hydraulic Valve Solenoids
Lower or lift any cutting units Lift any cutting units 6. Reconnect electrical connector to the solenoid. Lift/lower front, center cutting unit Lift/lower left and right front cutting units Lift/lower rear cutting units Reelmaster 5500-D Page 5 - 19 Electrical System (Rev. C)
Page 150: High Temperature Warning And Shutdown Switch
C. Connect green/white wire to sender. Apply skin- over grease to sender terminal. 7. Fill engine cooling system (see Check Cooling Sys- tem in Chapter 3 - Kubota Diesel Engine). Electrical System (Rev. C) Page 5 - 20 Reelmaster 5500-D...
Page 151: Warning Light Cluster
1. Turn ignition switch to ON; the light should come on. 2. Turn ignition switch to OFF: the light should go off. Reelmaster 5500-D Page 5 - 21 Electrical System (Rev. C)
Page 152: Run (Etr) Solenoid (Solenoid With 3 Wire Connector)
The solenoid should stay engaged. 6. Remove positive (+) voltage from the pin of the red/ blue wire. The solenoid should release. 7. Reconnect the wires to the solenoid. Electrical System (Rev. C) Page 5 - 22 Reelmaster 5500-D...
Page 153: Run (Etr) Solenoid (Solenoid With 2 Wire Connector)
5. Remove positive (+) voltage from the pull coil termi- nal. The solenoid should stay engaged. 6. Remove positive (+) voltage from the hold coil termi- nal. The solenoid should release. 7. Reconnect the wires to the run solenoid. Reelmaster 5500-D Page 5 - 23 Electrical System (Rev. C)
Page 154: Fuel Sender
5. Fuel tank 5. Replace sender as necessary. Reinstall sender into 3. Fuel sender fuel tank. Connect wires. 7.62 inch 100_ (19.4 cm) Figure 28 1. Full position 2. Empty position Electrical System (Rev. C) Page 5 - 24 Reelmaster 5500-D...
Page 155: Fuel Gauge
(full). 3. Turn off the voltage source. Disconnect voltage source, gauge, and variable resistance. Figure 30 1. Empty position 3. Glass face edge 2. Full position Reelmaster 5500-D Page 5 - 25 Electrical System (Rev. C)
Page 156: Temperature Sender
C. Connect blue/white wire to sender. Apply skin- over grease to sender terminal. 5. Fill engine cooling system (see Check Cooling Sys- tem in Chapter 3 - Kubota Diesel Engine). Electrical System (Rev. C) Page 5 - 26 Reelmaster 5500-D...
Page 157: Temperature Gauge
(105_C). 3. Turn off the voltage source. Disconnect voltage source, gauge, and variable resistance. Figure 34 1. Middle position 3. Edge of glass cover 2. High temp position Reelmaster 5500-D Page 5 - 27 Electrical System (Rev. C)
Page 158: Hour Meter
BACK Figure 35 Electronic Control Unit (ECU) The Toro electronic control unit (ECU) senses the condi- tion of various switches, such as the seat sensor, cutting unit down switches, traction neutral switch, etc., and di- rects power output to allow certain machine functions, such as engine run, cutting units engage, etc.
Page 159: Traction Speed Sensor
IMPORTANT: When replacing the sensor, see Trac- tion Speed Sensor Replacement in this section of this manual. Figure 37 1. Traction speed sensor 3. Front right axle 2. Differential gear box 4. Jam nut Reelmaster 5500-D Page 5 - 29 Electrical System (Rev. C)
Page 160: Speedometer
1. Verify with Ace Diagnostic tool that the traction speed sensor is operating properly. 2. Lift all wheels that will be moving off the ground. Figure 40 1. Pinion shaft (2WD) 2. Differential housing Electrical System (Rev. C) Page 5 - 30 Reelmaster 5500-D...
Page 161: Reels Enable/Disable And Backlap Switches
2. Instrument panel switch contacts open. switch Figure 43 1. Front Backlap switch 4. Rear backlap control 2. Rear backlap switch valve 3. Front backlap control 5. Reel hydraulic manifold valve block Reelmaster 5500-D Page 5 - 31 Electrical System (Rev. C)
Page 162: Traction Neutral Switch
4. Have the operator sit on the seat, slowly depressing the seat sensor magnet. The continuity tester should show continuity as the seat approaches the bottom of its travel. Electrical System (Rev. C) Page 5 - 32 Reelmaster 5500-D...
Page 163 Unit Serial No. Unit Serial No. 200000001-209999999 210000001 & Up Figure 47 1. Joy stick 3. Lift control mechanism 2. Micro switch Reelmaster 5500-D Page 5 - 33 Electrical System (Rev. C)
Page 164: Front Reels Down Sensor (Serial Number Below 230000000)
4. Switch bracket 8. Nut 2. Move switch bracket to lowest position in its adjust- ment slot. 3. Adjust gap between switch and lift arm flag to .0625” (1.6 mm). Electrical System (Rev. C) Page 5 - 34 Reelmaster 5500-D...
Page 165: Service And Repairs
(+) cable first. Coat battery posts and cable are explosive, keep open flames and electrical connectors with Grafo 112X (skin-over) grease (Toro sparks away from the battery; do not smoke. Part No. 505-47) or petroleum jelly to prevent corrosion.
Page 166: Battery Service
1. Perform following inspections and maintenance: A. Check for cracks. Replace battery if cracked or leaking. B. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. Electrical System (Rev. C) Page 5 - 36 Reelmaster 5500-D...
Page 167 6. Apply a light coat of skin-over grease on all battery er’s instructions. posts and cable connectors to reduce corrosion after connections are made. C. Make sure battery terminals are free of corrosion. Reelmaster 5500-D Page 5 - 37 Electrical System (Rev. C)
Page 168 The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for three consecutive readings. Electrical System (Rev. C) Page 5 - 38 Reelmaster 5500-D...
Page 169: Traction Speed Sensor Replacement
5. Lower the machine to the ground. Figure 53 1. O-ring 5. Machine screw 2. Mounting plate 6. Lock nut 3. Cover 7. Jam nut 4. Cap screw & lock washer 8. Sensor Reelmaster 5500-D Page 5 - 39 Electrical System (Rev. C)
Page 170 Electrical System (Rev. C) Page 5 - 40 Reelmaster 5500-D...
Page 171 The differential axle has a one-piece axle shaft with the flange being part of the axle stem (Fig. 2). Figure 1 Figure 2 Reelmaster 5500-D Page 6 - 1 Differential Axle...
Page 172: Specifications
Pinion gear end play 0.000 to 0.005 in. (0.000 to 0.127 mm) Special Tools Order special tools from your Toro Distributor. Differential Gear Holder Remove gear cover from right hand side of differential and bolt this tool in place to lock spur gear in position when removing nut that secures pinion coupler to differ- ential pinion shaft.
Page 173: Service And Repairs
Figure 4 1. Hydrostatic transmission 5. Differential axle 9. Pinion coupler 2. Transmission support 6. Brake cable 10. Seal 3. Transmission collar 7. Nut 11. Shim 4. Axle shim 8. Spacer Reelmaster 5500-D Page 6 - 3 Rev. C Differential Axle...
Page 174: Axle Shafts And Wheel Bearings
5. Install brake drums and wheels. Tighten wheel lug nuts to 45-55 ft-lbs. (61-75 Nm). Figure 6 1. Grease fitting Differential Axle Page 6 - 4 Reelmaster 5500-D...
Page 175 1/64 inch (0.4 mm). Wear protective safety goggles when breaking the retaining ring. Personal injury could result from flying metal particles. Keep all personnel away during this procedure. Reelmaster 5500-D Page 6 - 5 Differential Axle...
Page 176 Brakes chapter in this manual). 7. Use medium strength Loctiter thread locker and install the cap screws securing the bearing cap. Tighten the screws to 32 to 35 ft-lbs. (43 to 47 Nm). Differential Axle Page 6 - 6 Reelmaster 5500-D...
Page 177: Differential And Housing
4. To remove the differential assembly, place two wood- en devices (i.e. hammer handles) under the differential case and pry firmly upward. Mark the bearing cups and cones, they must be reinstalled in matched sets (Fig. 12). Figure 12 Reelmaster 5500-D Page 6 - 7 Differential Axle...
Page 178 (Fig. 15). Use a small drift punch as shown. WARNING To prevent personal injury, always wear a face shield or safety goggles when striking a drift punch with a hammer. Figure 15 Differential Axle Page 6 - 8 Reelmaster 5500-D...
Page 179 Figure 17 10.Remove the eight side cover capscrews. Remove the the side cover from the carrier assembly (Fig. 18). Clean the gasket material from the mating surfaces be- fore reassembly. Figure 18 Reelmaster 5500-D Page 6 - 9 Differential Axle...
Page 180 Figure 20 13.Removing the drive pinion releases the spur gear, bearing spacer, and outer pinion bearing for removal (Fig. 19 and 21). 14.Remove oil seal from housing (Fig. 19). Figure 21 Differential Axle Page 6 - 10 Reelmaster 5500-D Rev. D...
Page 181 Retain the shims located under the bearing cup (Fig. 24). If the shims are damaged, replace with new shims of the same thickness. Figure 24 Reelmaster 5500-D Page 6 - 11 Differential Axle...
Page 182 ONLY WHEN INSTALLING (Fig. 25). 3. Put the front housing on a press. Using a press plate, push the pinion outer bearing cup into the housing until it bottoms in the housing (Fig. 26). Figure 26 Differential Axle Page 6 - 12 Reelmaster 5500-D...
Page 183 A pinion gear etched -3 requires a pinion to ring gear dis- tance of 1.207 in. (-0.003 in. from standard). Adding 0.003 in. of bearing shims moves the pinion gear closer to the ring gear, decreasing the pinion to ring gear dis- tance. Reelmaster 5500-D Page 6 - 13 Differential Axle...
Page 184 Tap the pinion gear with a soft mallet to engage the splines in the spur gear (Fig. 29). Figure 29 7. Support the drive pinion in a suitable press (Fig. 30). Figure 30 Differential Axle Page 6 - 14 Reelmaster 5500-D...
Page 185 12.Install the spur gear cover. Use Permatex No. 2 or sil- icone sealant when installing the cover. Tighten the capscrews to a torque of 25-40 in.-lb. (3-4.5 Nm) (Fig. 33). Figure 33 Reelmaster 5500-D Page 6 - 15 Differential Axle Rev. D...
Page 186 15.Assemble the lock pin. Drive the pin to the approxi- mate center location of the pinion mate shaft. Peen the metal of the case to lock the pin in place (Fig. 36). Figure 36 Differential Axle Page 6 - 16 Reelmaster 5500-D...
Page 187 Tighten the cap screws to a torque of 45-65 ft-lbs. (61-88 Nm) (Fig. 37). Figure 37 Reelmaster 5500-D Page 6 - 17 Differential Axle...
Page 188 21.Check ring to pinion gear engagement (see Ring and Pinion Gear Engagement in this chapter of the manual). Figure 40 Differential Axle Page 6 - 18 Reelmaster 5500-D...
Page 189 22.Apply silicone sealant between the front and rear axle housings and install the eight housing cap screws. Tighten the cap screws to a torque of 18-23 ft-lbs. (24-31 Nm) (Fig. 41). Figure 41 Reelmaster 5500-D Page 6 - 19 Differential Axle...
Page 190 Example 1: Backlash correct. Thicker pinion position shims required (Fig. 44). Figure 45 Example 2: Backlash correct. Thinner pinion position shims required (Fig. 45). Differential Axle Page 6 - 20 Reelmaster 5500-D...
Page 191 (face contact) and toward the heel. Coast pattern (concave side of gear) moves to- ward the top of the tooth (face contact) and toward the heel. Reelmaster 5500-D Page 6 - 21 Rev. C Differential Axle...
Page 192 Differential Axle Page 6 - 22 Reelmaster 5500-D...
Page 193 Installation ....... . . Reelmaster 5500-D Page 7 - 1...
Page 194: Introduction
The brake pedals operate the brakes through a cable system to a strut and lever on the brake shoes. Figure 2 Steering and Brakes Page 7 - 2 Reelmaster 5500-D...
Page 195: Power Steering Schematics
Fluid leaving the steering cylinder flows back through Figure 5 the steering control valve, exits through the OUT port, travels to the lift manifold, and returns to the hydraulic reservoir. Reelmaster 5500-D Page 7 - 3 Steering and Brakes...
Page 196: Specifications
10 to 15 psi. (0.69 to 1.03 Bar) Brake pedal free travel 0.5 to 1.0 in. (6.0 to 25.0 mm) Special Tools Order these tools from your Toro Distributor. Hydraulic Tester (Pressure and Flow) - TOR214678 Figure 6 This tester requires O-ring face seal (ORFS) adapter fit- 4.
Page 197: Troubleshooting
Internal leakage in hydraulic cylinder. Excessive heat in hydraulic system Undersized replacement hose or tube line. Kinked or severely bent hose or tube line. Restricted oil cooler. Restricted re-centering of steering valve control valve plate. Reelmaster 5500-D Page 7 - 5 Steering and Brakes...
Page 198: Testing
Note: DO NOT turn the steering wheel to the right (clockwise) or the steering valve will meter oil out the dis- connected hydraulic hose. Steering and Brakes Page 7 - 6 Reelmaster 5500-D...
Page 199: Adjustments
0−0.125 in. (0.0−3.0 mm) less than the distance measured at the rear of the wheels. 8. Repeat steps 3. through 7. if necessary. 9. Tighten ball joint hex nut and install a new cotter pin. Reelmaster 5500-D Page 7 - 7 Steering and Brakes...
Page 200: Brake Adjustment
9. Remove jack stands or blocking and lower machine to floor. Tighten wheel lug nuts to a torque of 45 to 55 ft-lbs. (61 to 75 Nm). 10.Adjust brake cables (see step 2. of this procedure) Steering and Brakes Page 7 - 8 Reelmaster 5500-D...
Page 201: Repairs
(Fig. 13). Tighten the nut from 20 to 26 1. Steering wheel 3. Cover ft-lbs. (28 to 35 Nm). 2. Lock nut 4. Foam seal 3. Install steering wheel cover. Reelmaster 5500-D Page 7 - 9 Steering and Brakes Rev. D...
Page 202: 2Wd Rear Axle
6. Thrust washer 15. Thrust washer 24. Thrust washer 7. Jamnut 16. Jamnut 25. Locknut 17. Spindle 26. Steering pivot plate 8. Grease fitting 9. Capscrew 18. Capscrew 27. Steering pivot bushing Steering and Brakes Page 7 - 10 Reelmaster 5500-D...
Page 203: Axle Pivot Bushings
10.Lubricate the rear axle pivot bushings through the grease fitting on the pivot pin. 11. Install the hydraulic hoses to the steering cylinder. 12.Check steering cylinder hydraulic connections for leaks. Reelmaster 5500-D Page 7 - 11 Steering and Brakes...
Page 204: Rear Wheel Spindle Bushings
Slide the spindle, washer, and wheel assembly out 16.Check steering cylinder hydraulic connections for of the axle tube to expose the bushings. leaks. Steering and Brakes Page 7 - 12 Reelmaster 5500-D...
Page 205: Wheel Bearings
14.Fill the inside of the bearing with grease. Install bear- 3. Remove the cotter pin, retainer, slotted nut, and ing buddy and dust cap. washer. Slide the wheel off spindle shaft. 4. Pull the seal out of the wheel hub. Reelmaster 5500-D Page 7 - 13 Steering and Brakes...
Page 206: Steering Cylinder
2. Connect hydraulic hoses. Bleed the hydraulic sys- tem and check hydraulic connections for leaks (see Chapter 4−Hydraulic System “Bleeding the Hydraulic System” in this manual). Steering and Brakes Page 7 - 14 Reelmaster 5500-D...
Page 207: Steering Cylinder Service
16.Install head into tube and tighten by hand to properly engage threads. Tighten head with a spanner wrench. 7. Remove piston. Slide head off of piston rod. Reelmaster 5500-D Page 7 - 15 Steering and Brakes...
Page 208: Brake Shoe Replacement
9. Adjust brakes (see Brake Adjustment in this section of this manual). Figure 19 1. Return spring 3. Strut and lever 2. Cotter pins 4. Adjusting screw spring 5. Star wheel assembly Steering and Brakes Page 7 - 16 Reelmaster 5500-D...
Page 209: Steering Valve
6. Check hydraulic connections for leaks. 7. Install cap screws and cover to steering tower. 8. Install the front center cutting unit (see Chap- ter 8−Cutting Units in this manual). Reelmaster 5500-D Page 7 - 17 Steering and Brakes...
Page 210: Steering Valve Service
Before disconnecting the hydraulic lines, clean the port area of the steering control unit. Before disassembly, drain the oil, then plug the ports and thoroughly clean the exterior. During repairs, always protect machined sur- faces. Steering and Brakes Page 7 - 18 Reelmaster 5500-D...
Page 211 9. Remove the retaining ring and springs. CAUTION The centering springs are under tension. Re- move the retaining ring carefully. Reelmaster 5500-D Page 7 - 19 Steering and Brakes...
Page 212: Reassembly
21.Install the check ball and plug. Use a new o-ring and 10.Clamp the housing in a vise (Fig. 25). Use just tighten the plug to 17 Nm (150 in-lb). enough clamping force to hold the housing securely. Steering and Brakes Page 7 - 20 Reelmaster 5500-D...
Page 213 Lubrication ....... . . Reelmaster 5500-D Page 8 - 1...
Page 214: Specifications
Note: Use bedknife Part No. 93-9774 for height-of- use the same heavy duty ball bearings with two conven- cuts below 1/2”. tional single lip seals and a Toro labyrinth seal to provide four sealing surfaces to protect the bearings. REEL DIAMETER: 7 in. (178 mm).
Page 215: Special Tools
Special Tools Order special tools from your Toro Distributor. Some tools may have been supplied with your machine or available as TORO parts. Some tools may also be avail- able from a local supplier. Gauge Bar Assembly Use gauge bar to verify height of cut and bedknife atti- tude.
Page 216 Bedknife Screw Tool - 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. Make sure bedbar threads are clean and use new screws. Tighten screws to a torque of 250 - 300 in.lb.
Page 217: Troubleshooting
It is important to remember that the lower the height of cut, the more critical these factors are. Factors That Can Affect Quality of Cut Note: For additional information see Toro Commercial Products Aftercut Appearance Troubleshooting Aid (Part No. 00076SL).
Page 218 Check lift arms and cutting unit pivot linkages for wear, damage or binding. 13. Roller condition. All rollers should rotate freely. Replace bearings if they are worn, damaged, or have excessive radial play. Cutting Units Page 8 - 6 Reelmaster 5500-D...
Page 219: Initial Set-Up And Adjustments
Initial Set-up and Adjustments IMPORTANT: Toro strongly recommends the use of a leveling plate when setting-up or adjusting any reel type RIGHT cutting unit. The leveling plate will help to ensure accu- rate and consistent adjustments. Note: Right and left ends of cutting unit is determined by standing in the operator’s position (Fig.
Page 220: Bedknife To Reel Adjustment
(see Backlaping or Bedknife Re-grinding in this section of this manual, or refer to Toro manual for Sharp- ening Reel and Rotary Mowers, Form No. 80−300PT). A. Loosen the pivot hub lock nuts to allow move- ment of the pivot hub casting (Fig.
Page 221: Adjusting And Leveling Rollers
“A” Therefore, minimum recommended attitude is 1 degree. For setting consistent cutting unit attitude, Toro strongly recommends using a two-screw gauge bar, Toro part no. First Screw Second Screw 98-1852 (Fig.13). The first screw is set for height-of-cut, and the second screw is set for cutting unit attitude.
Page 222: Adjusting Attitude (New Cutting Units)
* Optional Low Cut Bedknife, Toro part no. 93-9774, is required for height-of-cut below 0.500” (13 mm). { For front (”B”) or rear roller distances (“C”) less than 1” (25 mm) order long cone nut (Part No. 95-2790) to replace bottom cone nut for improved support.
Page 223 Table 1 lists starting dimensions for setting up a new cut- ting unit with attitudes of 2, 4, 6 and 8 degrees. 1. Using a two-screw gauge bar, Toro Part No. 98-1852, set first screw to desired height-of-cut. This setting is from the bar face to the underside of the screw head (Fig.
Page 224 1. Rotate cutting unit backward to gain access to reel and bedknife. 2. Place an angle indicator, Toro Part No. 99−3503, on the bedknife and record the bedknife angle (Fig. 15). 3. Using a two-screw gauge bar, Toro Part No.
Page 225: Leveling Front Roller
The leveling plate will help to ensure accurate and consistent adjustments. Con- tact your local Toro Distributor for ordering a level- ing plate. 1. Position cutting unit on a flat surface.
Page 226: Final Height Of Cut Adjustment
1. Position cutting unit on a flat level surface. 2. Loosen flange head capscrew (Fig. 20) securing shield to left side plate, move shield to desired angle and tighten screw. Figure 20 1. Grass shield 2. Capscrew Rev. D Cutting Units Page 8 - 14 Reelmaster 5500-D...
Page 227 If by removing mounting bolts and repositioning frame in any of the front three cutting units lift off the ground when the bottom set of holes in the main frame. Reelmaster 5500-D Page 8 - 15 Cutting Units...
Page 228: Service And Repairs
“13.” Each posi- tion will increase speed approximately 100 rpm. After changing selector, wait 30 seconds for the system to sta- bilize at the new speed. Cutting Units Page 8 - 16 Reelmaster 5500-D...
Page 229 Move Lower Mow/Lift control forward to start backlap- ping operation on designated reels. 8. Apply lapping compound with a long handle brush (Toro Part No. 29-9100). Never use a short handled brush (Fig. 23). 9. If reels stall or become erratic while backlapping, stop backlapping by moving the Lower Mow/Lift control lever rearward.
Page 230: Bedbar Removal And Installation
10. Flat washer 28. Special screw 42. Decal - Danger 11. Grease fitting 29. Roll pin 43. Rivet 14. Plastic bushing 30. Screw 45. Side flap 15. Adjustment screw pivot 31. Screw 47. Bushing Cutting Units Page 8 - 18 Reelmaster 5500-D...
Page 231: Removal
Figure 27 6. Install bedknife adjusting knob assembly. Tighten locknut to compress spring to dimension shown (Fig. 27). 7. Adjust bedknife to reel (see Bedknife to Reel Adjust- ment). Reelmaster 5500-D Page 8 - 19 Cutting Units...
Page 232: Bedknife Replacement And Grinding
Remove small amounts of material with each Figure 29 pass of the grinder. Bedknife Regrinding Specifications (Fig. 29) Relief Angle Relief Angle Range 3_ - 6_ Front Angle Front Angle Range 13_ - 17_ Cutting Units Page 8 - 20 Reelmaster 5500-D...
Page 233: Preparing Reel For Grinding
Land Width Range .050I - .090I (1.3 - 2.3 mm) shape. Service Limit Reel Taper .060I (1.5 mm) BLADE RELIEF ANGLE REEL DIAMETER BLADE LAND WIDTH REEL DIAMETER TAPER = D Figure 30 Reelmaster 5500-D Page 8 - 21 Cutting Units...
Page 234: Reel And Reel Bearings
16. Lock nut 4. Grease seal 11. End weight 17. Bearing ring 5. Threaded insert 12. Screw 18. Plug 6. Reel assembly 13. Cap plug 19. Set screw 7. L.H. Bearing housing Cutting Units Page 8 - 22 Reelmaster 5500-D...
Page 235: Bearing Adjustment
5. Use a hammer and punch to drive out roll pins from L.H. bearing housing. Remove L.H. bearing housing. It is not necessary to remove the R.H. bearing housing. 6. Remove reel. Figure 34 1. Set screw 2. Bearing adjusting nut Reelmaster 5500-D Page 8 - 23 Cutting Units...
Page 236: Inspection
C. Pack bearings with No. 2 general purpose equipped with a speed sensor. grease before installing. Install bearings on reel 9. Install weight assembly. shaft by pressing on the inner bearing race. Cutting Units Page 8 - 24 Reelmaster 5500-D...
Page 237: Roller And Frame Service
21. Nut 33. Oil seal 10. Front roller 22. Thrust washer 34. Roller washer 11. Frame spacer 23. Compression spring 35. Retaining ring 12. Support rod 24. Spring rod 36. Grease fitting Reelmaster 5500-D Page 8 - 25 Cutting Units...
Page 238: Roller Bearing And Seal Replacement
Wipe off excess grease. 2. Install bearings: A. Use tool TOR4066 and handle TOR4073 to install bearing into one end of roller. Cutting Units Page 8 - 26 Reelmaster 5500-D...
Page 239: Cutting Unit Installation
1. Carrier frame 4. Lynch pin 2. Pivot knuckle 5. Steering pin 11. Insert the lynch pin into the cross hole on the pivot 3. Lift arm steering plate knuckle shaft (Fig. 39). Reelmaster 5500-D Page 8 - 27 Cutting Units...
Page 240: Lubrication
4. Apply grease until pressure is felt against handle. 5. Wipe excess grease away. Note: Apply grease to reel bearing cavities until a small amount is evident at the inboard reel seal. Cutting Units Page 8 - 28 Reelmaster 5500-D...
Page 241 Chapter 8.1 Groomer Table of Contents TROUBLESHOOTING ......Factors Affecting Grooming ....Groomer Reel Mechanical Problems .
Page 242: Troubleshooting
Troubleshooting Factors Affecting Grooming There are a number of factors that can affect the perfor- IMPORTANT: Improper or overaggressive use of mance of grooming. These factors vary for different golf the groomer (e.g. too deep or too frequent groom- courses and from fairway to fairway. It is important to in- ing) may cause unnecessary stress on the turf lead- spect the turf frequently and vary the grooming practice ing to severe turf damage.
Page 243: Groomer Reel Mechanical Problems
Groomer Reel Mechanical Problems Problem Possible Causes Correction No rotation of the groomer reel. Seized groomer reel or idler bear- Identify and replace faulty bear- ing(s) in groomer side plate(s). ing(s). Broken or damaged idler spring. Replace spring. The groomer belt is worn, broken or If the belt slips, it probably is worn damaged.
Page 244: Adjustments
Adjustments CAUTION Never work on the groomer with the engine running. Always stop the engine and remove the key from the ignition switch before working on the groomer. Groomer Height/Depth Adjustment Note: Grooming is performed above the soil level. When adjusting groomer height/depth, groomer blades should never penetrate the soil.
Page 245: Service And Repairs
Service and Repairs Groomer Belt Replacement The groomer drive belt should be inspected/replaced annually or after 750 hours of operation. 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.
Page 246: Groomer Reel
Groomer Reel 15 to 19 ft−lb (20.3 to 25.7 N−m) RIGHT FRONT Loctite #242 Figure 4 1. Groomer reel assembly 12. Flange head screw (3 used) 23. Flange nut 2. Square key 13. Groomer belt cover 24. Seal guard 3. Cap screw 14.
Page 247 5. Slide pulley spacer (item 19) from shaft. 10.Install groomer drive belt and belt cover to side of cut- ting unit (see Groomer Belt Replacement in this sec- 6. Remove two (2) cap screws (item 26) that secure tion). height of cut assembly (non−drive side) to the cutting unit side plates (Fig.
Page 248: Groomer Reel Service
Groomer Reel Service Inspect groomer reel blades frequently for damage and wear. Straighten bent blades with a pliers. Either replace worn blades or reverse the blades to put the sharpest blade edge forward (Fig. 7). Blades that are rounded to the midpoint of the blade tip must be reversed or re- placed for best groomer performance.
Page 249: Idler Assembly
Idler Assembly The drive side plate assembly groomer kit incorporates the idler system for tensioning the groomer drive belt. A torsion spring is used to maintain proper belt tension. Removal (Fig. 10) 1. Remove groomer belt cover and drive belt from groomer drive side of cutting unit (see Groomer Reel Removal in this section).
Page 250: Groomer Drive
Groomer Drive 15 to 19 ft−lb (20.3 to 25.7 N−m) Loctite #242 Figure 12 1. Flange nut 12. Driven pulley 22. Square key 2. Groomer belt cover 13. Retaining ring 23. Drive housing 24. Oil seal 3. Groomer drive belt 14.
Page 251 7. Remove two (2) flange head screws (item 20) that 8. Make sure that pulley spacer (item 15) and washer secure drive housing to cutting unit side plate. (item 31) are positioned on groomer shaft. Place square key (item 28) in groomer shaft slot and slide driven 8.
Page 252: Groomer Height Of Cut Assembly
Groomer Height of Cut Assembly Figure 15 1. Groomer reel assembly 7. Grease fitting 13. Adjustment bracket 8. Bearing housing 14. Retaining ring 2. Grease seal 3. Bearing 9. Grease seal 15. Plug 4. Height of Cut screw 10. Adjustment bracket 16.
Page 253 Disassembly (Fig. 15) 1. Remove groomer height of cut assembly from cut- ting unit (see Groomer Reel Removal in this section). 2. Disassemble groomer height of cut assembly using Figure 15 as a guide. Assembly (Fig. 15) 1. If bearing housing were disassembled, install bear- ings and grease seals noting proper orientation of com- ponents as shown in Figure 16.
Page 254 Groomer (Rev. C) Page 8.1 − 14 Reelmaster 5500−D...
Page 255 ........Gear Pattern Movement Summary ... Reelmaster 5500-D Page 9 - 1 4WD Rear Axle (Rev. C)
Page 256: Introduction
The following explanation is intended to clarify the op- eration of the 4WD rear axle and overrunning clutch used with this TORO product. A drive shaft connected to the front axle provides power to the rear 4WD axle. The drive shaft incorporates an overrunning clutch that transfers power in the forward direction only (Fig.
Page 257: Specifications
Tire pressure (front and rear) 10 to 15 psi. (0.69 to 1.03 Bar) Axle lubricant SAE 85W140 gear lube Four-Matict overrunning clutch lubricant No. 2 general purpose lithium grease Reelmaster 5500-D Page 9 - 3 4WD Rear Axle (Rev. C)
Page 258: Maintenance
7. When lubricant level is correct, install all check plugs and fill/vent plug. Figure 5 1. Check plug 2. Fill plug Figure 6 1. Check plug 4WD Rear Axle (Rev. C) Page 9 - 4 Reelmaster 5500-D...
Page 259: Repairs
5. Loosen capscrews and locknuts securing end yoke sion. to traction shaft, and slide drive shaft assembly off trac- tion shaft (Fig. 7). Reelmaster 5500-D Page 9 - 5 4WD Rear Axle (Rev. C)
Page 260: Installation
Tighten collar set screws (Fig. 7). 4. Slide end yoke of drive shaft assembly onto traction shaft and tighten end yoke capscrews and locknuts (Fig. 7). 4WD Rear Axle (Rev. C) Page 9 - 6 Reelmaster 5500-D...
Page 261: Overrunning Clutch
Tighten capscrews evenly. 6. Lubricate clutch through grease fitting with No.2 gen- eral purpose lithium grease. 7. Install drive shaft (see Drive Shaft Service in this sec- tion of this manual). Reelmaster 5500-D Page 9 - 7 4WD Rear Axle (Rev. C)
Page 262: 4Wd Rear Axle
9. Rear wheel & tire 14. Cylinder mounting bracket 4. Thrust washer 10. Tie rod assembly 15. Steering cylinder 5. Thrust washer 11. Tie rod ball joints 16. Hydraulic hoses 6. Jam nut 4WD Rear Axle (Rev. C) Page 9 - 8 Reelmaster 5500-D...
Page 263: Removal
Inspect the pin and bushings for wear or damage. Replace components as necessary. Figure 11 1. Steering stop bolt 2. Bevel gear case (LH) Reelmaster 5500-D Page 9 - 9 4WD Rear Axle (Rev. C) Rev. D...
Page 264: Bevel Gear Case And Axle Case
(Fig. 14). 57 to 67 ft−lb (77 to 91 N−m) Figure 14 1. Axle case 3. Mounting screw 2. Axle case support 4. Support shim 4WD Rear Axle (Rev. C) Page 9 - 10 Reelmaster 5500-D...
Page 265: Inspection
0.984 to 0.987 in. (25.00 to 25.08 mm) Figure 16 1. Knuckle pin 2. Axle case support 2. Inspect all gears, shafts, bearings, cases, and cov- ers for damage and wear. Replace components as nec- essary. Reelmaster 5500-D Page 9 - 11 4WD Rear Axle (Rev. C)
Page 266: Installation
1. Axle case cover 6. Spacer 2. Lower bevel gear 7. Upper bevel gear 3. Bevel gear shaft 8. Collar 4. Lower bearing 9. Upper bearing 5. Thrust washer 10. Knuckle pin 4WD Rear Axle (Rev. C) Page 9 - 12 Reelmaster 5500-D...
Page 267 (0.1 mm), 0.008 in. (0.2 mm), and 0.020 in. (0.5 mm) thickness. Figure 21 1. Axle cover assembly 4. Dial indicator 2. Lower bevel gear 5. Axle bearing shims 3. Axle gear Reelmaster 5500-D Page 9 - 13 4WD Rear Axle (Rev. C)
Page 268: Differential Shafts
Bevel Gear Case/Axle Case Assembly in this section of 1. Retaining ring 5. Spacer this manual). 2. Bevel gear 6. Bearing shims 3. Differential shaft 7. O-ring 4. Bearing 4WD Rear Axle (Rev. C) Page 9 - 14 Reelmaster 5500-D...
Page 269: Axle Shafts
(23 to 27 N−m). 1. Bearing 4. Spacer 2. Bevel gear 5. Retaining ring 3. Shims Figure 26 1. Axle shaft seal 3. Bearing 2. Axle cover 4. Axle shaft Reelmaster 5500-D Page 9 - 15 4WD Rear Axle (Rev. C)
Page 270: Input Shaft/Pinion Gear
0.7 N−m) of force is required to rotate the input shaft/ pinion gear in the bearing case. 8. Secure the lock nut with the stake washer. Figure 28 1. Oil seal 2. Bearing case 4WD Rear Axle (Rev. C) Page 9 - 16 Reelmaster 5500-D...
Page 271 14.Place the correct combination of shims on the bear- ing case. Tighten mounting screws to 35 to 41 ft-lbs. (47 Figure 30 to 56 N−m). 1. Axle case 3. Dial indicator 2. Screwdriver 4. Input shaft/pinion gear Reelmaster 5500-D Page 9 - 17 4WD Rear Axle (Rev. C)
Page 272: Differential Gear
1. Differential case 2. Spring pin Figure 33 1. Differential pinion shaft 5. Side gear shims 2. Pinion gear 6. Ring gear 3. Pinion washer 7. Differential case 4. Side gear 4WD Rear Axle (Rev. C) Page 9 - 18 Reelmaster 5500-D...
Page 273: Inspection
0.551 to 0.552 in. (13.10 to 14.02 mm) 3. Inspect all gears, shafts, bearings, cases and covers for damage and wear. Replace components as neces- sary. Figure 35 1. Pinion shaft 2. Pinion gear Reelmaster 5500-D Page 9 - 19 4WD Rear Axle (Rev. C)
Page 274: Installation
11. After backlash and tooth contact have been ad- justed, align the hole in the differential pinion shaft with the hole in the differential case and install a new spring pin. 4WD Rear Axle (Rev. C) Page 9 - 20 Reelmaster 5500-D Rev. D...
Page 275: Pinion Gear To Ring Gear Engagement
2. Bearing case shims shims 3. Differential gear case readjust backlash to the correct specification before checking the contact pattern. Reelmaster 5500-D Page 9 - 21 4WD Rear Axle (Rev. C) Rev. D...
Page 276: Gear Pattern Movement Summary
Figure 42 C. Repeat until proper tooth contact and pinion gear 1. Pinion shaft 2. Ring gear to ring gear backlash are correct. 4WD Rear Axle (Rev. C) Page 9 - 22 Reelmaster 5500-D Rev. D...
Page 277 230000000) ......Reelmaster 5500-D Electrical Diagrams (Rev. C) Page 10 - 1...
Page 278 Electrical Diagrams (Rev. C) Reelmaster 5500-D Page 10 - 2...
Page 279: Electrical Schematics
ECU COMMUNICATION PORT GLOW PLUGS AND LOOPBACK HOLD (A) PULL (B) ORANGE/RED CONNECTOR RED/WHITE BLACK BLACK/WHITE Reelmaster 5500-D LEAK DETECTOR OUTPUT (B) FIELD (R) Electrical Schematic (Serial Number Below 210000400) WRNG LIGHTS (L) All relays and solenoids are shown as de-energized. ALTERNATOR All ground wires are black.
Page 280: Electrical Schematic (Serial Number Below 210000400)
(MACHINES WITH SN ABOVE 220000001) Reelmaster 5500-D Electrical Schematic (Serial Number Above 210000400) All relays and solenoids are shown as de-energized. All ground wires are black. Page 10 - 4 Rev. C...
Page 281: Harness Drawing
J5 J6 P10 P11 J10 J11 Reelmaster 5500-D Harness Drawing (Serial Number Below 210000200) Page 10 - 5 Rev. C...
Page 282 Pink Black Green/Black Orange Black Orange/Red Black Black Black Black Black Green/Black Ye llow Open Blue/Green Open Violet Black Open Black Orange/ Red Black Green/White Reelmaster 5500-D Electrical Connector Drawing (Serial Number Below 210000200) Page 10 - 6 Rev. C...
Page 283 Wire Color Wire Color Wire Color Wire Color Wire Color Green Black Wire Color Wire Color Black Orange Orange Green/Blue Blue/White Green/White Orange Black Green/white Reelmaster 5500-D Electrical Connector Drawing (Cont.) (Serial Number Below 210000200) Page 10 - 7 Rev. C...
Page 284: Harness Drawing
Reelmaster 5500-D Harness Drawing (Serial Number 210000401 to 210999999) Page 10 - 8 Rev. C...
Page 285: Harness Diagram (Serial Number 210000401 To 210999999)
Reelmaster 5500-D Harness Diagram (Serial Number 210000401 to 210999999) Page 10 - 9 Rev. C...
Page 286: Harness Drawing (Serial Number 220000001 To 220999999)
Reelmaster 5500-D Harness Drawing (Serial Number 220000001 to 220999999) Page 10 - 10 Rev. C...
Page 287: Harness Diagram (Serial Number 220000001 To 220999999)
Reelmaster 5500-D Harness Diagram (Serial Number 220000001 to 220999999) Page 10 - 11 Rev. C...
Page 288: Harness Drawing (Serial Number Above 230000000)
Reelmaster 5500-D Harness Drawing (Serial Number Above 230000000) Page 10 - 12 Rev. C...
Page 289: Harness Diagram (Serial Number Above 230000000)
Reelmaster 5500-D Harness Diagram (Serial Number Above 230000000) Page 10 - 13 Rev. C...
Page 290 Reelmaster 5500-D...

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Toro Reelmaster 5500-D Service Manual

Table of Contents

Chapter 1 − Safety

Product Records and Maintenance

Chapter 2 - Product Records and Maintenance

Kubota Diesel Engine

Chapter 3 - Kubota Diesel Engine

Hydraulic System

Chapter 4 - Hydraulic System

Chapter 5 - Electrical System

Chapter 6 - Differential Axle

Chapter 7 - Steering and Brakes

Electrical System

Differential Axle

Steering and Brakes

Cutting Units

Chapter 8 SERVICE and REPAIRS

.1 Groomer

Wd Rear Axle

Chapter 9

Chapter 10

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Toro Reelmaster 5500-D