Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table Of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Kubota Diesel Engine
- 4 - Hydraulic System
- Specifications
- General Information
- Special Tools
- Hydraulic Schematics
- Hydraulic Flow Diagrams
- Troubleshooting
- Testing
- Traction Circuit Testing - Charge Pressure Test
- Traction Unit Testing - Wheel Motor Efficiency Tests
- Traction Circuit Testing - Piston Pump/Hydrostat Flow and Relief Pressure Test
- Cutting Unit Circuit Testing - Pressure Test
- Cutting Unit Circuit Testing - Reel Motor Efficiency/Case Drain Test
- Cutting Unit Circuit Testing - Reel Motor Cross-Over Relief Pressure Test (Reelmaster 3575-D)
- Cutting Unit Circuit Testing - Proportional Relief Valve (PRV) Pressure Test
- Cutting Unit Circuit Testing - Mow Control Manifold Relief Valve (RV) Pressure Test
- Cutting Unit Circuit Testing - Gear Pump (P1) Flow Test
- Steering/Lift Circuit Testing - Gear Pump (P2) Flow Test
- Steering/Lift Circuit Testing - Lift Relief Valve (RV1) Pressure Test (Reelmaster 3555-D and 3575-D)
- Steering/Lift Circuit Testing - Steering Relief Valve Pressure Test
- Steering/Lift Circuit Testing - Steering Control Valve and Steering Cylinder Test
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Priming Hydraulic Pumps
- Flush Hydraulic System
- Filtering Closed-Loop Traction Circuit
- Charge Hydraulic System
- Hydraulic Tank
- Radiator and Oil Cooler Assembly
- Hydraulic Pump Assembly
- Neutral Arm Assembly
- Piston Pump/Hydrostat
- Piston Pump/Hydrostat Service
- Gear Pump
- Gear Pump Service
- Front Wheel Motors
- Rear Wheel Motor
- Wheel Motor Service
- Cutting Unit Reel Motor
- Cutting Unit Reel Motor Service (Reelmaster 3550-D and 3555-D)
- Cutting Unit Reel Motor Service (Reelmaster 3575-D)
- Mow Control Manifold
- Mow Control Manifold Service
- Lift Control Manifold
- Lift Control Manifold Service (Reelmaster 3550-D)
- Lift Control Manifold Service (Reelmaster 3555-D and 3575-D)
- Control Manifold Cartridge Valve Service
- Steering Control Valve
- Steering Control Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Front Lift Cylinders
- Rear Lift Cylinders
- Lift Cylinder Service
- 5 - Electrical System
- General Information
- Electrical Schematic
- Special Tools
- Troubleshooting
- Electrical System Quick Checks
- Adjustments
- Component Testing
- Ignition Switch
- Main Power Relay
- Fuses
- Fusible Links
- Toro Electronic Controller (TEC)
- Parking Brake Switch
- Neutral Switch
- Lower/Raise Joystick Switches
- Reel Enable/Disable Switch
- Mow/Transport Switch
- Seat Switch
- Backlap Switch
- Turn Around Switch (Reelmaster 3555-D and 3575-D)
- Engine Temperature Sender
- Start Relay
- Fuel Stop Solenoid
- Fuel Pump
- Glow Relay
- Hydraulic Solenoid Valve Coils
- Indicator Lights
- CAN-bus Termination Resistors
- Hour Meter
- Oil Pressure Switch
- Worklight Switch
- Service and Repairs
- 6 - Chassis
- 7 - DPA Cutting Units
- 8 - Belt Driven Groomer (Optional)
- 9 - Universal Groomer (Optional)
- 10 - Foldout Drawings
- Electrical Drawing Designations
- Reelmaster 3550-D Hydraulic Schematic
- Reelmaster 3555-D/3575-D Hydraulic Schematic
- Reelmaster 3550-D Electrical Schematic (machine serial numbers below 316000300)
- Reelmaster 3550-D (machine serial numbers above 316000300) Electrical Schematic
- Reelmaster 3555-D/3575-D Electrical Schematic
- Reelmaster 3550--D/3555--D/3575--D Electrical Schematic (Serial Numbers Above 403446001)
- Reelmaster 3550-D (machine serial numbers below 316000300) Wire Harness Drawing
- Reelmaster 3550-D (machine serial numbers below 316000300) Wire Harness Diagram
- Reelmaster 3550--D/3555--D/3575--D (Machine serial number 316000301 to 403446000) Wire Harness Drawing
- Reelmaster 3550-D (machine serial numbers above 316000300) Wire Harness Diagram
- Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing(Machine serial number 316000301 to 403446000)
- Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing Serial Numbers 403446001 to 405999999)
- Reelmaster 3550--D/3555--D/3575--D Wire Harness Drawing (Serial Numbers Above 406000000)
Reelmaster 3550−D/3555−D/3575−D Hydraulic SystemPage 4 − 37
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-
ance.
Special Equipment Required:
S Pressure Gauge
S Flow Meter with Pressure Gauge that has at least
an 18 GPM (68 LPM) capacity.
S Phototach (non−contact tachometer).
1. Park machine on a level surface with the cutting units
lowered and the reel engage/disengage switch is in the
disengage position. Make sure engine is off and the
parking brake is engaged.
2. Read Precautions for Hydraulic Testing in this
chapter.
3. Make sure that traction pedal is adjusted to the neu-
tral position.
4. Disconnect the hydraulic hose at the piston pump/
hydrostat fitting just to the rear of the tow valve. This
hose comes from the steering control valve (T) port (Fig.
22).
5. Install a T−connector and pressure gauge between
the fitting and disconnected hose.
6. Disconnect hose from the lower hydraulic fitting on
the engine side of the hydrostat (Fig. 23).
7. Install tester in series with the pump and the discon-
nected hose. Make sure the tester flow control valve is
fully open.
8. Attach a heavy chain to the rear of the machine frame
and an immovable object to prevent the machine from
moving during testing.
9. Chock the wheels to prevent wheel rotation during
testing.
10.Start engine. Move throttle to full speed (3220 +
50
RPM).
11.Make sure hydraulic fluid is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
12.Verify with a phototach that the pump speed is ap-
proximately 3090 RPM.
1. Hydraulic hose 2. Piston pump tow valve
Figure 22
1
2
1. Lower hydraulic fitting 2. Piston pump
Figure 23
1
2
13.Record reading on pressure gauge from the lift con-
trol manifold (T) port. Charge pressure (without load)
should read from 150 to 200 PSI (10.3 to13.8 Bar). If
charge relief pressure specification is not met, consider
the following:
A. Gear pump (P2) is faulty (steering/lift circuit per-
formance will also be affected). Test gear pump (P2)
flow (see Gear Pump (P2) Flow Test in this chapter).
B. The piston pump charge relief valve is faulty. Re-
pair or replace the piston pump charge relief valve
(see Piston Pump Service in this chapter).
14.Sit in the operator’s seat, release the parking brake,
and slowly depress the forward traction pedal until 1000
to 1500 PSI (68.9 to 103.4 Bar) is reached on the flow
meter pressure gauge.
15.Record reading on pressure gauge from lift control
manifold (T) port (under load). Charge pressure (under
load) should not drop more than 20% when compared
to charge pressure (without load) recorded in step 13.
If specifications are not met, perform Piston Pump/Hy-
drostat Flow and Traction Relief Pressure Test as out-
lined in this chapter.
16.Release traction pedal, move throttle to low speed
and turn the engine off.
Hydraulic
System