Toro 3550-D User Manual
Part No. 15213SL
Service Manual
Preface
The purpose of this publication is to provide the service
technician with service information for service and
repair of major systems and components on the
Reelmaster 3550- D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Copies of the Operator’s Manuals and Parts
Catalog are available on the internet at www.Toro.com.
The ToroCompany reserves the right to changeproduct
specifications or this publication without notice.
Reelmaster
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
3550- D
R
EThe Toro Company - 2015
This page is intentionally blank.
Reelmaster 3550- D
Table Of Contents
Chapter 1 - Safety
General Safety Instructions 1 - 2..................
Jacking Instructions 1 - 4.........................
Safety and Instruction Decals 1 - 5................
Chapter 2 - Product Records and Maintenance
Product Records 2 - 1...........................
Maintenance 2 - 1...............................
Equivalents and Conversions 2 - 2................
Torque Specifications 2 - 3.......................
Chapter 3 - Kubota Diesel Engine
Specifications 3 - 3..............................
General Information 3 - 4........................
Service and Repairs 3 - 6........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Chapter 4 - Hydraulic System
Specifications 4 - 2..............................
General Information 4 - 3........................
Special Tools 4 - 8..............................
Hydraulic Schematic 4 - 14.......................
Hydraulic Flow Diagrams 4 - 16...................
Troubleshooting 4 - 26...........................
Testing 4 - 31...................................
Adjustments 4 - 62..............................
Service and Repairs 4 - 63.......................
EATON MEDIUM DUTY PISTON PUMP REPAIR
INFORMATION MODEL 70160 VARIABLE
DISPLACEMENT PISTON PUMP
PARKER TORQMOTOR
(TC, TB, TE, TJ, TF, TG, TH AND TL SERIES)
SAUER- DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
TM
SERVICE PROCEDURE
Chapter 5 - Electrical System
General Information 5 - 2........................
Electrical Schematic 5 - 3........................
Special Tools 5 - 4..............................
Troubleshooting 5 - 6............................
Electrical System Quick Checks 5 - 18.............
Component Testing 5 - 20........................
Service and Repairs 5 - 47.......................
Chapter 6 - Chassis
Specifications 6 - 2..............................
Special Tools 6 - 2..............................
Adjustments 6 - 3...............................
Service and Repairs 6 - 4........................
Chapter 7 - DPA Cutting Units
Specifications 7 - 2..............................
General Information 7 - 3........................
Special Tools 7 - 5..............................
Factors That Can Affect Cutting Performance 7 - 9..
Set Up and Adjustments 7 - 13....................
Service and Repairs 7 - 15.......................
Chapter 8 - Groomer (Optional)
Grooming Performance 8 - 2.....................
Troubleshooting 8 - 3............................
Service and Repairs 8 - 4........................
Chapter 9 - Foldout Drawings
Electrical Drawing Designations 9 - 2..............
Hydraulic Schematic 9 - 3........................
Electrical Schematic 9 - 4........................
Wire Harness Diagram 9 - 5......................
Wire Harness Drawing 9 - 6......................
SafetyProduct Records
and Maintenance
Kubota
Diesel Engine
System
Hydraulic
System
Electrical
Reelmaster 3550- D
Units
DPA Cutting Chassis
Groomer
Foldout
Drawings
This page is intentionally blank.
Reelmaster 3550−D
Table of Contents
GENERAL SAFETY INSTRUCTIONS 2............
Before Operating 2............................
While Operating 2............................
Maintenance and Service 3....................
JACKING INSTRUCTIONS 4.....................
SAFETY AND INSTRUCTION DECALS 5..........
Chapter 1
Safety
Safety
Reelmaster 3550−D Page 1 − 1 Safety
General Safety Instructions
The Reelmaster 3550−D has been tested and certified
by Toro for compliance with existing safety standards
and specifications. Although hazard control and accident prevention partially are dependent upon the design
and configuration of the machine, these factors are also
dependent upon the awareness, concern and proper
training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury
or death. To reduce the potential for injury or death, comply with the following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Review and understand the contents of the Operator’s Manuals and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
Additional copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting units are DISENGAGED.
While Operating
1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Engage the parking brake.
4. Since diesel fuel is flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
4. Do not touch engine, exhaust system components or
radiator while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage
may be adjusted incorrectly; therefore, shut engine
off and adjust traction pedal linkage until machine
does not move when traction pedal is released.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
A. Ensure that traction pedal is in neutral.
B. Engage parking brake.
C. Disengage PTO and wait for cutting unit reels to
stop rotating.
D. Stop engine and remove key from ignition switch.
E. Toro recommends that anytime the machine is
parked (short or long term), the cutting units should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of cutting
units accidentally lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
Reelmaster 3550−DPage 1 − 2Safety
Maintenance and Service
1. The T raction Unit and Cutting Unit Operator’s Manuals provide information regarding the operation, general
maintenance and maintenance intervals for your Reelmaster machine. Refer to these publications for additional information when servicing the machine.
2. Before servicing or making adjustments, lower cutting units, stop engine, set parking brake and remove
key from the ignition switch.
3. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
4. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
5. Make sure all hydraulic line connectors are tight and
all hydraulic hoses and lines are in good condition before applying pressure to the hydraulic system.
6. Keep body and hands away from pin hole leaks in hydraulic lines that eject high pressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
8. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
10.If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other moving parts. Keep bystanders away.
11.To assure safety and accuracy , check maximum engine speed.
12.Shut engine off before checking or adding oil to the
engine crankcase.
13.Disconnect battery before servicing the machine.
Disconnect negative battery cable first and positive
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive battery cable first and negative
cable last.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.When welding on machine, disconnect both battery
cables to prevent damage to machine electronic equipment. Disconnect negative battery cable first and positive cable last. Also, disconnect the wire harness
connector from th e m achine TEC controller and disconnect the terminal connector from the alternator.
17.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards and the warranty may be
voided.
18.When changing attachments, tires or performing
other service, use correct jacks, hoists and jack stands.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use appropriate jack stands to support
the raised machine. If the machine is not properly supported by jack stands, the machine may move or fall,
which may result in personal injury (see Jacking Instructions in this chapter).
19.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an environmentally safe manner . Follow all local codes and regulations when recycling or disposing of waste.
Safety
Reelmaster 3550−D Page 1 − 3 Safety
Jacking Instructions
Jacking the Rear End
CAUTION
When changing attachments, tires or performing other service, use correct jacks and supports. 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. Always chock or block wheels. Use
jack stands to support the raised machine. If the
machine is not properly supported by jack
stands, the machine may move or fall, which
may result in personal injury.
Jacking the Front End
1. If the front wheel or wheel motor is to be removed,
position jack securely under the round tube of the lower
frame as closely to the side plate as possible.
2. Use appropriate jack stands under the round tube to
support the machine.
1. Chock both front wheels.
IMPORTANT: Make sure jack is as close to the rear
fork as possible when raising the machine.
2. Place jac k s e c u r e l y u n d e r the rear lift arm support as
close to the fork as possible. Raise rear tire off the
ground.
3. Use appropriate jack stands under the frame to sup-
port the machine.
Reelmaster 3550−DPage 1 − 4Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
the Reelmaster 3550−D. If any decal becomes illegible
or damaged, install a new decal. Decal part numbers are
listed in your Parts Catalog.
Safety
Reelmaster 3550−D Page 1 − 5 Safety
This page is intentionally blank.
Reelmaster 3550−DPage 1 − 6Safety
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1.........................
MAINTENANCE 1..............................
EQUIVALENTS AND CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Using a Torque Wrench with an Offset Wrench 3..
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) 4...............
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) 5..........
Other Torque Specifications 6..................
Conversion Factors 6.........................
Product Records
Chapter 2
Product Records
and Maintenance
Insert Operator’s Manuals and Parts Catalog for your
Reelmaster at the end of this chapter. Additionally, insert
Installation Instructions, Operator’s Manuals and Parts
Catalogs for any accessories that have been installed
on your Reelmaster at the end of this section.
Maintenance
Maintenance procedures and recommended service intervals for your Reelmaster are covered in the Traction
Unit and Cutting Unit Operator’s Manuals. Refer to
those publications when performing regular equipment
maintenance. Several maintenance procedures have
break−in intervals identified in the Operator’s Manuals.
Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
Reelmaster 3550−D Page 2 − 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Reelmaster 3550−DPage 2 − 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects t h e
installation.
Fastener Identification
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Using a Torque Wrench with an Offset Wrench
Use of an offset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
If the listed torque recommendation for a fastener is
from 76 to 94 ft−lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft−lb.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Reelmaster 3550−D Page 2 − 3 Product Records and Maintenance
Figure 3
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
# 6 − 32 UNC
# 6 − 40 UNF 17 + 2 192 + 23 25 + 3 282 + 34
# 8 − 32 UNC
# 8 − 36 UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 − 24 UNC
# 10 − 32 UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 − 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
Grade 1, 5 &
8 with Thin
Height Nuts
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 169 + 23 23 + 3 262 + 34
29 + 3 328 + 34 41 + 5 463 + 56
42 + 5 475 + 56 60 + 6 678 + 68
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 − 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Reelmaster 3550−DPage 2 − 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm
M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 54 + 6 ft−lb 73 + 8 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 93 + 10 ft−lb 126 + 14 N−m
M16 X 2.0 166 + 17 ft−lb 225 + 23 N−m 229 + 23 ft−lb 310 + 31 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 46 ft−lb 610 + 62 N−m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Stronger Nuts)
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the
Product Records
and Maintenance
Reelmaster 3550−D Page 2 − 5 Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb
5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb
3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb
1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 − 32 UNC 20 + 5 in−lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 − 20 UNF
Grade 5
1/2 − 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in−lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft−lb 88 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
Baseline Torque*
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb
3/8 − 16 UNC 200 + 100 in−lb
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
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Reelmaster 3550−DPage 2 − 6Product Records and Maintenance
Table of Contents
SPECIFICATIONS 3............................
GENERAL INFORMATION 4.....................
Operator’s Manual 4..........................
Kubota Workshop Manual 4....................
Kubota Diesel Engine 4........................
SERVICE and REPAIRS 6.......................
Air Cleaner and Muffler 6......................
Fuel System 8................................
Radiator and Oil Cooler Assembly 10............
Engine 12....................................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
05 SERIES
Chapter 3
Kubota Diesel Engine
Kubota
Diesel Engine
Reelmaster 3550- D Page 3 - 1 Kubota Diesel Engine
This page is intentionally blank.
Reelmaster 3550−DPage 3 − 2Kubota Diesel Engine
Specifications
Item Description
Make / Designation Kubota D1105- E3B or D1105- E4B
4- Cycle, 3 Cylinder, Liquid Cooled, Diesel Engine
Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm)
Total Displacement 68.5 in3(1123 cc)
Firing Order 1 (fan end) - 2 - 3 (flywheel end)
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel or Biodiesel (up to B20) Fuel with Low or Ultra Low
Sulfur Content
Fuel Capacity 7.5 U.S. gallons (28.4 liters)
Fuel Injection Pump Bosch MD Type Mini
Injection Nozzle Mini Nozzle (DNOPD)
Governor Centrifugal Mechanical
Low Idle (no load) 1400 + 50 RPM
High Idle (no load) 3220 + 50 RPM
Kubota
Diesel Engine
Engine Oil API CH- 4, CI- 4 or higher
Engine Oil Viscosity See Traction Unit Operator’s Manual
Crankcase Oil Capacity 4 U.S. Quarts (3.8 Liters) with Filter
Oil Pump Trochoid Type
Coolant Capacity 6 U.S. Quarts (5.7 Liters)
Starter 12 VDC 1.4 KW
Alternator/Regulator 12 VDC
Alternator Output 40 amp
Engine Dry Weight 205 lb. (93 kg)
Reelmaster 3550- D Page 3 - 3 Kubota Diesel Engine
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Reelmaster
3550- D.
General maintenance procedures are described in your
Traction Unit Operator’s Manual. Information on engine
troubleshooting, testing, disassembly and assembly is
identified in the Kubota Workshop Manual: 05 Series
Diesel Engine.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
Operator’s Manual
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance and
maintenance intervals for the Kubota diesel engine that
powers your Reelmaster 3550- D. Refer to this publication for additional information when servicing the machine.
Kubota Workshop Manual
tools are described in the Kubota Workshop Manual: 05
Series Diesel Engine. The use of some specialized test
equipment is explained. However, the cost of the test
equipment and the specialized nature of some repairs
may dictate that the work be done at an engine repair facility.
Service and repair parts for the Kubota engine in your
Reelmaster are available from your Authorized Toro
Distributor. If no parts list is available, be prepared to
provide your distributor with the Toro model and serial
number.
The engine that powers your Reelmaster machine is a
Kubota model D1105. The Kubota Workshop Manual is
available for these engines. Make sure that the correct
engine manual is used when servicing the engine on
your Reelmaster 3550- D.
Kubota Diesel Engine
The Kubota D1105 engine used in your Reelmaster
3550- D is a naturally aspirated engine that complies
with either EPA emission regulations Tier 4i (model
D1105- E3B) or Tier 4 (model D1105- E4B) depending
on manufacture date. The engine includes a Bosch inline injection pump.
Figure 1
Reelmaster 3550- DPage 3 - 4Kubota Diesel Engine
This page is intentionally left blank.
Kubota
Diesel Engine
Reelmaster 3550−D Page 3 − 5 Kubota Diesel Engine
Service and Repairs
Air Cleaner and Muffler
10
11
12
14
19
21
16
4
3
15
18
17
13
12
20
12
7
8
1
9
5
2
6
4
5
1. Exhaust guard
2. Cap screw
3. Muffler
4. Flange head screw
5. Flange nut
6. Muffler bracket
7. Hex nut
Figure 2
8. Lock washer
9. Exhaust gasket
10. Hose clamp
11. Air inlet hose (upper)
12. Hose clamp
13. Air cleaner body
14. Filter cover
15. Burp (Actuator) valve
16. Mounting band assembly
17. Shoulder bolt
18. Compression spring
19. Lock nut
20. Air inlet hose (lower)
21. Air filter mount
Reelmaster 3550−DPage 3 − 6Kubota Diesel Engine
Check Air Filter, Dust Cup, & Burp Valve
The air cleaner body , air filter, dust cup, 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.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
2. Check air cleaner body for damage that could cause
possible air leaks. Make sure dust cup seals completely
to the air cleaner body (Fig. 3).
3. Check burp valve and dust cup for damage.
4. Make sure air hoses connecting the air cleaner to the
engine and radiator are secured tightly and free of possible air leaks.
1
2
4
3
1
Figure 4
1. Flange head nut
2. Flange head screw
3. Muffler plate
4. Muffler bracket
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Open engine hood to gain access to engine.
3. Remove exhaust guard.
4. Remove both flange head nuts and screws securing
the muffler plate to the muffler bracket (Fig. 4).
Kubota
Diesel Engine
3
Figure 3
1. Latch
2. Dust cup
3. Burp valve
Muffler Removal
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
5. Remove four hex nuts and lock washers from the exhaust manifold studs. Separate muffler flange from the
exhaust manifold. Remove muffler from the machine.
6. Remove exhaust gasket. Replace gasket if damaged or torn.
2
Muffler Installation
NOTE: Make sure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Place exhaust gasket on the exhaust manifold.
IMPORTANT: Finger tighten all fasteners before securing the muffler plate to the muffler bracket so
there is no preload on the exhaust manifold.
2. Position muffler flange to the exhaust manifold with
four lock washers and hex nuts.
3. Position mu ffler plate to the muffler bracket with both
flange head screws and nuts (Fig. 4).
4. Tighten muffler flange hex nuts and then muffler
plate screws and nuts.
5. Install exhaust guard.
6. Close and latch engine hood.
Reelmaster 3550−D Page 3 − 7 Kubota Diesel Engine
Fuel System
6
5
4
TO
PUMP
6
12
7
10
8
11
9
3
8
13
14
2
16
15
17
18
19
20
Thread
Sealant
(typical)
11
21
22
11
38
11
33
34
29
27
28
27
1
30
31
32
Thread
Sealant
(typical)
RIGHT
TO
TANK
39
35
37
36
23
24
25
26
11
7
40
FRONT
16
41
1. Fuel tank
2. Grommet
3. Fuel gauge
4. Seat support strap (2)
5. Heat shield
6. Washer head screw (4)
7. Fuel hose (tank to pump)
8. Bushing (2)
9. Elbow fitting
10. Stand pipe
11. Hose clamp (7)
12. Fuel hose (tee to tank)
13. Cap screw (2)
14. Fuel hose strap
Figure 5
15. Fuel cap
16. Hose clamp (2)
17. Flange nut (2)
18. R−Clamp
19. Fuel hose (filter to engine)
20. Grommet
21. Barbed fitting
22. Fuel hose (pump to filter)
23. Clamp
24. Washer head screw
25. Washer head screw
26. Fuel pump
27. Hose clamp (2)
28. Fuel hose (engine return to tee)
29. Barbed fitting
30. Barbed fitting
31. Tee fitting
32. Barbed fitting
33. Elbow fitting
34. Fuel/water separator element
35. Pump mount plate
36. Cap screw (3)
37. Fuel/water separator head
38. Flange head screw (2)
39. Tank support
40. Flange head screw (2)
41. Fuel hose (tee to vent tube)
Reelmaster 3550−DPage 3 − 8Kubota Diesel Engine
DANGER
3
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 engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and
wipe up any s p i l l e d diesel fuel before starting the
engine. Store fuel in a clean, safety−approved
container and keep cap in place. Use diesel fuel
for the engine only; not for any other purpose.
Fuel Tank Removal (Fig. 5)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing waste fuel.
2. Drain fuel from the tank into a suitable container. If
necessary.
3. Disconnect seat switch from the electrical harness.
Remove seat and seat support straps from the frame.
4. Remove fuel hose strap and both fuel hoses from the
fuel tank (Fig 6). Remove fuel tank from the machine.
Clean Fuel Tank
4
5
1
2
Figure 6
1. Seat support strap
2. Hex flange head screw
3. Electrical harness
4. Fuel hose strap
5. Fuel hose
4. Connect wire harness connector to the seat switch.
Route seat switch wire under seat support strap. Secure
seat support straps and seat to the frame (see Operator
Seat in Chapter 6 − Chassis in this manual).
5. Check that fuel tank support contacts the bottom of
the fuel tank but does not raise tank from machine
frame. Adjust location of support if necessary.
6. Check for correct seat operation. Also check that
seat switch wires and connector are not pinched and do
not contact any moving parts.
7. Fill fuel tank.
Kubota
Diesel Engine
Clean the fuel tank every 2 years. Also, clean the fuel
tank if the fuel system becomes contaminated or if the
machine is to be stored for an extended period.
1. Remove fuel tank from the machine (see Fuel Tank
Removal).
2. Flush fuel tank out with clean diesel fuel. Make sure
tank is free of contaminates and debris.
3. Install fuel tank to the machine (see Fuel Tank Installation).
Fuel Tank Installation (Fig. 5)
1. Position fuel tank to the machine.
2. Connect both fuel hoses to the tank and secure with
hose clamps.
3. Install fuel hose strap to top of tank making sure that
fuel lines are properly positioned in grooves in tank.
Reelmaster 3550−D Page 3 − 9 Kubota Diesel Engine
Radiator and Oil Cooler Assembly
21
2
27
19
21
18
9
20
9
10
22
25
10
5
8
16
11
14
3
4
12
24
13
21
33
23
34
Thread
Sealant
26
2
RIGHT
30
29
28
15
16
1
33
31
7
2
17
FRONT
32
6
1. Draincock valve
2. Flange head screw (8)
3. Flange nut (4)
4. Carriage bolt (4)
5. Radiator/oil cooler assembly
6. LH fan shroud
7. RH fan shroud
8. Flange head screw (4)
9. Hose clamp (2)
10. Flange head screw (6)
11. Overflow bottle bracket
12. Radiator lower shield
Figure 7
13. Magnet
14. Radiator hose (upper)
15. Radiator hose (lower)
16. Hose clamp (2)
17. Straight hydraulic fitting
18. Hose
19. Coolant expansion tank
20. Radiator cap
21. Flange nut (6)
22. Foam seal (2)
23. Adapter
24. LH radiator bracket
25. RH radiator bracket
26. Bottom radiator bracket
27. Top radiator bracket
28. Plastic plug (2)
29. Flange nut (4)
30. Flange head screw (4)
31. Flat washer (4)
32. O−ring
33. O−ring
34. O−ring
Reelmaster 3550−DPage 3 − 10Kubota Diesel Engine
Removal (Fig. 7)
Installation (Fig. 7)
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 hood from the machine.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene- glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly
labeled container away from children and pets.
IMPORTANT: Follow all local codes and regulations
when recycling or disposing engine coolant.
3. Drain radiator into a suitable container either by using the draincock near the lower left side corner of the
radiator or by removing the lower radiator hose from the
radiator.
4. Disconnect radiator hoses from the radiator.
1. Inspect seals around radiator location for wear or
damage. Replace seals if necessary.
2. If hydraulic fittings were removed from oil cooler, lubricate and place new O- rings onto fittings. Install fittings into port openings and tighten fittings (see
Hydraulic Fitting Installation in the General Information
section of Chapter 4 - Hydraulic System in this manual).
3. If draincock valve was removed from radiator, apply
thread sealant to draincock threads before installing it
into radiator.
4. Remove all plugs placed in radiator and hose openings during the removal procedure.
5. Carefully position radiator to the radiator brackets.
6. Secure radiator to the side radiator brackets with four
(4) carriage bolts and flange nuts. Secure top and bottom of radiator to brackets with flange head screws.
7. Connect hydraulic lines to fittings in oil cooler ports
(see Hydraulic Hose and Tube Installation in the General Information section of Chapter 4 - Hydraulic System
in this manual).
Kubota
Diesel Engine
5. Remove air cleaner inlet hose from radiator opening.
6. Read the General Precautions for Removing and
Installing Hydraulic System Components in the Service
and Repairs section of Chapter 4 - Hydraulic System in
this manual.
7. Thoroughly clean hydraulic lines at oil cooler ports.
Disconnect hydraulic lines and put caps or plugs on lines
to prevent contamination. Label disconnected hydraulic
lines for proper installation.
8. Remove coolant expansion tank and bracket from
machine.
9. Remove fan shrouds from machine.
10.Remove fasteners that secure radiator to the upper,
lower and side radiator brackets.
1 1 .Carefully separate radiator/oil cooler assembly from
brackets and remove from the machine.
12.If necessary, remove hydraulic fittings from oil cooler
and discard O- rings.
8. Position fan shrouds to radiator and secure with removed fasteners.
9. Secure coolant expansion tank and bracket to machine.
10.Connect radiator hoses to the radiator and secure
with hose clamps.
11. Install and secure air cleaner inlet hose.
12.Make sure radiator draincock valve is closed. Fill radiator with coolant.
13.Install hood to the machine. Close and latch hood.
14.Fill the hydraulic fluid tank.
15.Start the unit and run engine to normal operating
temperature. Use all of the hydraulic controls while the
engine is running to d istribute the hydraulic fluid
throughout the system.
16.Stop the engine and check the hydraulic fluid and
coolant levels. Adjust as necessary.
13.Plug all r adiator and hose openings to prevent contamination.
Reelmaster 3550- D Page 3 - 11 Kubota Diesel Engine
Engine
44
43
45
42
46
1
2
3
5
6
7
8
Thread Sealant
9
6
10
13
12
11
4
26
15
14
31
41
38
40
37
32
30
36
34
35
26
16
17
18
19
20
23
24
25
27
21
22
30
28
29
4
31
32
39
1. Engine mount bracket − RH
2. Cap screw
3. Hardened washer
4. Engine mount
5. Lower radiator hose
6. Hose clamp
7. Exhaust flange gasket
8. Coolant temperature switch
9. Upper radiator hose
10. Wire Harness − fusible link
11. Flat washer
12. Lock washer
13. Hex nut
14. Flange nut
15. Fuel filter bracket
16. External tooth lock washer
39
Figure 8
17. Engine ground wire
18. Flat washer
19. Cap screw
20. Throttle cable bracket
21. Cable clamp
22. Cap screw
23. Throttle cable
24. Swivel clamp
25. Cable stop
26. Cap screw
27. Engine mount bracket − LH
28. Hardened washer
29. Cap screw
30. Flange head screw
31. Hardened washer
32. Hex nut
33
17
34
33. Lock washer
34. Flange nut
35. Engine mount bracket − front
36. Engine mount
37. Hardened washer
38. Cap screw
39. Cable tie
40. Spacer (1)
41. Spacer (4)
42. Pump mount plate
43. Hardened washer
44. Cap screw
45. Cap screw
46. Hardened washer
Reelmaster 3550−DPage 3 − 12Kubota Diesel Engine
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. Disconnect air hose from the air cleaner and radiator.
Remove air cleaner assembly from the engine.
4. Disconnect both battery cables at the battery (see
Battery Service in Chapter 5 − Electrical System).
5. Remove muffler from the e x h a u s t manifold and muffler bracket (see Muffler Removal in this Chapter).
6. Drain radiator from the drain cock valve into a suitable container (see Radiator Removal in this Chapter).
Disconnect coolant hoses from the water pump and engine block.
7. Remove coolant expansion tank and bracket from
the top fan shroud. Remove top fan shroud from the radiator (see Radiator Removal in this Chapter).
8. Disconnect wire harness and electrical wires from
the following:
A. Battery, wire harness and engine grounds
(Fig. 9).
6
1. Battery ground cable
2. Wire harness ground
3. Throttle cable
2
4
3
1. Glow plug wire
2. Rear injector nozzle
3
2
1
Figure 9
1
Figure 10
4
5
4. Support bracket
5. Speed control lever
6. Fuel hose
Kubota
Diesel Engine
3. Fuel hose
4. Lift tab
B. Glow plug bus (Fig. 10) and fuel stop solenoid.
C. Engine temperature sensor, alternator, and low
oil pressure switch (Fig. 11).
9. Disconnect throttle cable from the support and swivel on the speed control lever (Fig. 9).
10.Disconnect fuel hose from the fuel pump (Fig. 9) and
front injector nozzle.
11.Remove traction control cable from the neutral arm
assembly on the piston pump. Remove all hydraulic
hoses from the piston and gear pumps (see Piston
Pump Removal in Chapter 4− Hydraulic System).
12.Remove cable ties securing the wire harness to the
front lift tab and other engine parts. Connect hoist or lift
to the front and rear lift tabs (Fig. 10).
1
1. Engine temp. sensor
2. Alternator
2
3
Figure 11
3. Oil pressure switch
Reelmaster 3550−D Page 3 − 13 Kubota Diesel Engine
CAUTION
CAUTION
Make sure lift or hoist can support the total
weight of the engine before removing the cap
screws from the engine and engine brackets.
13.Remove hex nuts, cap screws, and washers from the
center of the three engine mounts.
RIGHT
1
FRONT
2
3
One person should operate lift or hoist while the
other person guides the engine out of the machine.
IMPORTANT: Make sure not to damage the engine,
fuel and hydraulic lines, electrical harness, or other
parts while removing the engine.
14.Remove engine slowly from the machine.
4
5
6
7
1. Engine mount bracket
2. Flange nut
3. Flange screw
4. Pump mount plate
10
9
8
Figure 12
5. Hardened washer
6. 10 mm cap screw (4)
7. 8 mm cap screw (1)
8. Hardened washer
9. Long spacer (4)
10. Short spacer (1)
Reelmaster 3550−DPage 3 − 14Kubota Diesel Engine
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