Toro 03638 User manual

FormNo.3420-472RevA
8-BladeRadialReel,8-Blade
ForwardSweptReel,or11-Blade
ForwardSweptReelDPACutting
Unitwith7inReel
Reelmaster®5010-HSeriesTractionUnit
ModelNo.03638—SerialNo.400000000andUp
ModelNo.03639—SerialNo.400000000andUp
ModelNo.03641—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3420-472*A

WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
ThisproductcomplieswithallrelevantEuropean
directives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Introduction
Important:Tomaximizethesafety,performance,
andproperoperationofthismachine,carefully
readandfullyunderstandthecontentsofthis
Operator’sManual.Failingtofollowthese
operatinginstructionsortoreceiveproper
trainingmayresultininjury.Formoreinformation
onsafeoperatingpractices,includingsafetytips
andtrainingmaterials,gotowww.Toro.com.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
YoumaycontactT orodirectlyatwww.Toro.com
forproductsafetyandoperationtrainingmaterials,
accessoryinformation,helpndingadealer,orto
registeryourproduct.
Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanathorizedToro
distributororT oroCustomerServiceandhavethe
modelandserialnumbersofyourproductready.
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.
g027159
Figure1
1.Locationofthemodelandserialnumbers
ModelNo.
SerialNo.
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Contents
Safety.......................................................................3
SafetyandInstructionalDecals..........................4
Setup........................................................................5
1InspectingtheCuttingUnit...............................5
2UsingtheKickstand.........................................5
3AdjustingtheRearShield.................................6
4InstallingtheLooseParts.................................6
ProductOverview.....................................................8
Specications....................................................8
Attachments/Accessories...................................8
Operation..................................................................8
MakingAdjustments...........................................8
Height-of-CutChartTerms................................10
Maintenance...........................................................16
LubricatingtheCuttingUnits.............................16
Relief-GrindingtheReel...................................16
ServicingtheBedknife......................................17
ServicingtheBedbar........................................18
ServicingtheHDDualPointAdjusters
(DPA)............................................................20
ServicingtheRoller...........................................22
Safety
Thismachinehasbeendesignedinaccordancewith
ENISO5395:2013.
Improperuseormaintenanceofthisequipment
canresultininjuryordeath.Toreducethe
potentialforinjuryordeath,complywiththe
followingsafetyinstructions.
•Read,understand,andfollowallinstructionsinthis
Operator’sManualbeforeoperatingthecutting
unit.
•Lowerthecuttingunitstotheground,engagethe
parkingbrake,shutofftheengine,andremovethe
keyfromtheignitionswitchwheneveryouleave
themachineunattended.
•Besurethatthecuttingunitsareinsafeoperating
conditionbykeepingnuts,bolts,andscrewstight.
3

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal93-6688
93-6688
1.Warning—readthe
instructionsbefore
servicingorperforming
maintenance.
2.Cuttinghazardofhandor
foot—shutofftheengine
andwaitformovingparts
tostop.
4

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Cuttingunit1Inspectthecuttingunit.
2Nopartsrequired–Usethekickstandwhentippingthe
cuttingunit.
3Nopartsrequired–Adjusttherearshield.
Straightgreasetting1
4O-ring1Installthelooseparts.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual1
PartsCatalog(notincluded)—refertothe
includedpostcardforinformationonobtaining
thePartsCatalog
–Reviewthematerialandsaveitinanappropriateplace.
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
1
InspectingtheCuttingUnit
Partsneededforthisprocedure:
1Cuttingunit
Procedure
Afterthecuttingunitisremovedfromthebox,inspect
thefollowing:
1.Checkeachendofthereelforgrease.
Note:Greaseshouldbevisiblyevidentinthe
internalsplinesofthereelshaft.
2.Ensurethatallnutsandboltsaresecurely
tightened.
3.Makesurethatthecarrier-framesuspension
operatesfreelyanddoesnotbindwhenmoved
backandforth.
2
UsingtheKickstand
NoPartsRequired
Procedure
Wheneverthecuttingunithastobetippedtoexpose
thebedknife/reel,propuptherearofthecuttingunit
withthekickstand(suppliedwiththetractionunit)to
makesurethatthenutsonthebackendofthebedbar
adjustingscrewsarenotrestingontheworksurface
(Figure3).
5

g027160
Figure3
1.Kickstand
3
AdjustingtheRearShield
NoPartsRequired
Procedure
Undermostconditions,bestdispersionisattained
whentherearshieldisclosed(frontdischarge).When
conditionsareheavyorwet,therearshieldmaybe
opened.
Toopentherearshield(Figure4),loosenthecap
screwsecuringtheshieldtotheleftsideplate,rotate
theshieldtotheopenpositionandtightenthecap
screw.
g027161
Figure4
1.Capscrew2.Rearshield
4
InstallingtheLooseParts
Partsneededforthisprocedure:
1Straightgreasetting
1O-ring
Procedure
Thegreasettingmustbeinstalledonthereel-motor
sideofthecuttingunit.RefertoFigure5todetermine
thepositionofthereelmotors.
g031275
Figure5
1.Cuttingunit15.Cuttingunit5
2.Cuttingunit26.Reelmotor
3.Cuttingunit37.Weight
4.Cuttingunit4
1.Removeanddiscardthesetscrewonthe
reel-motorsideplate(Figure6).
g028640
Figure6
1.Capscrew(2)3.Greasetting
2.Setscrew4.Greasevent
6

2.Installthestraightgreasetting(Figure6).
3.Iftherearenocapscrewsonthereel-motorside
plate,installthem(Figure6).
4.InstalltheO-ringonthereelmotor(Figure7).
g033964
Figure7
1.O-ring
5.Installthereelmotor,andgreasethesideplate
untilexcessgreasecomesoutofthegrease
vent(Figure6).
7

ProductOverview
Specications
CuttingUnitWeight
0363854kg(118lb)
0363954kg(118lb)
0364155kg(121lb)
Attachments/Accessories
AselectionofToro-approvedattachmentsandaccessoriesisavailableforusewiththemachinetoenhance
andexpanditscapabilities.ContactyourAuthorizedServiceDealerorDistributororgotowww.Toro.comfor
alistofallapprovedattachmentsandaccessories
TobestprotectyourinvestmentandmaintainoptimalperformanceofyourToroequipment,countonT oro
genuineparts.Whenitcomestoreliability,Torodeliversreplacementpartsdesignedtotheexactengineering
specicationofourequipment.Forpeaceofmind,insistonTorogenuineparts.
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
MakingAdjustments
AdjustingtheBedknifetotheReel
Usethisproceduretosetthebedknifetothereeland
tochecktheconditionofthereelandbedknifeand
theirinteraction.Aftercompletingthisprocedure,
alwaystestthecuttingunitperformanceunderyour
eldconditions.Youmayneedtomakefurther
adjustmentstoobtainoptimalcuttingperformance.
Important:Donotovertightenthebedknifetothe
reeloryouwilldamageit.
•Afterbacklappingthecuttingunitorgrindingthe
reel,youmayneedtomowwiththecuttingunitfor
afewminutesandthenperformthisprocedure
toadjustthebedknifetothereelasthereeland
bedknifeadjusttoeachother.
•Youmayneedadditionaladjustmentsiftheturfis
extremelydenseoryourcuttingheightisverylow.
Youwillneedthefollowingtoolstocompletethis
procedure:
•Shim0.05mm(0.002inch)
•Cuttingperformancepaper
1.Positionthecuttingunitonaat,levelwork
surface.
2.Turnthebedbar-adjustingscrews
counterclockwisetoensurethatthebedbardoes
notcontactthereel(Figure8).
g019940
Figure8
1.Bedbar-adjustingscrew
3.Tipthecuttingunittoexposethebedknifeand
reel.
Important:Makesurethatthenutsonthe
backendofthebedbar-adjustingscrewsare
notrestingontheworksurface(Figure9).
g027160
Figure9
1.Kickstand
8

4.Rotatethereelsothatabladecrossesthe
bedknifeapproximately25mm(1inch)infrom
theendofthebedknifeontherightsideofthe
cuttingunit.
Note:Putanidentifyingmarkonthisbladeto
makesubsequentadjustmentseasier.
5.Insertthe0.05mm(0.002inch)shimbetween
themarkedreelbladeandthebedknifeatthe
pointwherethebladecrossesthebedknife.
6.Turntherightbedbaradjusterclockwiseuntil
youfeellightpressure(i.e.drag)ontheshim,
thenbackoffthebedbaradjuster2clicksand
removetheshim.
Note:Adjusting1sideofthecuttingunitaffects
theotherside,the2clickswillprovideclearance
forwhentheothersideisadjusted.
Note:Ifstartingwithalargegap,bothsides
shouldinitiallybedrawncloserbyalternately
tighteningtherightandlefthandsides.
7.Slowlyrotatethereelsothatthesameblade
thatyoucheckedontherightsideiscrossing
thebedknifeapproximately25mm(1inch)in
fromtheendofthebedknifeontheleftsideof
thecuttingunit.
8.Turntheleftbedbaradjusterclockwiseuntilthe
shimcanbeslidthroughthereeltobedknife
gapwithlightdrag.
9.Returntotherightsideandadjustasnecessary
togetlightdragontheshimbetweenthesame
bladeandbedknife.
10.Repeatsteps8and9untiltheshimcanbeslid
throughbothgapswithslightdrag,butoneclick
inonbothsidespreventstheshimfrompassing
throughonbothsides.
Note:Thebedknifeisnowparalleltothereel.
Note:Thisprocedureshouldnotbeneeded
ondailyadjustments,butshouldbedoneafter
grindingordisassembly.
11.Fromthisposition(i.e.,1clickinandshimnot
passingthrough)turnthebedbaradjusters
clockwise1clickeach.
Note:Eachclickturnedmovesthebedknife
0.022mm(0.0009inch).Donotovertighten
theadjustingscrews.
12.Testthecuttingperformancebyinsertingalong
stripofTorocuttingperformancepaperbetween
reelandbedknife,perpendiculartothebedknife
(Figure10).
Note:Slowlyrotatethereelforward;itshould
cutthepaper.
g027166
Figure10
Note:Ifexcessivereeldragoccurseither
backlaporgrindthecuttingunittoachievethe
sharpedgesneededforprecisioncutting.
AdjustingtheRearRoller
1.Adjusttherearrollerbrackets(Figure11)tothe
desiredheight-of-cutrangebypositioningthe
requiredamountofspacersbelowtheside-plate
mountingange(Figure11)pertheHOCChart.
g003324
Figure11
1.Spacer3.Side-platemountingange
2.Rollerbracket
2.Raisetherearofthecuttingunitandplacea
blockunderthebedknife.
3.Removethe2nutssecuringeachrollerbracket
andthespacertoeachside-platemounting
ange.
4.Lowertherollerandthescrewsfromthe
side-platemountingangesandspacers.
5.Placethespacersontothescrewsontheroller
brackets.
6.Re-securetherollerbracketandthespacersto
undersideoftheside-platemountinganges
withthenutspreviouslyremoved.
7.Verifythatthebedknife-to-reelcontactiscorrect.
Tipthemowertoexposethefrontandrear
rollersandthebedknife.
Note:Thepositionoftherearrollertothereel
iscontrolledbythemachiningtolerancesofthe
9

assembledcomponents,andsoparallelingis
notrequired.Alimitedamountofadjustmentis
possiblebysettingthecuttingunitonasurface
plateandlooseningtheside-platemountingcap
screws(Figure12).
g027167
Figure12
1.Side-platemountingcapscrews
8.Adjustandtightenthecapscrewsandtorque
thecapscrewsto37to45N∙m(27to33ft-lb).
Height-of-CutChartTerms
Height-of-CutSetting(HOC)
Thiscorrespondstothedesiredheightofcut.
BenchSetHeight-of-Cut
Thebenchsetheightofcutistheheightatwhich
thetopedgeofthebedknifeissetaboveaatlevel
surfacethatcontactsthebottomofboththefrontroller
andrearroller.
EffectiveHeightofCut
Thisistheactualheightthatthegrasshasbeen
cut.Foragivenbenchsetheight-of-cut,theactual
height-of-cutwillvarydependingonthetypeofgrass,
timeofyear,turf,andsoilconditions.Thecutting
unitsetup(aggressivenessofcut,rollers,bedknives,
attachmentsinstalled,turfcompensationsettings,
etc.)willalsoaffecttheeffectiveheightofcut.Check
theeffectiveheightofcutusingtheTurfEvaluator
(Model04399)regularlytodeterminethedesired
benchsetheightofcut.
AggressivenessofCut
Theaggressivenessofcuthasasignicantimpacton
theperformanceofthecuttingunit.Aggressiveness
ofcutreferstotheangleofthebedkniferelativetothe
ground(Figure13).
Thebestcuttingunitsetupisdependentonyour
turfconditionsanddesiredresults.Experiencewith
thecuttingunitonyourturfwilldeterminethebest
settingtouse.Aggressivenessofcutmaybeadjusted
throughoutthecuttingseasontoallowforvariousturf
conditions.
Ingeneral,lesstonormalaggressivesettings
aremoreappropriateforwarm-seasongrasses
(Bermuda,paspalum,zoysia)whilecool-season
grasses(bent,bluegrass,rye)mayrequirenormalto
moreaggressivesetups.Moreaggressivesetupscut
moregrassoffbyallowingthespinningreeltopull
moregrassupintothebedknife.
g033976
Figure13
1.Rearspacers3.Aggressivenessofcut
2.Side-platemountingange
RearSpacers
Thenumberofrearspacersdeterminesthe
aggressivenessofcutforthecuttingunit.Foragiven
heightofcut,addingspacersbelowtheside-plate
mountingangeincreasestheaggressivenessofthe
cuttingunit.Allcuttingunitsonagivenmachinemust
besettothesameaggressivenessofcut(number
ofrearspacers,ToroPartNo.106-3925);otherwise,
theafter-cutappearancecouldbenegativelyaffected
(Figure13).
ChainLinks
Thelocationatwhichthelift-armchainisattached
determinesthepitchangleoftherearroller(Figure
14).
10

g027170
Figure14
1.Liftchain3.Bottomhole
2.U-backet
Groomer
Thesearetherecommendedheight-of-cutsettings
whenagroomerkitisinstalledonthecuttingunit.
11

Height-of-CutChart
Thesearetherecommendedheight-of-cutsettingswhenagroomerkitisinstalledonthecuttingunit.
HOCSettingAggressivenessofCutNo.ofRearSpacersNo.ofChainLinksWithGroomerkits
installed**
0.64cm(0.250inch)Less
Normal
More
0
0
1
5
5
5
Y
Y
-
0.95cm(0.375inch)Less
Normal
More
0
1
2
5
5
5
Y
Y
-
1.27cm(0.500inch)Less
Normal
More
0
1
2
5
5
5
Y
Y
Y
1.56cm(0.625inch)Less
Normal
More
1
2
3
5
5
5
Y
Y
-
1.91cm(0.750inch)Less
Normal
More
2
3
4
5
5
5
Y
Y
-
2.22cm(0.875inch)Less
Normal
More
2
3
4
5
5
5
Y
Y
-
2.54cm(1.000inch)Less
Normal
More
3
4
5
5
5
4+
Y
Y
-
2.86cm(1.125inches)Less
Normal
More
4
5
6
5
5
5
-
-
-
3.18cm(1.250
inches)*+
Less
Normal
More
4
5
6
5
5
5
-
-
-
3.49cm(1.375
inches)*+
Less
Normal
More
4
5
6
5
5
5
-
-
-
3.81cm(1.500
inches)*+
Less
Normal
More
5
6
7
5
5
5
-
-
-
4.13cm(1.625
inches)*+
Less
Normal
More
6
7
8
4
4
4
-
-
-
4.44cm(1.750
inches)*+
Less
Normal
More
6
7
8
4
4
5
-
-
-
4.76cm(1.875
inches)*+
Less
Normal
More
7
8
9
4
5
5
-
-
-
5.08cm(2.000
inches)*+
Less
Normal
More
7
8
9
5
5
5
-
-
-
+IndicatesthattheU-bracket,ontheliftarm,ispositionedinthebottomhole(Figure14).
*TheHighHOCKit(PartNo.137-0890)mustbeinstalled.PositiontheHOCbracketinthetopside-platehole.
**YindicatesthatthiscombinationofHOCandspacerscanbeusedwithgroomers.
Note:Changing1chainlinkchangesthepitch-anglemovementoftherearrollerby4.5degrees.
Note:ChangingtheU-bracketontheliftarmtothebottomholeadds2.3degreestothepitchangleofthe
rearroller.
12

AdjustingtheHeightofCut(HOC)
Note:Forheightsofcutgreaterthan2.54cm(1.00
inch)theHighHeight-of-CutKitmustbeinstalled.
1.Loosenthelocknutssecuringtheheight-of-cut
armstothecutting-unitsideplates(Figure15).
g027171
Figure15
1.Adjustingscrew3.Height-of-cutarm
2.Locknut
2.Loosenthenutonthegaugebar(Figure16)
andsettheadjustingscrewtothedesiredheight
ofcut.
g003327
Figure16
1.Gaugebar4.Holesusedforsetting
groomerHOC
2.Heightadjustingscrew5.Holenotused
3.Nut
3.Measurethedistancebetweenthebottomofthe
screwheadandthefaceofthebartogetthe
heightofcut.
4.Hookthescrewheadonthecuttingedgeofthe
bedknifeandresttherearendofthebaronthe
rearroller(Figure17).
Note:ForcheckingtheHOConcuttingunits
installedwithshoulderrollers,placethegauge
baronthelargerdiametershouldersonthe
endsoftheshoulderroller.
5.Rotatetheadjustingscrewuntilthefrontroller
contactsthegaugebar(Figure17).
g027172
Figure17
6.Adjustbothendsoftherolleruntiltheentire
rollerisparalleltothebedknife.
Important:Whensetproperly,therear
andfrontrollerswillcontactthegauge
barandthescrewwillbesnugagainstthe
bedknife.Thisensuresthattheheightofcut
isidenticalatbothendsofthebedknife.
7.Tightenthenutstosecuretheadjustment.
Note:Donotovertightenthenuts.Tightenthem
justenoughtoremoveplayfromthewasher.
13

Usethefollowingcharttodeterminewhichbedknifeisbestsuitedforthedesiredheightofcut.
Bedknife/HeightofCutChart
BedknifePartNo.BedknifeLipHeightHeightofCut
LowHOC(Optional)110-40845.6mm
(0.220inch)
6.4to12.7mm
(0.250to0.500inch)
EdgeMax®LowHOC
(Model03641)
137-08325.6mm
(0.220inch)
6.4to-12.7mm
(0.250to0.500inch)
ExtendedLowHOC
(Optional)
120-16405.6mm
(0.220inch)
6.4to12.7mm
(0.250to0.500inch)
ExtendedEdgeMax®Low
HOC(Optional)
119-42805.6mm
(0.220inch)
6.4to12.7mm
(0.250to0.500inch)
EdgeMax®
(Models03638and03639)
137-08336.9mm
(0.270inch)
9.5to38.1mm
(0.375to1.50inches)*
Standard(Optional)108-90966.9mm
(0.270inch)
9.5to38.1mm
(0.375to1.50inches)*
HeavyDuty(Optional)110-40749.3mm
(0.370inch)
12.7to38.1mm
(0.500to1.50inches)
*Warm-seasongrassesmayrequiretheLowHOCbedknifefor12.7mm(0.500inch)andbelow.
g006510
Figure18
1.Bedknifelipheight
AdjustingtheTurf-Compensation
Settings
Theturf-compensationspringtransferstheweight
fromthefronttotherearroller.Thishelpstoreduce
awavepatternintheturf,alsoknownasmarcelling
orbobbing.
Important:Makethespringadjustmentswiththe
cuttingunitmountedtothetractionunit,pointing
straightaheadandloweredtotheshopoor.
1.Makesurethatthehairpincotterisinstalledin
therearholeinthespringrod(Figure19).
g027169
Figure19
1.Turf-compensationspring3.Springrod
2.Hairpincotter4.Hexnuts
2.Tightenthehexnutsonthefrontendofthe
springroduntilthecompressedlengthofthe
springis15.9cm(6.25inches)(Figure19).
Note:Whenoperatingthemachineonrough
terrain,decreasethespringlengthby12.7mm
(1/2inch).
Note:Theturf-compensationsettingwill
needtoberesetiftheHOCsettingorthe
aggressiveness-of-cutsettingischanged.
14

CheckingandAdjustingthe
CuttingUnit
Thedualknobbedknife-to-reeladjustmentsystem
incorporatedinthiscuttingunitsimpliesthe
adjustmentprocedureneededtodeliveroptimum
mowingperformance.Thepreciseadjustment
possiblewiththedualknob/bedbardesigngives
thenecessarycontroltoprovideacontinual
self-sharpeningaction-thusmaintainingsharpcutting
edges,ensuringgoodqualityofcut,andgreatly
reducingtheneedforroutinebacklapping.
Priortomowingeachday,orasrequired,checkeach
cuttingunittoverifyproperbedknife-to-reelcontact.
Thismustbeperformedeventhoughthequality
ofcutisacceptable.
1.Slowlyrotatethereelinareversedirection,
listeningforreel-to-bedknifecontact.
Note:Theadjustmentknobshavedetents
correspondingto0.018mm(0.0007inch)
bedknifemovementforeachindexedposition.
RefertoAdjustingtheBedknifetotheReel
(page8).
2.Testthecuttingperformancebyinsertinga
longstripofcuttingperformancepaper(T oro
Part125-5610)betweenreelandbedknife,
perpendiculartothebedknife(Figure20).Slowly
rotatethereelforward;itshouldcutthepaper.
g027166
Figure20
Note:Ifexcessivecontact/reeldragisevident
itwillbeeithernecessarytobacklap,refacethe
frontofthebedknife,orgrindthecuttingunitto
achievethesharpedgesneededforprecision
cutting(refertotheT oroManualforSharpening
ReelandRotaryMowers,FormNo.09168SL).
Important:Lightcontactispreferred
atalltimes.Ifyoudonotmaintainlight
contact,thebedknifeandreeledgeswill
notsufcientlyself-sharpenandwilldull
afteraperiodofoperation.Ifyoumaintain
excessivecontact,thebedknifeandreelwill
wearquicker,wearunevenly,andthequality
ofcutmaybeadverselyaffected.
Note:Afterextendedrunning,aridgewill
eventuallydevelopatbothendsofthebedknife.
Roundofforlethesenotchesushwiththe
cuttingedgeofthebedknifetoensuresmooth
operation.
Note:Overtime,youwillneedtogrindthe
chamfer(Figure21),asitisonlydesignedtolast
40%ofthebedknifelife.
g031270
Figure21
1.Lead-inchamferonright
endofbedknife
3.1.5mm(0.060inch)
2.6mm(0.25inch)
Note:Donotmakethelead-inchamfertoo
largeasitmaycauseturftufting.
15

Maintenance
LubricatingtheCutting
Units
Eachcuttingunithas5greasettings(Figure22)that
mustbelubricatedregularlywithNo.2lithiumgrease.
Thereare2lubricationpointsonthefrontroller,rear
roller,and1atthereelmotorspline.
Note:Lubricatingcuttingunitsimmediatelyafter
washinghelpspurgewateroutofthebearings
andincreasesbearinglife.
1.Wipeeachgreasettingwithacleanrag.
2.Applygreaseuntilcleangreasecomesoutof
therollersealsandthebearingreliefvalve.
3.Wipeanyexcessgreaseaway.
g027174
Figure22
Greasettinglocationsonthereelmotorside.
Relief-GrindingtheReel
Thenewreelhasalandwidthof1.3to1.5mm(0.050
to0.060inch)anda30degreereliefgrind.
Whenthelandwidthgetslargerthan3mm(0.120
inch)wide,dothefollowing:
1.Applya30degreereliefgrindonallreelblades
untilthelandwidthis1.3mm(0.050inch)wide
(Figure23andFigure24).
g028800
Figure23
Model03638
1.30degrees2.1.3mm(0.050inch)
g028838
Figure24
Models03639and03641
1.1.3mm(0.050inch)2.30degrees
2.Spingrindthereeltoachieve<0.025mm(0.001
inch)reelrun-out.
Note:Thiscausesthelandwidthtogrow
slightly.
Note:Toextendthelongevityofthesharpnessofthe
edgeofthereelandthebedknife—aftergrindingthe
reeland/orthebedknife—checkthereeltobedknife
contactagainaftercutting2faiways,asanyburrs
willberemoved,whichmaycreateimproperreelto
bedknifeclearanceandthusacceleratewear.
16

ServicingtheBedknife
Thebedknifeservicelimitsarelistedinthefollowingchart.
Important:Operatingthecuttingunitwiththebedknifebelowtheservicelimitmayresultinpoor
after-cutappearanceandreducethestructuralintegrityofthebedknifeforimpacts.
BedknifeServiceLimitChart
BedknifePartBedknifeLipHeight*ServiceLimit*GrindAngles
Top/FrontAngles
EdgeMax®LowHOC
(Model03641)
137-08325.6mm
(0.220inch)
6.4-12.7mm
(0.250-0.500inch)10/5Degrees
LowHOC(Optional)110-40845.6mm
(0.220inch)
4.8mm
(0.190inch)10/5Degrees
ExtendedEdgeMax®
LowHOC(Optional)
119-42805.6mm
(0.220inch)
4.8mm
(0.190inch)10/10Degrees
ExtendedLowHOC
(Optional)
120-16405.6mm
(0.220inch)
4.8mm
(0.190inch)10/10Degrees
EdgeMax®
(Models03638and
03639)
137-08336.9mm
(0.270inch)
4.8mm
(0.190inch)10/5Degrees
Standard(Optional)108-90966.9mm
(0.270inch)
4.8mm
(0.190inch)10/5Degrees
HeavyDuty(Optional)110-40749.3mm
(0.370inch)
4.8mm
(0.190inch)10/5Degrees
RecommendedTopandFrontBedknifeGrind
Angles(Figure25)
g027268
Figure25
1.Bedknifeservicelimit*
2.Topgrindangle
3.Frontgrindangle
Note:Allbedknifeservicelimitmeasurements
referencethebottomofthebedknife(Figure26)
g007165
Figure26
CheckingtheTopGrindAngle
Theanglethatyouusetogrindyourbedknivesis
veryimportant.
Usetheangleindicator(T oroPartNo.131-6828)and
theangle-indicatormount(ToroPartNo.131-6829)to
checktheanglethatyourgrinderproducesandthen
correctforanygrinderinaccuracy.
1.Placetheangleindicatoronthebottomsideof
thebedknifeasshowninFigure27.
17

g034113
Figure27
1.Bedknife(vertical)2.Angleindicator
2.PresstheAltZerobuttonontheangleindicator.
3.Placetheangle-indicatormountontheedge
ofthebedknifesothattheedgeofthemagnet
mateswiththeedgeofthebedknife(Figure28).
Note:Thedigitaldisplayshouldbevisiblefrom
thesamesideduringthisstepasitwasinstep1.
g034114
Figure28
1.Angle-indicatormount3.Bedknife
2.Edgeofthemagnetmated
withtheedgeofthe
bedknife
4.Angleindicator
4.Placetheangleindicatoronthemountasshown
inFigure28.
Note:Thisistheanglethatyourgrinder
produces,andshouldbewithin2degreesofthe
recommendedtopgrindangle.
ServicingtheBedbar
RemovingtheBedbar
1.Turnthebedbar-adjustingscrews
counterclockwisetobackthebedknife
awayfromthereel(Figure29).
g006498
Figure29
1.Bedbar-adjustingscrew3.Bedbar
2.Spring-tensionnut4.Washer
2.Backoutthespring-tensionnut,untilthewasher
isnolongertensionedagainstthebedbar
(Figure29).
3.Oneachsideofthemachine,loosenthelocknut
securingthebedbarbolt(Figure30).
g003334
Figure30
1.Bedbarbolt2.Locknut
4.Removeeachbedbarboltallowingbedbarto
bepulleddownwardandremovedfromthe
machinebolt(Figure30).
Note:Accountfor2nylonand1stampedsteel
washeroneachendofthebedbar(Figure31).
18

g027176
Figure31
1.Bedbarbolt3.Steelwasher
2.Nut4.Nylonwasher
AssemblingtheBedbar
1.Installthebedbar,positioningthemountingears
betweenthewasherandbedbaradjuster.
2.Securethebedbartoeachsideplatewiththe
bedbarbolts(nutsonbolts)andthe6washers.
Note:Positionanylonwasheroneachside
oftheside-plateboss.Placeasteelwasher
outsideeachofthenylonwashers(Figure31).
3.Torquethebedbarboltsto37to45N∙m(27to
33ft-lb).
Note:Tightenthelocknutsuntiltheoutside
steelwasherstopsrotatingandtheendplayis
removedbut,donotovertightenordeectthe
sideplates.Washersontheinsidemayhavea
gap.
4.Tightenthespringtensionnutuntilthespringis
collapsed,thenbackoff1/2turn(Figure32).
g006505
Figure32
1.Springtensionnut2.Spring
19

ServicingtheHDDualPoint
Adjusters(DPA)
1.Removeallparts(refertotheInstallation
InstructionsfortheHDDPAKitandtoFigure
33).
2.Applyanti-seizecompoundtotheinsideof
thebushingareaoncuttingunitcenterframe
(Figure33).
3.Alignthekeysonangebushingstotheslotsin
theframeandinstallthebushings(Figure33).
4.Installawavewasherontotheadjustershaftand
slidetheadjustershaftintotheangebushings
intheframeofthecuttingunit(Figure33).
5.Securetheadjustershaftwithaatwasherand
locknut(Figure33).
6.T orquethelocknutto20to27N∙m(15to20
ft-lb).
Note:Thebedbaradjustershafthasleft-hand
threads.
g016926
Figure33
1.Shaftadjuster4.Applyanti-seizecompound
here.
7.Applyanti-seizecompound
here.
10.Compressionspring
2.Wavewasher5.Flatwasher8.Bedbar-adjusterscrew11.Spring-tensionnut
3.Flangebushing6.Locknut9.Hardenedwasher
7.Applyanti-seizecompoundtothethreadsofthe
bedbar-adjusterscrewthattintotheadjuster
shaft.
8.Threadthebedbar-adjusterscrewintothe
adjustershaft.
9.Looselyinstallthehardenedwasher,spring,and
springtensionnutontotheadjusterscrew.
10.Installthebedbar,positioningthemountingears
betweenthewasherandthebedbaradjuster.
11.Securethebedbartoeachsideplatewiththe
bedbarbolts(nutsonbolts)and6washers.
Note:Positionanylonwasheroneachsideof
theside-plateboss.
12.Placeasteelwasheroutsideeachofthenylon
washers(Figure33).
13.Torquethebedbarboltsto37to45N∙m(27to
33ft-lb).
14.Tightenthelocknutsuntiltheoutsidesteel
washerstopsrotatingandendplayisremoved
butdonotovertightenordeectthesideplates.
Note:Washersontheinsidemayhaveagap
(Figure33).
15.Tightenthenutoneachbedbar-adjuster
assemblyuntilthecompressionspringisfully
compressed,thenloosenthenut1/2turn(Figure
33).
20