Toro Reelmaster 03657 User manual

FormNo.3397-660RevB
RearRollerBrushKit
Reelmaster®3550Series18-inchCuttingUnitwith5-inchReel
andUniversalGroomer
ModelNo.03657
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
DescriptionQty.Use
Nopartsrequired–Determinethepositionoftherollerbrushesandthereel
motors.
Roller-brushassembly5
Retainingring5
Rightbelt-cover/plateassembly2
Leftbelt-cover/plateassembly3
90-degreegreasetting5
Carriagebolt10
Weight5
Locknut10
Drivepulley5
Hex-drivebolt(5/16x1/2inch)15
Belt5
Shimwasher(asrequiredforbeltalignment)5
Belt-alignmenttool1
Frontbumperassembly1
Washer2
Rearbumperassembly1
Installthekit.
Highheight-of-cutbrush(optional)—Installthehighheight-of-cutbrush—forHOCgreaterthan
2.5cm(1inch).
Note:Installtheuniversalgroomerkitrst;referto
thegroomerinstallationinstructions.
Important:UsetheRearRollerBrushKitonly
whencuttingintheheight-of-cutrangeof6to
25mm(1/4to1inch).Usethehighheight-of-cut
brushwhencuttingabove25mm(1inch).Referto
theprocedureforInstallingtheHighHeight-of-Cut
Brush(Optional).
Note:Determinetheleftandrightsidesofthecutting
unitfrombehindthecuttingunit.
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3397-660*B

Determiningthe
Roller-BrushOrientation
Allcuttingunitsareshippedwiththecounterweight
mountedtotheleftendofthecuttingunit.Referto
Figure1todeterminethepositionoftherollerbrush
andreelmotors.
g027187
Figure1
1.Cuttingunit15.Cuttingunit5
2.Cuttingunit26.Reelmotor
3.Cuttingunit37.Rightroller-brushdrive
assembly
4.Cuttingunit48.Leftroller-brushdrive
assembly
Note:Theseinstructionsandillustrationsshowthe
installationofthekitoncuttingunitswiththeuniversal
groomermountedontheleftendofthecuttingunit.
InstallingtheKit
InstallingtheGreaseFitting
1.Removethegreasettingfortherollerfromthe
sideofthecuttingunitthathastheroller-brush
housing(Figure3).
g032170
Figure2
1.Greasetting
2.Installthe90-degreegreasettingsothatit
facesrearward(Figure2).
g032171
Figure3
1.6mm(1/4inch)spacer3.90-degreegreasetting
2.Side-platemountingange4.Flangelocknuts(remove)
2

InstallingtheWeights
Installtheweightstothecuttingunitsasshownin
Figure4.
g283859
Figure4
1.Carriagebolts(5/16x1
inch)
3.Weight
2.Flangenuts(5/16inch),
torqueto20to26N∙m(15
to19ft-lb)
InstallingtheRoller-Brush
Assembly
1.Removethe2angelocknutssecuringeach
rollerbrackettothesideplates,aswellasany
6mm(1/4inch)spacerspositionedonthe
topsideoftheside-platemountingange
(Figure3).
Note:Donotremovethebolts.Keeptheange
locknutsforfutureassembly.
2.Positiontheleftorrightroller-brush-assembly
mountingbracketsontotheroller-bracketbolts
(Figure5).
g033296
Figure5
1.Leftroller-brushassembly2.Roller-brushmounting
bracket
Important:Attachthemountingbrackets
fortheroller-brushassemblydirectlyto
thetopsurfaceoftheside-platemounting
angeofthecuttingunit.Donotputspacers
3

betweentheroller-brushmountingbrackets
andtheside-platemountinganges.Save
theadditional6mm(1/4inch)spacersfor
potentiallateruse.
3.Looselysecurethebrush-assemblymounting
bracketstothecutting-unitsideplateswiththe
previouslyremovednuts.
4.Slideeachexcludersealoutwarduntilthelip
sealsareinlightcontactwitheachbearing
housing(Figure6).
g033201
Figure6
1.Bearinghousing2.Excluderseal
InstallingtheRoller-Brush
Housing
1.Removeanddiscardgroomerdrivecap.
g283858
Figure7
1.Cap
2.Installtheleftorrightroller-brushhousing
(Figure8).
Note:Ensurethattheidler-pulleyassemblyis
installedonthebottomasshowninFigure8.
g033300
Figure8
1.Roller-brushhousing3.Bolt(2)
2.Retainingring4.Bearinghousing
3.Apply242Loctite(blue)tothe2bolts(5/16x
1/2inch)andusethemtomounttheroller-brush
housingtothebearinghousing(Figure8).
Note:T orquetheboltsto20to26N∙m(15to
19ft-lb).
4.Securetheroller-brushhousingtothe
groomer-drivehousingwiththeretainingring
(Figure8).
5.Ensurethattheroller-brushhousingisparallelto
thecutting-unitsideplate.Proceedasfollows:
4

A.Loosenthe2angelocknutssecuring
theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure9).
B.Rotatetheroller-brush-bearinghousinguntil
thebrushplateisparalleltothecutting-unit
sideplate(Figure9).
C.Tightenthe2angelocknutssecuring
theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure9).
g033203
Figure9
1.Loosentheseboltsforpositioningtherollerbrush.
2.Loosenthesenutsformakingtheroller-brushplateparallel.
PositioningtheRollerBrush
1.Loosenthe2boltssecuringeach
roller-brush-bearinghousingtotheroller-brush
mountingbracket(Figure9).
Note:Theboltsshouldbeloosefromthe
factory.
2.Positiontherollerbrushsothatitisjusttouching
orrestingontherearroller(Figure10).
Important:Theroller-brushshaftmustnot
contactthecutting-unitsideplate.
Important:Heavybrushcontactonthe
rollercausesprematurebrushwear.
g027303
Figure10
1.Bearinghousing(some
partsnotshown)
5.Lightcontact
2.Sideplate6.Rearroller
3.Rollerbrush7.Greasetting
4.Ensurethatthereis
clearancehere.
Note:Theroller-brushshaftmustbeparallel
totherearroller.
Important:Positionboth
roller-brush-bearinghousingssothat
theyareparalleltothegroundtoensure
clearancefortherear-rollergreasetting.
3.Tightenthe2boltssecuringeach
roller-brush-bearinghousingtotheroller-brush
mountingbrackets.
5

InstallingtheDrivePulley
1.Restrainthereelbeforeinstallingthedrive
pulley;refertoRestrainingtheReelforInstalling
ThreadedInserts(page13).
2.Installthedrivepulleyontothegroomershaft
(Figure11).
g033204
Figure11
1.Drivepulley2.Hex-drivebolt—torqueto
20to26N∙m(15to19
ft-lb)
3.Apply242Loctite(blue)tothehex-drivebolt
andusethebolttosecurethepulleytothe
driveshaft;refertoFigure11.
Note:Torquetheboltto20to26N∙m(15to
19ft-lb).
Important:Ifyoudonotproperlytorquethe
bolt,theboltwillcomeloose.
InstallingtheBelt
1.Installthebeltontothepulleysasfollows:
•Loopthebeltaroundthedrivepulleyand
thenoverthetopoftheidlerpulley(Figure
12).
g033205
Figure12
1.Drivepulley3.Belt
2.Idler-pulleyassembly4.Drivenpulley
•Startthebeltonthedrivenpulley(Figure
13).
•Usea9/16-inchdeep-wellsockettorotate
thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure13).
g033206
Figure13
1.Belt2.9/16-inchdeep-wellsocket
Important:Ensurethattheribsonthebelt
areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley.
6

2.Pushdownontheidlerpulleytoensurethatthe
idler-pulleyassemblypivotsfreely.
CompletingtheInstallation
1.Checkthealignmentofthebeltandpulleysas
follows:
Note:Thebeltmustbeproperlytensionedprior
tocheckingthealignment.
•Laythebelt-alignmenttoolalongtheouter
faceofthedrivepulley(Figure14).Donot
laythestraightedgeacrossboththedrive
pulleyandthedrivenpulley.
•Theouterfacesofthedrivepulleyandthe
drivenpulleyshouldbeinlinewithin0.76
mm(0.030inch).
•Ifthepulleysarenotaligned,referto
CheckingandAdjustingthePulleyAlignment
(page10).
•Ifthepulleysarealigned,continuewiththe
installation.
•Donotusetheidlerpulleytocheckthe
alignment.
Important:Thebeltmayfailprematurely
ifthepulleysarenotproperlyaligned.
g283870
Figure14
2.Alignthebeltcoverwiththemountingholesand
securethecoverwith4bolts(Figure15).
Important:Donotovertightenthebolts,as
damagetothecovermayoccur.
g033208
Figure15
1.Metalcover3.Screw(4)
2.Plasticcover
3.Tightenthenutssecuringthebrush-assembly
mountingbracketstothecutting-unitsideplates.
4.Lubricatethegreasettingsoneachofthe
rollerbrushbearinghousingswithNo.2lithium
grease(Figure16).
Note:Wipeoffanyexcessgrease,specically
aroundtheexcluderseals.
g033209
Figure16
7

InstallingtheBumperAssemblies
1.Lowerthecuttingunitstotheground.
2.Removetheexistingange-headboltsandthe
roundbumpers(Figure17).
Note:Retaintheange-headboltsforinstalling
thefrontbumperassembly.Discardtheround
bumpers.
g033297
Figure17
1.Flange-headbolt,existing
(2)
2.Roundbumper,existing
(2)—discard
3.Apply242Loctite(blue)tothethreadsofthe
bolts.
4.Looselyinstallthefrontbumperassemblyand
thewashersasshowninFigure18.
g033298
Figure18
1.Flange-headbolt,existing
(2)
3.Frontbumperassembly
2.Washer(2)
5.Adjustthefrontbumpersothatitcontactsthe
rear-roller-brushhousingswhenthecuttingunits
areraisedandlevel.
Note:Whenthebumperispositionedcorrectly,
torquetheboltsto91to113N∙m(67to83ft-lb).
6.Installtherearbumperassemblyasshownin
Figure19.
g033299
Figure19
1.Flange-headbolt(2)3.Locknut
2.Rearbumperassembly
8

InstallingtheHigh
Height-of-CutBrush
(Optional)
Installthehighheight-of-cutbrush(soldseparately)
whentheheightofcutis2.5cm(1inch)ormore(5or
morespacersinstalledbelowtheside-platepad).
1.Ifarollerbrushisinstalledonthecutting
unit,removethe2bolts,washers,andnuts
securingthenon-drive-bearinghousingtothe
bearing-housingmountingbracket(Figure20
andFigure21).
g033282
Figure20
1.Non-drive-bearinghousing
2.Slidethenon-drive-bearinghousingandthe
excludersealoffthebrushshaft(Figure21).
g033283
Figure21
1.Non-drive-bearinghousing3.Brushshaft
2.Excluderseal
3.Removethe2J-boltsandthenuts(Figure22).
4.Slidetheexistingbrushoffthebrushshaft
(Figure22).
5.Loosenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket(Figure22).
6.Slidethehighheight-of-cutbrushontothebrush
shaft(Figure22).
7.Clampthebrushontotheshaftwiththe2J-bolts
andnutspreviouslyremoved(Figure22).
Important:Insertthethreadedendofthe
J-boltsthroughtheouterholesofthebrush
shaftwhilehookingthecurvedendsofthe
J-boltsintotheinnerholes.
8.TorquetheJ-boltlocknutsto2to3N∙m(20to
25in-lb).
g027202
Figure22
1.Highheight-of-cutbrush3.Loosenthesebolts.
2.J-bolts
9.Installtheexcludersealandthe
non-drive-bearinghousingontothebrush
shaft(Figure21).
10.Mountthenon-drive-bearinghousingtothe
bearing-housingmountingbracketwiththe2
bolts,washers,andnutspreviouslyremoved.
Note:Becarefulnottoknockthesealspring
off.
11.Tightenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket.
9

Maintenance
•Ensurethatthebrushisparalleltotherollerwith
1.5mm(0.060inch)clearancetolightcontact.
•Greasethettingsevery50hoursandafterevery
washing.
•Whenreplacingarollerbrush,torquetheJ-bolts
to2to3N∙m(20to25in-lb).
•Whenreplacingthebrush-shaft-drivenpulley,
torquethenutto20to26N∙m(15to19ft-lb).
•Whenreplacingthebrush-drivepulley,apply242
Loctite(blue)andtorquetheboltto20to26N∙m
(15to19ft-lb).
Note:Therollerbrush,theidlerbearing,andthebelt
areconsideredconsumableitems.
CheckingandAdjustingthe
PulleyAlignment
1.Thedrivenpulley(attheroller-brushshaft)can
moveinorout(Figure23).
Note:Makenoteofwhichwaythepulleyneeds
tomove.
g033210
Figure23
1.Drivenpulley3.Driven-pulleynut
2.Idlerpulley
2.Whilerotatingthereel,whichrotatesthedrive
pulley,prythebeltoffthedrivepulley(Figure23
Note:Wearapaddedgloveoruseaheavyrag
torotatethereel.
3.Removethelocknutsecuringthedrivenpulley
tothebrushshaft(Figure23orFigure24).
Note:Usea1/2-inchwrenchontheroller-brush
shaftatstokeepitfromrotating.
4.Removethedrivenpulleyfromtheshaft(Figure
24).
5.Ifthepulleyneedstomoveout,adda0.8mm
(0.032inch)thickwasher(Figure24).
Note:Ifthepulleyneedstomovein,remove
theexisting0.8mm(0.032inch)thickwasher.
6.Installthepulley.
g033211
Figure24
1.Locknut4.Spacer
2.Drivenpulley5.Brushshaftats
3.Washer—0.8mm(0.032
inch)thick
7.Whileholdingtheatsoftheroller-brushshaft,
securethedrivenpulleyontheshaftwiththe
angenut(3/8–16)previouslyremoved.
Note:Seatthelocknut;thentorqueitto20to
26N∙m(15to19ft-lb).
8.Installthebeltontothepulleysasfollows:
A.Loopthebeltaroundthedrivepulleyand
thenoverthetopoftheidlerpulley(Figure
25).
g033205
Figure25
1.Drivepulley3.Drivenpulley
2.Idler-pulleyassembly4.Belt
B.Startthebeltonthedrivenpulley(Figure
25).
C.Usea9/16-inchdeep-wellsockettorotate
thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure26).
10

g033206
Figure26
1.Belt2.9/16-inchdeep-wellsocket
Important:Ensurethattheribsonthebelt
areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley.
9.Checkthepulleyalignmentagain,andrepeat
thisprocedureifnecessary.
g283870
Figure27
11

RestrainingtheReel
WARNING
Thecuttingreelbladesaresharpandcapable
ofamputatinghandsandfeet.
•Keepyourhandsandfeetoutsideofthe
reel.
•Ensurethatthereelisrestrainedbefore
servicingit.
RestrainingtheReelforRemoving
ThreadedInserts
1.Loosentheshield-boltontheleftsideofthe
cuttingunitandraisetherearshield(Figure28).
2.Insertalong-handledprybar(recommended
3/8"x12"withscrewdriverhandle)throughthe
backofthecuttingreel,closesttothesideofthe
cuttingunitthatyouwillbetorquing(Figure28).
3.Placetheprybaragainsttheweldsideofthe
reelsupportplate(Figure28).
Note:Inserttheprybarbetweenthetopofthe
reelshaftandthebacksof2reelbladessothat
thereelwillnotmove.
Important:Donotcontactthecuttingedge
ofanybladeswiththeprybar;thismay
damagethecuttingedgeand/orcauseahigh
blade.
Important:Theinsertontheleftsideof
thecuttingunithasleft-handthreads.The
insertontherightsideofthecuttingunithas
right-handthreads.
g280383
Figure28
1.Threadedinsertfor
removal
4.Reelshaft
2.Loosentheshieldbolt.5.Reelsupportplate
3.Rearshield6.Prybarinsertedalong
theweldsideofthereel
supportplate.
4.Restthehandleoftheprybaragainsttherear
roller.
5.Completetheremovalofthethreadedinsert
whileensuringthattheprybarstaysinplace,
thenremovetheprybar.
6.Lowertherearshieldandtightentheshield-bolt.
12

RestrainingtheReelforInstalling
ThreadedInserts
1.Insertalong-handledprybar(recommended
3/8"x12"withscrewdriverhandle)throughthe
frontofthecuttingreel,closesttothesideofthe
cuttingunitthatyouwillbetorquing(Figure29).
2.Placetheprybaragainsttheweldsideofthe
internalcuttingreelreinforcement(Figure29).
Note:Theprybarshouldcontactabladeatthe
front,thereelshaft,andabladeatthebackof
thebackofthereel,lockingitinplace.
Important:Donotcontactthecuttingedge
ofanybladeswiththeprybar;thismay
damagethecuttingedgeand/orcauseahigh
blade.
Important:Theinsertontheleftsideof
thecuttingunithasleft-handthreads.The
insertontherightsideofthecuttingunithas
right-handthreads.
g280384
Figure29
1.Threadedinsertfor
installation
3.Weldsideofsupportplate
2.Reelshaft4.Prybar
3.Restthehandleoftheprybaragainsttheroller
4.Pertheinsert’sinstallationinstructionsand
torquerequirements,completetheinstallationof
thethreadedinsertwhileensuringthatthepry
barstaysinplace,thenremovetheprybar.
13

Notes:

Notes:

DeclarationofIncorporation
TheToroCompany,8111LyndaleAve.South,Bloomington,MN,USAdeclaresthatthefollowingunit(s)
conform(s)tothedirectiveslisted,wheninstalledinaccordancewiththeaccompanyinginstructionsontocertain
ToromodelsasindicatedontherelevantDeclarationsofConformity.
ModelNo.SerialNo.ProductDescriptionInvoiceDescriptionGeneralDescriptionDirective
2000/14/EC
03657—
RearRollerBrushKit,
Reelmaster3550Series
18-inchCuttingUnitwith
5-inchReelandUniversal
Groomer
5INRRBKIT,UNIV
GROOMERFOR18INCURollerBrushKit2006/42/EC
RelevanttechnicaldocumentationhasbeencompiledasrequiredperPartBofAnnexVIIof2006/42/EC.
Wewillundertaketotransmit,inresponsetorequestsbynationalauthorities,relevantinformationonthispartly
completedmachinery.Themethodoftransmissionshallbeelectronictransmittal.
ThismachineryshallnotbeputintoserviceuntilincorporatedintoapprovedT oromodelsasindicatedonthe
associatedDeclarationofConformityandinaccordancewithallinstructions,wherebyitcanbedeclaredin
conformitywithallrelevantDirectives.
Certied:AuthorizedRepresentative:
MarcelDutrieux
ManagerEuropeanProductIntegrity
ToroEuropeNV
Nijverheidsstraat5
2260Oevel
Belgium
JohnHeckel
Sr.EngineeringManager
8111LyndaleAve.South
Bloomington,MN55420,USA
February1,2019