Toro 03200 Reelmaster 3100-D User manual

FormNo.3395-107RevA
27-inchor32-inchRearRollerBrushKit
Reelmaster®3100-Dand7000-DSeriesDPACuttingUnit
ModelNo.03186
ModelNo.03187
InstallationInstructions
Introduction
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
ThisproductcomplieswithallrelevantEuropeandirectives.
Fordetails,pleaseseetheDeclarationofIncorporation(DOI)
atthebackofthispublication.
Contents
Introduction..................................................................1
Safety...........................................................................1
SafeOperatingPractices...........................................1
Setup............................................................................2
1GatheringtheAppropriateTools.............................2
2DeterminingtheOrientationoftheRoller
Brushes..............................................................3
3RepositioningtheIdlerPulleyAssembly...................3
4RemovingtheBrushCoverDrainPlug.....................4
5InstallingtheRollerBrush......................................4
6InstallingtheHighHeight-of-CutBrush
(Optional)...........................................................9
Maintenance.................................................................10
AligningthePulleys................................................10
Safety
SafeOperatingPractices
•Read,understand,andfollowallinstructionsinthe
traction-unitandcutting-unitoperatormanualsbefore
operatingthecuttingunit.
•Read,understand,andfollowallinstructionsinthis
operator’smanualbeforeoperatingthebrushkit.
•Neverallowchildrentooperatethecuttingunits.Donot
allowadultstooperatethetractionunitorthecutting
unitswithoutproperinstruction.Onlytrainedoperators
whohavereadthismanualshouldoperatethecutting
units.
•Neveroperatethecuttingunitswhenundertheinuence
ofdrugsoralcohol.
•Keepallshieldsandsafetydevicesinplace.Ifashield,
safetydevice,ordecalisillegibleordamaged,repairor
replaceitbeforeoperationiscommenced.Alsotighten
anyloosenuts,bolts,andscrewstoensurethatthecutting
unitisinsafeoperatingcondition.
•Alwayswearsubstantial,slip-resistantshoes.Donot
operatethecuttingunitwhilewearingsandals,tennis
shoes,sneakers,orshorts.Also,donotwearloose-tting
clothingwhichcouldgetcaughtinmovingparts.Always
wearlongpants.Wearingsafetyglasses,safetyshoes,
andahelmetisadvisableandrequiredbysomelocal
ordinancesandinsuranceregulations.
•Removealldebrisorotherobjectsthatmightbepicked
upandthrownbythecutting-unitblades.Keepall
bystandersawayfromthemowingarea.
•Ifthebladesstrikeasolidobjectorthecuttingunit
vibratesabnormally,stopandshuttheengineoff.Check
thecuttingunitfordamagedparts.Repairanydamage
beforestartingandoperatingthecuttingunit.
•Lowerthecuttingunitstothegroundandremovethe
keyfromtheignitionswitchwheneverthemachineisleft
unattended.
•Besurethatthecuttingunitsandthebrushesareinsafe
operatingconditionbykeepingthenuts,bolts,andscrews
tight.
•Removethekeyfromtheignitionswitchtoprevent
accidentalstartingoftheenginewhenservicing,adjusting,
orstoringthemachine.
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.
•Performonlythosemaintenanceinstructionsdescribedin
thismanual.Ifmajorrepairsareeverneededorassistance
isdesired,contactanAuthorizedToroDistributor.
•Toensureoptimumperformanceandcontinuedsafety
certicationofthemachine,useonlygenuineToro
replacementpartsandaccessories.Replacementparts
andaccessoriesmadebyothermanufacturerscouldbe
dangerous,andsuchusecouldvoidtheproductwarranty.
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3395-107*A

Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Gathertheappropriatetools.
2Nopartsrequired–Determinethepositionoftheroller
brushesandreelmotors.
3Nopartsrequired–Repositiontheidlerpulleyassembly.
4Nopartsrequired–Removethebrushcoverdrainplug.
Roller-brushhousing1
Allen-headbolt,3/8x1inch2
Roller-brushassembly1
Shoulderbolt1
Beltcover/plateassembly1
Bolt,5/16x5/8inch2
Spacer1
Drivepulley1
Flange-headbolt,3/8x2inches1
Belt1
5
Shimwasher(asrequired)1
Installtherollerbrush.
6Highheightofcutbrush(optional)–Installthehighheight-of-cutbrush.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual1Readbeforeinstallingandoperating.
PartsCatalog1Usetolookupreplacementparts.
Note:Determinetheleftandrightsidesofthecuttingunit
frombehindthecuttingunit.
Important:TheRearRollerBrushKitisonlytobe
usedwhencuttingintheheightofcutrangeof6to25
mm(1/4to1inch).UsetheHighHeightofCutBrush,
Part115-0838(for27inchcuttingunits)and115-0849
(for32inchcuttingunits)whencuttingabove2.5to5.1
cm(1to2inches).RefertoInstallingtheHighHeight
ofCutBrush.
RearRollerBrushKitModel03186maybeusedonthe
following:
•Reelmaster3100CuttingUnitModels03180,03181,and
03183withthe27-inchLiftArmKit,Model03172
•Reelmaster7000CuttingUnitModels03710and03711
RearRollerBrushKitModel03187maybeusedonthe
following:
•Reelmaster3100CuttingUnitModel03182withthe
32-inchLiftArmKit,Model03173
•Reelmaster7000CuttingUnitModel03712
2

1
GatheringtheAppropriate
Tools
NoPartsRequired
Procedure
Acquirethefollowingtoolsbeforeproceedingwiththe
installation:
•1/2deep-wellsocket
•9/16socket
•5/8socket
•1/2wrench
•9/16wrench
•1/8Allenwrench
•5/16Allenwrench
•3/8-16tap
•12inchstraightedge(ToroPart114-5446)
•Torquewrench(foot-pound)
•Torquewrench(inch-pound)
•Blue242Loctite
2
DeterminingtheOrientationof
theRollerBrushes
NoPartsRequired
Procedure
Allcuttingunitsareshippedwiththecounterweightmounted
totheleftendofthecuttingunit.UsetheFigure1to
determinethepositionoftherollerbrushesandreelmotors
forReelmaster3100-DorFigure2forReelmaster7000-D.
Figure1
Reelmaster3100-D
1.#1cuttingunit4.Left-handrollerbrush
driveassembly
2.#2cuttingunit5.Reelmotor
3.#3cuttingunit6.Right-handrollerbrush
driveassembly
Figure2
Reelmaster7000-D
1.#1cuttingunit5.#5cuttingunit
2.#2cuttingunit6.Reelmotor
3.#3cuttingunit7.Right-handrollerbrush
driveassembly
4.#4cuttingunit8.Left-handrollerbrush
driveassembly
Note:Theseinstructionsandillustrationsshowthe
installationofthekitoncuttingunitswiththeendweights
mountedontheleftendofthecuttingunit.
3
RepositioningtheIdlerPulley
Assembly
NoPartsRequired
Procedure
Ontheleftfrontandleftrearcuttingunits,reversetheidler
pulleyassemblytomountontherightendofthecuttingunit
(Figure3),asfollows:
3

1.Removetheidlerpulleyassemblyfromtheleftendof
thecuttingunitandmountittothelowerholeinthe
brushplateontherightendofthecuttingunit(Figure
3).
Note:Theidlerpulleymustpivotfreely;donotover
tightenthelocknutontheidlerpivotbolt.
2.Removethecarriageboltandnutandrelocatethemto
theupperholepreviouslyoccupiedbytheidlerpulley
assembly(Figure3).
Figure3
1.Idlerpulleyinstallationfor
leftendofreel
3.Carriageboltandnut
2.Idlerpulleyinstallationfor
rightendofreel
4.Donotovertightenthis
locknut.
4
RemovingtheBrushCover
DrainPlug
NoPartsRequired
Procedure
Removeonlythebottomdrainplug(Figure4)fromthebrush
covers.Thisallowsmoisturetodrainfromthebeltarea.
Figure4
1.Brushcover2.Bottomdrainplug
5
InstallingtheRollerBrush
Partsneededforthisprocedure:
1Roller-brushhousing
2Allen-headbolt,3/8x1inch
1Roller-brushassembly
1Shoulderbolt
1Beltcover/plateassembly
2Bolt,5/16x5/8inch
1Spacer
1Drivepulley
1Flange-headbolt,3/8x2inches
1Belt
1Shimwasher(asrequired)
Procedure
1.Parkthetractionunitonalevelsurfaceandengagethe
parkingbrake.
2.Ensurethatthecuttingunitsaredisengaged.Turn
theengineoffandremovethekey.Removeallcutting
unitsfromthetractionunit.
Important:Checkthecuttingunitforthedesired
heightofcutandattitude.Resetitaccordingtothe
Operator’ s Man ual ,ifrequired,beforeinstalling
theRearRollerBrushKit.
4

3.Removethe2boltssecuringthecounterweighttothe
leftendofthecuttingunit.Removethecounterweight
(Figure5).
Figure5
1.Counterweight2.Cleanoutthesemounting
holes.
4.Usinga3/8-16tap,removethepaintintheouter
mountingholesintheside-plate(Figure5).
5.Mounttheroller-brushhousingtothereel-bearing
housingwith2Allen-headbolts(3/8x1inch)(Figure
6).Positiontheroller-brushhousingsothatthe
threadedholeistowardthefrontofthecuttingunit.
Note:MakesurethattheO-ringisproperlypositioned
intheroller-brushhousing.
Figure6
1.Roller-brushhousing3.O-ring
2.Threadedholeinhousing
6.Removethe2angelocknutssecuringeachroller
brackettotheside-plates(Figure7).Donotremove
thebolts.Also,removeany6mm(1/4inch)spacers
fromthetopsideoftheside-platemounting
ange.
Figure7
1.Removethenutssecuring
eachendoftheroller.
3.Side-platemountingange
2.6mm(1/4inch)spacer
7.Positiontheroller-brushmountingbracketsontothe
roller-bracketbolts(Figure8).
Figure8
1.Rollerbrushassembly2.Roller-brushmounting
bracket
Important:Theroller-brushmountingbrackets
mustbemounteddirectlytothetopsurfaceofthe
cutting-unitside-platemountingange.
Do not
put spacer s betw een the r oller -br ush mounting
brack ets and the side-plate mounting anges.
Installadditional6mm(1/4inch)spacersonthe
topsideoftheroller-brushmountingbracket
(Figure9).
5

Figure9
1.Roller-brushmounting
bracket
3.Extra6mm(1/4inch)
spacer
2.Cutting-unitside-plate
mountingange
8.Securetheroller-brushmountingbracketstothe
cutting-unitside-plateswiththenutspreviously
removed.
9.Slideeachexcludersealoutwarduntilthelipsealsare
inlightcontactwitheachbearinghousing(Figure10).
Figure10
1.Excluderseal3.Mountingbracket
2.Bearinghousing
10.Applyacoatingofgreasetotheinnerdiameterofthe
grommetinthebearinghousing(Figure11).
Figure11
1.Shoulderbolt5.Roller-brushmounting
bracket
2.Brushplate6.Flangelocknuts
3.Bolt7.Roller-brush-bearing
housing
4.Grommetinbearing
housing
11.Loosen,butdonotremove,theboltssecuringthe
roller-brush-bearinghousingtotheroller-brush
mountingbracket(Figure11).
12.Installtheroller-brushpivotplate(Figure11).
Note:Whenyouinserttheprotrusiononthepivot
plateintothegrommetinthebearinghousing,ensure
thatthegrommetstaysproperlyseatedinthehousing.
Note:Theroller-brushpivotplateisproperlyseated
whenthereisnoresistancefromtherubbergrommet
anditpivotsfreely.
13.Apply242Loctite(blue)tothe2bolts(5/16x5/8
inch)andusethemtomountthebrushplatetothe
roller-brush-bearinghousing(Figure11).
Note:Torquetheboltsto20to25N-m(15to19
ft-lb).
14.Checktomakesurethattheroller-brushplateis
paralleltothecutting-unitside-plate.Ifitisnotparallel,
proceedasfollows:
•Loosenthe2angelocknutssecuringthe
roller-brushmountingbrackettothecuttingunit
side-plate(Figure11).
•Rotatetheroller-brush-bearinghousinguntilthe
brushplateisparalleltothecutting-unitside-plate
(Figure11).
•Tightenthe2angelocknutssecuringthe
roller-brushmountingbrackettothecutting-unit
side-plate(Figure11).
15.Loosenthe2boltssecuringeachroller-brush-bearing
housingtotheroller-brushmountingbracket(Figure
12andFigure13).
6

Figure12
1.Loosenthesebolts.
Figure13
1.Loosenthesebolts.
16.Positiontherollerbrushsothatitjusttouchestherear
roller(Figure14).
Important:Theroller-brushshaftmustnot
contactthecutting-unitside-plate.
Important:Heavybrushcontactontheroller
causesprematurebrushwear.
Figure14
1.Side-plate4.Rearroller
2.Rollerbrush5.Ensurethatthereis
clearancehere.
3.Lightcontact
Note:Therollerbrushshaftmustbeparalleltothe
rearroller.
Note:Theorientationofthenon-drive
roller-brush-bearinghousingshouldbethesameas
drive-sidebearinghousing.
17.Tightenthe2boltssecuringeachroller-brush-bearing
housingtotheroller-brushmountingbrackets.
18.Apply242Loctite(blue)totheshoulderbolt(Figure
11).Securethebrushplatetotheroller-brushhousing
withtheshoulderbolt.(Figure11).
Note:Torquetheboltto20to25N-m(15to19ft-lb).
Note:Theshoulderboltshouldnotclamptheplate
tothehousing.
19.Installthespacerontotheshaftinthebearinghousing
(Figure15).
20.Insertthedrivepulleyintothespacerandontothe
driveshaft(Figure15).Makesurethatthepulleytabs
arepositionedintheslotinthedriveshaft.
21.Securethepulleyandspacertothedriveshaftwitha
ange-headbolt(3/8x2inch)(Figure15).
Note:Torquetheboltto47to54N-m(35to40ft-lb).
Important:Iftheboltis
not properlytorqued, the
bolt will come loose.
7

Figure15
1.Driveshaft3.Drivepulley
2.Spacer4.Bolt—torqueto47to54
N-m(35to40ft-lb)
22.Installthebeltontothepulleysasfollows:
•Loopthebeltaroundthedrivenpulleyandthen
overthetopoftheidlerpulley(Figure16).
Figure16
1.Drivepulley3.Drivenpulley
2.Idler-pulleyassembly4.Belt
•Startthebeltonthedrivepulley(Figure16).
•Whileguidingthebeltontothedrivepulley,rotate
thereelforwardtodrawthebeltontothedrive
pulley.
Note:Wearapaddedgloveoruseaheavyragto
rotatethereel.
Important:Makesurethattheribsonthebelt
areproperlyseatedinthegroovesineachpulley.
Also,makesurethatthebeltisinthecenterofthe
idlerpulley.
23.Pushdownontheidlerpulleytoensurethattheidler
pulleyassemblypivotsfreely.
24.Checkthealignmentofthebelt/pulleysasfollows:
•Thebeltmustbeproperlytensioned(installed)
priortocheckingalignment.
•Layastraightedgealongtheouterfaceofthedrive
pulley(Figure17).Donotlaythestraightedge
acrossboththedriveanddrivenpulleys.
•Theouterfacesofthedriveanddrivenpulleys
shouldbeinlinewithin0.76mm(0.030inch).
•Ifthepulleysarenotaligned,RefertoAligningthe
Pulleys(page10).
•Ifthepulleysarealigned,continuewiththe
installation.
•Donotusetheidlerpulleytocheckalignment.
Important:Thebeltmayfailprematurelyif
thepulleysarenotproperlyaligned.
Figure17
25.Slidethebeltcoverontothemountingboltsandsecure
with2angenuts(Figure18).
Important:Donotovertightentheangenuts,as
damagetothecovermayoccur.
Figure18
1.Beltcover
26.Lubricatethegreasettingsoneachofthe
roller-brush-bearinghousingsandontheremainderof
thecuttingunitwith#2general-purposelithium-based
grease(Figure19).
Note:Wipeoffanyexcessgrease,specicallyaround
theexcluderseals.
8

Figure19
6
InstallingtheHigh
Height-of-CutBrush(Optional)
Partsneededforthisprocedure:
–Highheightofcutbrush(optional)
Procedure
Installthehighheight-of-cutbrush,Part115-0838(for27
inchcuttingunits)and115-0849(for32inchcuttingunits)
whencuttingfrom2.5to5.1cm(1to2inches)heightofcut
(7maximumspacersinstalledbelowthesideplatepad).
1.Ifarollerbrushisinstalledonthecuttingunit,
removethe2bolts,washersandnutssecuringthe
non-drive-bearinghousingtothebearing-housing
mountingbracket(Figure20andFigure21).
Figure20
1.Non-drive-bearinghousing
2.Slidethenon-drive-bearinghousingandtheexcluder
sealoffthebrushshaft(Figure21).
Figure21
1.Non-drive-bearinghousing3.Brushshaft
2.Excluderseal
3.Removethe2J-boltsandnuts(Figure22).
Figure22
1.Highheight-of-cutbrush3.Loosenthesebolts
2.J-bolt
4.Slidetheexistingbrushoffthebrushshaft(Figure22).
5.Loosenthe2bolts,washers,andnutssecuringthe
drive-bearinghousingtothebearing-housingmounting
bracket(Figure22).
6.Slidethehighheight-of-cutbrushontothebrushshaft
(Figure22).
7.Clampthebrushontotheshaftwiththe2J-boltsand
nutspreviouslyremoved(Figure22).
Important:InsertthethreadedendoftheJ-bolts
thrutheouterholesofthebrushshaftwhile
hookingthecurvedendsoftheJ-boltsintothe
innerholes.
9

8.TorquetheJ-boltlocknutsto2to3N-m(20to25
in-lb).
9.Installtheexcludersealandthenon-drive-bearing
housingontothebrushshaft(Figure21).
10.Mountthenon-drive-bearinghousingtothe
bearing-housingmountingbracketwiththe2bolts,
washers,andnutspreviouslyremoved.
Note:Becarefulnottoknockthesealspringoff.
11.Tightenthe2bolts,washers,andnutssecuringthe
drive-bearinghousingtothebearing-housingmounting
bracket.
Maintenance
1.Makesurethatthebrushisparalleltotherollerwith
1.5mm(0.060inch)clearancetolightcontact.
2.Greasethettingsevery50hoursandafterevery
washing.
3.Whenreplacingrollerbrush,torquetheJ-boltsto2
to3N-m(20to25in-lb).
4.Whenreplacingthebrush-shaft-drivenpulley,torque
thenutto36to45N-m(27to33ft-lb).
5.Whenreplacingthebrush-drivepulley,torquethebolt
to47to54N-m(35to40ft-lb).
Important:Backlappingattheincorrectreel
speedmayloosenandstripthedrive-pulley
threads.RefertotheCuttingUnitOperator’s
Manualforthebacklappingprocedure.
6.Therollerbrush,idlerbearing,andbeltareconsidered
consumableitems.
AligningthePulleys
1.Thedrivenpulley(attheroller-brushshaft)canmove
inorout(Figure23).
Note:Makenoteofwhichwaythepulleyneedsto
move.
Figure23
1.Drivenpulley3.Driven-pulleynut
2.Idlerpulley
2.Whilerotatingthereel,whichrotatesthedrivepulley,
prythebeltoffthedrivepulley(Figure23).
Note:Wearapaddedgloveoruseaheavyragto
rotatethereel.
3.Removethelocknutsecuringthedrivenpulleytothe
brushshaft(Figure23orFigure24).
Note:Puta1/2-inchwrenchontheatsofthe
roller-brushshafttokeepitfromrotating.
4.Removethedrivenpulleyfromtheshaft(Figure24).
5.Ifthepulleyneedstomoveout,addone0.8mm(0.032
inch)thickspacer(Figure24).Ifthepulleyneedsto
movein,removetheexisting0.8mm(0.032inch)thick
spacer.
6.Installthepulley.
Figure24
1.Locknut3.Spacer(0.032inch(0.8
mm)thick)
2.Drivenpulley4.Brush-shaftats
7.Whileholdingtheatsoftheroller-brushshaft,secure
thepulleyontheshaftwiththe3/8-16angenut
previouslyremoved.
10

Note:Seatthelocknut,thentorqueitto36to45N-m
(27to33ft-lb).
8.Installthebeltontothepulleysasfollows:
•Loopthebeltaroundthedrivenpulleyandthen
overthetopoftheidlerpulley(Figure25).
Figure25
1.Drivepulley3.Drivenpulley
2.Idler-pulleyassembly4.Belt
•Startthebeltonthedrivepulley(Figure25).
•Whileguidingthebeltontothedrivepulley,rotate
thereelforwardtodrawthebeltontothedrive
pulley.
Note:Wearapaddedgloveoruseaheavyragto
rotatethereel.
Important:Makesurethattheribsonthebelt
areproperlyseatedinthegroovesineachpulley.
Also,makesurethatthebeltisinthecenterofthe
idlerpulley.
9.Checkthepulleyalignmentandadjustitifrequired.
11

DeclarationofIncorporation
TheT oroCompany,8111LyndaleAve.South,Bloomington,MN,USAdeclaresthatthefollowingunit(s)
conform(s)tothedirectiveslisted,wheninstalledinaccordancewiththeaccompanyinginstructionsontocertain
ToromodelsasindicatedontherelevantDeclarationsofConformity.
ModelNo.SerialNo.ProductDescriptionInvoiceDescriptionGeneralDescriptionDirective
03186—27-inchRearRollerBrushKitRM310027"REARROLLER
BRUSHKIT27inRRB2006/42/EC
03187—32-inchRearRollerBrushKitRM310032"REARROLLER
BRUSHKIT32inRRB2006/42/EC
RelevanttechnicaldocumentationhasbeencompiledasrequiredperPartBofAnnexVIIof2006/42/EC.
Wewillundertaketotransmit,inresponsetorequestsbynationalauthorities,relevantinformationonthispartly
completedmachinery.Themethodoftransmissionshallbeelectronictransmittal.
ThismachineryshallnotbeputintoserviceuntilincorporatedintoapprovedToromodelsasindicatedonthe
associatedDeclarationofConformityandinaccordancewithallinstructions,wherebyitcanbedeclaredin
conformitywithallrelevantDirectives.
Certied:EUT echnicalContact:
PeterT etteroo
ToroEuropeNV
B-2260Oevel-Westerloo
Belgium
DavidKlisTel.003214562960
Sr.EngineeringManagerFax003214581911
8111LyndaleAve.South
Bloomington,MN55420,USA
February26,2015
12