Toro 03621, 03623 Original Instructions Manual

FormNo.3397-860RevB

22-inch8-Bladeor11-BladeDPA
CuttingUnitwith5inReel

Reelmaster

ModelNo.03621—SerialNo.315000001andUp
ModelNo.03623—SerialNo.315000001andUp

®

5010SeriesTractionUnit

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3397-860*B

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

ThisproductcomplieswithallrelevantEuropeandirectives.
Fordetails,pleaseseetheDeclarationofIncorporation(DOI)
atthebackofthispublication.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafety-alertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safety-alertsymbol

Introduction

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
safetyandoperationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Contents

Safety...........................................................................3

SafetyandInstructionalDecals.................................3

Setup............................................................................4

1InspectingtheCuttingUnit....................................4

2UsingtheCutting-UnitKickstand...........................4

3AdjustingtheRearShield.......................................5

4InstallingtheLooseParts.......................................5

ProductOverview..........................................................7

Specications.........................................................7

Attachments/Accessories.........................................7

Operation.....................................................................7

MakingAdjustments................................................7

Height-of-CutChartTerms......................................9

Height-of-CutChart...............................................10

Maintenance.................................................................14

LubricatingtheMachine..........................................14

Relief-GrindingtheReel..........................................14

ServicingtheBedknife............................................15

ServicingtheBedbar...............................................16

ServicingtheHDDualPointAdjusters

(DPA)...............................................................17

ServicingtheRoller.................................................19

1.Locationofthemodelandserialnumbers

©2016—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Figure1

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Safety

ThismachinehasbeendesignedinaccordancewithENISO
5395:2013andANSIB71.4-2012.

Improperuseormaintenanceofthisequipmentcan
resultininjuryordeath.T oreducethepotentialfor
injuryordeath,complywiththefollowingsafety
instructions.

•Read,understand,andfollowallinstructionsinthe

tractionunitOperator’sManualbeforeoperatingthecutting
unit.

•Read,understand,andfollowallinstructionsinthis

Operator’sManualbeforeoperatingthecuttingunit.

•Neverallowchildrenoruntrainedpersonneltooperate

orservicethemachine.Localregulationsmayrestrictthe
ageoftheoperator.Theownerisresponsiblefortraining
alloperatorsandmechanics.

•Neveroperatethecuttingunitswhensick,tired,orunder

theinuenceofdrugsoralcohol.

•Keepallshieldsandsafetydevicesinplace.Ifashield,a

safetydevice,oradecalisillegibleordamaged,repairor
replaceitbeforeresumingoperation.Also,tightenany
loosenuts,bolts,andscrewstoensurethatthecutting
unitisinsafeoperatingcondition.

•Removealldebrisorotherobjectsthatmightbepicked

upandthrownbythereelbladesofthecuttingunit.Keep
allbystandersawayfromtheworkingarea.

•Ifthecuttingbladesstrikeasolidobjectortheunit

vibratesabnormally,stopandshuttheengineoff.Check
thecuttingunitfordamagedparts.Repairanydamage
beforestartingandoperatingthecuttingunit.

•Lowerthecuttingunitstothegroundandremovethekey

fromtheignitionswitchwheneveryouleavethemachine
unattended.

•Besurethatthecuttingunitsareinsafeoperating

conditionbykeepingnuts,bolts,andscrewstight.

•Removethekeyfromtheswitchtopreventaccidental

startingoftheenginewhenservicing,adjusting,orstoring
themachine.

•Performonlythosemaintenanceinstructionsdescribedin

thismanual.Ifmajorrepairsareeverneededorassistance
isdesired,contactanAuthorizedT oroDistributor.

•Toensureoptimumperformanceandcontinuedsafety

certicationofthemachine,useonlygenuineToro
replacementpartsandaccessories.Replacementparts
andaccessoriesmadebyothermanufacturerscouldbe
dangerous,andsuchusecouldvoidtheproductwarranty.

•Wearappropriateclothing,includingsafetyglasses,

slip-resistant,substantialfootprotection,andhearing
protection.Tiebacklonghairanddonotwearjewelry.

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

93–6688

1.Warning—readthe
Operator’sManualbefore
performingmaintenance.

2.Cuttinghazardofhandor
foot—stoptheengineand
waitforallmovingpartsto
stop.

3

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4

Cuttingunit

Nopartsrequired

Nopartsrequired

Straightgreasetting
O-ring
Screws

MediaandAdditionalParts

Description

PartsCatalog
Operator'sManual

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

Qty.

Qty.

1Inspectthecuttingunit.

–

–

1
1
2

1
1

Reviewthesematerialsandsavethemforfuturereference.

Usethekickstandwhentippingthe
cuttingunit.

Adjusttherearshield.

Installthelooseparts.

Use

Use

2

1

InspectingtheCuttingUnit

Partsneededforthisprocedure:

1

Cuttingunit

Procedure

Afteryouremovethecuttingunitfromthebox,inspectthe
following:

1.Checkeachendofthereelforgrease.

Note:Greaseshouldbevisiblyevidentinthereel
bearingsandinternalsplinesofthereelshaft.

2.Ensurethatallnutsandboltsaresecurelytightened.

3.Makesurethatthecarrier-framesuspensionoperates
freelyanddoesnotbindwhenyoumoveitbackand
forth.

UsingtheCutting-Unit Kickstand

NoPartsRequired

Procedure

Wheneverthecuttingunithastobetippedtoexposethe
bedknifeorthereel,propuptherearofthecuttingunitwith
thekickstand(suppliedwiththetractionunit)tomakesure
thatthenutsonthebackendofthebedbar-adjustingscrews
arenotrestingontheworksurface(Figure3).

4

Figure3

4

InstallingtheLooseParts

Partsneededforthisprocedure:

1

Straightgreasetting

1

O-ring

2

Screws

1.Cutting-unitkickstand

3

AdjustingtheRearShield

NoPartsRequired

Procedure

Undermostconditions,bestdispersionisattainedwhenthe
rearshieldisclosed(frontdischarge).Whenconditionsare
heavyorwet,youcanopentherearshield.

Toopentherearshield(Figure4),loosenthecapscrew
securingtheshieldtotheleftsideplate,rotatetheshieldto
theopenposition,andtightenthecapscrew.

Procedure

Installthegreasettingonthereel-motorsideofthecutting
unit.UseFigure5todeterminethepositionofthereel
motors.

Figure5

1.Cuttingunit15.Cuttingunit5

2.Cuttingunit2

3.Cuttingunit3

4.Cuttingunit4

1.Removeanddiscardthesetscrewonthereel-motor
sideplate(Figure6).

6.Reelmotor

7.Weight

1.Rearshield

Figure4

2.Capscrew

Figure6

1.Bolt(2)3.Greasetting

2.Setscrew4.Greasevent

2.Installthestraightgreasetting(Figure6).

3.Iftherearenoboltsonthereel-motorsideplate,install
them(Figure6).

4.InstalltheO-ringonthereelmotor(Figure7).

5

Figure7

1.O-ring

5.Installthereelmotor.

6.Greasethesideplateuntilexcessgreasecomesoutthe
greasevent(Figure6).

6

ProductOverview

Specications

ModelNumberNetWeight

03621

03623

Attachments/Accessories

AselectionofToro-approvedattachmentsandaccessoriesisavailableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealerorDistributororgotowww.Toro.comforalistofallapproved
attachmentsandaccessories

TobestprotectyourinvestmentandmaintainoptimalperformanceofyourToroequipment,countonTorogenuineparts.
Whenitcomestoreliability,Torodeliversreplacementpartsdesignedtotheexactengineeringspecicationofourequipment.
Forpeaceofmind,insistonT orogenuineparts.

51kg(1 12lb)

52kg(1 16lb)

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

MakingAdjustments

AdjustingtheBedknifetotheReel

Usethisproceduretosetthebedknifetothereelandtocheck
theconditionofthereelandbedknifeandtheirinteraction.
Aftercompletingthisprocedure,alwaystestthecutting
unitperformanceunderyoureldconditions.Youmay
needtomakefurtheradjustmentstoobtainoptimalcutting
performance.

Important:Donotovertightenthebedknifetothereel
oryouwilldamageit.

•Afterbacklappingthecuttingunitorgrindingthereel,you

mayneedtomowwiththecuttingunitforafewminutes
andthenperformthisproceduretoadjustthebedknifeto
thereelasthereelandbedknifeadjusttoeachother.

•Youmayneedadditionaladjustmentsiftheturfis

extremelydenseoryourcuttingheightisverylow .

Youwillneedthefollowingtoolstocompletethisprocedure:

•Shim(0.002inch)—ToroPartNo.125-5611

•Cuttingperformancepaper—ToroPartNo.125-5610

Figure8

1.Bedbar-adjustingscrew

2.Tipthemowertoexposethebedknifeandreel.

Important:Makesurethatthenutsontheback
endofthebedbaradjustingscrewsarenotresting
ontheworksurface(Figure9).

1.Positionthecuttingunitonaat,levelworksurface.
Turnthebedbar-adjustingscrewscounterclockwiseto
ensurethatthebedbardoesnotcontactthereel(Figure

8).

Figure9

1.Cutting-unitkickstand

3.Rotatethereelsothatabladecrossesthebedknife
approximately25mm(1inch)infromtheendofthe

7

bedknifeontherightsideofthecuttingunit.Putting

g027270

anidentifyingmarkonthisbladewillmakesubsequent
adjustmentseasier.Insertthe0.05mm(0.002inch)
shimbetweenthemarkedreelbladeandthebedknife
atthepointwherethebladecrossesthebedknife.

4.Turntherightbedbaradjusterclockwiseuntilyoufeel
lightpressure(i.e.,drag)ontheshim,thenbackoffthe
bedbaradjuster2clicksandremovetheshim.(Since
adjusting1sideofthecuttingunitaffectstheother
side,the2clicksprovidetheclearancethatyouneed
forwhenyouadjusttheotherside.)

Note:Ifthereisalargegap,drawbothsidescloserby
alternatelytighteningtherightandleftsides.

5.Slowlyrotatethereelsothatthesamebladethatyou
checkedontherightsideiscrossingthebedknife
approximately25mm(1inch)infromtheendofthe
bedknifeontheleftsideofthecuttingunit.

Note:Ifthereisexcessivereeldrag,eitherbacklap
orgrindthecuttingunittoachievethesharpedges
neededforprecisioncutting.

AdjustingtheRearRoller

1.Adjusttherearrollerbrackets(Figure11)tothedesired
height-of-cutrangebypositioningtherequiredamount
ofspacersbelowtheside-platemountingange(Figure

11)pertheHOCChart.

6.Turntheleftbedbaradjusterclockwiseuntilyoucan
slidetheshimthroughthereeltobedknifegapwith
lightdrag.

7.Returntotherightsideandadjustasnecessarytoget
lightdragontheshimbetweenthesamebladeand
bedknife.

8.Repeatsteps6and7untilyoucanslidetheshim
throughbothgapswithslightdrag,but1clickinon
bothsidespreventstheshimfrompassingthroughon
bothsides.Thebedknifeisnowparalleltothereel.

Note:Y oushouldnotneedtoperformthisprocedure
fordailyadjustments,butaftergrindingordisassembly.

9.Fromthisposition(i.e.,1clickinandashimnot
passingthrough)turnthebedbaradjustersclockwise2
clickseach.

Note:Eachclickturnedmovesthebedknife0.018
(0.0007inch).Donotovertightentheadjusting

screws.

10.Testthecuttingperformancebyinsertingalongstripof
cuttingperformancepaper(ToroPartNo.125-5610)
betweenthereelandthebedknife,perpendiculartothe
bedknife(Figure10).Slowlyrotatethereelforward;it
shouldcutthepaper.

Figure11

1.Spacer3.Side-platemountingange

2.Rollerbracket

2.Raisetherearofthecuttingunitandplaceablock
underthebedknife.

3.Removethe2nutssecuringeachrollerbracketand
spacertoeachside-platemountingange.

4.Lowertherollerandthescrewsfromtheside-plate
mountingangesandspacers.

5.Placespacersontoscrewsonrollerbrackets.

6.Securetherollerbracketandspacerstotheunderside
oftheside-platemountingangeswiththenuts
previouslyremoved.

7.Verifythatthebedknife-to-reelcontactiscorrect.Tip
themowertoexposethefrontandrearrollersandthe
bedknife.

Note:Thepositionoftherearrollertothereel
iscontrolledbythemachiningtolerancesofthe
assembledcomponentsandparallelingisnotrequired.
Alimitedamountofadjustmentispossiblebysetting
thecuttingunitonasurfaceplateandlooseningthe
side-platemountingbolts(Figure12).Adjustand
tightenthebolts.Torquetheboltsto37to45N∙m
(27to33ft-lb).

Figure10

Figure12

1.Side-platemountingbolts

8