Toro Reelmaster 3100-D Edge Series, Reelmaster 7000-D Edge Series, Reelmaster 03243, Reelmaster 03246 Installation Instructions Manual

FormNo.3407-833RevC

27inor32inRearRollerBrushKit

Reelmaster

ModelNo.03243

ModelNo.03246

®

3100-Dand7000-DEdgeSeriesCuttingUnit

InstallationInstructions

Introduction

ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.

WARNING

CALIFORNIA

Proposition65Warning

UseofthisproductmaycauseexposuretochemicalsknowntotheStateofCalifornia

tocausecancer,birthdefects,orotherreproductiveharm.

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

Nopartsrequired

Roller-brushhousing1
Hex-socketbolt(3/8x1inch)
Roller-brushassembly1
Shoulderbolt
Beltcover/plateassembly(left)
Bolt(5/16x1/2inch)
Spacer
Drivepulley1
Flange-headbolt(3/8x2inches)
Belt1
Shimwasher(asrequiredforbelt

alignment)
Driveshaft(right)
Driveshaft(left)
Greasetting(90°)

Highheight-of-cutbrush(optional)

Qty.

—

Use

–

2

1
1
2
1

1

1

1
1
1

Determinethepositionoftheroller
brushesandreelmotors.

Installtherollerbrush.

Installthehighheight-of-cutbrush—for
HOCgreaterthan2.5cm(1inch).

©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3407-833*C

MediaandAdditionalParts

Description

Operator'sManual

Note:Determinetheleftandrightsidesofthecutting

unitfrombehindthecuttingunit.

Important:TheRearRollerBrushKitisonlytobe

usedwhencuttingintheheightofcutrangeof6to
25mm(1/4to1inch).UsetheHighHeightofCut
Brush,PartNo.115-0838(for27inchcuttingunits)
andPartNo.115-0849(for32inchcuttingunits)
whencuttingabove2.5to5.1cm(1to2inches).
RefertoInstallingtheHighHeightofCutBrush.

Note:Ifyouaregoingtoinstallbothauniversal

groomerkitandarearrollerbrushkitonthecutting
unit,ordertheappropriaterearrollerbrushkit(Model

03242)forusewithauniversalgroomerkit.

RearRollerBrushKitModel03243maybeused
onthefollowing:

•Reelmaster3100CuttingUnitModels03188,

03189,and03190

•Reelmaster7000CuttingUnitModels03721and

03722

Qty.

Use

1

Readbeforeinstallingandoperating.

1

DeterminingtheOrientation
oftheRollerBrushes

NoPartsRequired

Procedure

UseFigure1todeterminethepositionoftheroller
brushesandreelmotorsforaReelmaster3100-D
machineandFigure2foraReelmaster7000-D
machine.

RearRollerBrushKitModel03246maybeused
onthefollowing:

•Reelmaster3100CuttingUnitModel03191

•Reelmaster7000CuttingUnitModel03727

Figure1

Reelmaster3100-D

1.#1cuttingunit4.Leftrollerbrushdrive

2.#2cuttingunit

3.#3cuttingunit

assembly

5.Reelmotor

6.Rightrollerbrushdrive
assembly

g029306

2

Important:Checkthecuttingunitforthe

desiredheightofcutandattitude.Make
adjustmentspertheOperator’sManual,if
required,beforeinstallingthekit.

InstallingtheDriveshaft

Figure2

Reelmaster7000-D

1.#1cuttingunit5.#5cuttingunit

2.#2cuttingunit

3.#3cuttingunit

4.#4cuttingunit8.Leftrollerbrushdrive

6.Reelmotor

7.Rightrollerbrushdrive
assembly

assembly

2

InstallingtheRollerBrush

Partsneededforthisprocedure:

1Roller-brushhousing

2

Hex-socketbolt(3/8x1inch)

1Roller-brushassembly

1

Shoulderbolt

1

Beltcover/plateassembly(left)

2

Bolt(5/16x1/2inch)

1

Spacer

1Drivepulley

1

Flange-headbolt(3/8x2inches)

1Belt

1

Shimwasher(asrequiredforbeltalignment)

1

Driveshaft(right)

1

Driveshaft(left)

1

Greasetting(90°)

g027187

forRemovingThreadedInserts(page12).

2.Removethecutting-unitthreadedinsertforthe
rear-roller-brushdrive(Figure1andFigure2)
anddiscardit(Figure3).

1.Restrainthereel;refertoRestrainingtheReel

g032009

Figure3

1.Threadedinsert

(left-handedinsertshown)

2.Theleftinserthasagroove

onthefaceoftheinsert
here.

3.Driveshaft

4.Applythread-locking
compoundhere.

Note:Left-handedinsertsareonReelmaster

3100CuttingUnits1and2(Figure1)and
Reelmaster7000CuttingUnits1,3,and5
(Figure2).

3.Restrainthereel;refertoRestrainingtheReel

forInstallingThreadedInserts(page13).

4.Applythread-lockingcompoundtothedriveshaft
threads(Figure3)andinstallthedriveshaft,
torquingitto115to128N∙m(85to95ft-lb).

Note:Theuseofanimpactgunisnotenough

toensureproperinstallation.Failuretoproperly
torquethedriveshaftcanresultintheassembly
unscrewingitselfduringoperation.

PreparingtheMachine

1.Parkthemachineonalevelsurfaceandengage
theparkingbrake.

2.Ensurethatthecuttingunitsaredisengaged.

3.Shutofftheengineandremovethekey .

4.Removeallthecuttingunitsfromthemachine.

3

MountingtheRoller-Brush

RepositioningtheIdlerPulley

Housing

1.EnsurethattheO-ringisinstalledonthe
roller-brushhousing(Figure4).

Figure4

1.Roller-brushhousing

2.Mounttheroller-brushhousingtothe
reel-bearinghousingwith2hex-socketbolts(3/8
x1inch);refertoFigure5.

Note:Positiontheroller-brushhousingsothat

thethreadedholeistowardthefrontofthe
cuttingunit.

2.O-ring

Assembly(ForRight-HandDrives
Only)

Note:Right-handdrivesareonReelmaster3100

CuttingUnit3(Figure1)andReelmaster7000Cutting
Units2and4(Figure2).

Forright-handrearrollerbrushdrives(Figure1and

Figure2),reversetheidlerpulleyassemblytomount

ontherightendofthecuttingunit(Figure6)as
follows:

1.Removetheidlerpulleyassemblyfromtheleft
endofthecuttingunitandmountittothelower
holeinthebrushplateontherightendofthe

g009051

cuttingunit(Figure6).

Note:Theidlerpulleymustpivotfreely;donot

overtightenthelocknutontheidlerpivotbolt.

2.Removethecarriageboltandnutandrelocate
themtotheupperholepreviouslyoccupiedby
theidlerpulleyassembly(Figure6).

Note:EnsurethattheO-ringisproperly

positionedintheroller-brushhousing.

Figure5

1.Roller-brushhousing3.Threadedhole

2.Hex-socketbolt

g029307

Figure6

g218674

1.Idlerpulleyinstallationfor

leftendofreel(assupplied
inkit)

2.Idlerpulleyinstallationfor

rightendofreel

3.Carriageboltandnut

4.Donotovertightenthis
locknut.

RemovingtheBrushCoverDrain
Plug

Removeonlythebottomdrainplug(Figure7)from
thebrushcovers.Thisallowsmoisturetodrainfrom
thebeltarea.

4

Figure7

1.Brushcover2.Bottomdrainplug

InstallingtheRollerBrush
Assembly

1.Removethegreasettingfortherollerfromthe
sideofthecuttingunitthathastheroller-brush
housing(Figure9).

g009049

1.6mm(1/4inch)spacer3.90°greasetting

2.Side-platemountingange4.Flangelocknuts(remove)

Figure9

g031873

3.Removethe2angelocknutssecuringeach
rollerbrackettothesideplates(Figure9).

Note:Donotremovethebolts.Also,remove

any6mm(1/4inch)spacerspositioned
onthetopsideoftheside-platemounting
ange.

4.Positiontheleftorrightroller-brushassembly
mountingbracketsontotheroller-bracketbolts
(Figure10).

Figure8

1.Greasetting

2.Installthe90°greasettingsothatitfaces
backward(Figure8).

g031872

g193248

Figure10

1.Leftroller-brushassembly

2.Roller-brushmounting
bracket

Important:Mounttheroller-brushassembly

mountingbracketsdirectlytothetopsurface
ofthecutting-unitside-platemounting
ange.Donotputspacersbetweenthe

5

roller-brushmountingbracketsandthe
side-platemountinganges.Savethe

additional6mm(1/4inch)spacersfor
potentiallateruse.

5.Securethebrush-assemblymountingbrackets
tothecutting-unitsideplateswiththenuts
previouslyremoved.

InstallingtheRollerBrushPlate

1.Slideeachexcludersealoutwarduntilthelip
sealsareinlightcontactwitheachbearing
housing(Figure11).

g218675

Figure12

Figure11

1.Bearinghousing2.Excluderseal

2.Applyacoatingofgreasetotheinnerdiameter
ofthegrommetintheroller-brushhousing
(Figure12).

1.Bolt

2.Shoulderbolt

3.Grommet

4.Cleanoutanypaint
fromthethreadsusing
a5/16–18tapbefore
screwingintheshoulder
bolt.

5.Roller-brushhousing

6.Roller-brushpivotplate
assembly

3.Installtheleftorrightroller-brushpivotplate
(Figure12).

Note:Whenyouinserttheprotrusiononthe

pivotplateintothegrommetintheroller-brush
housing,ensurethatthegrommetstaysproperly
seatedinthehousing.Theroller-brushpivot
plateisproperlyseatedwhenthereisno
resistancefromtherubbergrommetanditpivots

g027192

freely.

Note:Ensurethattheidler-pulleyassemblyis

installedonthebottomasshowninFigure12.

4.Applythread-lockingcompoundtothe2bolts
(5/16x1/2inch)andusethemtomountthe
brushplatetotheroller-brushbearinghousing
(Figure12).

Note:T orquetheboltsto20to25N∙m(15to

19ft-lb).

5.Cleanoutanypaintfromthethreadsinthe
roller-brushhousing,usinga5/16–18tap,before
screwingintheshoulderbolt(Figure12).

Important:Ifthethreadsarenotcleaned

beforetheshoulderboltisscrewedin,the
boltcouldbreak.

6.Applythread-lockingcompoundtotheshoulder
bolt(Figure12).

7.Securethebrushplatetotheroller-brush
housingwiththeshoulderbolt(Figure12).

Note:T orquetheboltto20to25N∙m(15to

19ft-lb).

6

Note:Theshoulderboltshouldnotclampthe

platetothehousing.

8.Checktoensurethattheroller-brushplateis
paralleltothecutting-unitsideplate.Ifitisnot
parallel,proceedasfollows:

A.Loosenthe2angelocknutssecuring

theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure13).

B.Rotatetheroller-brushbearinghousinguntil

thebrushplateisparalleltothecutting-unit
sideplate(Figure13).

C.Tightenthe2angelocknutssecuring

theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure13).

g027303

Figure14

Figure13

1.Loosentheseboltsforpositioningtherollerbrush.

2.Loosenthesenutsformakingtheroller-brushplateparallel.

PositioningtheRollerBrush

1.Loosenthe2boltssecuringeachroller-brush
bearinghousingtotheroller-brushmounting
bracket(Figure13).

Note:Theboltsshouldbeloosefromthe

factory.

2.Positiontherollerbrushsothatitisjusttouching
orrestingontherearroller(Figure14).

Important:Theroller-brushshaftmustnot

contactthecutting-unitsideplate.

Important:Heavybrushcontactonthe

rollerwillcauseprematurebrushwear.

1.Bearinghousing(some
partsnotshown)

2.Sideplate

3.Rollerbrush

4.Ensurethatthereis
clearancehere.

5.Lightcontact

6.Rearroller

7.Greasetting

Note:Theroller-brushshaftmustbeparallel

totherearroller.

g193249

Important:Positionbothroller-brush

bearinghousingssothattheyareparallel
tothegroundtoensureclearanceforthe
rear-rollergreasetting.

3.Tightenthe2boltssecuringeachroller-brush

bearinghousingtotheroller-brushmounting
brackets.

InstallingtheDrivePulley

1.Insertthespacerontotheshaftinthebearing

housing(Figure15).

2.Insertthedrivepulleyintothespacerandonto

thedriveshaft(Figure15).

Note:Ensurethatthepulleytabsarepositioned

intheslotinthedriveshaft.

3.Securethepulleyandspacertothedriveshaft

withaange-headbolt(3/8x2inches);refer
toFigure15.

Note:T orquetheboltto47to54N∙m(35to

40ft-lb).

7

Important:Iftheboltisnotproperly

torqued,theboltwillcomeloose.

Figure15

g027195

1.Driveshaft

2.Spacer

3.Drivepulley

4.Flange-headbolt—torque

InstallingtheBelt

1.Installthebeltontothepulleysasfollows:

•Loopthebeltaroundthedrivepulleyand

thenoverthetopoftheidlerpulley(Figure

16).

Figure16

1.Drivepulley3.Belt

2.Idler-pulleyassembly4.Drivenpulley

•Startthebeltonthedrivenpulley(Figure

17).

•Useadeep-wellsocket(9/16inch)torotate

thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure17).

to47to54N∙m(35to40
ft-lb)

g020390

Figure17

1.Belt

2.Deep-wellsocket(9/16
inch)

Important:Ensurethattheribsonthebelt

areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley .

2.Pushdownontheidlerpulleytoensurethatthe
idler-pulleyassemblypivotsfreely.

CompletingtheInstallation

1.Checkthealignmentofthebeltandpulleysas
follows:

•Thebeltmustbeproperlytensioned

(installed)priortocheckingthealignment.

•Layastraightedgealongtheouterfaceof

thedrivepulley(Figure18).Donotlaythe

g027196

straightedgeacrossboththedrivepulleyand
thedrivenpulley .

•Theouterfacesofthedrivepulleyandthe

drivenpulleyshouldbeinlinewithin0.76
mm(0.030inch).

•Ifthepulleysarenotaligned,referto

CheckingthePulleyAlignment(page1 1).

•Ifthepulleysarealigned,continuewiththe

installation.

•Donotusetheidlerpulleytocheckthe

alignment.

Important:Thebeltmayfailprematurely

ifthepulleysarenotproperlyaligned.

8

Figure18

2.Slidethebeltcoverontothemountingboltsand
securethecoverwith2angenuts(Figure19).

Important:Donotovertightenthenutsas

damagetothecovermayoccur.

g027197

Figure20

g031843

3

InstallingtheHigh
Height-of-CutBrush
(Optional)

(Optional)

Partsneededforthisprocedure:

—

Highheight-of-cutbrush(optional)

Figure19

1.Beltcover

2.Setscrewinstalled

3.Setscrewremoved

3.Lubricatethegreasettingsoneachofthe
roller-brushbearinghousingswithNo.2lithium
grease(Figure20).Wipeoffanyexcessgrease,
especiallyaroundtheexcluderseals.

g027198

Procedure

Installthehighheight-of-cutbrush(soldseparately)
whentheheightofcutis2.5cm(1inch)ormore(5or
morespacersinstalledbelowthesideplatepad).

1.Ifarollerbrushisinstalledonthecutting
unit,removethe2bolts,washers,andnuts
securingthenon-drivebearinghousingtothe
bearing-housingmountingbracket(Figure21
andFigure22).

g027200

Figure21

1.Non-drivebearinghousing

9

2.Slidethenon-drivebearinghousingandthe
excludersealoffthebrushshaft(Figure22).

Figure22

g027201

1.Non-drivebearinghousing

2.Excluderseal

3.Brushshaft

3.Removethe2J-boltsandthenuts(Figure23).

4.Slidetheexistingbrushoffthebrushshaft
(Figure23).

5.Loosenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket(Figure23).

6.Slidethehighheight-of-cutbrushontothebrush
shaft(Figure23).

7.Clampthebrushontotheshaftwiththe2J-bolts
andnutspreviouslyremoved(Figure23).

Important:Insertthethreadedendofthe

J-boltsthroughtheouterholesofthebrush
shaftwhilehookingthecurvedendsofthe
J-boltsintotheinnerholes.

8.TorquetheJ-boltlocknutsto2to3N∙m(20to
25in-lb).

Figure23

1.Highheight-of-cutbrush

2.J-bolts

3.Loosenthesebolts.

9.Installtheexcludersealandthenon-drive
bearinghousingontothebrushshaft(Figure22).

10.Mountthenon-drivebearinghousingtothe
bearing-housingmountingbracketwiththe2
bolts,washers,andnutspreviouslyremoved.

Note:Becarefulnottoknockthesealspring

off.

11.Tightenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket.

g027202

10

Maintenance

5.Ifthepulleyneedstomoveout,adda0.8mm
(0.032inch)thickwasher(Figure25).

•Ensurethatthebrushisparalleltotherollerwith

1.5mm(0.060inch)clearancetolightcontact.

•Greasethettingsevery50hoursandafterevery

washing.

•Whenreplacingarollerbrush,torquetheJ-bolts

to2to3N∙m(20to25in-lb).

•Whenreplacingthebrush-shaft-drivenpulley,

torquethenutto36to45N∙m(27to33ft-lb).

•Whenreplacingthebrush-drivepulley,apply

removablethread-lockingcompoundandtorque
theboltto47to54N∙m(35to40ft-lb).

Note:Therollerbrush,theidlerbearing,andthebelt

areconsideredconsumableitems.

CheckingthePulley
Alignment

1.Makenoteofwhichwaythepulleyneedsto
move.

Note:Thedrivenpulley(attheroller-brush

shaft)canmoveinorout(Figure24).

Note:Ifthepulleyneedstomovein,remove

theexisting0.8mm(0.032inch)thickwasher.

6.Installthedrivenpulley .

Figure25

1.Locknut

2.Drivenpulley

7.Whileholdingthebrush-shaftats,securethe
drivenpulleyontheshaftwiththeangenut
(3/8–16inch)previouslyremoved.

3.Washer—0.8mm(0.032
inch)thick

4.Brush-shaftats

g009077

Figure24

1.Drivenpulley3.Driven-pulleynut

2.Idlerpulleyassembly

2.Whilerotatingthereel,whichrotatesthedrive
pulley,prythebeltoffthedrivepulley(Figure24)

Note:Wearapaddedgloveoruseaheavyrag

torotatethereel.

3.Removethelocknutsecuringthedrivenpulley
tothebrushshaft(Figure24orFigure25).

Note:Usea1/2inchwrenchontheroller-brush

shaftatstokeepitfromrotating.

4.Removethedrivenpulleyfromtheshaft(Figure

25).

Note:Seatthelocknut;thentorqueitto36to

45N∙m(27to33ft-lb).

8.Installthebeltontothepulleysasfollows:

A.Loopthebeltaroundthedrivepulleyand

thenoverthetopoftheidlerpulley(Figure

26).

g020303

g031875

Figure26

1.Drivenpulley3.Drivepulley

2.Idler-pulleyassembly4.Belt

B.Startthebeltonthedrivenpulley(Figure

26).

C.Useadeep-wellsocket(9/16inch)torotate

thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure27).

11

Figure27

1.Belt

2.Deep-wellsocket(9/16
inch)

Important:Ensurethattheribsonthebelt

areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley .

9.Checkthepulleyalignmentagainandrepeat
thisprocedureifnecessary.

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

g020390

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.

12

Figure28

1.Threadedinsertfor
removal

2.Loosentheshieldbolt.5.Reelsupportplate

3.Rearshield6.Prybarinsertedalong

4.Reelshaft

theweldsideofthereel
supportplate.

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

g280383

blade.

Important:Theinsertontheleftsideof

thecuttingunithasleft-handthreads.The
insertontherightsideofthecuttingunithas
right-handthreads.

4.Restthehandleoftheprybaragainsttherear
roller.

5.Completetheremovalofthethreadedinsert
whileensuringthattheprybarstaysinplace,
thenremovetheprybar.

6.Lowertherearshieldandtightentheshield-bolt.

Figure29

1.Threadedinsertfor
installation

2.Reelshaft

3.Weldsideofsupportplate

4.Prybar

3.Restthehandleoftheprybaragainsttheroller

g280384

4.Pertheinsert’sinstallationinstructionsand

torquerequirements,completetheinstallationof
thethreadedinsertwhileensuringthatthepry
barstaysinplace,thenremovetheprybar.

13

Notes:

DeclarationofIncorporation

TheToroCompany,8111LyndaleAve.South,Bloomington,MN,USAdeclaresthatthefollowingunit(s)
conform(s)tothedirectiveslisted,wheninstalledinaccordancewiththeaccompanyinginstructionsontocertain
ToromodelsasindicatedontherelevantDeclarationsofConformity.

ModelNo.

SerialNo.

03243
03246

—
—

ProductDescriptionInvoiceDescription

27-inchRearRollerBrushKit
32-inchRearRollerBrushKit

27INRRBONL YKIT

32INRRBONLYKIT

GeneralDescription

27inRRB
32inRRB

Directive

2006/42/EC
2006/42/EC

RelevanttechnicaldocumentationhasbeencompiledasrequiredperPartBofAnnexVIIof2006/42/EC.

Wewillundertaketotransmit,inresponsetorequestsbynationalauthorities,relevantinformationonthispartly
completedmachinery.Themethodoftransmissionshallbeelectronictransmittal.

ThismachineryshallnotbeputintoserviceuntilincorporatedintoapprovedT oromodelsasindicatedonthe
associatedDeclarationofConformityandinaccordancewithallinstructions,wherebyitcanbedeclaredin
conformitywithallrelevantDirectives.

Certied:

JohnHeckel
Sr.EngineeringManager
811 1LyndaleAve.South
Bloomington,MN55420,USA
January24,2019

AuthorizedRepresentative:

MarcelDutrieux
ManagerEuropeanProductIntegrity
ToroEuropeNV
Nijverheidsstraat5
2260Oevel
Belgium