Toro Reelmaster 03657, Reelmaster 3550 Series Installation Instructions Manual

FormNo.3397-660RevB

RearRollerBrushKit

Reelmaster
andUniversalGroomer

ModelNo.03657

ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.

®

3550Series18-inchCuttingUnitwith5-inchReel

InstallationInstructions

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

Description

Nopartsrequired

Roller-brushassembly
Retainingring
Rightbelt-cover/plateassembly
Leftbelt-cover/plateassembly
90-degreegreasetting
Carriagebolt
Weight
Locknut10
Drivepulley
Hex-drivebolt(5/16x1/2inch)
Belt
Shimwasher(asrequiredforbeltalignment)
Belt-alignmenttool1
Frontbumperassembly1
Washer2
Rearbumperassembly1

Highheight-of-cutbrush(optional)

Qty.

10

15

—

Use

–

5
5
2
3
5

5

5

5
5

Determinethepositionoftherollerbrushesandthereel
motors.

Installthekit.

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.

Figure1

1.Cuttingunit15.Cuttingunit5

2.Cuttingunit2

3.Cuttingunit3

4.Cuttingunit48.Leftroller-brushdrive

6.Reelmotor

7.Rightroller-brushdrive
assembly

assembly

InstallingtheKit

InstallingtheGreaseFitting

1.Removethegreasettingfortherollerfromthe
sideofthecuttingunitthathastheroller-brush
housing(Figure3).

g027187

g032170

Figure2

1.Greasetting

Note:Theseinstructionsandillustrationsshowthe

installationofthekitoncuttingunitswiththeuniversal
groomermountedontheleftendofthecuttingunit.

2.Installthe90-degreegreasettingsothatit
facesrearward(Figure2).

g032171

Figure3

1.6mm(1/4inch)spacer3.90-degreegreasetting

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

2

InstallingtheWeights

InstallingtheRoller-Brush

Installtheweightstothecuttingunitsasshownin

Figure4.

Figure4

1.Carriagebolts(5/16x1
inch)

2.Flangenuts(5/16inch),
torqueto20to26N∙m(15
to19ft-lb)

3.Weight

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).

g283859

Figure5

1.Leftroller-brushassembly

2.Roller-brushmounting
bracket

Important:Attachthemountingbrackets

fortheroller-brushassemblydirectlyto
thetopsurfaceoftheside-platemounting
angeofthecuttingunit.Donotputspacers

g033296

3

betweentheroller-brushmountingbrackets
andtheside-platemountinganges.Save

theadditional6mm(1/4inch)spacersfor
potentiallateruse.

3.Looselysecurethebrush-assemblymounting
bracketstothecutting-unitsideplateswiththe
previouslyremovednuts.

4.Slideeachexcludersealoutwarduntilthelip
sealsareinlightcontactwitheachbearing
housing(Figure6).

InstallingtheRoller-Brush
Housing

1.Removeanddiscardgroomerdrivecap.

g283858

Figure7

1.Cap

2.Installtheleftorrightroller-brushhousing
(Figure8).

Figure6

1.Bearinghousing2.Excluderseal

Note:Ensurethattheidler-pulleyassemblyis

installedonthebottomasshowninFigure8.

g033201

g033300

Figure8

1.Roller-brushhousing

2.Retainingring4.Bearinghousing

3.Apply242Loctite(blue)tothe2bolts(5/16x
1/2inch)andusethemtomounttheroller-brush
housingtothebearinghousing(Figure8).

3.Bolt(2)

Note:Torquetheboltsto20to26N∙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).

PositioningtheRollerBrush

1.Loosenthe2boltssecuringeach
roller-brush-bearinghousingtotheroller-brush
mountingbracket(Figure9).

Note:Theboltsshouldbeloosefromthe

factory.

2.Positiontherollerbrushsothatitisjusttouching
orrestingontherearroller(Figure10).

Important:Theroller-brushshaftmustnot

contactthecutting-unitsideplate.

Important:Heavybrushcontactonthe

rollercausesprematurebrushwear.

Figure9

1.Loosentheseboltsforpositioningtherollerbrush.

2.Loosenthesenutsformakingtheroller-brushplateparallel.

g033203

g027303

Figure10

1.Bearinghousing(some

partsnotshown)

2.Sideplate

3.Rollerbrush

4.Ensurethatthereis

clearancehere.

5.Lightcontact

6.Rearroller

7.Greasetting

Note:Theroller-brushshaftmustbeparallel

totherearroller.

Important:Positionboth

roller-brush-bearinghousingssothat
theyareparalleltothegroundtoensure
clearancefortherear-rollergreasetting.

3.Tightenthe2boltssecuringeach
roller-brush-bearinghousingtotheroller-brush
mountingbrackets.

5

InstallingtheDrivePulley

InstallingtheBelt

1.Restrainthereelbeforeinstallingthedrive
pulley;refertoRestrainingtheReelforInstalling

ThreadedInserts(page13).

2.Installthedrivepulleyontothegroomershaft
(Figure1 1).

Figure11

1.Drivepulley2.Hex-drivebolt—torqueto

20to26N∙m(15to19
ft-lb)

1.Installthebeltontothepulleysasfollows:

•Loopthebeltaroundthedrivepulleyand

thenoverthetopoftheidlerpulley(Figure

12).

g033205

Figure12

g033204

1.Drivepulley3.Belt

2.Idler-pulleyassembly4.Drivenpulley

•Startthebeltonthedrivenpulley(Figure

13).

3.Apply242Loctite(blue)tothehex-drivebolt
andusethebolttosecurethepulleytothe
driveshaft;refertoFigure1 1.

Note:Torquetheboltto20to26N∙m(15to

19ft-lb).

Important:Ifyoudonotproperlytorquethe

bolt,theboltwillcomeloose.

•Usea9/16-inchdeep-wellsockettorotate

thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure13).

g033206

Figure13

1.Belt

2.9/16-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).

Figure15

1.Metalcover

2.Plasticcover

3.Screw(4)

3.Tightenthenutssecuringthebrush-assembly
mountingbracketstothecutting-unitsideplates.

g033208

•Ifthepulleysarealigned,continuewiththe

installation.

•Donotusetheidlerpulleytocheckthe

alignment.

Important:Thebeltmayfailprematurely

ifthepulleysarenotproperlyaligned.

Figure14

2.Alignthebeltcoverwiththemountingholesand
securethecoverwith4bolts(Figure15).

4.Lubricatethegreasettingsoneachofthe
rollerbrushbearinghousingswithNo.2lithium
grease(Figure16).

Note:Wipeoffanyexcessgrease,specically

aroundtheexcluderseals.

g033209

Figure16

g283870

Important:Donotovertightenthebolts,as

damagetothecovermayoccur.

7

InstallingtheBumperAssemblies

1.Lowerthecuttingunitstotheground.

2.Removetheexistingange-headboltsandthe
roundbumpers(Figure17).

Note:Retaintheange-headboltsforinstalling

thefrontbumperassembly.Discardtheround
bumpers.

g033299

Figure19

Figure17

1.Flange-headbolt,existing

(2)

2.Roundbumper,existing
(2)—discard

3.Apply242Loctite(blue)tothethreadsofthe
bolts.

4.Looselyinstallthefrontbumperassemblyand
thewashersasshowninFigure18.

1.Flange-headbolt(2)

2.Rearbumperassembly

g033297

3.Locknut

Figure18

1.Flange-headbolt,existing

(2)

2.Washer(2)

3.Frontbumperassembly

5.Adjustthefrontbumpersothatitcontactsthe
rear-roller-brushhousingswhenthecuttingunits
areraisedandlevel.

Note:Whenthebumperispositionedcorrectly ,

torquetheboltsto91to1 13N∙m(67to83ft-lb).

6.Installtherearbumperassemblyasshownin

Figure19.

g033298

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).

7.Clampthebrushontotheshaftwiththe2J-bolts
andnutspreviouslyremoved(Figure22).

Important:Insertthethreadedendofthe

J-boltsthroughtheouterholesofthebrush
shaftwhilehookingthecurvedendsofthe
J-boltsintotheinnerholes.

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

Figure20

1.Non-drive-bearinghousing

2.Slidethenon-drive-bearinghousingandthe
excludersealoffthebrushshaft(Figure21).

Figure21

1.Non-drive-bearinghousing

2.Excluderseal

3.Brushshaft

g033282

g027202

Figure22

1.Highheight-of-cutbrush

2.J-bolts

3.Loosenthesebolts.

9.Installtheexcludersealandthe
non-drive-bearinghousingontothebrush
shaft(Figure21).

10.Mountthenon-drive-bearinghousingtothe
bearing-housingmountingbracketwiththe2
bolts,washers,andnutspreviouslyremoved.

Note:Becarefulnottoknockthesealspring

off.

11.Tightenthe2bolts,washers,andnutssecuring

g033283

thedrive-bearinghousingtothebearing-housing
mountingbracket.

3.Removethe2J-boltsandthenuts(Figure22).

4.Slidetheexistingbrushoffthebrushshaft
(Figure22).

5.Loosenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket(Figure22).

6.Slidethehighheight-of-cutbrushontothebrush
shaft(Figure22).

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.

Note:Ifthepulleyneedstomovein,remove

theexisting0.8mm(0.032inch)thickwasher.

6.Installthepulley .

g033211

Figure24

CheckingandAdjustingthe
PulleyAlignment

1.Thedrivenpulley(attheroller-brushshaft)can
moveinorout(Figure23).

Note:Makenoteofwhichwaythepulleyneeds

tomove.

Figure23

1.Drivenpulley3.Driven-pulleynut

2.Idlerpulley

1.Locknut

2.Drivenpulley

3.Washer—0.8mm(0.032
inch)thick

7.Whileholdingtheatsoftheroller-brushshaft,

securethedrivenpulleyontheshaftwiththe
angenut(3/8–16)previouslyremoved.

4.Spacer

5.Brushshaftats

Note:Seatthelocknut;thentorqueitto20to

26N∙m(15to19ft-lb).

8.Installthebeltontothepulleysasfollows:

A.Loopthebeltaroundthedrivepulleyand

thenoverthetopoftheidlerpulley(Figure

25).

g033210

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).

g033205

Figure25

1.Drivepulley3.Drivenpulley

2.Idler-pulleyassembly4.Belt

B.Startthebeltonthedrivenpulley(Figure

25).

C.Usea9/16-inchdeep-wellsockettorotate

thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure26).

10

Figure26

g033206

1.Belt

2.9/16-inchdeep-wellsocket

Important:Ensurethattheribsonthebelt

areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley .

9.Checkthepulleyalignmentagain,andrepeat
thisprocedureifnecessary.

Figure27

g283870

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.

Figure28

1.Threadedinsertfor
removal

2.Loosentheshieldbolt.5.Reelsupportplate

3.Rearshield6.Prybarinsertedalong

4.Restthehandleoftheprybaragainsttherear

roller.

5.Completetheremovalofthethreadedinsert

whileensuringthattheprybarstaysinplace,
thenremovetheprybar.

6.Lowertherearshieldandtightentheshield-bolt.

4.Reelshaft

theweldsideofthereel
supportplate.

g280383

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.

Figure29

1.Threadedinsertfor

installation

2.Reelshaft

3.Weldsideofsupportplate

4.Prybar

3.Restthehandleoftheprybaragainsttheroller

4.Pertheinsert’sinstallationinstructionsand
torquerequirements,completetheinstallationof
thethreadedinsertwhileensuringthatthepry
barstaysinplace,thenremovetheprybar.

g280384

13

Notes:

Notes:

DeclarationofIncorporation

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

ModelNo.

SerialNo.

03657

—

ProductDescriptionInvoiceDescription

RearRollerBrushKit,

Reelmaster3550Series

18-inchCuttingUnitwith

5-inchReelandUniversal

Groomer

5INRRBKIT ,UNIV

GROOMERFOR18INCU

GeneralDescription

RollerBrushKit

Directive

2000/14/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
February1,2019

AuthorizedRepresentative:

MarcelDutrieux
ManagerEuropeanProductIntegrity
ToroEuropeNV
Nijverheidsstraat5
2260Oevel
Belgium