Toro 03723 Bedienungsanleitung

Operator’s Manual

Eenglish (EN, GB)

Form No. 3350–280

5, 7, and 11 Blade Cutting Units

Reelmaster 4000-D Series

Model No. 03752—230000001 and Up

Model No. 03753—230000001 and Up

Model No. 03723—230000001 and Up

Model No. 03724—230000001 and Up

Model No. 03725—230000001 and Up

Model No. 03726—230000001 and Up

Printed in the USA

2004 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Contents

Page

Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Safety and Instruction Decals 3. . . . . . . . . . . . . . .

Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Specifications 3. . . . . . . . . . . . . . . . . . . .

Optional Accessories 4. . . . . . . . . . . . . . . . . . . . . .

Assembly 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Tipper Plates and Weights to the Cutting

Units 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Floatation Kit 6. . . . . . . . . . . . . . . . .

Installing the Fixed Head Kit 6. . . . . . . . . . . . . . . .

Securing the Cutting Units to the Lift Arms 6. . . .

Mounting the #4 and #5 Tipper Brackets 7. . . . . .

Mount the Roller Bumpers (Floatation Kit Only) 7

Mounting the Hydraulic Motors to the Cutting

Units 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Reel to Bedknife Contact 9. . . . . . .

Adjusting the Height-of-Cut for a Floating Cutting

Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Method for Changing Height-of-Cut after Initial

Setup of a Floating Cutting Unit 11. . . . . . . . . . . .

Checking/Adjusting the Cutting Unit Attitude 12. .

Height-of-Cut Adjustment for a Fixed Cutting

Unit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Skids and Front Roller

(Fixed Head Kit) 13. . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Backlapping 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Bedknife/Bedbar 15. . . . . . . . . . . . . .

Servicing the Reel Assembly 16. . . . . . . . . . . . . . . .

Removing the Roller 18. . . . . . . . . . . . . . . . . . . . . .

Installing the Roller 19. . . . . . . . . . . . . . . . . . . . . . .

The Toro General Commercial Products Warranty 20. .

Introduction

Read this manual carefully to learn how to operate and

maintain your product properly. The information in this

manual can help you and others avoid injury and product

damage. Although Toro designs and produces safe

products, you are responsible for operating the product

properly and safely.

Whenever you need service, genuine Toro parts, or

additional information, contact an Authorized Service

Dealer or Toro Customer Service and have the model and

serial numbers of your product ready. They are located on

the reel sideplate opposite the drive housing.

Write the product model and serial numbers in the space

below:

Model No.

Serial No.

This manual identifies potential hazards and has special

safety messages that help you and others avoid personal

injury and even death. Danger, Warning, and Caution are

signal words used to identify the level of hazard.

However, regardless of the hazard, be extremely careful.

Danger signals an extreme hazard that will cause serious

injury or death if you do not follow the recommended

precautions.

Warning signals a hazard that may cause serious injury or

death if you do not follow the recommended precautions.

Caution signals a hazard that may cause minor or

moderate injury if you do not follow the recommended

precautions.

This manual uses two other words to highlight

information. Important calls attention to special

mechanical information and Note: emphasizes general

information worthy of special attention.

Safety

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any

area of potential danger. Replace any decal that is damaged or lost.

Part No. 67-7960

Part No. 93-6688 (for CE)

1. Danger—readthe

operator’s manual before

performing maintenance.

2. Cutting hazard to hands,

fingers, and feet—stop the

engine before going near

rotating reels.

Part No. 85-6410

Part No. 93-7814 (for CE)

1. Entanglementhazard—stay away from moving parts.

Specifications

General Specifications

Height-of-cut 5 Blade—1 to 3 in. (25 to 76 mm)

7 Blade—1/2 to 1-3/4 in. (9.5 to 45 mm)

11 Blade—3/8 to 3/4 in. (9.5 to 19 mm)

Height-of-cut adjustment Quick adjustment and positive locking is provided by locking type cone nuts.

Gauge marks of 1/4 in. (6.3 mm) are provided as a reference for easy changes of

height-of-cut.

Clip (variable to match

cutting conditions)

5 Blade Cutting Unit: .176 in. per mph (.352 in. at 2 MPH-1.32 in. at 7.5 mph)

7 Blade Cutting Unit : .126 in. per mph (.252 in. at 2 MPH-.945 in. at 7.5 mph)

11 Blade Cutting Unit: .080 in. per mph (.16 in. at 2 MPH-.600 in. at 7.5mph)

Optional Accessories

Floatation Kit (1 per machine) Model No. 03760

Fixed Head Kit (1 per machine) Model No. 03762

Wiehle Roller Kit (1 per machine) Model No. 03740

Side Skid Kit (1 per machine) Model No. 03744

Full Roller Kit (1 per machine) Model No. 03742

Dethatching Unit, RH

(3 per machine) Model No. 03732

Dethatching Unit, LH

(2 per machine) Model No. 03730

Rear Roller Scraper Kit

(1 per cutting unit) Part No. 59-6090

Front Full Roller Scraper Kit

(1 per cutting unit) Part No. 62-6220

Note: The front roller or other optional accessories for the

front of the cutting unit are shipped separately. Use the

instructions and parts supplied with the selected options

for installation on the cutting unit.

Assembly

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

Note: Use this chart as a checklist to ensure that all parts have been received. Without these parts, total setup cannot be

completed.

Description Qty. Use

Decals 2Affix to cutting unit for CE.

Operator’s manual 1Read before operating.

Parts catalog 1

Registration card 1Fill out and return to Toro.

The following parts are required to mount the cutting

units:

•3 Right-Hand Cutting Units

•2 Left-Hand Cutting Units

•1 Front Roller or Skid Kit

•1 Floatation Kit (includes 3 Weights, 1 Backlapping

Brush, and 1 Gauge Bar) or

•1 Fixed Head Kit (includes 3 Weights and 1

Backlapping Brush)

Important Thoroughly read both Cutting Unit and

Traction Unit Operator Manuals. Failure to do so may

result in damage to the cutting unit and/or poor

performance.

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and

seriously injure you or other bystanders.

Remove the key from the ignition before installing, servicing, or making adjustments to the

cutting units.

Installing the Tipper Plates and

Weights to the Cutting Units

1. Refer to Figure 1 and layout all five cutting units on

the floor in front of the machine. Position 3 right-hand

cutting units (all three are alike) as #1, #3 and #5.

Position the left-hand #2 and #4 cutting units also

(both are alike).

FRONT

Figure 1

Cutting Unit Layout

2. Install a front roller or skid kit to each cutting unit.

Installation instructions and cutting unit guards are

included with each kit.

3. On the #2 and #3 cutting units, remove 4 cover

capscrews located at the outside end of the cutting unit

drive housing. Discard cover screws. Mount a tipper

plate to front left-hand (#2) cutting unit and the front

right-hand (#3) cutting unit using flathead socket

screws and locknuts supplied with tipper plates

(Fig. 2).

Figure 2

1. Inboardcutting unit cover

2. Tipper plate 3. Flathead socket capscrew

Note: Do not install a tipper plate on the #1 cutting unit.

4. Mount one weight to each cutting unit guard (Fig. 3)

on the #1, #2 and #3 cuttings. Weights are located at

the opposite end of each cutting unit drive housing.

Use 1/2 in. carriage bolts provided with weights

(Fig. 3).

Figure 3

1. Weight 2. Guard

5. On the #4 and #5 cutting units, remove 4 cover

capscrews located at the outside end of the cutting unit

drive housing. Discard cover screws. Tipper brackets

will be mounted at these locations after the #4 and #5

cutting units are mounted on lift arms (Fig. 2).

Installing the Floatation Kit

Mount a Flotation Kit Assembly (Fig. 4) to each cutting

unit with U-bolts, lock washers and nuts supplied with

kits. Male end of floatation assembly to be positioned

forward. Tighten U-bolts evenly.

Fingers can be pinched in the floatation u-joint.

Keep hands and fingers away from the u-joint.

Caution

Note: When installing floating head assembly to cutting

unit, make sure flap on bottom of assembly is positioned

to the inside of the cutting frame tubes (Fig. 4, inset).

Figure 4

1. Floatationkit assembly

2. U-bolts

3. Lift arm bolts

4. Flap

5. Capscrew and jam nut

6. Capscrew

Installing the Fixed Head Kit

Note: Before mounting each fixed head assembly to

cutting unit, insert the pivot arm of assembly into the

appropriate lift arm block, align mounting holes and

determine how many thrust washers (if any) are required

to fill gap between assembly body and lift arm block. Add

required amount of washers to pivot arm before installing

fixed head assembly to lift arm.

Mount a Fixed Head Kit Assembly (Fig. 5) to each cutting

unit with a cover plate, attitude adjustment plate, U-bolts,

lockwashers and nuts supplied with kits. Male end of

floatation assembly to be positioned forward. Tighten

U-bolts evenly.

Figure 5

1. Fixed head assembly

2. Thrust washer

(as required)

3. Cover plate

4. Attitude adjustment plate

5. Lift arm

Securing the Cutting Units to

the Lift Arms

1. Remove three metric bolts from each of the lift arms

(Fig. 5).

Note: The smaller diameter bolt goes through both the

pivot arm and the lift arm. Keep these bolts separate.

2. With the parking brake on, start the traction unit and

adjust the engine to half throttle. Be sure to release the

lift arm lock lever for the #1, #2 and #3 cutting units

and put the reel lift control for the #1, #2 and #3

cutting units in the lower position (Fig. 6). Release the

lever and let it return to the neutral position.

Figure 6

1. Reel lift control

Important Do not allow lever to snap back into the

neutral position or the lift arms may not go into float.

3. Stop the traction unit and remove the key. Manually

pull the lift arms, one at a time, to floor level. Repeat

this procedure for the #4 and #5 cutting units.

Without the cutting units installed, restarting the

engine will result in the lift arms raising.

Caution

4. Roll the appropriate cutting unit to lift arm and match

the male end of pivot arm with hole in lift arm.

Note: It may be necessary to spread slotted block on lift

arm slightly to slide pivot arm fully into hole.

5. Reinstall 3 lift arm bolts but do not tighten (Fig. 5).

Mounting the #4 and #5 Tipper

Brackets

1. Loosely secure the hydraulic hoses to the underside of

each tipper bracket with hose clamps, spacers, clamp

plate, lock washers, and capscrew as shown in

Figure 7.

Figure 7

1. Tipper bracket

2. Hose clamp 3. Spacer

4. Clamp plate

2. Mount tipper brackets to cutting units with capscrews

and locknuts.

Important Raise and lower each cutting unit to ensure

that there is no binding of hoses during operation.

3. Tighten capscrews securing hose clamps to tipper

brackets.

Mount the Roller Bumpers

(Floatation Kit Only)

Note: Roller bumpers are required only when operating

cutting units in the float position and front rollers are

installed.

1. Locate mounting position of roller bumpers (Fig. 8) on

each side of frame tube in front of #1 cutting unit.

2. Loosely secure a roller bumper to each side of frame

tube, as shown in Figure 8, with U-bolts and locknuts.

3. Align the center of each bumper with the respective

end of the roller on the #1 cutting unit and tighten the

locknuts.

Figure 8

1. Rollerbumpers 2. Frame tube

Mounting the Hydraulic Motors

to the Cutting Units

1. Remove locknuts, bolts, shipping cover, and drive

plate shield (Fig. 9) from the cutting unit.

Figure 9

1. Shippingcover 2. Drive plate shield

2. Discard shipping cover and install the drive plate

shield onto the reel drive motor flange (Fig. 10). Be

sure the widest portion of the shield is at the top.

Figure 10

1. Drive plate shield 2. Reel drive motor flange

Note: Check to see that motor pulley set screws are tight

on motor shaft before installing motor onto cutting unit

(Fig. 11).

3. Insert the reel drive motor pulley through the housing

and slip the cutting unit drive belt over the pulley

(Fig. 11).

Figure 11

1. Hydraulicmotor

2. Motor pulley 3. Drive belt

4. Insert the 2 reel drive motor mounting bolts (heads on

inside of the drive housing—flat washer on top bolt)

through the reel motor flange holes. Thread the

locknuts onto the bolts. Rotate reel motor upward in

the slotted hole in the housing to tension the drive belt

and tighten the fasteners (Fig. 12) to approx. 25 ft. lb.

(34 Nm).

Note: Proper belt tension is achieved when belt deflects

approximately 1/8 in. (3 mm) at mid-point when 7 lb. of

force is applied. (Fig. 12).

Figure 12

1. Reel motor fasteners

Important Rotate motors by hand only. Never place a

bar between hose fittings on hydraulic motors—motor

damage may result.

5. Install the gasket and drive housing cover after making

sure the ends of the gasket are at the bottom of the

housing to allow for drainage.

Important When hydraulic motors have been mounted

to the cutting units, make sure hydraulic hoses lay flat and

do not contact the frame of the machine when the cutting

units are in the raised position. There should also be

sufficient slack so hoses are above and not in contact with

the floatation kit. If hoses appear twisted once the

hydraulic motors have been mounted and the belts

tightened, loosen swivel nuts at the motor and reposition

hoses. This can greatly increase the life of the hoses. With

cutting units down, all cutting unit hoses should have a

flat natural lay and be free from twist.

6. Tighten tipper bracket clamps on #4 and #5 cutting

units (Fig. 7).

Note: Refer to the Traction Unit Operator’s Manual for

instructions on setting the adjustable hydraulic

counterbalance, if so equipped.

Before adjusting reel to bedknife, raise and fully

latch cutting units. Remove key from the ignition

switch. Keep others off machine while adjusting

cutting units.

Caution

Adjusting the Reel to Bedknife

Contact

Before adjusting height-of-cut and each day before

operating, check reel to bedknife contact, regardless if

quality of cut had previously been acceptable.

Note: A 3/4 in. wrench is required for making the reel to

bedknife adjustment.

1. Slowly and carefully rotate the reel, listening for light

contact across the full length of the reel and bedknife.

2. If there is no contact, loosen the adjuster locking nut

on each adjuster (Fig. 13). Then, equally turn each

adjuster knob clockwise until light contact is felt and

heard.

Figure 13

1. Adjusterlocking nut 2. Adjustment knob

3. If there is excessive contact, turn the adjusting knobs

counterclockwise until no contact is noticed. Then

equally turn both adjusting knobs clockwise, until light

contact is felt and heard between the reel and

bedknife. Final adjustment should always be in the

tightening (clockwise) direction.

4. Tighten adjuster locking nuts when completed making

adjustments.

Sharp edges on the cutting units can cut or pinch

hands or fingers.

•When adjusting the cutting units, wear heavy

gloves.

•Use care when turning the reels by hand.

Caution

Important Adjusted correctly, the reel will cut paper

(approx. .03 in. thick) across its entire length.

The cutting units will provide optimum mowing

performance when adjusted and maintained correctly.

Keeping a precise reel to bedknife adjustment (light

contact), at each end of the cutting unit will produce a

continual self-sharpening action. Therefore, sharp cutting

edges are maintained, good quality of cut ensured, and the

need for corrective re-sharpening reduced.

Important Cutting units with excessive contact

between the reel and bedknife are noisy, consume

excessive power, shorten component life and result in

overall poor performance. Light contact between the reel

and bedknife, once the cutting unit is warmed up, provides

optimum mowing performance and component life.

Adjusting the Height-of-Cut for

a Floating Cutting Unit

Adjusting the Reel to Bedknife Contact

Adjust reel to bedknife contact on all cutting units. Refer

to Adjusting the Reel to Bedknife Contact, page 9.

Leveling the Rear Roller to the Reel

1. Start engine and lower the cutting units onto a flat

surface such as a piece of 3/4 in. or 1 in. plywood (at

least 20 in. x 30 in. in size). Stop engine and remove

key from switch. Lock cutting units in the fixed

position, by loosening the jam nut on lockout pin

(Fig. 14) and screwing pin into hole in pivot arm

(Fig. 15). Tighten nut to secure lockout. Raise the

front rollers up so they do not contact the flat surface.

Figure 14

Cutting Unit Float Position

1. Lockout pin 2. Jam nut

2. Insert a piece of bar stock 25–28 in. (70 cm) long

(Fig. 16), and approximately 3/8 in. (9.5 mm) thicker

than the desired height-of-cut, under the reel and up

against the bedknife cutting edge (Fig. 16). The reel

(not bedknife) must contact the bar stock along its full

length.

Note: Using a bar 3/8 in. (9.5 mm) thicker than

height-of-cut provides proper bedknife attitude (heeled

“up” in back) required for excellent low height-of-cut

performance.

1 2

Figure 15

Cutting Unit Fixed Position

1. Lockout pin 2. Jam nut

3. Loosen rear roller jam nuts and adjusting knobs and

push roller down against flat surface. At this point the

reel should be contacting the bar stock and the rear

roller contacting the flat surface. Contact should exist

along the entire length of the reel and rear roller.

Tighten rear roller adjustment knobs and jam nuts.

Recheck to be sure roller and reel are both still making

contact after the jam nuts have been tightened. Check

roller contact by trying to slide paper between the

roller and the flat surface.

3/8

Figure 16

Leveling the Rear Roller to the Reel

4. Rear roller is now leveled to the reel.

Adjusting the Final Height-of-Cut Using

the Gauge Bar

1. Raise cutting units and lock in the transport position.

Shut off the engine and remove the key.

2. Use gauge bar (Toro Part No. 98-1852) to set final

height-of-cut by adjusting front roller only.

Note: Position long cone nut (Fig. 17) on bottom for

heights of 1-1/4 in. or higher. Position short cone nut on

bottom for heights of below 1-1/4 in.

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