Form No. 3443-362 Rev A 27-inch 5, 8, or 11-Blade or 32-inch 8-Blade EdgeSeries™ DPA Cutting Unit Reelmaster® 3100-D or 3105-D Traction Unit Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 03188—Serial No. 03189—Serial No. 03190—Serial No. 03191—Serial No. 03192—Serial No.
This product complies with all relevant European directives. For details, please see the Declaration of Incorporation (DOI) at the back of this publication. Model No. Serial No. This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.
Safety Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol , which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death. This machine has been designed in accordance with EN ISO 5395 and ANSI B71.4–2017.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 Description Use Qty. Straight grease fitting 1 Install the reel grease fitting. No parts required – Adjust the cutting unit O-ring Cap screws (may come assembled) 1 2 Install the reel motors. No parts required – Adjust the shop roller assembly positions (Model 03192 only). Media and Additional Parts Description Qty.
3 Installing the Reel Motors Parts needed for this procedure: g028640 3. Grease fitting 2. Setscrew 4. Grease vent 2. O-ring 2 Cap screws (may come assembled) Procedure Figure 4 1. Cap screw (2) 1 Important: Before installing the reel motors, obtain and install the counter weights or other accessories on the opposite side of the cutting units from the reel motors as described in the instructions provided with the weights or accessories. Install the straight grease fitting (Figure 4).
Product Overview 4 Specifications Adjusting the Shop Roller Assemblies Model Number Model 03192 Only No Parts Required Weight 03188 57 kg (125 lb) 03189 60 kg (132 lb) 03190 62 kg (136 lb) 03191 67 kg (147 lb) 03192 54 kg (119 lb) Procedure Attachments/Accessories Adjust the shop roller positions before operating the cutting units for the first time; refer to Adjusting the Shop Roller Assemblies (page 10).
Operation Note: The adjustment knobs have detents corresponding to 0.022 mm (0.0009 inch) bedknife movement for each indexed position. Refer to Adjusting the Bedknife to the Reel (page 8). Refer to your traction unit Operator’s Manual for detailed operation instructions. Before using the cutting unit each day, adjust the bedknife; refer to Adjusting the Bedknife to the Reel (page 8). Test the quality of cut by cutting a test swath before using the cutting unit to ensure that the finished cut is correct.
g003322 Figure 9 1. Bedbar-adjusting screw 3. g031270 Figure 8 1. Lead-in chamfer on right end of bedknife 2. 6 mm (0.25 inch) 3. 1.5 mm (0.060 inch) Tip the cutting unit to expose the bedknife and reel. Important: Make sure that the nuts on the back end of the bedbar-adjusting screws are not resting on the work surface; use the kickstand (Figure 10). Note: Do not make the lead-in chamfer too large as it may cause turf tufting.
Note: Adjusting 1 side of the cutting unit affects the other side, the 2 clicks will provide clearance for when the other side is adjusted. 2. Raise the rear of the cutting unit and place a block under the bedknife. 3. Remove the 2 nuts securing each roller bracket and spacer to each side-plate mounting flange. 4. Lower the roller and screws from the side-plate mounting flanges and spacers. 5. Place the spacers onto the screws on the roller brackets. 6.
Adjusting the Shop Roller Assemblies Model 03192 Only Before the cutting units are lowered to the shop floor or removed from the traction unit, lower the shop roller assemblies to protect the reel and bedknife blades from hard surface contact. Before operating the cutting units, install them to the machine, raise the cutting units, and raise the shop roller assemblies to prevent them from touching the grass and interfering with operation. 1.
Adjusting the Height of Cut (HOC) Models 03188, 03189, 03190, and 03191 Only Note: Use Height-of-Cut Chart (Models 03188, 03189, 03190, and 03191) to determine the number of rear spacers needed for the desired aggressiveness-of-cut setting; refer to Height-of-Cut Chart (Models 03188, 03189, 03190, and 03191) (page 12). 1. g011864 Figure 16 3. Nut 1. Gauge bar Loosen the locknuts securing the height-of-cut brackets to the cutting-unit side plates (Figure 15). 2. Height-adjusting screw 3.
Height-of-Cut Chart (Models 03188, 03189, 03190, and 03191) HOC Setting Aggressiveness of Cut No. of 1/4 inch Rear Spacers HOC Setting Aggressiveness of Cut No. of 1/4 inch Rear Spacers 6 mm (0.250 inch) Less 0 Less 4 Normal 0 32 mm (1.
Adjusting the Height of Cut (HOC) Height-of-Cut Chart (Model 03192) HOC Setting No. of 1/4 inch Rear Spacers* No. of Thin Rear Spacers* 32 mm (1.25 inches) 5 0 34 mm (1.33 inches) 5 1 35 mm (1.38 inches) 5 2 38 mm (1.50 inches) 6 0 Note: Spacers installed above the side plate pad do 40 mm (1.58 inches) 6 1 not affect HOC. 42 mm (1.65 inches) 6 2 The adjustment (slotted) rear spacers are stored above the side plate pad; to increase HOC, move them below the side plate pad. 45 mm (1.
Use the following chart to determine which bedknife is best suited for the desired height of cut. Bedknife/Height-of-Cut Chart (Production Bedknife) Bedknife Part No. Bedknife Lip Height Height of Cut Low HOC 120-1641 (27 inch) 5.6 mm 6.4 to 12.7 mm 120-1642 (32 inch) (0.220 inch) (0.250 to 0.500 inch) 112-8910 (27 inch) 6.9 mm 9.5 to 50.8 mm 112-8956 (32 inch) (0.270 inch) (0.375 to 2.00 inches)* 114-9388 (Model 03188/89/90, 27 inch) 6.9 mm 9.5 to 50.
Height-of-Cut Chart Terms Aggressiveness of Cut Height-of-Cut Setting (HOC) The aggressiveness of cut has a significant impact on the performance of the cutting unit. Aggressiveness of cut refers to the angle of the bedknife relative to the ground (Figure 22). This corresponds to the desired height of cut. The best cutting-unit setup depends on your turf conditions and desired results. Experience with the cutting unit on your turf will determine the best setting to use.
Maintenance Lubricating the Cutting Units Using the Kickstand when Tipping the Cutting Unit Regularly lubricate the 5 grease fittings of each cutting unit (Figure 24) with No. 2 lithium grease. There are 2 lubrication points on the front roller, 2 on the rear roller, and 1 at the reel-motor spline.
Relief-Grinding the Reel 3. The new reel has a land width of 1.3 to 1.5 mm (0.050 to 0.060 inch) and a 30° relief grind. When the land width gets larger than 3 mm (0.120 inch) wide, do the following: 1. Using diameter measuring tape, measure the outside diameter of the reel at both ends (Figure 26); the difference in outside diameter between the ends should be less than 0.010 inches (0.250 mm). If the difference is greater, grind to correct the difference.
Servicing the Bedknife The bedknife service limits are listed in the following chart. Important: Operating the cutting unit with the bedknife below the service limit may result in poor after-cut appearance and reduce the structural integrity of the bedknife for impacts. Bedknife Service Limit Chart (Production Bedknife) Bedknife Part No. Low HOC 120-1641 (27 inch) Bedknife Lip Height Service Limit* Top/Front Grind Angles 5.6 mm (0.220 inch) 4.8 mm (0.190 inch) 10/5° 6.9 mm (0.270 inch) 4.
3. On each side of the machine, loosen the locknut securing the bedbar bolt (Figure 32). g003334 Figure 32 1. Bedbar bolt g034114 2. Locknut Figure 30 1. Angle-indicator mount 4. 3. Bedknife 2. Edge of the magnet mated 4. Angle indicator with the edge of the bedknife 4. Remove each bedbar bolt, allowing the bedbar to be pulled downward and removed from machine bolt (Figure 32). Account for 2 nylon washers and 1 stamped steel washer on each end of the bedbar (Figure 33).
5. Tighten the spring-tension nut until the spring is collapsed, then back off 1/2 turn (Figure 34). g006505 Figure 34 1. Spring-tension nut 2. Spring Installing the Bedknife 1. g279162 Figure 36 Remove the rust, scale, and corrosion from the bedbar surface and apply a thin layer of oil to the bedbar surface. 1. Bedknife screw tool 2. Clean the screw threads. 2. Install and torque these first to 1 N∙m (10 in-lb). 3.
Servicing the HD Dual Point Adjusters (DPA) 1. 2. 3. Remove all parts (refer to the Installation Instructions for the HD DPA Kit and to Figure 37). Apply anti-seize compound to the inside of the bushing area on cutting unit center frame (Figure 37). Align the keys on flange bushings to the slots in the frame and install the bushings (Figure 37). 4. Install a wave washer onto the adjuster shaft and slide the adjuster shaft into the flange bushings in the frame of the cutting unit (Figure 37). 5.
16. Repeat this procedure on the other end of the cutting unit. Servicing the Roller 17. Adjust the bedknife to the reel; refer to Adjusting the Bedknife to the Reel (page 8). The Roller Rebuild Kit (Part No. 114-5430) and the Roller Rebuild Tool Kit (Part No. 115-0803) (Figure 38) are available for servicing the roller. The Roller Rebuild Kit includes all the bearings, bearing nuts, inner seals, and outer seals to rebuild a roller.
Declaration of Incorporation The Toro Company, 8111 Lyndale Ave. South, Bloomington, MN, USA declares that the following unit(s) conform(s) to the directives listed, when installed in accordance with the accompanying instructions onto certain Toro models as indicated on the relevant Declarations of Conformity. Model No. Serial No.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
