Rear Roller Brush Kit

Reelmaster® 3550 Series 18-inch Cutting Unit with 5-inch Reel and Universal Groomer

Model No. 03657-Serial No. and Up

This product complies with all relevant European directives. For details, please see the Declaration of Incorporation (DOI) at the back of this publication.

Installation

Note: Install the universal groomer kit first; refer to the groomer installation instructions.

Important: Use the Rear Roller Brush Kit only when cutting in the height-of-cut range of 6 to 25 mm (1/4 to 1 inch). Use the high height-of-cut brush when cutting above 25 mm (1 inch). Refer to the procedure for Installing the High Height-of-Cut Brush (Optional).

Note: Determine the left and right sides of the cutting unit from behind the cutting unit.

Determining the Roller-Brush Orientation

All cutting units are shipped with the counterweight mounted to the left end of the cutting unit. Refer to Figure 1 to determine the position of the roller brush and reel motors.

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Figure 1

  1. Cutting unit 1
  2. Cutting unit 2
  3. Cutting unit 3
  4. Cutting unit 4
  5. Cutting unit 5
  6. Reel motor
  7. Right roller-brush drive assembly
  8. Left roller-brush drive assembly

Note: These instructions and illustrations show the installation of the kit on cutting units with the universal groomer mounted on the left end of the cutting unit.

Installing the Kit

Parts needed for this procedure:

Roller-brush assembly 5
Retaining ring5
Right belt-cover/plate assembly2
Left belt-cover/plate assembly3
90° grease fitting5
Carriage bolt10
Weight10
Locknut10
Drive pulley 5
Hex-drive bolt (5/16 x 1/2 inch)15
Belt 5
Shim washer (as required for belt alignment) 5
Belt-alignment tool1
Front bumper assembly1
Washer2
Rear bumper assembly1

Installing the Grease Fitting

  1. Remove the grease fitting for the roller from the side of the cutting unit that has the roller-brush housing (Figure 3).

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    Figure 2

    1. Grease fitting

  2. Install the 90° grease fitting so that it faces rearward (Figure 2).

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    Figure 3

    1. 6 mm (1/4 inch) spacer
    2. Side-plate mounting flange
    3. 90° grease fitting
    4. Flange locknuts (remove)

Installing the Weights

Install the weights to the cutting units as shown in Figure 4 .

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Figure 4

  1. Carriage bolts (5/16 x 1 inch)
  2. Flange nuts (5/16 inch), torque to 20 to 26 N∙m (15 to 19 ft-lb)
  3. Weights

Installing the Roller-Brush Assembly

  1. Remove the 2 flange locknuts securing each roller bracket to the side plates, as well as any 6 mm (1/4 inch) spacers positioned on the top side of the side-plate mounting flange (Figure 3).

    Note: Do not remove the bolts. Keep the flange locknuts for future assembly.

  2. Position the left or right roller-brush-assembly mounting brackets onto the roller-bracket bolts (Figure 5).

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    Figure 5

    1. Left roller-brush assembly
    2. Roller-brush mounting bracket

    Important: Attach the mounting brackets for the roller-brush assembly directly to the top surface of the side-plate mounting flange of the cutting unit. Do not put spacers between the roller-brush mounting brackets and the side-plate mounting flanges. Save the additional 6 mm (1/4 inch) spacers for potential later use.

  3. Loosely secure the brush-assembly mounting brackets to the cutting-unit side plates with the previously removed nuts.

  4. Slide each excluder seal outward until the lip seals are in light contact with each bearing housing (Figure 6).

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    Figure 6

    1. Bearing housing
    2. Excluder seal

Installing the Roller-Brush Housing

  1. Remove and discard groomer drive cap.

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    Figure 7

    1. Cap

  2. Install the left or right roller-brush housing (Figure 8).

    Note: Ensure that the idler-pulley assembly is installed on the bottom as shown in Figure 8.

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    Figure 8

    1. Roller-brush housing
    2. Retaining ring
    3. Bolt (2)
    4. Bearing housing

  3. Apply 242 Loctite (blue) to the 2 bolts (5/16 x 1/2 inch) and use them to mount the roller-brush housing to the bearing housing (Figure 8).

    Note: Torque the bolts to 20 to 26 N∙m (15 to 19 ft-lb).

  4. Secure the roller-brush housing to the groomer-drive housing with the retaining ring (Figure 8).

  5. Ensure that the roller-brush housing is parallel to the cutting-unit side plate. Proceed as follows:

    1. Loosen the 2 flange locknuts securing the roller-brush mounting bracket to the cutting-unit side plate (Figure 9).

    2. Rotate the roller-brush-bearing housing until the brush plate is parallel to the cutting-unit side plate (Figure 9).

    3. Tighten the 2 flange locknuts securing the roller-brush mounting bracket to the cutting-unit side plate (Figure 9).

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    Figure 9

    1. Loosen these bolts for positioning the roller brush.
    2. Loosen these nuts for making the roller-brush plate parallel.

Positioning the Roller Brush

  1. Loosen the 2 bolts securing each roller-brush-bearing housing to the roller-brush mounting bracket (Figure 9).

    Note: The bolts should be loose from the factory.

  2. Position the roller brush so that it is just touching or resting on the rear roller (Figure 10).

    Important: The roller-brush shaft must not contact the cutting-unit side plate.

    Important: Heavy brush contact on the roller causes premature brush wear.

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    Figure 10

    1. Bearing housing (some parts not shown)
    2. Side plate
    3. Roller brush
    4. Ensure that there is clearance here.
    5. Light contact
    6. Rear roller
    7. Grease fitting

    Note: The roller-brush shaft must be parallel to the rear roller.

    Important: Position both roller-brush-bearing housings so that they are parallel to the ground to ensure clearance for the rear-roller grease fitting.

  3. Tighten the 2 bolts securing each roller-brush-bearing housing to the roller-brush mounting brackets.

Installing the Drive Pulley

  1. Restrain the reel before installing the drive pulley; refer to Restraining the Reel for Installing Threaded Inserts.

  2. Install the drive pulley onto the groomer shaft (Figure 11).

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    Figure 11

    1. Drive pulley
    2. Hex-drive bolt—torque to 20 to 26 N∙m (15 to 19 ft-lb)

  3. Apply 242 Loctite (blue) to the hex-drive bolt and use the bolt to secure the pulley to the driveshaft; refer to Figure 11.

    Note: Torque the bolt to 20 to 26 N∙m (15 to 19 ft-lb).

    Important: If you do not properly torque the bolt, the bolt will come loose.

Installing the Belt

  1. Install the belt onto the pulleys as follows:

    • Loop the belt around the drive pulley and then over the top of the idler pulley (Figure 12).

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      Figure 12

      1. Drive pulley
      2. Idler-pulley assembly
      3. Belt
      4. Driven pulley

    • Start the belt on the driven pulley (Figure 13).

    • Use a deep-well socket (9/16 inch) to rotate the brush assembly and guide the belt onto the driven pulley (Figure 13).

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      Figure 13

      1. Belt
      2. Deep-well socket (9/16 inch)

    Important: Ensure that the ribs on the belt are properly seated in the grooves in each pulley and that the belt is in the center of the idler pulley.

  2. Push down on the idler pulley to ensure that the idler-pulley assembly pivots freely.

Completing the Installation

  1. Check the alignment of the belt and pulleys as follows:

    Note: The belt must be properly tensioned prior to checking the alignment.

    • Lay the belt-alignment tool along the outer face of the drive pulley (Figure 14). Do not lay the straightedge across both the drive pulley and the driven pulley.

    • The outer faces of the drive pulley and the driven pulley should be in line within 0.76 mm (0.030 inch).

    • If the pulleys are not aligned, refer to Checking and Adjusting the Pulley Alignment.

    • If the pulleys are aligned, continue with the installation.

    • Do not use the idler pulley to check the alignment.

      Important: The belt may fail prematurely if the pulleys are not properly aligned.

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      Figure 14

  2. Align the belt cover with the mounting holes and secure the cover with 4 bolts (Figure 15).

    Important: Do not overtighten the bolts, as damage to the cover may occur.

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    Figure 15

    1. Metal cover
    2. Plastic cover
    3. Screw (4)

  3. Tighten the nuts securing the brush-assembly mounting brackets to the cutting-unit side plates.

  4. Lubricate the grease fittings on each of the roller brush bearing housings with No. 2 lithium grease (Figure 16).

    Note: Wipe off any excess grease, specifically around the excluder seals.

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    Figure 16

Installing the Bumper Assemblies

  1. Lower the cutting units to the ground.

  2. Remove the existing flange-head bolts and the round bumpers (Figure 17).

    Note: Retain the flange-head bolts for installing the front bumper assembly. Discard the round bumpers.

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    Figure 17

    1. Flange-head bolt, existing (2)
    2. Round bumper, existing (2)—discard

  3. Apply 242 Loctite (blue) to the threads of the bolts.

  4. Loosely install the front bumper assembly and the washers as shown in Figure 18.

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    Figure 18

    1. Flange-head bolt, existing (2)
    2. Washer (2)
    3. Front bumper assembly

  5. Adjust the front bumper so that it contacts the rear-roller-brush housings when the cutting units are raised and level.

    Note: When the bumper is positioned correctly, torque the bolts to 91 to 113 N∙m (67 to 83 ft-lb).

  6. Install the rear bumper assembly as shown in Figure 19.

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    Figure 19

    1. Flange-head bolt (2)
    2. Rear bumper assembly
    3. Locknut

Installing the High Height-of-Cut Brush (Optional)

Parts needed for this procedure:

High height-of-cut brush (optional)—

Install the high height-of-cut brush (sold separately) when the height of cut is 2.5 cm (1 inch) or more (5 or more spacers installed below the side-plate pad).

  1. If a roller brush is installed on the cutting unit, remove the 2 bolts, washers, and nuts securing the non-drive-bearing housing to the bearing-housing mounting bracket (Figure 20 and Figure 21).

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    Figure 20

    1. Non-drive-bearing housing

  2. Slide the non-drive-bearing housing and the excluder seal off the brush shaft (Figure 21).

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    Figure 21

    1. Non-drive-bearing housing
    2. Excluder seal
    3. Brush shaft

  3. Remove the 2 J-bolts and the nuts (Figure 22).

  4. Slide the existing brush off the brush shaft (Figure 22).

  5. Loosen the 2 bolts, washers, and nuts securing the drive-bearing housing to the bearing-housing mounting bracket (Figure 22).

  6. Slide the high height-of-cut brush onto the brush shaft (Figure 22).

  7. Clamp the brush onto the shaft with the 2 J-bolts and nuts previously removed (Figure 22).

    Important: Insert the threaded end of the J-bolts through the outer holes of the brush shaft while hooking the curved ends of the J-bolts into the inner holes.

  8. Torque the J-bolt locknuts to 2 to 3 N∙m (20 to 25 in-lb).

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    Figure 22

    1. High height-of-cut brush
    2. J-bolts
    3. Loosen these bolts.

  9. Install the excluder seal and the non-drive-bearing housing onto the brush shaft (Figure 21).

  10. Mount the non-drive-bearing housing to the bearing-housing mounting bracket with the 2 bolts, washers, and nuts previously removed.

    Note: Be careful not to knock the seal spring off.

  11. Tighten the 2 bolts, washers, and nuts securing the drive-bearing housing to the bearing-housing mounting bracket.

Maintenance

  • Ensure that the brush is parallel to the roller with 1.5 mm (0.060 inch) clearance to light contact.

  • Grease the fittings every 50 hours and after every washing.

  • When replacing a roller brush, torque the J-bolts to 2 to 3 N∙m (20 to 25 in-lb).

  • When replacing the brush-shaft-driven pulley, torque the nut to 20 to 26 N∙m (15 to 19 ft-lb).

  • When replacing the brush-drive pulley, apply 242 Loctite (blue) and torque the bolt to 20 to 26 N∙m (15 to 19 ft-lb).

Note: The roller brush, the idler bearing, and the belt are considered consumable items.

Checking and Adjusting the Pulley Alignment

  1. The driven pulley (at the roller-brush shaft) can move in or out (Figure 23).

    Note: Make note of which way the pulley needs to move.

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    Figure 23

    1. Driven pulley
    2. Idler pulley
    3. Driven-pulley nut

  2. While rotating the reel, which rotates the drive pulley, pry the belt off the drive pulley (Figure 23).

    Note: Wear a padded glove or use a heavy rag to rotate the reel.

  3. Remove the locknut securing the driven pulley to the brush shaft (Figure 23 or Figure 24).

    Note: Use a 1/2-inch wrench on the roller-brush shaft flats to keep it from rotating.

  4. Remove the driven pulley from the shaft (Figure 24).

  5. If the pulley needs to move out, add a 0.8 mm (0.032 inch) thick washer (Figure 24).

    Note: If the pulley needs to move in, remove the existing 0.8 mm (0.032 inch) thick washer.

  6. Install the pulley.

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    Figure 24

    1. Locknut
    2. Driven pulley
    3. Washer—0.8 mm (0.032 inch) thick
    4. Spacer
    5. Brush shaft flats

  7. While holding the flats of the roller-brush shaft, secure the driven pulley on the shaft with the flange nut (3/8–16) previously removed.

    Note: Seat the locknut; then torque it to 20 to 26 N∙m (15 to 19 ft-lb).

  8. Install the belt onto the pulleys as follows:

    1. Loop the belt around the drive pulley and then over the top of the idler pulley (Figure 25).

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      Figure 25

      1. Drive pulley
      2. Idler-pulley assembly
      3. Driven pulley
      4. Belt

    2. Start the belt on the driven pulley (Figure 25).

    3. Use a 9/16-inch deep-well socket to rotate the brush assembly and guide the belt onto the driven pulley (Figure 26).

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      Figure 26

      1. Belt
      2. 9/16-inch deep-well socket

    Important: Ensure that the ribs on the belt are properly seated in the grooves in each pulley and that the belt is in the center of the idler pulley.

  9. Check the pulley alignment again, and repeat this procedure if necessary.

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    Figure 27

Restraining the Reel

Warning

The cutting reel blades are sharp and capable of amputating hands and feet.

  • Keep your hands and feet outside of the reel.

  • Ensure that the reel is restrained before servicing it.

Restraining the Reel for Removing Threaded Inserts

  1. Loosen the shield-bolt on the left side of the cutting unit and raise the rear shield (Figure 28).

  2. Insert a long-handled pry bar (recommended 3/8 x 12 inches with screwdriver handle) through the back of the cutting reel, closest to the side of the cutting unit that you will be torquing (Figure 28).

  3. Place the pry bar against the weld side of the reel support plate (Figure 28).

    Note: Insert the pry bar between the top of the reel shaft and the backs of 2 reel blades so that the reel will not move.

    Important: Do not contact the cutting edge of any blades with the pry bar; this may damage the cutting edge and/or cause a high blade.

    Important: The insert on the left side of the cutting unit has left-hand threads. The insert on the right side of the cutting unit has right-hand threads.

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    Figure 28

    1. Threaded insert for removal
    2. Loosen the shield bolt.
    3. Rear shield
    4. Reel shaft
    5. Reel support plate
    6. Pry bar inserted along the weld side of the reel support plate.

  4. Rest the handle of the pry bar against the rear roller.

  5. Complete the removal of the threaded insert while ensuring that the pry bar stays in place, then remove the pry bar.

  6. Lower the rear shield and tighten the shield-bolt.

Restraining the Reel for Installing Threaded Inserts

  1. Insert a long-handled pry bar (recommended 3/8 x 12 inches with screwdriver handle) through the front of the cutting reel, closest to the side of the cutting unit that you will be torquing (Figure 29).

  2. Place the pry bar against the weld side of the internal cutting reel reinforcement (Figure 29).

    Note: The pry bar should contact a blade at the front, the reel shaft, and a blade at the back of the back of the reel, locking it in place.

    Important: Do not contact the cutting edge of any blades with the pry bar; this may damage the cutting edge and/or cause a high blade.

    Important: The insert on the left side of the cutting unit has left-hand threads. The insert on the right side of the cutting unit has right-hand threads.

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    Figure 29

    1. Threaded insert for installation
    2. Reel shaft
    3. Weld side of support plate
    4. Pry bar

  3. Rest the handle of the pry bar against the roller

  4. Per the insert’s installation instructions and torque requirements, complete the installation of the threaded insert while ensuring that the pry bar stays in place, then remove the pry bar.