Toro 04482 200000001 User manual

OPERATOR S
MANUAL
FORM NO. 3323-377 Rev. A
MODEL NO. 04482 200000001 & UP
MODEL NO. 04483 200000001 & UP
(For Greensmaster®3200)
¤8- & 11-BLADE CUTTING UNITS
©The TORO Company—1999, 2000

Height-of-Cut: The cutting height is adjusted on
rear roller by two vertical screws and held by two
locking capscrews. Bench height-of-cut range is
2.4mm to 26mm. Cutting units will deliver differing
effective heights of cut, depending on their configura-
tion.In fact, effective cutting height may be influ-
enced by the following factors; turf conditions, roller
profiles, cutting unit attitude, cutting unit accessories,
weight of the cutting units and bedknife profile.
Therefore, bench setting a cutting unit does not equal
the effective (actual) height of cut you achieve. You
must determine how to adjust your cutter on the
bench to achieve a comparable height of cut to a cut-
ting unit of a different configuration, model, or brand.
Reel Construction: Reels are 13cm in diameter,
53.3 cm in length. High-carbon steel blades are weld-
ed to 5 stamped-steel spiders. and heat treated to RC
48-54 hardness. The reel is ground for diameter, con-
centricity. and back grind.
Reel Bearings: Two double-row ball bearings, 30
mm I.D., press fit onto the reel shaft. The inverted
seal is pressed onto the reel shaft. Bearing side load is
maintained by a 3-1⁄2turn wave washer, with no
adjusting nut.
Reel Drive: The reel shaft is a 1.375 inch (3.493
cm) diameter tube with drive inserts permanently
pressed in both ends. A replaceable floating coupler
with an internal eight-tooth spline is factory installed
on the right end, and held in place by a snap ring. The
floating coupler may be moved to the other end when
the cutting unit is used on the tractor’s front right
position.
Frame Construction: Asingle top tube is welded
to two side plates. A bolt-in cross rod acts to set the
front frame width and stiffen the assembly. The lift
straps have a replaceable roller that may be moved to
change transport height.
Bedknife: Replaceable, 13-screw, single-edged, high
carbon steel bedknife austempered to RC 48-55,
fastened to a machined cast iron bedbar. Tournament
bedknife is standard.
Bedknife Adjustment: Asingle control screw has
detents corresponding to .018 mm bedknife move-
ment for each indexed position. A linear adjustment
on the bedbar left end allows leveling of the bedknife
to the reel blades. A centered lever arm regulates the
knife-to-reel contact with two rubber bushings acting
as pivots.
Front Roller: The standard front roller is a 6.4 cm,
diameter full-radious Weihle. The right bracket has an
eccentric shoulder bolt to provide leveling. A second
eccentric may be added to the left bracket for
increased leveling range. The roller has a through
shaft with greaseable ball bearings.
Rear Roller: The standard rear roller is a 5.2 cm
diameter smooth roller. It has a through shaft with
greaseable ball bearings.
Front Shield: Asnap-in shield covers the lower
front of the reel. The shield helps improve grass
throwing into the basket and prevents the basket seal-
ing flap from being damaged by the reel.
Options:
Micro-Cut Bedknife Part No. 93-4262
Lo-Cut Bedknife Part No. 93-4264
High-Cut Bedknife Part No. 94-6392
Fairway Bedknife Part No. 94-6393
5-blade heavy duty reel Part No. 98-2181
8-blade heavy duty reel Part No. 98-2182
2
Specifications
Table of Contents
Page
Specifications 2
Adjusting the Cutting Unit 3
Adjusting The bedknife To The Reel 4
Leveling Front Roller To The Reel 4
Adjusting Shield Height 5
Adjusting Top Bar 5
Adjusting Height-of-Cut 5
Operating Instructions 6
Cutting Unit Daily Adjustments 6
Lubrication 7
Greasing Bearings And Bushings 7
Backlapping the Cutting Units 7

IMPORTANT: Read this operator's manual thor-
oughly before operating the cutting unit. Failure to
do so may result in damage to the cutting unit.
Note: Left and right sides of the cutting unit refer to
normal operating position.
After the cutting unit is unboxed, use the following
procedures to assure the cutting units are adjusted
properly.
1. Check each end of the reel for grease. Grease
should be visibly evident in the reel bearings.
2. Insure that all nuts and bolts are securely fas-
tened.
3. Position the lift roller to match suspension.
•Upper position for standard transport height
•Lower position for increased transport
height
4. Check to make sure the bedknife and reel are
parallel. Refer to Adjusting The Bedknife To The
Reel.
Adjusting the Bedknife to the
Reel (Fig. 1 & 2)
1. Remove the cutting units from the traction unit
and position them on a level work surface.
2. Make sure reel contact is removed by turning the
bedknife adjustment knob counterclockwise
(Fig. 1)
3. On either end of the front side of the reel, insert
a long strip of newspaper between the reel and
the bedknife. While slowly rotating the reel for-
ward, turn the bedknife adjusting knob clock-
wise, on click at a time, until paper is pinched
lightly, which results in a slight drag while paper
is pulled.
Figure 1
1. Bedknife Adjustment knob
2. Left-hand bedbar pivot housing
3. Flange nuts
4. Frame tab
Figure 2
4. Loosen the locknuts retaining the left-hand bed-
bar pivot housing.
3
High height-of-cut kit Part No. 99-1496
Weilhe rear roller Model No. 04488
Full front roller Model No.04496
Specifications and design are subject to change
without notice.
Adjusting the Cutting Units

5. Rotate the flange nuts (Fig 1, inset) on the top
and bottom of the frame tab, clockwise or coun-
terclockwise to raise or lower the end of the bed-
bar, as required. Do not loosen the bottom
flange nut. Tighten the flange nuts against the
frame tab when you achieve the desired adjust-
ment..
6. Check adjustments by repeating steps 2 and 3.
7. When light contact on the paper is evident at
each end of the bedknife, securely tighten the
locknuts retaining the pivot housing.
Choosing Cutting Unit Attitude
There are four positions for the front roller brackets.
Position 1: Least aggressive; use for very soft and
tender turf.
Height-of-cut range: 3.2mm–26mm
Position 2: Standard position; use for most condi-
tions.
Height-of-cut range: 2.4mm–24mm
Note: The top frame hole and top bracket hole
will yield position 2 (standard position).
Position 3: More aggressive; use on firm turf or
higher height of cuts.
Height-of-cut range: 2.4mm–21mm
Position 4: Most aggressive; use only on very firm
greens or at the higher heights of cut.
Height-of-cut range: 2.4mm–19mm
Note: Amore aggressive setting will increase
grass removal and provide a cleaner cut, but may
cause increased scalping and marking.
Note: Amore aggressive setting will be required
to compensate for reel wear.
Leveling the Front Roller to the
Reel (Fig. 3)
1. Position the cutting unit on a flat, level surface.
2. Position a 6 mm or thicker plate under the reel
blades and against the front face of the bedknife.
Note: Be sure the plate covers the full length of
the reel blades and three blades contact the plate.
3. Loosen the locknuts retaining the right-front
roller bracket.
4
Frame
Frame
Bracket
Bracket
POSITION 1
POSITION 2
Down
Down
POSITION 3
Down
Frame
Bracket
Frame
Bracket
POSITION 4
Down

Figure 3
1. Right front roller bracket
2. Upper right roller mounting bolt
4. While holding the reel securely on the plate and
maintaining pressure on the front roller, rotate
the upper right roller mounting bolt. This mount-
ing bolt has an offset, which when rotated, acts
as an eccentric (cam) to raise or lower the roller.
On the bolt head there is an internal diameter dot
which denotes the offset of the bolt. The dot
indicates in which direction the right end of the
roller moves when the bolt is turned.
Note: If additional adjustment is required,
replace one screw on the left-hand bracket with
another bolt, part no. 93-2573. Make sure that
both front roller brackets are in the same hole.
5. To verify whether the roller is level, try inserting
a piece of paper under each end of the roller.
6. When the roller is level, tighten the nuts secure-
ly.
Adjusting the Height of the Top
Shield
1. Loosen the capscrews and nuts securing the
shield to each side plate.
2. Adjust the shield to the desired position and
secure the fasteners
3. Repeat the procedure on the remaining cutting
units and adjust the top bar.
Note: The shield can be raised for extreme wet
conditions.
Adjusting the Top Bar
Adjust the top bar, under the rear shield, to assure
clippings are cleanly discharged from the reel area.
1. Loosen the screws securing the top bar. Insert a
1.5mm feeler gauge between the top of the reel
and the bar and tighten the screws. Assure the
bar and reel are equal distance apart across the
complete reel.
2. Repeat adjusting the settings on the remaining
cutting units.
Note: The bar is adjustable to compensate for
changes in turf conditions. It should be adjusted
closer to the reel when the turf is extremely wet.
By contrast, adjust the bar further away from the
reel when turf conditions are dry. The bar
should be adjusted whenever you change the top
shield height.
Adjusting the Height of Cut
(Fig. 4)
1. Verify that the front roller is level and the bed-
knife-to-reel contact is correct.
Figure 4
1. Gauge bar
2. Roller bracket capscrew
3. Height-of-cut knob
5

2. Turn the cutting unit over (90°) and rest it on the
rear roller and top rear tabs. Loosen the locknuts
on the capscrews that retain the rear roller brack-
ets.
3. On a gauge bar (Part no. 13-8199), set the head
the screw to the desired height of cut. This mea-
surement is from the bar face to the underside of
the screw head.
4. Place the bar across the front and rear rollers and
adjust the height-of-cut knob until the underside
of the screw head engages the bedknife cutting
edge.
IMPORTANT: Repeat the procedure on each end
of the bedknife and tighten locknuts that retain
rear roller brackets on each end.
NOTE: Cutting units will deliver differing effective
heights of cut, depending on their configuration.In
fact, effective cutting height may be influenced by the
following factors; turf conditions, roller profiles, cut-
ting unit attitude, cutting unit accessories, weight of
the cutting units and bedknife profile. Therefore,
bench setting a cutting unit does not equal the effec-
tive (actual) height of cut you achieve. You must
determine how to adjust your cutter on the bench to
achieve a comparable height of cut to a cutting unit of
a different configuration, model, or brand.
Cutting Unit Characteristics
The single-knob bedknife-to-reel adjustment system
incorporated in this cutting unit simplifies the adjust-
ment procedure needed to deliver optimum mowing
performance. The precise adjustment possible with
the single knob/bedbar design gives the necessary
control to provide a continual self-sharpening action,
thus maintaining sharp cutting edges, assuring good
quality of cut, and greatly reducing the need for rou-
tine backlapping.
Cutting Unit Daily Adjustments
Prior to each day's mowing, or as required, each cut-
ting unit must be checked to verify proper bedknife-
to-reel contact. This must be performed even
though quality of cut is acceptable.
1. Lower the cutting units onto a hard surface, shut
of the engine and remove the key from the igni-
tion.
2. Slowly rotate the reel in reverse direction, listen-
ing for reel-to-bedknife contact. If no contact is
evident, turn the bedknife adjusting knob clock-
wise, one click at a time, until light contact is
felt and heard.
3. If excessive contact is felt, turn the bedknife
adjusting knob counterclockwise, one click at a
time until no contact is evident. Then turn the
bedknife adjusting knob one click at a time
clockwise,until light contact is felt and heard.
IMPORTANT: Light contact is preferred at all
times. If light contact is not maintained, bedknife /
reel edges will not sufficiently self-sharpen and
dull cutting edges will result after a period of oper-
ation. If excessive contact is maintained, bed-
knife/reel wear will accelerate, uneven wear can
result, and quality of cut may be adversely affect-
ed.
Note: As the reel blades continue to run against the
bedknife, a slight burr will appear on the front cutting
edge surface the full length of the bedknife. Running
a file across the front edge to remove this burr will
improve cutting.
After extended running, a ridge will eventually devel-
op at both ends of the bedknife. These notches must
be rounded off or filed flush with the cutting edge of
the bedknife to assure smooth operation.
6

1. Position the machine on a clean, level surface,
lower the cutting units, stop the engine, engage
the parking brake and remove the key from the
ignition switch.
2. Remove the reel motors from the cutting units
and disconnect and remove the cutting units
from the lift arms.
3. Connect the backlapping machine to the cutting
unit by inserting a piece of 9mm square stock
into the splined coupling at the right end of the
cutting unit.
Note: Additional instructions and procedures on
backlapping are available in the TORO Sharpening
Reel & Rotary Mowers Manual Form No. 80-300PT.
Note: For a better cutting edge, run a file across the
front face of the bedknife after completing the lap-
ping operation. This will remove any burrs or rough
edges that may have built up on the cutting edge.
7
Greasing Bearings and
Bushings
Each cutting unit has (7) grease fittings that must be
lubricated regularly with No. 2 general purpose lithi-
um-base grease.
1. The grease fitting locations and quantities are:
Reel bearings (2) and front and rear rollers (2
ea.) (Fig. 5).
IMPORTANT: Lubricating the cutting units
immediately after washing helps purge water
from the bearings and increases bearing life.
2. Wipe each grease fitting with a clean cloth
3. Apply grease until pressure is felt against the
handle.
IMPORTANT: Do not apply too much pres-
sure or grease seals will be permanently dam-
aged.
4. Wipe away excess grease.
Figure 5
Backlapping the Cutting Units
Lubrication
Be careful when lapping the reel because contact
with the reel or other moving parts can result in
personal injury.
CAUTION