Toro GR 105 User manual

Commercial Products
Fundamentals of
Reel Mowers
PART NO. 98008SL, Rev. B

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Fundamentals of Reel Mowers 1
TOROService Training
Table of Contents
Historical Background .....................................................................................................2
Theory of Operation........................................................................................................4
Importance of the Operator.............................................................................................8
Preventive Maintenance..................................................................................................9
Set-up and Adjustments................................................................................................ 11
Sharpening....................................................................................................................17

2Fundamentals of Reel Mowers
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Historical Background
The concept of the reel mower goes back to
the 1800’s. It evolved out of a need for
groomed turf areas being maintained on a
regular basis.
Golf course development during the 1920’s
and 30’s brought about design improvements
in engines and mower drive systems.
These improvements continued, allowing for
lighter weight and easier to use equipment.

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The development of hydraulics during the 50's
and 60's improved the reliability, safety,
operator comfort and lowered maintenance
costs.
Although dramatic improvements have been
made in reel type mowers, some of the same
frustrations that developed working with reel
cutting units years ago are still present today.
If reel mowers unique characteristics are not
understood and responded to, the end result
will be a poor quality of cut and expensive
down time and repairs.

4Fundamentals of Reel Mowers
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Theory of Operation
There are three main structural members in a
reel cutting unit:
The REEL consists of varying numbers of helix
shaped blades attached to support spiders
which are mounted on a rotating shaft.
The BEDKNIFE is attached to the bedbar and
the assembly is mounted to the main frame in
a manner that allows for paralleling and
adjustment to the reel.
The FRAME supports the rollers, the bedbar
assembly and reel with it’s drive mechanism,
which can be hydraulic, belt driven or ground
driven.
A reel mower cuts grass with a scissors-like
shearing action as the moving helix shaped
blades pass over the stationary bedknife. The
cutting action requires that the bedknife and
reel blades be sharp, matched, and in close
relationship with each other.
When properly maintained and operated, reel
mowers provide superior quality of cut. It
cannot be overstated that reel mowers are
precision tools. It is essential that they be
adjusted and operated with this in mind.
Reel Mower Clip
To understand reel cutting theory, you must understand the concept of clip and the shear point. A shear
point is any single point of contact made between the reel blade and bedknife.
Clip is the forward distance traveled between
successive blade contacts at one shear point.

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Factors Affecting Clip
•The diameter of the reel
•The number of reel blades
•The speed of the reel
•The ground speed.
By following the blade path through two “clips”
as the machine moves forward we can
illustrate the actual process of cutting grass.
The bedknife pushes grass toward the shear
point while the reel blade gathers it in front.
Each blade path has one-half clip in which to
cut all the grass
Note that the grass outside of the forward half
clip is not easily gathered. The general rule of
thumb concerning height of cut vs. clip is that
both measurements should be within 20% of
each other. The best results will be obtained
when height of cut is equal to or close to the
clip.
Grass extending beyond the forward half clip,
yet tall enough to be within the blade path is
less likely to be cut. Reel blades may contact
the grass in this area several times prior to the
actual gathering of the grass. This is the so
called “fanning” process. This process is more
a mechanical striking of the grass that it is of
the commonly thought effect of a blowing
action.

6Fundamentals of Reel Mowers
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This is an extreme case corrugation. Because
of an imbalance between height of cut and
clip, the grass is cut with extreme valleys and
peaks.
NOTE: If you change equipment or height of
cut you may notice some corrugation after the
first mowing. This will go away after the grass
is maintained at the new height of cut over a
period of time.
The importance of the bedknife front angle is
visible from the side view. Note that the proper
angle allows the grass behind the bedknife
front edge to be more effectively cut.
A front view illustrates the angle between the
bedknife and the reel blade which is called the
helix angle.

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Another term known as “the cutting path” is the
result of the helix angle and the forward motion
of the cutting unit. The shear point moves
down the bedknife as the bedknife moves
forward. The grass is physically cut at an angle
to the bedknife.
Cross section of turf cut at various heights
1/2” 1” 1-1/2” 2”
Other factors which affect reel mowing are the
grass density and the grass acclimation or
grain. Grass tends to thicken at the normal
maintained height of cut. The denser the
grass, the easier it is for the bedknife and reel
to gather it. Grass density and grain can often
override other factors we have discussed
regarding the cutting action.
The basic requirements for good performance
of reel mowers are:
•The cutting edges on the reel blades
and bedknife must be straight and
sharp.
•The bedknife must be exactly parallel
with the reel.
•The bedknife should be positioned
against the reel with light contact.
These requirements will be discussed in more
detail later.

8Fundamentals of Reel Mowers
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Importance of the Operator
The Operator has a significant influence on the quality of cut that a reel mower can deliver.
The large investment in specialized mowing
equipment cannot be jeopardized by
unqualified operators. Before an operator can
be considered qualified to operate a piece of
equipment, there should be a significant effort
by the supervisor towards their training and
familiarization with each piece of equipment.
Make sure the operator reads and
understands the Operator’s Manual. Have the
operator watch the Operator Training Video,
then explain any unique methods or
procedures used on your grounds.
A supervisor should play a key role in
establishing the proper attitude and behavior
patterns toward operating turf equipment. A
supervisor should not create the impression
that a few minutes orientation on a piece of
equipment will qualify the operator.
Operators and service technicians play a
significant role in determining quality of cut,
down time, and life of mowing equipment.
Make a commitment to train and familiarize
staff with each product. Remember, that each
type of mowing equipment will have specific
operating characteristics, and noise qualities.
Operators should become familiar with the
product and listen for any unusual changes.
Concerns should be reported to the service
technician before significant problems develop.

Fundamentals of Reel Mowers 9
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Preventive Maintenance
To get the most out of your equipment investment, it is important to have a good preventive maintenance
program.
Doing scheduled maintenance and
adjustments will prolong the life of your
equipment, help prevent expensive downtime,
and give the best possible quality of cut and
performance. Experience has shown that a
high percentage of problems that occur in turf
equipment have developed over a period of
time and could have been prevented by
adjustment, lubrication, or other required
maintenance.
Follow the maintenance and adjustment
recommendations listed in the Operator’s
Manual. Some products may also have a
Quick Reference maintenance decal on the
machine. Recommended maintenance
intervals should be considered minimum
requirements. If the equipment is operated in
particularly harsh conditions, such as very hot
weather, during the “grow in” period after
construction, or on topdressed greens, these
procedures may have to be performed more
often.
Use original Toro parts when doing
maintenance or repairs. These parts have
been tested and designed for this specific,
very demanding, application. “Will fit” parts
may look the same and fit, but they can give
totally different performance. Don’t take a risk
on your important equipment investment by
saving a little money now that can cost you
expensive repairs or increased maintenance
intervals later.

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The operator and service technician should
make a thorough visual examination of the
product each day. This can identify oil leaks,
low oil levels, loose or bent components and
abnormal noises.
The maintenance charts and Operator’s
Manuals should be used for reference to
identify specific areas requiring ongoing
scheduled maintenance. Service Manuals and
Training Guides are also available for many
models.
Information about Service Education Materials,
Maintenance Schedules, Service Bulletins and
more is also available on the Internet at:
www.toro.com/golf/custsvc.html
Keep Thinking and Be Aware !
Mowing equipment is designed for a specific application and should be operated keeping those
restrictions in mind. Accidents and personal injuries can be minimized if persons will keep thinking and
be aware in their every day work habits.

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Set-up and Adjustments
Reel mower performance depends on proper set–up and adjustment procedures. An error of .010 inch or
.25 mm, in height end–to–end, or from one cutting unit to another, is visible as a mismatch on many golf
course greens. Although there are design variations in cutting units, most require the same basic
procedures. A surface plate, accurate height of cut tools and proper instruction are essential for setting up
a cutting unit.
Factors that affect quality of cut
•Tire pressure
•Engine governed speed
•Reel bearing
condition/adjustment
•Reel and bedknife
sharpness
•Bedknife parallel to reel
•Bedknife to reel contact
•Bedknife attitude (angle)
•Roller(s) parallel to reel
•Height of cut (bench set
vs. actual)
•Correct bedknife
•Cutting unit alignment
and ground following
•Roller and roller bearing
condition
•Reel speed
•Traction speed
•Cutting unit drop speed
and sequence
•Cutting unit
counterbalance or down
pressure setting
There are many factors that can affect quality
of cut, including condition of the mowing
equipment and agronomic factors. Turf
conditions such as excessive thatch,
“sponginess” or attempting to cut off too much
grass height may not always be overcome by
adjusting the machine. It is important to
remember that the lower the height of cut, the
more critical these factors are.
Remember that the “effective” or actual height
of cut depends on cutting unit weight, cutting
unit accessories and turf conditions. Effective
height of cut will be different than the bench
set height of cut.
Effective height of cut is the actual height the
grass has been cut. Making an accurate height
measurement on the turf is difficult due to
many variables. A true base is simply not
present. If the surface is uneven, spongy or
varies in density, color variations in the turf
may appear in the form of a streak. This is due
to the effective height of cut being too low for
the existing turf conditions. To correct
problems, start or change a cultural practice,
change cutting unit configuration or raise the
bench set height of cut. The lower your height
of cut, the more predictable and smooth the
turf surface must be.
To accurately maintain height of cut and performance, routinely check the following components:
•Reel Bearings
•Bedknife to Reel Adjustment
•Attitude Adjustment
•Roller Parallelism
•Height of Cut

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Check reel bearings for play and roughness.
Replace if necessary. If adjustable (tapered
roller bearing), adjust to “no“ lash while
maintaining free rotation of the reel.
Before performing any set–up procedures, it is
critical that the reel and knife cutting edges are
straight and sharp. Lap or grind as necessary.
Adjust as needed to ensure the knife and reel
contact their full length with LIGHT contact and
free reel rotation.
Note that different cutting unit models have
different methods of adjusting reel to bedknife
contact. The top illustration shows a four bolt
style adjustment mechanism. The bottom
illustration shows a single point adjustment
mechanism.
Single point adjust cutting units also have an
adjustment mechanism on one end of the
bedknife for adjusting the bedknife parallel to
the reel (not shown). This bedknife leveling
mechanism could may be an eccentric pivot
bolt on one end of the bedbar, or a capscrew /
jam nut assembly.

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Adjust the bedknife against the reel to
EVENLY pinch one paper thickness across the
entire width of the bedknife, then cut paper
strips to check blade sharpness. Put the
cutting unit on the turf and check for light
bedknife to reel contact and free reel rotation.
Do a final adjustment of bedknife to reel
contact if necessary.
Properly adjusting the bedknife to the reel is
one of the most effective preventive
maintenance practices for reel mowers. The
amount of contact and how frequently it is
checked are major factors in performance. A
light contact adjustment, if maintained, will
help keep cutting edges sharp on the reel and
bedknife. This requires that the adjustment be
checked frequently at a predetermined time
interval. Dulled cutting edges cannot be
corrected immediately by adjustment or over–
tightening.
Do not wait until the quality of cut has
deteriorated to check the bedknife to reel
adjustment. If the cutting edges on the reel
blades and bedknife are not straight and sharp
the mowing results may not be acceptable.
This is true even if all other set–up procedures
are correct.

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The cutting unit attitude is the angle between
the bottom of the bedknife and the ground
plane under the cutting unit. As the bedknife
attitude is changed, it is important to note that
the reel to bedknife shear point changes
relative to the center line of the reel. This can
change the after cut appearance of the grass.
The result may be better or worse depending
on several factors.
Bedknife attitude is adjusted by changing the
height of the front, rear, or both rollers. A
height of cut change is NOT necessarily part of
a change to the bedknife attitude. A large
angle is also referred to as an aggressive
bedknife attitude. A small angle (flat attitude)
can have most or all of the bedknife riding ON
the turf. This can influence after cut
appearance.
It will normally be an advantage to have the
front or the cutting edge of the bedknife lower
than the back. This help prevent the bedbar
from contacting the ground surface in very low
heights of cut. It will also prevent the streaking
or ruffling of the turf after it has been cut and
passed over by the bedbar.
There is a limit on how much of a forward
angle the bedbar can be positioned to. If the
rear is positioned too high the reel position can
become lower than the cutting edge, tearing
the grass and giving a poor quality of cut.
To achieve an acceptable quality of cut the
rollers must be parallel to the reel. Before
adjusting roller parallelism, check for loose
roller bearings. Adjust or replace the bearings
as necessary. First parallel the front or rear
roller, which ever is NOT used for setting the
height of cut. This paralleling roller is set to
match the reel using a surface plate fixture.
With the reel blades resting on a raised bar on
the plate, use a piece of paper as a feeler
gauge along the bottom of the roller between
the roller and plate.

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Set the height of cut to the desired height
using an accurate tool. This procedure must
be done exactly the same on each cutting unit.
Before doing this adjustment the bedknife and
roller not used for height of cut adjustment
must be parallel to the reel as described on
previous slides.
As reel cutting unit design and configuration
continue to evolve, height of cut settings may
need modifying to retain visual and playability
goals.
Remember, the setting you are making here,
the “bench set height of cut”, is different from
the effective or actual height of cut in the turf.
There are some basic patterns that can
appear on turf maintained with a reel mower.
The first pattern illustrates good adjustment
procedures and properly maintained cutting
edges.
The second pattern shows many stragglers.
This can be caused by:
•Incorrect bedknife to reel adjustment
•Dull cutting edges
•Mowing outside of the optimum clip
rate
•Not using preparation devices
•Inconsistent turf texture and density
•Using the wrong type of roller

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The third pattern illustrates a single streak.
This can be caused by:
•Rifled or uneven wear on bedknife
•Damaged area on bedknife from
hitting an object(s)
•Loose bedknife screws
•Bent reel blade
The fourth pattern shows multiple streaks. This
can be caused by heavy contact between the
bedknife and reel, resulting in a “rifled” or wavy
bedknife.
It is normal for the mower to leave after–cut
directional light and dark color paths. These
overall color paths are due to the turf being
rolled down in the direction the mower is
traveling. A cut path going away from you will
usually be lighter in color than the path coming
toward you. Smaller, individual color variations
can be due to differing turf types, density
variations and straight line mower marks. A
spongy area is evident by the momentary
impression left by feet on the surface.
Many turf discrepancies are subtle and require
closer examination. In these instances, the
TurfEvaluator grass viewing tool is helpful. It
can assist turf managers in determining
causes for poor reel mower performance and
comparing the effective height of cut of one
mowed surface to another.
Turf Evaluator Tool -Model 04399
Guide to Evaluating Reel Mower
Performance and Using the
Turf Evaluator -Part. No. 97931SL

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Sharpening
How can you tell if sharpening is necessary?
•The grass is not cut cleanly
•Streaks.
•Stragglers.
•The cutting unit is noisy.
•“Its that time of year”.
One sure way to determine the answer to this is by actually checking the cutting edges of the reel and
bedknife to see if they are dull, nicked, bent or being run without light contact against one another.
Cutting units should be kept as sharp as
possible to:
•Promote growth of healthy grass.
•Optimize cutting unit performance.
•Extend the life of the mower.
•Maximize operator mowing time.
•Allow the tractor to run most efficiently.
•Provide excellent finished appearance
of the turf.
A grooved or wavy (rifled) reel or bedknife is
most often caused by operating the cutting unit
with heavy bedknife to reel contact. This
condition can only be corrected by grinding the
reel and bedknife –BACKLAPPING WILL
NOT CORRECT THIS CONDITION.

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Reel blades, and the edge of the bedknife
should be checked for damage visually and by
carefully feeling the edges. Of course, this
should only be done when it is certain that the
reel cannot be started, and never slide your
fingers down the edges lengthwise.
Rounded edges on the reel blades and
bedknife will cause the grass blades to be
pinched and torn, rather than sheared off
cleanly. When light contact is not maintained,
dull edges will soon result.
Sharpening will also be required if the reel is
“cone shaped” (tapered). All reels eventually
become tapered with use. If the reel is not
adjusted or ground to a cylinder shape again, a
mismatch in the height cut between adjacent
reels can result.
Sharpening Methods
•Maintain proper ADJUSTMENT
•BACKLAP the bedknife and reel
•GRIND the reel and bedknife
There are several methods that may be used
to sharpen a cutting unit. The one that you
choose will depend upon the condition of the
cutting unit. It should also make the most
sense for the anticipated use. For example, if
you are about to mow greens that have been
core aerated or topdressed, you may not want
to grind the reels and install new bedknives.
As the reel blades run against the bedknife a
slight burr will appear at the front cutting edge
surface the full length of the bedknife.
Occasionally run a file or facing grinder across
the front edge to remove this burr to extend
the cutting performance of the machine.
Lapping must be done after single blade
grinding. This is done to establish a “land area”
and to insure a perfect match between the
bedknife and the reel edge.
Lapping is not intended to be a reconditioning
process to correct severely nicked or rounded
blades, rifling or taper. If, after 5 minutes of
lapping, the edge is not restored, it is time to
grind the reel.