Rotary Mower
Basics
PART NO. 09167SL
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Rotary Mowers
1
Table of Contents
Historical Background......................................................................................................2
Theory of Operation.........................................................................................................4
Cutting Action ..................................................................................................................6
Equipment Application.....................................................................................................8
Importance of the Operator ...........................................................................................10
Productive Equipment Operation...................................................................................11
Cutting Unit Adjustments...............................................................................................15
Inspection Maintenance and Repairs ............................................................................16
Rotary Blade Inspection and Sharpening ......................................................................20
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Rotary Mowers
Historical Background
The first practical concept of a rotary type mower
goes back to the 1930's. The concept evolved from
the need for a grass maintenance tool that could cut
long grass acceptably without the cost and
sophistication of a reel mower.
During the 1940's improvements in engines and
material brought about increased use of rotaries but
it wasn't until after World War II that their use
became a common sight.
During the 1960's the bagging concept evolved and
rotary designs incorporated multi- blade
configurations useful for cutting large commercial
type areas.
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Improvements in engines and drive systems have
resulted in the very effective commercial type rotary
mowers that are presently available.
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Rotary Mowers
Theory of Operation
Blade mounting
and drive system
Blade
Deck housing
There are three basic structural members to a rotary cutting unit.
Cutter Deck Housing
The deck housing supports the blade hubs with their drive mechanism and is shaped to carry the cut grass
clippings away from the deck in an effective manner.
Blade mounting and drive system
The blade is normally driven directly by the engine crankshaft, a hydraulic motor or through a belt pulley
system to each blade hub.
The blade
The blade has a sharpened cutting edge at each end with a curved up sail area to create an air flow. This air
flow will whip the grass blades exposing them to the blade cutting edge. The air flow also assists in carrying
the cut grass blades out the discharge.
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Power transfer from the engine to the blades is
typically done by way of belts and transfer shafts.
Belt drives typically transfer a high percentage of
the available horsepower to the blade and generally
produce much less noise than hydraulic drive
systems.
Blade spindle assembly
Solid Cold Finished
Steel Spindle Shaft
Large diameter shaft is
resistant to torsion and
bending failure
Large Diameter
Ductile Cast Iron
Spindle Support
Ductile cast iron,
stronger than
aluminum or
regular cast iron
Timken® Tapered
Roller Bearings
Support spindle
shaft better than
ball bearings
Blade Retainer &
Anti-Scalp Cup
50% more load
carrying capacity
than ball bearings
Eliminates blade
slippage and protects
turf from damage
The deck spindles usually run at approximately 2000 to 2500 RPM. They feature tapered roller bearing for
impact resistance and durability. The bearings can be greased, and if done properly can ensure long life
while also purging contaminates from the assembly.
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Rotary Mowers
Cutting Action
A rotary mower cuts grass by impacting the blade
cutting edge against the grass blades at a very high
velocity. This cutting action requires that the blade
cutting edge is sharp and rotating at an adequate
speed.
Three types of cutting decks are shown here; a
recycler deck, side discharge and contour deck.
Cutting action
From left to right. Low sail, high sail, medium sail,
recycler sail, and atomic mulching blade. Higher
sails, generate higher lift within the cutting chamber.
The type of blade utilized, depends on cutting deck
design and turf conditions.
Cutting Blade Design
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To understand rotary cutting theory you must
understand the concept of clip.
Rotary mower clip
Clip can be defined as the forward distance traveled
by the cutting unit during one revolution of the blade.
This distance is divided by the number of blade tips
to arrive at the clip dimension. The dotted lines
represent the cut path by the previous blade tip.
Although the blade cutting edge may be 3" - 4" long
the very tip is the primary contact point with the grass
blades on each pass.
The remaining portion of the cutting edge will tend to
cut off the stragglers from the previous blade pass.
The blade tips are normally lower than the rest of the
blade to avoid any drag on the turf absorbing rotating
horsepower and damaging the grass.
Factors which affect clip:
•
•
Blade speed
Ground speed
Three basic requirements for acceptable
performance:
Requirements for
acceptable performance
The blade must be straight with sharp cutting edges.
The blade must have the proper attitude in relation to
the ground surface.
The blade must rotate at the proper speed with an
accommodating ground speed to get an acceptable
clip.
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Rotary Mowers
Equipment Application
Rotary mowing equipment is designed for a specific application. The misapplication of rotary mowing
equipment can only result in abuse, poor qualities of cut and costly downtime. The following application
factors will affect the equipment requirements.
Type of Grass to be cut
Turf areas
Most types of grass can be cut with a rotary mower.
maintained with
Rotary mowers are generally used for cutting semi-
rotary mowers
formal and rough turf areas at heights of cut 2-inches
and above.
Due to the rotary mower having the capacity to cut
off greater lengths of grass than a reel type, the less
frequent cuttings with a rotary can result in grass
damage due to the excessive length of the grass that
is removed. It is best to cut only about 1/3 of the
grass blade. Cutting more than that is not
recommended unless grass is sparse, or it is late fall
when grass grows more slowly.
Type of Terrain
The type of terrain that would limit a reel mower's
performance would generally apply to rotary mowers
also. Rough and bumpy turf can be cut acceptably
with a rotary due to it’s wider individual width not
being affected by the bumps as readily as a reel
type.
Rotary mowers can be more prone to scalping than
reel type mowers. The shorter individual reel cutting
units conform to uneven terrain better than the wider
Type of terrain
rigid individual rotary cutting unit. Contour rotary
mowers with multiple independent cutting decks are
better able to deliver good after cut appearance in
these conditions.
If there are numerous trees and obstacles,
maneuverability and trimability are a prime
importance. Hilly terrain requires a high degree of
stability and traction.
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Capabilities and limitations
Capabilities and
limitations
Rotary mowers will not give the manicured cut
appearance of a reel mower, but will give an
acceptable appearance in more varied and adverse
conditions.
Rotary mowers are capable of cutting much higher
grass than reel mowers. When an excessive amount
of grass is removed, the cut appearance can become
unsightly due to the discharged grass building up in
clumps and ridges. If the grass is allowed to grow
longer than normal, or if it contains a high degree of
moisture, raise the cutting height higher than usual
and cut the grass at this setting. Then, cut the grass
again using the lower, normal setting.
The tolerances within a rotary cutting unit are not
nearly as critical as a reel type cutting unit.
Therefore, a rotary mower can withstand more abuse
than a reel type and maintain an acceptable quality
of cut.
Mower abuse
and quality of cut
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Rotary Mowers
The Importance of the Operator
and Equipment Manager
The large investment in specialized cutting
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
product. All too frequently this procedure is not
followed, with the end result being costly repairs,
down time and a decrease in equipment life. Cost for
these types of repairs far exceeds the cost expanded
in training and familiarization of the operator.
A supervisor should play a key role in establishing
the proper attitude and behavior patterns towards
operating turf equipment. A supervisor should not
create the impression that a few minutes orientation
on a piece of equipment will qualify the operator.
Importance of
the supervisor
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Productive Equipment Operation
Experience has shown that a high percentage of the
problems that develop on turf equipment do not
require an overhaul or disassembly type correction.
In many cases a problem has developed over a
period of time and it could have been corrected by
adjustment, lubrication, or similar required
maintenance. This requires that turf equipment be
checked on a regular basis and not operated until a
major breakdown occurs.
The operator and mechanic should make a thorough
visual examination of the product each day to include
listening for any abnormal sounds. Equipments
reliability, effectiveness and maintenance costs are
directly affected by how it is operated.
Visually inspect each
day and listen for
abnormal sounds
The maintenance schedules and owners manuals
should be used for reference to identify specific
areas requiring ongoing maintenance.
Information
Resources
The following operating characteristics on rotary
mowers should be made aware to operators and
practiced during their mowing routines.
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Rotary Mowers
Wheel traction
Wheel traction
and hill climbing
Tire pressure in the traction wheels is critical for
maximum traction capability. Over-inflated tire
pressure can cause spinning and tearing out of the
turf in adverse conditions. if lowering the tire
pressure does not correct or stop a spinning
condition, adding liquid to the tires may be required.
Avoid quick acceleration while operating mowing
equipment because a spinning tire can seriously
damage the turf. Try to maintain a constant speed
while going through turns and climbing hills to avoid
a spin out which would damage the turf.
Engine RPM
The correct engine speed is important for the
effective performance of a rotary cutting unit. Most
professional mowing equipment is designed to
operate at full engine RPM. All engine RPM
information is contained in the owner's manual for
each product. The engine speed should be checked
with a tachometer periodically.
Ground Speed
Ground speed
There are three basic problem areas resulting from
too fast a ground speed. It is unsafe, damaging to the
equipment and will result in a poor quality of cut.
The ground speed of a rotary mower must be limited
to a point that the blade can cut and discharge the
grass effectively while maintaining a good quality of
cut. If the cutting unit is becoming overloaded, the
ground speed must be lowered and/or the cutting
width should be reduced so the engine can regain its
normal operating speed.
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Mowing patterns
It is normally beneficial to cut a given area in a
Mowing patterns
pattern that will allow the grass to re discharged onto
the previously cut grass area. If this is not done, the
horsepower requirement increases due to the blade
having to cut the discharged grass again.
Debris on the Turf
All debris should be removed from areas where
rotary mowing equipment is being used to avoid
serious damage to the cutting unit resulting in costly
repairs and downtime. The operator should be
constantly watching for foreign objects in the turf and
when he sees an object, he should stop the mower
and pick it up.
Pick up debris
before mowing
Noise Level
Noise level and condition of equipment
The noise level of equipment is a good indication of
its condition. The operator and mechanic should
continually be aware of changes in noise levels as an
indication of a problem developing.
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Rotary Mowers
Transporting mowing equipment
Transporting mowing equipment requires discipline
and knowledge to reduce downtime and increase
equipment life. Operating the equipment in an
abusive manner while transporting can only reduce
its mowing efficiency.
Transporting
mowing equipment
Safety
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 think and be aware
in their every day work habits.
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Cutting Unit Adjustments
Height of cut adjustment and attitude
Height of cut and attitude
The height of cut is usually set by the placement of
spacers on the castor wheel shafts or with the height
of the rollers on contour type cutting units. The
effective height of cut can be checked on the turf.
This can be accomplished by inserting a narrow ruler
down into the turf.
Rotary cutting units are normally 1/8" - 1/4" lower at
the front than in the back. This attitude or slope of the
deck cuts down the horsepower requirement to turn
the blades due to the blade only cutting on for the
forward 180° of it’s rotation. If the deck has multi-
blades and this attitude is too far down at the front
the center will cut lower than the sides due to the
center blade being farther forward.
The attitude can be checked by measuring from a flat
surface up to the forward blade tip. Rotate the
forward tip to the rear and take the measurement at
the back. The difference in dimension is the attitude.
If the cutting unit has multi-blades, the blade tips
should be checked for height to see that they are all
at the same level to avoid mismatch. This can be
accomplished by pointing all the blade tips forward,
measuring up from a flat surface to each blade tip.
Different height readings could be caused by:
Consistent blade height
Bent or warped blades.
Bent blade spindles.
Height of cut adjustment different on each side.
The attitude or slope of the cutting unit deck being
incorrect.
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Rotary Mowers
Inspection Maintenance and Repairs
The efficiency of a rotary cutting unit is directly
related to the air flow within the deck.
Cutting efficiency and air flow
The underside of the cutting deck should be
examined periodically. The air flow is significantly
affected if the deck is not cleaned out periodically.
Inspect and
clean out
periodically to
maintain air flow
It is very important that the blade retainer nut/bolt be
properly tightened.
If the retainer is not tight enough, the blade may
loosen during operation. If the retainer is too tight,
thread damage may occur and compromise the
integrity of the fastener.
Blade Removal and Installation
Impact gun -
blade removal
only!
Start bolt by
hand and
properly torque.
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The deck spindles usually run at approximately 2000
to 2500 RPM. They feature tapered roller bearing for
impact resistance and durability. The spindles can
be disassembled and repaired, or a complete
assembly may be installed.
Spindle assembly
Pulley
Matched
Bearing Set
The spindle assemblies should be greased as part of
a regularly scheduled maintenance program. If done
properly this will ensure long life while also purging
contaminates from the assembly.
Housing
Shaft
The Spindle Housing.
Spacer and
Seal Surface
This component is usually reused when a spindle is
rebuilt unless it was damaged when the spindle
failed.
The Shaft
Running up through the center of the housing is the
shaft. This is the component that runs in the
bearings and the blade is fastened to it. This
component can usually be reused also unless it was
damaged during the failure or is possibly bent by the
blade contacting something. Before reassembling
the spindle assembly, the shaft should be checked to
see if it is bent, the areas on the shaft where the
bearing run needs to be examined, as well as any
areas where seals contact the shaft.
Matched Bearing Set
The matched bearing set includes the bearing races,
bearing cones (Roller bearings) and a set of spacers.
This must be replaced in a set.
Seals
The spindle assembly also includes two seals. The
orientation of these seals is also important to the
overall performance and longevity of the spindle
assembly.
Greasing a bearing after every use and after any
washing not only lubricates, but purges water which
is responsible for the majority of bearing failures on
this type of equipment.
Castor Wheels, Rollers, Lift Arms
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Rotary Mowers
Periodically inspect drive belts and pulleys. A good
time to do this is after cleaning the machine.
Inspecting drive belts and pulleys
•
•
•
•
Oil or grease contamination
Debris in pulleys
Damaged or rusted pulleys
Proper installation and tensioning
• Oil or grease
contamination
• Debris in pulleys
• Damaged or rusted
pulleys
• Proper installation
and tensioning
The most common causes of belt failures:
Drive belt failures
•
•
•
•
Alignment
Contamination
Loading
Installation Issues
Alignment refers to the alignment of one pulley in
relationship to the other. If this alignment is not
correct the belt may show excessive wear to one of
both sides of the belt. Some of the cords in the belt
may be broken or the belt may actually flip over.
Contamination refers to some other substance
coming in contact with the belt. This may be oil,
grease or other some other foreign object.
Drive belt failures
Loading refers to excessive loads or shock loading
the drive system.
The last one is installation issues. The belt is
actually damaged during installation.
By inspecting the failed belt the user can get a good
idea as to the cause of the belt failure and can
correct it when the new belt is installed.
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Rotary Mowers
Belt noise
19
A belt chirp is a small chirp or squeak that happens
during start-up of an implement. It is caused by
normal slippage an is completely normal. Never
instruct the customer to use belt dressing to prevent
chirps or squeaks. Do not recommend belt dressing
actually for any belt problem. Belt dressing is only a
band-aid and not a fix.
Chirp
Belt Chirp
•
•
•
•
•
Chirp occurs on all types of belts.
Caused by momentary slippage.
Dust can be a contributing factor.
Never apply belt dressing.
Chirps or squeaks will not harm
belts.
hirp
A belt squeal occurs during rapid shaft acceleration
or it can also occur under heavy load conditions. It is
usually caused by insufficient tension. A squealing
belt requires prompt attention because as the belt
squeals an extremely large amount of heat is
generated on the pulley. This heat will very rapidly
damage the belt and the pulley.
Belt Squeal
•
•
•
Occurs during shaft acceleration.
Result of insufficient Tension.
Requires prompt attention.
There are a few operational problems that the
customer may notice. These include, belt squeal, a
belt chirp or squeak, and vibrations or whipping.
Whipping or vibrations are usually caused by
insufficient belt tension. The belt is too loose and it
will vary it’s position in the pulley groove. To address
this problem adjust the belt according to the
manufacturers guidelines. If this situation is not
addressed, the belt and/or surrounding components
may be damaged.
Belt vibration or whipping
If you ever experiences a belt that flips or turns over
on the pulley, the belt must be replaced. As the belt
flips the cords in the belt will be stretched and the
belt will not want to run true again. The belt will
continuously turn over after that.
Belt turnover
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Rotary Mowers
Rotary Blade Inspection and Sharpening
To assure a quality of cut. The cutting edge of the
blade must be kept in a sharp condition. A dull blade
will produce a ragged cut and will require an
excessive amount of engine horsepower to rotate the
blade.
Inspect
the blades
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The most common causes for rotary mowers not
giving a good quality of cut are due to dull cutting
edges and/or bent blades.
Caution: Check cutter blade daily or before mower is
used or stored and whenever mower is serviced. If
bolt holding blade is loose, tighten it before using
mower.
If the blade is bent, the blade should be replaced. A
bent blade will cause two problems. The most
noticeable problem a increase in horsepower that is
required to operate the mower. This is caused by the
fact that when the grass is cut the at the outer edge
of the blade it is higher then the next area of the
blade. The grass is then cut again and again until
the height is the same as the lowest cutting edge.
The same grass blade could be cut several times.
This can take a considerable amount of power to
repeatedly cut the same grass blade.
The other problem is that this will adversely affect the
quality of cut. In this scenario, a very small amount of
grass is cut from the grass blade frequently. This
can cause the top of the grass blade to fray and it
leaves the grass blade with a unhealthy cut edge.
This will usually show up as a brown die-back from
the top of the grass blade.
In this situation the blade should be replaced.
NEVER straighten a Bent Blade as this could
weaken the blade and cause the blade to break.
Carefully examine cutting ends of blade, especially
where the flat and sail parts of the blade meet. When
mowing in dry or sandy areas, sand and abrasive
material can wear away the metal that joins the sail
and flat part of the blade. For safety, it is important
that when any wear is noticed, the blade must be
replaced. If the condition is not corrected and wear
continues, a slot will form. Eventually a piece of the
sail may break off and be thrown from under the
housing, possibly resulting in serious injury to
yourself or bystander.
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Rotary Mowers
When discussing rotary blades, keep in mind that
OEM blades are designed specifically to perform on
the intended deck. They have been thoroughly
tested to insure that they are hard enough to provide
the desired life, but not to hard as to be brittle and
risk breakage in the event that they contact a foreign
object. The are specifically designed to insure that a
foreign object that is hit by the blade is not expelled
from the deck in a unsafe manner.
OEM Blades
• Specifically designed for the intended deck.
• Meets all of the required tests.
– Hardness
– Object expulsion
• Meets the mowing and quality demands.
• Life expectancy.
The blades are also designed to insure the best
quality of cut and clippings dispersion from the deck.
The blade sail angle and height is specifically
designed to insure that the mower performs up to the
desired level.
And lastly, while the cost may be slightly higher in
some instances, the increased life expectancy,
coupled with all of the work that has gone into the
safety design of the blade makes original OEM
blades avalue.
Keep the blade cutting edges as sharp as possible. It
is important that the sharpening process be done
correctly. The four items that must be checked if a
blade is removed for sharpening are:
The blade must be checked to assure that it is not
bent and has the correct attitude in relation to the
housing and ground surface.
The blade must be sharpened in the correct manner.
The blade balance must be checked each time the
blade is reground.
It is very important that the blade retaining nut be
sufficiently tightened to assure that it will not loosen
during operation.
Typical Rotary Blade
Cutting Edge
Prior to sharpening the blade, it should be checked
for straightness. This can be checked by laying the
blade on a flat surface.
Caution:
Do not try to straighten a blade that is bent, and
never weld a broken or cracked blade. Always use a
new TORO blade to assure continued safety
certification of the product.
Grind the top surface of the blade only, trying to
maintain the original cutting edge angle. Do not grind
the bottom surface or a chisel shape will be the
result.
The lowest portion on the blade that contacts the
grass must be the cutting edge or the grass will not
be cleanly cut and excessive horsepower will be
needed.
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After the blade has been sharpened the balance
must be checked. This can best be accomplished
using a commercial balancer. An unbalanced blade
causes vibration damaging to adjoining parts.
Check blade balance
Warning: Always wear face shield or safety glasses
when grinding or sharpening is being done.
WARNING !
Always wear a face shield or safety
glasses when grinding or
sharpening.
Turf mowing equipment has unique characteristics
giving it the capability to maintain turf in a well
groomed manner.
Understanding and reacting to these characteristics
will significantly affect the equipments operating
costs, downtime and productivity.
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Rotary Mowers
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