Reel Mower
Basics
PART NO. 09168SL
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Reel Mowers
1
Table of Contents
Historical Background......................................................................................................2
Application.......................................................................................................................6
Theory .............................................................................................................................8
Importance of the Operator ...........................................................................................18
Preventive Maintenance................................................................................................19
Set-up and Adjustments ................................................................................................21
Quality of Cut and Aftercut Appearance ........................................................................30
Sharpening....................................................................................................................34
Bedknives, Rollers and Accessories..............................................................................47
Groomers and Thatchers...............................................................................................52
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Reel Mowers
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.
The first reel type fairway gang mowers were horse
drawn.
Here is an example of a horse drawn three gang
fairway mower.
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The first tractor drawn gang mower. (Toro “Bull”
Tractor in 1926).
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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Reel Mowers
Productivity and quality of cut improved.
The development of hydraulics during the 50's and
60's improved the reliability, safety, operator comfort
and lowered maintenance costs.
With the introduction of the riding greens mower, the
industry reached new heights in the areas of
productivity and efficiency.
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The introduction of hydraulically driven cutting units
greatly reduced wheel slippage and the resulting
turf stress.
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.
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Reel Mowers
Application
When properly maintained and operated, reel mowers provide superior quality of cut and aftercut
appearance. These mowers are typically dedicated to mowing formal turf areas at low heights of cut. A triplex
riding greens mower is shown here; a Toro Greensmaster 3150 with DPA (Dual Precision Adjust) cutting
units.
Golf course greens are intensely managed, and
mowed every day, at heights of cut from 1/16 in. –
1/4 in. (2.5 mm – 5 mm).
Applications
Average Height of Cut:
1/16 in. – 1/4 in.
(2.5 mm – 5 mm)
Mowing Frequency:
Daily
Greens
Greensmaster
Tees are typically mowed three times per week, at
heights of cut from 3/8 in. – 1/2 in. (9 mm – 12 mm).
Average Height of Cut:
3/8 in. – 1/2 in.
Tees
(9 mm – 12 mm)
Mowing Frequency:
Three times per week
Reelmaster
Greensmaster
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Fairways are typically mowed three times per week,
at heights of cut, from 3/8 in. – 3/4 in. (9 mm – 19
mm). Other areas, such as intermediate / semi-
roughs and surrounds may also be maintained with
reel mowers.
Average Height of Cut:
3/8 in. – 3/4 in.
(9 mm – 19 mm)
Mowing Frequency:
Three times per week
to daily
Fairway
Reelmaster
Reel mowers are also utilized, for mowing elite
sports fields and other finely manicured turf areas.
Other Applications
• Sports fields
• Other finely manicured
turf areas
Reelmaster
Greensmaster
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Reel Mowers
Theory
This section will describe the construction, and cutting action of a reel mower cutting unit.
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.
reel
frame
rear roller
bedknife
front roller
There are three main structural members in a reel cutting unit:
The REEL, consists of several helix shaped blades, mounted to 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 its 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.
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Construction Details
9
The reel consists of a number of helix shaped
blades, welded to supports and mounted to a shaft.
This weldment is then ground to be a perfect
cylinder.
Reel
Support
(Spider)
Reel Blade
The reel is rotated by a drive system, usually a
hydraulic motor.
Below the reel is the bedbar assembly. The
bedknife is held rigidly in position on the bedbar by
screws.
Shaft
The bedknife is sharpened to be flat and square so
the sharp edge contacts the reel blades across their
entire length.
Bedknife
Bedbar
If the bedknife is not flat, or the reel is not a perfect
cylinder, it is impossible to get the bedknife to
contact along the entire length of the reel.
The reel is supported by precision bearings held
within the side plates.
Construction Details
The side plates are held in place by a frame.
Side Plate
Frame
This becomes the reel assembly, and is a precision
cutting tool.
The reel assembly is supported by rollers, and
pulled along the ground by a carrier frame.
Bedbar Pivot Bolt
Bedbar Assembly
Everything comes together, to make a precision
cutting tool.
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Reel Mowers
Terminology
This drawing depicts the common terms used when referring to a reel mower.
We have already discussed the reel, and the bedknife.
The attitude, refers to the angle of the bedknife. This reference is in degree differential from the surface of
the turf, (or the line intersecting the bottom of the rollers).
The shear point, is the point that a reel blade contacts any given point on the bedknife at a specific point in
time.
The reel centerline, is the imaginary line drawn perpendicular to the turf dissecting the reel at its center.
This line is used to find the Behind Center Distance (BCD), this is the distance the shear point lies behind the
centerline.
There are two rollers. The rear roller trails the cutting unit, and is usually a solid roller. The front roller leads
the cutting unit, and due to the forces working on it may be any one of many types. The different types of
rollers will be discussed later in the program.
The Height of Cut (HOC) defines the distance between the roller plane and the shear point. Some cutting
units have a fixed front roller, and the rear roller is used to set the height of cut. Others, such as the newer
DPA design cutting units, have a fixed rear roller, and the front roller is used to set the height of cut.
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Think of the reel mower cutting action like a
scissors; two blades coming together, with light
contact, to cut the grass. Without sharp reel and
bedknife edges and properly maintained, light
contact, the reel mower will not cut the grass and
give a good quality of cut.
This illustrates the scissors-like cutting action, as
viewed, from turf level, below the cutting unit. Note
how the helix shaped reel blades, move across the
bedknife, to cut the grass.
To understand reel cutting theory, you must
understand the concept of clip and the shear point.
Clip
A shear point is any single point of contact made
between the reel blade and bedknife.
Here we can see the distance between two
successive shear points, one factor that affects the
clip rate.
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Reel Mowers
Clip is the forward distance traveled between successive blade contacts at one shear point.
This is viewed as a single contact point on the bedknife.
As the reel travels forward it pushes the grass in front of it, at the same time the reel blade is gathering the
grass it as it moves toward the bedknife.
The opposing forces working on the grass, bunch the grass together at the shear point creating a triangle.
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.
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• Diameter of reel
• Number of blades
• Speed of reel
Factors that affect the clip rate:
• Ground speed
The ideal situation is when H.O.C. = Clip Rate
If we observe multiple clips we get a series of triangles set side by side.
The top of the triangle represents the individual shear point.
The clip rate is therefore, the distance between the tips of the triangles.
The clip rate is critical to the appearance of the cut. Ideally, the clip rate should equal the height of cut.
Factors that affect the Clip Rate are listed in the illustration.
Generally, the lower the height of cut, the more blades are required, or the reel must rotate at a faster speed
to keep the clip range in sync. A greens mower cutting unit, for example, may be available with 8, 11, or even
14 blade cutting units.
Most cutting units have a preferred operating range and all cutting units can be adjusted beyond that
preferred range. Choose a cutting unit where the intended height of cut is in the middle of the height of cut
range
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Reel Mowers
Here is what the mowing action looks like when the
clip rate is ideal. The bedknife pushes grass
forward, while the reel blade gathers it toward the
bedknife. Optimum clip rate is achieved when the
bedknife and reel blades create small, even
gatherings that are then cut. The result is a small,
unnoticeable clip and an even aftercut appearance.
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If the reel speed is too slow in relation to the ground
speed, there is too much space between cuts,
resulting in visible clip marks and uncut grass.
Visible clip marks in the turf are the result of an
incorrect clip rate.
Clip Marks
NOTE: If you make a large change in height of cut,
you may notice some visible clip marks after the first
mowing. This will go away after the grass is
maintained at this height over a period of time.
If the reel speed is too fast, in relation to ground
speed, the leaves of the grass plants impacted
multiple times before being cut. This can cause leaf
tissue damage, and is detrimental to the long term
health of the turf.
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Reel Mowers
Reel Speed Chart
The speed of the reel can be adjusted on some machines. As we have discussed, it is important that the reel
speed be matched with the number of reel blades and the forward speed of the tractor.
Factors Affecting Performance
Grass density, and grain, can affect reel mower
cutting results. Grass grows denser at lower heights
of cut. The denser the grass, the easier it is for the
reel mower to cut it with good results.
Cross section of turf cut at various heights
3/4”
1/4”
1/2”
1”
(6 mm)
(13 mm)
(19 mm)
(25 mm)
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These are basic requirements for good performance
of reel mowers:
The cutting edges on the reel blades and bedknife
must be straight and sharp.
Requirements for good performance
The bedknife must be exactly parallel with the reel.
And, the bedknife should be positioned against the
reel with light contact.
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.
This illustrates a nice clean cut with all five cutting
units on a fairway mower set-up and adjusted
identically; rollers, bedknife and reel on each cutting
unit, all parallel, bedknife attitude, height of cut, and
bedknife to reel contact, set the same on every
cutting unit.
Here, the cutting units are not set-up the same, or
have different wear patterns between the individual
cutting units. This can cause a mismatched
appearance across the width of the mower.
Reel mower performance depends on proper set-up
and adjustment procedures. An error of .010 inch or
.25 mm, in height of cut, end to end, or from one
cutting unit to another, can be visible in the turf. In
after-cut appearance terms this is known as, miss-
match.
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Reel Mowers
Importance of the Operator
The Operator has a significant influence on the aftercut appearance 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 and take the on-line quiz at
toro.com, Customer Care. You should also take time
to explain the mowing practices used on your
grounds, and have the operator practice with the
equipment in an open area.
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.
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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 top-dressed 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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Reel Mowers
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 from your Toro Distributor for many models.
Information
Resources
Information about Service Education Materials,
Maintenance Schedules, Service Bulletins and more
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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Cutting Unit Setup and Adjustments
The following pages will cover basic requirements for cutting unit set-up and adjustment. Always use the
instructions in the Operator’s Manual or Service Manual when working on a specific model.
Reel mower performance depends on proper set–up, and adjustment procedures. An error of .010 inch or .25
mm in height of cut, end–to–end, or from one cutting unit to another, can be visible as miss-match. 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.
Prior to mowing each day there are several items
that should be checked. There are several more
items that should be checked periodically, according
To Maintain Performance
to the mowing conditions and mowing frequency.
Check Daily
• Bedknife to reel adjustment
• Edge sharpness
• Height of cut
Check Periodically
• Roller condition
• Reel bearings
• Bedknife attitude
• Roller Parallelism
• General mechanical condition
Greasing should also be a part of your daily
maintenance routine. Greaseable bearings should be
Lubrication
greased after every use and after any washing. This
not only lubricates, but purges water, which is
responsible for the majority of bearing failures on this
type of equipment.
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Reel Mowers
Before performing any set–up procedures, it is
critical that the reel and knife cutting edges are
straight, and sharp. Backlap, 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.
Bedknife to Reel
Adjustment
This illustration shows the dual precision adjustment
(DPA) mechanism used on the newer Toro cutting
unit designs. On this Greensmaster DPA cutting unit,
each click of the adjustment screw results in .0007
inch movement of the bedknife; a VERY precise
adjustment. On the Reelmaster DPA cutting unit,
each click results in .0009 inch of movement.
Dual Precision Adjustment (DPA)
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.
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“ Pull, and cut ”:
Parallel, Light Contact and Sharp
When the paper is used as a feeler gauge to set
even contact across the bedknife, it is held parallel to
the bedknife. The reel should pinch with the same
amount of resistance at both ends and the center.
The “feel” of this measurement should be somewhat
the same as pulling the paper between your fingers
while applying moderate pressure with your fingers.
The paper must be held perpendicular to the
bedknife in order to check sharpness by cutting the
paper. If it is not perpendicular it can be pinched
between the reel and the bedknife. This is possible
even if the components are sharp.
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 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.
Don’t wait until
quality of cut
deteriorates
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Attitude and Behind Center
Distance (BCD) of Bedknife
The cutting unit attitude is the angle between the bottom of the bedknife and the surface of the turf 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 is known as the Behind Center Distance (BCD). A change
in the behind center distance can change the after cut appearance of the turf. 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 depending on the design
of the cutting unit. 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 is also referred to as a less
aggressive bedknife attitude.
The front or the cutting edge must be lower than the back. This prevents the bedbar from contacting the
ground surface in low heights of cut. It will also prevent streaking or ruffling of the turf after it has been cut
and passed over by the bedbar.
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This illustrates the bedknife behind center distance
on an actual cutting unit.
BCD:
Greensmaster
DPA Cutting Unit
The bedknife angle and the behind center distance
have a direct correlation.
When one changes the other changes in the same
direction.
Behind Center Distance (BCD) has a
positive correlation to Bedknife Angle
Centerline
0
0
BCD @ 00
As the angle increases to 2 degrees, the behind
center distance has also increased.
Behind Center Distance (BCD) has a
positive correlation to Bedknife Angle
Centerline
20
BCD @ 00
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Reel Mowers
At seven degrees the behind center distance is even
greater.
Increasing the behind center distance results in a
more aggressive blade path.
Behind Center Distance (BCD) has a
positive correlation to Bedknife Angle
Centerline
0
7
BCD @ 00
An aggressive setting means the bedknife angle is
extreme. The bedknife is further from the centerline
of the reel and the reel blades approach is from an
aggressive angle.
Attitude
An aggressive setting is:
The result can be a crisp, clean cut, however;
differences in up and back appearance, a stripe, is
pronounced. The down side of this aggressive
setting is that any variation in reflections can be very
noticeable and perhaps undesirable.
•Bedknife angle is extreme
•The bedknife is further from the
centerline of the reel
•The reel blades approach is from an
aggressive angle
The result can be a crisp, clean cut,
however; differences in up and back
appearance, a stripe, is pronounced.
The down side of this aggressive setting
is that any variation in reflections can be
very noticeable and perhaps undesirable.
With a reduction in behind center distance, the reel
does not gather grass as cleanly; therefore the grass
blades can be different lengths.
Attitude
A flat setting (less aggressive) is:
This is by definition stragglers, however; the
difference can be negligible and tends to diffuse the
reflective qualities of the cut grass thereby masking
imperfections
•The angle of the bedknife is flat
•The bedknife is closer to the centerline
of the reel
•The reel blade approaches from a
horizontal direction
The result: A diffused appearance.
Reflective variations cannot be seen as
readily. The stripe is less defined. Cut is
prone to stragglers.
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On many cutting unit designs, the bedknife attitude
and behind center distance change as the reel wears
and its diameter get smaller. This can result in a
deteriorating quality of cut, and poor after-cut
appearance, including miss-match between cutting
units.
Here is a close up view of the problem. Note the
bedknife angle and behind center distance. This
illustrates how the quality of cut can deteriorate,
when the bedknife angle and behind center distance
change as the reel wears.
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Reel Mowers
On DPA cutting units, bedknife angle and behind
center distance are maintained as the reel wears.
This keeps the attitude, or aggressiveness,
consistent throughout the life of the bedknife and
reel.
As you can see, the reel diameter gets smaller as the
reel wears. Note that all cutting units have a specified
wear limit diameter for the cutting reel. The reel must
be replaced when this wear limit is reach. A chart,
with this, and other specifications is provided later in
this program.
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
feeler gauge along the bottom of the roller between
the roller and plate.
Rollers Parallel
to Reel
Newer DPA model cutting units, with a rigid, bolted
frame, normally do not require this procedure.
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, the one not used
for height of cut adjustment, must be parallel to the
reel, as described on previous pages.
Height of Cut
(H.O.C.)
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
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Bench Set vs. Effective H.O.C.
29
There can be a significant difference between a
bench set height of cut and the actual height of cut
when in the turf.
The bench set height of cut, is theoretical, based on
the assumption that the rollers will set at the same
place in the grass and that the turf is firm.
The turf can have varying densities. Different cutting
unit models can weigh more or less and the rollers
do not always set in the grass in the same manner.
In the circle above you see that after the grass is cut,
the remaining grass must make it under the bedknife.
After the grass is cut, the remaining grass must make
it under the bedknife. There is not a lot of room for
that to happen.
Effective H.O.C.
and Bedknife Selection
If there is too much grass under the bedknife, it can
lift up on the knife causing rifling or the appearance
can vary due to the rollers lifting from the turf as the
bedknife becomes the support and pivot point for the
cutting unit.
On the other hand, if we have too thin of a knife or
the height of cut is set higher; there may not be
enough grass to aid in heat dissipation.
HOC
Blade clearance
As you can see, selecting the proper bedknife for
your height of cut and turf conditions is important.
Bedknife selection will be discussed in more detail
later in the program
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Reel Mowers
Quality of Cut and Aftercut Appearance
The term Aftercut Appearance, is very specific to
appearance and is not the same thing as Quality of
Cut. Quality of Cut can affect the appearance, but
appearance does not, in itself, affect Quality of Cut.
Quality of Cut refers to how well the individual
leaves of the grass plant are cut. A quality cut
minimizes damage to the leaves of the grass plant.
After cut appearance, refers to the visual effects of
the turf after it has been cut and across the entire
width of the mower.
Aftercut Appearance
This is NOT the same thing as:
Quality of Cut
The standard rule for mowing, is never remove
more than 1/3 of the grass plant leaf. This is true of
all turf cultivars and any type of mowing device.
Turf plant stress increases with:
Leaf damage refers to quality of cut.
•
Too much tissue removed at one time (infrequent mowing).
Removal of more than 1/3 leaf tissue at one time can stop
root growth from 6 days to 2 weeks depending on the
amount of tissue removed.
In the case of leaf damage, poor quality of cut will
result in poor aftercut appearance.
•
•
Increased leaf damage (dull blade, sub-optimum setup)
Increased environmental stress in combination with mowing
Raising the height of cut is always an option that will
usually increase both the health and appearance of
the turf.
Ideal is to raise height of cut during periods of turf stress,
such as high heat and/or low moisture
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Quality of cut can be affected by reel blade
sharpness and contact with the bedknife. There is a
lot of discussion in the industry about the desirability
of running units with light contact. One camp says
light contact is not necessary while the other says it
is if you want the best quality of cut.
Related Mowing Quality Issue:
Reel mower sharpness and reel-to-bedknife
contact could affect:
We are interested not only in the effect of these
things on appearance, but the effect of leaf injury
resulting from a less than optimum set-up on plant
vigor and the plants susceptibility to disease. Most
believe that increasing injury increases susceptibility
to disease.
• Visual quality
• Plant vigor
• Susceptibility to disease
There are many factors that can affect after cut
appearance, 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.
Factors that can affect aftercut appearance
• Bedknife selection
• Roller selection
• Tire pressure
• Engine governed speed
• Cutting unit alignment
and ground following
• Roller and roller bearing
condition
• Reel speed
• Traction speed
• Cutting unit drop speed
and sequence
• Cutting unit
• Reel bearing
condition/adjustment
• Reel and bedknife
sharpness
• Bedknife parallel to reel
• Bedknife to reel contact
Also, remember that the effective or actual height of
cut depends on many factors, including, cutting unit
weight, cutting unit accessories, and turf conditions.
Effective height of cut will be different than the
bench set height of cut.
• Bedknife attitude
(angle)
counterbalance or down
pressure setting
• Roller(s) parallel to reel
• Height of cut (bench set
vs. actual)
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There are published resources available for troubleshooting aftercut appearance issues. The Aftercut
Appearance Troubleshooting Guide is setup with one page dedicated to each issue. At the top is a
description followed by a list of possible causes, then possible corrective actions.
Aftercut Appearance Troubleshooting Guide: Part No. 00076SL
First review the issue and then determine the complaint. Many complaints look very similar but if you have
duplicated the condition, this should be relatively easy to work through. Use the definition to pick out subtle
differences then review the possible causes. Compare to the issue and you can determine if some corrective
actions are easier to try than others. Determine a course of action.
Try one thing and only one thing at a time. Do so in a manner that the results can be watched over a period
of time, at least a week. Give it time to work. Remember that after cutting, the grass needs to heal before the
result will be realized.
While talking with others use the descriptions listed. Not, because it is the only correct description, but
because it has a definition that is identifiable to both of you.
You may download this publication directly from the location you obtained this document, or from toro.com,
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Some turf discrepancies are subtle and require
closer examination. In these instances, the Turf
Evaluator, 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.
Part No.
97931SL
Model 04399
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Reel Mowers
Sharpening
Sharpening is part of the required maintenance for proper function of a reel mower cutting unit.
How can you tell if sharpening is necessary?
The grass is not cut cleanly.
The color of the grass; it may have a dull appearance or have brown tips.
Streaks.
Stragglers.
The cutting unit is noisy.
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.
This profile drawing of the blades shows the result
of wear.
The leading edges are rounded and the angle of the
bedknife has worn to match the circle created by the
blade path.
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.
Here is light bedknife to reel contact, which gives a
clean cut and helps to maintain a sharp edge.
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If there is no contact (a gap between bedknife and
reel blade) it can result in faster wear of the cutting
edges and more frequent grinding.
No contact results in the leaves of the grass plant
being pinched or torn rather than cleanly cut. This
causes poor quality of cut and can actually
accelerate the wear process of the cutting edges.
The result? deteriorating aftercut appearance and
leaf tissue damage which is detrimental to the long
term health of the turf.
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Sharp vs. Dull Cutting Blades
Cutting units should be kept as sharp as possible. This will:
•
•
•
•
•
•
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.
And provide the best possible aftercut appearance of the turf.
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When the cutting unit blades become dull and
quality of cut deteriorates, the tendency is to want to
tighten the bedknife to reel contact, resulting in
heavy contact.
Heavy bedknife to reel contact can cause rifling,
which appears as a grooved or wavy wear pattern
on the reel and or bedknife. This condition can only
be corrected by grinding the reel and bedknife.
BACKLAPPING WILL NOT CORRECT THIS
CONDITION. The bedknife will usually need to be
replaced rather than just ground.
pressure
Rifling
Streaks of uncut grass, will appear on the low
areas of a grooved or wavy (rifled) bedknife
A barrel shaped reel, caused by flexing of the
cutting unit frame will also require grinding to bring
the reel back to a cylindrical shape.
Barrel Shaped Reel
It is more likely that this will occur on cutting units
with welded frames and not on the newer DPA
model cutting units with more rigid bolted frames.
Flexing of the frame can cause uneven wear and
eventually lead to rifling.
If the reel wears unevenly, it becomes difficult to
keep the bedknife parallel across the entire width of
the reel. You may be able to pinch paper in the
middle, but not on the ends, or vice-versa. When
adjusting a cutting unit with this condition, the
tendency is to want to tighten the bedknife to reel
contact, so the paper can be pinched and cut
across the entire bedknife and reel, resulting in
heavy contact.
Grinding will also be required if the reel is cone
shaped or tapered. Reels eventually become
tapered with use. If the reel is not ground to a
cylinder shape again, a mismatch, in the height of
cut between adjacent cutting units can result.
Cone Shaped Reel
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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 cut greens that
have been core aerated or top dressed, you may
not want to grind the reels and install new bed
knives.
Sharpening Methods
• Maintain proper ADJUSTMENT
• BACKLAP the bedknife and reel
• GRIND the reel and bedknife
By backlapping regularly, reel blade and bedknife
sharpness can be maintained longer between
grindings.
Backlapping cannot be used to sharpen a dull reel
or bedknife. Backlapping is an edge maintenance
practice.
As the reel blades run against the bedknife during
backlapping, a slight burr will appear at the front
cutting edge surface the full length of the bedknife.
Run a file or facing grinder across the front edge to
remove this burr.
Backlapping 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.
Backlapping is not intended to be a reconditioning
process to correct severely nicked or rounded
blades, rifling or taper. If, after approximately 5
minutes of lapping, the edge is not restored, it is
time to grind the reel and bedknife.
Backlapping is often a regularly scheduled
maintenance process, particularly with greens
mowers.
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WARNING:
Always use a brush with an extended handle to
apply the lapping compound to the rotating reel.
Using a short handle brush could cause your hand
to be pulled into the reel, and cause serious injury.
Keep your hands, feet and clothing away from
moving parts!
If you use backlapping as a regular maintenance
practice, backlap often, but for a very short time. For
example, five minutes per cutting unit.
BACKLAP OFTEN
but
VERY LITTLE
Approximately
5 Minutes per Cutting Unit
Before a reel can be ground correctly, the reel has
to be cleaned and checked for loose or bent blades.
The reel bearings must be in good condition, with
no end play evident. Make sure the cutting unit
frame and roller brackets are true and not bent or
damaged from impacts with trees, posts or cart path
edges. The cutting unit must be aligned so the
grinding wheel will travel parallel to the reel shaft.
This will result in the reel being ground to the
desired cylinder shape.
Follow the grinder manufacturer’s instructions for
set-up and operation of the grinder.
When grinding, be careful to not overheat the reel
blades. Remove small amounts of material with
each pass of the grinder.
After completing the grinding process, do a
complete set–up and adjustment procedure on each
cutting unit.
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There are several manufacturers of reel grinders.
These same manufacturers also produce bedknife
grinders.
Grinders
Remember to always wear a face shield or safety
glasses when grinding or backlapping.
WARNING !
Always wear a face shield or
safety glasses when grinding or
backlapping.
It is important to understand that Toro reel mowers
are designed and manufactured to optimize
available power from the engine and hydraulic
systems. To help do this, we put a “relief” or back
grind on every reel blade to reduce the width of reel
blade that contacts the bedknife. This has been
proven to reduce power requirements, as well as
allow the machine to operate more efficiently. This
can be very important, depending on the terrain,
type of grass and amount of grass being cut.
Milled Relief (Scalloped Blades)
Toro has two different methods of manufacturing
reel blades with a relief. The reel blades are made
from straight stock steel and then are either relief
ground or the relief is milled in. Either way, there is
a relief on the blade when it is manufactured. A
small, ground relief is also put on milled relief
blades, during manufacture.
Toro greens mowers and DPA fairway cutting units
are manufactured with a milled relief. Other trim,
utility, and fairway mowers have a ground relief.
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There are two methods of grinding reels. This
illustrates Spin Grinding (which is also known as
Flat Grinding).
Spin Grinding
(Flat Grinding)
With this method, both the reel and the grinding
stone are turning as the reel is being sharpened. It
is sometimes stated that backlapping is not required
after spin grinding because the reel is a perfect
cylinder when grinding is completed. This depends
on proper alignment of the reel in the grinder before
sharpening. Also, the bedknife and bedbar must be
straight and perfectly parallel to the reel when it is
mounted. Backlapping will remove burrs and rough
edges, producing a honed edge that will cut grass
evenly.
If using a spin grinder to sharpen straight stock reel
blades (such as on fairway mowers), some or all of
the relief will be ground off. If you are going to
restore the relief that was on the blade when was
manufactured, you will need to also use the other
method of grinding (single blade relief grinding). It is
recommended to do the relief grinding first, then
spin grind to restore the reel to a cylinder shape and
establish the land width.
This illustrates Single Blade Grinding (which is also
know as Relief, Grinding, or Back Grinding.
Single Blade Grinding
(Relief or Back Grinding)
With modern grinding equipment, spin (or flat)
grinding and single blade grinding are available on
the same machine. Single blade grind if necessary,
to restore the relief or back grind, then spin grind to
sharpen and return the reel to a cylinder shape.
Toro recommends a 30 degree relief angle on each
reel blade. The angle itself is not critical. You can
put as little or as much angle on the blade as you
think is proper. A larger angle will take off more
steel and the reel may have to be replaced sooner.
With a smaller angle, you may have to grind the reel
more often to maintain a relief. See the reel and
bedknife grinding guidelines chart, at the end of this
section, for grinding specifications on each cutting
unit model.
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Whichever grinder you use, be sure to compensate
for a cone or barrel shaped condition.
Reel Grinding
Grind parallel to the Reel Shaft
Do Not grind by equaling the spark pattern on each end
Grind parallel to the Reel Shaft. Do Not setup the
grinder by simply equaling the spark pattern on
each end. This will not remove the slight cone
shape of the worn reel.
A = B
Reels naturally wear more on one end then the
other.
Verify the reel centerline, which is the reel shaft, is
parallel to the grinder stone travel.
B
A
If replacing the bedknife it is important to use the
following procedures:
Bedknife Installation
•
Remove all rust, scale and corrosion from
the bedbar surface before installing new
bedknife.
•
•
Make sure the bedbar threads are clean.
Use new Toro screws. Apply anti–seize
lubricant to the screw threads before
installing.
Tighten the screws working from the center toward
each end of the bedbar. Do not use an impact
wrench.
Fairway/utility mowers:
250 – 300 in-lb. (288 – 345 KgCm)
Greens mowers:
200 - 250 in-lb. (230 - 288 KgCm)
Fairway and Utility Mowers:
250 – 300 in-lb. (288 - 345 KgCm)
Greens Mowers:
200 – 250 in-lb. (230 - 288 KgCm)
Since there can be variations in the mounting
surface of the bedbar, a new bedknife may not be
perfectly flat after it is installed. Because of this, it is
necessary to backlap or grind a new bedknife after
installing it to the bedbar. Follow the existing angle
that was ground into the bedknife and grind only
enough to make sure the top surface is true.
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This illustrates the characteristics for the bedknife
that are specified in the Toro Reel and Bedknife
Grinding Guidelines, such as Relief Angle and Front
Angle.
When regrinding a bedknife it is important to use the
following procedures:
•
Remove the bedbar and bedknife assembly
from the cutting unit before attempting to
grind a used bedknife.
•
•
Keep the bedknife fastened to the bedbar
when grinding.
When grinding, be careful to not overheat
the bedknife. Remove small amounts of
material with each pass of the grinder.
A lead-in provides a softened entry for the leading
side of the reel blade helix as it approaches the
bedknife. This helps eliminate rifling caused by
heavy contact and vibration. If the bedknife had the
lead-in originally, be sure to put it there when done
grinding the bedknife and reel.
.050 ± .015
Side View
Top View
Example specifications for this lead-in for a fairway
mower knife are as shown. These specifications are
only a suggestion. The idea is to get a grind in place
not to spend a lot of time making sure it is exact.
Using a file to make the lead-in is a perfectly
acceptable method. It is important not to make the
lead-in too long or you will notice that there is a
streak left behind at the edge of the cutting unit as
the reel will not cut well in the area of the grind or
may adversely affect the overlap area.
Lead-in
It is also important that the lead-in make a smooth
transition. Be sure to remove any burr that
develops as a result of making the lead-in. The
lead-in will lessen as a result of bedknife wear and
should be redressed with a file at the same time the
ears are removed.
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Reel Mowers
The Edge Max bedknife includes a leading edge of
harder steel.
• The EdgeMax™ bedknife
includes a leading edge of
harder steel
The Edge Max bedknife Holds an edge twice as
long as a standard bedknife, and reduces the need
for adjustments, backlapping and grinding.
•
Holds an edge twice as long and
reduces the need for adjustments,
backlapping and grinding
Set the bedknife to reel adjustment on an Edge Max
bedknife as usual. Light contact while running on
the ground.
•
•
Set bedknife to reel adjustment as usual
–
Light contact while running on the ground
No special requirements
There are no other special requirements.
A dull knife must be sharpened.
Maintaining the EdgeMax Bedknife
If backlapping is part of your maintenance practice,
be prepared to backlap for two to three times the
amount of time as compared to a standard bedknife.
Front face grinding is acceptable in moderation.
• A dull knife must be sharpened
• If backlapping is part of your maintenance practice, be
prepared to backlap for two to three times the amount of
time as compared to a standard bedknife
Any facing or grinding must be done with exacting
tolerances. Do not use a hand held grinder
• Front face grinding is acceptable in moderation
– Any facing or grinding must be done with exacting tolerances.
Do not use a hand held grinder
No special stones required.
Sharpening the EdgeMax Bedknife
Dress the stone more frequently. Before starting,
and at least once during grinding. One pass to
dress. Multiple passes will cause the stone to load
up.
• No special stones required
• Dress the stone more frequently
– Before starting and at least once during grinding
• One pass to dress
– Multiple passes will cause the stone to back up
When grinding, remove smaller amounts of material
(a shallower cut).
• When grinding, remove smaller amounts
of material (shallower cut)
• Expect a different spark pattern
Expect a different spark pattern.
Mild Steel: Many orange visible
Tool Steel: Few visible streaks with
streaks with few sparks
noticeable sparks
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This diagram illustrates the characteristics that are specified for the reel in the Toro Reel and Bedknife
Grinding Guidelines, such as the Reel Diameter, Blade Relief Angle, Blade Land Width and Reel Taper.
When regrinding a cutting unit reel or bedknife, use the specifications from the Toro Reel and Bedknife
Grinding Guidelines on the next page. If the reel diameter is less than the service limit shown, it must be
replaced.
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Bedknives, Rollers and Accessories
Greens Mower Bedknives
Fairway
Note: High-Cut has similar profile
.313 (8 mm) - 1 in (25 mm)
Low-Cut
Tournament
Micro-cut
Bedknife design must allow for maximum material to dissipate heat and yet allow the remaining uncut grass
under the bedknife.
Unfortunately, there is no set rule for space left under the knife, nor can there be. This is due primarily to
surface density and turf conditions. There is no measurable plane that works, other than, your mower, in
your turf.
The only thing that is absolute is that while on the bench, the bedknife can not touch the height of cut
adjusting tool. There must be a reasonable space between the bedknife and height of cut adjusting tool.
To look at that in a different manner, place the cutting unit on a table resting on the rollers so as you can look
at the end of the cutting unit. The bedknife can not touch the table top. This is the absolute! Everything else
depends on the agronomic conditions of the turf.
Listed here are popular Greens mower bedknives and their recommended operating range.
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DPA Fairway Mower Bedknives
EdgeMax ™
(Original Equipment)
Standard
HD
Low-Cut
Due to the height of cut variations on a fairway and the requirements of cutting conditions there is another
line of bedknives for the fairway or higher height of cut ranges.
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The basic groups of ground contacting rollers are
shown here.
Rollers
Wiehle
Full or Solid
Full rollers provide a stable platform using full width
contact. Some characteristics of full rollers include:
Increases, the effective cutting height.
Rides higher or floats more on the turf.
Can be made heavier or larger to help with cutting
unit control.
Full Rollers
(Also referred to as solid rollers)
Less likely to scuff the turf in turns.
Less likely to damage the turf when lowering onto it.
Narrower rear rollers can help address overlap roller
marks in cool season grasses. Note that the
narrower rollers can reduce the stability of the
cutting unit.
Wiehle (or grooved) rollers also provide a stable
platform with some different characteristics.
Contact line is broken into individual contact points
allowing for greater surface pressure at the contact
point.
Individual contact points allow for better incursion
into the turf canopy.
Wiehle Rollers
Allows seed heads to be cut and gathered better.
Note that these rollers can sometimes scuff the turf
in turns.
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Here are some adaptations of the Wiehle roller:
Aluminum lessens contact pressure due to weight
difference.
Cast iron increases cutting unit control by increasing
contact pressure.
Wiehle Rollers
Wider spacing tends to increase incursion into the
canopy due to increased contact pressure while
disturbing less grass.
Narrower spacing tends to lessen incursion into the
canopy acting more as a full roller.
The end of the roller is designed to allow for a clean
transition.
Tapered or wider transitions are less disruptive to
the turf during cutting unit steer.
Disc (flute or Wiehle) design modifies turf
interaction.
The shouldered Wiehle roller offers the same
ground engaging characteristics as a non-
shouldered Wiehle roller.
Shouldered Wiehle Rollers
Outermost grooves are filled to help minimize
stripping of grass due to cutting unit overlap in warm
season grasses.
There is an entire array of accessories available for
reel mower cutting units.
Accessories
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51
Combs and brushes are designed to be mounted
behind the front.
Generally these devices are used to just make
contact with the grass after the roller has pressed it
down. This is to help stand the grass up for a more
uniform cut.
Combs and Brushes
Brushes may also be in combination with scrapers
on front rollers.
Roller scrapers are designed to do just that, scrape
rollers. This is to keep grass clippings from building
up on the rollers, which can change the height of cut
during mowing.
Accessories
Scrapers are set with a small clearance from the
roller. Note that affixing the scraper too close or on
the trailing side of rotation will cause them to trap
clippings, cause excessive wear to the roller or
increase rolling resistance binding the roller.
Roller Scrapers
Powered rear roller brushes are also intended to
keep the rollers from collecting debris. The
difference is that these brushes help disperse the
debris and do an excellent job of cleaning up the
final appearance.
Accessories
Powered Rear Roller
Brushes
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Groomers and Thatchers
Groomers are intended to cut stolons, promote
upright growth and stand grass up for a more
uniform cut.
Warm season grasses such as Bermuda grass and
others, but also Creeping Bentgrass, which is
considered a cool season grass, all benefit from the
use of groomers on a regular basis.
One word of caution; groomers are used in a
straight line. Turning or engaging the turf with
groomers on cleanup passes can cause some
serious issues.
Groomer
A new variation is the Broomer. The brush helps to
stand the grass up better than the blades alone,
along with knocking off dew to reduce clumping.
Because of the stoloniferous growth of some
cultivars, the turf tends to be “grainy” as can be
seen in the photo.
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Because of the many leaves that are laying over,
the lie of the ball is quite low and the roll is
inconsistent.
As can be seen in this photo, grooming can greatly
improve the appearance of the turf area.
The precaution is that groomers are to be set just
below the height of cut. Grooming does not contact
the ground or thatch. Doing so can be very
disruptive to the turf, have a negative effect on the
appearance and possibly damage the equipment.
Overly aggressive grooming is detrimental to the
turf.
When grooming is done correctly and regularly it
can have a dramatic effect on the turf and the result
is a better lie. As you can see with a healthier
upright growth, the lie of the ball is much higher on
the turf.
IMPORTANT: Grooming is performed above the soil
level. Grooming promotes vertical growth of the
grass by cutting runners, or stolons, standing grass
blades up and encouraging denser growth and
deeper rooting. This can, in effect, yield a more
even grass with less grain, for faster and truer
action of the golf ball
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Grooming is similar to verti-cutting in its runner
cutting action. Grooming blades however, should
never penetrate the soil like verti-cutting or
dethatching. Groomer blades are spaced closer
together and are used more often than verti-cutters
so that they are more effective in cutting runners
and standing up the grass.
IMPORTANT: Improper use or over-aggressive use
of the grooming reel (such as too deep or too
frequent grooming) may cause unnecessary stress
on the turf, leading to severe damage to the green.
Use the groomer cautiously.
It is difficult to give precise recommendations on
the use of groomers because so many variables
affect the performance of grooming:
• Time of year and
weather pattern
• How long grooming has
been in use on a green
• General condition
of the green
• Frequency of
grooming/cutting
• Type of grass
on the green
• Overall greens
management program
– Irrigation, fertilizing,
spraying, coring, over-
seeding
It is important to determine the performance of the
groomer before putting it into regular use on greens.
We strongly suggest that a formal test procedure be
used to determine the proper depth setting for your
conditions.
– Number of cuttings per
week and number of
passes per cutting
• Height of cut
• Height of grooming
• Traffic
• Stress periods
It is difficult to give precise recommendations on the
use of groomers because so many variables affect
the performance of grooming.
– Temperature,
humidity, traffic
Here is an example of a thatching unit, on a triplex
riding greens mower.
Thatching Reel
Thatch is the accumulation of organic material at the
soil surface and comes primarily from stolen,
rhizome and root tissue in warm season grasses.
Thatching (vertical mowing) is a mechanical method
of removing excess thatch. Please note that
dethatching is very disruptive to turf. This
mechanical removal does not address the cause of
excess thatch.
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Reel Mowers
55
Conclusion
This document has provided you with a basic
knowledge of reel mower operating theory, set-up,
adjustment, and maintenance.
This information will not only help you understand
the how, but also give some insight into why some
operating, adjustment, and maintenance procedures
are so important.
Understanding that reel mowers are precision
machines, requiring regular maintenance and
adjustment, can help achieve attractive, consistent,
aftercut appearance, while reducing downtime and
operating costs.
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56
Reel Mowers
Notes:
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