8- or 11-Blade DPA Cutting Unit with 7in Reel

Use this procedure to set the bedknife to the reel and to check the condition of the reel and bedknife and their interaction. After completing this procedure, always test the cutting unit performance under your field conditions. You may need to make further adjustments to obtain optimal cutting performance.

Important: Do not overtighten the bedknife to the reel or you will damage it.

• After backlapping the cutting unit or grinding the reel, you may need to mow with the cutting unit for a few minutes and then perform this procedure to adjust the bedknife to the reel as the reel and bedknife adjust to each other.

• You may need additional adjustments if the turf is extremely dense or your cutting height is very low.

You will need the following tools to complete this procedure:

• Shim 0.05 mm (0.002 inch)—Toro Part No. 125-5611

• Cutting performance paper—Toro Part No. 125-5610

1. Position the cutting unit on a flat, level work surface. Turn the bedbar adjusting screws counterclockwise to ensure that the bedbar does not contact the reel (Figure 8).

   

   Figure 8

   1. Bedbar adjusting screw

2. Tip the cutting unit to expose the bedknife and reel.

   Important: Make sure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 9).

   

   Figure 9

   1. Cutting unit kickstand

3. Rotate the reel so that a blade crosses the bedknife approximately 25 mm (1 inch) in from the end of the bedknife on the right side of the cutting unit.

   Insert the 0.05 mm (0.002 inch) shim between the marked reel blade and the bedknife at the point where the blade crosses the bedknife.

   Note: Putting an identifying mark on this blade makes subsequent adjustments easier.

4. Turn the right bedbar adjuster clockwise until you feel light pressure (i.e., drag) on the shim, then back off the bedbar adjuster 2 clicks and remove the shim.

   Note: Since adjusting 1 side of the cutting unit affects the other side, the backing off the adjuster 2 clicks provides clearance when you adjust the other side.

   Note: If starting with a large gap, both sides should initially be drawn closer by alternately tightening the right and left sides.

5. Slowly rotate the reel so that the same blade that you checked on the right side is crossing the bedknife approximately 25 mm (1 inch) in from the end of the bedknife on the left side of the cutting unit.

6. Turn the left bedbar adjuster clockwise until you can slide the shim can through the reel to bedknife gap with light drag.

7. Return to the right side and adjust as necessary to get light drag on the shim between the same blade and bedknife.

8. Repeat steps 6 and 7 until you can slide the shim through both gaps with slight drag, but 1 click in on both sides prevents the shim from passing through on both sides. The bedknife is now parallel to the reel.

   Note: This procedure should not be needed on daily adjustments, but should be done after grinding or disassembly.

9. From this position (i.e., 1 click in and shim not passing through) turn the bedbar adjusters clockwise 1 click each.

   Note: Each click turned moves the bedknife 0.022 mm (0.0009 inch). Do not overtighten the adjusting screws.

10. Test the cutting performance by inserting a long strip of cutting performance paper (Toro Part No. 125-5610) between reel and bedknife, perpendicular to the bedknife (Figure 10).

    Note: Slowly rotate the reel forward; it should cut the paper.

    

    Figure 10

    Note: Should excessive reel drag be evident, backlap or grind the cutting unit to achieve the sharp edges needed for precision cutting.

1. Adjust the rear roller brackets (Figure 11) to the desired height-of-cut range by positioning the required amount of spacers below the side plate mounting flange (Figure 11) per the height-of-cut chart; refer to Height-of-Cut Chart.

   

   Figure 11

   1. Spacer
   2. Roller bracket
   3. Side plate mounting flange

2. Raise the rear of cutting unit and place a block under the bedknife.

3. Remove the 2 nuts securing each roller bracket and the spacer to each side plate mounting flange.

4. Lower the roller and the screws from the side plate mounting flanges and spacers.

5. Place the spacers onto the screws on the roller brackets.

6. Secure the roller bracket and the spacers to underside of the side plate mounting flanges with the nuts previously removed.

7. Verify that the bedknife to reel contact is correct. Tip the cutting unit to expose front and rear rollers and the bedknife.

   Note: The position of the rear roller to the reel is controlled by the machining tolerances of the assembled components, and so paralleling is not required. A limited amount of adjustment is possible by setting the cutting unit on a surface plate and loosening the side plate mounting cap screws (Figure 12). Adjust and tighten the cap screws. Torque the cap screws to 27 to 36 N∙m (240 to 320 ft-lb).

   

   Figure 12

   1. Side plate mounting cap screws

The number of rear spacers determines the aggressiveness of cut for the cutting unit. For a given height of cut, adding spacers, below the side plate mounting flange, increases the aggressiveness of the cutting unit. All cutting units on a given machine must be set to the same aggressiveness of cut (Number of rear spacers, Part No. 106-3925); otherwise, the after-cut appearance could be negatively affected (Figure 17).

The location at which the lift arm chain is attached determines the rear roller pitch angle (Figure 13).

Figure 13

1. Lift chain
2. U-backet
3. Bottom hole

The desired height of cut.

The bench set height of cut is the height at which the top edge of the bedknife is set above a flat level surface that contacts the bottom of both the front and rear roller.

This is the actual height that the grass has been cut. For a given bench set height of cut, the actual height of cut varies depending on the type of grass, time of year, turf, and soil conditions. The cutting unit setup (aggressiveness of cut, rollers, bedknives, attachments installed, turf compensation settings, etc.) also affects the effective height of cut. Check the effective height of cut using the Turf Evaluator, Model 04399, regularly to determine the desired bench set height of cut.

Cutting unit aggressiveness of cut has a significant impact on the performance of the cutting unit. Aggressiveness of Cut refers to the angle of the bedknife relative to the ground (Figure 17).

The best cutting unit setup depends on your turf conditions and desired results. Experience with the cutting unit on your turf determines the best setting to use. You can adjust the aggressiveness of cut throughout the cutting season to allow for various turf conditions.

In general, less-to-normal aggressive settings are more appropriate for warm season grasses (Bermuda, paspalum, zoysia) while cool season grasses (bent, bluegrass, rye) may require normal to more aggressive setups. More aggressive setups cut more grass off by allowing the spinning reel to pull more grass up into the bedknife.

Figure 17

1. Rear spacers
2. Side plate mounting flange
3. Aggressiveness of cut

These are the recommended height-of-cut settings when a groomer kit is installed on the cutting unit.

Note: Changing 1 chain link changes the rear roller pitch angle movement by 4.5°.

Note: Changing the U-bracket, on the lift arm, to the bottom hole adds 2.3° to the rear roller pitch angle.

Note: For heights of cut greater than 2.54 cm (1 inch), install the High Height-of-Cut Kit.

1. Loosen the locknuts securing the height-of-cut arms to the cutting unit side plates (Figure 18).

   

   Figure 18

   1. Height-of-cut arm
   2. Locknut
   3. Adjusting screw

2. Loosen the nut on the gauge bar (Figure 19) and set the adjusting screw to the desired height of cut.

   Note: The distance between the bottom of the screw head and the face of the gauge bar is the height of cut.

   

   Figure 19

   1. Gauge bar
   2. Height adjusting screw
   3. Nut
   4. Holes used for setting Groomer HOC
   5. Hole not used

3. Hook the screw head on the cutting edge of the bedknife and rest the rear end of the bar on the rear roller (Figure 20).

4. Rotate the adjusting screw until the front roller contacts the gauge bar (Figure 20). Adjust both ends of the roller until the entire roller is parallel to the bedknife.

   Important: When set properly, the rear and front rollers contact the gauge bar and the screw is snug against the bedknife. This ensures that the height of cut is identical at both ends of the bedknife.

   

   Figure 20

5. Tighten the nuts to secure the adjustment. Do not overtighten the nuts. Tighten them enough to remove play from the washer.

   Use the following chart to determine which bedknife is best suited for the desired height of cut.

   Bedknife/Height-of-Cut Chart

   Bedknife	Part No.	Bedknife Lip Height*	Height of Cut
   Low HOC (Optional)	110-4084	5.6 mm	6.4–12.7 mm
   		(0.220 inch)	(0.250 to 0.500 inch)
   Extended Low HOC (Optional)	120-1640	5.6 mm	6.4–12.7 mm
   		(0.220 inch)	(0.250 to 0.500 inch)
   EdgeMax® Low HOC (Production for Model 03693)	127-7132	5.6 mm	6.4–12.7 mm
   		(0.220 inch)	(0.250 to 0.500 inch)
   Extended Low HOC EdgeMax® (Optional)	119-4280	5.6 mm(0.220 inch)	6.4–12.7 mm
   		(0.270 inch)	(0.250 to 0.500 inch)
   EdgeMax® (Production for Models 03696 and 03697)	108-9095	6.9 mm	9.5–38.1 mm
   		(0.270 inch)	(0.375 to 1.50 inches)
   Standard (Optional)	108-9096	6.9 mm	9.5–50.8 mm
   		(0.270 inch)	(0.375 to 2.0 inches)
   Heavy Duty (Optional)	110-4074	9.3 mm	6.4–50.8 mm
   		(0.370 inch)	(0.500 to 2.0 inches)
   *Warm season grasses may require the low HOC bedknife for 12.7 mm (0.500 inches) and below.

   

   Figure 21

   1. Bedknife lip height*

The dual knob bedknife-to-reel adjustment system in this cutting unit simplifies the adjustment procedure. The precise adjustment possible with the dual knob/bedbar design gives the necessary control to provide a continual self-sharpening action-thus maintaining sharp cutting edges, ensuring good quality-of-cut and greatly reducing the need for routine back lapping.

Prior to mowing each day, or as required, check each cutting unit to verify proper bedknife-to-reel contact. Perform this procedure even though the quality of cut is acceptable.

1. Lower the cutting units onto a hard surface, shut off the engine, and remove the ignition key.

2. Slowly rotate the reel in a reverse direction, listening for reel-to-bedknife contact. If no contact is evident, turn the bedknife adjusting knobs clockwise, 1 click at a time, until light contact is felt and heard.

   Note: The reel must cut 1 sheet of paper, when inserted at a right angle to the bedknife, at both ends and the center of the reel.

   Note: The adjustment knobs have detentes corresponding to 0.022 mm (0.0009 inch) bedknife movement for each indexed position.

3. If excessive contact/reel drag is evident backlap, reface the front of the bedknife, or grind the cutting unit to achieve the sharp edges needed for precision cutting (Refer to the Toro Manual for Sharpening Reel and Rotary Mowers, Form No. 09168SL).

   Important: Light contact is preferred at all times. If light contact is not maintained, the bedknife/reel edges will not sufficiently self-sharpen and dull cutting edges will result after a period of operation. If excessive contact is maintained, bedknife/reel wear will be accelerated, uneven wear can result, and quality of cut may be adversely affected.

   Note: As the reel blades continue to run against the bedknife, a slight burr appears on the front cutting edge surface along the full length of the bedknife. You can remove burrs and improve cutting by occasionally running a file across the front edge.After extended running, a ridge eventually develops at both ends of the bedknife. Round off these notches or file them flush with the cutting edge of the bedknife to ensure smooth operation.

   Note: Over time, the chamfer (Figure 22) requires grinding, as it is designed to last only 40% of the bedknife life.

   

   Figure 22

   1. Lead-in chamfer on right end of bedknife

   Note: Do not make the lead-in chamfer too large as it may cause turf tufting.

The bedknife service limits and grind angles are listed in the following chart.

Important: Operating the cutting unit with the bedknife below the service limit may result in poor after-cut appearance and reduce the structural integrity of the bedknife for impacts.

Refer to Figure 23 and the dimensions and angles listed in the Bedknife Chart.

Figure 23

1. Bedknife Service Limit*
2. Top grind angle
3. Front grind angle

Note: All bedknife service limit measurements reference the bottom of the bedknife, refer to the Figure 24 and dimensions listed in the Bedknife Chart.

Figure 24

1. Turn bedbar adjuster screws counterclockwise to back the bedknife away from the reel (Figure 29).

   

   Figure 29

   1. Bedbar adjusting screw
   2. Spring tension nut
   3. Bedbar
   4. Washer

2. Back out the spring tension nut, until the washer is no longer tensioned against the bedbar (Figure 29).

3. On each side of the machine, loosen the locknut securing the bedbar bolt (Figure 30).

   

   Figure 30

   1. Bedbar bolt
   2. Lock nut

4. Remove each bedbar bolt allowing bedbar to be pulled downward and removed from machine bolt (Figure 30).

   Note: Account for 2 nylon and 1 stamped steel washers on each end of bedbar (Figure 31).

   

   Figure 31

   1. Bedbar bolt
   2. Nut
   3. Steel washer
   4. Nylon washer

1. Install the bedbar, positioning the mounting ears between the washer and bedbar adjuster.

2. Secure the bedbar to each side plate with the bedbar bolts (nuts on bolts) and the 6 washers.

   Note: Position a nylon washer on each side of the side plate boss. Place a steel washer outside each of the nylon washers (Figure 31).

3. Torque bedbar bolts to 27 to 36 N∙m (240 to 320 in-lb).

   Note: Tighten the locknuts until the outside steel washer stops rotating and the end play is removed but, do not overtighten or deflect the side plates. Washers on the inside may have a gap.

4. Tighten the spring tension nut until the spring is collapsed, then back off 1/2 turn (Figure 32).

   

   Figure 32

   1. Spring tension nut
   2. Spring