27-inch 5, 8, or 11-Blade or 32-inch 8-Blade EdgeSeries DPA Cutting Unit

This product is capable of amputating hands and feet. Always follow all safety instructions to avoid serious personal injury.

• Read and understand the contents of this Operator’s Manual before starting the machine.

• Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

• Do not put your hands or feet near moving components of the machine.

• Do not operate the machine without all guards and other safety protective devices in place and functioning properly on the machine.

• Keep clear of any discharge opening.

• Keep bystanders and children out of the operating area. Never allow children to operate the machine.

• Before you leave the operator’s position, do the following:

  • Park the machine on a level surface.

  • Lower the cutting unit(s).

  • Disengage the drives.

  • Engage the parking brake (if equipped).

  • Shut off the engine and remove the key (if equipped).

  • Wait for all movement to stop.

Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death.

• The cutting unit is only a complete machine when installed on a traction unit. Read the traction unit Operator’s Manual carefully for complete instructions on the safe use of the machine.

• Stop the machine, remove the key (if equipped), and wait for all movement to stop before inspecting the attachment after striking an object or if there is an abnormal vibration in the machine. Make all necessary repairs before resuming operation.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• Use only accessories, attachments, and replacement parts approved by Toro.

A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.

• On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate.

Parts needed for this procedure:

Install the grease fitting on the reel-motor side of the cutting unit. Refer to Figure 3 to determine the position of the reel motors based on the position of the cutting unit on the machine.

Figure 3

1. Cutting unit 1
2. Cutting unit 2
3. Cutting unit 3
4. Weight
5. Reel motor

1. Remove and discard the setscrew on the reel-motor side plate (Figure 4).

   

   Figure 4

   1. Cap screw (2)
   2. Setscrew
   3. Grease fitting
   4. Grease vent

2. Install the straight grease fitting (Figure 4).

1. Adjust the bedknife to the reel.

2. Adjust the rear roller for your height-of-cut requirements.

3. Set the height of cut.

4. Adjust the rear shield if necessary.

Refer to Adjusting the Cutting Unit for complete instructions for performing these adjustments.

Parts needed for this procedure:

Important: Before installing the reel motors, obtain and install the counter weights or other accessories on the opposite side of the cutting units from the reel motors as described in the instructions provided with the weights or accessories.

1. Install the cutting units onto the traction unit; refer to the traction unit Operator’s Manuals for instructions.

2. If there are no cap screws on the reel-motor side plate, install them (Figure 4).

3. Install the O-ring on the reel motor (Figure 5).

   

   Figure 5

   1. O-ring

4. Install the reel motor and secure it with the cap screws.

5. Grease the side plate until excess grease comes out of the grease vent (Figure 4).

Parts needed for this procedure:

1. Remove the nuts and washers securing the lift links to the cutting-unit side plate and carrier frame (Figure 7).

   

   Figure 6

   1. Nuts
   2. Washers

2. Using the number 2 holes, insert a fixed plate onto the bolts and secure it with the nuts removed.

   Note: The number 1 holes are to be positioned toward the front. Do not reuse the washers.

   Note: The number 1 hole is a less aggressive setting and the number 3 hole is a more aggressive setting.

   

   Figure 7

   1. Nuts
   2. Fixed plate

3. Loosen the locknuts securing the height-of-cut brackets to the cutting-unit side plates (Figure 8).

   

   Figure 8

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

4. Remove the height-of-cut brackets and the roller from the cutting unit.

5. Repeat the procedure on the remaining cutting units.

A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories.

To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

1. Loosen the locknuts securing the height-of-cut brackets to the cutting-unit side plates (Figure 17).

   

   Figure 17

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

2. Loosen the nut on the gauge bar (Figure 18) 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 bar is the height of cut.

   

   Figure 18

   1. Gauge bar
   2. Height-adjusting screw
   3. Nut

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 19).

4. Rotate the adjusting screw until the front roller contacts the gauge bar (Figure 19). Adjust both ends of roller until the entire roller is parallel to the bedknife.

   

   Figure 19

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

5. Tighten the nuts to secure adjustment.

   Note: Do not overtighten the nuts. Tighten them just enough to remove any play from the washer.

   Height-of-Cut Chart

   HOC Setting	Aggressiveness of Cut	No. of Rear Spacers		HOC Setting	Aggressiveness of Cut	No. of Rear Spacers
   6 mm (0.250 inch)	Less	0		38 mm (1.500 inches)	Less	5
   	Normal	0			Normal	6
   	More	1			More	7
   9 mm (0.375 inch)	Less	0		41 mm (1.625 inches)	Less	6
   	Normal	1			Normal	7
   	More	2			More	8
   13 mm (0.500 inch)	Less	0		44 mm (1.750 inches)	Less	6
   	Normal	1			Normal	7
   	More	2			More	8
   16 mm (0.625 inch)	Less	1		48 mm (1.875 inches)	Less	7
   	Normal	2			Normal	8
   	More	3			More	9
   19 mm (0.750 inch)	Less	2		51 mm (2.000 inches)*	Less	7
   	Normal	3			Normal	8
   	More	4			More	9
   22 mm (0.875 inch)	Less	2		54 mm (2.125 inches)*	Less	8
   	Normal	3			Normal	9
   	More	4			More	10
   25 mm (1.000 inch)	Less	3		57 mm (2.250 inches)*	Less	8
   	Normal	4			Normal	9
   	More	5			More	10
   29 mm (1.125 inches)	Less	4		60 mm (2.375 inches)*	Less	9
   	Normal	5			Normal	10
   	More	6			More	11
   32 mm (1.250 inches)	Less	4		64 mm (2.500 inches)*	Less	9
   	Normal	5			Normal	10
   	More	6			More	11
   35 mm (1.375 inches)	Less	4			* Fixed Plate Kits (Part No. 119-0646-03) are recommended for 51 to 64 mm (2.00 to 2.50 inch) heights of cut.
   	Normal	5
   	More	6

   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)	120-1641 (27 inch)	5.6 mm	6.4 to 12.7 mm
   	120-1642 (32 inch)	(0.220 inch)	(0.250 to 0.500 inch)
   EdgeMax® (Optional)	112-8910 (27 inch)	6.9 mm	9.5 to 63.5 mm
   	112-8956 (32 inch)	(0.270 inch)	(0.375 to 2.50 inches)*
   Standard (Production)	114-9388 (27 inch)	6.9 mm	9.5 to 63.5 mm
   	114-9389 (32 inch)	(0.270 inch)	(0.375 to 2.50 inches)*
   Heavy Duty (Optional)	114-9390 (27 inch)	9.3 mm	12.7 to 63.5 mm
   	114-9391 (32 inch)	(0.370 inch)	(0.500 to 2.50 inches)
   * Warm-season grasses may require the Low HOC bedknife for 12.7 mm (0.500 inch) and below.

   

   Figure 20

   1. Bedknife lip height*

6. To adjust the height of cut when fixed plate kits are installed on the cutting units, proceed as follows:

   • Remove the height-of-cut brackets and the front roller as described in Procedure 5 in the Setup section.

   • Install the cutting unit onto the traction unit as described in the traction unit Operator's Manual.

   • Lower the cutting unit to the floor and measure the distance from the floor to the top of the bedknife, as shown in Figure 21.

     

     Figure 21

     1. Fixed plate
     2. Upper mounting holes
     3. Rear height-of-cut spacers
     4. Height of cut

   • To attain the desired height of cut, adjust the rear roller brackets to the desired height-of-cut range by positioning the required amount of spacers below the side-plate mounting flange per the HOC chart. Refer to Adjusting the Rear Roller.

     Note: To achieve a less aggressive cut, mount the cutting unit links in the number 1 position or mount the links to the number 3 position for a more aggressive cut.

Whenever the cutting unit has to be tipped to expose the bedknife/reel, prop up the rear of the cutting unit with the kickstand (supplied with the traction unit) to make sure that the nuts on the back end of the bedbar adjusting screws are not resting on the work surface (Figure 23).

Figure 23

1. Kickstand

Figure 24

1. Relief valve

Each cutting unit has 5 grease fittings (Figure 24) that must be lubricated regularly with No. 2 lithium grease.

The lubrication points are the front roller (2), the rear roller (2), and the motor spline (1).

Note: Lubricating the cutting units immediately after washing helps purge water out of the bearings and increases bearing life.

1. Wipe each grease fitting with a clean rag.

2. Apply grease until clean grease comes out of the roller seals and the bearing relief valve.

3. Wipe excess grease away.

The new reel has a land width of 1.3 to 1.5 mm (0.050 to 0.060 inch) and a 30 degree relief grind.

When the land width gets larger than 3 mm (0.120 inch) wide, do the following:

1. Apply a 30 degree relief grind on all reel blades until the land width is 1.3 mm (0.050 inch) wide (Figure 25).

   

   Figure 25

   1. 30 degrees
   2. 1.3 mm (0.050 inch)

2. Spin grind the reel to achieve <0.025 mm (0.001 inch) reel run-out.

   Note: This causes the land width to grow slightly.

Note: To extend the longevity of the sharpness of the edge of the reel and the bedknife—after grinding the reel and/or the bedknife—check the reel to bedknife contact again after cutting 2 fairways, as any burrs will be removed, which may create improper reel to bedknife clearance and thus accelerate wear.

The bedknife service limits 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.

Figure 26

Recommended Top and Front Bedknife Grind Angles

1. Bedknife service limit*
2. Top grind angle
3. Front grind angle

Note: All bedknife service limit measurements relate to the bottom of the bedknife (Figure 27).

Figure 27

1. Remove all parts (refer to the Installation Instructions for the HD DPA Kit (Model No. 120-7230) and to Figure 36).

2. Apply anti-seize compound to the inside of the bushing area on the carrier frame of the cutting unit (Figure 36).

3. Align the keys on flange bushings to the slots in the frame and install the bushings (Figure 36).

4. Install a wave washer onto the adjuster shaft and slide the adjuster shaft into the flange bushings in the cutting unit frame (Figure 36).

5. Secure the adjuster shaft with a flat washer and lock nut (Figure 36). Torque the lock nut to 20 to 27 N-m (15 to 20 ft-lb).

   Note: The bedbar adjuster shaft has left-hand threads.

   

   Figure 36

   1. Shaft adjuster
   2. Wave washer
   3. Flange bushing
   4. Apply anti-seize compound here.
   5. Flat washer
   6. Locknut
   7. Apply anti-seize compound here.
   8. Bedbar-adjuster screw
   9. Hardened washer
   10. Compression spring
   11. Spring-tension nut

6. Apply anti-seize compound to the threads of the bedbar-adjuster screw that fit into the adjuster shaft.

7. Thread the bedbar-adjuster screw into the adjuster shaft.

8. Loosely install the hardened washer, spring, and spring-tension nut onto the adjuster screw.

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

10. Secure the bedbar to each side plate with the bedbar bolts (nuts on bolts) and 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 36). Torque the bedbar bolts to 27 to 36 N∙m (240 to 320 in-lb). Tighten the locknuts until the outside steel washer stops rotating and end play is removed, but do not overtighten or deflect the side plates. The washers on the inside may have a gap (Figure 32).

11. Tighten the nut on each bedbar-adjuster assembly until the compression spring is fully compressed, then loosen the nut 1/2 turn (Figure 33).

12. Repeat the procedure on the other end of the cutting unit.

13. Adjust the bedknife to the reel.

The Roller Rebuild Kit (Part No. 114-5430) and the Roller Rebuild Tool Kit (Part No. 115-0803) (Figure 37) are available for servicing the roller. The Roller Rebuild Kit includes all the bearings, bearing nuts, inner seals, and outer seals to rebuild a roller. The Roller Rebuild Tool Kit includes all the tools and the installation instructions required to rebuild a roller with the roller rebuild kit. Refer to your parts catalog or contact your authorized Toro distributor for assistance.

Figure 37

1. Roller Rebuild Kit (Part No. 114-5430)
2. Roller Rebuild Tool kit (Part No. 115-0803)
3. Inner seal
4. Bearing
5. Outer seal
6. Bearing nut
7. Inner seal tool
8. Washer
9. Bearing/outer-seal tool