Reelmaster® 5, 7, and 11-Blade Reel Mower

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.

1. Slit the four corners of the carton so that the sides lie flat.

2. Remove the shipping caps from the wheel hubs.

   Note: Keep the shipping caps. Install them on the wheel hubs to prevent grinding dust from entering wheel bearing whenever you grind the reel.

Parts needed for this procedure:

1. Remove the shipping caps from the wheel hubs.

2. Install the drive wheels with cap screws and lock washers (Figure 3).

   

   Figure 3

Important: After the cutting unit is set up and installed on the towing frame, the bedknife and reel must be adjusted for light contact. Adjust the bedknife to the reel while the cutting unit is sitting on the grass to be cut because the force of turf against underside of bedknife during actual operation must be duplicated to ensure the correct setting. To ensure sharp cutting edges, the bedknife and reel must have light contact.

1. Stand behind the cutting unit.

2. Disengage the reel throwout knobs (Figure 4). Carefully spin the reel backward to ensure free movement.

3. While spinning the reel backward, rotate the bedknife adjusting knob counterclockwise (Figure 4) until the bedknife does not touch the reel blades.

   

   Figure 4

   1. Throwout knobs
   2. Bedknife adjusting knob

4. While spinning the reel backward, rotate the adjusting knob clockwise (Figure 4), one click at a time, until light contact of the bedknife and the reel is noticed or a whispering cutting sound is heard.

   Note: The spring arm (clicker) may be adjusted for positive detent by loosening the capscrews securing the spring arm to the adjustment arm retainer, adjust until a solid clicking sound is achieved when the adjusting knob is turned, and retighten the capscrews.

5. Check the reel “carry over” by spinning the reel backward again. The reel should rotate one to two complete revolutions. Less than one revolution indicates heavy contact, which means the bedknife and reel must be readjusted for light contact; refer to steps 1, 3, and 4.

6. At the beginning of the cutting day, when the reels are cold, engage the reel throwout knobs (Figure 4). Operate the cutting units for 15 to 20 minutes so that the bedknife and reel reach normal operating temperature; then stop the operation. Next, disengage the reel throwout knobs and spin the reel backward. A whispering sound, not clicking, should be emitted, and this assures the correct adjustment. If a whispering sound is not heard, the bedknife and reel must be readjusted; refer to steps 3–5. By contrast, when the reels are warm from being used, use only steps 1–5 to maintain light contact between the bedknife and the reel.

   Important: Never adjust the bedknife to the reel for light contact if the cutting units are cold because the increase in temperature during operation could cause the metal to expand and result in heavy contact. Heavy contact causes uneven bedknife wear and poor quality of cut. However, light contact between the bedknife and the reel, which is desirable, minimizes the wear and keeps the cutting edges sharp. Adjust for light contact every four hours or sooner, even though quality of cut is acceptable. When cutting units are operated in sparse grass or the temperature of the air is high, the adjustment for light contact must be checked even more frequently to avoid heavy contact between the bedknife and reel. If cutting units are not operated for a short time, one hour after any use, check for light contact after resuming operation for 15 to 20 minutes; refer to steps 1–6.

1. Position the cutting unit on a level surface. Remove any paint and grease from the bedknife and the reel cutting edges.

2. Make sure that the throwout knobs (Figure 5) are disengaged and the bedknife to reel contact is removed by turning the bedknife adjustment knob counterclockwise.

3. Insert a long strip of newspaper between the reel blade and the bedknife. While rotating the reel backward, turn the bedknife adjusting knob (Figure 5) clockwise, one click at a time, until the paper is pinched lightly, which results in the paper being cut or a slight drag when the paper is pulled.

   

   Figure 5

   1. Throwout knobs
   2. Bedknife adjusting knob

4. Continue to check for light contact across the full length of bedknife using paper. If light contact is not evident, the bedknife is not parallel to the reel.

5. Loosen the nut on the left bedbar pivot bolt enough to ease turning of eccentric bolt.

6. Parallel the bedknife to the reel by rotating the left bed–bar pivot bolt (Figure 6). The left pivot bolt has an offset thread which, when rotated, acts as a cam to raise or lower the bedbar. On the left hand pivot bolt there is an offset dot (Figure 6) which denotes the thread of the bolt. When the dot is in the up position (Figure 6) the left end of bedbar is raised. As the bolt is turned clockwise and the dot is lowered, so is the left end of the bedbar. The identification dot is to be positioned within the rear (180 degree) position when adjusting.

   

   Figure 6

   1. Bedbar pivot bolt

7. Rotate the left pivot bolt to raise or lower the bedbar.

8. Insert a long strip of newspaper between the reel blade and the bedknife. While rotating the reel backward, turn the bedknife adjusting knob clockwise, one click at a time, until the paper is pinched lightly, which results in the paper being cut or a slight drag when the paper is pulled.

9. When light contact is evident across the full length of bedknife, tighten the pivot bolt nut, while holding the bolt in position and check to make sure that the pivot bolt did not become misadjusted when tightened. Readjust as required.

   Important: To make sure that the bedknife and the reel are not damaged while the cutting units are transported to or installed on the towing frame, rotate the bedknife adjusting knob counterclockwise until the bedknife does not touch the reel.

The height of cut is adjustable in approximately 2.38 mm (3/32 inch) increments by raising or lowering rear roller.

1. Loosen the capscrews securing the adjusting nuts in the roller brackets (Figure 7).

   

   Figure 7

   1. Bottom edge of adjusting nut
   2. 11 blade mounting hole
   3. 5 and 7 blade mounting hole

2. Position the roller adjusting nuts in the desired notches and tighten the capscrews. Make sure that the same number of notches show below the adjusting nuts.

3. If a higher height of cut is desired, every notch moved adds approximately 2.38 mm (3/32 inch) to the cutting height.

   Note: These are bench settings. The cutting unit will cut at a different height in turf because of grass conditions and the weight of the cutting unit.

4. To make a finer adjustment to the cutting height or to adjust the roller, the adjusting nut may be moved 1/2 notch or 1.19 mm (3/64 inch) by using the following procedure:

   1. Remove the capscrew and the adjusting nut securing the roller bracket to the gear case. Do not move the roller bracket.

   2. Reposition the capscrew and the adjusting nut to the upper hole in the gear case.

   3. Slide the roller bracket up or down 1/2 notch to position the adjusting nut into the correct notch and tighten the capscrew.

• Mowing Speed—The cutting unit is designed to cut grass well at any ground speed between 1.6 and 9.66 km/h (1 and 6 mph) but for most turf conditions, ground speeds of 6.4 to 9.66 km/h (4 to 6 mph) produce the best quality of cut. Ground speed, however, must be reduced when turning because excessive speed will cause the outside cutting units to bounce and skip on the turf. Excessive heat, caused by the reel spinning too fast, can also damage the bedknife and the reel. Since the grass lubricates the bedknife and reel during operation, slow down when cutting sparse grass, extremely dry grass, or when trimming. Any lack or significant reduction of lubrication produces excessive heat buildup and, subsequently, heavy contact between the bedknife and the reel, which results in uneven bedknife wear and poor quality of cut. Therefore, reels must be disengaged and stopped before mowers are transported across parking lots, roads, or whenever the lubrication is minimal.

• Height of Cut—To determine the effective height of cut, the length of the grass to be cut must be checked. The height of cut should be set and the turf mowed frequently so that no more than 1/3 of the leaf is cut off. If the cutting unit is equipped with pneumatic tires, pressure must be maintained at 241.3 kpa (35 psi). Low tire pressure can cause bedknife to dip into the grass and scalp the turf. An uneven cut will likely result.

• Operating Sound —A cutting unit that is adjusted correctly gives off a whispering sound when operated. If there are buzzing, clicking, or metallic sounds, the cutting unit has probably been operated with heavy contact between the bedknife and the reel. The reel or bedknife could also have hit a foreign object. A noisy cutting unit must be stopped, repaired, and adjusted or severe damage will result.

• Mowing Pattern—To prevent grass from lying down and improved appearance of the turf, alternate mowing directions if possible, each time an area is cut.

1. Bedknife/Reel Contact (Figure 8) – There must be light contact between the bedknife and the reel to keep the cutting edges sharp and to produce an excellent quality of cut. By contrast, cutting units operated without light contact allow abrasive materials and grass to pass between the bedknife and the reel. This eroding action rounds off the bedknife and the reel cutting edges, which results in a poor quality of cut. If the cutting edges become round, the bedknife and the reel must be lapped. Excessive rounding off of the cutting edges may require that the bedknife and the reel be ground and lapped. Never compensate for round cutting edges by tightening the bedknife adjusting knob until there is heavy contact because the bedknife and the reel will wear unevenly and cause a rifling effect.

   

   Figure 8

   1. Sharp edges, light contact
   2. No contact, edges get dulled
   3. Contact adjustment, dull edges

   Note: Rifling is the uneven or wavy condition that develops on the bedknife and the reel when there is heavy contact between these two parts (Figure 9). Streaks of uncut grass and an overall poor quality of cut are signs of rifling. Grinding the bedknife and reel is the only way to repair a rifled cutting unit.

   

   Figure 9

   1. Nicked reel blades

2. Noise – A cutting unit that has sharp cutting edges and is adjusted with light contact will emit a desirable whispering sound when the reel is spinning. By contrast, buzzing, clicking, or metallic sounds during operation indicate that the cutting unit is probably being operated with heavy contact between the bedknife and the reel. Heavy contact causes uneven or wavy wear on the bedknife and reel cutting edges. Grinding is required to repair a damaged bedknife and reel. Although the bedknife and reel are adjusted correctly for light contact, notches will eventually develop at both ends of the bedknife. These notches must be rounded off or filed flush with cutting edge of bedknife to assure smooth operation.

3. Loose Reel Bearings – If reel bearings are suspected to be loose, check them immediately or extensive damage may result; refer to Reel Bearing Adjustment.

4. Hitting a Foreign Object – The bedknife and the reel cutting edges can be damaged if a foreign object is hit. The damage, if it is not too severe, can be repaired in the field. Start by filing down high spots on the bedknife and the reel (Figure 10). Use a ball peen hammer to straighten any reel blades that may be bent. Since the bedknife usually springs away from the reel upon impact, the bedknife must be adjusted; refer to Parallel the Bedknife to the Reel.

   

   Figure 10

1. Position the cutting unit on a level surface.

2. Raise and block the back of the cutting unit until there is approximately 26 cm (10-1/4 inches) between the bottom of the gear case extending behind the roller bracket and the level surface (Figure 12).

   

   Figure 12

   1. 26 cm (10-1/4 inches)
   2. Filler plug

3. Remove the filler plug from inside of each gear case (Figure 12). Check the oil level in the gear case; it should be level with the bottom of the filler hole. If the oil is level with bottom of the hole, install the filler plug.

   Important: Check for oil leaks caused by a worn or improperly installed O–ring or gasket, and loose side-plate bolts. Make all repairs before adding oil to the gear cases.

4. If the oil level is low, fill the gear case with 80W-90 gear lubricant to the point of overflowing and then install the filler plug.

   Important: Do not overfill the gear case.

The gear cases have been fully lubricated at the factory. Once each season, drain and clean the right and left gear cases. When the gear cases are clean, add 80W-90 gear lubricant; refer to Checking the Gear Case Oil.

1. Remove the wheels.

2. Rotate the wheel hub (Figure 13) to check the bearing adjustment. You should feel a slight drag when you rotate the hub. If drag is not evident, tighten the wheel hub nut (Figure 13) until you feel a slight drag when you rotate the hub.

   

   Figure 13

   1. Wheel hub
   2. Wheel hub nut
   3. O–ring

   Important: Do not over–tighten the wheel hub nut because the bearing will wear rapidly.

3. Check the O–ring to assure it is not damaged, and make sure that it is seated in the inside diameter of the wheel hub (Figure 13).

   Important: An O–ring that is damaged or installed incorrectly will allow oil to leak out of the gear case. If enough oil leaks out, mechanical damage will likely result.

4. If pneumatic wheels are installed, set the tire pressure at 241.3 Kpa (35 psi).

5. Install the drive wheels with cap screws and lock washers (Figure 14).

   

   Figure 14

1. Rotate the center adjusting knob until the bedknife does not contact the reel. Try to spin the reel. If the reel does not spin, adjust the reel bearings; refer to Adjusting the Reel Bearing in the Maintenance Section. If the reel spins freely, proceed to the next step.

2. Try to move the reel back and forth. If the reel can be moved, adjust the reel bearings; refer to Adjusting the Reel Bearings .

3. Check and tighten all nuts, bolts, and screws to ensure that all parts are secure.

If end play is evident in the reel or if the cutting unit has been disassembled, an adjustment to the reel bearing may be necessary.

1. Remove the 4 screws securing the left wheel to the wheel hub and remove the wheel. Place the wheel under the gear case for support.

2. Raise and block the back of the cutting unit until there is 0.178 to 0.203 m (7 to 8 inches) between the bottom of the gear case extending behind the roller bracket and the level surface.

3. Remove the 3 cap screws securing the inspection cover to the gear case cover.

4. In small increments, rotate the adjusting nut on the reel shaft, in the clockwise direction to remove all end play from the reel.

   Note: Stop the reel from rotating.

5. When the end play is removed, rotate the nut an additional 1/4 turn to preload the bearing.

6. Install the inspection cover and the wheel.

Note: For detailed sharpening information, refer to the Toro Manual for Sharpening Reel and Rotary Mowers, Form No. 09168SL.

New and old bedknives should be ground attached to the bedbar; this ensures rigidity during grinding and ensures a true knife. Refer to Figure 15 when grinding the knives and obtain as near as possible the relief angles indicated. In grinding, avoid hard contact between the knife and the grinding wheel. Hard contact causes excessive heat buildup, resulting in premature wearing of the grinding wheel and reduced life of the knife.

Figure 15

1. Front face
2. Cutting face

The land area and relief angle of the reel blade are pointed out in Figure 16. The land area is the part of the reel blade that actually comes in contact with the bedknife and cuts the grass in a scissors action. The relief or back grind angle is ground into the reel blade to provide clearance or relief behind the contacting edges to reduce drag or friction. The recommended relief angle is 15 degrees.

Figure 16

1. Bed knife
2. Reel blade
3. 15 to 20 degree relief angle
4. Land area established by lapping

Note: After a reel has run for an extended period of time the blade contact point or land area will keep getting wider and eventually will be the full blade width. This is normal and does not mean that the reel has to be reground to stay effective. A cutting unit can cut effectively with full width blades if the adjustment is checked frequently to maintain sharp cutting edges.After the reel and bedknife have been ground, perform the following adjustments:

1. Set the height of cut.

2. Adjust the bedknife to the reel.

   Note: As the reel blades continue to run against the bedknife a slight burr will appear on the front cutting edge surface the full length of the bedknife. If a file is occasionally run across the front edge to remove this burr, improved cutting can be obtained.

   If the reel blade edges and the bedknife edge are slightly rounded and do not have severe nicks, lapping only with a lapping compound may restore the edges and match. Oftentimes a cutting unit is deemed by users to need grinding when the reel bearing adjustment, bedknife adjustment and/or lapping is all that is necessary.

Prepare the cutting unit for lapping as follows:

1. Remove the right wheel.

2. Place the wheel under the gear case for support.

3. Remove the reel pinion cover (Figure 17).

   

   Figure 17

   1. Reel pinion cover

4. Disengage the reel.

5. Connect the lapping machine coupler to the nut on the end of the reel shaft.

   When lapping, use a good grade of commercial lapping compound. A medium grit should be for initial lapping and a fine grit for finishing. A solution of 1 part liquid detergent and 2 parts lapping compound is recommended. The liquid detergent greatly eases washing away the compound when finished. Water soluble oil may also be used as a compound carrier.

   Note: The lapping solution must be kept in free flowing condition to get even distribution on the bedknife and reel.

   The lapping procedure is as follows:

1. Adjust the bedknife to the reel so that light contact is evident.

2. Operate the lapping machine so that the reel turns in a reverse direction. Apply lapping solution continuously and maintain light bedknife-to-reel contact.

3. Stop the lapping machine periodically to check the cutting surfaces for sharpness. Continue lapping until the sharp cutting edges have been restored.

   Note: If the cutting edges are severely rounded, both sharpening and lapping may be required.

4. Wash off all the lapping solution. Using paper, check for sharpness along the entire length of each reel blade. If the paper cannot be cut cleanly along the entire length of each reel blade, continued lapping is necessary.

1. To replace the bedknife, remove the 11 screws holding the knife to the bed bar.

2. Remove the rust, scale, and corrosion from the bedbar surface and apply a thin layer of oil to the bedbar surface.

3. Clean the screw threads.

4. Apply anti-seize compound to the screws and install the bedknife to the bedbar as follows (Figure 18):

   

   Figure 18

   1. Bedbar
   2. Bedknife
   3. Screw

   1. Torque the 2 outer screws to 1 N∙m (10 in-lb); refer to Figure 19.

   2. Working form the center of the bedknife, torque the screws to 23 to 28 N∙m (200 to 250 in-lb); refer to Figure 19.

      

      Figure 19

      1. Bedknife screw tool
      2. Install and torque these first to 1 N∙m (10 in-lb).
      3. Torque to 23 to 28 N∙m (200 to 250 in-lb).

5. True the bedknife attached to the bedbar by grinding. Refer to the Toro Manual for Sharpening Reel and Rotary Mowers, Form No. 09168SL

6. After the bedknife has been ground and is true, adjust the reel, roller, and wheel bearing; refer to Adjusting the Reel, Roller, and Wheel Bearing.

After the initial 30 operating hours, check the reel bearing, roller bearing, and wheel bearing. Thereafter, check these parts every 200 to 250 operating hours. If necessary, adjust the reel bearing. If necessary, adjust the roller bearing. If necessary, adjust the wheel bearing.