8-Blade, 11-Blade, or 14-Blade EdgeSeries™ DPA Cutting Unit

Greensmaster® 3300 or 3400 Series Traction Unit

Model No. 04651-Serial No. 408000000 and Up

Model No. 04653-Serial No. 408000000 and Up

Model No. 04655-Serial No. 408000000 and Up

Introduction

This cutting unit is designed for cutting turf on greens and small fairways of golf courses. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.

Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.

Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.

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Figure 1

  1. Model and serial number location

This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

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Figure 2

Safety-alert symbol

This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

This product complies with all relevant European directives. For details, please see the Declaration of Incorporation (DOI) at the back of this publication.

Safety

This machine has been designed in accordance with EN ISO 5395 and ANSI B71.4–2017.

General Safety

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 engine.

  • 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 working on the machine.

  • Keep clear of any discharge opening. Keep bystanders and pets away from the machine.

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

  • Park the machine on a level surface, lower the cutting units, disengage the drives, engage the parking brake (if provided), shut off the engine, and remove the key before leaving the operator's position for any reason.

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 Graphic, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with these instructions may result in personal injury or death.

Cutting Unit Safety

  • The cutting unit is only a part of 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, and wait for all moving parts 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.

Blade Safety

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

  • Inspect the reel and bedknife periodically for wear or damage.

  • Use care and wear gloves when checking or servicing the reel and bedknife.

  • On machines with multiple cutting units, take care as rotating 1 reel can cause other reels to rotate.

Safety and Instructional Decals

Graphic

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.
decal137-9706

137-9706

  1. Cutting hazard of the hand or foot—shut off the engine, remove the key or disconnect the spark plug, wait for all moving parts to stop, and read the Operator’s Manual before performing maintenance.

Setup

Installing the Roller

The cutting unit is shipped without a front roller. Obtain a roller from your dealer and install it on the cutting unit, as follows:

  1. Remove the plow bolt, washer, and flange nut securing one of the height-of-cut arms to the cutting unit side plate (Figure 3).

    g278288

    Figure 3

    1. Height-of-cut arm
    2. Adjusting screw
    3. Plow bolt
    4. Flange nut
    5. Roller-mounting screw

  2. Loosen the roller-mounting screws in the height-of-cut arms (Figure 3).

  3. Slide the roller shaft into the height-of-cut arm on the opposite end of the cutting unit (Figure 3).

  4. Slide the height-of-cut arm onto the roller shaft (Figure 3).

  5. Loosely secure the roller to the cutting unit with the height-of-cut arm and fasteners previously removed (Figure 3).

  6. Center the roller between the height-of-cut arms.

  7. Tighten the roller-mounting screws (Figure 3).

  8. Adjust to the desired height-of-cut and tighten the height-of-cut arm mounting fasteners.

Adjusting the Cutting Unit

  1. Support the cutting unit; refer to Supporting the Cutting Unit.

  2. Adjust the bedknife to the reel.

  3. Adjust the rear roller height.

  4. Adjust the height of cut.

  5. Adjust the cut-off bar.

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

Product Overview

Model NumberWeight
0465132 kg (71 lb)
0465334 kg (74 lb)
0465535 kg (77 lb)

Attachments/Accessories

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.

Operation

Refer to your traction unit Operator’s Manual for detailed operation instructions. Before using the cutting unit each day, adjust the bedknife; refer to Adjusting the Bedknife Daily. Test the quality of cut by cutting a test swath before using the cutting unit to ensure that the finished cut is correct.

Adjusting the Cutting Unit

Adjusting the Bedknife-to-Reel Contact

Adjusting the Bedknife Daily

Prior to mowing each day, or as required, 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, adjust the bedknife as follows:

      1. Turn the bedbar adjusting screws clockwise (Figure 4), 1 click at a time, until you feel and hear light contact.

        Note: The bedbar adjusting screws have detents corresponding to 0.018 mm (0.0007 inch) bedknife movement for each indexed position.

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        Figure 4

        1. Bedbar adjusting screw
        2. Bedbar-adjusting-screw nut (2)

      2. Insert a long strip of cutting performance paper between the reel and bedknife, perpendicular to the bedknife (Figure 5), then slowly rotate the reel forward; it should cut the paper; if not, repeat steps 1 and 2 until it does.

    • 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 you do not maintain light contact, the bedknife/reel edges will not sufficiently self-sharpen, and dull cutting edges will result after a period of operation. If you maintain excessive contact, bedknife/reel wear will be accelerated, uneven wear can result, and the quality of cut may decline.

    Note: As the reel blades continue to run against the bedknife, a slight burr will appear on the front cutting edge surface along the full length of the bedknife. Occasionally run a file across the front edge to remove this burr to improve cutting.After extended running, a ridge will eventually develop 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.

Adjusting the Bedknife to the Reel

Use this procedure during initial cutting-unit setup and after grinding, backlapping, or disassembling the reel. This is not a daily adjustment.

  1. Position the cutting unit on a flat, level work surface.

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

    Note: Ensure that the nuts on the back of the bedbar adjusting bolts are not resting on the work surface (Figure 12).

  3. Rotate the reel so that 1 of the blades crosses the bedknife edge between the first and second bedknife bolt heads located on the right side of the cutting unit.

  4. Make an identifying mark on the blade where it crosses the bedknife edge.

    Note: This will make later adjustments easier.

  5. Insert a 0.05 mm (0.002 inch) shim between the blade and the bedknife edge at the point marked in step 4.

  6. Turn the right bedbar adjusting bolt (Figure 4) until you feel light pressure on the shim when sliding it side-to-side. Remove the shim.

  7. For the left side of the cutting unit, slowly rotate the reel so that the closest blade crosses the bedknife edge between the first and second bolt heads.

  8. Repeat steps 4 through 6 for the left side of the cutting unit and left bedbar adjusting bolt.

  9. Repeat steps 5 and 6 until there is light pressure at the contact points on both the left and right sides of the cutting unit.

  10. To obtain light contact between the reel and bedknife, turn each bedbar adjusting bolt clockwise 3 clicks.

    Note: Each click on the bedbar adjusting bolt moves the bedknife 0.018 mm (0.0007 inches). Do not overtighten the adjusting bolts.Turning the adjusting bolt clockwise moves the bedknife edge closer to the reel. Turning the adjusting bolt counterclockwise moves the bedknife edge away from the reel.

  11. Insert a long strip of cutting performance paper between the reel and bedknife, perpendicular to the bedknife (Figure 5), then slowly rotate the reel forward; it should cut the paper; if not, turn each bedbar adjusting bolt clockwise 1 click and repeat this step until it cuts the paper.

    g000487

    Figure 5

Note: 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).

Adjusting the Rear-Roller Height

Depending on your desired height-of-cut range, you need to adjust the rear-roller brackets (Figure 6 or Figure 7) to the low or high position:

  • Position the spacer above the sideplate-mounting flange (factory setting) when the height-of-cut settings range from 1.5 mm to 6 mm (1/16 inch to 1/4 inch) as shown in Figure 6.

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    Figure 6

    1. Spacer
    2. Sideplate-mounting flange
    3. Roller bracket

  • Position the spacer below the sideplate-mounting flange when the height-of-cut settings range from 3 mm to 25 mm (1/8 inch to 1 inch) as shown in Figure 7.

    g014405

    Figure 7

    1. Sideplate-mounting flange
    2. Spacer
    3. Roller bracket

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

  2. Remove the 2 nuts securing each roller bracket and spacer to each sideplate mounting flange.

  3. Lower the roller and bolts from the sideplate mounting flanges and spacers.

  4. Place the spacers onto the bolts above or below the roller brackets, as required (Figure 6 or Figure 7).

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

Note: The position of the rear roller to the reel is controlled by the machining tolerances of the assembled components and paralleling is not required.

Adjusting the Height of Cut

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

BedknifePart No.Height-of-Cut
Edgemax Micro-cut (Standard)115-18801.5 to 4.7 mm (0.062 to 0.188 inch)
Edgemax Tournament (Optional)115-18813.1 to 12.7 mm (0.125 to 0.500 inch)
Micro-cut (Optional)93-42621.5 to 4.7 mm (0.062 to 0.188 inch)
Tournament (Optional)93-42633.1 to 12.7 mm (0.125 to 0.500 inch)
Extended Micro-cut (Optional)108-43031.5 to 4.7 mm (0.062 to 0.188 inch)
Extended Tournament (Optional)108-43023.1 to 12.7 mm (0.125 to 0.500 inch)
Low-cut (Optional)93-42644.7 to 25.4 mm (0.188 to 1.00 inch)
High-cut (Optional)94-63927.9 to 25.4 mm (0.312 to 1.00 inch)
Fairway (Optional)137–60979.5 to 25.4 mm (0.375 to 1.00 inch)
Fairway EdgeMax (optional)137-60929.5 to 25.4 mm (0.375 to 1.00 inch)

Note: For heights of cut greater than 9.5 mm (0.375 inch), install the high-height-of-cut kit.

Adjusting the Height-of-Cut Gauge

Before adjusting the height of cut, set the height-of-cut gauge as follows:

  1. Loosen the nut on the gauge bar and set the adjusting bolt to the desired height of cut (Figure 8).

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

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    Figure 8

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

  2. Tighten the nut.

Adjusting the Height of Cut

  1. Loosen the locknuts securing the height-of-cut arms to the cutting-unit side plates (Figure 9).

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    Figure 9

    1. Height-of-cut arm
    2. Flange locknut
    3. Adjusting bolt

  2. Hook the bolt head of the height-of-cut gauge onto the right side of the cutting edge of the bedknife and rest the rear end of the bar onto the rear of the roller (Figure 10).

    g014408

    Figure 10

    1. Gauge bar

  3. Rotate the adjusting bolt until the roller contacts the front of the gauge bar.

  4. Repeat steps 2 and 3 for the left side.

  5. 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 bolt is snug against the bedknife. This ensures that the height of cut is identical at both ends of the bedknife.

  6. Tighten the nuts to secure the adjustment enough to remove play from the washer.

  7. Verify that the height-of-cut setting is correct; repeat this procedure if necessary.

Adjusting the Cut-Off Bar

Adjust the cut-off bar to ensure that the clippings are cleanly discharged from the reel area, as follows:

Note: The bar is adjustable to compensate for changes in turf conditions. Adjust the bar closer to the reel when the turf is extremely dry. By contrast, adjust the bar further away from the reel when the turf conditions are wet. The bar should be parallel to the reel to ensure optimum performance. Adjust it whenever you sharpen the reel.

  1. Loosen the bolts securing the top bar (Figure 11) to the cutting unit.

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    Figure 11

    1. Cut-off bar

  2. Insert a 1.5 mm (0.060 inch) feeler gauge between the top of the reel and the bar then tighten the bolts.

    Important: Ensure that the bar and reel are equal distance apart across the complete reel.

    Note: Adjust the gap as needed for your turf conditions.

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Supporting the Cutting Unit

Whenever you need to tip the cutting unit to expose the bedknife/reel, prop up the rear of the cutting unit to ensure that the nuts on the back end of the bedbar-adjusting bolts are not resting on the work surface (Figure 12).

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Figure 12

  1. Prop (not provided)
  2. Bedbar-adjusting-screw nut (2)

Servicing the Bedbar

Only a properly trained mechanic should service the bedbar and bedknife to prevent damage to the reel, bedbar, or bedknife. Ideally, take the cutting unit to your authorized Toro distributor for service. Refer to the Service Manual for your traction unit for complete instructions, special tools, and diagrams for servicing the bedknife. Should you ever need to remove or assemble the bedbar yourself, instructions are provided below, as are the specifications for servicing the bedknife.

Important: Always follow the bedknife procedures detailed in your Service Manual when servicing the bedknife. Failure to install and grind the bed knife correctly can lead to damage to the reel, bedbar, or bedknife.

Removing the Bedbar

  1. Turn the bedbar adjusting screw, counterclockwise, to back the bedknife away from the reel (Figure 13).

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    Figure 13

    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 13).

  3. On each side of the machine, loosen the locknut securing the bedbar bolt (Figure 14).

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    Figure 14

    1. Bedbar bolt
    2. Locknut

  4. Remove each bedbar bolt allowing the bedbar to be pulled downward and removed from the cutting unit (Figure 14).

    Account for the 2 nylon washers and 1 steel washer on each end of the bedbar (Figure 15).

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    Figure 15

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

Assembling the Bedbar

  1. Install the bedbar, positioning the mounting ears between the washers and the bedbar-adjusting screw (Figure 13).

  2. Secure the bedbar to each side plate with the bedbar bolts (nuts on bolts) and 3 washers (6 total).

  3. Position a nylon washer on each side of the side-plate boss. Place a steel washer outside each of the nylon washers (Figure 15).

  4. Torque the bedbar bolts to 27 to 36 N∙m (240 to 320 inch-lb).

  5. Tighten the locknuts until you remove the end play from steel washers, but you are able to rotate them by hand. The washers on the inside may have a gap.

    Important: Do not overtighten the locknuts or they will deflect the side plates.

  6. Tighten the spring tension nut until the spring is collapsed, then back it off 1/2 turn (Figure 16).

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    Figure 16

    1. Spring-tension nut
    2. Spring

  7. Adjust the bedknife to the reel; refer to Adjusting the Bedknife-to-Reel Contact.

Bedknife Specifications

Installing the Bedknife

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

  2. Clean the screw threads.

  3. Apply never-seize compound to the screws and install the bedknife to the bedbar.

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    Figure 17

    1. Bedbar
    2. Bedknife
    3. Screw

  4. Torque the 2 outer screws to 1 N∙m (10 in-lb).

  5. Working form the center of the bedknife, torque the screws to 23 to 28 N∙m (200 to 250 in-lb).

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    Figure 18

    1. Bednife 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).

  6. Grind the bedknife.

Preparing the Reel for Grinding

  1. Ensure that all cutting unit components are in good condition and correct any issues before grinding.

  2. Follow the reel grinder manufacturer’s instructions to grind the cutting reel to the following specifications.

    Reel Grinding Specifications
    New Reel Diameter128.5 mm (5.06 inches)
    Reel Diameter Service Limit114.3 mm (4-1/2 inches)
    Blade Relief Angle30° ± 5°
    Blade Land Width1.0 mm (0.04 inches)
    Blade Land Width Range.8 to 1.2 mm (0.03 to 0.05 inches)
    Reel Diameter Taper Service Limit0.25 mm (1/100 inch)

Relief-Grinding the Reel

The new reel has a land width of 0.8 to 1.2 mm (0.03 to 0.05 inches) and a 30° relief grind.

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

  1. Apply a 30° relief grind on all reel blades until the land width is 0.76 mm (0.030 inch) wide (Figure 19.

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    Figure 19

    1. 30°
    2. .76 mm (0.030 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.

  3. Adjust the cutting unit; refer to your cutting unit Operator’s Manual.

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 at the end of each day, as any burrs will be removed, which may create improper reel to bedknife clearance and thus accelerate wear.

Bedknife Grinding Specifications

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Figure 20

  1. Relief angle
  2. Top face
  3. Remove burr
  4. Front face
  5. Front angle
Standard bedknife relief angle3° minimum
Extended bedknife relief angle7° minimum
Front Angle Range13° to 17°

Checking the Top Grind Angle

The angle that you use to grind your bedknives is very important.

Use the angle indicator (Toro Part No. 131-6828) and the angle-indicator mount (Toro Part No. 131-6829) to check the angle that your grinder produces and then correct for any grinder inaccuracy.

  1. Place the angle indicator on the bottom side of the bedknife as shown in Figure 21.

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    Figure 21

    1. Bedknife (vertical)
    2. Angle indicator

  2. Press the Alt Zero button on the angle indicator.

  3. Place the angle-indicator mount on the edge of the bedknife so that the edge of the magnet mates with the edge of the bedknife (Figure 22).

    Note: The digital display should be visible from the same side during this step as it was in step 1.

    g034114

    Figure 22

    1. Angle-indicator mount
    2. Edge of the magnet mated with the edge of the bedknife
    3. Bedknife
    4. Angle indicator

  4. Place the angle indicator on the mount as shown in Figure 22.

    Note: This is the angle that your grinder produces, and should be within 2 degrees of the recommended top grind angle.

Backlapping the Cutting Unit

Danger

Contact with the reel or other moving parts can result in personal injury.

Keep your fingers, hands, and clothing away from the reels or other moving parts.

  • Stay away from the reel while backlapping.

  • Never use a short-handled paint brush for backlapping. Long-handled brushes are available from your local authorized Toro distributor.

  1. Position the machine on a clean, level surface, lower the cutting units, stop the engine, engage the parking brake, and remove the ignition key.

  2. Remove the reel motors from the cutting units and disconnect and remove the cutting units from the lift arms.

  3. Connect the backlapping machine to the cutting unit by inserting a piece of 3/8 inch square stock into the splined coupling in the end of the cutting unit.

    Note: Additional instructions and procedures on Backlapping are available in your traction unit Operator’s Manual and the Toro Sharpening Reel and Rotary Mowers Manual, Form Number 80-300PT.

    Note: For a better cutting edge, run a file across the front face of the bedknife and reel when the lapping operation is completed. This will remove any burrs or rough edges that may have built up on the cutting edge.

Servicing the Roller

The Greens Roller Rebuild Kit (Part No. 140-5552) and the Greens Roller Rebuild Tool Kit (Part No. 140-5553) (Figure 23) are available for servicing the roller. The Roller Rebuild Kit includes all the bearings, bearing nuts, and 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.

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Figure 23

  1. Greens Roller Rebuild Kit (Part No. 140-5552)
  2. Greens Roller Rebuild Tool kit (Part No. 140-5553)
  3. Bearing
  4. Seal
  5. V-ring
  6. Bearing locknut
  7. Flat washer
  8. Bearing/outer-seal tool