Reel Basics

8/3/2019 Reel Basics

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Commercial Products

Fundamentals ofReel Mowers

PART NO. 98008SL, Rev. C


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Fundamentals of Reel Mowers 1

TORO Service Training

Table of Contents

Historical Background ..................................................................................................... 2

Theory of Operation ........................................................................................................ 4

Importance of the Operator............................................................................................. 8

Preventive Maintenance.................................................................................................. 9

Set-up and Adjustments................................................................................................ 11

Sharpening.................................................................................................................... 17


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2 Fundamentals of Reel Mowers


Historical Background

The concept of the reel mower goes back tothe 1800s. It evolved out of a need forgroomed turf areas being maintained on aregular basis.

Golf course development during the 1920s

and 30s brought about design improvementsin engines and mower drive systems.

These improvements continued, allowing forlighter weight and easier to use equipment.


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The development of hydraulics during the 50'sand 60's improved the reliability, safety,operator comfort and lowered maintenancecosts.

Although dramatic improvements have beenmade in reel type mowers, some of the samefrustrations that developed working with reelcutting units years ago are still present today.If reel mowers unique characteristics are not

understood and responded to, the end resultwill be a poor quality of cut and expensivedown time and repairs.


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Theory of Operation

There are three main structural members in areel cutting unit:

The REEL consists of varying numbers of helix

shaped blades attached to support spiderswhich are mounted on a rotating shaft.

The BEDKNIFE is attached to the bedbar andthe assembly is mounted to the main frame ina manner that allows for paralleling andadjustment to the reel.

The FRAME supports the rollers, the bedbarassembly and reel with its drive mechanism,which can be hydraulic, belt driven or grounddriven.

A reel mower cuts grass with a scissors-likeshearing action as the moving helix shapedblades pass over the stationary bedknife. Thecutting action requires that the bedknife andreel blades be sharp, matched, and in closerelationship with each other.

When properly maintained and operated, reelmowers provide superior quality of cut. Itcannot be overstated that reel mowers areprecision tools. It is essential that they beadjusted and operated with this in mind.

Reel Mower ClipTo understand reel cutting theory, you must understand the concept of clip and the shear point. A shearpoint is any single point of contact made between the reel blade and bedknife.

Clip is the forward distance traveled betweensuccessive blade contacts at one shear point.


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Factors Affecting Clip The diameter of the reel

The number of reel blades

The speed of the reel

The ground speed.

By following the blade path through two clipsas the machine moves forward we canillustrate the actual process of cutting grass.The bedknife pushes grass toward the shearpoint while the reel blade gathers it in front.Each blade path has one-half clip in which tocut all the grass

Note that the grass outside of the forward halfclip is not easily gathered. The general rule ofthumb concerning height of cut vs. clip is thatboth measurements should be within 20% ofeach other. The best results will be obtainedwhen height of cut is equal to or close to theclip.

Grass extending beyond the forward half clip,yet tall enough to be within the blade path isless likely to be cut. Reel blades may contactthe grass in this area several times prior to theactual gathering of the grass. This is the socalled fanning process. This process is morea mechanical striking of the grass that it is ofthe commonly thought effect of a blowingaction.


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This is an extreme case corrugation. Becauseof an imbalance between height of cut andclip, the grass is cut with extreme valleys andpeaks.

NOTE: If you change equipment or height ofcut you may notice some corrugation after thefirst mowing. This will go away after the grass

is maintained at the new height of cut over aperiod of time.

The importance of the bedknife front angle isvisible from the side view. Note that the properangle allows the grass behind the bedknifefront edge to be more effectively cut.

A front view illustrates the angle between the

bedknife and the reel blade which is called thehelix angle.


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Another term known as the cutting path is theresult of the helix angle and the forward motionof the cutting unit. The shear point movesdown the bedknife as the bedknife movesforward. The grass is physically cut at an angleto the bedknife.

Cross section of turf cut at various heights

1/2 1 1-1/2 2

Other factors which affect reel mowing are thegrass density and the grass acclimation orgrain. Grass tends to thicken at the normalmaintained height of cut. The denser thegrass, the easier it is for the bedknife and reelto gather it. Grass density and grain can oftenoverride other factors we have discussedregarding the cutting action.

The basic requirements for good performanceof reel mowers are:

The cutting edges on the reel bladesand bedknife must be straight andsharp.

The bedknife must be exactly parallelwith the reel.

The bedknife should be positionedagainst the reel with light contact.

These requirements will be discussed in moredetail later.


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Importance of the Operator

The Operator has a significant influence on the quality of cut that a reel mower can deliver.

The large investment in specialized mowing

equipment cannot be jeopardized byunqualified operators. Before an operator canbe considered qualified to operate a piece ofequipment, there should be a significant effortby the supervisor towards their training andfamiliarization with each piece of equipment.

Make sure the operator reads andunderstands the Operators Manual. Have theoperator watch the Operator Training Video,then explain any unique methods orprocedures used on your grounds.

A supervisor should play a key role inestablishing the proper attitude and behaviorpatterns toward operating turf equipment. Asupervisor should not create the impressionthat a few minutes orientation on a piece ofequipment will qualify the operator.

Operators and service technicians play asignificant role in determining quality of cut,down time, and life of mowing equipment.Make a commitment to train and familiarizestaff with each product. Remember, that eachtype of mowing equipment will have specificoperating characteristics, and noise qualities.Operators should become familiar with theproduct and listen for any unusual changes.Concerns should be reported to the servicetechnician 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 maintenanceprogram.

Doing scheduled maintenance andadjustments will prolong the life of yourequipment, help prevent expensive downtime,and give the best possible quality of cut andperformance. Experience has shown that ahigh percentage of problems that occur in turfequipment have developed over a period oftime and could have been prevented byadjustment, lubrication, or other requiredmaintenance.

Follow the maintenance and adjustmentrecommendations listed in the OperatorsManual. Some products may also have a

Quick Reference maintenance decal on themachine. Recommended maintenanceintervals should be considered minimumrequirements. If the equipment is operated inparticularly harsh conditions, such as very hotweather, during the grow in period afterconstruction, or on topdressed greens, theseprocedures may have to be performed moreoften.

Use original Toro parts when doingmaintenance or repairs. These parts havebeen tested and designed for this specific,very demanding, application. Will fit partsmay look the same and fit, but they can givetotally different performance. Dont take a riskon your important equipment investment bysaving a little money now that can cost youexpensive repairs or increased maintenanceintervals later.


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The operator and service technician shouldmake a thorough visual examination of theproduct each day. This can identify oil leaks,low oil levels, loose or bent components andabnormal noises.

The maintenance charts and OperatorsManuals should be used for reference toidentify specific areas requiring ongoingscheduled maintenance. Service Manuals andTraining Guides are also available for many

models.

Information about Service Education Materials,Maintenance Schedules, Service Bulletins andmore is also available on the Internet at:

www.toro.com/golf/custsvc.html

Keep Thinking and Be Aware !Mowing equipment is designed for a specific application and should be operated keeping thoserestrictions in mind. Accidents and personal injuries can be minimized if persons will keep thinking andbe aware in their every day work habits.


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Set-up and Adjustments

Reel mower performance depends on proper setup and adjustment procedures. An error of .010 inch or.25 mm, in height endtoend, or from one cutting unit to another, is visible as a mismatch on many golfcourse greens. Although there are design variations in cutting units, most require the same basicprocedures. A surface plate, accurate height of cut tools and proper instruction are essential for setting up

a cutting unit.

Factors that affect quality of cut Tire pressure

Engine governed speed

Reel bearingcondition/adjustment

Reel and bedknifesharpness

Bedknife parallel to reel

Bedknife to reel contact

Bedknife attitude (angle)

Roller(s) parallel to reel Height of cut (bench set

vs. actual)

Correct bedknife

Cutting unit alignmentand ground following

Roller and roller bearingcondition

Reel speed

Traction speed

Cutting unit drop speedand sequence

Cutting unitcounterbalance or downpressure setting

There are many factors that can affect qualityof cut, including condition of the mowingequipment and agronomic factors. Turfconditions such as excessive thatch,sponginess or attempting to cut off too muchgrass height may not always be overcome byadjusting the machine. It is important toremember that the lower the height of cut, themore critical these factors are.

Remember that the effective or actual height

of cut depends on cutting unit weight, cuttingunit accessories and turf conditions. Effectiveheight of cut will be different than the benchset height of cut.

Effective height of cut is the actual height thegrass has been cut. Making an accurate heightmeasurement on the turf is difficult due tomany variables. A true base is simply notpresent. If the surface is uneven, spongy orvaries in density, color variations in the turfmay appear in the form of a streak. This is dueto the effective height of cut being too low for

the existing turf conditions. To correctproblems, start or change a cultural practice,change cutting unit configuration or raise thebench set height of cut. The lower your heightof cut, the more predictable and smooth theturf surface must be.

To accurately maintain height of cut and performance, routinely check the following components:

Reel Bearings

Bedknife to Reel Adjustment

Attitude Adjustment Roller Parallelism

Height of Cut


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Check reel bearings for play and roughness.Replace if necessary. If adjustable (taperedroller bearing), adjust to no lash whilemaintaining free rotation of the reel.

Before performing any setup procedures, it iscritical that the reel and knife cutting edges arestraight and sharp. Lap or grind as necessary.Adjust as needed to ensure the knife and reelcontact their full length with LIGHT contact and

free reel rotation.

Note that different cutting unit models havedifferent methods of adjusting reel to bedknifecontact. The top illustration shows a four boltstyle adjustment mechanism. The bottomillustration shows a single point adjustmentmechanism.

Single point adjust cutting units also have anadjustment mechanism on one end of thebedknife for adjusting the bedknife parallel tothe reel (not shown). This bedknife leveling

mechanism could may be an eccentric pivotbolt on one end of the bedbar, or a capscrew /

jam nut assembly.


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Adjust the bedknife against the reel toEVENLY pinch one paper thickness across theentire width of the bedknife, then cut paperstrips to check blade sharpness. Put thecutting unit on the turf and check for lightbedknife to reel contact and free reel rotation.Do a final adjustment of bedknife to reelcontact if necessary.

Properly adjusting the bedknife to the reel isone of the most effective preventivemaintenance practices for reel mowers. Theamount of contact and how frequently it ischecked are major factors in performance. Alight contact adjustment, if maintained, willhelp keep cutting edges sharp on the reel andbedknife. This requires that the adjustment bechecked frequently at a predetermined timeinterval. Dulled cutting edges cannot becorrected immediately by adjustment or overtightening.

Do not wait until the quality of cut hasdeteriorated to check the bedknife to reeladjustment. If the cutting edges on the reel

blades and bedknife are not straight and sharpthe mowing results may not be acceptable.This is true even if all other setup proceduresare correct.


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The cutting unit attitude is the angle betweenthe bottom of the bedknife and the groundplane under the cutting unit. As the bedknifeattitude is changed, it is important to note thatthe reel to bedknife shear point changesrelative to the center line of the reel. This canchange the after cut appearance of the grass.The result may be better or worse depending

on several factors.

Bedknife attitude is adjusted by changing theheight of the front, rear, or both rollers. Aheight of cut change is NOT necessarily part ofa change to the bedknife attitude. A largeangle is also referred to as an aggressivebedknife attitude. A small angle (flat attitude)can have most or all of the bedknife riding ONthe turf. This can influence after cutappearance.

It will normally be an advantage to have the

front or the cutting edge of the bedknife lowerthan the back. This help prevent the bedbarfrom contacting the ground surface in very lowheights of cut. It will also prevent the streakingor ruffling of the turf after it has been cut andpassed over by the bedbar.

There is a limit on how much of a forwardangle the bedbar can be positioned to. If therear is positioned too high the reel position canbecome lower than the cutting edge, tearingthe grass and giving a poor quality of cut.

To achieve an acceptable quality of cut therollers must be parallel to the reel. Beforeadjusting roller parallelism, check for looseroller bearings. Adjust or replace the bearingsas necessary. First parallel the front or rearroller, which ever is NOT used for setting theheight of cut. This paralleling roller is set tomatch the reel using a surface plate fixture.With the reel blades resting on a raised bar onthe plate, use a piece of paper as a feelergauge along the bottom of the roller betweenthe roller and plate.


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Set the height of cut to the desired heightusing an accurate tool. This procedure mustbe done exactly the same on each cutting unit.Before doing this adjustment the bedknife androller not used for height of cut adjustmentmust be parallel to the reel as described onprevious slides.

As reel cutting unit design and configurationcontinue to evolve, height of cut settings mayneed modifying to retain visual and playabilitygoals.

Remember, the setting you are making here,the bench set height of cut, is different fromthe effective or actual height of cut in the turf.

There are some basic patterns that canappear on turf maintained with a reel mower.

The first pattern illustrates good adjustmentprocedures and properly maintained cuttingedges.

The second pattern shows many stragglers.This can be caused by:

Incorrect bedknife to reel adjustment

Dull cutting edges

Mowing outside of the optimum cliprate

Not using preparation devices

Inconsistent turf texture and density

Using the wrong type of roller


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The third pattern illustrates a single streak.This can be caused by:

Rifled or uneven wear on bedknife

Damaged area on bedknife fromhitting an object(s)

Loose bedknife screws

Bent reel blade

The fourth pattern shows multiple streaks. Thiscan be caused by heavy contact between thebedknife and reel, resulting in a rifled or wavybedknife.

It is normal for the mower to leave aftercutdirectional light and dark color paths. Theseoverall color paths are due to the turf beingrolled down in the direction the mower istraveling. A cut path going away from you willusually be lighter in color than the path comingtoward you. Smaller, individual color variationscan be due to differing turf types, densityvariations and straight line mower marks. A

spongy area is evident by the momentaryimpression left by feet on the surface.

Many turf discrepancies are subtle and requirecloser examination. In these instances, theTurfEvaluator grass viewing tool is helpful. Itcan assist turf managers in determiningcauses for poor reel mower performance andcomparing the effective height of cut of onemowed surface to another.

Turf Evaluator Tool - Model 04399

Guide to Evaluating Reel Mower

Performance and Using theTurf Evaluator - Part. No. 97931SL


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Sharpening

How can you tell if sharpening is necessary?

The grass is not cut cleanly

Streaks.

Stragglers. The cutting unit is noisy.

Its that time of year.

One sure way to determine the answer to this is by actually checking the cutting edges of the reel andbedknife to see if they are dull, nicked, bent or being run without light contact against one another.

Cutting units should be kept as sharp aspossible to:

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.

Provide excellent finished appearanceof the turf.

A grooved or wavy (rifled) reel or bedknife ismost often caused by operating the cutting unitwith heavy bedknife to reel contact. This

condition can only be corrected by grinding thereel and bedknife BACKLAPPING WILLNOT CORRECT THIS CONDITION.


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Reel blades, and the edge of the bedknifeshould be checked for damage visually and bycarefully feeling the edges. Of course, thisshould only be done when it is certain that thereel cannot be started, and never slide yourfingers down the edges lengthwise.

Rounded edges on the reel blades and

bedknife will cause the grass blades to bepinched and torn, rather than sheared offcleanly. When light contact is not maintained,dull edges will soon result.

Sharpening will also be required if the reel iscone shaped (tapered). All reels eventuallybecome tapered with use. If the reel is notadjusted or ground to a cylinder shape again, amismatch in the height cut between adjacentreels can result.

Sharpening Methods

Maintain proper ADJUSTMENT

BACKLAP the bedknife and reel

GRIND the reel and bedknife

There are several methods that may be usedto sharpen a cutting unit. The one that youchoose will depend upon the condition of thecutting unit. It should also make the mostsense for the anticipated use. For example, ifyou are about to mow greens that have been

core aerated or topdressed, you may not wantto grind the reels and install new bedknives.

As the reel blades run against the bedknife aslight burr will appear at the front cutting edgesurface the full length of the bedknife.Occasionally run a file or facing grinder acrossthe front edge to remove this burr to extendthe cutting performance of the machine.

Lapping must be done after single bladegrinding. This is done to establish a land areaand to insure a perfect match between thebedknife and the reel edge.

Lapping is not intended to be a reconditioningprocess to correct severely nicked or roundedblades, rifling or taper. If, after 5 minutes oflapping, the edge is not restored, it is time togrind the reel.


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It is important to understand that Toro reelmowers are designed and manufactured tooptimize available power from the engine andhydraulic systems. To help do this, we put arelief on every reel blade to reduce the widthof reel blade that contacts the bedknife. Thishas been proven to reduce powerrequirements, as well as allow the machine to

operate more efficiently. This can be veryimportant, depending on the terrain, type ofgrass and amount of grass being cut.

Toro has two different methods ofmanufacturing reel blades with a relief. Thereel blades are made from straight stock steeland then are either relief ground or the relief ismilled in. Either way, there is a relief on theblade when it is manufactured. A small groundrelief is also put on milled relief blades duringmanufacture.

There are two methods of grinding reels. Thisslide illustrates Spin Grinding (which is alsoknow as Flat Grinding).

With this method, both the reel and thegrinding stone are turning as the reel is beingsharpened. It is sometimes stated thatbacklapping is not required after spin grinding,because the reel is a perfect cylinder whengrinding is completed. This depends on properalignment of the reel in the grinder beforesharpening. Also, the bedknife and bedbarmust be straight and perfectly parallel to the

reel when it is mounted. Backlapping willremove burrs and rough edges, producing ahoned edge that will cut grass evenly.

If using a spin grinder to sharpen straight stockreel blades (such as on fairway mowers) someor all of the relief will be ground off. If you aregoing to restore the relief that was on theblade when was manufactured, you will needto also use the other method of grinding(single blade relief grinding). It isrecommended to do the relief grinding first,then spin grind to restore the reel to a cylindershape.


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This slide illustrates Single Blade Grinding(which is also know as Relief Grinding orBack Grinding).

Toro recommends a 30 degree relief angle oneach reel blade. The angle itself is not critical.You can put as little or as much angle on theblade as you think is proper. A larger angle will

take off more steel and the reel may have tobe replaced sooner. With a smaller angle, youmay have to grind the reel more often tomaintain a relief.

It is a good idea to follow a blade grindingsequence during the single blade grindingprocess so that the reel ends up as close to acylinder shape as possible. This will reduce theamount of backlapping needed after grindingis completed. The numbers shown in theillustration indicate one example of thesequence that may be used. Remember that afinal grind in a spin grinder, and/or somebacklapping will get the reel into a truecylindrical shape.

It will normally take several passes acrosseach reel blade to renew the sharp edge andremove the taper from the reel. This examplemay have required 4 or 5 passes and then wascompleted with a backlapping job to create theland area. NOTE: It is acceptable practice togrind in both directions across the blades. Thegoal is approximately a 30 degree back angleand a land area.


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If replacing the bedknife it is important to usethe following procedures:

Remove all rust, scale and corrosionfrom the bedbar surface beforeinstalling new bedknife.

Make sure the bedbar threads areclean.

Use new Toro screws. Apply anti

seize lubricant to the screw threadsbefore installing.

Tighten the screws working from thecenter toward each end of the bedbar.DO NOT use an impact wrenchFairway/utility mowers:250 300 in.lb. (288 345 KgCm)Greensmowers:200 - 250 in.lb. (230 - 288 KgCm)

Since there can be variations in the mountingsurface of the bedbar, a new bedknife may notbe perfectly flat after it is installed. Because ofthis, it is necessary to backlap or grind a new

bedknife after installing it to the bedbar. Followthe existing angle that was ground into thebedknife and grind only enough to make surethe top surface is true.

When regrinding a bedknife it is important touse the following procedures:

Remove the bedbar and bedknifeassembly from the cutting unit beforeattempting to grind a used bedknife.

Keep the bedknife fastened to thebedbar when grinding.

When grinding, be careful to not

overheat the bedknife. Remove smallamounts of material with each pass ofthe grinder.

Tighten the screws with a torque wrenchworking from the center toward each end of thebedbar.


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TOROService Training

When regrinding a cutting unit reel or bedknife. Use the specifications from the Toro Reel and BedknifeGrinding Guidelines. See the bedknife diagram on the previous page and the reel diagram on the following pagefor illustrations of each characteristic listed in the charts below. If the reel diameter is less than the service limitshown, it must be replaced.


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The basic information provided in this manualshould not only help you understand the howbut also give some insight into why someoperating, adjustment and maintenance

procedures are so important.

Understanding that reel mowers are precisionmachines requiring regular maintenance andadjustment can help achieve attractive,consistent after cut appearance while reducingdowntime and operating costs.


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