Toro Greensmaster Cutting Unit Manual

Introduction

This cutting unit is designed to cut grass on golf course greens and short fairways. Using this product for purposes other than its intended use can cause injury to yourself and others.

Read this information carefully to learn how to operate and maintain the product and to prevent possible injuries and property damage. It is your responsibility to operate the product safely and correctly.

Visit www.Toro.com for training materials, accessory information, to find a dealer, or to register your product.

For service, original Toro parts, or additional information, contact an Authorized Toro Service Center or Toro Customer Care. Have your model and serial numbers ready. Figure 1 indicates the location of the model and serial numbers on the product. Record them in the spaces provided.

This manual uses two words to highlight information: Important draws attention to specific mechanical information, and Note highlights general information that should be considered.

Safety

General Safety

This product can amputate hands and feet. Always follow all safety instructions to prevent serious personal injury.

• Read and understand this manual before operating the machine.
• Pay full attention to your work. Do not let distractions cause injury or property damage.
• Keep hands and feet away from moving parts of the machine.
• Do not operate the machine unless all guards and safety devices are in place and functioning properly.
• Keep away from discharge openings.
• Keep children and bystanders away from the work area. Never allow children to operate the machine.
• Before leaving the operator's position: Park the machine on a level surface. Lower the cutting unit(s). Disengage the drive system(s). Engage the parking brake (if equipped). Stop the engine and remove the key.

Cutting Unit Safety

The cutting unit is part of a complete machine only when mounted to a traction unit. Read the traction unit Operator's Manual for complete safety instructions.

• Stop the machine, remove the key, or disconnect the spark plug wire, wait for all moving parts to stop, and inspect parts before continuing if the machine hits an object or vibrates abnormally. Perform any necessary repairs before resuming operation.
• Keep all parts in good working order and all hardware tight. Replace damaged or missing labels with new ones.
• Use only Toro-approved accessories, attachments, and replacement parts.

Blade Safety

A worn or damaged blade can break and scatter pieces, causing serious injury or death.

• Inspect blades regularly for wear or damage.
• Handle blades with care. Wear gloves when performing maintenance on blades. Replace or sharpen blades; never straighten or weld blades.
• On multi-blade machines, be aware that rotation of one blade can cause other blades to rotate.

Safety and Instruction Decals

Safety decals are placed on all points of potential hazard where the operator can easily see them. Replace damaged or missing decals with new ones.

⚠️ [Warning Symbol] - Keep away from moving parts; keep all guards and shields in place.

Installation

1. Front Roller Installation

The cutting unit is shipped without the front roller. Purchase a roller from your Toro dealer and attach it as follows:

Procedure:

1. Remove the blade bolt, washer, and flanged nut securing the cutting height arm to the cutting unit side plate (See Figure 3).
2. Loosen the cylinder mounting screws.
3. Slide the cylinder into the cutting height arm on the opposite side of the cutting unit.
4. Slide the cutting height arm onto the cylinder shaft.
5. Loosely secure the cylinder with the cutting height arm and fasteners removed in step 1.
6. Center the cylinder between the cutting height arms.
7. Tighten the cylinder mounting screws.
8. Adjust to the desired cutting height and tighten the cutting height arm fasteners.

Figure 3 shows parts for roller installation: 1. Blade bolt, 2. Cylinder, 3. Cutting height arm, 4. Adjustment screw, 5. Washer, 6. Flanged nut, 7. Cylinder mounting screw, 8. Cutting unit assembly.

2. Attaching Cutting Unit to Traction Unit

Attach the cutting unit to the traction unit; refer to the traction unit Operator's Manual for instructions.

3. Cutting Unit Adjustment

Procedure:

1. Lower the cutting unit arm to the ground to access the traction unit (See Figure 4).
2. Adjust the bottom blade to the reel; refer to "Bottom Blade to Reel Adjustment" (Page 8).
3. Adjust the cutting height; refer to "Cutting Height Adjustment" (Page 9).
4. Adjust the grass guard; refer to "Grass Guard Adjustment" (Page 13).

Figure 4 illustrates lowering the cutting unit.

Product Overview

Specifications

Optional Parts/Accessories

Various Toro-approved parts and accessories are available to enhance machine functionality. Contact your Toro dealer or visit www.Toro.com for a list. Use only genuine Toro parts and accessories for optimal performance and safety. Non-Toro parts may create hazards and void the warranty.

Operation

Refer to the traction unit Operator's Manual for detailed operating instructions. Adjust the bottom blade daily before mowing; refer to "Bottom Blade Daily Adjustment" (Page 7). Test cut on a practice area to ensure correct final cut quality.

Bottom Blade-to-Reel Adjustment

Check the bottom blade-to-reel contact daily before mowing or as needed. Perform this even if cutting quality is acceptable.

Note: This can be done with the cutting unit attached to the traction unit.

1. Stop the traction unit engine.
2. Lower the cutting unit arm to the ground to access the cutting unit (See Figure 5).
3. Slowly rotate the reel and listen for contact between the reel and bottom blade.
4. If there is no contact, adjust the bottom blade:Turn the bottom blade seat adjustment screws (See Figure 6) clockwise, one click at a time, until light contact is felt and heard.
5. Insert a strip of cutting performance paper (Toro Part No. 125-5610) between the reel and bottom blade. Slowly rotate the reel forward; the paper should be cut. If not, repeat steps A-B until the paper is cut.
6. If excessive contact/reel drag is noticed, perform back-lapping or sharpen the front edge of the bottom blade, or lap the cutting unit for sharp edges. Refer to the Toro Reel and Rotary Mower Lapping Manual (Form No. 09168SL).

Important: Light contact is preferred. If light contact cannot be achieved, the reel and bottom blade edges may not self-sharpen sufficiently and will dull over time. If there is excessive contact, the bottom blade/reel will wear faster, leading to uneven wear and reduced cutting quality.

Figure 5 shows lowering the cutting unit. Figure 6 shows the bottom blade seat adjustment screw.

Cutting Height Adjustment

Adjust the cutting height using the cutting height indicator to your desired height. Ensure the cutting unit is equipped with the appropriate bottom blade for the desired cutting height; refer to "Cutting Height and Bottom Blade Selection Tables" (Page 10).

Adjusting the Cutting Height Indicator

Before adjusting cutting height, set the cutting height indicator as follows:

1. Loosen the indicator arm nut and adjust the adjustment screw to your desired cutting height (See Figure 9).
2. Tighten the nut.

Figure 9 shows the cutting height indicator components: 1. Indicator arm, 2. Height adjustment screw, 3. Nut.

Adjusting Cutting Height

Loosen the locking nuts securing the cutting height arms to the cutting unit side plates (See Figure 10).

Figure 10 shows the cutting height adjustment mechanism: 1. Adjustment screw, 2. Locking nut, 3. Cutting height arm.

2. Position the cutting height indicator's screw tip against the right side of the bottom blade's cutting edge, and rest the rear of the arm on the traction reel (See Figure 11).
3. Turn the adjustment screw until it contacts the front of the indicator arm.
4. Repeat steps 2-3 for the left side.
5. Adjust both ends of the reel until the entire reel is parallel to the bottom blade.

Important: Proper adjustment ensures the reel and traction reel indicator arm contact, and the screw is snug against the bottom blade. This ensures consistent cutting height across both ends of the bottom blade.

6. Tighten the nuts to secure the adjustment, taking up any play in the linkage.
7. Confirm the cutting height is correct; repeat if necessary.

Figure 11 shows the cutting height adjustment setup: 1. Indicator arm, 2. Reel, 3. Bottom Blade, 4. Traction reel.

Maintenance

Cylinder Drive Shaft Greasing

Service Interval: Annually

1. Remove the hardware securing the cylinder drive assembly to the side plate (See Figure 12).
2. Remove the cylinder drive assembly, washers, lock washers, and spacers from the side plate (See Figure 12).
3. Check the grease level inside the cylinder drive shaft (See Figure 13).

If insufficient grease is present, add grease to the male and female splined shafts.

Figure 12 shows parts for removing the cylinder drive assembly: 1. Flat head screw, 2. Spacer, 3. Washer, 4. Lock washer, 5. Nut. Figure 13 shows the cylinder drive shaft.

4. Reattach the cylinder drive assembly to the side plate using the previously removed flat head screws, washers, and spacers.
5. Attach the cutting unit to the traction unit; refer to the traction unit Operator's Manual.

Cylinder Drive Belt Tension Adjustment

Service Interval: Annually

1. Remove the 3 screws holding the cover and remove the cover from the cylinder drive housing.
2. Loosen the idler arm bolt and rotate the idler arm to release belt tension.
3. Using a beam-type torque wrench, apply 6 to 7 N·m of force to the inner idler arm screw (See Figure 14).
4. Tighten the idler arm bolt to secure the idler arm.
5. Install the cover with the 3 screws.

Figure 14 shows belt drive components: 1. Flat head screw, 2. Belt cover, 3. Belt, 4. Idler arm hex bolt, 5. Idler arm, 6. Idler arm bolt.

Reel Speed Adjustment

Reel speed is determined by the following machine adjustments:

• Reel Speed: Reel speed can be set to a high or low speed; refer to the traction unit Operator's Manual.
• Reel Drive Pulley Position: The reel drive pulleys (22-tooth and 24-tooth) can be adjusted to 2 positions:
  • HIGH position: See Figure 15 "A".
  • LOW position: See Figure 15 "B".

Note: The pulley position is factory set to the LOW position.

To adjust pulley positions:

1. Remove the belt cover to access the belt (See Figure 16).
2. Loosen the idler arm bolt and rotate the idler arm to release belt tension.
3. Remove the belt (See Figure 16).

Figure 15 shows pulley positions: 1. 24-tooth pulley, 2. 22-tooth pulley. Figure 16 shows belt removal: 1. Cylinder drive assembly housing, 2. Belt, 3. Idler arm hex bolt, 4. Idler arm, 5. Idler arm bolt, 6. Belt cover, 7. Flat head screw.

4. Loosen the nut on each pulley, remove the pulleys, and install them in the desired configuration using the nuts.
5. Tighten the pulley nuts to 37 to 45 N·m.
6. Install the belt and tension it by rotating the idler arm using the idler arm hex bolt to 6 to 7 N·m, as shown in Figure 16.
7. Tighten the idler arm bolt and install the belt cover.

Grass Guard Adjustment

Adjust the grass guard to ensure clean discharge of clippings from the reel area.

Note: The guard can be adjusted to compensate for varying turf conditions. If the turf is excessively dry, adjust the guard closer to the reel. If the turf is excessively wet, adjust the guard farther from the reel. For optimum performance, the guard should be parallel to the reel. Readjust the guard after the reel has been lapped using a reel lapping unit.

1. Loosen the screws securing the grass guard (See Figure 18) to the cutting unit.
2. Insert a 1.5 mm feeler gauge between the top of the reel and the guard, then tighten the screws.

Important: Check that the guard and reel are equidistant along the entire reel.

Note: Adjust the clearance based on your turf conditions.

Figure 18 shows grass guard adjustment: 1. Grass guard, 2. Bolt (2), 3. Side plate, 4. Support bracket.

Blade Maintenance

Bottom Blade Specifications

To prevent damage to the reel or reel seat, only trained technicians should service the bottom blade and reel seat. It is recommended to take your cutting unit to an Authorized Toro Dealer for maintenance. Refer to the traction unit Maintenance Manual for all instructions, special tools, and blade maintenance diagrams. If you must remove the bottom blade seat yourself, follow the instructions below, which include bottom blade maintenance instructions.

Important: Always follow the bottom blade procedures detailed in the Maintenance Manual when servicing the bottom blade. Improper installation or sharpening of the bottom blade can damage the reel, reel seat, or bottom blade.

Removing Bottom Blade / Blade Assembly

1. Turn the bottom blade seat adjustment screw counter-clockwise to move the bottom blade away from the reel (See Figure 19).
2. Remove and turn the spring tension nut counter-clockwise until the tension on the washer against the bottom blade seat is released (See Figure 19).
3. On each side of the machine, loosen the locking nut as shown in Figure 20.
4. Remove each bottom blade seat bolt to allow the bottom blade seat to be pulled down and removed from the cutting unit. Account for the 2 steel washers and 1 plastic washer on each end of the bottom blade seat (See Figure 20).
5. Remove the bottom blade by loosening all screws holding it in place. Use the Bottom Blade Wrench (Part No. TOR510880) and a socket wrench.

Note: You can use a mechanical or pneumatic impact wrench to loosen the bottom blade screws.

Note: Discard the bottom blade and screws.

Figure 19 shows blade seat adjustment: 1. Bottom blade seat adjustment screw, 2. Spring tension nut, 3. Bottom blade seat. Figure 20 shows blade seat bolts: 1. Bottom blade seat bolt, 2. Nut, 3. Steel washer, 4. Plastic washer, 5. Bottom blade seat.

Installing New Bottom Blade

1. Select a new bottom blade; refer to "Cutting Height and Bottom Blade Selection Tables" (Page 10).
2. Clean the bottom blade seat surface of rust, debris, and corrosion. Apply a thin coat of oil to the bottom blade seat surface.

Important: Do not remove cast material from the bottom blade seat. The center portion of the bottom blade seat is concave by design; do not lap this area.

3. Clean the threads on the bottom blade seat.
4. Apply lubricant to the new bottom blade screws and install the bottom blade onto the bottom blade seat (See Figure 21).

Important: Use only new bottom blade screws.

Note: The quantity of screws may vary depending on the bottom blade seat.

Figure 21 shows a 13-bolt bottom blade seat: 1. Bottom blade seat, 2. Bottom blade, 3. Screw.

5. Tighten 2 outer screws to 1 N·m.
6. Starting from the center of the bottom blade, tighten the screws to 25.9 +/- 1.4 N·m.

Important: Do not use a mechanical or pneumatic impact wrench to tighten the bottom blade screws.

7. Sharpen the new bottom blade; refer to "Bottom Blade Sharpening Specifications" (Page 15).

Bottom Blade Sharpening Specifications

The angle used for sharpening your bottom blades is very important.

Use the angle gauge (Toro Part No. 131-6828) to check the angle produced by your sharpening machine and correct any errors. Refer to Figure 24.

Figure 23 shows sharpening angles: 1. Support bevel angle, 2. Top surface, 3. Burr removal, 4. Front surface, 5. Front angle.

Bottom Blade Clearance (Top) Angle: Refer to Cutting Height and Bottom Blade Selection Tables (Page 10).

Front Angle Range: 13° to 17°

Fairway Bottom Blade Front Angle: 10°

Checking Top Bevel Angle

Place the angle gauge as shown in Figure 24, onto the lowest part of the bottom blade.

Figure 24 shows using the angle gauge: 1. Angle Gauge, 2. Angle gauge mounting element.

1. Press the Alt Zero button on the angle gauge.
2. Position the angle gauge mounting element so the magnet edge aligns with the blade edge (See Figure 25).

Note: In this step, the digital display should be visible from the same side as step 1.

Figure 25 shows positioning the angle gauge: 1. Angle Gauge Mounting Element, 2. Magnet edge aligned with blade edge, 3. Bottom Blade, 4. Angle Gauge.

4. Place the angle gauge onto the mounting element as shown in Figure 25.

Note: This is the angle produced by your sharpening machine and should be within 2 degrees of the recommended top bevel angle.

Installing Blade / Blade Seat Assembly

1. Install the blade/blade seat assembly by placing the mounting ears between the washers and the bottom blade seat adjustment screw (See Figure 19).

Important: Align the DPA adjusters as shown in Figure 26, centered on the bottom blade seat ears. If DPA adjusters are mounted opposite the bottom blade seat ears, this may adversely affect bottom blade-to-reel contact.

Figure 26 shows DPA adjusters: 1. Bottom blade seat ears, 2. DPA adjuster.

2. Secure the bottom blade to the seat using the bottom blade seat bolts (with nuts) and 3 washers (6 total) on each side plate.
3. Place one nylon washer on each side of the side plate projection. Place one steel washer on the outside of each nylon washer (See Figure 27).
4. Tighten the bottom blade seat bolts to 27 to 36 N·m.
5. Tighten the locking nuts until the end play of the steel washers is taken up, but you can still turn the washers by hand. There may be play in the inner washers.

Important: Do not overtighten the locking nuts, as this can deform the side plates.

6. Tighten the spring tension nut until the spring is compressed, then back it off 1/2 turn (See Figure 27).

Figure 27 shows spring adjustment: 1. Spring tension nut, 2. Spring.

7. Adjust the bottom blade to the reel; refer to "Bottom Blade to Reel Adjustment" (Page 8).

Cylinder Sharpening

Preparing the Reel for Sharpening

1. Before sharpening, inspect all cutting unit components and correct any problems.
2. To sharpen the reel according to the following specifications, follow the reel sharpening machine manufacturer's instructions.

Perform a circular grind on the reel to achieve a reel-to-blade clearance of less than 0.025 mm.

Note: This will result in a slight increase in the support width.

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

Note: To ensure reel edge sharpness and extend bottom blade life, sharpen the reel and/or bottom blade, then cut 2 greens and recheck reel-to-blade contact (any burrs will be removed this way). Burrs can affect the clearance between the reel and bottom blade, accelerating wear.

Reel Back-Lapping

Use the Access Reel Back-Lapping Kit (Model No.: 139-4342) or Reel Back-Lapping Kit (Model No.: 04800); refer to the installation instructions in the kit. Contact your authorized Toro distributor to purchase these kits.

Company Information

Toro Company Statement

Toro Company, 8111 Lyndale Ave. South, Bloomington, MN, USA, declares that the following units, when installed according to the instructions provided with various Toro models and as specified in the relevant Declaration of Conformity, comply with the listed directives.

Relevant technical documents are prepared as provided in Annex VII, Part B of Directive 2006/42/EC.

Toro agrees to provide information regarding this partially assembled machine to national authorities upon request. Information will be provided electronically.

EU Declaration of Conformity: This machine must not be put into service until it has been incorporated into approved Toro models as specified in the relevant Declaration of Conformity and all instructions have been followed.

UK Declaration of Incorporation: This declaration has been issued under the sole responsibility of the manufacturer. The object of the declaration is in conformity with relevant UK legislation.

Toro Warranty

Toro Company warrants its Commercial Products for two years or 1,500 hours of operation, whichever comes first, against defects in material and workmanship. This warranty applies to all products except Aerators (refer to separate warranty statements for these products). If a condition arises during the warranty period, Toro will repair the product free of charge, including labor, parts, and transportation, at no charge. This warranty begins on the date the product is shipped to the original retail purchaser.

* A hour meter is installed on the product.

Obtaining Warranty Service: It is your responsibility to notify your Commercial Products Distributor or Authorized Commercial Products Dealer immediately if you believe there is a warranty condition. If you need help finding a Commercial Products Distributor or Authorized Dealer, or have questions about your warranty rights and responsibilities, contact us at:

Toro Commercial Products Service Department
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-952-2740
Email: commercial.warranty@toro.com

Owner's Responsibilities: As the owner of the product, it is your responsibility to perform the required maintenance and adjustments as outlined in the Operator's Manual. Repairs of problems caused by the failure to perform required maintenance and adjustments are not covered by this warranty.

Exclusions and Conditions: This warranty does not cover any failures or breakdowns that occur during the warranty period that are not based on defective material or workmanship. This warranty does not cover:

• Product failures resulting from the use of replacement parts not supplied by Toro, or from the installation and use of attachments or modifications not manufactured by Toro.
• Product failures resulting from failure to perform recommended maintenance and/or adjustments.
• Product failures resulting from the operation of the product in a negligent, careless, or reckless manner.
• Consumable parts that are not defective and are used up in normal operation. Examples of parts that are consumed or wear out during normal operation include, but are not limited to, brake pads and linings, clutch discs, blades, coils, bearings (sealed or lubricated), bed knives, spark plugs, tires and bearings, tires, filters, and belts, as well as diaphragms, nozzles, flow meters, and check valves for specific spray components.
• Failures resulting from external causes, including but not limited to, weather conditions, storage practices, contamination, improper fuels, coolant, lubricants, additives, fertilizers, water, or chemicals.
• Failures and performance issues resulting from fuels that do not conform to applicable industrial standards (e.g., gasoline, diesel, or biodiesel).
• Normal noise, vibration, wear, tear, and deterioration. Normal "wear and tear" includes, but is not limited to, damage to bearings from wear or scoring, wear on painted surfaces, and scratches on labels or glass.
• Replacement of parts scheduled as required maintenance activity is covered by the warranty until the scheduled replacement time for that part. Parts replaced under this warranty remain covered for the remainder of the original product warranty period and become Toro's property. Toro reserves the right to make the final decision on whether to repair or replace any part. Toro may use remanufactured parts for warranty repairs.

Privacy Statement: Toro respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company/dealer. Toro may use this information to register your warranty, process your warranty claim, or contact you in the event of a product recall, or for legitimate business purposes such as measuring customer satisfaction, improving our products, or providing you with product information that may be of interest. Toro may share this information with its affiliates, subsidiaries, dealers, or other business partners involved in such activities. We may also disclose your personal information if required by law or in connection with the sale, acquisition, or merger of a business. We will never sell your personal information to another company for marketing purposes.