Part No. 92783SL, Rev. B Service Manual Reelmaster 216/216-D ® Preface This publication provides the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 216 and Reelmaster 216-D REFER TO THE REELMASTER 216 OR 216-D OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided at the end of Chapter 2 in this publi cation to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Table Of Contents Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29 Chapter 2 - Product Records and Manuals Chapter 6 - Electrical System Chapter 1 - Safety Product Records. . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 1 Safety Table of Contents While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs . . . . . . . . . . . . . 3 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating. . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Instructions The Reelmaster 216/216-D has been tested and veri fied for compliance with the B71.
7. Make sure interlock switches are adjusted correctly so engine cannot be started unless traction pedal is in NEUTRAL and cutting units are DISENGAGED. 9. Since gasoline and diesel fuel is flammable, handle it carefully: A. Use an approved fuel container. B. Do not remove fuel tank cap while engine is hot or running. C. Do not smoke while handling fuel. D. Fill fuel tank outdoors and only to within an inch (25 mm) from the top of the tank, not the filler neck. Do not overfill. E. Wipe up any spilled fuel.
While Doing Maintenance, Troubleshooting, Testing, Adjustments or Repairs 25. Before servicing or making any adjustments, stop engine and remove key from switch. 26. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 27. Make sure all hydraulic line connections are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system. 28.
Safety Instructions Page 1 - 4 Reelmaster® 216/216-D
Chapter 2 Product Records and Manuals Table of Contents 1 2 2 2 3 3 3 MAINTENANCE CHARTS . . . . . . . . . . . . . . . . . . . . 4 Reelmaster 216 . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Reelmaster 216-D . . . . . . . . . . . . . . . . . . . . . . . . 5 Record information about your Reelmaster 216/216-D on the SERVICE HISTORY REPORT form. Use this information when referring to your machine.
Equivalents and Conversions Decimal and Millimeter Equivalents ___________________________________________________________________________________________________ Fractions Decimals mm Fractions Decimals mm ___________________________________________________________________________________________________ 1/64 0.015625 1/32 ––––– 0.03125 3/64 0.046875 1/16 –––––––––––– 0.0625 5/64 0.078125 3/32 ––––– 0.9375 7/64 0.109275 1/8 ––––––––––––– 0.1250 9/64 0.140625 5/32 ––––– 0.15625 11/64 0.
Torque Specifications The torque values listed below are for lubricated threads. Plated threads are considered to be lubricated. Use these torque values when specific torque values are not given. DO NOT use these values in place of specified values. Capscrew Markings and Torque Values - U.S.
Torque Specifications Page 2 - 4 Rev.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTER® 216 TORO Model and Serial Number:__________-__________ Engine Numbers: ____________________ Transmission Numbers: ____________________ Date Purchased: ____________________ Warranty Expires __________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone ______
REELMASTER® 216 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Check Battery Fluid/Connections Every 25hrs Lubricate Grease Fittings Service Air Filter Pre-Cleaner † Change Engine Oil † Check Traction Belt Tension Service Air Filter Paper Element Service Spark Plug † Torque Wheel Lug Nuts Every 100hrs Every 50hrs Every 200hrs Every 400hrs A Level Service B Level Service C Level Service † Replace Hydraulic Filter Adjust Electric
REELMASTER® 216 Daily Maintenance Check List Unit Designation: __________ Daily Maintenance: (duplicate this page for routine use) TORO ID#:_______-_______ Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _______HRS _______HRS _______HRS _______HRS _______HRS _______HRS _______HRS Safety Interlock Operation Brake Operation Engine Oil Level Air Filter Pre-Cleaner Clean Engine Cooling Fins Unusual Engine Noises Unusual Operating Noises Hydr
REELMASTER® 216 Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use) Unit Designation: TORO I.D.
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTER® 216-D TORO Model and Serial Number:__________-__________ Engine Numbers: ____________________ Transmission Numbers: ____________________ Date Purchased: ____________________ Warranty Expires__________ Purchased From: ____________________ ____________________ ____________________ Contacts: Parts ____________________ Phone __________________ Service ____________________ Phone __________________ Sales ____________________ Phone _____
REELMASTER® 216-D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Inspect Air Filter, Dust Cup, and Baffle Every 50hrs Lubricate All Grease Fittings † Change Engine Oil † Check Fan and Alternator Belt Tension † Change Engine Oil Filter † Check Traction Belt Tension Every 100hrs Every 200hrs Every 400hrs A Level Service B Level Service Service Air Filter Replace Fuel Filter/Water Separator C Level Service † Replace Hydraulic Filt
REELMASTER® 216-D Daily Maintenance Check List Unit Designation:__________ Daily Maintenance:(duplicate this page for routine use) TORO ID#:_______-_______ Daily Maintenance Check For Week Of _____________ Maintenance Check Item MON TUES WED THURS FRI SAT SUN _______HRS _______HRS _______HRS _______HRS _______HRS _______HRS _______HRS Safety Interlock Operation Brake Operation Engine Oil Level Cooling System Fluid Level Drain Water/Fuel Separator Air Filter, Dust Cup, Baffle Radiator & Screen
REELMASTER® 216-D Supervisor Maintenance Work Order Date:______________ (duplicate this page for routine use) Unit Designation: TORO I.D.
Chapter 3 Kohler Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Carburetor Adjustments. . . . . . . . . . . . . . . . . . . .
Adjustments Carburetor Adjustments Lack of power accompanied by black sooty exhaust smoke is usually caused by a rich carburetor setting. Since a dirty air cleaner element causes the same conditions, check it before adjusting carburetor. High RPM Setting Low RPM Setting 3600 ± 100 1200 ± 100 IMPORTANT: Check to make sure the choke is op erating correctly before the carburetor is adjusted. 1. Main fuel screw – Close screw by gently rotating it clockwise.
Chapter 4 Perkins Diesel Engine Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 2 Bleeding the Fuel System . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Throttle Linkage Adjustment . . . . . . . . . . . . . . . .
General Information Bleeding The Fuel System (Fig. 1, 2) 2 CAUTION Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill fuel tank while engine is running, hot or when machine is in an enclosed area. Always fill fuel tank outside and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety-approved container and keep cap in place. Use diesel fuel for the engine only; not for any other purpose.
Adjustments Throttle Linkage Adjustment 1. Adjust low engine speed to 1250 ± 50 RPM at engine. 2. With the engine off, adjust throttle stop on back side of control panel so throttle lever on engine goes against low speed adjustment screw at the same time throttle lever on control panel bottoms out. 3. Adjust high engine speed to 3200 ± 100 RPM at engine. 4. With engine off, move throttle control lever on control panel up to high speed position.
Adjustments Page 4 - 4 Reelmaster® 216/216-D
Chapter 5 Hydraulic System Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Fitting Information . . . . . . . . 3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . 6 Reelmaster 216 . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Reelmaster 216 3WD . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description __________________________________________________________________________________________ Pump (Fig.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature de terioration. Inspect the hoses frequently for signs of deterioration or damage. When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings.
SAE Straight Thread O-Ring Port - Non-adjustable (Fig. 6) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O-ring seal when this type of fitting shows signs of leakage. 3. Lubricate the O-ring with a light coating of oil. O-Ring 4. Install the fitting into the port and tighten it down full length until finger tight. 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
Towing (Fig. 9) In case of an emergency, the Reelmaster 216/216-D can be towed for a short distance. However, Toro does not recommend this as a standard procedure. 1 IMPORTANT: Do not tow the machine faster than 2 to 3 MPH because drive system may be damaged. If machine must be towed a longer distance, trans port it on a truck or trailer. 1. To tow machine rotate by-pass valve on pump coun terclockwise until it is fully open. 2.
WHEEL MOTOR (RIGHT) CHARGE CHECK VALVE OUT 5 CHARGE CHECK VALVE PILOT OPERATED VALVE 4 8 7 A - LOWER B - UPPER 6 TOP BY-PASS VALVE BOTTOM B B A IN CONTROL VALVE A FRONT Hydraulic Schematic (Reelmaster 216) RESERVOIR LIFT CYLINDER VARIABLE DISPLACEMENT PUMP 2 FILTER 3 FORWARD REVERSE CHARGE PUMP 1 CHARGE RELIEF VALVE IMPLEMENT RELIEF VALVE COOLER REAR PUMP WHEEL MOTOR (LEFT) Hydraulic Schematic (Reelmaster 216) Page 5 - 6 Reelmaster® 216/216-D
WHEEL MOTOR (RIGHT) FRONT Hydraulic Schematic (Reelmaster 216 3WD) FORWARD REVERSE CONTROL VALVE 8 5 OUT B SELECTOR (3WD) 4 PILOT OPERATED VALVE RESERVOIR IMPLEMENT RELIEF VALVE CHARGE RELIEF VALVE CHARGE PUMP WHEEL MOTOR (REAR) 1 TOP 7 FORWARD REVERSE LIFT CYLINDER CHARGE CHECK VALVE 6 A - LOWER B - UPPER BY-PASS VALVE CHARGE CHECK VALVE BOTTOM B A IN TOP A P.C. FLOW CONTROL 1.
Hydraulic Schematic (Reelmaster 216-D) WHEEL MOTOR (RIGHT) CONTROL VALVE VALVE TOP A VALVE BOTTOM B IN A - TOP BOTTOM - B BY-PASS VALVE 6 B - UPPER CHARGE CHECK VALVE CHARGE CHECK VALVE OUT 5 A - LOWER 7 8 4 BOTTOM FRONT LIFT CYLINDER RESERVOIR CHARGE RELIEF VALVE IMPLEMENT RELIEF VALVE FILTER REVERSE FORWARD CHARGE PUMP VARIABLE DISPLACEMENT PUMP 1 3 TOP FRONT 2 COOLER PUMP WHEEL MOTOR (LEFT) Hydraulic Schematic (Reelmaster 216-D) Page 5 - 8 Reelmaster® 216/216-D
Hydraulic Schematic (Reelmaster 216-D 3WD) Reelmaster® 216/216-D Page 5 - 9 Rev.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reelmaster 216 or Reelmaster 216-D Parts Catalog. Some tools may also be available from a local supplier. Hydraulic Pressure Test Kit (Fig. 10) Used to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports (if equipped) without tools.
Hydraulic Tester - With Pressure and Flow Capabilities (Fig. 11) Load Valve Low Pressure Gauge Outlet Hose Flow Meter Gauge Protector Valve High Pressure Gauge Inlet Hose Figure 11 You must have o-ring face seal (ORFS) adapter fittings for this tester to use it on the Reelmaster 216/216-D. 1. INLET HOSE: Hose connected from the system circuit to the inlet side of the hydraulic tester. 2. LOAD VALVE: If required, upon turning the valve to restrict flow, a simulated working load is created in the circuit.
Hydraulic Oil Reservoir Plug (Fig. 13) Used to temporarily plug the outlet of the hydraulic tank to retain most of the fluid when the hydraulic filter is removed. Figure 13 Special Tools Page 5 - 12 Rev.
Troubleshooting The cause of an improperly functioning hydraulic sys tem is best diagnosed with the use of proper testing equipment and a thorough understanding of the com plete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
Troubleshooting Page 5 - 14 Reelmaster® 216/216-D
Reelmaster® 216/216-D Page 5 - 15 NOTE: Before checking for problems in hydrau lic system, make sure brakes are released. Check for debris in brakes.
Troubleshooting Page 5 - 16 Reelmaster® 216/216-D
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
TEST HOOK-UP NO. 1: Charge Pump Flow and Implement Relief Pressure (Fig. 14, 15, 16) (Using Tester With Pressure and Flow Capabilities) Tester Connection Connect tester in series between implement pressure port of hydrostatic pump and pressure inlet port of lift valve (Flow Control Open). Reelmaster 216: Install tester between hose and fitting at front of valve. Reelmaster 216-D: Install tester between hose and fitting at bottom front of pump.
TEST HOOK-UP NO. 2: Traction Pump Flow, Traction Motors Mechanical Drag and Traction Motors Efficiency (Fig. 17, 18, 19) (Using Tester With Pressure and Flow Capabilities) Tester Connection Connect tester in series between traction forward pres sure port of hydrostatic pump and tee connection (Flow Control Open). Reelmaster 216: Install tester between hose coming from bottom front of pump and T-connection on tube line.
TEST B: Traction Motors Mechanical Drag TEST C: Traction Motors Efficiency 1. Make sure hydraulic oil is at operating temperature. 1. Make sure hydraulic oil is at operating temperature. 2. Block up one traction wheel off floor. 2. All wheels on floor. 3. Place blocks in front of two remaining wheels. 3. Block front of all wheels. 4. Operate engine at full speed: 4.
Test Hook-up No. 3: Charge Pressure and Implement Relief Pressure (Fig. 20) Gauge Connection Connect a 1000 PSI hydraulic pressure gauge to charge pressure gauge port. TEST A: Charge Pressure 1. Make sure hydraulic oil is at operating temperature. 1 2. Operate engine at full speed: Reelmaster 216: Reelmaster 216-D: 3600 ± 100 RPM 3200 ± 100 RPM 3. Traction pedal and lift valve in neutral. Parking brake engaged. TESTER READINGS: 70 – 150 PSI. TEST B: Implement Relief Pressure 1.
Test Hook-up No. 4: Traction Pressure (Fig. 21) Gauge Connection Connect a 10,000 PSI hydraulic pressure gauge to forward traction pressure gauge port. 1 TEST A: Traction Pressure 1. Make sure pump drive belt is properly adjusted and in good condition. 2. Make sure hydraulic oil is at operating temperature. 3. Operate engine at full speed: Reelmaster 216: Reelmaster 216-D: 3600 ± 100 RPM 3200 ± 100 RPM 4. Attach a heavy chain to rear frame of machine and then to something solid in shop.
Test Hook-up No. 5: Traction Pressure (Reelmaster 216-D only) (Fig. 22) Gauge Connection Connect a 10,000 PSI hydraulic pressure gauge with extension hose to forward traction pressure quick dis connect fitting on hydraulic tube line. TEST A: Traction Pressure 2 1. Make sure pump drive belt is properly adjusted and in good condition. 1 2. Make sure hydraulic oil is at operating temperature. 3. Operate engine at full speed: Reelmaster 216: Reelmaster 216-D: 3600 ± 100 RPM 3200 ± 100 RPM Figure 22 4.
Adjustments Adjusting Transmission For Neutral (Reelmaster 216) (Fig. 23) If the machine “creeps” when the traction control pedal is in the neutral position, the spring leaf assembly must be adjusted. 1. Block up under the frame so one of the front wheels is off the floor. Place selector control in two wheel drive position. 2. Start engine, move throttle to SLOW and check front wheel that is off shop floor; it must not be rotating.
Adjusting Transmission For Neutral (Reelmaster 216-D) (Fig. 24, 25) If the machine “creeps” when the traction control pedal is in the neutral position, the spring leaf assembly must be adjusted. 1 1. Block up under the frame so one of the front wheels is off the floor. Place selector control in two wheel drive position. 2. To expose spring leaf assembly, remove (4) screws securing right fender to frame and remove fender. 3.
Adjusting Tracton Pedal (Reelmaster 216) (Fig. 26, 27) If traction pedal contacts footrest when pushed fully forward or you cannot get maximum forward traction speed, an adjustment to the traction pedal linkage is required. There should be 3/8 inch clearance between pedal shaft and footrest when pedal is pushed fully forward. 1. Remove (3) self-tapping screws securing support screen to hydraulic support panel. Remove screen. 2. Loosen jam nuts on each end of traction rod. 3.
Adjusting Traction Pedal (Reelmaster 216-D) (Fig. 28, 29) If traction pedal contacts footrest when pushed fully forward or you cannot get maximum forward traction speed, an adjustment to the traction pedal linkage is required. There should be 1/16 inch between pedal stop cam and R.H. footrest when pedal is pushed fully forward. 1 1. To expose traction rod, remove (4) screws securing right fender (Fig. 58) to frame and remove fender. 2 2. Loosen jam nuts on each end of traction rod. 3.
Pump Belt Adjustment (Fig. 30) Make sure belts are properly tensioned to assure proper operation ot the machine and unnecessary wear. Check belt midway in span of belt. Check tension again on new belts after 8 hours of operation. Tighten nut on adjustment rod until desired belt tension is attained. Belt should be tightened to 140 lbs. of tension. NOTE: Tighten belt to eliminate slippage (squeeling under load) but do not overtighten. Figure 30 1. Nut 2.
Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. After Repair or Replacement of Components 1.
Charge Pump (Fig. 31) 1. Note orientation of charge pump housing to adjacent housing. Scribe a line or make punch marks to assure proper re-installation. 26 2. Clean the shaft extension to remove all sharp edges, burrs and abrasive residue to prevent shaft seal dam age. 3. Remove hex head screws (Item 24) and slide the housing assembly (Item 21, 22, & 23) over shaft holding the charge pump (gerotor) cartridge and remove drive pin (Item 26 ). 21 24 27 25 4.
Pump Shaft & Trunnion Seals (Fig. 32) Lip type seals are used throughout the pump. These seals can be replaced without disassembly of the pump; however, replacement of either the input or output seal requires removal of the pump from the machine. 1. Pry the seal carefully out of the housing bore, using care not to distort the housing or damage the bore or shaft. Once removed, the seal is not reusable. 10 23 11 2.
Pump Relief Valves (Fig. 34) 1. Remove plug ,then slide the spring and poppet out of the housing. IMPORTANT: Do not interchange parts between charge and implement relief valves. Do not alter shims unless adjusting pressure setting of valve. 17 51 15 18 2. Inspect the poppet and seat in housing for damage and remove any foreign material in the valve area. 14 3. Replace parts as required and reinstall into housing bore.
Pump Disassembly (Fig. 35, 36, 37, 38) The following procedures are for major repair of the variable displacement pump. These instructions begin with the removal of the end cap. Remove the charge pump, seals, check valves and relief valves before doing major disassembly (See procedures on previous pages of this section). Figure 35 45 44 41 46 43 42 40 8 Figure 36 1. When cap screws (Item 46) are loosened, internal spring loading will cause end cap (Item 45) to separate slightly.
5 8 39 Figure 37 4. Lift out the cylinder block assembly (Item 5). The pistons may come out of the cylinder block. There is no special orientation of piston to bore that needs to be maintained. Do not attempt to disassemble the spring and other parts from the center bore of the cylinder block. The entire cylinder block assembly (Item 5) should be replaced if any of its components are damaged. Repairs 5. Visually inspect wear surfaces of valve plate, cylinder block and slippers for damage.
37 6 34 38 8 12 36 35 28 9 Figure 38 7. Place the pump housing (Item 8) with the large cavity up. Use care not to scratch the port face surface. bore, the shaft can be removed easily. The swashplate (Item 37) is then removed from the pump housing. 8. Using a 3/16 in. diameter drift punch, drive spring pin (Item 38) ou t o f tr u nnion and control sh afts (Item 12 & 28). The pump housing is provided with a cast recess so that the pins can be driven free of trunnion and control shafts. 10.
Assembly of Pump (Fig. 39, 40, 41, 42) 37 6 34 38 8 12 36 35 28 9 Figure 39 1. Before assembling, wash parts in solvent. Dry parts with compressed air. Do not wipe them dry with a cloth or paper as lint and dirt may remain. Apply a light coating of hydraulic oil to parts before assembling. IMPORTANT: Most parts have critical, high toler ance surfaces. Use caution to prevent damage to these surfaces during assembly. Protect exposed surfaces, opens and ports from damage and foreign material. 3.
Figure 40 6. Install new pins through swashplate and shaft. Use two (2) pins in control shaft (Item 28), installing first pin until second pin can be started, then driving in both pins together until the last pin is 1/4 inch below swashplate. 8. The swashplate should swing freely in the pump housing to 150° each side of center. 7. Install one (1) pin in trunnion shaft (Item 12), driving it in until it is 1/4 inch below swashplate.
5 8 39 Figure 41 9. Lubricate thrust plate (Item 39) with clean hydraulic oil and insert in counterbore of swashplate. 10. Assemble cylinder block parts if necessary and lubricate with clean hydraulic oil. There is no special orientation of piston to bore that needs to be maintained. 12. Slide cylinder block assembly (Item 5) over shaft and engage spline. Be certain that pistons and thrust plate remain in place. When properly installed a slight spring tension can be felt when pushing on cylinder block.
45 44 41 46 43 42 40 8 Figure 42 14. Properly orient the end cap (Item 45) and housing (Item 8). Align the O-rings (Item 44) with the mating holes in the housing. 15. Press bearing (Item 42) into end cap leaving 3/32 to 1/8 inch protruding beyond face. The valve plate (Item 40) pilots on this bearing. 16. Insert locating pin (Item 41) into end cap. Lubricate the slotted side of the pump valve plate (Item 40) and slip it over the pin and protruding bearing. 18.
Wheel Motor (Fig. 43) Figure 43 1. Screw 2. Cover & bearing ass’y 3. Plug 4. Seal 5. IGR assembly 6. Check ball 7. Valve plate 9. Body & bearing assembly 10. Shaft 11. Key 12. O-ring 13. Nut 14. Snap ring 15. Dust seal Disassembly of Shaft and Front Seal Assembly 1. Put the motor on a clean, flat surface with the shaft facing up. Clean the front end of the motor to avoid contaminating the internal parts during the procedure. 16. Retainer pin 17. Lip seal 19. Thrust washer 20. Thrust bearing 21.
4. Gently slide the oiled seal retainer assembly (Item 15, 16, 17) over the shaft, chamfered side first, and press into the body bore. When fully in place, the body snap ring groove will be visible. 3. Insert the shaft (Figure 37, Item 10) and install seals and thrust bearings. (See Assembly of Shaft and Front Seal Assembly under Main Shaft Seal and/or Shaft Replacement.) 5.
Lift Control Valve (Fig. 44) 1. After removing control valve from machine, wash valve in solvent and dry it thoroughly. 2. Carefully mount control valve into a vise so that control valve mounting pads are against jaws of vise. The control valve spool snap ring (Item 14) should be facing up. 3. Remove plug (Item 1) from side of valve body. Inside the valve body, under the plug, there is a spring (Item 3), ball (Item 4), and cam pin (Item 6); remove these parts. 4. Repeat step 3 for the other plug. 5.
Lift Cylinder (Fig. 45, 46, 47) 6 5 4 7 8 3 1 9 2 10 11 12 13 Figure 45 1. After removing cylinder, pump oil out of cylinder into a drain pan by SLOWLY moving cylinder’s piston in and out of cylinder bore. 2. Plug ports and clean the outside of cylinder. Spanner wrench IMPORTANT: To prevent damage when clamping cylinder barrel in a vise, clamp only on pivot end. 3. Mount cylinder in a vise so shaft end of cylinder is tilted up slightly.
5. Grasp end of shaft (Item 4) and use a twisting and pulling motion to carefully extract piston (Item 8), shaft (Item 4), and head (Item 3) from barrel (Item 6). IMPORTANT: Do not clamp vise jaws against shaft surface. Protect shaft surface before mounting in vise. 6. Securely mount shaft (Item 4) in a vise, clamping vise on flats of shaft. Remove lock nut (Item 5) from the piston end of shaft. Remove the piston. Slide head (Item 3) off of shaft. 7.
3WD Selector Valve (Fig. 48) Figure 48 1. After removing selector valve from machine, wash valve in solvent and dry it thoroughly. 2. Carefully mount valve assembly into a vise so that control valve mounting pads are against jaws of vise. 3. Remove retaining ring (Item 3) from end of spool. 4. Use knob (Item 9) to carefully pull and twist valve spool out of the valve body. 5. Remove roll pin (Item 5). Be careful not to scratch or damage spool. 6.
Repairs Page 5 - 46 Reelmaster® 216/216-D
Chapter 6 Electrical System Table of Contents WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . 2 Reelmaster 216 (S/N 99999 & Below) . . . . . . . . . . . . 2 Reelmaster 216 (S/N 10001 – 19999) . . . . . . . . . . . . 3 Reelmaster 216 (S/N 20001 & Up) . . . . . . . . . . . . . . 4 Reelmaster 216-D . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING (Reelmaster 216) . . . . . . . . . . . 8 Starting Problems . . .
Wiring Schematics Reelmaster 216 (S/N 99999 & Below) Wiring Schematics Page 6 - 2 Reelmaster® 216/216-D
Reelmaster 216 (S/N 10001 – 19999) Reelmaster® 216/216-D Page 6 - 3 Wiring Schematics
Reelmaster 216 (S/N 20001 & Up) Wiring Schematics Page 6 - 4 Reelmaster® 216/216-D
Reelmaster 216-D Reelmaster® 216/216-D Page 6 - 5 Wiring Schematics
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be available from a local supplier. Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off. Figure 1 Volt - Ohm - Amp Meter The meter can test electrical components and circuits for current, resistance, or voltage draw.
Skin-Over Grease Special non-conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts.
Troubleshooting (Reelmaster 216) Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou bleshooting or testing.
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Nothing happens when start attempt is made. Reelmaster® 216/216-D Battery is dead. Charge battery. Replace battery if it will not hold a charge. Loose or corroded battery cables. Loose or corroded ground. Clean and tighten or repair as necessary. Fuse open.
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks, but does not start. Engine wiring connector or wires loose, corroded or damaged. Repair wiring. Engine, engine ignition, or fuel system problem. See Troubleshooting section of Kohler Magnum Engine Service Manual. Interlock module faulty. Replace interlock module.
General Run and Transport Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but should not) when traction pedal is depressed with no operator on seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge.
Cutting Unit Operation Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but should not) when cutting unit clutch switch is ON with no opera tor on the seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED. In addition, the engine will stop when the cutting unit engagement switch is engaged or traction pedal is depressed with the operator off the seat. CAUTION The interlock switches are for the operator’s protection, so do not disconnect them.
Troubleshooting (Reelmaster 216-D) Study the operating characteristics preceding the elec trical failure to help identify the area of difficulty. Try to isolate the failure to a specific functional system; then check that area, repairing one component at a time. Attempting to repair more than one system at one time will lead to confusion. CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trou bleshooting or testing.
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Nothing happens when start attempt is made. Reelmaster® 216/216-D Battery is dead. Charge battery. Replace battery if it will not hold a charge. Loose or corroded battery cables. Loose or corroded ground. Clean and tighten or repair as necessary. “Engine” fuse open.
Starting Problems (continued) Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine cranks, but does not start (if engine cranks, cause of prob lem is not in interlock system). Injection pump ETR solenoid wiring loose, corroded or damaged. Repair wiring. Injection pump ETR solenoid faulty. Test solenoid. Replace if faulty.
General Run and Transport Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but should not) when traction pedal is depressed with no operator on seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge.
Cutting Unit Operation Problems Condition Possible Cause Correction ________________________________________________________________________________________________________________________________________________________ Engine continues to run (but should not) when cutting unit clutch switch is ON with no opera tor on the seat. Seat switch plunger depressed with no operator on seat. Check for seat support spring that is broken, missing or stuck in down position. Check for binding seat pivot hinge.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the traction pedal is in NEUTRAL and the cutting unit engagement switch is DISENGAGED. In addition, the engine will stop when the cutting unit engagement switch is engaged or traction pedal is depressed with the operator off the seat. CAUTION The interlock switches are for the operator’s protection, so do not disconnect them.
Testing This section will define components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. CAUTION For accurate resistance and/or continuity checks, elec trically disconnect the component being tested from the circuit (e.g. unplug the seat switch connector before doing a continuity check).
Seat Switch (Fig. 6, 7) The seat switch is a normally open (N.O.) switch that closes when the operator is on the seat. If the cutting unit clutch (reel drive) switch or traction switch is open and the operator raises off the seat, the engine will stop. 1. Raise the seat to get access to the seat switch wiring connector. 2. Disconnect the seat switch wiring connector and install a continuity tester or ohm meter between the two leads of the seat switch. 3. Lower the seat.
Traction (Neutral) Switch (Fig. 8) The traction switch is normally open and closes when traction pedal is in neutral. IMPORTANT: The traction switch has three (3) ter minals. Make sure the wires are connected to the “COMMON” and “N.O.” terminals. 1 Test switch by disconnecting wires from switch termi nals and connecting a continuity tester across COMMON and N.O. terminals. With engine off, slowly push traction pedal in forward and reverse direction while watching continuity tester.
Cutting Unit Clutch (Reel Drive) Switch (Fig. 11, 12) Reelmaster 216 (S/N 19999 and below) To test switch independent of wiring harness, discon nect wire harness connector(s) from switch terminals. When the switch is ON (Engage), there should be continuity between terminals A – B only. When the switch is OFF (Disengage), terminals C – D and B – E should show continuity.
Start and High Temp. Relays (Reelmaster 216-D only) (Fig. 13, 14, 15) To test the relay, disconnect the relay wire connector and install a continuity tester between the relay termi nals (terminals 30 and 87). The relay should make and break continuity at terminals 30 and 87 as 12 V.D.C. is connected and disconnected to terminal 85 with termi nal 86 connected to ground. 1 Figure 13 1. Start relay (Item 39) 1 Figure 14 1. High temp.
Glow Plugs (Reelmaster 216-D only) Check for continuity between plug terminal and body. If there is no continuity, heat wire in glow plug is broken. Measure resistance between plug terminal and ground. Resistance should be 1.6 ± 0.16 OHM. Resistance of 0 indicates a short circuit. Battery (Fig. 17, 18) Use a hydrometer to test the battery. Charge the battery if necessary (see Battery Service). Electrolyte specific gravity Fully charged: 1.250 - 1.280 Discharged: less than 1.
Injection Pump (ETR) Solenoid (Reelmaster 216-D only) (Fig. 19) The Reelmaster® 216-D has an energize-to-run (ETR) fuel stop solenoid mounted on the engine block next to the fuel injection pump with a purple wire attached. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1 1. Disconnect the wire from the solenoid. 2. Remove the solenoid from the injector pump. 3.
Gauges and Indicator Lights Oil Pressure Light (Reelmaster 216-D only) Oil pressure lamp should come on when the ignition key switch is in the RUN position with the engine not running or if the oil pressure switch closes during operation - oil pressure below 7 psi (0.5 kg/cm2). Test the lamp and relay by disconnecting the wire from high temperature shut-down switch and grounding it against the engine. The light should come on when the wire is grounded with the ignition switch in the ON position.
High Temperature Shut-Down Switch (Fig. 20, 21) (Reelmaster 216-D only) 1 Switch is located on cylinder head facing front of ma chine with tan wire attached. 2 1. Lower the coolant level in the engine and remove the high temperature shut-down switch. 3 2. Put the switch in a container of oil with a thermometer and heat the oil. 3. The switch is normally open (N.O.) and should close at 213 - 228o F (101 - 109o C). Figure 20 CAUTION 1. High temp. shut-down switch 2. Temp.
Engine Oil Pressure Switch (Reelmaster 216-D only) (Fig. 20) Switch is located on cylinder head facing rear of ma chine with brown wire attached. The switch is normally closed (NC) and opens with pressure. Oil pressure switch operating range: 2.8 - 5.7 psi (0.2 - 0.4 kg/cm2). 1. Turn ignition key switch ON. Oil pressure lamp should be on. If lamp is not on: 1. Disconnect wire from switch and touch wire to a good ground, such as the engine block. 2. If lamp comes on, replace switch. 3.
Starter Solenoid (Reelmaster 216 only) (Fig. 24) To test the starter solenoid, disconnect the wires from the solenoid terminals and install a continuity tester between the large diameter terminals. The large diame ter terminals should show continuity when a 12 V.D.C. battery is connected to the small diameter terminals. 1 Figure 24 1.
Repairs IMPORTANT: Before welding on the machine, dis connect both battery cables from the battery and disconnect the terminal connector from the alter nator to prevent damage to the electrical system. Battery Service (Fig. 28) IMPORTANT: To prevent damage to electrical com ponents, do not operate the engine with the battery cables disconnected. Keep the terminals and entire battery case clean. To clean the battery, wash the entire case with a solution of baking soda and water. Rinse with clear water.
Fuses Reelmaster 216 (Fig. 29) The starter circuit is protected by a 30A fuse located on the dash panel. Reelmaster 216 (Fig. 30) The electrical system is protected by a 15A “ACC” fuse located on the dash panel, a 15A “ENGINE” fuse in the wiring harness near the ignition switch and a fusible link in the wiring harness near the starter solenoid. 1 Figure 29 (Reelmaster 216) 1. Fuse holder 1 2 Figure 30 (Reelmaster 216-D) 1. Accessory fuse 2.
Traction (Neutral) Switch Replacement (Fig. 31) 1. Remove the two wires that are connected to the traction switch. 2. Have a helper push the traction pedal down into either the FORWARD or REVERSE position; this will take the switch arm tension off of the switch. Loosen two (2) screws and remove the switch. 1 3. Install new switch. DO NOT over-tighten screws as the switch case could break. NOTE: Apply “Loctite 271” or equivalent to threads of switch screws before installing.
Cutting Unit Interlock Switch Replacement (Fig. 32, 33) 1. Raise cutting units and stop the engine. Engage the parking brake. Raising the cutting units will take tension off of the switch. 1 2. Remove the two wires that are connected to the cutting unit interlock switch. 3. Loosen two (2) screws and remove the switch (lo cated on left side of machine on bottom of hydraulic lift cylinder. 3. Install new switch. DO NOT over-tighten screws as the switch case could break.
Chapter 7 Wheels, Brakes & Steering Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Adjustment (Reelmaster 216 – S/N 19999 & Below) . . . . . . . . . . . Parking Brake Adjustment (Reelmaster 216 S/N 20001 & Up, Reelmaster 216-D) . . Steering Column Adjustment. . . . . . . . . . . . . . . . Steering Stop Adjustment . . . . . . . . . . . . . . . . . . Reelmaster® 216/216-D 2 3 3 REPAIRS .
Specifications Item Specification __________________________________________________________________________________________ Tire pressure 12 - 16 PSI ________________________________________________________________________________________________________________________________________________________ Wheel lug nut torque 45 - 65 ft-lb ________________________________________________________________________________________________________________________________________________________ Wheel motor sp
Adjustments Hand Brake Adjustment (Fig. 1) (Reelmaster 216 - S/N 19999 & Below) Brake spacers Figure 1 D. Right brake shoe should have approximately 1/16 in. clearance from upper and lower brake spac ers in an approximately centered position. Use the following procedure to adjust: 1. Jack up front of machine and support under frame with jack stands. Remove both front wheels. 2. Make sure there are four (4) return springs on each return spring bracket.
Hand Brake Adjustment (Fig. 2) (Reelmaster 216, S/N 20001 & Up, Reelmaster 216-D) 1. Jack up front of machine and support under frame with jack stands. Remove both front wheels. 2. Make sure brake is in OFF position. 3. Loosen jam nut on clevis. Remove cotter pin securing of clevis to lower brake lever. Rotate clevis, one turn at a time, to decrease distance between upper and lower brake levers. 4. Install clevis to lower brake lever and tighten jam nut. Repeat procedure on opposite side of machine. 5.
Steering Stop Adjustment (Fig. 4) To increase or decrease turning radius of machine when steering wheel is turned fully left or right, adjust steering stop screws. 1. Loosen locknuts securing stop screws to tabs on steering sector. 2. Thread stop screws in or out until desired turning radius is attained. 3. Check adjustment and tighten locknuts. Figure 4 1. Stop screws 2.
Repairs Brake Service (Fig. 5) (Reelmaster 216 — S/N 19999 & below) Figure 5 1. Park machine on a level surface. Jack up front of machine and support under frame with jack stands. Remove both front wheels. 5. Replace parts that are worn or damaged. 6. After installing brake shoes, install extension springs. NOTE: Stronger springs (Item 17) go on top. 2. Remove extension springs (Item 17, 21). 3. Remove cotter pin (Item 22).
Brake Service (Fig. 6) (Reelmaster 216 — S/N 20001 & Up, Reelmaster 216-D) Figure 6 1. Park machine on a level surface. Lift front wheel off the ground using a jack. Block front and rear of other wheels. 2. Remove wheel nuts (Item 22) and remove wheel. Remove spindle nut (Item 23) from wheel hub. 3. Mount a wheel puller to wheel mount studs and remove wheel hub (Item 19) and brake drum (Item 18). Remove key (Item 10) from wheel motor shaft.
Repairs Page 7 - 8 Reelmaster® 216/216-D
Chapter 8 Cutting Unit Drive System Table of Contents ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Unit Drive Belt Adjustment . . . . . . . . . . . Clutch Adjustment (Reelmaster 216) . . . . . . . . . . . . Jackshaft Belt Adjustment (Reelmaster 216) . . . . . . Jackshaft Belt Adjustment (Reelmaster 216-D) . . . . . REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Removal and Installation (Reelmaster 216) .
Adjustments Cutting Unit Belt Adjustment Cutting unit drive belts should have a maximum deflec tion of 1/2 in. with 10 lb. load applied to middle of belt span. NOTE: When new belts have been installed, check tension again after the first 8 hours of operation. Old Style Belt Tensioner Assembly (Fig. 3) Loosen jam nut on front end of belt tension rod. Rotate rod to lengthen or shorten rod to desired length. Tighten jam nut. To release belt tension to cutting units: A.
Clutch Adjustment (Reelmaster 216) (Fig. 7) 1. Check adjustment by inserting a feeler gauge through slots next to flange studs on clutch (Item 21). 2. Correct disengaged clearance between clutch plates is 0.006 to 0.012 in. It will be necessary to check this clearance at each of the three slots to make sure the plates are parallel to each other and equal at all three locations. 3. Adjust by tightening or loosening locknuts on flange studs. Jackshaft Belt Adjustment (Reelmaster 216) (Fig.
Repairs Clutch Replacement (Reelmaster 216) (Fig. 7) Installing Clutch Removing Clutch 1. Loosen tension on jackshaft drive belt (Item 25) and slip belt off of clutch pulley. 1. Make sure clutch stop (Item 19) is installed in engine block. Clutch stop should extend 0.75 ± 0.03 inch. Tighten nut (Item 20) to 38 - 32 ft-lb. 2. Install clutch spacer (Item 18) onto engine shaft with CHAMFER TOWARD ENGINE. 2. Disconnect clutch electrical connector. 3. Remove capscrew (Item 24) and washers. 3.
Jackshaft and Bearing Service (Reelmaster 216) (Fig. 8) Figure 8 1. Remove tension from cutting unit drive belts and jackshaft drive belt. 2. With cutting unit belts off pulleys, remove capscrews (Item 19) and locknuts (Item 12) securing bearing mounts (Item 27) to the frame. 3. Slip jackshaft drive belt off electric clutch pulley, lower jackshaft assembly and slide it from under the machine. 4. Loosen pulley set screws (Item 21).
Jackshaft, Bearing and Clutch Service (Reelmaster 216-D) (Fig. 9) Figure 9 2. Remove nut (Item 14) and screw (Item 29) securing clutch to clutch retainer. 6. Inspect bearings (Item 8) and replace if necessary. If replacing bearing, remove bearing assembly (Item 7) from bearing support (Item 6). Install bearing flanges so grease zerks are accessible from front of machine on right side and from rear on left side. 3.
10. Align clutch pulley with engine pulley so a straight edge laid across engine pulley face will not have more than a 0.30 in. gap with flanges on clutch pulley, then tighten collars (Item 11) to secure clutch and pulley in position. Tighten nut (Item 12) against collar (Item 11) to a torque of 60 - 70 ft-lb. Tighten nut against collar to 60 - 70 ft-lb 11. Install screw (Item 29) and nut (Item 14) to secure clutch to clutch retainer. 12. Align cutting unit pulleys and tighten setscrews. 13.
Clutch Service (Reelmaster 216) (Fig. 11) The clutch has a rotor that is driven by the engine crankshaft. When the reel engagement circuit is ener gized, and electromagnet pulls the armature into con tact with the rotor to drive the pulley. Failure to get clutch engagement would likely be caused by a clutch air gap that is too large (see Clutch Adjust ment), a circuit fault in the clutch electromagnet, or other electrical problem (see Troubleshooting section of Chapter 6 - Electrical System).
Clutch Service (Reelmaster 216-D) (Fig. 12) The clutch has a rotor and pulley that is driven from the engine crankshaft by a belt . When the reel engagement circuit is energized, an electromagnet pulls the armature into contact with the rotor to drive the jackshaft. Failure to get clutch engagement would likely be caused by a clutch air gap that is too large, a circuit fault in the clutch electromagnet, or other electrical problem (see Troubleshooting section of Chapter 6 - Electrical Sys tem).
Repairs Page 8 - 10 Reelmaster® 216/216-D
Chapter 9 Cutting Units Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4 SET UP AND ADJUSTMENTS. . . . . . . . . . . . . . . . . 6 Adjustment Summary and Checklist . . . . . . . . . . 6 Cutting Unit Characteristics. . . . . . . . . . . . . . . . . 7 Bedknife to Reel Contact . . . . . . . . . . . . . . . . . .
Specifications Width/Height of Cut: 72 in. (183 cm) width of cut. 5, 8, or 11 blade floating: 1/4 – 1-3/4 in. (6.4 – 44.4 mm); 5 blade fixed: 1/2 – 2-5/8 in. (12.7 – 65.6 mm). Height of Cut Adjustment: Positive position settings with separate fine adjustments for leveling either end of roller, or extending height range. Frequency of Clip: Bedknife To Reel Adjustment: Single knob screw adjustment for bedknife to reel, located at center of bedbar. Adjustment knob detent with .001 in.
Special Tools NOTE: Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may be listed in the Reel master 216 or Reelmaster 216-D Parts Catalog. Some tools may also be available from a local supplier. Handle Assembly (Fig. 1) For applying lapping compound to cutting units while keeping hands a safe distance from the rotating reel assembly. Figure 1 Bedknife Screw Tool (Fig. 2) Fits Toro bedknife attaching screws.
Troubleshooting There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height of cut, the more critical these factors are.
Factor Possible Problem/Correction ___________________________________________________________________________________________ 8. Height of cut. All cutting units set at same height of cut. Bench set height of cut and actual (effective) height of cut are different. Effective height of cut depends on cutting unit weight, counterbalance spring adjustment, cut ting unit accessories and turf conditions.
Set Up and Adjustments Adjustment Summary and Check List DETAILED ADJUSTMENT INSTRUCTIONS FOLLOW THIS SUMMARY AND CHECK LIST. Study this informa tion and refer to it often to get maximum life and per formance from the cutting units. Monthly Adjustments NOTE: Remove cutting unit from traction unit. 1. Visually check for sharp reel and bedknife. Backlap or grind reel and bedknife if necessary.
Cutting Unit Characteristics The single knob bedknife-to-reel adjustment system incorporated in this cutting unit simplifies the adjustment procedure needed to deliver optimum mowing perform ance. The precise adjustment possible with the single knob/bedbar design gives the necessary control to pro vide a continual self-sharpening action — thus maintain ing sharp cutting edges, assuring good quality-of-cut, and greatly reducing the need for routine backlapping.
Height of Cut Adjustment and Leveling Rear Roller (Fig. 4) (Floating Cutting Units) 1. Position cutting unit on a flat level table or board. 2. Slightly loosen (crack) nut securing each roller bracket to angle bracket. 3. Adjust support capscrew to achieve 1-1/16 in. dimen sion between Height-of-Cut support and front roller bracket (2 places). 4. Adjust support capscrew to achieve 5/8 ± 1/16 in. dimension between Height-of-Cut support and rear roller bracket (2 places). 5.
Height of Cut Adjustment and Leveling Rear Roller (Fig. 5) (Fixed Cutting Units) 1. Position cutting unit on flat level surface or board. 2. Slightly loosen (crack) nuts securing roller brackets to angle brackets. 3. Adjust support capscrews to achieve 5/8 ± 1/16 in. dimension between Height-of-Cut support and roller bracket (2 places). 4. Remove hairpin cotters securing Height-of-Cut pins and reinstall in hole at desired setting as indicated on Height-of-Cut plate. 5.
Parallel Bedknife to Reel (Fig. 6, 7, 8) (Floating or Fixed Cutting Units) 1. Make sure reel contact is removed by turning bed knife adjustment knob counterclockwise. Tip cutting unit to gain access to reel and bedknife. 2. On either end of reel, insert a long strip of dry newspaper between reel and bedknife. While slowly rotating reel into bedknife, turn bedknife adjusting knob clockwise, one click at a time until paper is pinched lightly, which results in a slight drag when paper is pulled. 3.
Verifying Height of Cut Adjustment and Leveling Front Roller (Fig. 9) (Floating Cutting Units) 1. On gauge bar, set head of screw to desired Height-of -Cut. This measurement is from bar face to underside of screw head. Gauge bar (Toro Part No. 13-8199) may be obtained from your local Toro Distributor. 2. Slightly loosen (crack) nut securing each front roller bracket to angle bracket. 3.
Service and Repairs Front Roller Installation (Fig. 11) (Floating Cutting Units) 1. Remove (2)locknuts securing each angle bracket to cutting unit. 2. Remove height-of-cut pins. 3. Insert smaller diameter. shaft end of roller into white bushing in roller bracket, making sure flanged end of nylon bushing faces inside toward roller. Hex of roller bracket must mate with hex of nut adjustment. 4. Press roller bracket onto shaft end of roller. Hex of roller bracket must mate with hex of nut adjustment. 5.
Installing Cutting Units (Fig. 12) (Floating Cutting Units) 1. Slide a thrust washer onto lift arm pivot rod. 2. Slide cutting unit carrier frame onto pivot rod and secure with a flat washer, lockwasher and capscrew. Figure 12 1. Thrust washer 2. Carrier frame 3. Flat washer, lockwasher, capscrew Installing Cutting Units (Fig. 13) (Fixed Cutting Units) 1. Slide a thrust washer onto lift arm pivot rod. 2. Slide cutting unit support onto pivot rod and secure with a flat washer, lockwasher, and capscrew. 3.
Drive Belt and Belt Tensioner Installation (Fig. 14) (Floating Cutting Units) 1. Route V-belts around jackshaft pulleys and reel pulleys. 2. On pulley end of front cutting units and both ends of rear cutting unit, remove nut from bolt securing carrier frame to tensioner bracket. 3. Install a spacer,belt tension rod and washer onto capscrew. NOTE: Belt tension rods to be in locked position when installing. Loosen jam nut and rotate rod to adjust rod length for installation. 4.
Counterbalance Spring Installation (Figs. 16, 17, 18) 1. Remove capscrew securing counterbalance arm to frame. 2. Remove hairpin cotter and clevis pin next to arm. 3. Pivot front arms outward and rear arm inward. 4. Hook one end of spring into second hole (from bottom) on cutting unit lift tab. Note: On rear counterbalance spring install vinyl cover over spring before installing. 5.
Cutting Unit Overhaul (Fig. 19, 20) Loctite Anti-seize compound Anti-seize compound Anti-seize compound Torque to 35 ft-lb Anti-seize compound both ends Torque to 200 in-lb Anti-seize compound Figure 19 (8 blade floating cutting unit shown) It is recommended that the following new parts be installed when overhauling a cutting unit. These parts are available in an overhaul kit (Fig. 19): When assembling cutting unit, apply anti-seize com pound in the following locations (Fig.
When assembling reel (Fig. 19): When assembling S.P.A. handle (Fig. 19): Tighten large jam nut (Item 56) on reel shaft against washer (Item 57) and bearing (Item 30) so that when capscrew (Item 34) on end of reel shaft is tightened, there will be a 0.060 in. gap between end of bedbar and reel blades. Tighten capscrew (Item 34) on end of reel shaft to 35 ft-lb. Tighten locknut (Item 10) so compression spring (Item 11) is 0.86 in. long.
Backlapping The cutting units may be backlapped in position on the machine by releasing tensioning to the drive belts and removing the capscrew securing the left end of the carrier frame to the cutting unit. Otherwise, remove cutting units completely before backlapping. Connect a lapping machine to the capscrew on the left end of reel shaft with an extension coupler and a 9/16 in. socket. Backlap according to procedures in the Toro Sharpening Reel and Rotary Mowers Manual Form No. 80-300-SL.
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