FORM NO. 3318-360 MODEL NO. 0342040007 & UP OPERATOR’'S rho MODEL NO. 0342540001 & UP MANUAL ? k REEL MASTER 216-D Traction Units o assure maximum safely, optimum performance, and to gain knowledge of the product, iris essential that you or any other operator of the mower read and understand the contents of this manual before the engine is ever slatted. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol.
FOREWORD The REEL MASTER 216D was developed to provide an efficient, reliable and time—saving method of mowing high quality turf. The latest concepts in engineering and design have been incorporated into this machine along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. We know, since you have purchased the industry leader in mowing excellence, that future performance and dependability are of prism importance.
SAFETY INSTRUCTIONS Before Operating .. While Operating . Maintenance SAFETY INSTRUCTIONS & DECALS SPECIFICATIONS LOOSE PARTS CHART .. SET-UP INSTRUCTIONS . Install Rear Wheel TABLE OF CONTENTS Bleeding Fus! System Adjust Steering Column Towing Traction Unit .. Training Period Before Mowing .. Transport Operation . Bleeding Cooling System .. Check Operation of Interlock Switches . Operating Characteristics Page Install Steering Hes! . .
A SAFETY INSTRUCTIONS Improper use or maintenance by the operator or owner of the machine can result in injury. To reduce the potential for any injury, comply with the following safety instructions. WARNING: Engine exhaust contains carbon monoxide which is an odorless, deadly poison. Garbo monoxide is also known 1o the State of California to cause birth defects. Do not run engine indoors or inn enclosed area. BEFORE OPERATING 1.
A SAFETY INSTRUCTIONS 16. This product may exceed noise levels of 85 dB(A} at the operator position. Ear protectors are recommended for prolonged exposure to reduce the potential of permanent hearing damage. 17. Raise the cutting units when driving from one work area to another. 18. Do not touch engine, muffler, exhaust pipe or hydraulic tank while engine is running or soon after it has stopped because these areas could be hot enough to cause burns.
A SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are affixed to the traction unit. if any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog Order replacements from your Authorized Toto Distributor. Riel S g ACCESSORY THROTTLE @ o ERMINE CUTTING 10868 (GAIT ION INSTRUMENT PANEL (Part No. 82-3178) A DANGER ~ NEVER PLACE HANDS DR FEET IN REEL v AREA WHILE ENGINE IS RUNNING. ON CUTTING UNIT SHIELD {Part No.
SPECIFICATIONS Engine: Perkins, 4 cycle, 3 cylinder, liquid cooled, vertical overhead valve, diesel engine with centrifugal water pump. 18.5 hp governed to a maximum speed of 3000 rpm. 87.60 cu. in. displacement. Forced lubrication gear pump. Mechanical fuel transfer pump. Fuel filter/water separator with replaceable filter element. Heavy duty remote mounted air cleaner. Radiator: Side mounted radiator, industrial construction. Cooling system capacity is 5—1/4 quarts. Electrical: 12 vomit starter.
Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these LOOSE PARTS CHART parts, total set-up cannot be completed. Some parts may have already been assembled at factory. Wheel Says Spacers Flat washers Castor Axle Lockout Install rear wheel on model 03420. Wheel Says. Lug Nuts install rear wheel on model 03425 Roll Pin Mount steering wheel. Pivot Rod 18x Lock washers install to Front Lift Arms.
SET-UP INSTRUCTIONS INSTALL REAR WHEEL (Fig. 1 &2) Model 03420 ~ Two wheel drive 1. Mount wheel assembly to rear castor fork with (2) spacers, {2) flat washers, castor axle and lockout. Spacers to be positioned on inside of fork and washers outside of fork. Torque nut to 4565 ft—1b, Figure 1 1. Wheel assembly 2. Rear castor fork 3. Spacer (2} 4, Castor axle W Model 03430 — Three wheel drive 1. Mount wheel assembly onto rear wheel hub. Figure 2 1, Wheel assembly 2. Rear wheel hub 3. Lug nut 2.
SET-UP INSTRUCTIONS 3. On Deluxe Seat, remove machine screws securing upper slides to seat bottom. Move seat slides inward to next set of mounting holes and re secure with machine screws and (4} M8 lockouts. Apply Locate to fasteners. 4. Loosely secure slides to seat plate with fasteners supplied with seat. Note: Mount seat in forward holes to attain forward adjustment. 5. Tighten flange nuts and check operation of seat.
SET-UP INSTRUCTIONS 6. Roller brackets must be aligned for installation onto cutting unit. If necessary to align after bearing adjustment, remove roller bracket on side with flanges eyeliner, align with opposite roller bracket within + one hex flat and replace. 7. Reinstall Height—of Cut pins. 8. Reinstall (2) lockouts securing each angle bracket to cutting unit. SET HEIGHT OF CUT AND LEVEL REAR ROLLER (Fig. 7) (Floating Cutting Unit) 1. Position cutting unit on a flat level table or board. 2.
SET-UP INSTRUCTIONS 2. On either end of reel, insert a long strip of dry newspaper between reel and bed knife, While slowly rotating reel into bed knife, tum bed knife adjusting knob clockwise, one click at a time until paper is pinched lightly, which results in a slight drag when paper is pulled. FLOATING CUTTING UNIT SHOWN Figure 10 3. Check for light contact at other end of reel using paper. If light contact is not evident, proceed to next step. 4. Loosen {2) carriage bolls on bed bar adjuster (Fig. 11).
SET-UP INSTRUCTIONS Note: When mounting rear cutting unit, thrust washer to be positioned between putting unit support and flat washer at rear. Figure 14 1. Thrust washer 2. Cutting unit support 3. Flat washer & cap screw 3. Front cutting units should be parallel to front wheels. To adjust, loosen cap screws securing supports to cutting units, adjust cutting units until paralegal, then, re tighten screws. INSTALL CUTTING UNIT DRIVE BELTS (Fig. 15) (Floating Cutting Units) 1.
SET-UP INSTRUCTIONS 2. Adjust cleaner bracket so there is approximately 080 ~ .060 clearance between bracket and pulley, then tighten cap screw and lockout. Figure 17 1. Cleaner bracket INSTALL COUNTERBALANCE SPRINGS (Figs. 18-20) A WARNING Use caution when pensioning springs as they are under heavy load. 1. Hook one end of spring into second hole {from bottom) on cutting unit lift tab (Fig. 18). Figure 18 1. Cutting unit it tab 2.
SET-UP INSTRUCTIONS ADD REAR BALLAST This unit complies with ANSI B71 .4—1984 Standard when equipped with rear ballast. Use chart below to determine weight or combinations of weights needed. Cutting Unit Weight Required Configuration Fixed (no Calcium Chloride in rear carrier frame) tire. Calcium Chloride in rear tire ard rear weight, Part No. 83-8370. Calcium Chloride in rear tire and (2} rear weights, Part No. 83—8370.
SET-UP INSTRUCTIONS A CAUTION Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting to or disconnecting charger leads from battery posts. 2.
BEFORE OPERATING FILL FUEL TANK (Fig. 25) The engine runs on No. 2 diesel fuel. Fuel tank capacity is approximately 6.5 gallons. 1. Clean area around fuel tank cap. Figure 25 1. Suet tank cap 2. Remove fuel tank cap. A DANGER Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fief tank. Do not fill fuel tank while engine is running, hot, or when machine is in an enclosed area.
BEFORE OPERATING CHECK HYDRAULIC SYSTEM FLUID (Fig. 28) The hydraulic system is designed ta operate with Mobil MIDTERM or equivalent anti—wear hydraulic fluid. The machine’s system is filled at the factory with approximately 3.3 gallons of fluid, However, check level of hydraulic food before engine is first started and daily thereafter.
CONTROLS Traction and Stopping Pedal (Fig. Traction pedal has three functions® one, to make the machine move forward, two, to move it backward and three, to stop machine. Using the heel and toe of the right goat, depress top of pedal to move forward and bottom of pedal to move backward or fo assist in stopping when moving forward. Also, allow pedal to move or move pitta neutral position ta stop machine. For aerator comfort, do not rest heel of foot on reverse when operating forward, Starter Switch (Fig.
CONTROLS Cutting Unit Drive Switch (Fig. 32} — The switch has two positions: ENGAGE and DISENGAGE. Push—Pull switch engages electromagnetic clutch to drive cutting units. Amber light on dash indicate when reels are rotating. Hour Meter (Fig. 32) — Indicates the total hours of machine operation. The Hour Meter starts to function whenever the key switch is rotated to "ON” position. Fuse Holders (Fig. 32) — Two 15 Amp fuses are incorporated to protects the engine and accessory circuits.
OPERATING INSTRUCTIONS STARTING/STOPPING ENGINE IMPORTANT: The fuel system may have to be bled if any of the following situations have occurred: A. Initial start up of a new engine, B. Engine has ceased running due to lack of fuel. C. Maintenance has been performed upon fuel system components; i.e. filter replaced, ete. Refer to Bleeding Fuel System 1. Be sure parking brake is set and Reel Drive switch is in DISENGAGE position. 2. Remove foot from traction pedal and make sure pedal is in neutral position.
OPERATING INSTRUCTIONS Figure 38 1. Transfer pump screw 2. Injection pump inst screw location 3. Injection pump inlet screw 4, Priming lever 5. Note fitting angle BLEEDING COOLING SYSTEM (Fig. 39) if system is being completely filled or more than a quart of coolant is being added to system, cooling stern may need to be bled. 1. Unlatch and raise hood. 2. Remove radiator cap. A CAUTION i engine has been running, pressurized hot coolant can escape when radiator cap is removed and cause burns. 3.
OPERATING INSTRUCTIONS Figure 40 1. Steering column 2. Frame bracket TOWING TRACTION UNIT (Fig. 41) In case of emergency, the Reel master 216—D can be towed for a short distance. However, Toto does not recommend this as a standard procedure. IMPORTANT: Do not tow the machine faster than 23 mph because drive system may be damaged. i machine must be moved a considerable distance, transport it on a truck or trainer. 1. Rotate by—pass valve on pump counterclockwise unit it is fully open. Figure 41 1.
OPERATING INSTRUCTIONS INSPECTION AND CLEAN-UP AFTER MOWING At the completion of mowing operation, thoroughly wash the machine with a garden hose ~ without a nozzle s0 excessive wale pressure will not cause contamination and damage to seals and bearings. Make sure radiator screen, radiator and oil cooler are kept free of dirt or grass clippings.
MAINTENANCE A\ caution Before servicing or making adjustments to the machine, stop engine and remove key from the switch, HOOD REMOVAL (Fig. 51) Hood may be easily removed 1o ease maintenance procedures in engine area of machine. 1. Unlatch and raise hood. 2. Remove one of the cotter pins securing hood pivot 1o mounting brackets. 1. Loosen thumb screw until dust cup and baffle can be removed. Separate dust cup and baffle. Figure 51 1. Carter pins 3.
MAINTENANCE 1. Remove and service dust cup; refer to Servicing Dust Cup and Baffle. 2. Remove wing nut w/gasket and slide filter element out of air cleaner body. 3. Clean the element by washing it in & solution of filter cleaner (Toto Part No. 27-7220) and water, or blow dirt out of filter by using compressed air. SERVICING AIR CLEANER FILTER (Fig. 53) Note: Compressed air is recommended when element must be used immediately after servicing because a washed element must be dried before it is used.
MAINTENANCE CHANGING HYDRAULIC SYSTEM FLUID AND FILTER (Fig. 55-56) The hydraulic system filter must be changed initially, after the first five hours of operation, and thereafter every 250 hours of operation or yearly, whichever comes first. Use a genuine Toto ol filter for replacement. The hydraulic fluid must be changed every 500 hours of operation or yearly, whichever comas first, 1. Park the machine on a level surface, lower the cutting units, set parking brake and turn the engine off. 2.
MAINTENANCE ADJUSTING TRANSMISSION FOR NEUTRAL (Fig. 58-59) 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. To expose spring leaf assembly, remove (4) screws securing right fender to frame and remove fender. Figure 58 1. Right fender 2, Fender mounting screws 3.
MAINTENANCE Cutting Unit Drive Belts (Fig. 61} 1. The curling unit drive belts should have a maximum deflection of 1/2 inch with a 10 pound load applied. 2. Loosen jam nut on front end of belt tension rod. Rotate rod to lengthen or shorten rod to desired length. Tighter jam nut. Figure 61 1. Belt tension rod 2. Belt tension rod cup retainer 3. Jam nut 3. To release belt tension to cutting units, push retaining cup rearward and pivot yoke downward .
MAINTENANCE Figure 64 1. Lower brake ever 2. Upper brake lever 3. Clevis 4. Reinstall clevis to upper brake lever and tighten jam nut. Repeat procedure on opposite side of machine. 5. After any brake adjustment, operate the vehicle at a low speed {one mph or less) and check that brakes engage equally on both wheels. Readjust as necessary. ADJUST HOOD LATCH (Fig. 66) 1. To adjust hood latch, loosen nuts securing larch to hood and reposition latch as required. Figure 65 1. Hood latch BATTERY CARE 1.
MAINTENANCE BACKSLAPPING CUTTING UNITS The cutting units may be back lapped on the machine. Release tension to the drive belts and remove the cap screw securing the left end of the carrier frame to the cutting unit. Otherwise, remove cutting units completely before backslapping. Connect a lapping machine to the cap screw on the left end of reset shaft with an extension couplet and a /16 socket. Back lap according to procedures in the Toto Sharpening Reel and Rotary Mowers Manual Form No. PT. A\ caution Be c
15° AND 20° SLOPE CHART Read all safety decals and safety instructions in this manual . ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE. BUILDING, FENCE POST, POLE ETC.
The Toto Promise A One Year Limited Warranty The Toto Company promises to repair your TOR Reel master 216D if defective in materials or workmanship. The following time periods from the date of purchase apply: Commercial Products *Cutting unit drive bets . . .