Toro Reelmaster 216-D User Manual

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, MAIN-
TENANCE 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. Replacement Operator’s
Manuals are available by sending complete Model and
Serial Number of traction unit and cutting unit to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
The Toro Company reserves the right to change product
specifications or this publication without notice.
see
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY IN-
STRUCTION. When you this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or
repair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to
prevent damage to systems or components on the
machine.
Reelmaster 216 Reelmaster 216-D
© The Toro Company - 1991, 1994, 1996

Toro Reelmaster 216-D Specifications

General

Transmission	Hydrostatic
Drive System	Hydraulic
Blade Type	Reel
Number of Reels	3
Number of Blades	5
Fuel Capacity	24.6 L
Fuel Tank Capacity	24.6 L
Engine	Kohler CH740
Height of Cut	0.25 - 2.5 inches
Cutting Height	0.25 - 2.5 inches

Summary

Chapter 1 Safety

Safety Instructions

Key safety checks and precautions before, during, and after operation.

REELMASTER® 216 Maintenance Schedule

REELMASTER® 216 Daily Maintenance Check List

REELMASTER® 216-D Maintenance Schedule

Minimum Recommended Maintenance Intervals

REELMASTER® 216-D Daily Maintenance Check List

Chapter 3 Kohler Engine

Chapter 4 Perkins Diesel Engine

Chapter 5 Hydraulic System

TROUBLESHOOTING

System Operates Hot

Loss of Power or Unit Will Not Operate in Either Direction

Unit Will Not Lift or Lifts Slowly

TESTING

Procedures for testing hydraulic system components using specialized equipment.

TEST HOOK-UP NO. 1: Charge Pump Flow and Implement Relief Pressure

Procedure for testing charge pump flow and implement relief pressure.

TEST HOOK-UP NO. 2: Traction Pump Flow, Traction Motors Mechanical Drag and Traction Motors Efficiency

Tests for traction pump flow, motor drag, and efficiency.

TEST HOOK-UP No. 3: Charge Pressure and Implement Relief Pressure

Procedure to test charge pressure and implement relief pressure.

Test Hook-up No. 4: Traction Pressure

Procedure to test traction system pressure.

Test Hook-up No. 5: Traction Pressure (Reelmaster 216-D only)

Specific test for traction pressure on the Reelmaster 216-D.

Chapter 6 Electrical System

TROUBLESHOOTING (Reelmaster 216)

Troubleshooting guide for electrical issues on the Reelmaster 216.

Engine Starting Problems

Diagnosing and correcting engine starting issues.

TROUBLESHOOTING (Reelmaster 216-D)

Troubleshooting guide for electrical issues on the Reelmaster 216-D.

Starting Problems

Diagnosing and correcting engine starting issues on the 216-D.

General Run and Transport Problems

Troubleshooting common operational and transport issues on the 216-D.

Cutting Unit Operation Problems

Diagnosing problems related to cutting unit operation on the 216-D.

Verify Interlock System Operation

Steps to check the interlock system on the 216-D.

TESTING

Procedures for testing electrical components.

Ignition Key Switch

Testing the ignition key switch for proper circuit completion.

Seat Switch

Testing the seat switch for correct operation.

Traction (Neutral) Switch

Testing the neutral switch for proper function.

Cutting Unit Interlock Switch

Testing the interlock switch for cutting unit engagement.

Cutting Unit Clutch (Reel Drive) Switch

Testing the switch that engages the cutting unit clutch.

Battery Service

Detailed procedures for battery maintenance and servicing.

Chapter 7 Wheels, Brakes & Steering

Hand Brake Adjustment (Fig. 1)

Hand Brake Adjustment (Fig. 2)

Brake Service (Fig. 5)

Steps for servicing the brake system on older Reelmaster 216 models.

Brake Service (Fig. 6)

Steps for servicing the brake system on newer Reelmaster 216 and 216-D models.

Chapter 8 Cutting Unit Drive System

ADJUSTMENTS

Cutting Unit Belt Adjustment

Instructions for adjusting the tension of the cutting unit drive belts.

REPAIRS

Procedures for repairing the cutting unit drive system.

Clutch Replacement (Reelmaster 216)

Steps for removing and installing the clutch on Reelmaster 216.

Chapter 9 Cutting Units

TROUBLESHOOTING

Guide for diagnosing and correcting issues affecting cutting unit performance.

Factors Affecting Quality of Cut

Lists factors and their impact on the quality of cut produced by the unit.

SET UP AND ADJUSTMENTS

Procedures for setting up and adjusting the cutting units.

Bedknife to Reel Contact

Procedure for setting the correct contact between the bedknife and reel.

Height of Cut Adjustment and Leveling Rear Roller (Floating Cutting Units)

Adjusting height of cut and leveling rear roller for floating units.

Height of Cut Adjustment and Leveling Rear Roller (Fixed Cutting Units)

Adjusting height of cut and leveling rear roller for fixed units.

Parallel Bedknife to Reel

Procedure to ensure the bedknife is parallel to the reel.

Verifying Height of Cut Adjustment and Leveling Front Roller (Floating Cutting Units)

Verifying height of cut and leveling front roller for floating units.

SERVICE AND REPAIRS