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Toro 2300-D Lawn Mower User Manual

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5. Electrical System 3 Page 5 Reelmaster 2300 D 2600 D uaismo pen i HO1YJIONI sun9119 ung eier d 00ez Ja1seuesy pip KEEN 7 035019 MO19 LINA LH9I HO LVOIONI xovigina Li ONIONIS ATIWWHON S NINYNL 1434 diNa L Seel Z m E 3unss3ud 1NY1000 I HOLIMS Houms G 10 MOT dala alv 3NION3 m Vs LYVLS 9 S v 2 g A a109 3 yovia 8 LA a HE o BAG fi NO NMOHS d 55 a aaan 7 HNOH l 9 S 3onvo y 2 somd MO19 dwar 51 3NION3 NMOHS xovig aau xovig qau 8 S e 2 ES gt _ gt E 3NION3 VOL anta E MOTI3A MOTA gov vor 3ONYHO N3399 N3399 N3399 36uvHo voz 3LIHM das Avl38 NMOGLNHS HOLIMS ap ue D I 455 JLAM NMOGiNHS GION310S dW
6. High Pressure Low Pressure Return or Suction Flow Hydraulic System ty RETURN FROM MANIFO COOLER Figure 13 Page 4 22 Reelmaster 2300 D 2600 D Procedure for Charge Pump Flow Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Make sure machine is parked on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Make sure the hydraulic tank is full A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 4 Disconnect outside top hose from the discharge fit ting of the charge pump Connect gage end of tester to the pump discharge fitting 5 Connect the other end of the tester to the discon nected hose A CAUTION Make sure that all hoses are free of the fly wheel after installation 6 Operate engine at full soeed 3200 100 RPM 7 Make sure hydraulic oil is at operating temperature 8 Make sure that traction pedal and lift valve are in neutral and the parking brake is engaged 9 Watch flow and pressure gauges carefully while slowly closing the flow control valve until the pressure gauge reads 500 PSI 10 Minimum flow gauge reading should be 2 5 GPM If specification is not met repair or replace pump Procedure for Implement Relief Check A CAUTION
7. Low Pressure Return or Suction Flow Figure 12 Hydraulic System Page 4 20 Reelmaster 2300 D 2600 D Procedure for Traction Pump Flow Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Make sure machine is parked on a level surface with the cutting units lowered and off Make sure engine is off 3 Make sure the hydraulic tank is full 4 Make sure that traction pedal is adjusted to the neu tral position see Traction Pedal in the Adjustments Sec tion 5 Make sure that pump drive belt is adjusted properly see Hydraulic Pump Drive belt in the Adjustments Sec tion 6 Blockup one front traction wheel off the floor to allow flow through the traction circuit 7 Chock remaining wheels to prevent movement of the machine 8 Attach a heavy chain to the rear of the machine frame and something solid in the shop 9 Make sure parking brake is off 10 Put 2WD 3WD selector to 2WD so the rear wheel A CAUTION will not spin Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil Reelmaster 2300 D 2600 D Page 4 21 11 Clean hose fitting and disconnect hose from the el bow connection on the top of the traction pump IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester a
8. 5 Make sure mounting and O ring sealing surfaces on reel motor drive pump 2 and traction charge pump 4 are clean 6 Inspect O ring 3 and replace if damaged or worn Apply clean hydraulic oil to O ring Place O ring on reel motor drive pump 2 7 Position reel motor drive pump 1 to traction charge pump 4 Secure reel motor drive pump to traction charge pump with cap screws 1 8 Coat all O rings with clean hydraulic oil Install hy draulic fittings 7 8 15 and 16 and O rings 34 into the traction charge pump 4 Torque these fittings from 23 to 27 ft lb and as close to their original position 9 Coat all O rings with clean hydraulic oil Install hy draulic fittings 17 and O rings 35 into the traction charge pump 4 Tighten these fittings as close to their original position as possible 10 Connect hoses 5 and 6 to hydraulic fittings 7 and 8 tighten both hose clamps Connect hose connec tions 9 10 11 and 12 to hydraulic fittings 15 16 and 17 Tighten all hose connections 11 Replace cap screw 40 through the pump control rod 41 spacer 42 and pump lever assembly 20 Se cure lock nut 39 to the capscrew and tighten 12 Install pump drive belt 26 onto pulley 27 Align the holes of the mounting plate 22 with the holes of the belt adjustment yoke 25 and slide clevis pin 24 through holes Secure clevis pin with the cotter pin 23 13 Adjust pump drive belt s
9. Hydraulic System INLET PORT SIDE OUTLET PORT Figure 54 1 Retaining ring 6 O ring 11 Drive gear 2 Shaft seal 7 Dowel pin 12 Idler gear 3 Mounting flange 8 End cover 13 Rear bearing block 4 Backup ring 9 Bolt 14 Front bearing block 5 E seal 10 Gear housing Disassembly Fig 54 1 Tape the shaft end of the drive gear 11 to prevent damaging the shaft seal when the shaft is removed or reinstalled 2 Matchmark the inlet side of the gear housing 10 with the mounting flange 3 and the end cover 8 with the gear housing 10 to make sure proper orientation of these three parts during reassembly 3 Position the pump with the drive end facing down 4 Remove the four bolts 9 Lift off the end cover 8 and and two dowel pins 7 and them aside 5 Remove the gear housing 10 ensuring the rear bearing block 13 front bearing block 14 drive gear 11 and idler gear 12 remain together Remove the re maining two dowel pins from the gear housing Hydraulic System Page 4 58 6 Remove the rear bearing block 13 from the drive and idler gear shafts 7 Remove the idler gear 12 8 Remove the drive gear 11 shaft slowly from the mounting flange 3 Remove the front bearing block 14 from the drive gear 11 shaft Shaft Seal Replacement Fig 54 1 Place the mounting flange 3 on a clean working surface with the shaft seal up 2 Remove the retaining ring 1 Note
10. 1 Place thrust washer on pivot rod front cutting units only and slide carrier frame onto pivot rod Fig 17 Note On rear cutting unit reinstall thrust washer be tween the rear of the carrier frame and the flat washer 2 Secure flat washer and flange head cap screw onto pivot rod Fig 17 3 Connect tipper chain to the front carrier frame Fig 18 Figure 17 1 Flange head capscrew 3 Pivot rod 2 Flat washer 4 Thrust washer Cutting Units Page 7 14 Reelmaster 2300 D 2600 D Note Onrear counterbalance spring make sure that the vinyl cover is on prior to reinstalling the spring 4 Make sure one end of spring is secured to the spring shackle and the other end is hooked into the lift tab hole noted in step 6 5 Secure counterbalance spring and lifttab to the car rier frame with the capscrews and lock washers Fig 16 6 Inserta breaker barinto the square hole inthe coun terbalance arm and pivot the counterbalance arm back to its original position aligning the cap screw hole fig 15 7 Secure bottom of counter balance arm to frame with the bottom capscrew Tighten top cap screw Fig 15 5 E RM2600 TIPPER CHAIN IS CONNECTED TO THE BOTTOM OF THE FRAM SS Figure 18 1 Tipper chain Reelmaster 2300 D 2600 D Page 7 15 2 Carrier frame Cutting Units 5 E 3 Bedbar Removal and Installation Fig 19 through Fig 21 Bedbar Removal 1 Turn bedknife adjusting handle t
11. 3 Lift front wheel off the ground using a jack Block 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Hex nut Adjusting rod thrust washer Brake shaft Wheel motor LH Spacer Lock nut Valve stem Extension spring Pivot pin Brake plate O ring O ring O ring O ring Key front and rear of other wheels 1 Park machine on a level surface Ensure engine is off 2 Make sure brake is in the OFF position Wheels and Brakes 4 Remove lug nuts 22 and tire and rim assembly 20 and 21 Remove lock nut 40 from wheel hub 18 Page 6 6 Reelmaster 2300 D 2600 D IMPORTANT DO NOT hit wheel hub 18 with a ham mer during removal or installation Hammering may cause damage to the wheel motor 12 or 38 5 Use a pullerto remove the wheel hub 18 and brake drum 19 Remove the key 49 from the wheel motor shaft 6 Remove brake extension springs 42 from brake shoes 17 Remove brake shoes from brake plate 44 7 Remove cotter pin 27 from the clevis pin 31 Re move clevis pin from the brake lever assembly 32 Separate brake lever assembly from the clevis 33 8 Remove hex head screws 16 and lock nuts 13 holding the brake plate 44 and grass brake shield 15 to the brake bracket 25 IMPORTANT DO NOT remove brake lever assembly 32 from the brake plate 44 9 Remove brake plate 44 flat washers 14 and grass brake shield 15 from the bra
12. Cap screw Lock flange nut Hex head screw Hex head screw Guard Europe Air cleaner housing Radiator top shroud Air cleaner 4 Tighten bolts securing the alternator to the engine PINA ox NOO 5 Reinstall air cleaner housing Fig 7 A Unplug air cleaner hose and hose inlet to the air cleaner B Place air cleaner housing 6 on the radiator top shroud 7 Reconnect upper end of the air cleaner hose to the air cleaner 8 Align holes to receive fasteners C On European models reinstall hex head screws 4 into guard 5 through the air cleaner housing 6 D Secure cap screws 1 and lock flange nuts 2 to air cleaner housing and radiator top shroud 7 E Secure hex head screws 3 into the air cleaner housing and radiator assembly Figure 8 1 Engine belt F Tighten hose clamp securing the hose to the air cleaner Reelmaster 2300 D 2600 D Page 3 7 Engine Throttle Linkage 1 Verify high engine speed at 3200 50 RPM with the cold start button depressed 2 If engine speed is out of specification loosen cap screw nut and throttle cable clamp on the throttle cable bracket enough to allow the cable to slide freely within the bracket 3 Move throttle lever up fully to the high speed posi tion 4 Pull cable toward flywheel end of the engine until the governor lever on the engine is up against the high speed adjustment screw Tighten cap screw and nut se curing the throttle cabl
13. Installation Fig 63 1 Coat new O rings lightly with clean hydraulic oil Install hydraulic fittings 3 and 4 and new O rings 15 on the lift cylinder 10 2 Position lift cylinder 10 inside pivot support 8 Slide lift pivot shaft 9 through pivot support and lift cyl inder Make sure lift pivot groove is aligned to accept the ram pivot pin 7 Install ram pivot pin 7 and cap screw 6 3 Swing the lift cylinder 10 up so its clevis is posi tioned between the lift arm 13 slots Slide a flat washer 14 onto the clevis pin 12 Slide clevis pin through the lift arm slots and the lift cylinder 10 clevis Install re maining flat washer and then cotter pin 11 onto the cle vis pin 4 Install hose connections 1 and 2 onto hydraulic fit tings 3 and 4 Tighten hose connections 5 If rod clevis 14 has been removed verify that the distance between the carrier frame rollers bumpers on later models and the foot step is about 1 4 inch 6 mm with the cutting units fully raised Adjust rod clevis as necessary Fig 63 A Lower cutting units Engage parking brake stop the engine and remove key from the ignition switch B Remove cotter pin 11 from clevis pin 12 Slide clevis pin out of the lift arm 13 removing flat wash ers 14 Fig 64 C Separate rod clevis from lift arm 13 Fig 63 D Loosen jam nut 13 and adjust rod clevis 14 as necessary Fig 64 Tighten jam nut
14. NMOGLNHS Fog ec dIN3L HDIH ILHM 1 GIONIT0S 4 dW3L HOIH zig Le Zug Am 9 m GNG mum d d e o 1212 NYL 5 B 5 AUD ovig VN m m ovia pesa Ov 06 6L MOTD gle ques bes o 7121 26 OHOL Zi OW 0 os 1HVIS AV T3H NEN 971 01 VO pl HIM Ov oel NO HALHWIS eh x ANITATAISNA HOLIMS NOILIN I RE 311HM 038 319V8 38 SI YIONITAD N3HM 0380719 N3dO ATIYWHON 8 HOLIMS NOOTHALNI z NNHOLAIZIYHIN3 T Sa GION310 E S o gt m anwatans ji 31dund 7 3ONVHO weg e m Fauna yowla day 3IIHWSONVHO Xovi8 ES N3399 ANIYA GION310S gt m LINA ONILLNO ONISNOH quvog pova 31dund HOLO3NNOO LINOHIO NvHOvIa e 440 3IIHW3ONVHO MOVIE 30010 3G01d gqoia ovi8 1389 paaa 1V3S NI HOLYH3dO HLIM 035079 y o Xovi8 SBIIHWSONVHO y HYE m H N3dO ATIYWHON HOLMS Lahad 2 sawa B 8 El Gael HOLIMS MOOTHSLNI LVIS ew A n Xovi8 O awe 31dund e a 3ONVHO Yal311038 4O1WINO38 Sang a Diels 31 yrs 3uHwsdund yovig NOUS El El le D k BANNOHO D Bl ovi8 XOV18 A3H9 OVIS Gong H H YOLVNHALIV Sovia NOLLISOd TWHLNAN NI 139019 a N3dO ATIYWHON HOLIMS YOOTHSLNI NOLLOVH L REA nakay Sg HOLIMS dVDIOVE ama aa Electrical System 7 Page 5 Reelmaster 2300 D 2600 D
15. 1 Remove bedbar assembly see Bedbar Removal and Installation 2 Remove front roller and brackets see Roller Re moval and Installation Note Most reel grinders require that the rear roller assembly be mounted to the cutting unit for proper sup port in the reel grinder The rear roller must be parallel to the reel shaft to remove taper when grinding or the cutting unit must be aligned so the grinding wheel will travel parallel to the reel shaft This will result in the the reel being ground to the desired cylinder shape Note When grinding be careful to not overheat the reel blades Remove small amounts of material with each pass of the grinder 3 After completing grinding process A Install front roller and brackets see Roller Re moval and Installation B Install bedbar assembly see Bedbar Removal and Installation C Complete cutting unit set up and adjustment se quence see Adjustments section 3807 5 m 050 to 090 1 3 to 2 3 mm 0607 15m BLADE RELIEF ANGLE REEL DIAMETER TAPER D Figure 27 Cutting Units Page 7 24 Reelmaster 2300 D 2600 D Fixed Side Plate Installation Fig 28 and Fig 29 1 Remove pop rivets and rear height of cut plates from both sides of the cutting unit Fig 28 2 Remove lock nuts capscrews washers and both links from the cutting unit Fig 28 3 Align fixed side plate with holes on the cutting unit Fig 29 4 Att
16. 5 Mount a wheel puller to the wheel hub studs and re move the wheel hub off the wheel motor shaft Remove the woodruff key 6 Remove rust from all parts with a wire brush prior to installation Clean all parts Replace any worn or dam aged parts Installation 1 Install woodruff key and wheel hub onto the wheel motor shaft 2 Install lock nut to wheel motor shaft and tighten to a torque of 250 to 400 ft lb 34 6 to 55 3 kg m 3 Install wheel assembly and secure the lug nuts to the wheel hub studs 4 Tighten lug nuts evenly in a crossing pattern to a torque of 45 to 65 ft lb 6 22 to 8 98 kg m Wheels and Brakes Page 6 4 PINA Lug nut Wheel hub stud Wheel assembly Lock nut Figure 2 Wheel motor shaft Wheel hub Woodruff key Wheel motor exon Reelmaster 2300 D 2600 D Rear Wheel 2WD Removal 1 Park machine on a level surface Ensure engine is off Set hand brake and block front wheels 2 Lift rear wheel off the ground using a jack Secure back of the frame 3 Remove lock nut 1 and flat washer 2 from the castor axle 3 Slide castor axle from the castor fork 4 and remove wheel 4 Ifthe wheel was removed because of bad bearings proceed as follows A Remove spacer 5 from the rim 6 B Pull bearings 7 from the rim Figure 3 Installation atio 1 Lock nut 5 Spacer 2 Flat washer 6 Rim 1 Ifthebearings 7 were removed from the rim 6 re 3 Castor axle
17. OIMEIP H ANIYA TOHLNOO MOT B dn peuonisod si anjea jo uo i INVA isd 000 pazibiaua ap UMOUS SI LS piougjos 0798 E 44O NO 33134 uva zd 1334 1534 ck SHOLON 1324 ns MOL lt on T uonong JO Une ISd 0031 NP ER 431734 HINO SSOHO CD sa NWA D abjey9 almssalg M0 Eke ANIYA 21501 SN ONIddv biova 101 9Jnssa8Jgd UBIH Law LN n dent iun Dun esie LE tH pa 20 i m suun un 9 H H ps 1 0092 Q 00 2 1eiseuieeu aw F Y3TIOYLNO9 03348 1338 OLLVIN3HOS YOLOW 1338 xc v 19 ld 99461 d us Fun uvao Eu ct BE 1431 471009 HOLOW 133HM LNOUS D E GE DND nn 4 A diNnid NOILOYHL uvau INOH4 i 831171 48 QuvMHO4 ASUAASY NOTWO EZ BIOAHIS3E WOLLO fat i co r Y gt 75 TAO 1317 OLLVIN3HOS YOLOW 133HM 1437 t 3 006 9 3unssaud MOT E EN ev WON NOUOI Ok Vanina 30uvHO pozet wall A Y aano ua eul ZL dOL 0 r ie uvau poe S SL y gt HOLOW 133HM isdogi oor C darmuaouvHo WOLLOS dOL saap Jr L y DEEN 43734 L417 Nous Reeg Ne A TAO 1417 Y I i Y ES Nae Leon T 1 Hee Ly L zi A ion a waaan a om j dOL WOLLO A Y OME NI NMOHS U INIYA MOL l HO10313S AME AMZ uvau INO TTE J K r kaa Ca aa aaa aaa aaa Ta Unou NI TOL gt V d0l BAYAW CM amor Hd ANIYA 1OH1NOO wages ae 2119339 TOHLNO9 MOT Od o O 00 61 gu z 3Su3A3u Nr HAS SS HOLOW 133HM CHVMEOS d Hydraulic System Page 4 9 Reelmaster 2300 D 2600 D Traction Forward Th
18. Page 3 4 Some tools may be listed in the Reelmaster 2300 D 2600 D Parts Catalog Tools may also be available from a local supplier Figure 1 Figure 2 Figure 3 Reelmaster 2300 D 2600 D Nozzle Test Adapter This adapter is required to test the fuel injection nozzles Figure 4 Reelmaster 2300 D 2600 D Page3 5 Engine General Information Fuel Shutoff Valves These valves should be shut when removing the engine or placing the unit in long term storage Figure 5 1 Fuel shut off under the fuel tank Figure 6 1 Fuel shut off valve on the fuel filter Engine Page 3 6 Reelmaster 2300 D 2600 D Adjustments Alternator Belt 1 Gain access to the alternator belt Fig 7 A Loosen top hose clamp securing the upper por tion of the hose connected to the air cleaner 8 B Remove cap screws 1 and lock flange nuts 2 Remove hex head screws 3 C On European models remove hex head screws 4 from the guard 5 and air cleaner housing 6 D Pull air cleaner housing from the radiator top shroud 7 and hose Plug air cleaner hose and hose inlet to the air cleaner 2 Loosen bolts securing alternator to the engine and adjusting strap 3 Adjust alternator belt to the proper tension Tension alternator belt so it deflects 0 20 inch with a 2 to 3 pound load applied midway between the crankshaft and alter nator pulleys Fig 8 Figure 7
19. Remove and discard dust seal 12 backup washer 9 and O rings 7 and 8 from the head 10 Note If the rod clevis 14 is to be removed from the shaft 6 note the number of threads exposed between the jam nut 13 and the smooth surface of the shaft to help reassembly 7 Loosenjamnut 13 and remove clevis if necessary Inspection Fig 64 A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect internal surface of barrel 1 for deep scratches out of roundness and bending Replace if worn or damaged Reelmaster 2300 D 2600 D Page 4 73 3 Inspect head 10 shaft 6 and piston 3 for ex cessive pitting scoring and wear Replace any worn or damaged parts Reassembly Fig 64 1 Coat new dust seal uni ring backup washer and all O rings lightly with hydraulic oil Install new O ring 5 and uni ring 4 to the piston 3 Install O rings 7 and 8 and backup washer 9 to the head 10 Press dust seal 12 into head 10 IMPORTANT Do not clamp vise jaws against shaft 6 surface Protect shaft surface before mounting in the vise 2 Mount shaft 6 securely in a vise Adjust clevis 14 and jam nut 13 so the number of threads exposed be tween the jam nut 13 and the smooth surface of the shaft is the same as noted during disassembly The jam nut must be tight against rod clevis for this
20. 2 3 mph because drive system may be damaged If machine must be moved a considerable distance transport it on a truck or trailer 1 Locate by pass valve on pump and rotate it 90 so the by pass valve is horizontal 2 Before the starting engine close by pass valve by rotating it 90 so the by pass valve is vertical Do not start engine when valve is open Figure 9 1 By pass valve Hydraulic System Page 4 6 Reelmaster 2300 D 2600 D Hydraulic Schematic MIS OIMNEIP H INIYA 1OH1NOO MOT Si EN SLINN AMS NO Q3Sf LON INVA isd 0008 pe de oa GE SI LINOYIO 3MYOTI3HM YV38 za x SHOLOW 1338 ag Es TE mE W peziDJoue op 9W E UMOUS SI Le piougjos ISd 0081 uo 431734 d3AO SSOHO ea BN SE iH SN ONIddV Iova 101 JIJEWSYIS one pAH Law LW CC d 009Z q 00E7 Jajsewjoay l j l Ka gt lt 02761 ul 103 E ener 1431 YOLOW 133HM ZN ra H3TIOHLN
21. 22 with seal ring side up 20 If shuttle valve components items left hand motor only were removed from the end cover 24 screw a plug with a new O ring 25 loosely into one end of the valve cavity in the end cover Insert spring valve and second spring into the other end of the valve cavity Turn second plug with a new O ring 25 loosely into the end cover valve cavity A 3 16 inch allen wrench is required Fig 49 Note Ifthe end cover 24 has a valve shuttle use line that was previously scribed on the end cover to radially align it into its original position 21 Assemble new seal ring 5 into end cover 24 and assemble end cover over the alignment studs and onto the commutator set Fig 50 Hydraulic System Page 4 52 NM 2 Figure 49 Figure 50 Reelmaster 2300 D 2600 D Note The cap screws 14 required for use with the shuttle valve left hand motor only end cover 24 are longer than the bolts required with standard end cover Refer to Toro Parts Catalog for correct service part num ber if replacement is required 22 Assemble seven cap screws 14 and screw them in finger tight Remove and replace the two alignment studs with bolts after the other bolts are in place Alter nately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 45 to 55 ft lb 6 2 to 7 6 kg m Reelmaster 2300 D 2600 D Page 4 53 23 Torque the two
22. 8 pa Yaddn 8 S dOL WOLLOS ME NI NMOHS 3 NIVA MOL 40193173S QM Mz away LNO PI as MOLIOR LNOYS NI PA V dOL 3ATVA USMOTN H r Ke Wdd US gt H JOYLNOD MOT Od A 00261 eui 3SY3M38 ra IHOIH E YOLOW TH3HM CHVMEOW Hydraulic System Page 4 15 Reelmaster 2300 D 2600 D Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Contains one each 1000 5000 and 10000 PSI gauges Use gauges as recommended in Testing section of this chapter Hydraulic Tester Pressure and Flow Some tools may also be available from a local supplier Figure 11 This tester requires o ring face seal ORFS adapter fit tings for use on this machine 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to provide accurate reading at low pressure 0 to 1000 PSI Hydraulic System Page 4 16 A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH
23. 8 Wearing safety glasses safety shoes long pants and a helmetis advisable and required by some local or dinances and insurance regulations While Operating 11 Do not run the engine in a confined area without ad equate ventilation Exhaust fumes are hazardous and could be deadly 12 Sit on the seat when starting and operating the ma chine 13 Check interlock switches daily for proper operation see Checking Interlock Switches of the Operator s Manual Do not rely entirely on safety switches shut off engine before getting off the seat If a switch fails re place it before operating the machine The interlock sys tem is for your protection so do not bypass it Replace all interlock switches every two years 14 When starting the engine A Engage parking brake B Be sure traction pedal is in neutral and reel drive is in the disengage position C After the engine starts release parking brake and keep foot off the traction pedal The machine must not move If movement is evident the neutral control linkage is incorrectly adjusted therefore shut engine off and adjust until the machine does not move when the traction pedal is released see Adjusting Transmission for Neutral of the Opera tor s Manual D Hills over 15 degrees should be mowed up and down not side to side see Slope Gauge of the Op erator s Manual E Mowing hills may be dangerous Hills over 20 degrees should not be mowed see Slope Gauge
24. Disconnect electrical connector to the fuel stop so lenoid to prevent engine from starting 7 Turn ignition key switch engage starter for ten 10 seconds to the prime pump Repeat this step again 8 Connect electrical connector to the fuel stop sole noid 9 Start engine and let it idle at low speed for a mini mum of two 2 minutes 10 Increase engine speed to high idle for minimum of one 1 minute under no load Reelmaster 2300 D 2600 D Page 4 79 Figure 68 1 Hydraulic reservoir cap 2 Sight gauge Figure 69 1 Hydraulic filter 11 Raise and lower cutting units several times 12 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic reservoir and add correct oil if necessary 13 Operate the machine for two 2 hours under normal operating conditions 14 Check condition of hydraulic oil If the flushing fluid shows any signs of contamination or if you are changing to biodegradable fluid repeat steps 1 through 14 again 15 Assume normal operation and follow recom mended maintenance intervals Hydraulic System Hydraulic System Start up Note Wheninitially starting the hydraulic system with new or rebuilt components such as motors pumps or lift cylinders it is important that this start up procedure be used This procedure reduces the chance of damag ing the system or its components from not purging the System of air 1 After the hydraulic system c
25. Do not allow charge pressure to exceed 650 PSI 1 Fully open control valve on the tester Reelmaster 2300 D 2600 D Page 4 23 2 Operate engine at full speed 3200 100 RPM 3 Make sure hydraulic oil is at operating temperature 4 Watch pressure gauge carefully Make sure lift lever to the cutting units is in the neutral position Record the pressure 5 While holding the lift lever in the raised position watch the pressure gauge Record pressure the relief valve opens at 6 Return lift lever to neutral position Shut off engine 7 Subtract the relief valve closed pressure from the relief valve open pressure see example below The dif ference should be from 450 to 500 PSI A If this specification is not met adjust relief valve B If this specification is met go to step 9 Example Calculation Relief Valve Open Lever to Raise Relief Valve Closed Lever in Neutral Open less Closed Pressure 450 to 500 PSI Adjusting the relief valve pressure as follows A Remove the cap from the relief valve B To increase the relief valve pressure set point use an allen wrench and turn set screw slightly clockwise C To decrease the relief valve pressure set point use an allen wrench and turn set screw slightly counterclockwise D Repeat steps 1 through 8 above until the relief valve pressure set point is correct Reinstall cap on valve when valve is set properly E If the relief val
26. Reassembly Fig 32 1 Lubricate all seals and seal rings with clean hydrau lic oil before assembly A WARNING Since they are flammable be extremely careful when using any solvent Even a small explosion or fire could cause injury or death A CAUTION Use eye protection such as goggles when using compressed air 2 Wash all parts in a clean petroleum based solvent before assembly Blow parts dry with compressed air 3 Press anew dirt and water seal 1 into the housing 3 outer bearing counterbore Press seal in with the lip facing out and until the seal is 0 020 inch 0 51 mm be low the end of housing 4 Place housing 3 into a soft jawed vise with the cou pling shaft bore down clamp against the mounting flange IMPORTANT Early model wheel motors that do not have backup washer 6 when inspected must be as sembled with a new backup washer 4 new backup washer 6 and new seal 7 5 Ahousing 3 that does not require replacement will require that the two thrust washers 8 and thrust bear ing 9 be unseated and vertical to the counterbore and the new backup washer 4 new backup washer 6 and new seal 7 be worked around the thrust bearing package and placed into their respective counterbores Fig 44 and 43 The seal lip must face out of the seal counterbore and toward the inside of wheel motor Fig 45 Be sure the thrust bearing package is reseated cor rectly after assembly of the new seal and
27. of the block Install the three pins into the special grooves in the piston block D Install a washer spring and second washer into the piston block E Place cap screw through one of the flat washers Insert cap screw through the center of the piston block Install second flat washer onto the capscrew so the washer rests on the three pins Screw nut onto the cap screw F Compress spring by tightening the nut onto the cap screw Install the retaining ring into the piston block G Unscrew the nut and remove washer and cap screw from the piston block H Install spider pivot onto the three pins and place the spider on the spider pivot I Insert piston assemblies through the spider and into the piston block with the piston shoes resting on the spider 10 Set rotating kit assembly 29 on a working surface with the piston shoes facing up Insert shaft 31 through the rotating kit assembly with the flanged end of the housing assembly up Position rotating kit assembly into the housing assembly 11 Make sure piston block and shaft 31 splines are aligned Make sure piston block is engaged fully so the piston shoes are in contact with the camplate 20 Make sure all parts are in their proper position be for pro ceeding to the next step 12 Hold rotating kit assembly 29 in place and clamp housing assembly 15 with the flange end down into a vise with protected jaws Install gasket 24 and two dowel pins 18 into t
28. screws and hydraulic fittings tight 26 Before applying pressure to the hydraulic system make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition 27 Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have suffi cient force to penetrate the skin and cause serious inju ry If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Reelmaster 2300 D 2600 D Page1 3 Rev A D Stop the engine and remove the key from the ig nition switch 21 Whenever the machine is left unattended make sure the reels are not spinning the key is removed from ignition switch and the parking brake is set 28 Before disconnecting or performing any work on the hydraulic system all pressure in system must be re lieved by stopping the engine and lowering cutting units to the ground 29 If major repairs are ever needed or if assistance is desired contact an Authorized Toro Distributor 30 Reduce potential fire hazards Keep the engine area free of excessive grease grass leaves and accu mulation of dirt 31 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any other parts of the body away fr
29. 0 105 to 0 115 in Maga to 2 03 mm i 2 67 to 2 92 mm BEARING HEIGHT ROLL PIN HEIGHT Figure 28 FLANGE END OF rk 0 062 to 0 078 in 1 57 to 1 98 mm F lt NUMBERED END Figure 29 5 Inspect housing assembly 15 see Fig 24 A Verify that bearing depth on the numbered end meets the dimension in Figure 29 B Bearing needles must move freely and remain in their cage Hydraulic System 6 Inspect rotating parts kit see Fig 26 A Verify that piston O D finish shows no wear or deep scratches Piston shoes should fit snuggly onto the ball end of the pistons The shoe surface that contacts the camplate should be smooth and flat Do not lap piston shoes B Examine the mutual contact surfaces on the spi der and spider pivot both contact areas should be smooth and free of wear C The piston block surface that makes contact with the valve plate should be smooth and free of deep scratches Do not lap piston shoes D The bore areas of the piston block should be free of scoring and contamination Pistons should move freely in the bore areas Reassembly Fig 24 1 Make sure all parts are clean Lubricate all critical moving parts and O rings with clean hydraulic oil 2 f necessary press new bearing 14 into housing assembly 15 to the dimension shown in Figure 29 3 Insert camplate 20 into the housing assembly 15 4 On the short trunnion side of the camplate 20 install b
30. 1 Safety Maintenance and Service 3 SAFETY AND INSTRUCTION DECALS 4 A WARNING To reduce the potential for injury or death comply with the following safety instruc tions Use the Model and Serial Number when referring to your machine If you have questions about this Service Manual please contact The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis Minnesota 55420 1196 2 Only trained operators skilled in slope operation and who have read the Operator s Manual should oper ate the machine Never allow children to operate the machine or adults to operate it without proper instruc tions 3 IMPORTANT Always use proper rear ballast as specified in the operator s manual see Rear Ballast of the Operator s Manual 4 Become familiar with the controls and know how to stop the machine and engine quickly Safety 5 Do not carry passengers on the machine Keep ev eryone especially children and pets away from the ar eas of operation 6 Keep all shields safety devices and decals in place If a shield safety device or decal is damaged malfunc tioning or illegible repair or replace it before operating the machine 7 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in jury
31. 12 Disconnect tester from manifold and hose Recon nect hose to the pump 13 Ifflow was less than 5 4 GPM or a pressure of 1500 PSI cannot be obtained check for restriction in the pump intake line If line is not restricted remove pump and re pair or replace as necessary Hydraulic System TEST NO 5 Manifold Relief Valve Pressure TESTER FROM REEL DRIVE PUMP kr J gt TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR SHUTTLE VALVE High Pressure Low Pressure Return or Suction Flow Install tester in series between fitting and hose at the motor right hand motor shown Figure 16 Hydraulic System Page 4 28 Reelmaster 2300 D 2600 D Procedure for Manifold Relief Valve Pressure Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Make sure machine is parked on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Make sure the hydraulic tank is full A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 4 Clean hose connection and right hand reel motor Disconnect the hose leading from the right hand reel motor to port M2 on the hydraulic manifo
32. 19 from the muffler 14 and muffler tube 15 B Loosen nut 20 and U clamp 17 Separate muffler tube from muffler and slide muffler tube through U clamp C Remove cap screws 36 and washers 13 from the muffler and right rear mount bracket 46 Reelmaster 2300 D 2600 D 1 2 Hydraulic return hose 1 2 Hydraulic supply hose Page 3 15 Figure 20 3 Hydraulic fitting 4 Hydraulic reservoir Hose clamp Figure 21 3 Hydraulic elbow fitting 4 Hydraulic manifold Hose clamp D Remove cap screws 39 and flat washers 11 from the muffler and exhaust manifold Remove muffler and muffler gasket 53 from the engine Disconnect throttle cable Fig 19 A Loosen cap screw 43 enough to separate the throttle cable from the throttle cable clamp 30 B Remove cotter pin 30 from clevis pin 29 Re move clevis pin throttle tab 31 and throttle cable from the engine governor lever C Secure throttle cable away from the engine Engine 14 Disconnect electrical connections Fig 19 Note Label all electrical leads for reassembly pur poses 15 Engine A Disconnect connector with blue leads from the alternator B Disconnect connector with blue white leads from the traction clutch C Disconnect connector from the front lift cylinder microswitch D Remove white black lead from the temperature sender located on the top of the water pump E Remove t
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34. 5 The charge pump adapter assembly 2 can be dis assembled as follows see Fig 25 A Unscrew and remove spring retainer from the charge pump adapter assembly B Remove spring and cup poppet from the charge pump adapter assembly 6 Remove gerotor assembly 3 inner ring and cou pler from the shaft 31 7 Lift backplate assembly 25 up and off from the shaft 31 and housing assembly 15 Remove valve plate 6 from the backplate assembly or rotating parts kit 29 8 Remove valve assembly 5 and O rings 38 and 39 from the backplate assembly 25 Disassembly of the valve assembly is not necessary 9 Remove both plugs 21 O rings 40 spring 22 and seats 23 from the backplate assembly 25 10 Remove gasket 24 from the housing 15 or back plate assembly 25 Note To remove the rotating parts kit 29 from the shaft 31 a table or workbench with a hole in the work ing surface is required for the protruding shaft 11 The rotating parts kit 29 can be removed from the shaft 31 as follows A Hold rotating parts kit 29 in place and remove the pump from the vise B Position the housing assembly 15 end of the pump up and lower the shaft 31 through the hole in the table or workbench Allow rotating parts kit 29 to rest on the table C Remove rotating parts kit 29 by lifting away the housing assembly 15 and shaft 31 12 The rotating parts kit 29 can be disassembled as
35. 6 One person should sit on the seat and operate the machine while another person reads the tester Start en gine and set throttle to full speed 3200 100 RPM A CAUTION Keep away from reels during test to pre vent personal injury from the rotating reel blades A CAUTION Do not allow system pressure to exceed 1700 PSI Shut off unit to prevent an over pressure condition 7 Engage cutting units Observe pressure gauge Motor Position Right Hand Pressure Range PSI 1500 to 1600 1540 to 1640 Left Hand 1580 to 1680 8 Disengage cutting units and stop engine lf specifi cations are not met replace cross over relief If specifi cations are met remove block of wood from cutting unit and repeat test on other reels in mow direction Reelmaster 2300 D 2600 D Page 4 31 9 Remove test gauge and put cap on manifold port G1 IMPORTANT Each reel motor has two cross over reliefs Test reliefs in the backlap direction only if they are expected to be the problem After testing cross over reliefs in the backlap direction make sure the reel motor couplings are torqued see Hy draulic Motor Removal and Installation of Chapter 7 Cutting Units and Reel Motor in the Service and Repair section 10 Clean left hand reel motor and its hose connection leading to manifold port M3 Disconnect hose connec tion and install pressure gauge with a T connection be tween the hose connection and the motor 11
36. 69 bar 4 ply Newer models 12 to 16 PSI 0 83 to 1 10 bar Front and rear wheel lug nut torque 45 to 65 ft lb 6 22 to 8 98 kg m Wheel planetary mounting cap screw torque 250 to 400 ft lb 34 6 to 55 3 kg m Wheels and Brakes Page 6 2 Reelmaster 2300 D 2600 D Adjustments Hand Brake 1 Ensure machine is parked on a level surface with the cutting units lowered Ensure engine is off 2 Jack up the front of the machine and support it from under the frame with jack stands Remove both front wheels 3 Make sure brake is in the OFF position 4 Turnby pass valve on traction pump to the by pass position as described in the General Information section of Chapter 4 Hydraulic System 5 Loosen jam nut 1 on the clevis 2 6 Adjust brake arm lever distance A Remove cotter pin 3 securing the clevis 2 to the upper brake arm lever 4 Disconnect clevis from the upper brake arm lever B Rotate clevis one turn at a time clockwise to de crease the distance between the upper brake arm lever and lower brake arm lever 5 C Install clevis to upper brake arm lever Install cot ter pin to clevis D Repeat steps 6 A through 6 C until the brake shoes firmly contact the brake drums the wheel will not turn by hand E When the wheel will not turn by hand back the brake shoes off the brake drum Remove cotter pin securing top of the clevis to the upper brake arm le ver Disconnect clevis from the uppe
37. 7 Bearing 4 Castor fork place with new bearings as follows A Press a new bearing into one side of the rim until the flange of outer race is flush with the rim B Slide spacer 5 through the bearing until the end of the spacer is flush with the outside of the bearing inner race C Pressthe remaining new bearing 7 into the oth er side of the rim and over the spacer so the flange of outer race is flush with the rim D The spacer must not extend beyond the inner race of either bearing 2 Install wheel and slide castor axle 3 through the castor fork 4 and wheel 3 Secure flat washer 2 and lock nut 1 to the castor axle 3 Torque lock nut from 45 to 65 ft lb 6 2 to 9 0 kg m E sg ox o O o X e Reelmaster 2300 D 2600 D Page 6 5 Wheels and Brakes Front Wheel and Brake Lock nut Lock nut Flat washer Hex head screw Flange nut Adjusting rod Parking brake assembly Flanged screw Spring 10 Hydraulic fitting 11 Elbow fitting 12 Wheel motor RH 13 Lock nut 14 Flat washer 15 Grass brake shield 16 Hex head screw 17 Brake shoe OO ADAN Removal 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 LEFT WHEEL SHOWN Figure 4 Wheel hub Brake drum Lug tire Lock rim Lug nut Wheel hub stud Socket head screw Brake bracket Wheel shield Cotter pin Brake arm assembly RH Brake arm assembly LH Roll pin Clevis pin Brake lever assembly Clevis
38. ADV ia SHIIHWSONVHO d it Y y N3dO ATIVIAHON HOLMS Il add Sive ala o selo o HOLIMS MOOTHALNI LVIS NNO 5 MOV 18 giaund dl dive a OX AA e e 3ONvHO Yala11038 401VIN938 11HMW3148Nd E ollo mE jene LIHW31d8Nd 39VLIOA EES j Nnou9 3 LAJN j e VONT enee EI e wovia XOV18 A3HO GEESS OVE H NnOHO H H NOLLISOd TWHLNAN NI 035019 N ama N3349 NadO ATIYWHON A35 d Xovi8 A3uo ov HOLIMS X90 1H31NI NOLLOVEL Sg wovig MOTISA NOILISOd MOW NI NMOHS 3m18 d3u HOLIMS dYINOVA Electrical System 5 Page 5 Reelmaster 2300 D 2600 D uoneoipu YALSN10 pen J9MOd YOLVOIGNI syn9119 depjoeg ung Dee HOLVNYSLW O a 159 SEW 5O 9nd a 0062 y das010 O mors LINA Lem HOLVOIONI 1918
39. B Use new screws Apply anti seize lubricant to screw threads before installing IMPORTANT DO NOT use an impact wrench C Tighten screws to a torque of 250 to 300 in Ib 288 to 345 kg cm working from the center toward each end of the bedbar Fig 22 5 Since there can be variations in the mounting sur face of the bedbar a new bedknife will not be perfectly flat after it is installed Because of this it is necessary to backlap or grind a new bedknife after installing it to the bedbar Follow the existing angle that was ground into the bedknife and grind only enough to make sure the top surface is true Regrinding Bedknife Remove bedbar bedknife assembly from cutting unit before attempting to regrind a used bedknife see Bed bar Removal and Installation Note When grinding be careful to not overheat the bedknife Remove small amounts of material with each pass of the grinder Note If the height of cut is 1 2 inch or lower on the cutting unit the front angle can be increased to 30 for improved performance Bedknife Regrinding Specifications Front Angle 15 see Note above Front Angle Range 13 to 17 Cutting Units Page 7 18 Use a torque wrench and bedknife screw tool Tighten screws to a torque of 250 to 300 in Ib 288 to 345 kg cm starting in the middle of the bedknife Figure 22 Top Face Relief Angle Front ange Figure 23 Reelmaster 2300 D 2600 D Roller Re
40. Cap screw Cap screw Cap screw Fuel hose Muffler gasket Right rear mount bracket Reelmaster 2300 D 2600 D 9 Close fuel shut off valves under the fuel tank and on the fuel filter 10 Disconnect hoses from engine Fig 19 A Loosen upper hose clamp securing the air filter hose extending from the engine to the air cleaner B Loosen hose clamps 23 Disconnect upper ra diator hose 18 and lower radiator hose 24 from the engine C Loosen hose clamp 38 and disconnect fuel hose 44 from the lift pump Plug hose to prevent leakage D Loosen hose clamp and disconnect fuel hose return from the injector nozzle piping Plug hose to prevent leakage A CAUTION The hydraulic fluid may be hot To avoid possible burns allow the hydraulic sys tem to cool before disconnecting hoses 11 Disconnect hydraulic hoses to oil cooler A Loosen hose clamp 1 and disconnect hydraulic return hose 2 from the hydraulic fitting 3 Plug hose and fitting to prevent leakage and contamina tion Fig 20 B Loosen hose clamp 1 and disconnect hydraulic supply hose 2 from the hydraulic elbow fitting 3 Plug hose and fitting to prevent leakage and con tamination Fig 21 A CAUTION The muffler and muffler tube may be hot To avoid possible burns allow the ex haust system to cool before working on the muffler and muffler tube 12 Remove exhaust system Fig 19 A Remove muffler clamp
41. D 2600 D Traction Electric Clutch Fig 27 through 31 The clutch circuitis normally energized when the engine is starting or running When energized an electromag net pulls the armature into contact with the rotor to drive the pulley and the traction motor through a fan belt Failure to engage the clutch is likely caused by too large ofa clutch air gap a circuit fault in the clutch electromag net or another electrical problem see Wiring Schemat ics Note The air gap is not adjustable The clutch must Figure 27 be serviced as a whole and individual parts can not be 1 Flanged nut 3 Traction arm replaced 2 Dampener 4 U bracket support Removal 1 Make sure the engine is off and the fuel solenoid is disconnected 2 Lift the hood and disconnect the clutch electrical connection Make sure the connection is free of the cable harness and the R bracket holding it to the engine block 3 Remove the right and left front panels to access the Figure 28 clutch and U bracket support icc 4 Adjusting yoke 2 Cotter pin 5 Pump mount 4 Remove the flanged nut securing the dampener to 3 Clevis pin the traction arm Remove nut lock washer and flat washer securing the dampener to the U bracket sup port Remove the dampener Fig 27 5 Remove the two bolts flat washers and grommets holding the tank to the U bracket support Remove the nuts carriage bolts and U bracket support from the frame Fig 29
42. E Position rod clevis into lift arm 13 Fig 63 F Install clevis pin 12 and flat washers 14 into the lift arm 13 and rod clevis Secure clevis pin with cotter pin 11 Fig 63 G Check distance betweenthe carrier frame rollers bumpers on later models and the foot step as de scribed above Figure 64 1 Barrel 6 Shaft 11 Retaining ring 2 Locknut 7 O ring 12 Dust seal 3 Piston 8 O ring 13 Jam nut 4 Uni ring 9 Backup washer 14 Rod clevis 5 O ring 10 Head Hydraulic System Page 4 72 Reelmaster 2300 D 2600 D Disassembly Fig 64 1 Remove oil from cylinder into a drain pan by slowly pumping the cylinder shaft 6 Plug both ports and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot end only Do not close vise enough to distort the barrel 1 2 Mount lift cylinder in a vise so that the shaft 6 end tilts up slightly 3 Remove retaining ring 11 from the barrel 1 4 Grasp clevis rod 14 extract shaft 6 head 10 and piston 3 by carefully twisting and pulling on the shaft out from the barrel 1 IMPORTANT Do not clamp vise jaws against shaft surface Protect shaft surface before mounting in the vise 5 Mount shaft 6 securely in a vise Remove locknut 2 and piston 3 from the shaft Slide head 10 off the shaft 6 Remove and discard uni ring 4 and O ring 5 from the piston 3
43. Hydraulic Hoses Hydraulic Fitting Installation Checking the Hydraulic System Fluid Changing the Hydraulic System Fluid and Filter Pushing or Towing the Traction Unit HYDRAULIC SCHEMATIC HYDRAULIC FLOW DIAGRAMS Raise Cutting Units Traction Forward Traction Reverse Mow SPECIAL TOOLS Hydraulic Pressure Test Kit Hydraulic Tester Pressure and Flow TROUBLESHOOTING Hydraulic Oil Leaks Foaming Hydraulic Fluid Hydraulic System Operates Hot Neutral Is Difficult to Find or Operates in One Direction Only Traction Response Is Sluggish No Traction in Either Direction Wheel Motor Will Not Turn Wheel Motor Will Not Hold Load In Neutral Noisy Wheel Motor Drive Pump Cavitation Reels Will Not Turn Reel Speed Is Erratic Reel Motor Case Drain Flow Is Excessive Cutting Units Will Not Lift or Lift Slowly Cutting Units Raise but Will Not Stay Up Reelmaster 2300 D 2600 D Chapter 4 Hydraulic System 2 TESTING 22222 19 3 Test No 1 Traction Pump Flow 20 3 Test No 2 Charge Pump Flow and 3 Implement Relief Pressure 22 5 Test No 3 Charge Relief Pressure 24 6 Test No 4 Real Drive Pump Efficiency 26 6 Test No 5 Manifold Relief Valve Pressure 28 7 Test No 6 Cross over Relief Pressures 30 8 Test No 7 Reel Motor Case Drain 32 8 ADJUSTMENTS 2 2200 34 10 Transmission for Neuma uuu 34 12 Traction Pedal 2i zen Nian praan 35 14 Traction Pedal
44. Make sure backlap knob on the valve block is in the backlap position 12 One person should sit on the seat and operate the machine while another person reads the gauge Start engine and move the throttle to full speed 3200 100 RPM A CAUTION Keep away from reels during test to pre vent personal injury from the rotating reel blades A CAUTION Do not allow system pressure to exceed 1700 PSI Shut off unit to prevent an over pressure condition 13 Engage cutting units Observe pressure gauge Motor Position Right Hand Pressure Range PSI 1580 to 1680 1540 to 1640 Left Hand 1500 to 1600 14 Disengage cutting units and stop engine If specifi cations are not met the cross over relief needs replac ing Remove block of wood from cutting unit and repeat test on other reels in the same direction of flow 15 Remove test gauge and reconnect hose to motor Adjust bed bedknife to reel on all cutting units see Ad justment section of Chapter 7 Cutting Units Hydraulic System TEST NO 7 Reel Motor Case Drain G CASE DRAIN FLOW HE TEST CONNECTION FOR R H REEL MOTOR SHOWN FROM REEL MOTOR DRIVE PUMP FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR High Pressure HYDRAULIC MANIFOLD Low Pressure Return or Suction Flow Figure 18 Hydraulic
45. Service Manuals for specifications and procedures Product Records and Manuals Page 2 6 Reelmaster 2300 D 2600 D REELMASTER 2300 D 2600 D Daily Maintenance Check List Unit Designation TORO ID Daily Maintenance duplicate this page for routine use Daily Maintenance Check For Week Of Maintenance Parrot 222 Paa an Pama Eeer AE AAA pa EGRE A E M PESA Eis ud oii A E a a Paa EE Eeer E E ka Pa E E A E SAA LEA AA A a Ka a aa Pa kaan akan P a Kana cune pr AAA Height of Cut Adjustment Lubricate All Grease Fittings 12 Check proper section of Operator s Manual for fluid specifications 2 Check glow plug and injector nozzles if hard starting excess smoke or rough running is noted 3 Accomplish immediately after every washing regardless of the interval listed Notation for areas of concern Inspection performed by DONNE MEME BIS AAA S EE See Operator s and Service Manuals for specifications and procedures Reelmaster 2300 D 2600 D Page 2 7 Product Records and Manuals 18 228 86 ON W104 Suel 39 A19S BUOMPPY p nb 99198 g pue y O NG seunpeooud pue suolyeoisjioeds 10J enuen 2211199 pue s JoJelJadg ees usn j ure4q xue oineapAH usni3 ure1q qUe jen jejsouuoeu eoejdeu pin 4 998 day ysn 4 ueis S 1ue oo2 s14 g Ala nZ soyojms jajes eoejdau sesoH Bulaon eoe deu CT E13 E13 L1 EJ E31 F1 EI E sjeioods p
46. System Page 4 32 Reelmaster 2300 D 2600 D Procedure for Reel Motor Case Drain Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Make sure machine is parked on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil Position Case Drain Motor Return 3 On suspected bad motor clean hose connection and disconnect hose from motor that returns to the man ifold see table IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose 4 Install tester in series with the motor and the discon nected return hose Make sure the flow control valve is fully open 5 Make sure backlap knob on the valve block is in the mow position 6 One person should sit on the seat and operate the machine while another person reads the tester Start en gine and move the throttle to full soeed 8200 100 RPM Reelmaster 2300 D 2600 D Page 4 33 A CAUTION Keep away from reels during test to pre vent personal injury from the rotating reel blades 7 Engage reels by pulling the knob on the instrument panel out While watching pressure gauges slow
47. Table of Contents SAFETY INSTRUCTIONS 2 222 1 Before Operating aan 1 While Operating 2 Safety Instructions The REELMASTER 2300 D 2600 D conforms to the American National Standards Institute s ANSI safety standards for riding mowers when equipped with rear ballast see Operator s Manual Although hazard con trol and accident prevention are partially dependent upon the design and configuration of the machine these factors are also dependent upon the awareness con cern and proper training of the personnel involved in the operation transport maintenance and storage of the machine Improper use or maintenance of the machine can result in injury or death Before Operating Improper use or maintenance by the operator or owner of the machine can result in injury Reduce the potential for any injury by complying with the following safety in structions A WARNING The engine exhaust contains carbon monoxide which is an odorless and deadly poison Carbon monoxide is also known to the state of California to cause birth defects Do not run engine indoors or in an enclosed area 1 Read and understand the contents of the traction unit and cutting unit operator s manuals before operat ing the machine To get replacement manuals send complete model and serial number to The Toro Company 8111 Lyndale Avenue South Minneapolis Minnesota 55420 1196 Reelmaster 2300 D 2600 D Page 1 1 Chapter
48. Turnthebacklap knob counterclockwise to the mow position while watching the multimeter Continuity should be broken as the switch opens 5 Reconnect the electrical connector Electrical System Page 5 26 Figure 23 1 Cutting unit interlock switch Figure 24 1 Backlap switch 3 Backlap knob 2 Connector Reelmaster 2300 D 2600 D Service and Repairs NOTE See the Perkins 100 Series Workshop Manual for more component repair information Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extend Additionally battery and electrical component failure can be prevented A CAUTION When working with batteries use ex treme caution to avoid slashing or spil ling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group 55 Battery 450 Amp Cranking Performance at 0 F 17 8 C 60 Minute Reserve Capacity at 80 F 26 7 C Removal IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove the battery hold down clamp Slide battery forward 2 Disconnect the ground cable first to prevent short circuiting the battery other components o
49. as replacement items 11 The face of the backplate 7 and frontplate 14 should be free of excessive scoring Replace if scoring a depth of 0 0015 in 0 038 mm 12 Replace body 12 if the inside diameter of the gear pockets exceeds 1 713 in 43 5 mm Hydraulic System Page 4 62 13 Make sure both plugs 1 are secure if they or the backplate is not being replaced Reassembly Fig 56 1 Ifreplacing the relief valve assembly 19 install ball 5 spring 4 shim 3 O ring 2 and plug 1 into the backplate 7 Hand tighten plug 1 and then torque from 10 to 12 ft lb 1 38 to 1 66 kg m 2 Coat O ring 11 lightly with petroleum jelly and install in groove on the front plate 14 3 Apply a thin coat of petroleum jelly to both gear pockets of the body 12 Install alignment pin 13 into body 12 4 Align matchmarks and slip body 12 onto front plate 14 until alignment pin 13 is engaged 5 Dip idler gear 8 and drive gear 9 into clean hy draulic oil and slip into front plate 14 bushings 6 Coat O ring 11 lightly with petroleum jelly and install in groove on the back plate 7 7 Install alignment pin 13 into back plate 7 8 Align matchmarks and slip back plate 7 over gear shafts onto body 12 until alignment pin 13 is en gaged 9 Handtighten cap screws 15 and torque in a criss cross pattern from 25 to 28 ft lb 3 46 to 3 87 kg m 10 Place washer 18
50. backup washer light ly with hydraulic oil Install new O ring 7 and uni ring 9 to the piston 8 Install O rings 2 and 5 and backup washer 4 to the head 3 IMPORTANT Do not clamp vise jaws against shaft 6 surface Protect shaft surface before mounting in the vise 2 Mount shaft 6 securely in a vise by clamping vise on the ends of the shaft Slide head 3 onto the shaft Install piston 8 and locknut 10 onto the shaft and tighten lock nut 10 3 Remove shaft 6 from the vise IMPORTANT Prevent damage when clamping the barrel 11 into a vise clamp on the pivot end only Do not close vise enough to distort barrel 4 Mount barrel 11 in a vise so that the shaft end tilts up slightly 5 Coatallinternal lift cylinder parts with a light coat of hydraulic oil Slide piston 8 shaft 6 and head 3 as sembly into barrel 11 being careful not to damage the seals 6 Secure head 3 in barrel 11 by installing retaining ring 1 Align key slot in head with the access groove in the barrel Rotate head clockwise as far as the retaining ring will allow The offset end of the retaining ring will be againstthe left side of the barrel groove as shown in Fig ure 62 Hydraulic System Page 4 70 Reelmaster 2300 D 2600 D Rear Lift Cylinder ROD CLEVIS Figure 63 1 Hose connection 6 Cap screw 11 Cotter pin 2 Hose connection 7 Ram pivot pin 12 Clevis pin 3 Hydraulic fitting 8 Pivot suppo
51. be about 11 5 ohms 4 Connect the wire to the solenoid Live testing 1 Disconnect the wire from the solenoid Note The solenoid may be removed from the engine or tested in place 2 Connect a positive test lead from a 12 VDC Figure 18 source to the solenoid terminal 3 Touch a negative test lead from the 12 VDC source to the solenoid body The plunger should retract making an audible click SE ER o 25 OI 4 Disconnect the test leads from the solenoid 5 Connect the wire to the solenoid if tested in place Cutting Unit Solenoid Valve Coil Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect solenoid valve electrical connector 2 Measure resistance between the two connector ter minals The resistance should be about 7 2 ohms Figure 19 1 Solenoid Valve Coil Reelmaster 2300 D 2600 D Page 5 23 Electrical System 3 Connect solenoid valve electrical connector Traction Electric Clutch Note When disconnecting the clutch use the electri cal connector that connects the clutch directly to the wir ing harness Do not use the connector attached to the traction clutch switch This
52. black lead to the temperature sender located on the top of the water pump F Reconnecttan lead to the high temperature shut down switch located on the water pump behind the fan G Reconnect purple lead to the fuel valve solenoid located above the lift pump H Reconnect brown lead to the oil pressure switch located on the front of the cylinder head Reconnect white lead to the glow plugs located on the front right side of the cylinder head Reelmaster 2300 D 2600 D J Reconnect gray red and white leads to the en gine starter solenoid located on below the exhaust manifold K Reconnect battery ground to the traction clutch side of the cylinder head or the left side of the cylin der block 7 Reconnect throttle cable Fig 19 A Run throttle cable to engine 25 B Reinstall clevis pin 29 throttle tab 30 and throttle cable to the engine governor lever Reinstall and lock cotter pin 31 to the clevis pin C Install throttle cable into the throttle cable clamp 26 Tighten cap screw 43 8 Reinstall exhaust system Fig 19 A Position muffler 14 and muffler gasket 45 onto the exhaust manifold Install capscrews 39 and flat washers 11 to the muffler and exhaust manifold Tighten cap screws B Reinstall cap screws 36 and washers 13 into the muffler and right rear mount bracket 46 C Slide muffler tube through the U clamp 17 Connect muffler tube to the muffler Tighten nut 2
53. check valve seat 5 only if it needs re placement it is press fitted in 3 Remove plug 1 and O ring 2 from the valve body 7 Remove spring 8 ball 4 cam pin 6 4 Repeat step 3 for the other plug 1 5 Remove snap ring 14 from the bottom of the valve body 7 Remove spool snap ring 13 spring retainer 10 spacer 12 and spring 11 6 Push and twist spool 8 carefully out of the valve body 7 Set spool aside 7 Remove O rings 9 using a soft hooked scribe or a thin screwdriver and being careful not to scratch the valve bore finish Control Valve Inspection Fig 66 A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect spool 8 for bending and flatness Signs of wear on one side of the spool may indicate it s bent Re place a worn or damaged spool if necessary 3 Inspect parts for wear or damage and replace if necessary Control Valve Reassembly Fig 66 1 Coat all new O rings with hydraulic oil Install new O rings 9 into the bore of the valve body 7 2 Coat spool 8 lightly with hydraulic oil Push and twist spool carefully into the valve body 7 Avoid dam aging O rings 9 Hydraulic System Page 4 76 Figure 66 1 Plug 8 Spool 2 O ring 9 O ring 3 Spring 10 Spring retainer 4 Ball 11 Spring 5 Check valve seat 12 Spacer 6 Cam pin 13 Spool snap rin
54. circuits during various operational checks See the Special Tools section in this Chapter A CAUTION Failure to use gauges with recommended pressure psi rating as listed in test pro cedures could result in damage to gauge and possible personal injury from leaking hot oil Before Performing Hydraulic Tests All obvious areas such as oil supply filter binding link age loose fasteners or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced A WARNING Before disconnecting or performing any work on the hydraulic system all pres sure in the system must be relieved by stopping the engine and lowering or supporting the cutting units or other implements Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or card board not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury If fluid is injected into the skin it must be surgical ly removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Reelmaster 2300 D 2600 D Page 4 19 1 Thoroughly clean the machine before disconnect ing or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hydraulic equipment Contamination will cause exces
55. components daily If necessary clean any debris off these parts Clean these components more frequently in dusty dirty conditions 1 Remove radiator screen 1 2 Remove four cap screws and nuts that hold the plastic cover to the radiator assembly Remove plastic cover from the radiator assembly 3 Loosen both quick release knobs on the front end of the radiator assembly Now the oil cooler 3 can be removed from the radiator for cleaning A CAUTION Use eye protection such as goggles when using compressed air 4 Working from fan side of radiator 2 either spray the radiator with a hose or blow with compressed air 5 Thoroughly clean oil cooler 3 Clean off any other debris that may have collected around components 6 Reinstall the oil cooler 3 Tighten both quick re lease knobs on the front end of the radiator assembly 7 Reinstall plastic cover onto the radiator assembly Reinstall four cap screws and nuts that hold the plastic cover to the radiator assembly Tighten fasteners 8 Clean radiator screen 1 and reinstall A z Figure 13 1 Radiator screen 3 Oil cooler 2 Radiator Reelmaster 2300 D 2600 D Page 3 11 Engine Changing the Engine Oil and Filter Change oil and filter initially after the first 20 hours of op eration Thereafter change oil every 50 hours and filter every 100 hours 1 Position machine on a level surface 2 Locate engine oil drain plug on the bottom of
56. connector contains a diode in the circuit which will give incorrect resistance read ings Deenergized Testing Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect the clutch electrical connector from the wiring harness 2 Using a digital multimeter measure the resistance between the connector terminals The resistance should be from 3 0 to 4 0 ohms Traction Neutral Interlock Switch The traction interlock switch is normally open and closes when the traction pedal in in the neutral position 1 Disconnect the electrical connector to the switch 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 3 With the engine off slowly push the traction pedal in the forward and reverse direction while watching the multimeter Continuity should be broken in the forward and reverse directions 4 Allow the traction pedal to return to the neutral posi tion There should be continuity across the terminals 5 Reconnect the electrical connector to the switch Electrical System Page 5 24 3 Connectthe clutch electrical connector to the wiring harness N
57. from the bearing housing HOUSING FACE 3 Position the hydraulic motor away from the cutting unit prior to removing or working on the cutting unit Inspection 1 Inspect spider coupling for wear Replace worn cou pling with new one 2 Check coupling inside bearing housing If coupling is loose remove and check for worn threads Replace coupling if threads are worn Reinstall coupling see Reel Removal and Bearing Replacement Install Reel Installation Figure 14 Note The cutting unit can be installed with the hy 1 Capscrew 4 Spider couping draulic motor driving the unit from the other side If so 2 Hydraulic motor 5 O ring 3 Bearing housing remove the bearing housing cap screws cover and cover gasket reinstall them on the opposite bearing housing from the motor 1 Dip spider coupling in No 2 General Purpose Lithi um Base Grease Reinstall spider coupling into the bearing housing 2 Reinstall hydraulic motor A On models without the O ring clean bearing housing face and place a bead of RTV around the face of the housing to form a seal Mount hydraulic motor to the bearing housing Secure motor with the two capscrews B On models with O rings replace if necessary Make sure O ring is on the front plate of the motor Mount hydraulic motor to the bearing housing Se cure motor with the two capscrews 3 Grease bearing housing sufficiently to fill housing with grease see Greasing Bearings Bushi
58. hydraulic lines to drain into a suitable con tainer Putcaps or plugs on disconnected hoses and fittings to prevent contamination D Remove cap screws 10 from the hydraulic manifold E Support hydraulic manifold 6 and remove flange screws 7 from the hydraulic manifold Re move hydraulic manifold from the cylinder support bracket 8 Reelmaster 2300 D 2600 D Page 4 63 Figure 57 1 Screw 6 Hydraulic manifold 2 Lock washer 7 Flange screw 3 Flat washer 8 Cylinder support bracket 4 Micro switch 9 Solenoid valve 5 Spacer 10 Cap screw Installation Fig 57 1 Secure hydraulic manifold 6 to the cylinder sup port bracket 8 with cap screws 10 and flange screws 7 2 Make sure all hydraulic connections ports and fit tings are clean 3 Connect hydraulic lines to the manifold Tighten all hydraulic fittings and connections 4 Reconnect solenoid valve 9 and micro switch 4 electrical connectors Hydraulic System Seal kit Plug O ring O ring Plug Seal kit Spool valve O ring 10 Solenoid coil 11 Nut CONDAL Hydraulic System Cartridge logic valve Figure 58 O ring Plug Cartridge relief valve Spool flow control valve Locating plate w pin Seal kit Spool two position directional valve Locating plate w pin Plug O ring Page 4 64 Manifold body Ball 2 per assembly Spring 2 per ass
59. indication circuit see Indicating and Safety Circuits 5 Return ignition switch to OFF and connect the brown wire to the switch Hour Meter 1 Connect the positive terminal of a 12 VDC source to the positive terminal of the hour meter 2 Connect the negative terminal of the voltage source to the other terminal of the hour meter 3 The hour meter should move a 1 10 of an hour in six minutes 4 Disconnect the voltage source from the hour meter Reelmaster 2300 D 2600 D Page 5 19 Figure 7 1 Oil pressure switch 6 Remove switch and install test gauge in the oil pres sure switch port 7 Start the engine and check for a minimum of 30 psi at 1400 RPM If the engine oil pressure is low shut off the engine immediately 8 Shut off the engine and remove the test gauge 9 Ifthe engine oil pressure is good replace the switch waer Hor Figure 8 Electrical System Electrical System Indicator Lights and Circuits Note Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should light with the engine running when the oil pressure drops below 4 PSI 0 3 kg cm 1 Disconnect the brown wire from the oil pressure switch 2 Ground the brown wire to the engine block 3
60. is clean and re painted if necessary 3 Make sure all battery cables and connection are in good condition and thatthe battery hold down clamp has been repaired or replaced 4 Lift seat and place the battery near its compartment Push the positive cable connector onto positive battery post Do nothammer this will damage the battery Tight en bolts with two wrenches 5 Placethe battery in its compartment and make sure it is level and flat Tighten the battery hold down bolts uniformly to prevent cracking or distorting the battery case 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect the negative ground cable connector to the negative battery post Reelmaster 2300 D 2600 D Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops A CAUTION Follow the manufacturer s instructions when using a battery charging 1 Determine the battery charge level from either its open circu
61. m 20 Coat C ring 26 and outer ring of gerotor assembly 3 with a light coat of petroleum jelly Install O ring and outer ring onto the charge pump adapter assembly 2 Install charge pump adapter plate onto the backplate as sembly 25 Make sure O ring and outer ring of gerotor assembly stay in place 21 Secure charge pump adapter assembly 2 and backplate assembly 25 to the housing assembly 15 with cap screws 1 and 27 Torque cap screws from 17 to 20 ft lb 2 3 to 22 8 kg m Hydraulic System Wheel Motor Front Wheel Removal Fig 30 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Remove wheel and brake assembly from unit see Repair section of Chapter 6 Wheels and Brakes 3 Clean wheel motor 1 and hydraulic connections Label all tube hose connections for reassembly pur poses Put caps or plugs on any hydraulic lines or fittings left open or exposed 4 Disconnecttube connections 2 and 3 from hydrau lic fittings b and 6 On the left hand wheel motor also disconnect hose connection 4 from hydraulic fitting 7 Allow hydraulic oil to drain from tubes and hose into a suitable container 5 Support wheel
62. mm or longer than cap screw 14 Note Use any alignment marks put on the coupling shaft 11 and drive link 13 before disassembly to as semble the drive link splines in their original position in the mating coupling shaft splines 10 Install drive link 13 with the long splined end down into the coupling shaft 11 Engage the drive link splines so they mesh with the coupling shaft splines Fig 47 11 Assemble wear plate 18 over the drive link 13 and alignment studs onto the housing 3 12 Apply a small amount of clean grease to a new seal ring 5 and assemble it into the seal ring groove on the wear plate side of the stator 21 Note The rotor set consists of the rotor 19 vanes 20 and stator 21 Rotor set components may be come disassembled during service procedures Note It may be necessary to turn one alignment stud out of the housing 3 temporarily to assemble rotor set over the drive link 13 Note The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor drive link spline contact A ro tor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent to de termine which side was down The rotor set seal ring groove faces toward the wear plate 18 13 Install assembled rotor set onto wear plate 18 with rotor 19 counterb
63. motor 1 Remove four cap screws 10 and lock nuts 11 from support frame 12 Remove brake bracket 13 grass shield 14 and spacers 15 Pull wheel motor from the support frame 6 Remove hydraulic fittings 5 and 6 and O ring from the wheel motor 1 On the left hand wheel motor also remove hydraulic fitting 7 from the wheel motor Front Wheel Installation Fig 30 1 Place and support wheel motor 1 into the support frame 12 Insert four cap screws 10 through the sup port frame and wheel motor 2 Slide spacers 15 grass shield 14 and brake bracket 13 onto the cap screws 10 and wheel motor 1 Tighten lock nuts 11 onto cap screws 3 Install hydraulic fittings 5 and 6 onto the wheel mo tor 1 On the left hand wheel motor also install hy draulic fitting 7 onto the wheel motor Tighten hydraulic fittings Hydraulic System Page 4 44 Figure 30 1 Wheel motor 10 Cap screw 2 Tube connection 11 Lock nut 3 Tube connection 12 Support frame 4 Hose connection 13 Brake bracket 5 Hydraulic fitting 14 Grass shield 6 Hydraulic fitting 15 Spacer 7T Hydraulic fitting 16 O ring 8 O ring 17 O ring 9 O ring 4 Install tube connections 2 and 3 to hydraulic fit tings 5 and 6 On the left hand motor also ins hose connection 4 to hydraulic fitting 7 Tighten connec tions 5 Install wheel and brake to unit see Repair section of Chapter 6 Wheels and Brakes R
64. o Safety and Instruction Decals Chapter 2 Product Records and Manuals Product Hecords oz eet cad a iere ved Equivalents and Conversions Torque Specifications o o ooooooo Maintenance Interval Chart Operation and Service History Report Chapter 3 Engine Introduction oocoocococco henon nanr i Specifications oooooooooooommmmmo Special Tools Adjustments Service and Repairs Perkins 100 Series Workshop Manual Chapter 4 Hydraulic System SpecIfiCalions cues dux er b a hee General Information Hydraulic Schematic oooooooomoo o Hydraulic Flow Diagrams Reelmaster 2300 D 2600 D Special Tools Troubleshooting cece eee eee eee RL le DEE Adjustments 000 cee ee o Service and Repairs Chapter 5 Electrical System Wiring Schematics a Special Tools Troubleshooting cece eee eee ee Electrical System Quick Checks Component Testing a Service and Repairs Chapter 6 Wheels and Brakes Specifications 00 ccc eee eee ee Adjustments Service and Repairs Chapter 7 Cutting Units Specifications 0 ccc eee eee Special Tools Trouble Shooting eee eee eee Adjustments Service and Repairs Cutting Units This page is blank
65. of the traction circuit causes a delay in the response of the traction pedal in reverse until traction flow exceeds 2 1 GPM 7 9 LPM through the PC flow controller The charge and shuttle valve circuits function the same in reverse as they did in the forward direction Reelmaster 2300 D 2600 D ooz gz Eu te X SHOLOW 1334 ISd 00S 33 1348 HHAO SSOHO DILVW3HOS HOLOW 13938 xl Q DILVNW3HOS HOLOW 133HM 1497 09 61 Eu ZL uva HOLOW T33HM WOLLOS dol M ES HO193 138 AME AMZ ame NI NMOHS MIS OIMEIP H FATWA 10H1NOO OH i p R D 4 H INIYA isd 000 Era D 44O NO 331134 za 1334 1534 TN Ww p j nrn 9N IS HLO 2 2 22 ar aao H a t SATA iH D INVA 91901 1 SN ONIddV OVE 101 i Law HA eg 1 He m Y ee Ka bo ed 193 Ed La H3T1OH1NOO Q33dS 1338 Y 19 ld 1 Les es e e e 4 000 8 gt de us gu pp d Wd UV39 431009 1 1 1NOtH 1 r 4 5 1 D ba Y 4 M 99 g oz voeem m 3 SEN 43111 ze NOTIVO Z HIOAH3S3H EES rs E pum poem isd Zy 3338 LIN WOLLOG i sayan 3unssa3ud MON WON NOUOIIN DL Yad 1NOyW3 r im giis ANI
66. pressure hydraulic valves Use compressed air for cleaning 6 Reinstall the spool valve 8 A Lubricate new O ring and backup ring of seal kit 7 with clean hydraulic oil and install The O ring and backup ring must be arranged properly on the spool valve 8 for proper operation and sealing B Thread spool valve 8 carefully into port S1 The valve should go in easily without binding Reelmaster 2300 D 2600 D Page 4 65 Note Usecare when handling the spool valve 8 slight bending or distortion of the stem tube can cause binding and malfunction C Torque spool valve 8 using a deep socket to 35 ft lb 4 8 kg m D Make sure a new O ring 9 is at each end of the solenoid coil 10 install solenoid coil to the spool valve 8 Apply Loctite 242 or equivalent to the threads of the spool valve torque nut 11 to 15 in Ib 17 kg cm E If problems still exit remove valve and clean again or replace valve Cartridge Logic and Relief Valves Fig 58 1 Make sure the manifold is clean before removing the cartridge valve 1 or 14 and seal kit 2 or 7 2 Remove the cartridge valve 1 or 14 3 Visually inspect the port in the manifold 22 for damage to the sealing surfaces damaged threads and contamination 4 Visually inspect cartridge valve 1 or 14 for dam aged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in
67. screw the set screw completely into the spool 5 Then loctite the exposed threads and screw the valve stop onto the set screw and spool Torque valve stop from 85 to 100 in lb 4 Coat spool 5 with clean hydraulic oil and carefully push and twist spool into the valve housing 9 Ensuring not to damage the seals 5 Install plug 2 and new O ring 3 into the spool 5 Torque plug from 85 to 100 in lb 6 Press valve cap 1 onto valve housing 9 If the valve cap is damaged or will not fit tightly onto the the valve housing replace the valve cap with a new one Hydraulic System Page 4 56 Reelmaster 2300 D 2600 D Reel Motor Drive Pump Removal Fig 53 1 Before removing any parts from the hydraulic man ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Clean reel motor drive pump 1 and hydraulic con nections Install plug into the hydraulic reservoir Label all hose connections for reassembly purposes Put caps or plugs on any hydraulic lines or fittings left open or ex posed 3 Loosen hose clamp 2 and remove hose 3 from fitting 4 Allow hydraulic oil to drain from hose into a suitable container 4 Disconnect hose 5 from elbow fitting 6 Allow hy draulic oil to
68. shuttle valve plugs in the end cover 24 from 9 to 12 ft lb 1 2 to 1 6 kg m if end cover is so equipped 24 Check motor shaft for rotation Torque require to ro tate shaft should not exceed 50 ft lb 6 9 kg m Hydraulic System 2WD 3WD Two Position Valve 10 Sa A D Figure 51 1 Two position valve 6 Hydraulic connection 11 Hydraulic fitting 2 Nut 7 Hydraulic connection 12 Hydraulic fitting 3 Cap screw 8 Hydraulic connection 13 O ring 4 Tub clamp 9 Hydraulic connection 14 Cap screw 5 Hydraulic tube 10 Hydraulic fitting 15 O ring Removal Fig 51 1 Before removing any parts from the hydraulic man ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Clean two position valve 1 and hydraulic fittings 3 Put caps or plugs on any hydraulic lines or fittings left open or exposed Put labels on disconnected hy draulic lines and hoses for proper reassembly 4 Loosen nut 2 and cap screw 3 so the tubes clamps 4 will allow movement of the hydraulic tubes 5 Hydraulic System Page 4 54 5 Disconnect hydraulic connections 6 7 8 and 9 from hydraulic fittings 10 11 and 12 Allow hydraulic oil to drain from tubes into a suitable container 6
69. sive wear of components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condition Use a tachometer when making a hydraulic test Engine speed can affect the accuracy of the tester readings 4 Toprevent damage to tester or components the in let and the outlet hoses must be properly connected and not reversed tester with pressure and flow capabili ties 5 To minimize the possibility of damaging compo nents completely open load valve in hydraulic tester when using tester with pressure and flow capabilities 6 Install fittings finger tight far enough to insure that they are not cross threaded before tightening with a wrench 7 Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage 8 Check the oil level in the reservoir 9 Check the control linkage for improper adjustment binding or broken parts 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Hydraulic System TEST NO 1 Traction Pump Flow WHEEL MOTOR FORWARD TO REAR WHEEL MOTOR REVERSE A FROM REAR WHEEL MOTOR PC FLOW CONTROL FROM CONTROL VALVE TO CONTROL VALVE FROM FROM RESERVOIR REVERSE FRONT TO RESERVOIR LINE FORWARD DISCHARGE WHEEL MOTOR LEFT High Pressure
70. switch is faulty or short circuited o of a 1 o0 9 Lu Reelmaster 2300 D 2600 D Page 5 11 Electrical System General Run and Transport Problems Engine continues to run but should not when the traction pedal is depressed with no operator on the seat Engine kills when the traction pedal is depressed or the cutting unit switch is pulled ON with the operator in the seat Battery does not charge Engine kills during operation operator sitting on seat Electrical System Page 5 12 Possible Causes Seat switch is faulty out of adjustment or short circuited Traction neutral interlock switch is out of adjustment faulty or short circuited Operator is sitting too far forward on the seat seat switch not depressed Seat hinge support pin or spring binding is preventing the seat switch from closing Seat switch is faulty or out of adjustment Seat switch wiring is loose corroded or damaged Wiring to the charging circuits see Wiring Schematics components is loose corroded or damaged Voltage regulator rectifier is faulty Alternator is faulty Charge fuse 20 amp is open Fuse block is faulty Battery is dead Operator moved too far forward on the seat seat switch not depressed Engine overheated Wiring to the run circuits see Wiring Schematics components became broken or disconnected Reelmaster 2300 D 2600 D Cutting Unit Operating Problems Engine Conti
71. the seat approaches the bottom of its travel 5 Connect switch electrical connector Reelmaster 2300 D 2600 D Page 5 25 H i 1 1 Figure 21 Seat interlock switch Figure 22 Seat interlock switch Electrical System SE TO o0 o5 OI Cutting Unit Interlock Switch This switch is normally open and closes when the lift cyl inder is retraced cutting units lowered The switch and its electrical connector are located behind and below the hydraulic manifold on the cylinder support bracket 1 Disconnect switch electrical connector 2 With the cutting units lowered check the continuity of the switch by connecting a multimeter ohms setting across the connector terminals There should be conti nuity across the switch 3 Raise the cutting units and check the continuity of the switch There should be no continuity across the switch with the lift cylinder extended 4 Connect switch electrical connector Backlap Switch The backlap switch is located on the hydraulic manifold It is normally open and is closed when the backlap knob is turn clockwise to the backlap position 1 Disconnect the electrical connector 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 3 With the engine off turn the backlap knob clockwise to the backlap position while watching the multimeter Continuity should be made as the switch closes 4
72. the shaft 31 15 Remove screws 7 trunnion cover 8 O ring cov er 9 O ring 10 washer 11 inner race 12 and bearing 13 Remove screws 7 seal cover 16 shaft seal 17 washer 11 and bearing 13 16 Position camplate 20 to one side and remove from the housing assembly 15 Inspection A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect charge pump adapter assembly see Fig 25 A Check relief valve seat inside suction port Make sure that seat is smooth and free of burrs or other defects Relief valve spring must not be damaged B Bearing needles must remain in bearing cage and move freely Verify that bearing depth on the flange side meets the dimension in Figure 27 C Make sure gerotor pocket inside the pump is not excessively scored 3 Inspect backplate assembly 25 see Fig 24 A Bearing needles must remain in bearing cage and move freely Verify that bearing height on the numbered end meets the dimension in Figure 28 B Check that the roll pin is tight and meets the height in Figure 28 C Replace entire assembly as a unit 4 Inspect camplate assembly 20 see Fig 24 There should be no signs of scoring on the piston shoe surfaces Reelmaster 2300 D 2600 D Page 4 41 FLANGE 0 090 to 0 100 in 2 54 to 2 89 mm BEARING DEPTH 0 070 to 0 080 in
73. two years to assure maximum safety 1 Move the machine to a wide open area free of debris and bystanders Raise the cutting units and stop the en gine Engage the parking brake Keep hands and feet away from cutting units 2 Make sure the mow backlap knob is in the mow position turned counterclockwise Sit on the seat Pull the cutting unit switch to the ON position Try to start the engine If the engine cranks there may be a malfunction in the interlock system Repair the problem immediately If the engine does not crank proceed to step 3 3 Make sure the mow backlap knob is in the mow position turned counterclockwise the traction pedal is in neutral and the cutting unit switch is pushed to the OFF position With the operator off the seat start the en gine Depress the traction pedal with the operator out of the seat the engine should stop If the engine does not Electrical System Page 5 14 stop there may be a malfunction in the interlock system Repair the problem immediately If the engine does stop proceed to step 4 4 Make sure the mow backlap knob is in the mow position turned counterclockwise the traction pedal is in neutral and the cutting unit switch is pushed to the OFF position With the operator off the seat start the en gine Pull the cutting unit switch to the ON position the engine should stop If the engine does not stop there may be a malfunction in the interlock system Repair the pro
74. 0 and U clamp D Reinstall muffler clamp 19 to the muffler 14 and muffler tube 15 9 Reconnect hydraulic hoses from the oil cooler A Unplug hydraulic hose 2 and hydraulic elbow fitting 3 Connect hydraulic supply hose to the hy draulic elbow fitting Tighten hose clamp 1 Fig 21 B Unplug hydraulic return hose 2 and hydraulic fitting 3 Connect hydraulic return hose to the hy draulic fitting Tighten hose clamp 1 Fig 20 10 Connect hoses to the engine Fig 19 A Connectfuel hose return to the injector nozzle piping and tighten hose clamp B Unplug fuel hose 44 Connect fuel hose to the lift pump and tighten hose clamp 38 C Connect upper radiator hose 18 and lower ra diator hose 24 to the engine Tighten hose clamps 23 D Connect air filter hose to the engine 25 Reelmaster 2300 D 2600 D Page 3 19 11 Open fuel shut off valves under the fuel tank and on the fuel filter 12 Fill hydraulic reservoir with hydraulic fluid as de scribed in the General Information section of Chapter 4 Hydraulic System Check reservoir for leaks 13 Add antifreeze to radiator as described in Checking the Cooling System 14 Slide the left foot rest 5 Fig 17 onto the adjusting rod 2 Fig 18 Reinstall cap screws 3 and flange nut 4 securing the left footrest 5 to the frame Tighten cap screws Fig 17 15 Connect adjusting rod to brake arm 3 Install and l
75. 0010 3ao a xovg A3H5 330 1V3S NI HOLVH3dO HLIM 035079 NO xovg aumwaoNvuo Y Nye El ki N3dO ATIYWHON vous H LIN A E B HOLIMS MOOTHALNI LVIS A Jovia NS UAM Jor ee a eE El aes Hau Lo3u uo1vino3u Fidund C a J NYYO SIHMW31d8Nd 3 I G 2 CP ZRECK 39YLIOA To OT SE pe P i XOvi8 XOVIS A3HO avid annoys Hi H NOLLISOd TVELN3N NI 130719 YOLVNUSLTV ER N3dO ATIVWHON gt ang N3SHD Lor ON HOLIMS MOOTHAINI NOLLOVEL A240 NG 7 NOTED j SS eme NOLLISOd MOWN NI NMOHS No mug RES HOLIMS dv Diov8 Page 5 2 Reelmaster 2300 D 2600 D Electrical System wa sAg SE uoneoipu uaismo LHON 19M0d YOLVOIONI Sinalo pes geng mE YOLYNYILIY E a 00 S 4ojseuj oeH Wi LINA 1H917 HOLVOIGNI wovig amia 35019 L THON amp ASI ONINSNS1338 gt z g 3unssaud 1NV1009 HOLIMS Houms G 10 MOT ajalalolaly ANIONS m 3unssa3ud iuvis Z 9 slofefelr E 10 qo zz yong g zi p d m e EELER J 55 e o e A omo NE sonid MOTD moia xovigaau xov
76. 1 4 to 1 3 4 6 4mm to 44 4mm Fixed Cutting Unit 1 2 to 2 5 8 12 7 mm to 65 6 mm POWER Reel motors allow easy removal from or instal lation onto the cutting unit Cutting units can be driven from either end HEIGHT OF CUT amp ROLLER ADJUSTMENT Height of cut adjustment is made with the rear roller by a quick locating pin and or threaded micro adjustment Front roller position is adjustable to 3 locations to set cut ting unit attitude BEDKNIFE AND BEDBAR ADJUSTMENT A single knob screw adjustment for bedknife to reel is located at the center of the bedbar The adjustment knob detent al lows 0 001 inch bedknife movement for each indexed position CLIP FREQUENCY With variable speed set to maxi mum rpm 5 blade at 880 reel rpm moving 4 mph 6 4 km h 96 24 4 mm clip Cutting Units Page 7 2 5 blade at 880 reel rpm moving 5 mph 8 km h 1 19 30 3 mm clip 8 blade at 880 reel rpm moving 4 mph 6 4 km h 60 15 2 mm clip 8 blade at 880 reel rpm moving 5 mph 8 km h 75 19 1 mm clip RM2300 D OPTIONAL EQUIPMENT Full Roller Kit Model No 03440 Sectional Roller Kit Model No 03445 Wiehle Roller Kit Model No 03450 Anti Scalp Roller Kit Model No 03447 Grass Basket Kit Model No 03443 Roller Scraper Kit Part No 60 9560 Comb Kit Part No 67 9400 Fixed Kit Part No 93 6915 Skid Kit Part No 94 3664 RM2600 D OPTIONAL EQUIPMENT Sectional Roller Kit Model No 03476 Wiehle Roller
77. 12 3 Rotate head 3 with a spanner wrench and remove retaining ring 1 as shown in Figure 61 4 Grasp end of shaft 6 extract shaft head 3 and piston 8 by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against shaft 6 surface Protect shaft surface before mounting in the vise 5 Mount shaft 6 securely in a vise by clamping vise on the flats of the shaft Remove locknut 10 and piston 8 from the shaft Slide head 3 off the shaft Reelmaster 2300 D 2600 D Page 4 69 9 Uni ring 10 Lock nut 11 Barrel 12 Dust seal Spanner wrench Retaining ring Figure 61 Removing retaining ring 6 Remove and discard O ring 7 and uni ring 9 from the piston 8 Remove and discard both O rings 2 and 5 and backup washer 4 from the head 3 Hydraulic System Inspection Fig 60 A CAUTION Spanner wrench Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed a Offset end against left side of barrel groove after installing Figure 62 Installing retaining ring 2 Inspect internal surface of barrel 11 for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect head 3 shaft 6 and piston 8 for exces sive pitting scoring and wear Replace any worn or damaged parts Reassembly Fig 60 1 Coatall O rings uni ring and
78. 2600 D Traction Reverse The traction circuit operates essentially the same in re verse as it does in the forward direction However the flow through the circuit is reversed and by passes the rear wheel motor With the engine running clutch engaged and traction pedal in the neutral position the traction pump supplies no flow to the wheel motors When the traction pedal is pressed to the reverse position the linkage from the pedal positions the swash plate in the traction motor so oil flows out the bottom port of the pump Oil flow out of the bottom port goes to the wheel motors and turns them in the reverse direction The 2WD 3WD selector valve by passes the rear wheel in both the 2WD and 3WD positions Oil flowing out of the wheel motors returns to the top port ofthe traction pump and is continuously pumped out the Hydraulic System Page 4 12 bottom port However oil flow to the rear wheel motor is blocked by the check valve portion of the PC flow con troller and forced through the restriction before going to the motor Flow is limited to 2 1 GPM to the rear wheel motor This flow is sufficient to prevent cavitation on the rear motor in reverse Because of the by passing of the rear wheel motor in re verse and the resistance to flow of the two front wheel motors all the traction flow is by passed directly back to the traction pump when the traction pedal is initially pushed in the reverse direction This direct bypassing
79. 30 3 Apply never seize to the spindle shaft and keyway Slide the clutch rotor Fig 31 onto the spindle shaft with the bracket side towards the spindle base Fig 30 Make sure that the capscrews with the flat washers stay in the spindle holes 4 Apply never seize to the key Insert the key into the keyway Slide the armature Fig 31 onto the shaft and key Fig 30 5 Place the the capscrews through the lock washers and secure the pulley to the clutch Place the lock wash er and large flat washer onto the capscrew and secure them to the shaft torque from 40 to 50 ft lb Fig 30 6 Place the clutch and spindle up to the flywheel Screw one of the capscrews into the flywheel to support the spindle during alignment Secure all the capscrews while pushing the spindle into the flywheel tighten in a crisscross pattern Fig 30 7 Align the wire bracket with the long capscrew into their original position Secure the long capscrew and jam nut through the bracket into the engine block Fig 30 8 Run the electrical connector through the R bracket with the cable harness and reconnect Make sure the wires do not make contact with moving parts of the clutch and that the R bracket capscrew is tight 9 Tilt the pump mount and install the belt to the clutch and pump pulleys Align the adjusting yoke with the pump mount holes and secure with the clevis and cotter pins Fig 28 Adjust the belt see Adjustments section of C
80. 300 D 2600 D Warranty Expires Phone Phone Phone See your TORO Distributor for other Publications Manuals and Videos from the TORO company Reelmaster 2300 D 2600 D Page 2 5 Product Records and Manuals REELMASTER 2300 D 2600 D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval amp Service Every Every Ever Inspect Air Filter Dust Cup and Baffle SE MOORE 200hrs SEN Lubricate All Grease Fittings Change Engine Oil Aval Check Fan and Alternator Belt Tensions Service Change Engine Oil and Filter B Level Check Traction Belt Tension Service Service Air Filter Replace Fuel Filter Water Separator Replace Hydraulic Filter C Level Torque Wheel Lug Nuts Service Replace Hydraulic Fluid Check Battery Level Connections Inspect Traction Linkage Movement Inspect Spider Coupling for Wear D Level Torque Head Bolts and Adjust Valves Service Check Engine RPM idle and full throttle Initial break in at 10 hours Every 400 hours or annually whichever occurs first Initial break in at 50 hours Replace all Moving Hoses Annual Recommendations Replace Safety Switches Items listed are recommended every 1000 hours E or 2 years whichever occurs first Cooling System Flush Replace Fluid Replace Thermostat Fuel Tank Drain Flush Hydraulic Tank Drain Flush See Operator s and
81. 4 Make initial reel to bedknife adjustments appropri ate for backlapping on all cutting units Start engine and set engine to low idle speed 5 Engage reels by pulling out knob on instrument panel A CAUTION Be careful when lapping the reel because contact with the reel or other moving parts can result in personal injury 6 Apply lapping compound with a long handled brush Cutting Units Page 7 12 Figure 13 2 Reel speed knob 1 Backlap knob 7 To make an adjustment to the cutting units while backlapping turn reels OFF by pushing in on the knob on instrument panel and turning the engine OFF After adjustments have been completed repeat steps 4 6 8 When backlap operation is completed rotate back lap knob counter clockwise to the MOW position set reel speed controls to the desired mowing setting and wash all lapping compound off the cutting units Note Additional instructions and procedures on Backlapping are available in the TORO Sharpening Reel amp Rotary Mowers Manual Form No 80 300SC Note For a better cutting edge run a file across the front face of the bedknife when the lapping operation is completed This will remove any burrs or rough edges that may have built up on the cutting edge Reelmaster 2300 D 2600 D Hydraulic Motor Removal and Installation Removal 1 Removetwo capscrews holding the hydraulic motor to the bearing housing 2 Remove hydraulic motor and spider coupling
82. 40 25 30 45 60 35 45 50 70 55 55 70 40 55 75 60 80 95 85 65 90 95 Reelmaster 2300 D 2600 D Page 2 3 Product Records and Manuals Maintenance Interval Chart O QUICK REFERENCE AID CHECK SERVICE ENGINE OIL LEVEL ENGINE OIL DRAIN 17mm socket HYDRAULIC OIL LEVEL center of sight glass BELTS Fan Water Pump Hydraulic Pump COOLANT LEVEL FILL FUEL Diesel Only GREASE POINTS 11 3WD 12 2WD RADIATOR SCREEN AIR CLEANER WATER SEPARATOR FUEL FILTER BATTERY TIRE PRESSURE 12 16 psi 8 1 1 bar 13 FUSES sch N O o FLUID SPECIFICATIONS CHANGE INTERVALS SEE OPERATOR S MANUAL FLUIDTYPE CAPACITY CHANGEINTERVAL FILTER FOR INITIAL CHANGES L ar FLUID FILTER PARTNO ENGINE OIL 7251410 SAE10W 30CD 28 30 50 HRS 100 HRS 85 4930 A HYD CIRCUIT OIL MOBILFLUID 424 125 13 400 HRS 200 HRS 54 0110 B FUEL FILTER Inspect daily for contaminants amp water 200 HRS Jee C AIR CLEANER Clean every 50 hours 200 HRS 93 2195 D FUEL NO 2 Diesel 245 28 Drain and flush 2 yrs COOLANT 50 50 Ethylene 47 glycol water 93 6903 Product Records and Manuals Page 2 4 Reelmaster 2300 D 2600 D EQUIPMENT OPERATION AND SERVICE HISTORY REPORT TORO Model and Serial Number Engine Numbers Transmission Numbers Date Purchased Purchased From Contacts Parts Service Sales for REELMASTER 2
83. 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7116 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Manuals Page 2 2 Reelmaster 2300 D 2600 D Torque Spec
84. ALHOIH ANId dos o YILUVIS AdaLiva dau H a 2 9 3NION3 2 2 9 Ny RS 3 lt dE 7 Xovig aad A399 3 I Sp xovi8 g m m day yovia nee OV 06 6L MOTO Veit o vo VILI Z6 OHOL LL OV 0 09 1HVIS Av134 2 91 0k VOY HIM Ov oe NO ualuvis cad x FRERES HOLIMS NOLLINO day gt 31IHWG3H G31ovai3u SI IONITAO N3HM 13019 Y N3dO ATIYWHON 1 HOLIMS NOOTHILNI z NnHOLG3ZIOHSN3 T E CEET I GION310S S a s m INA 13N3 31duNd T J NYYO yovid C g m xov18 q3u 3IHNSONVHO vg 31dund z N33u9 3AWA GIONS10S Sunon avos OV EET m LINN ONILLNO HOL93NNOo LINOHIO Wvuovia lt gt 31IHW3ONVHO MOVIE 200 30010 3aoid XoV18 1399 0c 1V3S NI HOLVHAdO HLIM OSC y NO Esou BUHWSONvuO r d m Y NadO ATIVWHON HOLS SE sawa bi S e sols o HOLIMS MOOTHALNI 1V3S SNe a yovla q div El ary SEN FONVHO 83l311938 401VIND38 SIIHMWa dnd JE SEN FOVLION annou El a de AV annoy Bai ADVIV ATED pannoo B WOR ENROL Y H HOLVNHSLIV sta NOLLISOd TVHLNAN NI GIS010 Y es ama N33u9 N3dO ATIYWHON Ov HOLIMS YOOTHSINI NOLLOVH L A340 NG WOVTB AdHO Ze xovia MOTIBA ET NOLLISOd MOW NI NMOHS 3m18 d3u HOLIMS dV DIOV8 Reelmaster 2300 D 2600 D Page 5 4 Electrical System w S S 1891119913
85. Avoid scratching or marring the shaft seal bore in the mounting flange 3 Large scratches may cause the shaft seal 2 to leak around the outer diameter of the seal Reelmaster 2300 D 2600 D 2 Removethe shaft seal 2 Clean any contamination from the seal bore 3 Place a new shaft seal 2 with the part number side up into the seal bore Apply uniform pressure to the face of the shaft seal while pressing it into the bore This method should prevent damage or misalignment of the seal in the bore 4 Install new retaining ring 1 into the mounting flange E seal and Backup Ring Replacement Fig 54 1 Place the front bearing block 14 on a clean sur face Remove the old backup ring 4 and E seal 5 Clean any contamination from the E seal groove 2 Apply a light coat of petroleum jelly in the E seal groove of the front bearing block 14 and on the flat side of the E seal 5 to help keep the seals in place during assembly 3 Place the E seal 5 with its flat side up into the seal groove on the front bearing block 14 Place the backup ring 4 into the groove made by the E seal and bearing block Make sure the notches in the center ofthe backup ring and E seal line up so that the backup ring sits flush with the E seal 4 Repeat the above steps for the rear bearing block O ring Replacement Fig 54 1 Remove the old O rings 6 from the gear housing Clean any contamination from the O ring groove 2 App
86. D Page 7 21 7 Install a bearing cone into the bearing cup at each end of the roller shaft Then install shim washer if it was previously installed 8 Install outer seal onto each end of the roller shaft Make sure hard surface of seal faces out 9 Slide the roller shaft through the roller 10 Install remaining adjustment nut and tighten it to seat both bearings Roller should be rotated to seat both bearings 11 Back off both adjustment nuts to allow the roller to spin freely Tighten both adjustment nuts again to a max imum of 5 in lb 5 8 kg cm rolling torque with no bear ing end play 12 Grease both bearings see Greasing Bearings Bushings and Pivot Points Cutting Units 5 E 3 Reel Removal and Bearing Replacement COVER GASKET NOT SHOWN GROOVE E OUT OF POSITION Figure 26 1 Cutting unit 2 Capscrew 3 Bearing cover Remove Reel 1 Remove bedbar assembly from cutting unit see Bedbar Removal and Installation 2 Remove front roller from cutting unit see Roller Re moval and Installation 3 Remove capscrews bearing cover and cover gas ket from the bearing housing Note A 3 8 inch drive ratchet with an extension will fit into the square hole of the coupling 4 Unscrew male coupling LH from the reel This coupling is left hand threaded 5 Unscrew male coupling RH from the reel This coupling is right hand threaded IMPORTANT Support reel to prevent it
87. Damper ss 35 16 Hydraulic Pump Drive Belt 36 16 SERVICE AND REPAIRS 005 37 16 Traction Charge Pump a 37 17 Wheel Motor eee eee ee eens 44 17 2WD 3WD Two Position Valve 54 17 Reel Motor Drive Pump 57 17 Reel Motor 60 Hydraulic Manifold 63 17 Front Lift Cylinder aaa 67 17 Rear Lift Cylinder 71 17 Control and Implement Relief Valves 74 18 Hydraulic Reservoir 77 18 Flushing the Hydraulic System 79 18 Hydraulic System Start up 80 18 18 18 18 18 Page 4 1 Hydraulic System Specifications Item Description Traction Pump Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow Maximum Rated Speed and Pressure Variable displacement piston pump 3000 PSI 207 bar 5000 PSI 345 bar 3600 RPM 17 GPM 64 LPM Charge Pump Maximum Operating Pressure Maximum Rated Speed Rated Flow Maximum Rated Speed and Pressure Charge Pressure Gerotor pump 500 PSI 34 5 bar 3600 RPM 3 5 GPM 13 2 LPM 100 to 150 PSI 6 9 to 10 0 bar Implement Lift Relief Valve Implement Relief Pressure Differential area relief valve 450 525 PSI 31 1 to 36 2 bar Wheel Motors Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow Maximum Rated Speed and Pressure Orbital rotor pump wit
88. E New bedknife must be ground or backlapped after installing on bedbar 7 Bedknife to reel adjustment Check bedknife to reel contact daily Bedknife must have light contact all across reel No contact will cause cutting edges to become dull Excessive contact accelerates wear quality of cut may be adversely affected Slightly dull cutting edges may be corrected by backlapping Excessively dull cutting edges must be corrected by grinding the reel and bedknife 8 Front roller position Make sure front rollers on all cutting units are in the same position 9 Rear roller parallel to reel Rear roller must be set so that it is parallel with the reel before setting height of cut 10 Height of cut Make sure all cutting units are set at the same height of cut Set units as specified in the Operator s Manual 11 Bedbar stability Check bedbar end bushings adjuster pivot bushings and nylon flanged bushings for wear or damage Check adjustment knob to make sure detent holds adjustment 12 Number of reel blades Use cutting unit model with correct number of blades for clip frequency and optimum quality of cut range see Specifications 13 Cutting unit alignment and ground following Check lift arms and cutting unit pivot linkages for wear damage binding or bent pivot pins 14 Roller condition All rollers should rotate freely Make sure bearings are properly lubricated Replace bearings if worn damaged Cutting Units P
89. Electrical System 6 Loosen nut on adjusting yoke Remove the cotter and clevis pins from the adjusting yoke Tilt pump mount and remove the pump belt Fig 28 7 Remove long capscrew with the jam nut from en gine block Retain the position of the jam nut on the capscrew Fig 30 8 Remove the spindle with the clutch attached by al ternately loosening all spindle capscrews and then pull ing on the clutch Fig 30 When the spindle is free of the fly wheel slide it up along the flywheel and rotate it out to clear the traction pedal and foot rest 9 Remove the capscrews lock washers and pulley from the clutch Fig 30 Figure 29 1 Capscrew 3 Grommet 5 Nut 10 Remove the capscrew lockwasher and flat washer 2 Flat washer 4 Hydraulictank 6 Carriage bolt from the spindle Slide the clutch and key from the clutch spindle Fig 30 Reelmaster 2300 D 2600 D Page 5 31 Electrical System Installation 1 When installing an new clutch remove the wire bracket from the old clutch and install it with the flat washers and new pop rivets on the new clutch Run the wires through the bracket and tie wrap to them to the bracket as on the original clutch Make sure wires are tight against the clutch wire bracket or they will catch in the spindle bolts Fig 30 2 Make sure the spindle is free of dirt and rust Insert the capscrews with flat washers through the spindle base from the shaft side Fig
90. Height of Cut and Leveling Rear Roller Note Both floating and fixed cutting units can use this method for making height of cut adjustments and level ing both front and back rollers 1 Position cutting unit on a flat level table or board 2 Slightly loosen crack nut securing each roller bracket to the angle bracket 3 For the rear roller adjust support cap screw to achieve 5 8 1 16 15 9 mm 1 6 dimension between both Height of Cut supports and rear roller brackets 4 For the front roller adjust support cap screw to achieve 1 1 16 25 4 mm 1 6 dimension between both Height of Cut supports and front roller brackets 5 For the rear roller remove hairpin cotters securing rear Height of Cut pins and reinstall in the 1 2 setting as indicated on the rear Height of Cut plate 6 For the front roller remove hairpin cotters securing front Height of Cut pins and reinstall in the 1 4 setting as indicated on the front Height of Cut plate to allow clearance between front roller and table 7 Position a 1 2 or thicker bar under the reel blades and againstthe front face ofthe bedknife Make sure bar covers the full length of reel blades 8 Verify that rear roller is level by attempting to insert a piece of paper under each end of roller The paper should not fit between the roller and the table 9 Level rear roller by adjusting the appropriate sup port cap screw on rear roller supports until the rolle
91. Kit Model No 03475 Anti Scalp Roller Kit Model No 03477 Roller Scraper Kit Model No 03478 Fixed Kit Part No 93 6915 Skid Kit Part No 94 3664 CUTTING UNIT LIFT Hydraulic lift has an automatic reel shut off All units are controlled from one lever SUSPENSION SYSTEM Adjustable counterbalance spring provide for a fully floating suspension L I N K S cutting unit suspension system provides fore and aft oscillation Main center pivot allows side to side os cillation With optional Fixed Kit Part No 93 6915 cut ting units can be locked into fixed fore aft position for use with skids or anti scalp rollers Reelmaster 2300 D 2600 D Special Tools Order special tools from the TORO SPECIAL TOOLS Some tools may have been supplied with your machine AND APPLICATIONS GUIDE COMMERCIAL PROD or available as TORO parts Some tools may also be UCTS available from a local supplier Gauge Bar Assembly Use gauge bar to verify height of cut Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel Figure 3 5 E 3 Reelmaster 2300 D 2600 D Page 7 3 Cutting Units Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at taching screws Use this bit with a torque wrench to se cure the bedknife to the bedbar DO NOT use and air or manual impact wrench with this tool H Figure 4 Cutting Units Page 7 4 Ree
92. LOWERED WHEN GOING DOWN SLOPES FOA STEERING CONTROL 87 5380 FOR BRAKING MOVE TRACTION PEDAL TO NEUTRAL OR DIRECTION OPPOSITE TRAVEL DIRECTION KEEP ALL GUARDS IN PLACE KEEP PEOPLE AND PETS AWAY FROM MACHINE ON I NSI D E O F SVOP ENGINE BEFORE ADDING FUEL OR SEAVICING MACHINE FRONT RIGHT PANEL E is Part No 67 5360 ON SKIRT PANEL Part No 83 9550 Safety Page 1 4 Reelmaster 2300 D 2600 D DANGER Rotating Reel Will Cut Hands and Feet See Adjustment Procedures An ES AN S STOP ON SHIELD Part No 93 8064 Reelmaster 2300 D 2600 D Page1 5 Safety Safety Page 1 6 Reelmaster 2300 D 2600 D Chapter 2 Product Records and Manuals Table of Contents PRODUCT RECORDS sssss 1 TORQUE SPECIFICATIONS 3 EQUIVALENTS AND CONVERSIONS 2 Capscrew Markings and Torque Values U S 3 Decimal and Millimeter Equivalents 2 Capscrew Markings and Torque Values Metric 3 U S to Metric Conversions 2 MAINTENANCE INTERVAL CHART 4 OPERATION AND SERVICE HISTORY REPORT 5 Product Records Record information about your Reelmaster Insert Operator s Manuals and Parts Catalogs for your 2300 D 2600 D on the OPERATION AND SERVICE Reelmaster 2300 D 2600 D at the end of this section HISTORY REPORT form Use this information when re ferring to your machine Reelmaster 2300 D 2600 D Page 2 1 Product Records an
93. O UINJOH BIS Cy a 77 a IMYA la 7 ebreyo eJnsseJd MO SE S AWA 91901 a SN ECKER 101 A INSS ld UD LN Ly Y or pJeMIOJ UONOBIL H Ka Ba Q 0808 i 103 uon 009Z 0 0067 Jelsewjeey ZN a 1 ITIOYINOO 0334S 1334 1 Y Ko Id d 1 lt Cam ase 5 1 Fun uvao kale ssd 431009 B 1NOUJ Y Pd esee oo Sm 1 1 ow quvMHOJ asuanay Klee Kater DK 4311128 NOTIVO EZ HIOAH3S3H WOLLOS eum 3unssa3ud MOT isd 051 001 JarmuaouvHo dWNd NOILOVHI J 0069 ENI Zi AA WOLLOS INIYA MOL L WON NOHOIW 01 uar dol m M r d 1NOUJ AERA Poy REDE ANIYA 10H1NOO Po Ei l 1391338 li Fo j a nm g xt NA MA rj NG Ko dol V L L avas ino TT T NOUJNI a nouos m FI Y dOL3AWA POY L quvMHuo4 Wd9 kz IOHINOO MO 14 Od Y uvad l TAO Lan m YANNI 1NOy4 TAO Lin uaddn a lt HIMOT V 09464 gulat TRS Lee YOLOW 133HM Hydraulic System Page 4 11 Reelmaster 2300 D
94. OO Q33dS 1338 OLIVIW3HOS HOLOW 1334 v 15 D ld VY ME uv3o u31009 INOH3 Nn nn uvau 1NOHJ qu vMHO4 3Su3A3u N 00 g oz o u pa l Wd NOILOWHL oam ze NOTIVO Z HIOAH3S3H WOLLOS uvau DYA 0069 TAO Lal OILYW3HOS YOLOW HM 1331 ENI 2 3unss3ud MOT INNd 3DUVHO WON NOHOIN 01 90461 ald uaino YANNI guizi dOL uvau HOLOW 133HM WOLLOG isd G p iNOus isd 081 001 INOWS 43034 LIN Janay 3ouvuo TAO Lal IVA 1OH1NOO 13111334 3 O N ON O H ei eege u3ddn a Se dok WOLLOS ame NI NMOHS ANIYA MOL HOLO3TAS AME AMZ uvau INO PY LNOYW NI P 3 AIR V dOL SATIVA HIMOTV K Wd9 KZ H TOHINOO MOTH Od 3984338 du VMyOY HOLOW 133HM LHSIY Hydraulic System Page 4 7 Reelmaster 2300 D 2600 D Hydraulic Flow Diagrams Raise Cutting Units The charge pump is part of the traction pump and is di rectly coupled to it lt supplies hydraulic pressure for raising and lowering cutting units and maintaining 100 to 150 PSI to the low pressure side of the traction circuit piston pump The pump takes its suction through a fil ter from the reservoir During conditions of not lifting or lowering cutting units flow from the charge pump goes to the control valve and is by passed control valve position not shown directly to the suction of the piston pump and the charge relief valve When the cutting units are to be raised the control valve spool is positioned down and flow is directed out the top o
95. One of the pump suction lines has an air leak Hydraulic system operates hot Transmission pressure is high due to load or brakes applied Oil level in reservoir is low or inlet filter is loose or clogged Oil is contaminated or too light Heat exchanger is damaged or plugged By pass relief is stuck open or air flow is obstructed Charge pressure is low Towing by pass valve is open or defective Wheel motor s or reel motor s are worn or damaged Traction pump is worn or damaged Neutral is difficult to find or unit oper ates in one direction only damaged External control linkage is misadjusted disconnected binding or Traction pump is worn or damaged Traction response is sluggish Charge pressure is low Hydraulic oil is very cold Towing by pass valve is open or worn Brake is not released Traction pump or wheel motor s are worn or damaged No traction in either direction Brake is not released Oil level in reservoir is low Towing by pass valve is open Charge pressure is low Traction pump or wheel motor s are worn or damaged Reelmaster 2300 D 2600 D Page 4 17 Hydraulic System Problem Possible Cause Wheel motor will not turn Internal parts in wheel motor are damaged Brakes are binding Key on wheel motor shaft is sheared or missing Wheel motor will not hold load in Make up fluid from charge pump is not available neutral nA Flow control setting is wrong for rev
96. PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5 000 PSI 5 FLOWMETER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit Reelmaster 2300 D 2600 D 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 has a potential for 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 Problem Hydraulic oil leaks Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a machine malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Possible Cause Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Foaming hydraulic fluid Oil level in reservoir is low Hydraulic system has wrong kind of oil
97. Remove cap screws 14 from two position valve 1 7 Remove fittings 10 11 and 12 and O rings 15 from two position valve 1 Installation Fig 51 1 Install hydraulic fittings 10 11 and 12 and O rings 15 into two position valve 1 2 Secure cap screws 14 to two position valve 1 through the skirt assembly 3 Install hydraulic connections 6 7 8 and 9 to hy draulic fittings 10 11 and 12 and tighten fittings 4 Tighten nut 2 and cap screw 3 so the tube clamps 4 will prevent movement of the hydraulic tubes 5 Reelmaster 2300 D 2600 D Figure 52 1 Valve cap 6 Spring pin 2 Plug 7 Back up ring 3 O ring 8 O ring 4 Ball 9 Valve housing 5 Spool 10 Boot retainer Disassembly Fig 52 1 Wash valve in solvent and thoroughly dry Mount valve carefully in a vise ensuring the mounting pads are against the vise jaws 2 Remove boot retainer 10 from the valve housing 9 3 Carefully remove valve cap 1 from the valve hous ing 9 The valve cap is press fitted 4 Secure valve stop 13 and remove plug 2 and O ring 3 from the spool 5 5 Hold knob 15 and carefully slide spool 5 out of the valve housing 9 Note The valve stop 13 and set screw are loctited together and should remain together when removed from the spool 5 6 Separate valve stop 13 and set screw 12 from the spool 5 Carefully remove boot 11 from the valve stop 7 R
98. Remove housing 3 from the vise and invert it Re move dirt and water seal 1 A blind hole bearing or seal puller is required Hydraulic System Inspection Fig 32 1 Inspect bolts 14 for damaged threads and sealing rings under the bolt head Replace if damaged Fig 36 Note A polished pattern not scratches on the cover from rotation of the commutator 16 is normal Discolor ation would indicate excess fluid temperature thermal shock or excess speed and require system investiga tion for cause and close inspection of end cover com mutator manifold and rotor set A CAUTION Use eye protection such as goggles when using compressed air 2 Thoroughly wash end cover 24 in proper solvent and blow dry Make sure the end cover valve apertures including the internal orifice plug are free of contamina tion Inspect end cover for cracks and the bolt head re cesses for good bolt head sealing surfaces Replace end cover as necessary Fig 37 3 Inspect commutator ring 23 for cracks and burrs Replace commutator ring as necessary 4 Inspect commutator 16 for cracks burrs wear scoring chipping and peening If any of these condi tions exist replace commutator and commutator ring 23 as a matched set 5 Inspect manifold 22 for cracks surface scoring peening chipping Replace manifold if any of these conditions exist A polished pattern on the ground sur face from commutator or rotor rotatio
99. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Reelmaster 2300 D 2600 D REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR S MANUALS FOR OPERATING MAINTENANCE AND ADJUSTMENT INSTRUC TIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Catalogs for your machine Replacement Operator s Manuals are available by sending complete Model and Serial Num ber 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 Part No 96876SL Rev A Service Manual Reelmaster 2300 D 2600 D A This safety symbol means DANGER WARN ING or CAUTION PERSONAL SAFETY INSTRUCTION When you see 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 re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 1996 1998 This page is blank Table Of Contents Chapter 1 Safety Safety Instructions 0oooooooommmmo
100. TS Fan Water Pump Hydraulic Pump 5 COOLANT LEVEL FILL PARKING o 6 FUEL Diesel Only BRAKE 7 GREASE POINTS 11 3WD 12 2WD e 3 RADIATOR SCREEN jo MATER CEP ARATORFUEL FILTER O N L E FT F E N D E R SO Part No 84 1650 12 TIRE PRESSURE 12 16 psi 8 1 1 bar 13 FUSES FLUID SPECIFICATIONS CHANGE INTERVALS SEE OPERATORS MANUAL FLUID TYPE CAPACITY CHANGEINTERVAL FOR INTIAL CHANGES L ar rcu ricter PARTNO ENGINE OIL ae SAET0W 30CD 28 3 0 50 HRS 100 HRS 85 4930 a HYD CIRCUITO WOBILFLUID 424 125 13 400 nes 200 HRS 54 0110 B FUEL FILTER Inspect dally for contaminants amp water 200 HRS Sos C 93 6696 AIR CLEANER Clean every Bo Fours 200 HRS 93 2195 D mem Jil ON LIFT ARMS Part No 93 6696 ON UNDER SEAT WARNING Spring Loaded Mechanism Part No 93 6903 Read Disassembly Procedure A DANGER FAILURE TO COMPLY WITH THE FOLLOWING SAFETY REQUIREMENTS JAY RESULT IN PERSONAL INJURY OR DEATH READ AND UNDERSTAND OPERATOR S MANUAL BEFORE OPERATING THIS MACHINE ES PRECISO ENTRENAR A LOS OPERADORES PARA UNA OPERACION SEGURA ADANGER DO NOT OPERATE THIS UNIT UNLESS ALL SHIELDS ARE FIRMLY SECURED USE EXTREME CAUTION ON HILLS SLOPES AND ROUGH TERRAIN ERATOR MUST BE SKILLED ANO TRAINED IN SLOPE OPERATION AVOID SUDDEN STARTS STOPS HOLES DAOP OFF S OR HIDDEN HAZARDS IN TERRAIN CUTTING UNITS MUST BE
101. Turnthe ignition switch to ON the light should come on 4 Turn the ignition switch to OFF and connect the brown wire to the oil pressure switch High Temperature Water Shutdown Light The temperature light should come on only if the high temperature shutdown switch and relay have stopped the engine when the coolant temperature is above 206 F 97 C The ignition switch must be in either the ON or START position for the light to come on 1 Disconnect the tan wire from the high temperature shutdown switch 2 Ground the tan wire to the engine block 3 Turnthe ignition switch to ON the light should come on and the high temperature shutdown relay should Click 4 Turn the ignition switch to OFF and connect the tan wire to the high temperature shutdown switch Glow Light The glow light should come on with the ignition in the GLOW or START position 1 Turnthe ignition switch to GLOW or START the light should come on 2 Turn the ignition switch to OFF Electrical System Page 5 20 Battery Light The battery light should come on when the ignition Switch is in ON with the engine not running or with an im properly operating charging circuit while the engine is running 1 Turnignition switch to ON the light should come on 2 Turn ignition switch to OFF OIL FRONT RED PES El lt BATT AMBER GLOW AMBER Figure 10 Reelmaster 2300 D 2600 D Temperature Sending Unit The swit
102. Unscrew lock nut 1 and remove coupling 2 from reel motor 3 using a puller 4 Clean motor fittings and hose connections Note The position of the fittings on the reel motor is critical to reconnecting hydraulic hoses 5 Label all hose connections 4 for reassembly pur poses Matchmark reel motor and all hydraulic fittings 5 for reassembly purposes 6 Remove hose connections 4 from hydraulic fit tings 5 Allow hydraulic oil to drain from hose into a suit able container Put caps or plugs on disconnected hoses to prevent contamination 7 Remove hydraulic fittings 5 and O rings 7 from reel motor 3 Installation Fig 55 1 Install coupling 2 and secure lock nut 1 to the reel motor 3 and torque to 35 ft lb 4 8 kg m 2 Make sure hydraulic fitting ports and O ring sealing surfaces on the reel motor 3 are clean 3 Apply clean hydraulic oil to all O rings 4 Inspectthreads and sealing surfaces of hydraulic fit tings 5 Replace any damaged or worn fittings Hydraulic System Page 4 60 Figure 55 1 Locknut 5 Hydraulic fittings 2 Coupling 6 O ring 3 Reel motor 7 O ring 4 Hose connection 5 Place C ring 7 on face seal of hydraulic fitting 5 Secure hydraulic fitting to the reel motor 3 ensuring that the matchmarks are aligned Repeat this step for the remaining hydraulic fittings 6 Inspect threads and sealing surfaces of hose con nections 4 Replace any da
103. WA IOHLINOO 1311 1334 pu L pit uvau INO e m LNOH23 NI di dNNd NOILOYHL o96 9 ENI e dWNd 3DHYHI us 3OuvHO lg HS E dOL a WOLLO A WOLLOS INIYA MOL as cq eee a e 09 61 eul ZL 1431 pazibiaua ap UMOUS SI LS plousjoS MO J uonons Jo uinjeH ainssaid eDjeu9 wo einsseJg UBIH SJ A HY UONJLIL soron aan 0097 0067 191SEW 33YH L E DL Wd9 rz QquvMHo4 uvag TAO L417 ualno YANNI 1NOUJ TAO LAT Y3ddNn 8 HIMOT V Hydraulic System Page 4 13 Reelmaster 2300 D 2600 D Mow The reel motor drive pump is directly coupled to the the traction pump which is driven directly by the engine through the electric clutch Taking its suction directly from the reservoir the reel motor drive pump supplies oil flow to the hydraulic manifold block and to the reel mo tors With the engine running the clutch engaged and the cutting unit switch pushed in to the OFF position oil flows into inlet port P1 and through deenergized sole noid valve S1 bypassing the reel motors Oil then flows directly back to the reservoir through the oil cooler When the cutting unit switch is pulled out to the ON posi tion with the engine running and the cl
104. ZL OWv 0 0S LHVIS Avay Y en at Vo ri 38M Ov 0E NO DEI S REES HOLIMS NOLLINO Ka Eh FER 3118038 0319V8138 SI H3NHA9 N3HM 135079 NadO ATIYWHON UE HOLIMS MOOTHALNI lt NAY OL d3ZIDU3N3 T INA SNLIRS I GIONITOS E S a s m ANIYA 13n4 31dund 3 J 3ONVHO vg C m Fauna 2 Dove 31IHW3ONVHO ovi8 z US NA GION310S e m Geck LINN DNILLAD ONISNOH Quvog ova 31dund YOLOANNOO LINOHI Wvyovia 140 3IIHW3ONVHO WON ERD 30010 gaold wovia ABH 1V3S NI HOlVH3dO HLIM 135079 i NO xovia SIHNVSONVHO Y E m 7 NadO ATIVINHON HOLIMS Sand oie 8 a ell E HOLIMS MOOTHALNI LVIS onting A ls Xovia aidund S dE E 3 wn 4 3ONVYO Yal411938 dO1WIN938 311HW31d8Nd gg HA dnd 39VLIOA J NnoHO i El e a L zva annona EI 5 movi ovig A3u9 NOVIA ounsee Gi H YOLVNS3LTV sta NOILISOd TVHLNAN NI 138079 e ania N33H5 NadO ATIYWHON Ov HOLIMS YOOTHSINI NOLLOVH L A340 NT WOVTB AdHO Ze xovia MOTIBA NOI LISOd MON NI NMOHS ama dau HOLIMS dV DIOV8 Page 5 8 Reelmaster 2300 D 2600 D Electrical System Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of
105. a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Skin Over Grease Special non conductive grease which forms a light pro tective skin which helps waterproof electrical switches and contacts Reelmaster 2300 D 2600 D Page 5 9 Some tools may also be available from a local supplier Figure 1 Figure 2 Electrical System of 0 a 1 o 25 FT Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and A CAUTION 3 J components used on this machine see Wiring Sche matics section of this chapter Remove all jewelry especially rings and watches before doing any electrical trou If the machine has any interlock switches by passed bleshooting or testing Disconnect the they must be reconnected for proper troubleshooting battery cables unless the test requires and safety battery voltage Starting Problems Starter solenoid clicks but starter will not crank Battery charge is low if solenoid clicks problem is not in safety interlock system Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter mounting bolts are loose or not supplying a sufficient ground for solenoid Starter is faulty cau
106. ach new capscrews washers and flanged lock nuts to the fixed side plate and the cutting unit Fig 29 5 Tighten lock nuts and capscrews 6 Fasten new height of cut plate to the cutting unit with new pop rivets Fig 29 Fi 2 7 Repeat steps 1 through 6 for the other side of the igure 28 1 Poprivet 4 Capscrew cutting unit 2 Height of cut plate 5 Washer 3 Locknut 6 Link Figure 29 1 Fixed side plate 4 Flanged lock nut 2 Capscrews 5 Height of cut plate 3 Washers 6 Poprivet 5 E d Reelmaster 2300 D 2600 D Page 7 25 Cutting Units Skid Kit Installation 1 Remove front roller from the cutting unit see Roller Removal and Installation 2 Align skid slots with the angle bracket holes on the cutting unit 3 Secure skid to the cutting unit with both flange head screws flat washers and lock nuts 4 Adjust skid height as necessary by loosening lock nuts and flange head screws then retighten fasteners Figure 30 1 Skid 4 Flat washer 2 Angle bracket holes 5 Lock nut 3 Flange head screw Cutting Units Page 7 26 Reelmaster 2300 D 2600 D This page is blank TORO Commercial Products O The Toro Company
107. adjustment 3 Coat shaft 6 lightly with hydraulic oil Slide head 10 onto the shaft being careful not to damage O ring 7 and dust seal 12 4 Install piston 3 onto the shaft being careful not to damage C ring 5 Install locknut 2 onto the shaft and tighten 5 Remove shaft 6 from the vise IMPORTANT Prevent damage when clamping the barrel 1 into a vise clamp on the pivot end only Do not close vise enough to distort barrel 6 Mount barrel 1 in a vise so that the shaft end tilts up slightly 7 Coat all internal lift cylinder parts with a light coat of hydraulic oil Slide piston 3 shaft 6 and head 10 as sembly into barrel 1 being careful not to damage the seals 8 Secure head 3 in barrel 11 by installing retaining ring 1 into barrel groove Hydraulic System Control and Implement Relief Valves Hose connection Hydraulic fitting Washer Cap screw Lock nut Valve lever Knob Connecting link assembly PASARAN Hydraulic System Figure 65 Control valve Hydraulic fitting Hose connection Tube Hydraulic fitting Hose connection Hose connection Lock nut Page 4 74 Support bracket Tube Relief valve body Relief valve cartridge O ring O ring O ring O ring Reelmaster 2300 D 2600 D 1 Before removing any parts from the control lift valve assembly park the machine on a level surface engage the parking br
108. age 7 6 Reelmaster 2300 D 2600 D Adjustments A CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running Always stop the engine and re move the key first Lift Arm Counterbalance Spring A WARNING Use caution when tensioning springs as they are under heavy load Do not move lift lever cutting units can lower without the engine running DO NOT REMOVE THESE PINS 1 Raise cutting units to relieve tension on the counter balance springs 2 Make sure machine is shut off and parking brake is set 3 Remove cotter pin and clevis pin securing the spring shackle to the counterbalance arm Do not remove the other clevis pin Figure 5 4 Move shackle up or down the counter balance arm q until it aligns with the desired hole of the arm 1 Clevis pin amp cotter pin 3 Counterbalance arm 2 Spring Shackle 4 Counterbalance spring Counterbalance Arm Application Hole Position Middle Hole for 5 blade reels Second Hole from Top for 8 blade reels without baskets Top Hole for 8 blade reels with baskets IMPORTANT These are recommended settings Readjust spring positions to attain optimum per formance By raising spring locations on counter balance arms cutting unit weight on ground is reduced and traction is increased 5 E 3 5 Reinstall clevis pin through the desired hole then attach cotter pin Reelmaster 2300 D 2600 D Page 7 7 Cutting Units
109. age spikes The remaining diode is used as part of the safety circuit logic Diode D1 This diode allows a current path through the traction in terlock switch when the seat interlock switch is open The engine can be started and run with no operator in the seat when the traction pedal is in the neutral position Possible indications of diode failure may be The engine will crank but not start with the operator out of the seat with the traction pedal in neutral the engine will shut down when the operator leaves the seat with the cutting unit switch in the off position and the traction pedal in neutral or the engine cranks with the traction pedal not in neutral Diode D2 This diode protects the cutting unit switch interlock switch and indicator light from inductive voltage spikes caused by the cutting unit solenoid valve Possible indications of diode failure may be the failure or repeated failure of those components above associated with the cutting unit solenoid valve circuit Diode D3 This diode protects the ignition switch and starter relay contacts from induction voltage spikes caused by the starter solenoid Possible indications of diode failure may be the failure or repeated failure of those components above associated with the starter solenoid circuit Diode D4 This diode protects the seat interlock switch and cutting unit switch from induction voltage spikes caused by the fuel valve solenoid Possible indicat
110. ake lower the cutting units and stop the engine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Remove side panels lift hood to gain access to the control valve and relief valve Control Valve Removal Fig 65 1 Disconnect hose connections 1 11 14 and 15 from hydraulic fittings 2 and 13 Allow hoses to drain to a suitable container 2 Remove lock nuts 5 and 16 Slide cap screw 4 and washer 3 from the control valve 9 3 Slide control valve 9 from the support bracket 17 and remove from the unit 4 Unsnap and remove connecting link assembly 8 Remove valve lever 6 from the control valve 9 5 Disconnect tube 18 from hydraulic fitting 2 Dis connect tube 12 from hydraulic fitting 10 6 Remove hydraulic fittings 2 10 and 13 and O rings 21 and 23 from the control valve 9 Control Valve Installation Fig 65 1 Install O rings 21 and 23 and hydraulic fittings 2 10 and 13 to the control valve 9 2 Install tube 12 to hydraulic fitting 10 Connect tube 18 to hydraulic fitting 24 3 Install valve lever 6 to the control valve 9 by snapping the connecting link assembly 8 to the valve lever and control valve Reelmaster 2300 D 2600 D Page 4 75 4 Position control valve 9 into unit and slide onto support bracket 17 5 Slide c
111. al bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when using a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery B Ifthe battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure the battery terminals are free of corro sion D Measure the temperature of the center cell E Connect a battery load tester to the battery ter minals following the manufacturer s instruc tions Connect a digital multimeter to the battery terminals F Apply atestload of one half the Cranking Perfor mance rating see Fig 25 of the battery for 15 se conds G Take a voltage reading at 15 seconds then re move the load Electrical System Page 5 28 H Using the table below determine the minimum voltage for the cell temperature reading Voltage Temperature e CC 10 0 C 4 4 C 8 RECH Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure the ignition switch and all accessories are off 2 Make sure the battery compartment
112. amps for 15 minutes to al low sufficient mixing of the electrolyte 2 Conducta hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell Electrical System o of 0O a o0 2 5 Lu B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the battery Charge at the recommended rate and time given in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific grav ity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commerci
113. an lead from the high temperature shut down switch located on the water pump behind the fan F Remove purple lead from the fuel valve solenoid located above the lift pump G Remove brown lead from the oil pressure switch located on the front of the cylinder head H Remove white lead from the glow plugs located on the front traction pump side of the cylinder head Remove gray red and white leads from the en gine starter solenoid located on below the exhaust manifold J Disconnect battery ground from the traction clutch side of the cylinder head or the fan side of the cylinder block K Remove cap screw 10 and flat washer 11 from R clamp 12 Pull wiring harness and hydrau lic hoses away from the engine to keep them from snagging the engine when it is removed The har ness and hoses may be tied to the reservoir support brackets Remove radiator assembly A Support the radiator assembly while removing fasteners B Remove cap screws 1 and whiz nuts 2 from the radiator rear bracket 3 and frame 4 Fig 22 C Remove carriage bolts 1 and whiz nuts 2 from the radiator bracket 3 and frame 4 Fig 23 D Pull radiator assembly out and then up from the engine to prevent the engine cooling fan from catch ing the radiator top and bottom shrouds o o A gt R S Figure 22 1 Cap screws 3 Radiator rear bracket 2 Whiz nut 4 Frame Figure 23 1 Car
114. and carriage bolts and verify adjust ment Figure 7 1 Bedknife adjusting screw WYK WwW Figure 9 1 Carriage bolts 3 Adjustment nuts 2 Bedbar adjuster 5 E d Reelmaster 2300 D 2600 D Page 7 9 Cutting Units Height of Cut and Front Roller Level 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 nuts securing each front roll er bracket to the angle bracket 3 Place the bar across the front and rear rollers and adjust both front roller support capscrews until the un derside of the head of screw on the gauge bar engages the bedknife cutting edge Do this on both ends of reel 4 Tighten all nuts securing the roller brackets Cutting Units Page 7 10 Pon Figure 10 Gauge bar 5 Front roller support cap Front roller bracket nut screw Front roller bracket 6 Bedknife Angle bracket Reelmaster 2300 D 2600 D Service and Repairs Greasing Bearings Bushings and Pivot Points Fig 11 and Fig 12 Note Each cutting unit has 8 grease fittings with optional front roller installed that must be lubricated regularly with No 2 General Purpose Lithium Base Grease Note On earlier production cutting units the grease fittings for the reels are locate on the inside ofthe cutting unit Later production models
115. ap screw 4 into control valve 9 and install washer 3 Secure lock nuts 5 and 16 6 Connect hose connections 1 11 14 and 15 to hy draulic fittings 2 and 13 and tighten connections Relief Valve Removal Fig 65 Note This procedure may be used if only the relief valve needs removal from the unit 1 Disconnect hose connection 11 from hydraulic fit ting 2 Allow hose to drain to a suitable container 2 Disconnect tube 18 from hydraulic fitting 2 Allow fitting to drain to a suitable container 3 Remove relief valve body 19 and hydraulic fitting 2 from tube 12 4 Remove hydraulic fitting 2 tube 18 and both O rings 23 from the relief valve body 19 Relief Valve Installation Fig 65 Note This procedure may be used if only the relief valve has been removed from the unit 1 Install hydraulic fitting 2 and O ring 23 to the re lief valve body 19 2 Install tube 18 and O ring 23 to the relief valve body 19 3 Set relief valve body 19 and attachments into the unit 4 Connect tube 18 to hydraulic fitting 2 5 Connect tube 12 to hydraulic fitting 2 6 Connect hose connection 11 to hydraulic fitting 2 Hydraulic System Control Valve Disassembly Fig 66 1 Wash control valve in solvent and dry it thoroughly 2 Mountcontrol valve into avise so the mounting pads are against the jaws of the vice and snap ring 14 faces up Note Remove
116. aulic hoses if worn or leaking Hydraulic System Page 4 78 Reelmaster 2300 D 2600 D Flushing the Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or the system is contaminated oil appears milky or black or con tains metal particles IMPORTANT Flush hydraulic system when chang Ing from petroleum base hydraulic fluid such as Mobil 424 to biodegradable fluid such as Mobil EAL 224H Operate machine under normal operat ing conditions for at least four 4 hours before draining 1 Park machine on a level surface Lower cutting units stop engine engage parking brake and remove key from ignition switch 2 Clean area around filter mounting area Remove fil ter and drain reservoir into a suitable container Drain hydraulic system Make sure lift cylinders hoses and tube lines are drained while the system is warm Discard filter 3 Inspect and clean reservoir see Inspecting Reser voir Parts 4 Make sure filter mounting surface is clean Apply hydraulic oil to gasket on the new filter Screw filter on until gasket contacts mounting plate then tighten filter half a turn Note Use biodegradable fluid such as Mobil EAL 224H for this step if you are changing to this type of fluid Use only hydraulic fluids specified in Checking Hydrau lic System Fluid see General section of this chapter Other fluids could cause system damage 5 Fill hydraulic reservoir 6
117. backup wash ers 6 Apply masking tape around splines or keyway on coupling shaft 11 to prevent damage to seal IMPORTANT The outer bearing 2 is not lubricated by the system s hydraulic fluid Make sure it is thor oughly packed with the recommended grease Hydraulic System Page 4 50 Thrust Washers Steel Washer Thrust Backup Bearing 3 Washer xeu Shaft EE m Figure 45 Note Coupling shaft 11 should be approximately 0 10 inch 2 54 mm below the housing wear plate sur face to allow the assembly of thrust bearing 12 The coupling shaft must rotate smoothly on the thrust bear ing 9 and thrust washer 8 Fig 46 7 Make sure that a generous amount of clean corro sion resistant grease has been applied to the outer bear ing 2 Install the coupling shaft 11 into housing 3 and seat shaft against the second thrust washer 8 Reelmaster 2300 D 2600 D 8 Install thrust bearing 12 onto the end of coupling shaft 11 9 Apply asmall amount of clean grease to a new seal ring 5 and insert it into the housing 3 seal ring groove Note Oneortwo alignment studs screwed finger tight into housing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of com ponents as required in the following procedures The studs can be made by cutting off the heads of 3 8 24 UNF 2A bolts so they are 0 5 inch 12 7
118. below the radiator pipe plug Re move pipe plug from the bottom of the radiator Al low antifreeze to drain into the container Reelmaster 2300 D 2600 D Page 3 13 Figure 17 1 Left fender 4 Flange nut 2 Left fender bracket 5 Left footrest 3 Cap screw 6 Clinch nut Figure 18 3 Brake arm 1 Cotter pin 2 Adjusting rod 8 Drain hydraulic reservoir A Clean hydraulic oil filter and area around the fil ter B Place clean drain pan below hydraulic oil filter to collect the draining hydraulic oil C Remove hydraulic oil filter from bottom of the fil ter housing with a bottom type filter wrench Let oil drain into the drain pan install filter when drained Engine Cap screw Lock washer Clutch washer Engine pulley Cap screw Wire bracket Nut Pop rivet Key Cap screw Flat washer R clamp Washer Muffler Muffler tube Muffler bracket Engine 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 CONNECTED TO AIR FILTER HOSE Figure 19 U bolt Upper radiator hose Muffler clamp Nut Lock washer Left rear mount bracket Hose clamp Lower radiator hose Engine Throttle cable clamp Flange nut Throttle cable bracket Clevis pin Cotter pin Throttle tab Page 3 14 Flat washer Lock washer Front mount bracket Insert nut Cap screw Clutch spindle Hose clamp Cap screw Electric clutch
119. blem immediately If the engine does stop proceed to step 5 5 Make sure the mow backlap knob is in the backlap position turned clockwise the traction pedal is in neu tral and the cutting unit switch is pushed to the OFF position With the operator off the seat start the engine Pull the cutting unit switch to the ON position the engine should not stop If the engine does stop there may be a malfunction in the interlock system Repair the prob lem immediately If the engine does not stop proceed to step 6 6 Withthe cutting units in the raised position sit on the seat and start the engine Pull the cutting unit switch to the ON position Lower the cutting units to the ground The cutting unit reels should turn and the reels turning light should glow when the cutting units are lowered Raise the cutting units and verify that the reels stop and the reels turning light is out If the reels do not stop there may be a malfunction in the interlock system Repair the problem immediately Reelmaster 2300 D 2600 D Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead the the negative bat
120. ch is located on top of the water pump The pump is on the left end of the engine inside of the fan pulley assembly There is a white black wire attached to the switch 1 Lower the coolant level in the engine and remove the high temperature sending unit 2 Putthe switch in a container of oil with a thermome ter and slowly heat the oil Fig 12 A CAUTION Handle the hot oil with extreme care to prevent personal injury or fire Figure 11 1 Temperature sending unit 3 Check the resistance of the sender with a multime ter ohms setting asthe temperature increases The fol lowing resistance readings should be indicated 158 to 202 OHM at 130 F 54 C 63 to 79 OHM at 180 F 82 C Figure 12 Temperature Gauge SE ER o0 o5 OI The temperature gauge can be tested using a new gauge as a substitute or by the use of a DC voltage source and a variable resistance box 63 TO 79 OHMS VARIABLE RESISTANCE 1 Connect the temperature gauge to the variable re sistance and DC voltage source Fig 13 2 Adjustthe resistance until the gauge needle points to the 180 F tic mark the resistance setting should be from 63 to 79 ohms 3 Disconnectthe voltage source gauge and variable resistance Figure 14 Reelmaster 2300 D 2600 D Page 5 21 Electrical System Diode Circuit Board The circuit board contains four diodes Three diodes are used for circuit protection from inductive volt
121. cutting units lowered Make sure engine is off and the parking brake is engaged 5 Operate engine at full speed 3200 100 RPM 3 Make sure the hydraulic tank is full dE 6 Make sure hydraulic oil is at operating temperature 7 Make sure that traction pedal and lift valve are in A CAUTION neutral and the parking brake is engaged 8 Pressure gauge should read from 100 to 150 PSI If Specification is not met replace charge relief valve Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 9 Shut off engine 10 Disconnect gauge and T connection from the 4 Disconnect hose from the front fitting of the charge pump and hose Reconnect hose to the pump pump leading to the control valve Connect T connector and gauge to the pump and hose fitting Reelmaster 2300 D 2600 D Page 4 25 Hydraulic System TEST NO 4 Reel Drive Pump Efficiency FILTER TO CHARGE PUMP r a lt 4 BOTTOM RESERVOIR TO TRACTION PUMP a Hard REEL DRIVE PUMP High Pressure Low Pressure Return or Suction gt Flow FROM LEFT WHEEL MOTO Ny L n ff ng L Y L a _ HYDRAULIC MANIFOLD Figure 15 1 Hose fitting 2 Reel drive pump 3 O ring Hydraulic System Page 4 26 Reelmaster 2300 D 2600 D Procedure
122. d Manuals Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1116 0 0625 1 588 916 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3116 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 034375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22
123. d prior to instal ling them onto the cutting unit If necessary after bearing adjustment align roller brackets as follows A Remove roller bracket on the side with the flanged bushing B Replace roller bracket so it is aligned to within one hex flat of the roller adjustment nut C Align both roller brackets Reelmaster 2300 D 2600 D Page 7 19 Figure 24 1 Height of cut pin 7 Front roller assembly 2 Hairpin cotter 8 Flanged bushing 3 Roller bracket 9 Bushing 4 Locknut 10 Carriage bolt 5 Capscrew 11 Lock nut 6 Angle bracket 6 Mount roller roller brackets and angle brackets to the cutting unit Secure roller brackets and angle brack ets to the cutting unit with capscrews 7 Install both height of cut pins and hairpin cotters 8 Install both locknuts to the capscrews and secure each angle bracket to the cutting unit 9 Adjustroller level see Height of Cut and Leveling Both Rollers Cutting Units 5 E 3 Roller Bearing and Seal Replacement Figure 25 4 Full roller 5 Outer seal 6 Shim washer 9 Inner seal 1 Adjustment nut 2 Roller shaft 3 Grease fitting Note A rear full roller is shown Bearing and seal configurations are the same for full and wiehle rollers The wiehle roller does not have the a inner seal and shim washer The shim washer is not u
124. drain from hose into a suitable container 5 Remove fittings 4 and 6 and O rings 8 and 9 from the pump 6 Support reel motor drive pump 1 and remove two cap screws 10 Separate reel motor drive pump 1 and O ring 11 from the traction pump 12 Installation Fig 53 1 Make sure mounting and O ring sealing surfaces on reel motor drive pump 1 and traction pump 12 are clean 2 Replace all O rings with new ones Apply clean hy draulic oil to all O rings 3 Place O ring 11 on reel motor drive pump 1 Reelmaster 2300 D 2600 D Page 4 57 INLET PORT 10 6 7 ANG R BN lt gt DA O Figure 53 1 Reel motor drive pump 7 O ring 2 Hose clamp 8 O ring 3 Hose 9 O ring 4 Fitting 10 Cap screw 5 Hose 11 O ring 6 Elbow fitting 12 Traction pump 4 Position reel motor drive pump 1 to traction pump 12 the inlet port should be facing up 5 Secure reel motor drive pump 1 to traction pump 12 with cap screws 10 Torque cap screws from 27 to 31 ft lb 3 7 to 4 3 kg m 6 Inspect threads and sealing surfaces of connectors Replace any damaged or worn connectors 7 Install O rings 8 and 9 Install fitting 4 and orient to the 2 o clock position Install elbow connector 6 and orient to the 45 down 8 Secure hose 3 to connector 4 and tighten hose clamp 2 Secure hose 5 to elbow fitting 6 and tighten hose connector 9 Remove plug from hydraulic reservoir
125. e 17 Raise the cutting units when driving from one work area to another 18 Do not touch engine muffler exhaust pipe or hy draulic tank while engine is running or soon after it has stopped These areas could be hot enough to cause burns 19 If acutting unit strikes a solid object or vibrates ab normally stop cutting unit immediately Turn the engine off wait for all motion to stop and inspect for damage A damaged reel or bedknife must be repaired or re placed before operation is continued Reelmaster 2300 D 2600 D 20 Before getting off the seat A Move the traction pedal to neutral B Set the parking brake C Disengage the cutting units and waitforthe reels to stop spinning Maintenance and Service 22 Before servicing or making adjustments to the ma chine stop the engine and remove the key from the switch to prevent accidental starting of the engine 23 When changing attachments tires or performing other service use the correct blocks hoists and jacks Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine If the traction unit is not properly supported by blocks or jack stands the unit may move or fall resulting in per sonal injury 24 Check performance of all interlock switches daily Do not defeat interlock system It is for your protection 25 Ensure the entire machine is in good operating condition Frequently check and keep all nuts bolts
126. e clamp 5 Loosen capscrews 1 and nuts 2 securing the throttle stop 3 6 With the cold start button depressed carefully ad just low engine speed to 1400 50 RPM with the throttle control lever 4 adjust low speed stop screw if necessary Figure 9 7 Make sure throttle control lever 4 is down so the 1 Cap screw 3 Throttle stop governor lever on the engine touches the low speed ad 2 Nut 4 Throttle control leve justment screw 8 Adjust throttle stop 3 until it contacts the bottom of the throttle control lever 4 Tighten cap screws 1 and nuts 2 securing the throttle stop 9 Make sure governor lever on the engine goes against the high speed adjustment screw when the throttle control lever 4 is movedto the high speed posi tion When the throttle control lever is moved to the low speed position the governor lever on the engine should contact the low speed adjustment screw at the same time the throttle control lever contacts the throttle stop 3 Engine Page 3 8 Reelmaster 2300 D 2600 D Service and Repairs Bleeding the Fuel System IMPORTANT The fuel system must be primed when a new or rebuilt engine is started for the first time if it runs out of fuel or if maintenance is per formed on the fuel system 1 Park machine on a level surface Make sure fuel tank is at least half full 2 Unlatch and raise hood A DANGER Because diesel fuel is flammable use caution when storing or hand
127. e of Contents SPECIFICATIONS 2 222 2 SERVICE AND REPAIRS 00005 11 SPEGIAL TOOLS 2500 eet eere exe 3 Greasing Bearings Bushings and Pivot Points 11 TROUBLESHOOTING kesite ireas peaa ienaa 5 le ee e WEE 12 ADJUSTMENTS sssssseses eee 7 Hydraulic Motor Removal and Installation 13 Lift Arm Counterbalance Spring 7 Cutting Unit Removal and Installation 14 Height of Cut and Leveling both Rollers 8 Bedbar Removal and Installation 16 Bedknife Parallel to Reel 9 Bedknife Replacement and Grinding 18 Height of Cut and Front Roller Level 10 Roller Removal and Installation 19 Roller Bearing and Seal Replacement 20 Reel Removal and Bearing Replacement 22 Preparing a Reel for Grinding 24 Fixed Side Plate Assembly 25 Skid Kit Installation 26 5 E 3 Reelmaster 2300 D 2600 D Page 7 1 Cutting Units Specifications Figure 1 MOUNTING All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions REEL CONSTRUCTION 5 or 8 blades of 7 18 cm di ameter welded to 5 stamped steel spiders Reels are mounted on greaseable self aligning ball bearings The RM2300 D reel is 27 inches long and the RM2600 D reel is 32 inches long HEIGHT OF CUT RANGE Floating Cutting Unit
128. e the key from the start switch Chock wheels to keep the machine from moving 2 Disconnect positive and then negative bat tery cables at the battery 3 Gain access to the engine A Open and remove hood from the machine B Remove right side panel to gain access to the traction pump drive belt C Remove left rear panel radiator side which supports the instrument panel 4 Remove left fender 1 and fender bracket 2 from the radiator side of the frame Fig 17 A Remove cap screw 3 and flange nut 4 holding the left foot rest 5 to the left fender B Remove remaining cap screws 3 and flange nuts 4 securing the fender to the fender bracket and frame Remove fender from the frame C Remove both cap screws 3 and left fender bracket 2 from the frame 5 Remove cotter pin 1 from adjusting rod 2 Dis connect adjusting rod from brake arm 3 Fig 18 6 Remove cap screws 3 and flange nut 4 securing the left footrest 5 to the frame Fig 17 Slide the left foot rest off the adjusting rod 2 Fig 18 A CAUTION DO NOT open radiator cap or drain coolant if the engine or radiator is hot Pressurized hot coolant can escape and cause burns Ethylene gycol antifreeze is poisonous Dispose of it properly or store it in a proper ly labeled container away from children and pets 7 Drain antifreeze from radiator A Slowly remove radiator cap from the radiator B Place drain pan
129. e traction pump is driven by the engine through the pulley pump drive belt and electric clutch The traction circuit of the hydraulic system acts essentially as a closed loop Taking its suction directly from the return side of the wheel motors of the traction circuit the trac tion pump supplies oil flow to the wheel motors through the supply side of the traction circuit With the engine running clutch engaged and traction pedal in the neutral position the traction pump supplies no flow to the wheel motors When the traction pedal is pressed to the forward position the linkage from the pedal positions the swash plate in the traction motor so oil flows out the top port of the pump Oil flow out of the top port goes to the wheel motors and turns them in the forward direction The 2WD 3WD selector valve allows flow to the rear wheel in the 3WD position and by passes the rear wheel in the 2WD position Oil flowing out of the wheel motors returns to the bottom port of the traction pump and is continuously pumped out the top port However oil flow out of the rear wheel motor must pass through the check valve portion of the PC flow controller before returning to the traction pump Hydraulic System Page 4 10 A small amount of hydraulic oil leaves the traction circuit through the bi directional shuttle valve in the front left wheel motor This oil is cooled as it flows through the cooler and returned to the reservoir Filtered hydrau
130. earing 13 with numbered side to the inside of the pump Install inner race 12 with the chamfer to wards the inside of the pump Install washer 11 O ring 10 O ring cover 9 and trunnion cover 8 Secure trunnion cover with two screws 7 torque them from 36 to 48 in Ib 42 to 55 kg cm 5 On the long trunnion side of the camplate 20 install bearing 13 with numbered side to the inside of the pump Install washer 11 and press shaft seal 17 into place Secure seal cover 16 with two screws 7 and torque them from 36 to 48 in Ib 42 to 55 kg cm 6 Install retaining ring 32 towards the keyed end of the shaft 31 Slide washer 33 thrust bearing 34 se cond washer 33 and second retaining ring 32 into place over the splined end of the shaft 7 Position washer 35 and shaft seal 36 onto the shaft 31 from the keyed end 8 Install shaft 31 into the housing assembly 15 from the flanged end Press shaft seal 36 into position with a seal driver Install retaining ring 37 into the flanged end of the housing assembly 15 Hydraulic System Page 4 42 9 Reassemble rotating parts kit as follows Fig 26 A Use the following parts to reassemble the piston block 2 5 16 in I D x 15 16 in O D flat washers 1 5 16 in x 2 7 8 in N C cap screw 1 5 16 in N C nut B Compress retainer and install into the spline of the piston block C Position the head end of pins towards the inside
131. ecommended for ambi ent temperatures consistently below 100 F ISO type 46 68 anti wear hydraulic fluid Mobil Mobil Fluid 424 Amoco Amoco 1000 International Harvester Hy Tran Texaco TDH Shell Donax TD Union OII Hydraulic Tractor Fluid Chevron Tractor Hydraulic Fluid BP Oil BP HYD TF Boron OII Eldoran UTH Exxon Torque Fluid Conoco Power Tran 3 Kendall Hyken 052 Phillips HG Fluid Note The fluids within this group are interchange able Group 2 Hydraulic Fluid Biodegradable ISO VG 32 46 anti wear hydraulic fluid Mobil EAL 224 H IMPORTANT Due to the nature of biodegradable fluids it is critical that the fluid be changed at the recommended intervals or severe hydraulic compo nent damage may occur Note The fluid in this group is not compatible with the fluids in group 1 IMPORTANT These hydraulic fluids are specified to allow optimal operation of the machine in a wide range of temperatures encountered The group 1 fluids are a multi viscosity hydraulic fluids which allows operation at lower temperatures without the increased viscosity that is associated with straight viscosity fluids Note When changing from one type of hydraulic fluid to the other be certain to remove all the old fluid from the System because some brands of one type are not com pletely compatible with some brands of the other type of hydraulic fluid Reelmaster 2300 D 2600 D Page4 5 Figure 6 1 Hydraulic reservoir cap 2 Sigh
132. ed 11 89 V 0 charged Battery Charge Level Fully charged 100 75 charged Start the engine and run at 3200 RPM Allow the battery to charge for at least 3 minutes Record the battery volt age Test results should be example At least 0 50 volt over initial battery voltage 12 30v 12 80v 0 50 v Initial Battery Voltage Battery Voltage after 3 Minute Charge Difference instructions Set the multimeter on the volts scale With the key off or Glow Switch in the OFF position place the current transducer around the main glow plug power supply wire s and read the meter prior to activating glow plug system Adjust the transducer to read zero if applicable Cycle the glow plug system at least two times per instructions in Operator s Manual and record the final results The Reelmaster 2300 D glow plug system should have a reading of about 21 Amps Electrical System o of 0 4 o0 9 Lu Starting System Test This is an excellent test to use when a slow crank no start problem is encountered It will tell you if the prob lem is due to an electrical open short or high resistance in the starter circuit NOTE The Battery condition and state of charge must checked before testing the starter system Tool s required Digital multimeter and or AC DC current transducer Hall Effect Test instructions Properly connect current transducer to the digital multimeter refer to manufac
133. ee Adjustments section Tighten lock nut 21 and torque from 60 to 70 ft 1b 8 3 to 9 7 kg m 14 Remove plug from the hydraulic reservoir Reelmaster 2300 D 2600 D Cap screw Charge pump adapter assembly Gerotor assembly Bearing Valve assembly Valve plate Screw Trunnion cover O ring cover O ring Washer Inner race Bearing 14 Bearing SPA PONS ch ch O sch ON Disassembly Fig 24 1 Position pump into a vise with protected jaws so the charge pump drive shaft is pointed up Clamp onto the mounting flange of the traction pump COUPLER OUTER RING INNER RING Figure 24 Housing assembly Seal cover Shaft seal Dowel pin Key Camplate Plug Spring Seat Gasket Backplate assembly O ring Cap screw Bearing Rotating parts kit Key Drive shaft Retaining ring Bearing race Thrust bearing Washer Shaft seal Retaining ring O ring O ring O ring 4 Remove outer ring from either the inner ring of the gerotor assembly 3 or the charge pump adapter as 2 Remove cap screws 1 and 27 and slide charge pump adapter assembly 2 from the backplate assem bly 25 clear of the shaft 31 and gerotor assembly 3 3 Remove O ring 26 from the charge pump adapter assembly 2 Reelmaster 2300 D 2600 D Page 4 39 sembly 2 Further disassembly of the gerotor assem bly is not necessary Hydraulic System
134. eelmaster 2300 D 2600 D 3WD Rear Wheel Removal Fig 31 1 Before removing any parts from the hydraulic sys tem park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Clean wheel motor 1 and hydraulic connection Put caps or plugs on any hydraulic lines or fittings left open or exposed Figure 31 3 Remove wheel and wheel hub from unit see Repair 9 section of Chapter 6 Wheels and Brakes le MES motor 5 Cap screw 2 Hose connection 6 Lock nut V 3 Hydraulic fitting 7 Rear wheel fork 4 Disconnect hose connection 2 from hydraulic fit 4 O ring 8 O ring tings 3 Remove O ring 4 Allow hydraulic oil to drain from the hose into a suitable container 5 Support wheel motor 1 Remove four cap screws 5 and lock nuts 6 from the rear wheel fork 7 Pull wheel motor from the rear wheel fork 6 Remove hydraulic fitting 3 and O ring 8 from the wheel motor 1 Rear Wheel Installation Fig 31 1 Place and support wheel motor 1 into the rear wheel fork 7 Insert four cap screws 5 through the rear wheel fork and wheel motor 2 Tighten lock nuts 6 onto cap screws 5 3 Install hydraulic fitting 3 and O ring 8 onto the wheel motor 1 Tighten hydraulic fit
135. embly Knob Jam nuts Indicator plate Detent plate Set screw Spring 2 per assembly Indicator plate Reelmaster 2300 D 2600 D Solenoid Valve Fig 58 1 Make sure the manifold is clean before removing the spool valve 8 2 Remove the spool valve 8 A Remove the nut 11 from the spool valve 8 D Remove the solenoid coil 10 and both O rings 9 Note Use care when handling the spool valve slight bending or distortion of the stem tube can cause binding and malfunction C Remove spool valve 8 with a deep socket wrench Remove seal kit 7 3 Visually inspect the port in the manifold 22 for damage to the sealing surfaces damaged threads and contamination 4 Visually inspect spool valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunc tion B If spool valve 8 sealing surfaces appear pitted or damaged the hydraulic system may be overheat ing or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 Clean spool valve 8 using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Use a probe to push the internal spool in and out 20 to 30 times to flush out contamination Particles as fine as talcum powder can affect the operation of high
136. emove spring pin 6 and ball 4 from the spool 5 being careful no to scratch or damage the spool Also be careful not to drop the ball 8 Remove back up rings 7 and O rings 8 from the valve housing with a hooked scribe or thin screw driver Be careful not to scratch the bore surface Reelmaster 2300 D 2600 D Page 4 55 11 Boot 12 Set screw 13 Valve stop 14 Lock washer 15 Knob Inspection Fig 52 A CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts with compressed air 2 Inspect spool 5 for bending and flatness Signs of wear on one side of the spool may indicate it s bent Re place a worn or damaged spool if necessary 3 Inspect parts for wear or damage and replace if necessary Reassembly Fig 52 1 Coat all new O rings and back up rings with hy draulic oil Install new O rings 8 and new back up rings 7 into the bore of the valve housing 9 2 Install ball 4 and spring pin 6 into the spool 5 so the ball is held in by the pin Make sure both ends of the spring pin are flush with the sides of the spool 3 Carefully install boot 12 onto the valve stop 13 Hydraulic System A If the valve stop 13 and set screw 7 did not separate during disassembly screw them into the spool 5 and torque valve stop from 85 to 100 in lb B Ifthe valve stop 13 and set screw 7 separated during disassembly
137. ers or other appropriate turning device Rotate coupling shaft drive link 13 and rotor 19 to seat the rotor and the assembled vanes 20 into the stator 21 This rotation should create the nec essary clearance to assemble the seventh or re maining vanes Use minimum force when assembling the remaining vane s F Remove the two assembled bolts 14 if used to retain stator and wear plate Note The manifold 22 is made up of several plates bonded together permanently to form an integral com ponent The manifold surface that must contact the rotor set has it s series of irregular shaped cavities on the larg est circumference or circle around the inside diameter The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set 15 Apply clean grease to a new seal ring 5 and as semble it in the seal ring groove in the rotor set contact side of manifold 22 16 Assemble the manifold 22 over the alignment studs and drive link 13 and onto the rotor set Be sure the correct manifold surface is against the rotor set 17 Apply grease to a new seal ring 5 and insert it in the seal ring groove exposed on the manifold 22 18 Assemble the commutator ring 6 over alignment studs onto the manifold 22 Fig 48 19 Assemble a new commutator seal 15 flat side up into commutator 16 and assemble commutator over the end of drive link 13 onto manifold
138. erse Noisy reel motor drive pump cavita Reservoir oil level is low tion Suction line is restricted Suction line has an air leak Reels will not turn Cross over relief valve s are stuck open The other reels will still rotate Valve S1 is stuck open An electrical problem exists See Chapter 5 Electrical System Relief valve R1 is stuck open LC1 logic valve is stuck open Reel motor drive pump is damaged Reel speed is erratic Reel to bedknife adjustment is too tight Reel bearing s are damaged Reel motor case drain flow is exces Excessive internal wear in wheel motor exists sive Flow is greater than 0 7 GPM at 1200 PSI 2 6 LPM at 82 8 bar Reel bearing s are damaged Cutting units will not lift or lift slowly Engine speed is too low Pump pulley drive belt is loose Charge pump is damaged Lift valve control linkage is binding or broken Lift cylinder bushings bind Reservoir oil level is low Inlet filter is loose or clogged Charge pump pressure or flow is insufficient Implement relief valve is stuck open Lift control valve is damaged Lift cylinders leak internally Cutting units raise but will not stay Lift cylinders leak internally up Lift valve leaks Hydraulic System Page 4 18 Reelmaster 2300 D 2600 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
139. follows see Fig 26 A Remove nine piston assemblies spider and spi der pivot from the piston block A CAUTION Be careful when removing the spring from the piston block the spring is highly compressed Safely compress the spring before removing the retaining ring Hydraulic System Page 4 40 SPRING RETAINER SPRI dme CUP POPPET SUCTION PORT BEARING CHARGE PUMP ADAPTER ASSEMBLY Figure 25 VALVE PLATE END WASHER O YR En SS PISTON ASSEMBLIES CAMPLATE END Figure 26 B Use the following parts to disassemble the pis ton block 2 5 16 in I D x 15 16 in O D flat washers 1 5 16in x 2 7 8 in N C cap screw 1 5 16 in N C nut C Place cap screw through one of the flat washers Insert cap screw through the center of the piston block Install second flat washer onto the capscrew so the washer rests on the three pins Screw nut onto the cap screw D Compress spring by tightening the nut onto the cap screw Remove the retaining ring from the pis ton block E Slide washer spring second washer three pins and retainer from the piston block Reelmaster 2300 D 2600 D 13 Remove retaining ring 37 from the bore on the flange end of the housing assembly 15 Press the shaft 31 shaft seal 36 and washer 35 from the housing assembly 14 Remove retaining ring 32 washer 35 thrust bearing 34 second washer 35 and second retaining ring 32 from
140. for Reel Drive Pump Efficiency Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes 2 Make sure machine is parked on a level surface with the cutting units lowered Make sure engine is off and the parking brake is engaged 3 Make sure the hydraulic tank is full A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 4 Clean hose connection and reel drive pump Dis connect hose connection on the reel drive pump leading port P1 on the hydraulic manifold IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump through the tester and into the valve block Reelmaster 2300 D 2600 D Page 4 27 5 Install tester in series with reel drive pump and the disconnected hose leading to port P1 of the hydraulic manifold Make sure the flow control valve is fully open 6 Make sure backlap knob on the valve block is in the mow position 7 Make sure tester load valve is fully before starting the engine 8 Start engine and move throttle to full speed 3200 100 RPM Do not engage the cutting units 9 Watch pressure gauge carefully while slowly clos ing the flow control valve until 1500 PSI is obtained Verify with a phototac that the pump speed is 2900 RPM 10 Flow indication should be 5 4 GPM minimum 11 Shut off engine
141. from dropping when the bearing housings are removed Cutting Units 4 Male coupling LH 5 Male coupling RH 6 Capscrew Page 7 22 7 Bearing housing 8 Bearing 9 Reel 6 Remove capscrews from both bearing housings Pull bearing housings and bearings from reel 7 Rotate bearings within the bearing housings and remove bearings from both bearing housings through the loading grooves 8 Remove reel from cutting unit Inspect Reel 1 Replace reel if the diameter has decreased to the service limit see Reel Grinding Specification in Prepar ing Reel For Grinding 2 Replace reel if blades are bent or cracked 3 Check for a bent reel shaft by placing the reel shaft ends in V blocks Replace reel if the reel shaft is bent Reelmaster 2300 D 2600 D Install Reel 1 Inspect bearings and replace if worn or damaged 2 Make sure bearing seating surfaces and threads on reel shaft ends are clean Apply anti seize lubricant to both bearing seating surfaces 3 Align reel inside the cutting unit with the bearing housing holes The reel must be positioned so that the grooved end of the shaft left hand threads is on the left side of the cutting unit Fig 26 4 Clean inside of the bearing housing before instal ling 5 Install bearing into bearing housing as follows A Load bearing through loading grooves B Position bearing so its outer grease holes will be 90 to the loading grooves C Rotate bear
142. fthe control valve to the lower and outer portions of the Hydraulic System Page 4 8 lift cylinders Hydraulic pressure against the cylinder pistons pushes the shafts out Atthe same time the pis tons push the hydraulic fluid in the upper and inner por tions ofthe lift cylinders out and through the control valve tothe piston pump suction When the control valve lever is released spring action returns the spool to the center position and by passes flow back to the piston pump suction Lift cylinder movement is stopped The cylinder position is locked in place since there is no complete cir cuit of flow to and from the lift cylinders Circuit operation for lowering the lift cylinders is similar to raising them However the control valve spool is shifted up and flow is reversed to and from the lift cylin ders thus moving the cutting units down Reelmaster 2300 D 2600 D MIS
143. g 7 Body 14 Snap ring 3 Install spring retainer 10 spring 11 spacer 12 other spring retainer 10 and spool snap ring 13 onto the spool 8 Install snap ring 14 into the valve body 7 4 If check valve seat b was damaged and removed press fit it into the valve body 7 5 Install campin 6 ball 4 and spring 3 Place new O ring 2 on plug 1 and install them into the valve body 7 Tighten plug 1 6 Repeat steps 4 and 5 for the other plug 1 and valve assembly Reelmaster 2300 D 2600 D Hydraulic Reservoir Shoulder screw Sight glass Hose clamp Barb fitting Flange nut Cap assembly Filler screen Hydraulic tank Tank bracket SAND NS Reelmaster 2300 D 2600 D Figure 67 Grommet Flat washer Cap screw Carriage screw Hose clamp Hydraulic hose Hydraulic fitting U bracket support Cap screw Page 4 77 Hydraulic hose Oil filter element Oil filter head 90 fitting Hydraulic hose Hydraulic hose Hydraulic hose O ring Hydraulic fitting Hydraulic System Inspecting Reservoir Parts Fig 67 4 Make sure cap screws 12 are secure If loose re move and reinstall cap screws with loctite 1 Clean tank 1 and filler screen 7 with solvent 5 Make sure all bracket fasteners are tight 2 Inspect tank 1 for leaks cracks or other damage 3 Replace hydr
144. g Fig 20 7 Install adjusting handle on the cutting unit by screw ing it in Fig 19 8 Apply Never Seize to both hex socket set screws Seat both hex socket set screws into the bedbar yoke and tapered seats of the pivot hub with a slight preload Fig 19 Cutting Units Page 7 16 Figure 19 4 Bedbar yoke 5 Cutting unit 6 Pivot hub Adjusting handle Jam nut Hex socket set screw on Figure 20 3 Carriage bolt and nut 1 Adjusting lock nut 2 Adjusting housing 9 Tighten jam nuts onto the hex socket set screws The handle should be centered within the bedbar yoke The handle should turn freely with a good solid clicking action 10 Adjust bedknife to reel see Bedknife to Parallel to Reel Adjustment Reelmaster 2300 D 2600 D La ge W I Figure 21 1 Carriage bolt and nut 6 Flat washer 2 Bedbar housing 7 Spacer 3 Bedbar 8 Bedbar washer 4 Capscrew 9 Adjusting housing 5 Lock washer Reelmaster 2300 D 2600 D Page 7 17 10 Bushing assembly 11 Flanged bushing 12 Bedknife screw 13 Bedknife 5 E d Cutting Units Bedknife Replacement and Grinding Fig 22 and Fig 23 1 Remove bedbar from cutting unit see Bedbar Re moval and Installation 2 Remove bedknife screws and remove bedknife 3 Remove all rust scale and corrosion from bedbar surface before installing new bedknife 4 Install new bedknife A Make sure bedbar threads are clean
145. h shuttle valve on left front motor 2000 PSI 138 bar 3000 PSI 207 bar 267 RPM 15 GPM 57 LPM Reel Motor Drive Pump Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow Maximum Rated Speed and Pressure Positive displacement gear type pump 4000 PSI 276 bar 4400 PSI 304 bar 4000 RPM 8 5 GPM 32 LPM Hydraulic Manifold Relief Valve Cutting Circuit Relief Pressure Differential area relief valve 2700 to 3300 PSI 186 3 to 227 7 bar Reel Motor Cross over Relief Pressure Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow Maximum Rated Speed and Pressure Gear motor 1350 to 1650 PSI 93 2 to 113 9 bar 2250 PSI 155 bar 3000 PSI 207 bar 3000 RPM 28 6 GPM 108 LPM Lift Control Valve Spool type directional control valve Hydraulic Filter 10 Micron spin on cartridge type Hydraulic Oil Mobil 424 Shell Donax TD or equivalent Hydraulic Reservoir Reservoir capacity 2 3 gal U S 8 7 L Total system capacity approximately 3 3 gal U S 12 5 L Hydraulic System Page 4 2 Reelmaster 2300 D 2600 D 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 ca
146. hapter 4 Hydraulic System 10 Secure the U bracket support to the frame using the carriage bolts and nuts Place the two capscrews Electrical System Page 5 32 through the flat washers and grommets apply loctite to capscrew threads Secure the hydraulic tank to the U bracket support with the two capscrews Fig 29 11 Attach the dampener to the traction pedal and U bracket support Fig 27 Adjust the traction pedal see Adjustments section of Chapter 4 Hydraulic System 12 Replace and secure panels to the unit Reconnect the fuel solenoid Figure 30 1 Longcapscrew 7 Clutch 13 Flat washer 2 Jamnut 8 Capscrew 14 Key 3 Clutch spindle 9 Lock washer 15 Wire bracket 4 Flywheel 10 Pulley 16 Pop rivet 5 Capscrew 11 Capscrew 17 Flat washer 6 Flat washer 12 Lock washer Figure 31 2 Armature 1 Rotor Reelmaster 2300 D 2600 D Chapter 6 Wheels and Brakes Table of Contents SPECIFICATIONS 0 000 eee ee eee eee 2 SERVICE AND REPAIRS sueuuu 4 ADJUSTMENTS 3 re RE ER fe 3 Rear Wheel GW 4 Hand Brake Adjustment aa 3 Rear Wheel GW 5 Front Wheel and Brake 6 E E Dx D S Er e Reelmaster 2300 D 2600 D Page 6 1 Wheels and Brakes Specifications Item Description Front tire pressure 12to 16 PSI 0 83 to 1 10 bar Rear tire pressure 2 ply Older models 8 to 10 PSI 0 55 to 0
147. have the grease fittings lo cated on the outside portion of the bearing housing 1 The grease fitting locations and quantities are A Bedknife adjuster 2 Fig 11 Grease these fit tings every 50 hours Figure 12 B Reel bearings inside sideplate 2 and front and rear rollers 2 ea Fig 12 Grease these fit tings every 8 hours IMPORTANT Lubricating cutting units immediately af ter washing helps purge water out of bearings and in creases bearing life 2 Wipe each grease fitting with a clean rag 3 Apply grease until pressure is felt against the han dle 4 Wipe excess grease away Figure 11 5 E 3 Reelmaster 2300 D 2600 D Page 7 11 Cutting Units Backlapping A DANGER TO AVOID PERSONAL INJURY OR DEATH e Never place hands or feet in reel area while engine is running e While backlapping reels may stall and then restart e Do not attempt to restart reels by hand or foot e Do not adjust reels while engine is running e f reel stalls stop engine before attempting to clear reel e Reel motors are connected in series moving one motor moves the other two 1 Position machine on a clean level surface lower the cutting units stop the engine engage parking brake and remove key from the ignition switch 2 Unlatch and raise hood to expose the controls 3 Rotate backlap knob on valve block clockwise to backlap position Rotate reel speed knob to position 1
148. he housing assembly 15 13 If necessary press new bearing 4 or roll pin into backplate assembly 25 to the dimension shown in Fig ure 28 Bearing should be installed with numbered end outward Roll pin should be installed with split oriented away from the bearing Reelmaster 2300 D 2600 D 14 Install seat 23 and spring 22 into backplate 25 Install new O ring 40 and plug 21 into the backplate assembly Torque plug from 95 to 105 ft lb 13 1 to 14 5 kg m 15 Install new O rings 38 and 39 and valve assembly b into the backplate assembly 25 Torque valve as sembly from 27 to 30 ft lb 3 7 to 4 1 kg m 16 Coat valve plate 6 with light coat of petroleum jelly on the steel side Align the valve plate to the roll pin on the backplate 25 Install steel side of the valve plate to the backplate 17 Install backplate assembly 25 to the housing as sembly 15 Make sure gasket 24 valve plate 6 and dowel pins 18 stay in place 18 Install inner ring and coupler of gerotor assembly 3 into the backplate assemble 25 so that the V groove on the coupler end enters the backplate assembly first Lubricate the inner ring of the gerotor Reelmaster 2300 D 2600 D Page 4 43 19 Reassemble charge pump adapter assembly 2 as follows see Fig 25 A Install cup poppet spring and spring retainer into the charge pump adapter assembly B Torque retainer from 5 to 7 ft lb 0 7 to 1 0 kg
149. he num ber 5 Simultaneously tighten upper jam nut 26 and turn knob so it is tight and the arrow is pointing at the number 1 on the locating plate 16 J On spool two position directional valve 18 turn knob 25 counterclockwise so the arrow is 90 with the back of the manifold body 22 Simulta neously tighten upper jam nut 26 and turn knob so itis tight and the arrow is pointing 45 to the right in line with the indicator plate 31 Reelmaster 2300 D 2600 D Front Lift Cylinder INSTALL FLANGE BUSHING 18 FROM THE INSIDE A pa Figure 59 1 Hose connection 8 Lift cylinder 15 Clevis 2 Hose connection 9 Cotter pin 16 Cylinder guide 3 Hose connection 10 Clevis pin 17 Cylinder support bracket 4 Hose connection 11 Cap screw 18 Flange bushings 5 Hydraulic fittings 12 Lift hub 19 Valve mount bracket 6 O ring 13 Cotter pin 20 Clevis 7 O ring 14 Clevis pin Reelmaster 2300 D 2600 D Page 4 67 Hydraulic System Removal Fig 59 1 Before removing any parts from the hydraulic man ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Raise and remove hood to get access to the front lift cylinder Label all connections for reassembly 3 Disconnect hose co
150. he open side of the E seal 5 over the rear bearing block 13 Slide the gear housing down over the gears and front bearing block 14 8 Make sure the rear bearing block 13 face sits just below the back face of the gear housing 3 If the rear bearing block sits higher than the rear face of the gear housing remove the gear housing Check that the E seal 5 backup ring 4 or O ring 6 did not shift out of place during assembly 9 Placethe remaining two dowel pins 7 into the rear of the gear housing 3 Align matchmarks and set end cover 8 on the rear of the gear housing 10 Insert the four bolts 9 through the bolt holes in the end cover 8 and gear housing 3 Hand tighten each bolt and torque to 40 ft lb 5 5 kg m 11 Place a small amount of oil in the inlet of the pump rotate the drive shaft away from the inlet one revolution If the drive shaft binds disassemble the pump and then reassemble it The pump is ready for use Hydraulic System Reel Motor Removal Fig 55 1 Before removing any parts from the hydraulic man ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Remove reel motor from cutting unit see Repair section of Chapter 7 Cutting Units 3
151. ia a3u ANAL R 3NION3 9m e I m 3NION3 VOL amas MOTA MOTA 29v VOI 3ONYHO NISUS EET N3399 SEIN VOZ DEVHO Ge Av134 NMOQINHS fog Les a lt HOLIMS AWIL HOIH JUHM NMOQLNHS dW3LH9IH iNId 1 ION310S qu 18 ve 08 9 w HILUVIS Audllv8 PIE 3 ANIONS wa Ez 9 1 lt 8 S i EISE E ai gt ADV 18 m m Q3 ovia E v OUT DW 08 6 MOTD 48 gV28 438 2 entwert SHIM Zi OW 0 0S LHVIS AN IO NN 2 YALYVLS gt ANN 371814 Ov 0 NO E 2 HOLIMS NOLLINOI aay gt va gt aai1ovulau SI 3ONITAO N3HM d3SO19 Y N3dO ATIYWHON HOLIMS NOOTHILNI NNY O1 G3ZIDYANA Es TNR Ge z GION310 S I ANIYA land ddund S 3ONvHO ova m a m 31dund x9v18 038 3IIHW3ONVHO vg Z N33H5 INIVA GIONITOS ONISNOH Quvoa s pova 31dund m LINA ove HOLO3NNOO LINOHID NV49vIa ovi8 3aoid 3aoia 30010 sora X385 Wee 3IIHWSONVHO 1V3S NI HOLVHAdO HIM OSC NO Xov18 v anve Y Y HOLIMS 8l dive El ET N3dO ATIVINEON TINA ovi8 9 live D g e a 3lg e y HOLIMS NOOTHILNI 1V3S ONILIND Xidundg imp 3ONVHO uaidiLo3u do1vino3u IWS idund Ho g 4 LIHW3 dtiNd 39VI10 gt 3 NnoH5 E El a VW 5innowa bi D X0v18 XOVIS A3HO AMM nouo HI H NOLLISOd TWHLNAN NI OSCH a HOIVNH3 LIV ova NadO ATIYWHON e o ama N3349 l HOLIMS MOOTHALNI NOLLOVEL A349 Wl NOY TH A34O OY Sovia MOTA lt NOLLISOd MOM NI NMOHS ge 3ma an HOLIMS dv ova
152. ifications Use these torque values when specific torque values specified values Torque values listed are for lubricated are not given DO NOT use these values in place of threads Plated threads are considered to be lubricated Capscrew Markings and Torque Values U S Customary SAE Grade Number 8 Capscrew Head Markings ec ZO Capscrew Torque Grade 5 Capscrew Torque Grade 8 Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum Nm ft lb Nm Nm ft lb Nm 1 4 20 9 6 8 15 9 12 28 12 7 9 18 10 14 5116 18 20 12 16 30 18 24 24 23 14 19 33 19 25 3 8 16 40 20 25 55 30 40 24 40 25 35 60 35 45 7 16 14 60 35 45 90 50 65 20 65 40 55 95 55 75 1 2 13 95 55 75 130 75 100 20 100 60 80 150 90 120 9 16 12 135 80 190 110 150 18 150 85 210 125 170 5 8 11 180 255 150 205 18 210 290 170 230 3 4 10 325 460 270 365 16 365 515 300 410 7 8 9 490 745 440 600 14 530 825 490 660 1 8 720 1100 660 890 14 800 1200 710 960 Capscrew Markings and Torque Values Metric Commercial Steel Class 8 8 Capscrew Head Markings Thread Capscrew Torque Class 8 8 Capscrew Torque Class 10 9 Capscrew Torque Class 12 9 Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum mm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm 5 9 4 7 9 14 7 11 9 14 7 11 9 14 7 11 14 18 11 14 18 23 18 18 25 14 18 23 32 18 25 27 36 28 30
153. ign lift hub 12 holes with the slots on the cylinder support bracket 17 Install flange bushings 18 into the cylinder support bracket slots 5 Make sure flange bushings 18 are aligned with the lift hub 12 holes Slide cylinder guide 16 through the cylinder support bracket 17 flange bushings 18 and lift hub 12 6 Secure cylinder guide 16 by screwing cap screw 11 fully into lift hub 12 7 Secureclevis 15 tothe cylinder guide 16 with cle vis pin 4 and cotter pin 13 8 Slideclevis pin 10 through the valve mount brack et 19 and lift cylinder 8 Install and lock cotter pin 9 into the clevis pin 9 Install hydraulic fittings b and O rings 7 into the lift cylinder 8 10 Remove caps or plugs from disconnected hoses Connect hose connections 1 2 3 and 4 to hy draulic fittings 5 Tighten hose connections Reelmaster 2300 D 2600 D Figure 60 1 retaining ring 5 O ring 2 O ring 6 Shaft 3 Head 7 O ring 4 Backup washer 8 Piston Disassembly Fig 60 1 Remove oil from the cylinder into a drain pan by slowly pumping the cylinder shaft 6 Plug both ports and clean the outside of the lift cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the pivot only Do not close vise enough to distort barrel 11 2 Mount lift cylinder in a vise so that the shaft 6 end tilts up slightly Remove and discard dust seal
154. ilter 12 ADJUSTMENTS 22222 7 Checking the Cooling System 12 Alternator Belt c cece eee eee 7 Engine Removal 13 Throttle Linkage 0 0 cece eee eee 8 Engine Reinstallation 18 PERKINS 100 SERIES WORKSHOP MANUAL Reelmaster 2300 D 2600 D Page 3 1 Engine Introduction This Chapter gives information about specifications maintenance troubleshooting testing and repair of the diesel engine used in the Reelmaster 2300 D 2600 D mower Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Special Tools section The use of some specialized test equipment is explained How Engine Page 3 2 ever the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Perkins engines are sup plied through your local Perkins Detroit Diesel dealer If no parts list is available be sure to provide your dealer or distributor with the Perkins model and serial number Reelmaster 2300 D 2600 D Specifications Item Description Make Designation Perkins vertical in line 4 stroke water cooled Diesel 103 07 KL 70275 amp KL 70372 Combustion Chamber IDI special swirl combustion type Number of Cylinders Bore x Stroke mm in 67 x 64 2 64 x 2 52 Total D
155. ing inside of the housing so the ex tended part of the inner race is facing the inside of the housing 6 Side the bearings and bearing housings onto the reel shaft 7 On earlier production models make sure bearing housings are installed with the grease fittings pointing to the front of the cutting unit Reelmaster 2300 D 2600 D Page 7 23 8 Secure bearing housings and bearings on the reel shaft ends and cutting unit with the capscrews Alternate evenly between capscrews when when tightening 9 Degrease threaded end of male couplings and reel shaft Make sure grease is completely removed A Apply removable Loctite 242 or equivalent to the threads B Do not get Loctite on the bearing seal 10 Screw male coupling RH from the reel This cou pling is right hand threaded 11 Screw male coupling LH from the reel This cou pling is left hand threaded 12 Torque both couplings from 55 to 65 ft lb 7 6 to 9 0 kg m 13 Install front roller to cutting unit see Roller Removal and Installation 14 Install bedbar assembly to cutting unit see Bedbar Removal and Installation 15 Complete cutting unit set up and adjustment se quence see Adjustments section 16 Grease both bearings see Greasing Bearings Bushings and Pivot Points Cutting Units 5 E 3 Preparing a Reel for Grinding Note Check to make sure reel bearings are in good condition and properly adjusted before grinding reel
156. ions of diode failure may be the failure or repeated failure seat interlock switch Testing The diodes can be individually tested using a digital multimeter ohms setting and the table to the right Electrical System Page 5 22 DIODE DIAGRAM Figure 15 gt elei ei mia e DIODE CIRCUIT BOARD Figure 16 Red Lead Black Lead on on Continuity Terminal Terminal Ko pa pos ENS UNE PERE E m EC ERG O 9 s 1 3 Reelmaster 2300 D 2600 D Fuel Valve Solenoid The fuel valve solenoid must be energized for the en gine to run It is mounted on the engine block next to the injection pump and has a purple wire attached to it In Place Testing Note Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 1 Disconnect the wire from the solenoid Figure 17 e D ut C4100 9810n83 2 Using a digital multimeter ground one lead to the engine block and connect the other to the solenoid ter minal TERMINAL PLUNGER 3 The resistance should
157. irty side C Dry filter element 4 using warm flowing air 160 F maximum or allow element to air dry Do not use a light bulb to dry the filter element because damage could result Compressed Air Method A CAUTION Use eye protection such as goggles when using compressed air A Blow compressed air from the inside to the out side of the dry filter element 4 Do not exceed 100 psi to prevent damage to the filter element Engine Page 3 10 Figure 12 3 Latch 4 Filter element 1 Air cleaner body 2 Air cleaner cover B Keep air hose nozzle at least 2 inches from the filter element 4 Move nozzle up and down while rotating the filter element Inspect for holes and tears by looking through the filter element toward a bright light 7 Inspect new filter element 4 for shipping damage Check sealing end of new or used filter element Do not install a damaged filter element 8 Insert filter element 4 properly into the air cleaner body 1 Make sure filter element is sealed properly by applying pressure to the outer rim of the filter element when installing Do not press onthe flexible center of the filter element 9 Reinstall air cleaner cover 2 and secure latches 3 Make sure cover is positioned with top side up Reelmaster 2300 D 2600 D Cleaning the Radiator and Screen To prevent the engine from overheating the radiator screen radiator and oil cooler must be kept clean Check these
158. isplacement cc cu in 676 41 23 Compression Ratio 24 1 Firing Order 1 2 3 Dry Weight approximate kg Ib 64 141 Fuel Grade No 2D diesel fuel ASTM specification Fuel Injection Pump Bosch type plunger Governor Mechanical ldle Speed no load 1400 50 RPM High Idle no load 3200 50 RPM Fuel Injector Nozzle Bosch throttle type Fuel Injection Working Pressure kg cm psi 115 to 125 1636 to 1778 Injection Timing 28 5 to 30 5 B T D C Engine Oil SAE 10W30 SF CD Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 2 8 3 0 with filter Water Pump Belt driven centrifugal type Cooling System Capacity liter U S qt 4 7 5 0 Starter 12 VDC 1 2KW Alternator Regulator 12 VDC 14 AMP Glow Plug Sheathed type Reelmaster 2300 D 2600 D Page 3 3 Engine Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE Commercial Products Filter Cleaner Mix with water and use solution to wash the Donaldson air cleaner element Diesel Engine Compression Test Kit This O to 1000 PSI gauge allows testing of diesel en gines for checking the general operating condition ofthe engine The kit includes a case gauge with hose glow plug hole adapters and instructions Nozzle Tester This tests the condition and opening pressure of fuel in jection nozzles Engine
159. it Board 22 Starting Problems 10 Fuel Valve Solenoid uuu 23 General Run and Transport Problems 12 Cutting Unit Solenoid Valve Coil 23 Cutting Unit Operating Problems 13 Traction Electric Clutch 24 Verify Interlock System Operation 14 Traction Neutral Interlock Switch 24 ELECTRICAL SYSTEM QUICK CHECKS 15 Seat Interlock Switch 25 Battery Test Open Circuit 15 Cutting Unit Interlock Switch 26 Charging System Test 15 Backlap Switch 26 Glow Plug System Test 15 SERVICE AND REPAIRS susus 27 Starting System Test 16 Battery Service 27 Cutting Unit Solenoid Valve Coil 30 Traction Electric Clutch 31 Reelmaster 2300 D 2600 D Page 5 1 Electrical System o of 0 a 1 o0 9 Lu Wiring Schematics oneuieuos 291119913
160. it voltage or specific gravity Level Voltage Gravity 100 12 68 1 265 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Reserve Battery Charge Level Capacity Percent of Fully Charged eee 80 or less 3 8 hrs 7 5hrs 11 3hrs 15 hrs 3 amps 3 amps 3 amps 3 amps 81 to 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs o o 4amps 4amps 4 amps 4 amps 126 to 5 5 hrs 11 hrs 16 5 hrs 22 hrs 170 5 amps 5amps 5 amps 5 amps 171 to 5 8 hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Reelmaster 2300 D 2600 D Page 5 29 A CAUTION Do not charge a frozen battery because it can explode and cause injury Let the bat tery warm to 60 F 15 5 C before con necting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and electrical spark away from the battery Do not smoke Nausea may result if the gases are in haled Unplug the charger from the elec trical outlet before connecting or discon necting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following
161. ke bracket 25 10 Remove rust from all parts with a wire brush prior to installation Clean all parts Inspect brake shoe contact surfaces of the brake drum for excessive wear Replace any worn or damaged parts Reelmaster 2300 D 2600 D Page 6 7 Installation 1 Secure flat washers 14 grass brake shield 15 and brake plate 44 to the brake bracket 25 with the hex head screws 16 and lock nuts 13 Tighten fasten ers 2 Connect brake lever assembly 32 to the clevis 33 Install clevis pin 31 through the brake lever as sembly and clevis Install and lock cotter pin 27 into the clevis pin 31 3 Install brake shoes 17 onto the brake plate 44 Install extension springs 42 into the holes on each end of the brake shoes Springs should be installed in oppo site directions of each other 4 Mountkey 49 in the wheel motor shaft then install the wheel hub 18 and the brake drum 19 onto the wheel motor shaft 5 Install the lock nut 40 onto the wheel motor shaft and tighten to torque of 250 to 400 ft lb 34 6 to 55 3 kg m 6 Adjust and check brakes 7 Install tire and wheel assembly items 20 and 21 and secure the lug nuts 22 to the wheel hub studs 23 Tighten lug nuts evenly in a crossing pattern to a torque of 45 to 65 ft lb 6 22 to 8 98 kg m Wheels and Brakes E E ag og o e Wheels and Brakes Page 6 8 Reelmaster 2300 D 2600 D Chapter 7 Cutting Units Tabl
162. ld IMPORTANT Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the hose through the tester and into the motor 5 Install tester in series with the hose and motor Make sure the flow control valve is fully open 6 Make sure backlap knob on the valve block is in the mow position Make sure reel speed knob is set to posi tion 9 or greater A CAUTION Keep away from reels during test to pre vent personal injury from the rotating reel blades Reelmaster 2300 D 2600 D Page 4 29 7 Start engine and move throttle to full speed 3200 100 RPM Engage the cutting units 8 Watch pressure gauge carefully while slowly clos ing the flow control valve until the manifold relief opens 9 System pressure should be from 2700 to 3300 PSI A If specification is not met adjust relief valve B If this specification is met go to step 11 10 Adjusting the relief valve pressure as follows A Remove the cap from the relief valve B To increase the relief valve pressure set point use an allen wrench and turn set screw slightly clockwise C To decrease the relief valve pressure set point use an allen wrench and turn set screw slightly counterclockwise D Repeat steps 1 through 10 above until the relief valve pressure set point is correct Reinstall cap on valve when valve is set properly E If the relief valve pressure set point can not be adjusted to specification go t
163. le 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 fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Holdthe fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight F F F T Step 4 Size F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 Hydraulic System Page 4 4 Figure 3 Lock Nut Back up Washer O Ring Figure 4 Figure 5 Reelmaster 2300 D 2600 D Checking the Hydraulic System Fluid The hydraulic system is designed to operate on anti wear hydraulic fluid The machine s reservoir is filled at the factory with approximately 3 3 gallons 12 5 liters of Mobil 424 hydraulic fluid Check level of hydraulic fluid before engine is first started and daily thereaf ter Group 1 Hydraulic Fluid R
164. lic oil is supplied to the traction circuit from the charge pump though the lift control valve and back through the charge circuit check valves This fil tered oil replaces oil losses from flow through the shuttle valve and small amounts of leakage The charge pump and shuttle valve circuits allow for indirect cooling and filtering of the traction circuit In the forward direction the PC flow controller has a spe cial function When a unit is moving downhill the opera tor will return the traction pedal to the neutral position In this situation the front wheel motors act as hydraulic pumps and reverse the oil flow through the traction cir cuit The PC flow controller will restrict flow to the rear motor sufficiently so the reverse flow is by passed through the 2WD 3WD selector check valve around the rear wheel motor This action will prevent a loss of steering control should the rear motor turn in the reverse direction As a result there is no 3WD in reverse Reelmaster 2300 D 2600 D ooz gz Eu vg t x SHOLOW 1334 ISd 0051 33 1348 HHAO SSOHO SILVIW3HOS HOLOW 13938 kk r SLIVIN3HOS HOLON 133HM 1337 09 61 guizi uvau HOLON 133HM dol WOLLOS ame NI NMOHS HOL0313S OMEIOMG een IS poeziDuouo op isd 000 UMOUS SI LS piougjos m 33734 1 za 1334 D b lt Di 0 0 Wild sa b 9n PN H uonong J
165. ling it Do not smoke while filling the fuel tank Do not fill the fuel tank while the engine is hot running or when the in an enclosed area Always fill the fuel tank outside Wipe up any spilled diesel fuel before starting the engine Store fuel in a clean safety approved container with its cap on Use diesel fuel for the engine only and no other purpose 3 Open fuel shutoff valve 1 located under the fuel tank and on the fuel filter Fig 10 4 Open both bleed screws 2 located on the side of the fuel filter mounting head Allow bowl 3 to refill with fuel Close bleed screws when the bowl is filled Fig 10 5 On the front of the engine by the oil filter find trans fer pump inlet screw location 2 Note fitting angle 5 on the transfer pump inlet and loosen left transfer pump screw 1 only Fig 11 6 When asteady stream of fuel flows out of the trans fer pump screw 1 tighten screw and retain noted fitting angle 5 from step 5 above Fig 11 7 Loosen injection pump inlet screw 3 on the front of the engine Fig 11 8 Pump priming lever 4 until a steady stream of fuel flows out of injection pump inlet screw 3 then tighten screw Do not over tighten inlet screw Fig 11 Reelmaster 2300 D 2600 D Page 3 9 Figure 10 1 Fuel shutoff valve 3 Bowl 2 Bleed screws See Figure 11 Transfer pump screw Transfer pump inlet screw location Injection pump inlet screw Pri
166. lmaster 2300 D 2600 D Note Be ready to catch the shuttle valve or relief valve components that will fall out of the end cover valve cavity when the plugs are removed Note O ring 25 is not included in the seal kit but can be serviced separately if required Note Theinsertand if included the orifice plug in the end cover assembly 24 must not be removed as they are serviced as an integral part of the end cover 4 Ifthe end cover 24 is equipped with shuttle valve components left hand motor only remove both pre viously loosened plugs and O rings 25 5 Remove commutator ring 23 A CAUTION Use eye protection such as goggles when using compressed air 6 Remove commutator 16 and commutator seal 15 Remove commutator seal from the commutator using an air hose to blow air into the ring groove until the commutator seal is lifted out Fig 34 Note The manifold 22 is constructed of plates bonded together to form an integral component not sub ject to further disassembly for service Compare config uration of both sides of the manifold to make sure that same surface is reassembled against the rotor set 7 Remove manifold 22 Remove seal rings 5 that are on both sides of the manifold Note The rotor set consists of the rotor 19 vanes 20 and stator 21 Rotor set components may be come disassembled during service procedures Note Marking all rotor components and mating spline components f
167. lmaster 2300 D 2600 D Troubleshooting There are a number of factors that can contribute to un satisfactory 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 Remember that the effective or actual height of cut de pends on cutting unit weight and turf conditions Effec tive height of cut will be different than the bench set height of cut Factors That Can Affect Quality of Cut 1 Engine maximum governed speed 2 Reel speed and ground speed 3 Cutting unit counter balance tension adjustment 4 Tire pressure Reelmaster 2300 D 2600 D Page 7 5 Check maximum governed engine speed Adjust speed to specifications if necessary If engine is not running at specified maximum governed RPM reel speed settings may not match ground speed Adjust reel speed to setting shown on REEL SPEED SETTINGS graph for the number of reel blades 5 or 8 and the desired ground speed see Operator s Manual All reels should rotate at about the same speed All cutting units should have equal bedknife to reel contact If checking RPM do not run reel too long without cutting grass or bedknife and or reel may overheat and rifle See other items in Troubleshooting secti
168. lt Make sure pump belt is properly tensioned to assure proper operation of the machine and prevent unneces sary wear On new belts check tension after 8 hours op eration A new hydraulic pump belt should tensioned so it de flects 0 120 inch with a 15 to 17 pound load applied mid way in span of belt A used belt should tensioned so that it deflects 0 120 inch with a 11 to 13 pound load applied midway in span of belt Note Tighten belt to eliminate slippage squealing under load but do not overtighten 1 Tighten nut on adjustment rod until desired belt ten Figure 22 sion is attained 1 Nut 2 Adjustment rod Hydraulic System Page 4 36 Reelmaster 2300 D 2600 D Service and Repairs Traction Charge Pump Cap screw Reel motor drive pump O ring Traction charge pump Hose Hose Hydraulic fitting Hydraulic fitting Hose connection Hose connection Hose connection Hose connection O ring O ring Hydraulic fitting CEN PON s ch O Ana ORON Reelmaster 2300 D 2600 D Figure 23 Hydraulic fitting Hydraulic fitting Cap screw Flat washer Pump lever assembly Lock nut Pump mount Cotter pin Clevis pin Belt adjustment yoke Pump drive belt Pulley Cap screw Lock washer Page 4 37 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Tapered lock bushing Cap screw Lock nut Washer O ring O ring Set scre
169. ly close flow control valve until a pressure of 1200 PSI is obtained 8 Disengage cutting units and stop engine 9 Clean hose fitting and disconnect hose from case drain on the manifold block see table Plug the man ifold port 10 Put case drain hose into 1 quart container gra duated in ounces 1 liter container graduated in millili ters 11 One person should sit on the seat and operate the machine while another person holds the hose and reads the tester Start engine and move the throttle to full speed 3200 100 RPM 12 While sitting on seat engage cutting units by pulling the knob on the instrument panel out Make sure gauge pressure still reads 1200 PSI After 15 seconds push knob on the instrument panel in to disengage cutting units Stop the engine 13 Measure the amount of oil collected in the container Divide the number of ounces collected by 32 to get gal lons per minute Divide the number of milliliters col lected by 250 to get liters per minute 14 Disconnect tester from motor and hose Reconnect hose to the pump 15 Remove cap from manifold fitting Reconnect case drain hose to the motor 16 If flow was greater than 0 7 GPM 2 6 LPM repair or replace the reel motor as necessary Hydraulic System Adjustments Transmission for Neutral If the machine creeps when the traction control pedal is in the neutral position the neutral return mechanism must be adjusted 1 Block
170. ly a light coat of petroleum jelly in the O ring grooves of the gear housing 10 Place a new O ring 6 in each groove Reassembly Fig 54 1 Place the mounting flange 3 with the shaft seal 2 side down onto a clean working surface Make sure that the back side of the mounting flange is free of any con tamination 2 Place the front bearing block 14 with its seal side down onto the mounting flange 3 The open side of the E seal 5 must point away from the matchmark on the inlet side of the mounting flange Reelmaster 2300 D 2600 D Page 4 59 3 Apply a light coating of oil to the exposed face of the front bearing block 14 Make sure the tape is on the shaft end of the drive gear 10 Insert the shaft end of the drive gear 11 slowly through the front bearing block 14 and the shaft seal 2 being careful not to damage the shaft seal 4 Place the shaft of the idler gear 12 into the remain ing position of the front bearing block 14 Apply a light coating of oil the back face of the drive and idler gears 5 Place the rear bearing block 13 with the seal side on the drive and idler gear shaft ends Make sure that the open side of the E seal 5 is pointing towards the inlet of the pump 6 Install the two dowel pins 7 into the mounting flange 3 7 Align the matchmarks on the gear housing 10 and mounting flange 3 Place the gear housing with the mounting flange side down andthe inlet port on t
171. maged or worn connec tions 7 Secure hose connection 4 to the hydraulic fitting 5 Repeat this step for the remaining hydraulic fittings 8 Install reel motor to cutting unit see Repair section of Chapter 7 Cutting Units Reelmaster 2300 D 2600 D Figure 56 Disassembly Fig 56 1 Make sure key 10 is removed from the drive gear 9 shaft 2 Matchmark frontplate 14 body 12 and back plate 7 to assure proper reassembly 3 Secure the motor in a vise with the drive shaft up 4 Remove all eight screws 15 5 Removethe motor from the vise Remove the front plate 14 from the body 12 A wooden block or soft face hammer might be used the gently tap the motor when freeing the frontplate 14 6 Remove alignment pin 13 from the body 12 Re move drive gear 9 and idler gear 8 fromthe body 12 Reelmaster 2300 D 2600 D Page 4 61 1 Plug 8 Idler gear assembly 14 Frontplate 2 O ring 9 Drive gear assembly 15 Screw 3 Shim 10 Key 16 Retaining ring 4 Spring 11 O ring 17 Oil seal 5 Ball 12 Body 18 Backup washer 6 Relief valve seal 13 Alignment pin 19 Relief valve assembly 1 thru 5 7 Backplate 7 Remove body 12 from the backplate 7 Remove O rings 11 from the body 12 and backplate 7 8 Remove Alignment pin 13 from the backplate 7 9 Remove retaining ring 16 oil seal 17 and back up washer 18 from the frontplate 14 IMPORTANT Do
172. ming lever Note fitting angle Injector nut DABON 9 Start engine If engine does not run smoothly after several minutes crack open each injector nut 6 until fuel with no bubbles comes out Torque each injector nut from 14 4 to 18 0 ft lb 2 0 to 2 5 kg m Engine Air Cleaner 1 Service the air cleaner filter every 400 hours more frequently in extreme dusty or dirty conditions Do not over service air filter 2 Check air cleaner body 1 for damage which could possibly cause an air leak Replace damaged air clean er body 3 Make sure air cleaner cover 2 is sealing around the air cleaner body 1 4 Release latches 3 securing the air cleaner cover 2 to the air cleaner body 1 Separate cover from body Clean inside of air cleaner cover 5 Gently slide filter element 4 out of the air cleaner body 1 to reduce the amount of dust dislodged Avoid knocking filter element against air cleaner body 6 Inspect filter element 4 and discard if damaged Do not wash or reuse a damaged filter Washing Method A Prepare a solution of filter cleaner and water Soak filter element 4 in the solution for 15 minutes Refer to directions on filter cleaner carton for com plete information B After soaking filter element 4 for 15 minutes rinse it with clear water Maximum water pressure must not exceed 40 psi to prevent damage to the fil ter element Rinse filter element from the clean side to the d
173. motor was replaced or rebuilt run the cutting units at the minimum speed setting under no load for 10 minutes in both directions B If a reel motor drive pump was replaced or re built run the cutting units at the minimum speed set ting under no load for 10 minutes C Ifatraction pump or a wheel motor was replaced or rebuilt run the traction unit so the wheels slowly turn for 10 minutes 10 Operate the traction unit and cutting unit by gradual ly increasing their work load to full over a 10 minute peri od 11 Stop the machine Check reservoir and fill if neces sary Check hydraulic components for leaks and tighten any loose connections Reelmaster 2300 D 2600 D Table of Contents Chapter 5 Electrical System WIRING SCHEMATICS 2 2220 2 COMPONENT TESTING 0000005 17 Electrical Schema 2 Ignition Key Switch 17 Start Circuits oi Bah cuore ee d A Er 3 Starter and High Temperature Shutdown Relays 18 RUN CIRCUITS erem a KEE 4 High Temperature Shut Down Switch 18 Run Mow Circuits 5 Oil Pressure Switch 19 Run Backlap Circuits 6 Hour Meier 19 Charging Circuits oooooccccocccccono 7 Indicator Lights and Circuits 20 Indication and Safety Circuits 8 Temperature Sending Unit 21 SPECIAL TOOLS 0 0c cece eee eee ee 9 Temperature Gauge 21 TROUBLESHOOTING eeeseeess 10 Diode Circu
174. moval and Installation Note This section can be used for both the front and rear rollers Roller Removal 1 Remove both height of cut pins and hairpin cotters from each roller bracket 2 Remove both locknuts from the capscrews securing each angle bracket to the cutting unit 3 Remove capscrews from both angle brackets and the cutting unit 4 Separate roller assembly roller brackets and angle brackets from the cutting unit 5 Remove roller brackets from the roller assembly Roller Installation 1 Inspect flanged bushing and bushings for wear re place if necessary Note The flanged end of the flanged bushing must face inside toward the roller when the roller bracket is installed onto the cutting unit Note A soft hammer may be needed to tap the roller bracket into position on the hex adjustment nut of the roller 2 Insert smaller diameter roller shaft into the flanged bushing bushing and roller bracket Make sure hex of the roller bracket mates with the hex adjustment nut on the roller 3 Insert the other end of the roller shaft into the other bushing and roller bracket Make sure hex of the roller bracket mates with the hex adjustment nut on the roller 4 Holdone roller bracket stationary and use the other bracket as a wrench to loosen or tighten bearing clear ance The roller must not exceed 5 in Ib 5 8 kg cm rol ling torque and have no bearing end play 5 Make sure roller brackets are aligne
175. n hydraulic system all pressure in system must be relieved by stopping the engine and lowering or supporting the box and or other attachment Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or card board not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is injected into the skin it must be surgical ly removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Figure 1 Final Position Mark Nut and Body Initial Extend Line Finger Tight Figure 2 Hydraulic System Position After Proper Tightening SAE Straight Thread O Ring Port Non adjustable 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 fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 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 F F F T 4 1 4 in nominal hose or tubing 1 00 25 6 3 8 in 1 50 25 8 1 2 in 1 50 25 10 5 8 in 1 50 25 12 3 4 in 1 50 25 16 1 in 1 50 25 SAE Straight Thread O Ring Port Adjustab
176. n is normal Note The rotor set consists of the rotor 19 vanes 20 and stator 21 Rotor set components may be come disassembled during service procedures 6 Inspect the rotor set in its assembled form for nicks scoring and chipping on any surface Inspect for broken and worn splines If the rotor set component requires re placement the complete rotor set must be replaced as it is a matched set 7 Place rotor set and wear plate 18 on a flat surface and center the rotor 19 in the stator 21 such that two rotor lobes 180 degrees apart and a roller vane 20 center line are on the same stator center line Check the rotor lobe to roller vane clearance with a feeler gage at this common center line If there is more than 0 005 inch 0 13 mm of clearance replace the entire rotor set Fig 38 Hydraulic System Page 4 48 Figure 37 Figure 39 Reelmaster 2300 D 2600 D 8 Inspect the wearplate 18 for cracks peening and scoring A polished pattern on the wear plate from rotor rotation is normal Replace as necessary 9 Inspect drive link 13 for cracks and worn or dam aged splines No perceptible lash play should be noted between mating spline parts of the rotor 19 or coupling shaft 11 Replace as necessary Fig 39 10 Inspect thrust bearing 12 for wear peening corro sion and a full complement of retained rollers Replace as necessary 11 Inspect coupling shaft 11 internal and e
177. nd manifold block 22 2 Make sure the manifold is clean before removing the spool valve 15 or 18 3 Remove the spool valve 15 or 18 and seal kit 7 or 17 4 Visually inspect the port in the manifold 22 for damage to the sealing surfaces damaged threads and contamination 5 Visually inspect spool valve 15 or 18 for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunc tion B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 f necessary clean spool valve 15 or 18 using clean mineral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as tal cum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning 7 Reinstall the spool valve 15 or 18 Hydraulic System Page 4 66 A Lubricate new O ring and backup ring of seal kit 7 or 17 with clean hydraulic oil and install The O ring and backup ring of seal kit must be arranged properly on the spool valve 15 or 18 for proper op eration and sealing B Thread spool valve 15 or 18 carefully into the applicable port FC1 or MD1 The valve should go in easily without binding Tor
178. nd into the hose 12 Install tester in series with the motor and the discon nected hose Make sure the flow control valve is fully open 13 One person should sit on the seat and operate the machine while another person reads the tester Start en gine and move the throttle to full speed 3200 100 RPM A CAUTION Use extreme caution when taking gauge readings The front tire on the ground will be trying to move the machine forward 14 Slowly push traction pedal into fully forward posi tion 15 Close flow control valve until pressure gauges read 1000 PSI Verify pump speed of 2700 RPM with a photo tac 16 Observe flow gauge TESTER READING minimum flow of 13 GPM 17 Release traction pedal and turn off machine 18 Disconnect tester from elbow connection and hose Reconnect hose to elbow connection 19 If specifications are not met the traction pump needs to be repaired or replaced as necessary Hydraulic System TEST NO 2 Charge Pump Flow and Implement Relief Pressure CHARGE PUMP TRACTION PUMP CONTROL VALVE TO WHEEL MOTORS VALVE TOP TO LIFT CYLINDER A A BOTTOM FROM LIFT CYLINDER gt Se BOTTOM A IMPLEMENT RELIEF Pelee eee cece eee lt gt ELE 4 BOTTOM RESERVOIR REEL MOTOR DRIVE PUMP FRONT TO MANIFOLD
179. ngine C Reinstall engine 25 onto the frame Make sure fastener holes of the mount brackets 22 34 and 46 are aligned with the holes on the frame D Secure cap screws 42 and flange nuts 27 to the mount brackets 22 34 and 46 and frame Engine Page 3 18 E On the right rear mount bracket 46 tighten cap screws 36 Torque cap screws from 34 to 42 ft lb 4 7 to 5 8 kg m Reinstall radiator assembly A Place radiator assembly down and then into the engine to preventthe engine cooling fan from catch ing the radiator top and bottom shrouds B Connect air filter hose extending from the engine to the air cleaner Tighten hose clamp C Support the radiator assembly while installing the fasteners D Install carriage bolts 1 and whiz nuts 2 to the radiator bracket 3 and frame 4 Fig 23 E Install cap screws 1 and whiz nuts 2 to the ra diator rear bracket 3 and frame 4 Fig 22 Reconnect electrical connections Fig 19 A Untie harness and hoses from the reservoir sup port brackets Pull wiring harness and hydraulic hoses into position keep them from contacting moving parts Install cap screw 10 and flat washer 11 to R clamp 12 and tighten to cylinder head B Reconnect connector with blue leads to the al ternator C Reconnect connector with blue white leads to the traction clutch D Reconnect connector to the front lift cylinder mi croswitch E Reconnect white
180. ngs and Piv ot Points 5 E 3 Reelmaster 2300 D 2600 D Page 7 13 Cutting Units Cutting Unit Removal and Installation Fig 15 through Fig 18 Remove Cutting Unit 1 Raise cutting units to relieve the tension on the counterbalance springs 2 Make sure traction unit is shut off and parking brake is set NSERT BREAKER BAR Use caution when relieving tension or tensioning springs as they are under RE Figure T Se P ottom capscrew ounterbalance arm heavy load Do not move lift lever cutting 2 Top capscrew 4 Counterbalance spring units can lower without the engine run ning 3 Loosentop cap screw Put breaker bar in the square hole and hold tension of spring Fig 15 4 Remove bottom cap screw and slowly relieve the re maining tension on the spring Fig 15 5 Remove capscrews lock washers and lift tab se curing the spring to the carrier frame Remove spring from the carrier frame Fig 16 6 Note from which hole on the lift tab the spring is re moved from Note On rear cutting unit also remove the thrust washer The thrust washer is located between the rear of the carrier frame and the flat washer Figure 16 z 1 Capscrew and lock washer 3 Spring 2 Lifttab 4 Carrier frame 7 Remove flange head cap screw and flat washer from the pivot rod Fig 17 8 Disconnect tipper chain on front carrier frame Fig 18 Slide carrier frame off the pivot rod Install Cutting Unit
181. nnections 1 2 3 and 4 from hydraulic fittings 5 Allow hoses to drain into a suitable container 4 Put caps or plugs on disconnected hoses and fit tings to prevent contamination 5 Remove hydraulic fittings 5 and O rings 7 from the lift cylinder 8 6 Remove cotter pin 9 from the clevis pin 10 Pull clevis pin from the lift cylinder 8 7 Remove cap screw 11 from the lift hub 12 Remove cotter pin 13 and clevis pin 14 from the clevis 15 that is on the hydraulic fitting side of the cylinder guide 15 8 Support lift cylinder 8 and slide cylinder guide 16 from the lift hub 12 A Reach up from the bottom and rotate lift cylinder so the bottom port comes out of the slot in the frame B Drop lift cylinder down and out from the frame Lift hub from the cylinder support bracket 17 Hydraulic System Page 4 68 9 Remove flange bushings 18 from the cylinder support bracket 17 10 Remove lift hub 12 from the lift cylinder 8 Installation Fig 59 1 Thread lift hub 12 onto lift cylinder 8 2 Position lift cylinder 8 inside the cylinder support bracket 17 and valve mount bracket 19 Make sure the inlet and outlet ports of the lift cylinder face the fitting side of the cylinder support bracket 3 Alignlift cylinder 8 holes with holes at bottom of the valve mount bracket 18 Slide clevis pin 14 through holes and secure pin with cotter pin 9 4 Al
182. not remove the relief valve assem bly 19 unless testing shows it to be faulty The re lief valve assembly must be replaced as a complete unit Both relief valve seals 6 are sealed in place with loctite do not remove them 10 Remove plug 1 O ring 2 shim 3 spring 4 and ball 5 from the backplate 7 Hydraulic System Inspection Fig 56 1 Remove all nicks and burrs from all parts with an A CAUTION emery cloth Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive gear 9 shaft for a broken or chipped keyway 4 Inspect drive gear 9 and idler gear 8 shafts at the bushing points and seal area for rough surfaces and ex cessive wear 5 Replace drive gear 9 or idler gear 8 if the shaft in the bushing area diameter measures less than 0 748 in 19 0 mm A single gear may be replaced separately 6 The drive gear 9 and idler gear 8 face should be free of excessive scoring and wear 7 Replace drive gear 9 or idler gear 8 if gear width is less than 1 140 in 29 96 mm 8 Make sure that retaining rings are in the grooves on both sides of the gear for both the drive gear 9 and idler gear 8 9 Break sharp edges of gear teeth with emery cloth 10 Replace backplate 7 and frontplate 14 if bushing inside diameters exceed 0 755 in 19 2 mm The bush ings are not available
183. ntinuity between switch termi nals A CAUTION When testing electrical components for continuity with a multimeter ohms set ting make sure that power to the circuit has been disconnected POSITION Reelmaster 2300 D 2600 D Page 5 17 CONTINUITY AMONG TERMINALS Figure 3 30 19 AC 30 17 50 AC Electrical System Electrical System Starter and High Temperature Shut Down Relays 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting Resistance should be from 80 to 90 ohms 2 Connect multimeter ohms setting leads to relay terminals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is ap plied and removed from terminal 85 Figure 4 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 4 Connect multimeter ohms setting lead to relay ter minal 30 and 87A Apply 12 VDC to terminal 85 The relay should break and make continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 5 Disconnect voltage from and multimeter leads from relay terminals High Temperature Shutdown Switch The switch is located on top of the water pump The pump is on the left end of the engine inside of the fan pulley assembly There is a tan wire attached to the switch 1 Lower the coolant level in the engine and remove the high tem
184. nues to run but should not when the cutting unit switch is ON with no operator in the seat Cutting units run but should not when raised However they shut off with the cutting unit switch Cutting units shut off when raised However they do not shut off with the cutting unit switch Cutting units do not engage Reelmaster 2300 D 2600 D Page 5 13 Possible Causes Backlap switch is in the backlap position Backlap switch is faulty or out of adjustment Wiring to the run mow backlap circuits see Wiring Schematics components is loose corroded or damaged Seat switch is faulty out of adjustment or short circuited Cutting unit interlock switch is faulty Cutting unit switch is faulty or short circuited Wiring to run mow backlap circuits see Wiring Schematics components is loose corroded or damaged ACC fuse 10 amp is open Fuse block is faulty Cutting units are not lowered Cutting unit switch is faulty Cutting unit interlock switch is faulty Cutting solenoid valve is faulty Electrical System o of T6 a Oo 25 Lu Verify Interlock System Operation A CAUTION The interlock switches are for the opera tor s protection do not disconnect them Check the operation of the switches daily to assure the interlock system is operat ing If a switch is defective replace it be fore operating the machine Regardless if switches are operating properly or not replace them every
185. o loosen bedknife to reel contact Fig 19 2 Remove both jam nuts and hex socket set screws from the bedbar yoke Fig 19 3 Unscrew adjusting handle left hand threaded un til it is removed from the cutting unit Fig 19 4 Loosen both adjusting lock nuts on the adjusting housing Fig 20 5 Remove both carriage bolts and nuts from the ad justing housing Fig 20 6 Remove both carriage bolts and nuts from the bed bar housing Remove bedbar from the cutting unit Fig 21 7 Remove capscrew lock washer flat washer and spacer from the end of the bedbar Fig 21 8 Remove adjusting housing and bedbar housing from the bed bar Remove bedbar washer Fig 21 9 Sharpen or replace bedknife as necessary see Bedknife Replacement and Grinding Bedbar Installation 1 Inspect flanged bushings and bushing assemblies for wear replace if necessary Fig 21 2 Clean and apply anti seize lubricant to both bedbar pivots Install bedbar washer on the bedbar Fig 21 3 Install bedbar adjusting housing and bedbar hous ing on the bed bar Reinstall spacer flat washer lock washer and cap screw on the bedbar Fig 21 4 Install bedbar assembly on the cutting unit 5 Secure bedbar housing to the cutting unit with both carriage bolts and nuts Fig 21 Secure adjusting hous ing to the cutting unit with both carriage bolts and nuts Fig 20 6 Tighten both adjusting lock nuts on the adjusting housin
186. o step 11 and replace the relief valve 11 Disengage cutting units Shut off engine 12 Disconnect tester from manifold and hose Recon nect hose to the pump Hydraulic System TEST NO 6 Cross over Relief Pressures TEST GAUGE O TESTING IN MOW G1 FROM REEL DRIVE PUMP FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR T CONNECTION AND GAUGE HYDRAULIC MANIFOLD TESTING IN BACKLAP High Pressure Low Pressure Return or Suction Flow Figure 17 Hydraulic System Page 4 30 Reelmaster 2300 D 2600 D Procedure for Cross over Relief Pressures Check 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for approximately 10 minutes Make sure the hydraulic tank is full 2 Make sure machine is parked on a level surface with the cutting units lowered Make sure engine is off and parking brake is engaged Back bedknives off all reels A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 3 Clean manifold port G1 Remove cap and install pressure gauge in manifold port G1 4 Puta block of wood between the blades of the cut ting unit being tested to prevent the reel from rotating 5 Make sure backlap knob on the valve block is in the mow position
187. ock cotter pin 1 to the adjusting rod 2 Fig 18 16 Reinstall fender bracket 2 and left fender 1 to the radiator side of the frame Fig 17 A Secure both cap screws 3 and left fender bracket 2 to the frame B Reinstall remaining cap screws 3 and flange nuts 4 securing the fender to the fender bracket and frame C Secure cap screw 3 and flange nut 4 to the left foot rest 5 and the left fender 1 17 Replace traction pump drive belt as described in Traction Electric Clutch of the Service and Repairs section of Chapter 5 Electrical System 18 Adjust traction pump drive belt as described in the Adjustment section of Chapter 4 Hydraulic system 19 Connect negative and then positive battery cables at the battery 20 Adjust hand brake as described in the Adjustment section of Chapter 6 Wheels and Brakes 21 Adjust throttle linkage as described in the Adjust ment section of this chapter 22 Bleed fuel system See Bleeding the Fuel System 23 Check oil level as describedin Changing the Engine Oll and Filter 24 Replace access covers to the engine A Reinstall left rear panel radiator side which supports the instrument panel B Reinstall right side panel which accesses the traction pump drive belt C Reinstall hood to the machine and close Engine Engine Page 3 20 Reelmaster 2300 D 2600 D Table of Contents SPECIFICATIONS GENERAL INFORMATION
188. of the Operator s Manual Safety Page 1 2 9 Make sure the work area is clear of objects which might be picked up and thrown by the reels 10 Fill the fuel tank with diesel fuel before starting the engine Avoid spilling any fuel Since fuel is highly flam mable handle it carefully A Use an approved fuel container B Do not remove the cap from the fuel tank when engine is hot or running C Do not smoke while handling diesel fuel D Fill fuel tank outdoors and not over one inch from the top of the tank bottom of the filler neck Do not overfill F Stay alert for holes in terrain and other hidden hazards Use extreme care when operating close to sand traps ditches creeks steep hillsides or other hazards G Reduce speed when making sharp turns Avoid sudden stops and starts Use reverse pedal for braking The cutting units must be lowered when going down slopes for steering control H Before backing up look to the rear and assure that no one is behind the machine Watch out for traffic when near or crossing roads Always yield the right of way 15 Keep hands feet and clothing away from moving parts and the reel discharge area Grass baskets if so equipped must be in place during reel operation for maximum safety 16 This product may exceed noise levels of 85 dB A at the operator position Ear protectors are recom mended for prolonged exposure to reduce the potential of permanent hearing damag
189. oil pan and place a collecting pan below it Remove drain plug and let oil flow into the collecting pan When the oil stops draining install drain plug 3 Locate engine filter on the front of the engine Re move oil filter Apply a light coat of clean oil to the new filter seal before screwing it on DO NOT OVERTIGH TEN Note The crankcase capacity is approximately 2 8 qts 3 0 L with filter The engine uses any high quality 10W30 detergent oil having the American Petroleum In stitute API service classification CD 4 Addoilto the crankcase A Remove oil fill cap Fig 14 and gradually add small quantities of oil B Check oil level frequently until the level reaches the FULL mark on dipstick Fig 15 When removing the dipstick wipe it with a clean rag prior to inserting it to check the oil level C Push dipstick down into dipstick tube and make sure it is seated fully when finished Fig 15 Checking the Cooling System A CAUTION If the engine has been running pressur ized hot coolant or steam can escape when the radiator cap is removed Burns may result Do not open radiator cap when the radiator or engine is hot 3 NOT OVERFILL 4 Engine Page 3 12 Figure 14 1 Oil fill cap Figure 15 1 Dipstick Figure 16 1 Radiator cap r DO Reelmaster 2300 D 2600 D Engine Removal 1 Park machine on a level surface lower the cutting units stop the engine and remov
190. om the cutting units and any moving parts Keep everyone away 32 Do not overspeed the engine by changing governor settings To assure safety and accuracy have an Autho rized Toro Distributor check maximum engine speed with a tachometer 33 The engine must be shut off before checking oil or adding oil to the crankcase 34 To insure optimum performance and safety use genuine TORO replacement parts and accessories Re placement parts and accessories made by other man ufacturers could be dangerous and such use could void the product warranty of The Toro Company Safety Safety and Instruction Decals The following safety and instruction decals are affixed below and in your Parts Catalog Order replacements to the traction unit lf any decal becomes illegible or from your Authorized Toro Distributor damaged install a new decal Part numbers are listed CHARGING 2WD DA WD io PY swp ON LEFT SIDE OF SEAT PANEL E UNDER CONTROL PANEL Part No 92 7270 ue Part No 93 6902 Model 03427 only A D n ON CARRIER FRAME Part No 94 3353 WARNING Pinch Point between Carrier Frame and js ACAUTION DO NOT USE STARTING FLUID ON FAN SHROUD ON INSTRUMENT PANEL Part No 77 3100 Part No 94 4985 Rotating Parts QUICK REFERENCE AID CHECK SERVICE ON gen gt OFF 1 ENGINE OIL LEVEL 2 ENGINE OIL DRAIN 17mm socket 0 3 HYDRAULIC OIL LEVEL center of sight glass 4 BEL
191. omponents have been properly installed and if the traction pump was rebuilt or replaced make sure traction pump housing is at least half full of clean hydraulic oil 2 Make sure all hydraulic connections and lines are secured tightly 3 Make sure hydraulic reservoir is full Add correct oil if necessary see Checking the Hydraulic System Fluid Drain flush and refill hydraulic system reservoir and change oil filter if component failure was severe or sys tem is contaminated 4 Disconnect electrical connector to the fuel stop so lenoid to prevent engine from starting 5 After repairs check control linkage for proper ad justment binding or broken parts 6 Make sure traction pedal is in neutral and the cut ting unit switch is off Turn ignition key switch engage starter for fifteen 15 seconds to the prime pump 7 Connect electrical connector to the fuel stop sole noid 8 Make sure traction pedal is in neutral and the cut ting unit switch is off Start engine and run it at low idle The charge pump should pick up oil and fill the hydraulic system If there is no indication of fill in 30 seconds stop the engine and determine the cause Hydraulic System Page 4 80 A CAUTION Be careful when operating the cutting unit reels Contact with the reel or other mov ing parts can result in personal injury 9 Afterthe hydraulic system starts to show signs of fill accomplish the following A If a reel
192. on of Chapter 4 Hydraulic System The counter balance spring on each cutting unit lift arm can be adjusted to compensate for different turf conditions Decreased counter balance tension will help keep the cutting units on the ground when mowing at higher speeds and it helps maintain a uniform height of cut in rough conditions or in areas of thatch build up Increased counterbalance tension will improve traction by increasing weight on the front tires Also the spring may be adjusted at the cutting unit pivot point Raising the spring at the lift tab decreases the cutting unit weight at the outboard end Lowering the spring at the lift tab increases the cutting unit weight at the outboard end NOTE Decreased counter balance tension may lower the actual or effective height of cut Check each tire s pressure Adjust to pressures specified in Specifications section of Chapter 6 Wheels and Brakes Cutting Units Cutting Units 5 Reel bearing condition All reels should rotate freely Make sure bearings are properly lubricated Replace bearings if worn or damaged 6 Reel and bedknife sharpness Reel and or bedknife that has rounded cutting edges or rifling cannot be corrected by tightening bedknife to reel contact Grind reel to remove taper and or rifling grooved or wavy appearance Grind bedknife to sharpen and or remove rifling Most common cause of rifling is bedknife to reel contact that is too tight NOT
193. or exact repositioning at assembly will make sure maximum wear life and performance of rotor set and wheel motor 8 Mark surface of rotor 19 and stator 21 that is fac ing up with etching ink or a grease pencil before remov ing from the wheel motor This will make sure correct reassembly of the rotor into the stator and the rotor set into wheel motor 9 Remove rotor set and wearplate 18 together and retain the rotor set in its assembled form with the same vane 20 to stator 21 contact surfaces The drive link 13 may come away from the coupling shaft 11 with the rotor set and wearplate You may have to shift the ro tor set on the wearplate to work the drive link out of the rotor 19 and wearplate Fig 35 Reelmaster 2300 D 2600 D Page 4 47 Figure 35 10 Remove seal ring 5 that is between the rotor set and wearplate 11 Remove drive link 13 from the coupling shaft 11 if it was not removed with rotor set and wear plate 18 Remove seal ring 5 from housing 3 12 Remove thrust bearing 12 from the top of the cou pling shaft 11 13 Check exposed portion of coupling shaft 11 to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the dirt and water seal 1 and outer bearing 2 Crocus cloth or fine emery paper may be used 14 Remove coupling shaft 11 push on the output end of the shaft Remove seal ring b from housing 3 15
194. ore and seal ring side down The splines should mesh with the drive link 13 splines 14 If disassembled rotor 19 stator 21 and vanes 20 cannot be readily assembled by hand assemble with the following procedures A Place stator 21 onto wear plate 18 with seal ring 5 side down Be sure the seal ring is in place Reelmaster 2300 D 2600 D Page 4 51 Figure 46 Figure 47 B If assembly alignment studs are not being uti lized align stator 21 bolt holes with wear plate 18 and housing 3 bolt holes Screw two cap screws 14 finger tight into bolt holes approximately 180 de grees apart to retain stator and wear plate station ary Note If the manifold 22 side of the rotor 19 was etched during wheel motor disassembly this side should be up If the rotor is not etched and does not have a counterbore use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate C Place rotor 19 with counterbore down if appli cable into stator 21 and then onto wearplate 18 so rotor splines mesh with drive link 13 splines IMPORTANT Do not force rotor vanes into place the coating applied to stator vane pockets could shear off D Assemble six vanes 20 or as many vanes that will readily assemble into the stator vane pockets Hydraulic System E Grasp the output end of coupling shaft 11 with locking pli
195. ote Low resistance may be accompanied by the 10 amp engine fuse blowing from drawing high current High resistance may be accompanied by the clutch not engaging from drawing insufficient current Live Testing 1 Disconnect the clutch electrical connector from the wiring harness 2 Connecta 12 VDC source across the electrical con nector terminals The clutch should engage with a dis tinct audible click 3 Disconnect the 12 VDC source from the connector terminals 4 Connectthe clutch electrical connector to the wiring harness Figure 20 1 Connector leads 2 Interlock switch Reelmaster 2300 D 2600 D Seat Interlock Switch This switch is a normally open switch that closes when the operator is on the seat If the cutting unit switch or traction interlock switch is open and the operator raises out of the seat the engine will stop The switch and its electrical connector are located under the skirt below the seat 1 Disconnect switch electrical connector 2 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals Note Make sure the compression spring and pin hold the seat off the switch when there is no operator in the seat 3 With the seat lowered and no operator in the seat there should be no continuity between the terminals 4 Have an operator slowly sitin the seat There should be continuity as
196. over the drive shaft into the front plate 14 housing Apply a liberal coat of hydraulic oil to the oil seal 17 Install oil seal 17 over the drive shaft being careful not tho cut the rubber seal lips 11 Place 1 1 16 inch O D sleeve over the drive shaft and press in the oil seal 17 until the retaining ring groove appears 12 Press retaining ring 16 into the housing using the sleeve until it seats in the groove Reelmaster 2300 D 2600 D Hydraulic Manifold Removal Fig 57 1 Before removing any parts from the hydraulic man ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 2 Raise and remove hood to get access to the man ifold Note The ports on the manifold are marked for easy identification of components Example R1 is the reel cir cuit relief valve and G1 is the test gauge connection port See Hydraulic Schematics to identify the function of the hydraulic lines and cartridge valves at each port loca tion 3 Ifnecessary the hydraulic manifold can be removed Figure 57 A Disconnect solenoid valve 9 and micro switch 4 electrical connectors B Clean manifold and hydraulic connections Dis connect hydraulic lines Label all connections for reassembly C Allow
197. perature shutdown switch 2 Putthe switch in a container of oil with a thermome ter and slowly heat the oil Fig 6 A CAUTION Handle the hot oil with extreme care to prevent personal injury or fire Figure 5 1 High temperature shutdown switch 3 Check the continuity of the switch with a multimeter ohms setting The switch is normally open and should close at 206 to 218 F 97 to 103 C 4 Allow the oil to cool The switch should open at 194 F 90 C Figure 6 Electrical System Page 5 18 Reelmaster 2300 D 2600 D Oil Pressure Switch The switch is located on the front cylinder head above the injection pump and governor assembly It is a nor mally closed switch and opens with pressure The oper ating range for the switch is 2 8 to 5 7 PSI 0 2 to 04 kg cm Testing with the engine off 1 Turnthe ignition switch to ON The oil pressure lamp should be on 2 Ifthe lamp is not on disconnect the brown wire from the switch and ground it to the engine block 3 Ifthe lamp comes on the switch is bad 4 Ifthe lamp does not come on after step 2 check the indicating circuit see Indicating and Safety Circuits Testing with the engine on 1 Ifthe lamp is on with the engine running shut off the engine immediately 2 Disconnect the brown wire from the switch 3 Turnthe ignition switch to ON The oil pressure lamp should go out 4 Ifthe light is still on check for short circuiting in the
198. que valve to 35 ft lb 4 8 kg m Reinstall knob assembly A Install applicable locating plate 16 or 19 so that the pin seats into the locating hole B Turn the threaded spool valve 15 or 18 stem carefully clockwise until it stops C Face detent plate 28 counterbore down Thread detent plate 28 down onto the valve stem until it is stopped by the locating plate 16 or 19 Turn detent plate 28 back counterclockwise 1 4 turn D Center one detent plate hole over a locating plate indentation Drop a ball 23 into each hole then drop a spring 24 or 30 into each hole E On spool flow control valve 15 place indica tor plate 27 over the detent plate 28 Make sure the arrow points to the right at 45 F On spool two position directional valve 18 place indicator plate 31 over the detent plate 28 Make sure the arrow points directly at the number 1 on the locating plate 16 G While pushing down on the indicator plate 27 or 31 and compressing the springs 24 or 30 thread down a jam nut 26 While tightening the set screw 29 tighten jam nut 26 at the same time using a 7 16 inch wrench H Thread second jam nut 26 all the way down the valve 15 or 18 stem Apply Loctite 242 or equiva lent the valve stem threads Screw knob 25 all the way down until it hits the upper jam nut 26 I Onspool flow control valve 15 turn knob 25 counterclockwise until the arrow points at t
199. r brake arm le ver F Rotate clevis one turn at a time counterclock wise to increase the distance between the upper brake arm lever and lower brake arm lever by 5 8 inch 7 Install clevis 2 to the upper brake arm lever 4 Install and lock cotter pin 3 into the clevis Tighten jam nut 1 8 Repeat procedure for the other wheel 9 Checkbrake adjustment and adjust again as neces sary 10 Install wheels Reelmaster 2300 D 2600 D Page 6 3 Brake Arm Lever Distance Figure 1 1 Jam nut 4 Upper brake arm lever 2 Clevis 5 Lower brake arm lever 3 Cotter pin 11 Turn by pass valve on traction pump to the closed position as described in the General Information section of Chapter 4 Hydraulic System 12 After any brake adjustment operate the vehicle at alow speed one mph or less and check that brakes en gage equally on both wheels Readjust as necessary Wheels and Brakes a c i o o E o o x A a Service and Repairs Rear Wheel 3WD Removal 1 Park machine on a level surface Ensure engine is off Set hand brake and block front wheels 2 Lift rear wheel off the ground using a jack Secure back of the frame 3 Remove lug nuts from the wheel hub studs Slide off wheel assembly 4 Remove lock nut from the wheel motor shaft IMPORTANT DO NOT hit wheel hub with a hammer during removal or installation Hammering may cause damage to the wheel motor
200. r is parallel and the entire length of roller contacts the table A piece of paper inserted between the roller and the table should not fit 10 When roller is level adjust both rollers to desired Height of Cut with pins Tighten nuts securing roller brackets and replace hairpin cotters to the Height of cut pins Cutting Units Page 7 8 PINA Nut Rear roller bracket 5 Support capscrew 6 Height of Cut support Front roller bracket 7 Height of Cut pins 8 Angle bracket Height of Cut plate Reelmaster 2300 D 2600 D Bedknife Parallel to Reel Fig 7 through Fig 9 1 Remove any reel contact by turning the bedknife ad justment knob counterclockwise Fig 7 Tip cutting unit to gain access to the reel and bedknife Fig 8 2 Oneither end of reel insert a long strip of dry news paper between reel and bedknife While slowly rotating reel into bedknife turn bedknife adjusting knob clock wise one click at a time until paper is pinched lightly which results in a slight drag when paper is pulled 3 Checkfor light contact at other end of reel using pa per If light contact is not evident proceed to next step 4 Loosen both carriage bolts on bedbar adjuster Fig 9 5 Adjustnuts to move bedbar adjuster up or down un til paper is pinched along entire bedknife surface when bedknife adjustment knob is adjusted to no more than two clicks beyond first contact of reel bedknife Fig 9 6 Tighten nuts
201. r the op erators hands Disconnect the positive cable 3 Make sure that the filler caps are on tightly 4 Remove battery from the battery compartment to a service area This will minimize possible battery dam age and allow better access for inspection and service Inspection Maintenance and Testing 1 Perform the following inspection and maintenance tasks A Check for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking Reelmaster 2300 D 2600 D Page 5 27 B Check battery terminal posts for corrosion Use a terminal brush or steel wool to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly FILLER CAPS CAP TUBES COVER SEAL Figure 25 C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or mis sing filler cap overcharging loose terminal post or overfilling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Replace the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the lev el is below the tops of the plates in any cell fill all cells with distilled water to the bottom of the cap tubes Charge at 15 to 25
202. riage bolt 3 Radiator bracket 2 Whiz nut 4 Frame Page 3 16 Reelmaster 2300 D 2600 D 16 Remove traction pump drive belt as described in Traction Electric Clutch of the Service and Repairs section of Chapter 5 Electrical System 17 Remove engine Fig 19 A Attach short section of chain between both lift tabs 1 located on each end of the cylinder head 2 Fig 24 B Connect a hoist or chain fall at the center of the short section of chain Apply enough tension on the short chain so that the engine will be supported when the cap screws 42 securing the engine mount brackets 22 34 and 46 are removed C Remove cap screws 42 and flange nuts 27 Figure 24 from the engine mount brackets 22 34 and 46 1 Lifting tab 2 Cylinder head and the frame Note One person should operate the chain fall or hoist while another person guides the engine out of the frame Note Be careful not to damage the engine fuel lines hydraulic hoses electrical harness or other parts while removing the engine D Remove engine 25 from the frame E Mount engine onto an engine rebuilding stand Reelmaster 2300 D 2600 D Page 3 17 Engine Engine Reinstallation 1 Make sure machine is parked on a level surface with cutting units lowered and key removed from the start switch Chock wheels to keep the machine from moving 2 Make sure that all parts remove from the engine during maintenance or rebuilding are reins
203. rt 13 Lift arm 4 Hydraulic fitting 9 Lift pivot shaft 14 Flat washer 5 O ring 10 Lift cylinder 15 O ring Removal Fig 63 1 Before removing any parts from the hydraulic man A CAUTION ifold park the machine on a level surface engage the parking brake lower the cutting units and stop the en The rear lift cylinder is located near the gine Remove the key from the ignition switch muffler exhaust pipe To avoid possible burns allow the exhaust pipe to cool be fore working on the rear lift cylinder A CAUTION 2 Label all connections for reassembly Disconnect Operate all hydraulic controls to relieve hose connections 1 and 2 from hydraulic fittings 3 and system pressure and avoid injury from 4 Allow hoses to drain into a suitable container pressurized hydraulic oil Reelmaster 2300 D 2600 D Page 4 71 Hydraulic System 3 Put caps or plugs on disconnected hoses and fit tings to prevent contamination 4 Remove cap screw 6 and ram pivot pin 7 from pivot support 8 Slide lift pivot shaft 9 from pivot sup port 5 Rotate lift cylinder 10 while swinging the lift cylin der down from the pivot support 8 so the hydraulic fit tings 3 and 4 are clear the exhaust pipe 6 Remove cotter pin 11 from clevis pin 12 Support lift cylinder 10 and slide clevis pin out of the lift arm 13 removing flat washers 14 7 Remove hydraulic fittings 3 and 4 and O rings 15 from the lift cylinder 10
204. sed on all full roll ers Remove Seals and Bearings 1 Clean inside roller around both adjusting nuts and roller shaft ends Both areas should be free of dirt and debris 2 Remove an adjusting nut from one end of the roller shaft 3 Keep roller level and slide the shaft with the remain ing adjusting nut out of the roller Cutting Units Page 7 20 7 Bearing cone 8 Bearing cup 4 Ifdisassembling a full roller pour the oil from inside the roller into a suitable container 5 Secure roller in a vise 6 Remove outer seals and shim washers if installed 7 Remove both bearing cones Note Anelectric arc welder can be used to shrink the bearing cup to simplify its removal Only a small arc in one location on the cup is required 8 Remove both bearing cups from the roller Remove both inner seals if installed 9 Discard seals and bearings Reelmaster 2300 D 2600 D Install New Seals and Bearings 1 Make sure all parts are clean prior to installing bear ings and seals 2 Install inner seals onto both ends of the roller shaft if previously installed 3 Press both bearing cups into the roller Make sure narrow end of taper faces inside of the roller 4 Keep roller level and secured roller in a vise 5 f assembling a full roller fill the inside of roller tube with 6 oz of SAE 90 oil 6 Pack both bearing cones with No 2 general pur pose lithium base grease Reelmaster 2300 D 2600
205. sing incomplete circuit for solenoid Nothing happens when start attempt is made Cutting unit switch is ON pulled out or faulty Battery is dead Battery cables are loose or corroded Battery ground to frame is loose or corroded Fusible link is open Wiring to the start circuit see Wiring Schematics components is loose corroded or damaged Ignition switch is faulty Starter relay is faulty Starter solenoid is faulty Engine fuse 10 amp is open Fuse block is faulty High temperature shutdown relay and or switch are faulty Traction neutral interlock switch out of adjustment or faulty Electrical System Page 5 10 Reelmaster 2300 D 2600 D Starting Problems continued Engine cranks but does not start Wiring to start circuits see Wiring Schematics is loose corroded or damaged Diode D1 circuit board connector housing is open if engine starts with operator in the seat Fuel valve solenoid is faulty Glow plugs are faulty Engine or fuel system is malfunctioning see Chapter 6 Engine Engine and fuel may be to cold Engine cranks but should not with the traction pedal Traction neutral interlock switch is out of adjustment out of the neutral position faulty or short circuited Diode D1 circuit board connector housing is short circuited Engine cranks but should not with the cutting unit Backlap mow switch is in the backlap position switch ON pulled out p Cutting unit
206. small valve orifices or seal areas causing malfunc tion B If sealing surfaces appear pitted or damaged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 5 Clean cartridge valve 1 of 14 using clean mineral spirits Submerge valve in clean mineral spirits to flush out contamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves Use compressed air for cleaning 6 Reinstall the cartridge valve 1 or 14 A Lubricate new O ring and backup ring of seal kit 7 with clean hydraulic oil and install The O ring and backup ring must be arranged properly on the cartridge valve 1 or 14 for proper operation and sealing Hydraulic System B Thread cartridge valve 1 or 14 carefully into the applicable port LC1 or R1 The valve should go in easily without binding Torque the valve to 35 ft lb 4 8 kg m Spool Flow Control and Two Position Directional Valves Fig 58 1 Remove knob assembly A Unscrew and remove knob 25 Remove both jam nuts 26 B Slide off applicable indicator plate 27 or 31 be ing careful not to lose springs 24 or 30 Remove spring C Loosen set screw 29 and slide detent plate 28 off the applicable spool valve 15 or 18 stem D Remove the applicable locating plate with pin 16 or 19 from the spool valve 15 or 18 stem a
207. st 1 Parkthe machine on a level surface lower the cut ting units set parking brake and turn the engine off 2 If only the filter is to be changed remove reservoir cap andinsertreservoir plug Fig 7 to block outlet This will retain most of the fluid in reservoir when filter is re moved Figure 7 3 Clean the area around the hydraulic oil filter Re move filter from the bottom of the filter housing and allow the oil to flow into a drain pan Use a bottom type filter wrench Dispose of the oil filter properly 1 Reservoir plug 2 Reservoir outlet 4 Apply a film of oil on the filter gasket Install filter by hand until gasket contacts the mounting head then tighten filter an additional three fourths turn 5 Fill the reservoir to proper level refer to Checking the Hydraulic System Fluid 6 Place all controls in neutral or disengaged position and start engine Run engine at lowest possible RPM to purge the system of air Figure 8 7 Run engine until lift cylinders extend and retract and 1 Hydraulic oil filter forward and reverse wheel motion is achieved 8 Stopthe engine and check the oil level in reservoir add oil if necessary 9 Check all connections for leaks Pushing or Towing the Traction Unit In case of emergency the Reelmaster 2300 D can be towed for a short distance However Toro does not rec ommend this as a standard procedure IMPORTANT Do not tow the machine faster than
208. t gauge IMPORTANT Use only types of hydraulic fluids specified Other fluids could cause system damage Note Ared dye additive for the hydraulic system fluid is available in 2 3 oz bottles One bottle is sufficient for 4 to 6 gallons 15 to 22 liters of hydraulic fluid Order Part No 44 2500 from your Authorized Toro Distributor 1 Position machine on a level surface Make sure en gine is off and parking brake is set 2 Check level of the fluid by viewing into the sight gauge If the fluid is cold the level should be at the bot tom of the gauge If the fluid is hot the level should be at the center of the gauge 3 If fluid level is not at center of gauge remove cap from the hydraulic fluid reservoir and slowly fill reservoir with Mobil 424 or equivalent hydraulic fluid until level reaches center of sight gauge DO NOT OVERFILL IMPORTANT To prevent system contamination clean top of hydraulic fluid containers before punc turing Assure pour spout and funnel are clean 4 Install reservoir cap Wipe up any fluid that may have spilled Hydraulic System Changing the Hydraulic System Fluid and Filter The hydraulic system filter must be changed initially af ter the first five hours of operation and thereafter every 200 hours of operation or yearly whichever comes first Use a genuine Toro oil filter for replacement The hy draulic fluid must be changed every 400 hours of opera tion or yearly whichever comes fir
209. talled to the engine 3 Ifmountbrackets 22 34 and 46 were removed re install them as follows Fig 19 A For front mount brackets 34 secure brackets to the engine 25 with cap screws 36 lock wash ers 33 and washers 13 Torque cap screws from 34 to 42 ft lb 4 7 to 5 8 kg m B For left rear mount bracket 22 secure bracket to the engine 25 with two cap screws 36 lock washers 33 and washers 13 through the left holes Leave the right holes open for the muffler Torque cap screws from 34 to 42 ft lb 4 7 to 5 8 kg m C For right rear mount bracket 46 secure brack ets to the engine 25 with cap screws 36 lock washers 33 and washers 13 Leave cap screws loose enough so that the position of the bracket can be adjusted after the engine is installed 4 Reinstall engine Fig 19 A Attach short section of chain between both lift tabs 1 located on each end of the cylinder head 2 Fig 24 B Connect a hoist or chain fall at the center of the short section of chain Apply enough tension on the short chain so that the engine will be supported when the engine is removed from the engine re building stand Remove engine from the engine re building stand Note One person should operate chain fall or hoist while another person guides the engine into the frame Note Be careful not to damage the engine fuel lines hydraulic hoses electrical harness or other parts while reinstalling the e
210. tery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if a charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post Leave the test leads con nected and record the battery voltage Note Upon starting the engine the battery voltage will drop and then increase once the engine is running Note Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Glow Plug System Test This is a fast simple test that can help you determine a glow plug system s integrity and operation The test should be run anytime hard starting cold is encoun tered on a diesel engine equipped with a glow plug sys tem Tool s required Digital multimeter and or AC DC current transducer Hall Effect Testinstructions Properly connectthe currenttransduc er to the digital multimeter refer to manufacturer s Reelmaster 2300 D 2600 D Page 5 15 Voltage Measured 12 68 V or higher 12 45 V 12 24 V 50 charged 12 06 V 25 charg
211. the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System bh o E T6 Eech o0 9 FT Cutting Unit Solenoid Valve Coil The solenoid valve coil can be easily replaced without opening the hydraulic system Removal 1 Disconnect the electrical connector 2 Remove the nut from the spool assembly 3 Slide the coil assembly and O rings from the spool assembly Discard the coil assembly and O rings 4 Clean any corrosion or dirtfrom the spool assembly Installation 1 Coat new O rings lightly with petroleum jelly Slide new O rings and new coil assembly onto the spool as sembly Align the coil assembly evenly with the manifold body 2 Apply Loctite 242 or equivalent to the threads Screw the nut onto the spool assembly and torque to 15 in Ib 17 KG CM Do not over tighten Figure 26 3 Connect the electrical connector 1 Nut 3 O ring 2 Coil assembly 4 Spool assembly Electrical System Page 5 30 Reelmaster 2300
212. the pulley 27 and taper lock bushing 30 Run cap screws into tapped holes in the pulley then drive pulley off the taper lock bushing 9 Support traction charge pump 4 Remove both cap screws 31 lock nuts 32 and washers 33 from the traction charge pump and pump mount 22 Sepa rate traction charge pump from the pump mount Note Steps 10 and 11 may be performed depending on the extent of the pump repair 10 Remove fittings 7 8 15 16 and 17 and O rings 34 and 35 from the traction charge pump 4 11 Unscrew set screw 36 enough to loosen tapered lock bushing 30 Slide tapered lock bushing off the pump shaft Remove key 37 from pump shaft Hydraulic System Page 4 38 Installation Fig 23 1 Mount the traction charge pump 4 to the pump mount 22 Place both cap screws 31 through the pump mount and pump base Install washers 33 and lock nuts 32 onto cap screws Tighten cap screws 2 Place key 37 in the keyway on the pump shaft Slide taper lock bushing 30 into place on the pump shaft Tighten set screw 36 3 Insert cap screws 28 through washers 29 and pulley 27 Install pulley to taper lock bushing 30 Start cap screws into bushing and leave cap screws loose 4 Loosenset screw 36 and adjust pulley 27 so the gap between the pulley and pump mount is 0 20 inch Evenly torque cap screws from 90 to 120 in lb 104 to 138 kg cm three times each Readjust as required
213. ting 4 Install O ring 4 while connecting hose connec tions 2 onto the hydraulic fitting 8 Tighten connec tion 5 Install wheel and wheel hub to unit see Repair sec tion of Chapter 6 Wheels and Brakes Reelmaster 2300 D 2600 D Page 4 45 Hydraulic System SHUTTLE VALVE 24 SPRING 24 PLUG o 25 24 PLUG LEFT HAND MOTOR ONLY Figure 32 1 Dirt and water seal 10 Inner bearing 18 Wear plate 2 Outer bearing 11 Coupling shaft 19 Rotor 3 Housing 12 Thrust bearing 20 Vane 4 Backup washer 13 Drive link 21 Stator 5 Sealring 14 Cap screw 22 Manifold 6 Backup washer 15 Commutator seal 23 Commutator ring 7T Inner seal 16 Commutator 24 End cover assembly 8 Thrust washer 17 Woodruff key 25 O ring 9 Thrust bearing Disassembly Fig 32 If the wheel motor is not held firmly in the vise it could dislodge during service and cause injury 1 Place wheel motor in a soft jawed vice with the cou pling shaft 11 pointed down and the vise jaws clamping firmly on the sides of the housing 3 2 Scribe an alignment mark down and across the wheel motor components from the end cover 24 to the Figure 33 housing 3 for facilitating reassembly Fig 33 If in cluded in end cover loosen both shuttle valve plugs 3 Remove seven cap screws 14 Remove end cover left hand motor only for disassembly later assembly 24 and seal ring 5 Hydraulic System Page 4 46 Ree
214. traction ped al linkage is required 1 To expose traction rod remove screws securing right fender to frame and remove fender 2 Loosen jam nuts on each end of traction rod 3 Rotate rod until pedal stop cam clearance is from 0 03 to 0 09 inch 0 8 to 2 3 mm with the pedal de pressed 4 Retighten jam nuts securing traction rod adjust ment IMPORTANT Verify reverse speed with one front wheel off the ground in 2WD and the engine at high idle Reverse wheel speed should be from 120 to 140 RPM Damage may result to rear motor if this speed Figure 20 is exceeded 1 Traction rod 4 Damper bracket 2 Damper 5 Pedal cam stop 5 The stop for reverse travel under pedal may be ad Damper pivot justed for slower travel PEDAL STOP CAM p0 0 03 to 0 09 in 0 8 to 2 3 mm za CL FOOT PLATE Figure 21 Traction Pedal Damper Fig 20 1 Toexpose traction pedal damper remove right hand 4 Fully compress damper and then release it allowing panel it to extend 0 08 inch 2 0 mm Tighten locknut securing the damper pivot to the damper bracket 2 Loosen locknut securing damper pivot to the damp er bracket 5 When traction pedal is fully depressed in reverse direction traction pedal must contact reverse stop so 3 Depress traction pedal fully forward and hold the damper does not act as the stop in either direction Reelmaster 2300 D 2600 D Page 4 35 Hydraulic System Hydraulic Pump Drive Be
215. turers instruc Electrical System Page 5 16 tions Setthe multimeter on volts scale With the key off place the current transducer around the main negative battery cable and read the meter prior to activating the starter system Adjust the transducer to read zero if applicable Crank the engine for at least 3 seconds and record the results Typical starter system draw for the RM 2300 D is about 155 Amps at 65 F If current draw is significantly higher than listed check for a shorted condition If current draw is significantly lower than listed check for high resistance Reelmaster 2300 D 2600 D Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnecting the component NOTE See the Perkins 100 Series Workshop Manual for more component testing information Ignition Key Switch The ignition key switch has four positions GLOW OFF ON and START The terminals are marked as shown The circuitry of the ignition switch is shown in the chart With the use of a multimeter ohms setting the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position Verify co
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217. up under the frame so one of the front wheels is off the floor Place selector control in two wheel drive position 2 Startengine move throttle to SLOW and checkfront wheel that is off shop floor it must not be rotating Loos en pump plate nuts and rotate pump plate until creep does not occur in either direction When wheel stops ro tating tighten nuts locking adjustment Verify the adjust ment with throttle in SLOW and FAST position 3 Should the wheel continue to rotate check for the following A Ball bearing is loose or worn out B Loose or missing fasteners C Worn fasteners D Pump lever loose on control shaft E Weak or damaged leaf springs Replace F Internal pump component malfunction 4 After adjusting the pump plate check neutral switch operation and if necessary adjust as follows A Loosen locknut securing switch adjusting screw Thread away from switch until capscrew head clears switch B Rotate adjusting screw toward switch until circuit through switch is made Then turn adjusting screw an additional 2 1 2 turns C Tighten locknut Hydraulic System Page 4 34 Figure 19 1 Pump plate nut 4 Adjusting screw 2 Pump 5 Locknut 3 Neutral switch Reelmaster 2300 D 2600 D Traction Pedal If traction pedal stop cam contacts the footrest when pushed fully forward or maximum forward traction speed is unattainable an adjustment to the
218. use damage or premature dete rioration Some hoses are more susceptible to these conditions than others 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 This can be done by observing the imprint on the hose Use two wrenches hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect flats from finger tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 75 25 6 3 8 in 754 25 8 1 2 in 754 25 10 5 8 in 1 00 25 12 3 4 in 754 25 16 1 in 75 25 Reelmaster 2300 D 2600 D Page 4 3 A WARNING Before disconnecting or performing any work o
219. utch engaged so lenoid valve S1 is energized and shut hydraulic system pressure builds up and flow is diverted to the reel motors Oil flow from port P1 flows through the 11 position reel speed control valve Flow across the speed control valve is pressure compensated by the logic car Hydraulic System Page 4 14 tridge valve LC1 The logic cartridge valve maintains a pressure differential of 75 PSI 5 2 bar across the speed control valve Any excess flow above what the speed control valve is setfor is bypassed to the reservoir through the logic cartridge valve With the backlap valve MD1 in the mow position oil flows through the valve and reel motors which are connected in series Oil flows through the right center and then left reel motor as it turns the motors in the mow direction The oil then re turns to the reservoir Relief valve R1 limits system pressure and is set at 3000 PSI 207 bar When the valve opens oil is di verted back to the reservoir Backlapping operation is the same as mowing opera tion except for the position of the backlap valve MD1 The backlap valve is in the backlap position allowing oil flow through the left center and then right reel motor as it turns the motors in the backlap direction Reelmaster 2300 D 2600 D MIS
220. ve pressure set point can not be adjusted to specification go to step 9 and replace the relief valve Note Ifthe pressure and flow are within specification but the cutting units do nat lift or lift slowly check for me chanical binding or internal leakage of the lift cylinder 9 Disconnecttester from the pump and hose Recon nect hose to the pump Hydraulic System TEST NO 3 Charge Pump Relief Pressure gt TO WHEEL MOTORS VALVE TOP TO LIFT CYLINDER m BOTTOM IN FROND EL LLL FROM LIFT CYLINDER gt a 7 LI our REAR H o BOTTOM IMPLEMENT RELIEF Se ac FILTER CHARGE PUMP A lt gt iaa Ja BOTTOM RESERVOIR TRACTION PUMP gt FRONT COOLER REEL MOTOR DRIVE PUMP I RETURN FROM MANIFOLD TO MANIFOLD Se High Pressure SS sA LS Low Pressure TO CHARGE Be Return or Suction RELIEF SC CAL gt f A Flow eg A o S p M FRONT l LS Figure 14 Hydraulic System Page 4 24 Reelmaster 2300 D 2600 D Procedure for Charge Pump Relief Check 1 Make sure hydraulic oil is at normal operating tem A CAUTION perature by operating the machine for approximately 10 minutes Make sure that all hoses are free of the fly wheel after installation 2 Make sure machine is parked on a level surface with the
221. w Key Key Lock nut Cap screw Pump control rod Spacer Nut Hydraulic System Removal Fig 23 1 Before removing any parts park the machine on a level surface engage parking brake lower cutting units and stop engine Remove key from the ignition switch A CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy draulic oil 2 Clean pump assembly and hydraulic connections Label all hose connections for reassembly purposes Put caps or plugs on any hydraulic lines or fittings left open or exposed Install plug into the hydraulic reser voir 3 Remove both cap screws 1 from the pump assem bly Carefully separate the reel motor drive pump 2 and O ring 3 from the traction charge pump 4 Position reel motor drive pump away from traction charge pump 4 Remove hoses 5 and 6 from hydraulic fittings 7 and 8 Remove hose connections 9 10 11 and 12 from hydraulic fittings 15 16 and 17 Allow hoses to drain to a suitable container 5 Remove cap screw 40 and lock nut 39 from the pump control rod 41 spacer 42 and pump lever as sembly 20 6 Loosenlock nut 21 at the pump mount 22 and nut 43 at the belt adjustment yoke 25 Remove cotter pin 23 and clevis pin 24 from the belt adjustment yoke 7 Tilt pump mount 22 and remove pump drive belt 26 from the pulley 27 8 Remove cap screws 28 and lock washers 29 from
222. xternal splines and keyway for damage and wear Inspect bear ing and sealing surfaces of the coupling shaft for chip ping nicks grooves severe wear corrosion and discoloration Replace coupling shaft if any of these conditions exist Minor shaft wear in seal area is permis sible If wear exceeds 0 020 inch 0 51 mm diametrical ly replace coupling shaft A slight polish is permissible on the shaft bearing areas Fig 40 Note Do notremove inner bearing 10 thrust wash ers 8 thrust bearing 9 inner seal 7 backup wash ers 6 and 4 and outer bearing 2 from the housing 3 These parts should be inspected in place 12 Inspect housing 3 for cracks Inspect machined surfaces for nicks burrs peening and corrosion Re move burrs that can be removed without changing di mensional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas discard the housing assembly Fig 41 13 If the housing 3 has passed inspection to this point inspect outer bearing 2 inner bearing 10 thrust washers 8 and thrust bearing 9 Bearing roll ers must be firmly retained in the bearing cages but must rotate and orbit freely All rollers and thrust washers must be free of peening and corrosion If any bearing or thrust washer does not pass inspection replace the housing 3 as a complete assembly Fig 42 Figure 42 Reelmaster 2300 D 2600 D Page 4 49 Hydraulic System
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Toro 2300-D Lawn Mower User Manual

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