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Reelmaster 2300–D/2600–D

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Product Records and Manuals

Torque Specifications

Summary of Contents for REELMASTER 2300-D

Page 1: ...able 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 ING or CAUTION PERSONAL SAFETY Failure to obey the instructions may result in This safety symbol means DANGER WARN INSTRUCTION When you see this symbol carefully read the instruct...

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Page 3: ...l Information 4 3 Hydraulic Schematic 4 7 Hydraulic Flow Diagrams 4 8 Special Tools 4 16 Troubleshooting 4 17 Testing 4 19 Adjustments 4 34 Service and Repairs 4 37 Chapter 5 Electrical System Wiring Schematics 5 2 Special Tools 5 9 Troubleshooting 5 10 Electrical System Quick Checks 5 15 Component Testing 5 17 Service and Repairs 5 27 Chapter 6 Wheels and Brakes Specifications 6 2 Adjustments 6 3...

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Page 5: ...ety in structions 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 WARNING 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...

Page 6: ...al 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 Manu...

Page 7: ...ole 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 lf 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 28 Before d...

Page 8: ...4 3353 WARNING Pinch Point between Carrier Frame and Cutting Unit ON FAN SHROUD ON INSTRUMENT PANEL Part No 77 3100 Part No 94 4985 UNDER CONTROL PANEL Part No 93 6902 ON LEFT SIDE OF SEAT PANEL Part No 92 7270 Model 03427 only ON LEFT FENDER Part No 84 1650 ON LIFT ARMS Part No 93 6696 Rotating Parts ON UNDER SEAT WARNING Spring Loaded Mechanism Part No 93 6903 Read Disassembly Procedure ON INSID...

Page 9: ...DANGER Rotating Reel Will Cut Hands and Feet See Adjustment Procedures ON SHIELD Part No 93 8064 Safety Reelmaster 2300 D 2600 D Page 1 5 Safety ...

Page 10: ...Safety Page 1 6 Reelmaster 2300 D 2600 D ...

Page 11: ...AND SERVICE HISTORY REPORT form Use this information when re ferring to your machine TORQUE SPECIFICATIONS 3 Capscrew Markings and Torque Values U S 3 Capscrew Markings and Torque Values Metric 3 MAINTENANCE INTERVAL CHART 4 OPERATION AND SERVICE HISTORY REPORT 5 Insert Operator s Manuals and Parts Catalogs for your Reelmaster 2300 D 2600 D at the end of this section Product Records and Manuals Re...

Page 12: ...Equivalents and Conversions Product Records and Manuals Page 2 2 Reelmaster 2300 D 2600 D ...

Page 13: ...Product Records and Manuals Reelmaster 2300 D 2600 D Page 2 3 Product Records and Manuals Torque Specifications ...

Page 14: ...Maintenance Interval Chart Product Records and Manuals Page 2 4 Reelmaster 2300 D 2600 D ...

Page 15: ...mbers _________________________ Transmission Numbers _________________________ Date Purchased _________________________ Warranty Expires___________ Purchased From _________________________ Contacts Parts Phone___________________ Service Phone___________________ Sales Phone___________________ Product Records and Manuals See your TORO Distributor for other Publications Manuals and Videos from the TO...

Page 16: ...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 Switc...

Page 17: ...al Engine Noises2 n Unusual Operating Noises n Hydraulic System Oil Level1 n Hydraulic Hoses for Damage n Fluid Leaks n Fuel Level1 n Tire Pressure n Instrument Operation n Reel to Bedknife Adjustment n Height of Cut Adjustment Lubricate All Grease Fittings3 Touch up Damaged Paint 1 Check proper section of Operator s Manual for fluid specifications 2 Check glow plug and injector nozzles if hard st...

Page 18: ...600 D REELMASTER R 2300 D 2600 D Supervisor Maintenance Work Order Date ________________ Duplicate this page for routine use Unit Designation Hours __________________ __________________ Service to perform circle A B C D Other Remarks Technician TORO I D A Service every 50 hours Inspect Air Filter Dust Cup and Baffle Lubricate All Grease Fittings Change Engine Oil Check Fan and Alternator Belt Tens...

Page 19: ... Cleaner 10 GENERAL INFORMATION 6 Cleaning the Radiator and Screen 11 Fuel Shutoff Valves 6 Changing the Engine Oil and Filter 12 ADJUSTMENTS 7 Checking the Cooling System 12 Alternator Belt 7 Engine Removal 13 Throttle Linkage 8 Engine Reinstallation 18 PERKINS 100 SERIES WORKSHOP MANUAL Reelmaster 2300 D 2600 D Page 3 1 Engine Engine ...

Page 20: ...d in the Special Tools section The use of some specialized test equipment is explained How 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 deale...

Page 21: ...tion Fuel Injection Pump Bosch type plunger Governor Mechanical Idle Speed no load 1400 50 RPM High Idle no load 3200 50 RPM Fuel Injector Nozzle Bosch throttle type Fuel Injection Working Pressure kg cm2 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...

Page 22: ...er and use solution to wash the Donaldson air cleaner element Figure 1 Diesel Engine Compression Test Kit This 0 to 1000 PSI gauge allows testing of diesel en gines for checking the general operating condition of the engine The kit includes a case gauge with hose glow plug hole adapters and instructions Figure 2 Nozzle Tester This tests the condition and opening pressure of fuel in jection nozzles...

Page 23: ...Nozzle Test Adapter This adapter is required to test the fuel injection nozzles Figure 4 Engine Reelmaster 2300 D 2600 D Page 3 5 Engine ...

Page 24: ...ves These valves should be shut when removing the engine or placing the unit in long term storage 1 Figure 5 1 Fuel shut off under the fuel tank 1 Figure 6 1 Fuel shut off valve on the fuel filter Engine Page 3 6 Reelmaster 2300 D 2600 D ...

Page 25: ...or pulleys Fig 8 4 Tighten bolts securing the alternator to the engine 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 ...

Page 26: ...e speed to 1400 50 RPM with the throttle control lever 4 adjust low speed stop screw if necessary 7 Make sure throttle control lever 4 is down so the governor lever on the engine touches the low speed ad 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 en...

Page 27: ...w 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 a steady stream of fuel flows out of the trans fer pump screw 1 tighten screw and retain noted fitting angle 5 from step 5 abo...

Page 28: ...se filter element from the clean side to the dirty 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 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 no...

Page 29: ...er 3 can be removed from the radiator for cleaning 3 CAUTION Use eye protection such as goggles when using compressed air Figure 13 1 Radiator screen 3 Oil cooler 2 Radiator 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 c...

Page 30: ...with filter The engine uses any high quality 10W30 detergent oil having the American Petroleum In stitute API service classification CD 4 Add oil to the crankcase A Remove oil fill cap Fig 14 and gradually add 1 small quantities of oil Figure 15 B Check oil level frequently until the level reaches 1 Dipstick the FULL mark on dipstick Fig 15 When removing the dipstick wipe it with a clean rag prior...

Page 31: ...nut 4 securing the left footrest 5 to the frame Fig 17 Slide the left foot rest off the adjusting rod 2 Fig 18 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 f...

Page 32: ... 15 Muffler tube 16 Muffler bracket 17 U bolt 18 Upper radiator hose 19 Muffler clamp 20 Nut 21 Lock washer 22 Left rear mount bracket 23 Hose clamp 24 Lower radiator hose 25 Engine 26 Throttle cable clamp 27 Flange nut 28 Throttle cable bracket 29 Clevis pin 30 Cotter pin 31 Throttle tab 32 Flat washer 33 Lock washer 34 Front mount bracket 35 Insert nut 36 Cap screw 37 Clutch spindle 38 Hose clam...

Page 33: ...ulic elbow fitting 3 Plug hose and fitting to prevent leakage and con tamination Fig 21 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 19 from the muffler 14 and muffler tube 15 B Loosen nut 20 and U clamp 17 Separate muffler tube from muf...

Page 34: ...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 ...

Page 35: ...ll be supported when the cap screws 42 securing the engine mount brackets 22 34 and 46 are removed 1 2 C Remove cap screws 42 and flange nuts 27 from the engine mount brackets 22 34 and 46 and the frame 1 Lifting tab Figure 24 2 Cylinder head 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 ...

Page 36: ...talling the engine 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 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 5 Reinstall radiator assembly A Place radiat...

Page 37: ...hose to the engine 25 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...

Page 38: ...Engine Page 3 20 Reelmaster 2300 D 2600 D ...

Page 39: ...mp Cavitation 18 Reels Will Not Turn 18 Reel Speed Is Erratic 18 Reel Motor Case Drain Flow Is Excessive 18 Cutting Units Will Not Lift or Lift Slowly 18 Cutting Units Raise but Will Not Stay Up 18 TESTING 19 Test No 1 Traction Pump Flow 20 Test No 2 Charge Pump Flow and Implement Relief Pressure 22 Test No 3 Charge Relief Pressure 24 Test No 4 Real Drive Pump Efficiency 26 Test No 5 Manifold Reli...

Page 40: ...ed Speed and Pressure 15 GPM 57 LPM Reel Motor Drive Pump Positive displacement gear type pump Maximum Operating Pressure 4000 PSI 276 bar Maximum Intermittent Pressure 4400 PSI 304 bar Maximum Rated Speed 4000 RPM Rated Flow Maximum Rated Speed and Pressure 8 5 GPM 32 LPM Hydraulic Manifold Relief Valve Differential area relief valve Cutting Circuit Relief Pressure 2700 to 3300 PSI 186 3 to 227 7...

Page 41: ...enetrate the injected into the skin it must be surgical ly removed within a few hours by a doctor Hydraulic fluid escaping under pressure skin and cause serious injury If fluid is familiar with this type of injury Gangrene may result from such an injury WARNING Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any for...

Page 42: ...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...

Page 43: ...ich 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 Page 4 5 1 2 ...

Page 44: ...ontacts 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 rever...

Page 45: ...3 25 2cc GEAR PUMP 49 in3 8 0cc TRACTION PUMP 1 24 in3 20 3 cc CHARGE PUMP 42 IN3 6 9CC REEL RELIEF 3000 psi FCI CROSS OVER RELIEF 1500 PSI Hydraulic Schematic Reelmaster 2300 D 2600 D Solenoid S1 is shown de energized Hydraulic System Hydraulic Schematic TOP BOTTOM WHEEL MOTOR FORWARD 2WD 3WD SELECTOR WHEEL MOTOR WHEEL MOTOR LIFT CYL LIFT CYL VALVE TOP A BOTTOM FORWARD VALVE OUT REAR BOTTOM TOP T...

Page 46: ...ut the top of the control valve to the lower and outer portions of the lift cylinders Hydraulic pressure against the cylinder pistons pushes the shafts out At the same time the pis tons push the hydraulic fluid in the upper and inner por tions of the lift cylinders out and through the control valve to the piston pump suction When the control valve lever is released spring action returns the spool ...

Page 47: ...M LOW PRESSURE COOLER MD1 BACKLAPPING REEL ON OFF OUTER 12 in3 197cc 12 in3 197cc 12 in3 197cc 2 3 GALLON 8 7 LITER 475 psi CHARGE RELIEF 100 150 psi 1 54 in3 25 2cc GEAR PUMP 49 in3 8 0cc TRACTION PUMP 1 24 in3 20 3 cc CHARGE PUMP 42 IN3 6 9CC REEL RELIEF 3000 psi FCI CROSS OVER RELIEF 1500 PSI TOP BOTTOM WHEEL MOTOR FORWARD 2WD 3WD SELECTOR WHEEL MOTOR WHEEL MOTOR LIFT CYL LIFT CYL VALVE TOP A B...

Page 48: ...ck valve portion of the PC flow controller before returning to the traction pump 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 hydraulic oil is supplied to the traction circuit from the charge pump though the lift control valv...

Page 49: ...L ON OFF OUTER 12 in3 197cc 12 in3 197cc 12 in3 197cc 2 3 GALLON 8 7 LITER 475 psi CHARGE RELIEF 100 150 psi 1 54 in3 25 2cc GEAR PUMP 49 in3 8 0cc TRACTION PUMP 1 24 in3 20 3 cc CHARGE PUMP 42 IN3 6 9CC REEL RELIEF 3000 psi FCI CROSS OVER RELIEF 1500 PSI Traction TOP BOTTOM WHEEL MOTOR FORWARD 2WD 3WD SELECTOR WHEEL MOTOR WHEEL MOTOR VALVE TOP A BOTTOM FORWARD VALVE OUT REAR BOTTOM TOP TOP TOW VA...

Page 50: ...of the traction pump and is continuously pumped out the 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 w...

Page 51: ...L ON OFF OUTER 12 in3 197cc 12 in3 197cc 12 in3 197cc 2 3 GALLON 8 7 LITER 425 psi CHARGE RELIEF 100 150 psi 1 54 in3 25 2cc GEAR PUMP 49 in3 8 0cc TRACTION PUMP 1 24 in3 20 3 cc CHARGE PUMP 42 IN3 6 9CC REEL RELIEF 3000 psi FCI CROSS OVER RELIEF 1500 PSI Traction TOP BOTTOM WHEEL MOTOR FORWARD 2WD 3WD SELECTOR WHEEL MOTOR WHEEL MOTOR VALVE TOP A BOTTOM FORWARD VALVE OUT REAR BOTTOM TOP TOP TOW VA...

Page 52: ...ntrol valve Flow across the speed control valve is pressure compensated by the logic car 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 set for is bypassed to the reservoir through the logic cartridge valve With the backlap valve MD1 in the mow position oil flows thr...

Page 53: ...LAPPING REEL ON OFF OUTER 12 in3 197cc 12 in3 197cc 12 in3 197cc 2 3 GALLON 8 7 LITER 425 psi CHARGE RELIEF 100 150 psi 1 54 in3 25 2cc GEAR PUMP 49 in3 8 0cc TRACTION PUMP 1 24 in3 20 3 cc CHARGE PUMP 42 IN3 6 9CC REEL RELIEF 3000 psi FCI CROSS OVER RELIEF 1500 PSI Hydraulic System Valve MD1 is selected to mow TOP BOTTOM WHEEL MOTOR FORWARD 2WD 3WD SELECTOR WHEEL MOTOR WHEEL MOTOR LIFT CYL LIFT C...

Page 54: ... 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 A protector valve cuts out when pressure is about to exceed the normal range for th...

Page 57: ...us injury If fluid is familiar with this type of injury Gangrene may result from such an injury WARNING 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 sive wear of components 2 Put caps or plugs on any hydraulic lines left open or exposed d...

Page 58: ...STER FRONT DISCHARGE High Pressure Low Pressure Return or Suction Flow TOP BOTTOM WHEEL MOTOR FORWARD WHEEL MOTOR FORWARD BOTTOM TOP FORWARD TO REAR WHEEL MOTOR FROM REAR WHEEL MOTOR FROM CONTROL VALVE TO CONTROL VALVE FROM FROM RESERVOIR TO RESERVOIR TO HYDRAULIC MANIFOLD PORT T2 Figure 12 Hydraulic System Page 4 20 Reelmaster 2300 D 2600 D ...

Page 59: ...ystem pressure and avoid injury from pressurized hydraulic oil 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 and 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...

Page 60: ...ACTION PUMP REEL DRIVE PUMP COOLER TESTER RETURN FROM MANIFOL FRONT DISCHARGE High Pressure Low Pressure Return or Suction Flow TOP BOTTOM CONTROL VALVE VALVE TOP BOTTOM FILTER OUT REAR BOTTOM MOTOR TO LIFT CYLINDER FROM LIFT CYLINDER TO WHEEL MOTORS TO MANIFOLD Figure 13 Hydraulic System Page 4 22 Reelmaster 2300 D 2600 D ...

Page 61: ...ift 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...

Page 62: ...E PUMP COOLER RETURN FROM MANIFOLD FRONT RELIEF High Pressure Low Pressure Return or Suction Flow TOP BOTTOM CONTROL VALVE VALVE TOP BOTTOM FILTER OUT REAR BOTTOM MOTOR T CONNECTION AND GAUGE TO LIFT CYLINDER FROM LIFT CYLINDER TO WHEEL MOTORS TO MANIFOLD TO CHARGE Figure 14 Hydraulic System Page 4 24 Reelmaster 2300 D 2600 D ...

Page 63: ...ulic oil is at operating temperature CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 7 Make sure that traction pedal and lift valve are in 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 9 Shut off engine 10 Disconnect gauge and T conne...

Page 64: ... M6 M4 D2 M3 T2 High Pressure Low Pressure Return or Suction Flow COOLER FC1 FROM LEFT HYDRAULIC MANIFOLD TESTER 2 1 3 3 FILTER BOTTOM TO CHARGE PUMP WHEEL MOTOR TO TRACTION PUMP REEL DRIVE PUMP Figure 15 1 Hose fitting 2 Reel drive pump 3 O ring Hydraulic System Page 4 26 Reelmaster 2300 D 2600 D ...

Page 65: ...perate 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 9 W...

Page 66: ...e Low Pressure Return or Suction Flow HYDRAULIC MANIFOLD FROM REEL DRIVE PUMP TESTER Install tester in series between fitting and hose at the motor right hand motor shown TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR SHUTTLE VALVE Figure 16 Hydraulic System Page 4 28 Reelmaster 2300 D 2600 D ...

Page 67: ... 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 ...

Page 68: ...D2 M3 High Pressure Low Pressure Return or Suction Flow HYDRAULIC MANIFOLD FROM REEL DRIVE PUMP TESTING IN BACKLAP TESTING IN MOW TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR TEST GAUGE T CONNECTION AND GAUGE Figure 17 Hydraulic System Page 4 30 Reelmaster 2300 D 2600 D ...

Page 69: ...o 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 manif...

Page 70: ...R H REEL MOTOR SHOWN G1 FROM REEL MOTOR DRIVE PUMP M2 RH D1 MD1 TESTER M1 TO COOLER M5 CTR D3 M6 M4 LH FROM CARTRIDGE D2 VALVES AND LEFT WHEEL MOTOR M3 High Pressure HYDRAULIC MANIFOLD Low Pressure Return or Suction Flow Figure 18 Hydraulic System Page 4 32 Reelmaster 2300 D 2600 D ...

Page 71: ...st 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 slowly 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...

Page 72: ...le 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 Figure 19 3 4 5 1 2 E Weak or damaged Ieaf springs Replace 1 Pump plate nut 4 Adjusting screw 2 Pump F Internal pump component malfunction 3 Neutral switch 5 Lock nut 4 After adjusting the pu...

Page 73: ...y result to rear motor if this speed is exceeded 5 The stop for reverse travel under pedal may be ad justed for slower travel 1 2 3 4 5 Figure 20 1 Traction rod 4 Damper bracket 2 Damper 5 Pedal cam stop 3 Damper pivot PEDAL STOP CAM 0 03 to 0 09 in 0 8 to 2 3 mm FOOT PLATE Figure 21 Hydraulic System Traction Pedal Damper Fig 20 1 To expose traction pedal damper remove right hand panel 2 Loosen lo...

Page 74: ... 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 1 1 Nut 2 Adjustment rod Hydrauli...

Page 75: ...itting 17 Hydraulic fitting 18 Cap screw 19 Flat washer 20 Pump lever assembly 21 Lock nut 22 Pump mount 23 Cotter pin 24 Clevis pin 25 Belt adjustment yoke 26 Pump drive belt 27 Pulley 28 Cap screw 29 Lock washer 30 Tapered lock bushing 31 Cap screw 32 Lock nut 33 Washer 34 O ring 35 O ring 36 Set screw 37 Key 38 Key 39 Lock nut 40 Cap screw 41 Pump control rod 42 Spacer 43 Nut Figure 23 1 13 10 ...

Page 76: ...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 an...

Page 77: ...aft seal 10 O ring 24 Gasket 37 Retaining ring 11 Washer 25 Backplate assembly 38 O ring 12 Inner race 26 O ring 39 O ring 13 Bearing 27 Cap screw 40 O ring 14 Bearing Disassembly Fig 24 4 Remove outer ring from either the inner ring of the gerotor assembly 3 or the charge pump adapter as 1 Position pump into a vise with protected jaws so the sembly 2 Further disassembly of the gerotor assem charg...

Page 78: ...he 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 follows see Fig 26 A Remove nine piston assemblies spider and spi der pivot from the piston block CAUTION Be careful when removing the spring before removing the retaining ring from...

Page 79: ... 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...

Page 80: ...tall retaining ring 37 into the flanged end of the housing assembly 15 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 15 16 in O D flat washers 1 5 16 in 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 of the block...

Page 81: ... 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 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 m 20 Coat O ring 26 and outer ring of gerotor assembly...

Page 82: ...rt 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...

Page 83: ...ner 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 screw...

Page 84: ...f 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 1 firmly on the sides of the housing 3 2 Scribe an alignment mark down and across the cause injury WARNING Place wheel motor in a soft jawed vice with the cou pling shaft 11 pointed down and the vise jaws clamping wheel motor components from the end cover 24 to...

Page 85: ...ne components for 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...

Page 86: ...y 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 rotation is normal Note The rotor set consists of the rotor 19 vanes 20 and stator 21 Rotor set components may be come disassembl...

Page 87: ...ft A slight polish is permissible on the shaft bearing areas Fig 40 Note Do not remove 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 changi...

Page 88: ... 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 ...

Page 89: ...in 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 counterbore and seal ring ...

Page 90: ... 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 ov...

Page 91: ...lace 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 23 Torque the two 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 requir...

Page 92: ...key from the ignition switch 1 CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil 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 2 Clean two position valve 1 and ...

Page 93: ...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 11 Boot 12 Set screw 13 Valve stop 14 Lock washer 15 Knob Inspection Fig 52 CAUTION Use eye protection such as goggles when using compressed air 1 Wash all parts in solvent Dry parts...

Page 94: ...he 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...

Page 95: ...e 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 12 1 3 2 4 8 10 6 7 11 9 5 INLET PORT Figure 53 1 Reel motor drive pump 7 O ring 2 Hose clamp 8 O rin...

Page 96: ...Note 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 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 hous...

Page 97: ...inlet side of the mounting flange 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 fr...

Page 98: ...isconnected 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 Inspect threads and sealing surfaces of h...

Page 99: ...17 and back plate 7 to assure proper reassembly up washer 18 from the frontplate 14 3 Secure the motor in a vise with the drive shaft up IMPORTANT Do not remove the relief valve assem bly 19 unless testing shows it to be faulty The re 4 Remove all eight screws 15 lief valve assembly must be replaced as a complete unit Both relief valve seals 6 are sealed in place 5 Remove the motor from the vise R...

Page 100: ...ockets exceeds 1 713 in 43 5 mm backplate is not being replaced Reassembly Fig 56 1 If replacing 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...

Page 101: ...fold and hydraulic connections Dis connect hydraulic lines Label all connections for reassembly C Allow hydraulic lines to drain into a suitable con tainer Put caps 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 fr...

Page 102: ...alve 16 Locating plate w pin 17 Seal kit 18 Spool two position directional valve 19 Locating plate w pin 20 Plug 21 O ring 22 Manifold body 23 Ball 2 per assembly 24 Spring 2 per assembly 25 Knob 26 Jam nuts 27 Indicator plate 28 Detent plate 29 Set screw 30 Spring 2 per assembly 31 Indicator plate Figure 58 2 3 4 5 6 7 8 10 11 16 17 18 19 20 21 22 12 13 14 15 3 3 3 3 4 4 4 4 3 4 9 9 7 20 21 12 13...

Page 103: ...asily without binding Note Use care 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...

Page 104: ...8 Make sure damage to the sealing surfaces damaged threads and the arrow points to the right at 45_ contamination F On spool two position directional valve 18 5 Visually inspect spool valve 15 or 18 for damaged place indicator plate 31 over the detent plate 28 sealing surfaces and contamination Make sure the arrow points directly at the number 1 on the locating plate 16 A Contamination may cause v...

Page 105: ...ngs 6 O ring 7 O ring 8 Lift cylinder 9 Cotter pin 10 Clevis pin 11 Cap screw 12 Lift hub 13 Cotter pin 14 Clevis pin 15 Clevis 16 Cylinder guide 17 Cylinder support bracket 18 Flange bushings 19 Valve mount bracket 20 Clevis Figure 59 1 6 2 6 3 9 7 16 6 4 13 14 16 11 18 18 19 10 5 8 12 INSTALL FLANGE BUSHING 18 FROM THE INSIDE FITTING SIDE 15 Hydraulic System ...

Page 106: ... and out from the frame Lift hub from the cylinder support bracket 17 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 brack...

Page 107: ...ith 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 ...

Page 108: ...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 ...

Page 109: ...ace engage the parking brake lower the cutting units and stop the en gine Remove the key from the ignition switch 2 Label all connections for reassembly Disconnect hose connections 1 and 2 from hydraulic fittings 3 and 4 Allow hoses to drain into a suitable container CAUTION CAUTION The rear lift cylinder is located near the burns allow the exhaust pipe to cool be Operate all hydraulic controls to...

Page 110: ... 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 Adj...

Page 111: ...d bending Replace if worn or damaged 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 IM...

Page 112: ...8 Connecting link assembly 9 Control valve 10 Hydraulic fitting 11 Hose connection 12 Tube 13 Hydraulic fitting 14 Hose connection 15 Hose connection 16 Lock nut 17 Support bracket 18 Tube 19 Relief valve body 20 Relief valve cartridge 21 O ring 22 O ring 23 O ring 24 O ring Figure 65 6 5 8 23 9 4 3 2 1 24 24 23 18 23 19 17 21 13 22 15 14 22 13 21 23 2 24 12 24 10 24 11 20 7 16 ...

Page 113: ...draulic 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 4 Position control valve 9 into unit and slide onto support bracket 17 5 Slide cap 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 connectio...

Page 114: ...ing 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 val...

Page 115: ...at washer 12 Cap screw 13 Carriage screw 14 Hose clamp 15 Hydraulic hose 16 Hydraulic fitting 17 U bracket support 18 Cap screw 19 Hydraulic hose 20 Oil filter element 21 Oil filter head 22 90_ fitting 23 Hydraulic hose 24 Hydraulic hose 25 Hydraulic hose 26 O ring 27 Hydraulic fitting Figure 67 14 22 20 2 15 10 13 5 11 18 17 5 4 13 8 15 27 6 12 3 7 1 9 10 11 12 5 25 14 21 16 14 19 3 23 24 14 26 2...

Page 116: ...e 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 hydraulic hoses if worn or leaking Hydraulic System Page 4 78 Reelmaster 2300 D 2600 D ...

Page 117: ...n Note Use biodegradable fluid such as Mobil EAL 1 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 Disconnect electrical connector to the fuel stop so lenoid to prevent engine from starting 7 Turn ignition key s...

Page 118: ...ngage 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 CAUTION Be careful wh...

Page 119: ...stem Test 15 Starting System Test 16 COMPONENT TESTING 17 Ignition Key Switch 17 Starter and High Temperature Shutdown Relays 18 High Temperature Shut Down Switch 18 Oil Pressure Switch 19 Hour Meter 19 Indicator Lights and Circuits 20 Temperature Sending Unit 21 Temperature Gauge 21 Diode Circuit Board 22 Fuel Valve Solenoid 23 Cutting Unit Solenoid Valve Coil 23 Traction Electric Clutch 24 Tract...

Page 120: ...SING 3 AMP 3 AMP B A CONNECTOR GREY PURPLE BLACK BLACK PURPLE SOLENOID PURPLE FUEL VALVE ENERGIZED TO RUN PURPLE WHITE BLACK BLACK BLACK RED B S ENGINE WHITE RED RED FUSIBLE LINK WIRE 14 GA 10 LG RED WHITE RED BLACK WHITE WHITE IGNITION SWITCH 50 19 17 AC 30 ON GLOW SOLENOID BATTERY STARTER TORO 92 1714 GRAY START 30 AC 50 30 AC 17 19 30 AC 85 86 87A 30 STARTER RELAY 87 BLACK GREY TAN ORANGE WHITE...

Page 121: ...7 AC 30 ON GLOW ENGINE GLOW PLUGS ORANGE WHITE WHITE 85 86 30 87A 87 BLACK 86 85 87 30 87A GREY SWITCH HIGH TEMP SHUTDOWN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE B...

Page 122: ...ORANGE WHITE WHITE 85 86 30 87A 87 BLACK 86 85 87 30 87A GREY SWITCH HIGH TEMP SHUTDOWN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE BLACK PINK PURPLE WHITE Run Circuit...

Page 123: ... AC 30 ON GLOW ENGINE GLOW PLUGS ORANGE WHITE WHITE 85 86 30 87A 87 BLACK 86 85 87 30 87A GREY SWITCH HIGH TEMP SHUTDOWN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE BL...

Page 124: ... 86 85 87 30 87A GREY SWITCH HIGH TEMP SHUTDOWN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE BLACK PINK PURPLE WHITE Run Backlap Circuits Reelmaster 2300 D HIGH TEMP SH...

Page 125: ...AC 30 ON GLOW ENGINE GLOW PLUGS ORANGE WHITE WHITE 85 86 30 87A 87 BLACK 86 85 87 30 87A GREY SWITCH HIGH TEMP SHUTDOWN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE BLA...

Page 126: ...WN GREEN YELLOW BROWN WHITE 1 2 3 4 5 6 GREEN GREEN BROWN BROWN OIL PRESSURE SWITCH BLUE YELLOW GREEN RED BLUE BLACK TRACTION CLUTCH CLOSED BLUE WHITE COLD SWITCH ORANGE WHITE BLACK REELS TURNING RED BLACK BLACK I TEMP GAUGE G S RED BLACK HOUR METER TEMP SENDING UNIT BLACK WHITE BLACK PINK PURPLE WHITE Indication and Safety Circuits Reelmaster 2300 D HIGH TEMP SHUTDOWN SOLENOID CLOSED ON LOW PRESS...

Page 127: ...olt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of 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 Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin which helps waterproof electr...

Page 128: ...ow 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 causing incomplete circuit for solenoid Nothing happens when start attempt is made Cutting unit switch is ON pulled out or faulty Battery is dead Battery cable...

Page 129: ...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 p...

Page 130: ...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 Battery does not charge 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 ...

Page 131: ... should not when raised Cutting unit interlock switch is faulty However they shut off with the cutting unit switch Cutting units shut off when raised However they do Cutting unit switch is faulty or short circuited not shut off with the cutting unit switch Cutting units do not engage Wiring to run mow backlap circuits see Wiring Schematics components is loose corroded or damaged ACC fuse 10 amp is...

Page 132: ...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 malf...

Page 133: ...g 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 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 Initial Battery Voltage 12 30v Battery ...

Page 134: ...cer to the digital multimeter refer to manufacturers instruc tions Set the 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 ...

Page 135: ...nected When testing electrical components for continuity with a multimeter ohms set 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 t...

Page 136: ...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 temperature shu...

Page 137: ...ure lamp should go out 4 If the light is still on check for short circuiting in the indication circuit see Indicating and Safety Circuits 5 Return ignition switch to OFF and connect the brown wire to the switch 1 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 p...

Page 138: ...e 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 Turn the 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 co...

Page 139: ...tting as the 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 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 S I G VARIABLE RESISTANCE 63 TO 79 OHMS 12 VDC 1 Connect the temperature gauge to the var...

Page 140: ...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 D4 DIODE A B C D E F G H D2 D3 D1 CIRCUIT BOARD contacts from induction voltage spikes...

Page 141: ... The solenoid may be removed from the engine or tested in place TERMINAL PLUNGER 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 4 Disconnect the test leads from the solenoid 5 Connect the wire to the solenoid if tested in place Cutting ...

Page 142: ...m 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 Connect a 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 Connect the ...

Page 143: ...ch 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 Figure 21 1 3 With the seat lowered and no operator in the seat 1 Seat interlock switch there should be no continuity between the terminals 4 Have an operator slowly sit in the seat There should be continuity as ...

Page 144: ...t switch electrical connector 1 Figure 23 1 Cutting unit interlock switch 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...

Page 145: ...ng inspection and maintenance tasks A Check for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking 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 COV...

Page 146: ...the manufacturer s instruc tions Connect a digital multimeter to the battery terminals F Apply a test load 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 Minimum Voltage Battery Electrolyte Temperature 9 6 70_F and up 21 1_C and up 9 5 60_F 15 6_C 9 4 50_F 10 0_C 9 3 40_F 4 4_C 9 1 30_F 1 1_C 8 9 2...

Page 147: ...urer s instructions con nect the charger cables to the battery Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 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 Minutes Minutes 75 50 25 0 80 or less 3 8 hrs 7 5 hrs 11 3 ...

Page 148: ... corrosion or dirt from 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 lb 17 KG CM Do not over tighten 4 2 Loctite 242 Figure 26 3 Connect th...

Page 149: ...asher 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 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 ca...

Page 150: ...hten 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 tigh...

Page 151: ...kes Table of Contents SPECIFICATIONS 2 SERVICE AND REPAIRS 4 ADJUSTMENTS 3 Rear Wheel 3WD 4 Hand Brake Adjustment 3 Rear Wheel 2WD 5 Front Wheel and Brake 6 Reelmaster 2300 D 2600 D Page 6 1 Wheels and Brakes Wheels and Brakes ...

Page 152: ...ure 2 ply Older models 8 to 10 PSI 0 55 to 0 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 ...

Page 153: ...e 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 upper 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...

Page 154: ...ub 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...

Page 155: ...rim 6 re 3 Castor axle 7 Bearing place with new bearings as follows 4 Castor fork 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 Press the remaining new bearing 7 into the oth er side of the rim and over the spacer so the flange...

Page 156: ...20 Lug tire 21 Lock rim 22 Lug nut 23 Wheel hub stud 24 Socket head screw 25 Brake bracket 26 Wheel shield 27 Cotter pin 28 Brake arm assembly RH 29 Brake arm assembly LH 30 Roll pin 31 Clevis pin 32 Brake lever assembly 33 Clevis 34 Hex nut 35 Adjusting rod 36 thrust washer 37 Brake shaft 38 Wheel motor LH 39 Spacer 40 Lock nut 41 Valve stem 42 Extension spring 43 Pivot pin 44 Brake plate 45 O ri...

Page 157: ...m for excessive wear Replace any worn or damaged parts 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 Inst...

Page 158: ...Wheels and Brakes Page 6 8 Reelmaster 2300 D 2600 D ...

Page 159: ...asing Bearings Bushings and Pivot Points 11 Backlapping 12 Hydraulic Motor Removal and Installation 13 Cutting Unit Removal and Installation 14 Bedbar Removal and Installation 16 Bedknife Replacement and Grinding 18 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...

Page 160: ...dexed 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 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 Mode...

Page 161: ...S Some tools may have been supplied with your machine or available as TORO parts Some tools may also be available from a local supplier Gauge Bar Assembly Use gauge bar to verify height of cut Gauge Bar Figure 2 Handle Assembly For applying lapping compound to cutting units while keep hands a safe distance from the rotating reel Figure 3 Cutting Units ...

Page 162: ...pe 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 Figure 4 Cutting Units Page 7 4 Reelmaster 2300 D 2600 D ...

Page 163: ...te 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 section of Chapter 4 Hydraulic System 3 Cutting unit counter balance tension adjustment The counter balance spring on each cutting unit lift arm can be adjusted to com...

Page 164: ...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 unit...

Page 165: ... 3 2 4 lift lever cutting units can lower without WARNING Figure 5 4 Move shackle up or down the counter balance arm until it aligns with the desired hole of the arm 1 Clevis pin 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 bla...

Page 166: ...ring 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 against the front face of the 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 o...

Page 167: ...aper is pinched lightly which results in a slight drag when paper is pulled 3 Check for 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 Adjust nuts 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 t...

Page 168: ...ghtly 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 Figure 10 1 Gauge bar 2 Front roller bracket nut 3 F...

Page 169: ...n models 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 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 ou...

Page 170: ...pulling out knob on instrument panel 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 1 2 Figure 13 1 Backlap knob 2 Reel speed 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 en...

Page 171: ...e unit from the other side If so 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 ...

Page 172: ... 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 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 1 Place thrust washer on pivot rod f...

Page 173: ...r rier frame with the capscrews and lock washers Fig 16 6 Insert a breaker bar into the square hole in the coun terbalance arm and pivot the counterbalance arm back to its original position aligning the cap screw hole fig 15 1 RM2600 TIPPER CHAIN IS CONNECTED TO THE BOTTOM OF THE FRAME 7 Secure bottom of counter balance arm to frame with Figure 18 the bottom capscrew Tighten top cap screw Fig 15 1...

Page 174: ...ly 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 c...

Page 175: ... 9 1 5 6 7 4 2 9 10 8 1 Carriage bolt and nut 2 Bedbar housing 3 Bedbar 4 Capscrew 5 Lock washer 6 Flat washer 7 Spacer 8 Bedbar washer 9 Adjusting housing 10 Bushing assembly 11 Flanged bushing 12 Bedknife screw 13 Bedknife 13 3 12 Figure 21 Cutting Units ...

Page 176: ...nstalling 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 ...

Page 177: ... 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 Hold one 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 lb 5 8 kg cm rol ling torque and have no bearing end play 5 Make sure roller brackets are aligned prior to in...

Page 178: ...n 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 4 If disassembling a full roller pour the oil from inside the roller into a suitable container 5 Secure roller in a vise 6 Remove outer sea...

Page 179: ...l 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 bo...

Page 180: ...to 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 from dropping when the bearing housings are removed 6 Remove capscrews from both bearing housings Pull bearing housings and bearings from reel 7 Rotate bearings within the b...

Page 181: ...sure bearing housings are installed with the grease fittings pointing to the front of the cutting unit 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 ...

Page 182: ...eing 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 Ad...

Page 183: ...g unit Fig 29 4 Attach 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 7 Repeat steps 1 through 6 for the other side of the cutting unit 1 Pop rivet 2 Height of cut plate 3 Lock nut 4 Capscrew 5 Washer 6 Link 4 6 1 2 5 3 Figure 28 1 Fixed...

Page 184: ...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 3 1 4 5 2 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 ...

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Page 186: ...Commercial Products The Toro Company ...

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Toro REELMASTER 2300-D, Service Manual, Page: 13 / 186

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