Toro 2600D manual

Part No. 96876SL Rev . A Service Manual Reelmaster  2300–D/2600–D 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 OPERA TOR’S MANUALS FOR OPE[...]

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Reelmaster 2300–D/2600–D T able Of Contents Chapter 1 – Safety Safety Instructions 1 – 1 . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and Instruction Decals 1 – 4 . . . . . . . . . . . . . . . . Chapter 2 – Product Records and Manuals Product Records 2 – 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents[...]

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W ARNING Reelmaster 2300–D/2600–D Page 1 – 1 Safety Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 1 . . . . . . . . . . . . . . . . . . . . . . Before Operating 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service 3 . . . . . . . .[...]

Reelmaster 2300–D/2600–D Page 1 – 2 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. lf a shield, safety device or decal is damaged, malfunc- tioning or illegible, repair or replace it before operating t[...]

Safety Rev . A Reelmaster 2300–D/2600–D Page 1 – 3 Safety 20. Before getting off the seat: A. Move the traction pedal to neutral. B. Set the parking brake. C. Disengage the cutting units and wait for the reels to stop spinning. D. Stop the engine and remove the key from the ig- nition switch. 21. Whenever the machine is left unattended, make [...]

Reelmaster 2300–D/2600–D Page 1 – 4 Safety Safety and Instruction Decals The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed below and in your Parts Catalog. Order replacements from your Authorized T oro Distributor . ON INSTRUMEN[...]

Reelmaster 2300–D/2600–D Page 1 – 5 Safety    ') &   &))!%  # !## *) %( % )  "*()$%) '&*'( Safety[...]

Reelmaster 2300–D/2600–D Page 1 – 6 Safety[...]

Reelmaster 2300–D/2600–D Page 2 – 1 Product Records and Manuals Chapter 2 Product Records and Manuals T able of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . EQUIV ALENTS AND CONVERSIONS 2 . . . . . . . . . . . Decimal and Millimeter Equivalents 2 . . . . . . . . . . . . U.S. to Metric Conversions 2 . . . . . . [...]

Reelmaster 2300–D/2600–D Page 2 – 2 Product Records and Manuals Equivalents and Conversions[...]

Product Records and Manuals Reelmaster 2300–D/2600–D Page 2 – 3 Product Records and Manuals T orque Specifications[...]

Reelmaster 2300–D/2600–D Page 2 – 4 Product Records and Manuals Maintenance Interval Chart[...]

Reelmaster 2300–D/2600–D Page 2 – 5 Product Records and Manuals EQUIPMENT OPERA TION AND SER VICE HISTOR Y REPORT for REELMASTER  2300–D/2600–D TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ T ransmission Numbers: _________________________ Date Purchased: _________________________ W [...]

Reelmaster 2300–D/2600–D Page 2 – 6 Product Records and Manuals REELMASTER R 2300–D/2600–D Maintenance Schedule Minimum Recommended Maintenance Intervals: Inspect Air Filter , Dust Cup, and Baffle Lubricate All Grease Fittings { Change Engine Oil { Check Fan and Alternator Belt T ensions Maintenance Procedure Every 50hrs Every 100hrs E[...]

Unit Designation: ____________ TORO ID #: ________–________ Reelmaster 2300–D/2600–D Page 2 – 7 Product Records and Manuals REELMASTER R 2300–D/2600–D Daily Maintenance Check List Daily Maintenance: (duplicate this page for routine use) Maintenance Daily Maintenance Check For Week Of ________________ Maintenance Check Item b MON ____[...]

REELMASTER 2300–D/2600–D Supervisor Maintenance Work Order R Date: ________________ Unit Designation: Hours: T echnician: TORO I.D. #: __________________–__________________ Service to perform (circle): A B C D Other Remarks: Form No. 95–872–SL (See Operator ’s and Service Manual for specifications and procedures.) A– Service (every 50[...]

Reelmaster 2300–D/2600–D Page 3 – 1 Engine Chapter 3 Engine T able of Contents INTRODUCTION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 6 . . . . . . . . . [...]

Reelmaster 2300–D/2600–D Page 3 – 2 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 de[...]

Reelmaster 2300–D/2600–D Page 3 – 3 Engine Specifications Item Description Make / Designation Perkins, vertical in–line, 4–stroke, water–cooled Diesel, 103–07 KL 70275 & KL 70372 Combustion Chamber IDI special swirl–combustion type Number of Cylinders 3 Bore x Stroke mm (in.) 67 x 64 (2.64 x 2.52) T otal Displacement cc (cu. in.[...]

Reelmaster 2300–D/2600–D Page 3 – 4 Engine Special T ools Order special tools from TORO SPECIAL T OOLS AND APPLICA TIONS GUIDE (Commercial Products ). Some tools may be listed in the Reelmaster 2300–D/2600–D Parts Catalog. T ools may also be available from a local supplier . Filter Cleaner Mix with water and use solution to wash the Donal[...]

Reelmaster 2300–D/2600–D Page 3 – 5 Engine Nozzle T est Adapter This adapter is required to test the fuel injection nozzles. Figure 4 Engine[...]

Reelmaster 2300–D/2600–D Page 3 – 6 Engine General Information Fuel Shutoff V alves 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) 1 Figure 6 1 1. Fuel shut off valve (on the fuel filter)[...]

Reelmaster 2300–D/2600–D Page 3 – 7 Engine 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 ([...]

Reelmaster 2300–D/2600–D Page 3 – 8 Engine Throttle Linkage 1. V erify 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 throt[...]

Reelmaster 2300–D/2600–D Page 3 – 9 Engine Service and Repairs Bleeding the Fuel System IMPORT ANT : 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 fu[...]

Reelmaster 2300–D/2600–D Page 3 – 10 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 [...]

Reelmaster 2300–D/2600–D Page 3 – 1 1 Engine Cleaning the Radiator and Screen T o prevent the engine from overheating, the radiator screen, radiator , and oil cooler must be kept clean. Check these components daily . If necessary , clean any debris off these parts. Clean these components more frequently in dusty dirty conditions. 1. Remove ra[...]

Reelmaster 2300–D/2600–D Page 3 – 12 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 oil pan and place a collecting pan b[...]

Reelmaster 2300–D/2600–D Page 3 – 13 Engine Engine Removal 1. Park machine on a level surface, lower the cutting units, stop the engine, and remove 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. O[...]

Reelmaster 2300–D/2600–D Page 3 – 14 Engine 4 10 41 25 39 14 34 42 36 33 13 34 19 20 21 19 19 15 16 17 22 LH 3 2 1 25 43 27 11 30 9 8 6 7 18 12 28 11 7 5 32 26 35 13 44 38 11 31 29 39 40 24 23 37 45 46 RH Figure 19 1. Cap screw 2. Lock washer 3. Clutch washer 4. Engine pulley 5. Cap screw 6. Wire bracket 7. Nut 8. Pop rivet 9. Key 10. Cap scr[...]

Reelmaster 2300–D/2600–D Page 3 – 15 Engine 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 [...]

Reelmaster 2300–D/2600–D Page 3 – 16 Engine 14. Disconnect electrical connections (Fig. 19). Note: Label all electrical leads for reassembly pur- poses. 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 micr[...]

Reelmaster 2300–D/2600–D Page 3 – 17 Engine 16. Remove traction pump drive belt as described in T raction (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. Con[...]

Reelmaster 2300–D/2600–D Page 3 – 18 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 reinstalled to the engine. [...]

Reelmaster 2300–D/2600–D Page 3 – 19 Engine 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 engi[...]

Reelmaster 2300–D/2600–D Page 3 – 20 Engine[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 1 Chapter 4 Hydraulic System T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 3 . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fitting Installation 3[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 2 Specifications Item Description T raction Pump V ariable displacement piston pump Maximum Operating Pressure 3000 PSI (207 bar) Maximum Intermittent Pressure 5000 PSI (345 bar) Maximum Rated Speed 3600 RPM Rated Flow @ Maximum Rated Speed and Pressure 17 GPM (64 LPM) Charge Pump Gerotor pum[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 3 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather , sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. These conditions can cause damage o[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 4 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 [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 5 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 firs[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 6 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 T oro oil filter for replacement. The hy- draulic fl[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 7 Hydraulic Schematic TOP BOTTOM FRONT WHEEL MOT OR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE 2WD/3WD SELECTOR (SHOWN IN 3WD) WHEEL MOT OR LEFT WHEEL MOT OR REAR RH CTR LH LIFT CYL FRONT LIFT CYL REAR V AL VE TOP A BOTTOM B B–UPPER A–LOWER REVERSE (FRONT LINE) FORW ARD (REAR LINE) R1[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 8 Hydraulic Flow Diagrams Raise Cutting Units The charge pump is part of the traction pump and is di- rectly coupled to it. It 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 [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 9 Raise Cutting Units High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 2300–D/2600–D Solenoid S1 is shown de–energized Control valve is positioned up TOP BOTTOM FRONT WHEEL MOT OR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE 2WD/3WD SELECTOR (SHOWN IN 3WD) WHEEL M[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 10 T raction Forward The 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. T aking its suction directly from the return side of the wheel motors of the traction circu[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 1 1 High Pressure Low Pressure (Charge) Return or Suction Flow T raction Forward Reelmaster 2300–D/2600–D Solenoid S1 is shown de–energized TOP BOTTOM FRONT WHEEL MOT OR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE 2WD/3WD SELECTOR (SHOWN IN 3WD) WHEEL MOT OR LEFT WHEEL MOT OR REAR RH[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 12 T raction 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 positi[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 13 High Pressure Low (Charge) Pressure Return or Suction Flow T raction Reverse Reelmaster 2300–D/2600–D Solenoid S1 is shown de–energized TOP BOTTOM FRONT WHEEL MOT OR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE 2WD/3WD SELECTOR (SHOWN IN 3WD) WHEEL MOT OR LEFT WHEEL MOT OR REAR RH [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 14 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. T aking its suction directly from the reservoir , the reel motor drive pump supplies oil flow to the hydraulic manifold block and to the reel mo- t[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 15 Mow High Pressure Low Pressure (Charge) Return or Suction Flow Reelmaster 2300–D/2600–D Solenoid S1 is shown energized V alve MD1 is selected to mow TOP BOTTOM FRONT WHEEL MOT OR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE 2WD/3WD SELECTOR (SHOWN IN 3WD) WHEEL MOT OR LEFT WHEEL MOT [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 16 Special T ools Order these tools from the TORO SPECIAL T OOLS AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Some tools may also be available from a local supplier . Hydraulic Pressure T est Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provid[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 17 T roubleshooting 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.[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 18 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 neutral Make up fluid from charge pump is not available. Flow control setting is wrong for rever[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 19 T esting The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special T ools section in this Chapter .) CAUTION Failure to use gauges[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 20 TEST NO. 1: T raction Pump Flow Figure 12 TOP BOTTOM FRONT WHEEL MOTOR RIGHT PC FLOW CONTROL 2.1 GPM FORW ARD REVERSE WHEEL MOTOR LEFT REVERSE (FRONT LINE) FORW ARD (REAR LINE) BOTTOM FRONT CHARGE PUMP TRACTION PUMP TESTER FRONT DISCHARGE TOP FORW ARD High Pressure Low Pressure Return or S[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 21 Procedure for T raction 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 th[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 22 TEST NO. 2: Charge Pump Flow and Implement Relief Pressure Figure 13 TOP BOTTOM FRONT CONTROL V AL VE RESERVOIR V AL VE TOP BOTTOM FIL TER IN (FRONT) OUT (REAR) BOTTOM FRONT 1 2 IMPLEMENT RELIEF CHARGE PUMP TRACTION PUMP REEL MOTOR DRIVE PUMP COOLER TESTER TO LIFT CYLINDER FROM LIFT CYLIND[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 23 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 en[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 24 TEST NO. 3: Charge Pump Relief Pressure Figure 14 TOP BOTTOM FRONT CONTROL V AL VE RESERVOIR V AL VE TOP BOTTOM FIL TER IN (FRONT) OUT (REAR) BOTTOM FRONT 1 2 IMPLEMENT RELIEF CHARGE PUMP TRACTION PUMP REEL MOTOR DRIVE PUMP COOLER T–CONNECTION AND GAUGE TO LIFT CYLINDER FROM LIFT CYLINDE[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 25 Procedure for Charge Pump Relief 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 [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 26 TEST NO. 4: Reel Drive Pump Efficiency 1. Hose fitting 2. Reel drive pump 3. O–ring Figure 15 RESERVOIR RH CTR LH FIL TER R1 S1 LC1 MD1 G1 P1 BOTTOM FRONT M2 D1 M1 M5 D3 M6 M4 D2 M3 T2 High Pressure Low Pressure Return or Suction Flow COOLER FC1 TO CHARGE PUMP FROM LEFT HYDRAULIC MANIFOL[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 27 Procedure 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 b[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 28 TEST NO. 5: Manifold Relief V alve Pressure Figure 16 RH CTR LH MD1 G1 M2 D1 M1 M5 D3 M6 M4 D2 M3 High Pressure Low Pressure Return or Suction Flow TO COOLER HYDRAULIC MANIFOLD FROM REEL DRIVE PUMP FROM CARTRIDGE V AL VES AND LEFT WHEEL MOTOR TESTER Install tester in series between fitting[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 29 Procedure for Manifold Relief V alve 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 park[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 30 TEST NO. 6: Cross–over Relief Pressures Figure 17 RH CTR LH MD1 G1 M2 D1 M1 M5 D3 M6 M4 D2 M3 High Pressure Low Pressure Return or Suction Flow TO COOLER HYDRAULIC MANIFOLD FROM REEL DRIVE PUMP FROM CARTRIDGE V AL VES AND LEFT WHEEL MOTOR TEST GAUGE T–CONNECTION AND GAUGE (TESTING IN B[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 31 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. [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 32 TEST NO. 7: Reel Motor Case Drain Figure 18 RH CTR LH MD1 G1 M2 D1 M1 M5 D3 M6 M4 D2 M3 High Pressure Low Pressure Return or Suction Flow TO COOLE R HYDRAULIC MANIFOLD FROM REEL MOTOR DRIVE PUMP FROM CARTRIDGE V AL VES AND LEFT WHEEL MOTOR TESTER MEASURE CASE DRAIN FLOW HERE TEST CONNECTIO[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 33 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 sur[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 34 Adjustments T ransmission 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 up under the frame so one of the front wheels is off the floor . Place selector control in two wheel drive p[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 35 T raction Pedal If traction pedal stop cam contacts the footrest when pushed fully forward or maximum forward traction speed is unattainable, an adjustment to the traction ped- al linkage is required. 1. T o expose traction rod, remove screws securing right fender to frame and remove fende[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 36 Hydraulic Pump Drive Belt 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[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 37 Service and Repairs T raction/Charge Pump 1. Cap screw 2. Reel motor drive pump 3. O–ring 4. T raction/charge pump 5. Hose 6. Hose 7. Hydraulic fitting 8. Hydraulic fitting 9. Hose connection 10. Hose connection 1 1. Hose connection 12. Hose connection 13. O–ring 14. O–ring 15. Hydra[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 38 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. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- draul[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 39 1. Cap screw 2. Charge pump adapter assembly 3. Gerotor assembly 4. Bearing 5. V alve assembly 6. V alve plate 7. Screw 8. T runnion cover 9. O–ring cover 10. O–ring 1 1. W asher 12. Inner race 13. Bearing 14. Bearing 15. Housing assembly 16. Seal cover 17. Shaft seal 18. Dowel pin 19.[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 40 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- p[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 41 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 (3[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 42 6. Inspect rotating parts kit (see Fig. 26). A. V erify 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 [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 43 14. Install seat (23) and spring (22) into backplate (25). Install new O–ring (40) and plug (21) into the backplate assembly . T orque 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 (5) into the backplate assembly (25). T orque[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 44 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. CAUTION Operate all hydraulic controls [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 45 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. CAUTION Operate all hydraulic controls to reliev[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 46 1. Dirt and water seal 2. Outer bearing 3. Housing 4. Backup washer 5. Seal ring 6. Backup washer 7. Inner seal 8. Thrust washer 9. Thrust bearing 10. Inner bearing 1 1. Coupling shaft 12. Thrust bearing 13. Drive link 14. Cap screw 15. Commutator seal 16. Commutator 17. Woodruff key 18. W[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 47 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: The insert and ,if included, the orifice [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 48 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,[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 49 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 p[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 50 Reassembly (Fig. 32) 1. Lubricate all seals and seal rings with clean hydrau- lic oil before assembly . Since they are flammable, be extremely careful when using any solvent. Even a small explosion or fire could cause injury or death. W ARNING CAUTION Use eye protection such as goggles whe[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 51 8. Install thrust bearing (12) onto the end of coupling shaft (1 1). 9. Apply a small amount of clean grease to a new seal ring (5) and insert it into the housing (3) seal ring groove. Note: One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180 deg[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 52 E. Grasp the output end of coupling shaft (1 1) with locking pliers 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 asse[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 53 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 T oro Parts Catalog for correct service part num- ber if replacement is required. 22. Assemble seven cap screws (1[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 54 2WD/3WD T wo Position V alve 1. T wo position valve 2. Nut 3. Cap screw 4. T ub clamp 5. Hydraulic tube 6. Hydraulic connection 7. Hydraulic connection 8. Hydraulic connection 9. Hydraulic connection 10. Hydraulic fitting 1 1. Hydraulic fitting 12. Hydraulic fitting 13. O–ring 14. Cap sc[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 55 1. V alve cap 2. Plug 3. O–ring 4. Ball 5. Spool 6. Spring pin 7. Back–up ring 8. O–ring 9. V alve housing 10. Boot retainer 1 1. Boot 12. Set screw 13. V alve stop 14. Lock washer 15. Knob Figure 52 1 3 5 7 9 7 11 13 15 2 4 6 8 8 10 12 14 Disassembly (Fig. 52) 1. W ash valve in solv[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 56 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. If the valve stop (13) and set screw (7) separated during disassembly , screw the set screw completely into the spool (5). Then l[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 57 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. CAUTION Operate all hydraulic controls [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 58 Figure 54 1 2 3 6 7 8 4 5 9 4 5 7 6 10 11 12 14 13 1. Retaining ring 2. Shaft seal 3. Mounting flange 4. Backup ring 5. E–seal 6. O–ring 7. Dowel pin 8. End cover 9. Bolt 10. Gear housing 1 1. Drive gear 12. Idler gear 13. Rear bearing block 14. Front bearing block OUTLET PORT INLET PO[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 59 2. Remove the 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 o[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 60 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. CAUTION Operate all hydraulic controls to relieve [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 61 1. Plug 2. O–ring 3. Shim 4. Spring 5. Ball 6. Relief valve seal 7. Backplate 8. Idler gear assembly 9. Drive gear assembly 10. Key 1 1. O–ring 12. Body 13. Alignment pin 14. Frontplate 15. Screw 16. Retaining ring 17. Oil seal 18. Backup washer 19. Relief valve assembly (# 1 thru 5) F[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 62 Inspection (Fig. 56) 1. Remove all nicks and burrs from all parts with an emery cloth CAUTION 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 .[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 63 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. CAUTION Operate all hydraulic controls to [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 64 1. Cartridge (logic) valve 2. Seal kit 3. Plug 4. O–ring 5. O–ring 6. Plug 7. Seal kit 8. Spool valve 9. O–ring 10. Solenoid coil 1 1. Nut 12. O–ring 13. Plug 14. Cartridge (relief) valve 15. Spool (flow control) valve 16. Locating plate w/ pin 17. Seal kit 18. Spool (two position [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 65 Solenoid V alve (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 (1 1) from the spool valve (8). B. Remove the solenoid coil (10) and both O–rings (9). Note: Use care when handling the spool valve. slight b[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 66 B. Thread cartridge valve (1 or 14) carefully into the applicable port (LC1 or R1). The valve should go in easily without binding. T orque the valve to 35 ft–lb (4.8 kg–m). Spool (Flow Control and T wo Position Directional) V alves (Fig. 58) 1. Remove knob assembly: A. Unscrew and remo[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 67 Front Lift Cylinder 1. Hose connection 2. Hose connection 3. Hose connection 4. Hose connection 5. Hydraulic fittings 6. O–ring 7. O–ring 8. Lift cylinder 9. Cotter pin 10. Clevis pin 1 1. Cap screw 12. Lift hub 13. Cotter pin 14. Clevis pin 15. Clevis 16. Cylinder guide 17. Cylinder s[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 68 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. CAUTION Operate all hydraulic controls to relieve system pres[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 69 1. retaining ring 2. O–ring 3. Head 4. Backup washer 5. O–ring 6. Shaft 7. O–ring 8. Piston 9. Uni–ring 10. Lock nut 1 1. Barrel 12. Dust seal Figure 60 5 1 3 7 8 9 11 6 4 2 12 10 Disassembly (Fig. 60) 1. Remove oil from the cylinder into a drain pan by slowly pumping the cylinder [...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 70 Inspection (Fig. 60) CAUTION Use eye protection such as goggles when using compressed air 1. W ash all parts in solvent. Dry parts with compressed air . 2. Inspect internal surface of barrel (1 1) for deep scratches, out–of–roundness, and bending. Replace if worn or damaged. 3. Inspect[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 71 Rear Lift Cylinder 1. Hose connection 2. Hose connection 3. Hydraulic fitting 4. Hydraulic fitting 5. O–ring 6. Cap screw 7. Ram pivot pin 8. Pivot support 9. Lift pivot shaft 10. Lift cylinder 1 1. Cotter pin 12. Clevis pin 13. Lift arm 14. Flat washer 15. O–ring Figure 63 8 7 6 3 2 5[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 72 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 sup[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 73 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 . IMPORT ANT : Prevent damage when clamping the lift cylinder into a vise; clamp on the pivot end only . Do not close vise[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 74 Control and Implement Relief V alves 1. Hose connection 2. Hydraulic fitting 3. W asher 4. Cap screw 5. Lock nut 6. V alve lever 7. Knob 8. Connecting link assembly 9. Control valve 10. Hydraulic fitting 1 1. Hose connection 12. T ube 13. Hydraulic fitting 14. Hose connection 15. Hose conn[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 75 1. Before removing any parts from the control lift valve assembly , park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine. Remove the key from the ignition switch. CAUTION Operate all hydraulic controls to relieve system pressure and avo[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 76 Control V alve Disassembly (Fig. 66) 1. W ash control valve in solvent and dry it thoroughly . 2. Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring (14) faces up. Note: Remove check valve seat (5) only if it needs re- placement; it is press[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 77 Hydraulic Reservoir 1. Shoulder screw 2. Sight glass 3. Hose clamp 4. Barb fitting 5. Flange nut 6. Cap assembly 7. Filler screen 8. Hydraulic tank 9. T ank bracket 10. Grommet 1 1. Flat washer 12. Cap screw 13. Carriage screw 14. Hose clamp 15. Hydraulic hose 16. Hydraulic fitting 17. U?[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 78 Inspecting Reservoir Parts (Fig. 67) 1. Clean tank (1) and filler screen (7) with solvent. 2. Inspect tank (1) for leaks, cracks, or other damage. 3. Replace hydraulic hoses if worn or leaking. 4. Make sure cap screws (12) are secure. If loose, re- move and reinstall cap screws with loctit[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 79 Flushing the Hydraulic System IMPORT ANT : 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). IMPORT ANT : Flush hydraulic system when chang- Ing from petroleum base hydraulic flu[...]

Reelmaster 2300–D/2600–D Hydraulic System Page 4 – 80 Hydraulic System Start–up Note: When initially 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 [...]

Reelmaster 2300–D/2600–D Page 5 – 1 Electrical System Chapter 5 Electrical System T able of Contents WIRING SCHEMA TICS 2 . . . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic 2 . . . . . . . . . . . . . . . . . . . . . . . . . Start Circuits 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Circuits 4 . . . .[...]

Reelmaster 2300–D/2600–D Page 5 – 2 Electrical System Wiring Schematics DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BL[...]

Reelmaster 2300–D/2600–D Page 5 – 3 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 4 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 5 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 6 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 7 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 8 Electrical System DIODE CONNECTOR HOUSING H GROUND GROUND GROUND G F 3 AMP 3 AMP 3 AMP 3 AMP E D C B A D1 BLACK H G F E D C B A D3 D2 D4 BLACK BLACK PURPLE/WHITE PURPLE WHITE PURPLE ORANGE/WHITE DIODE CIRCUIT BOARD H A B C D E F G D2 D4 D3 D1 DIODE DIAGRAM BLACK BLACK PURPLE/WHITE BLACK BLACK GREY/BLACK GRE[...]

Reelmaster 2300–D/2600–D Page 5 – 9 Electrical System Special T ools Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . Some tools may also be available from a local supplier . Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: T oro recomm[...]

Reelmaster 2300–D/2600–D Page 5 – 10 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trou- bleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of th[...]

Reelmaster 2300–D/2600–D Page 5 – 1 1 Electrical System Starting Problems (continued) Problem Possible Causes 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 [...]

Reelmaster 2300–D/2600–D Page 5 – 12 Electrical System General Run and T ransport Problems Problem Possible Causes Engine continues to run (but should not) when the traction pedal is depressed with no operator on the seat. Seat switch is faulty , out of adjustment, or short circuited. T raction (neutral) interlock switch is out of adjustment,[...]

Reelmaster 2300–D/2600–D Page 5 – 13 Electrical System Cutting Unit Operating Problems Problem Possible Causes Engine Continues to run (but should not) when the cutting unit switch is ON with no operator in the seat. Backlap switch is in the backlap position. Backlap switch is faulty or out of adjustment. Wiring to the run/mow/backlap circuit[...]

Reelmaster 2300–D/2600–D Page 5 – 14 Electrical System V erify Interlock System Operation 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. [...]

Reelmaster 2300–D/2600–D Page 5 – 15 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) 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 acces[...]

Reelmaster 2300–D/2600–D Page 5 – 16 Electrical System Starting System T est 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 bef[...]

Reelmaster 2300–D/2600–D Page 5 – 17 Electrical System Component T esting 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 V olt power connection can als[...]

Reelmaster 2300–D/2600–D Page 5 – 18 Electrical System Starter and High T emperature Shut Down Relays 1. V erify 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[...]

Reelmaster 2300–D/2600–D Page 5 – 19 Electrical System 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 2 ). T esting with the engine off 1. T ur[...]

Reelmaster 2300–D/2600–D Page 5 – 20 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 ru[...]

Reelmaster 2300–D/2600–D Page 5 – 21 Electrical System T emperature Sending Unit 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 white/black wire attached to the switch. 1. Lower the coolant level in the engine and remove the high temperature sending unit[...]

Reelmaster 2300–D/2600–D Page 5 – 22 Electrical System Diode Circuit Board The circuit board contains four diodes. Three diodes are used for circuit protection from inductive voltage 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 t[...]

Reelmaster 2300–D/2600–D Page 5 – 23 Electrical System Fuel V alve 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 T esting Note: Prior to taking small resistance readings with a digital multimeter , short th[...]

Reelmaster 2300–D/2600–D Page 5 – 24 Electrical System T raction (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 connector contains a diode in the circuit which will give incorr[...]

Reelmaster 2300–D/2600–D Page 5 – 25 Electrical System 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 unde[...]

Reelmaster 2300–D/2600–D Page 5 – 26 Electrical System 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 [...]

Reelmaster 2300–D/2600–D Page 5 – 27 Electrical System 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 failu[...]

Reelmaster 2300–D/2600–D Page 5 – 28 Electrical System B. T emperature 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 T emperature 100  [...]

Reelmaster 2300–D/2600–D Page 5 – 29 Electrical System Charging T o 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. CAUTION Follow the manufacture[...]

Reelmaster 2300–D/2600–D Page 5 – 30 Electrical System Cutting Unit Solenoid V alve 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 th[...]

Reelmaster 2300–D/2600–D Page 5 – 31 Electrical System T raction (Electric) Clutch (Fig. 27 through 31) The clutch circuit is 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 eng[...]

Reelmaster 2300–D/2600–D Page 5 – 32 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 [...]

Reelmaster 2300–D/2600–D Page 6 – 1 Wheels and Brakes Chapter 6 Wheels and Brakes T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Brake Adjustment 3 . . . . . . . . . . . . . . . . . . . . . . SER VICE AND REP AIRS 4 . .[...]

Reelmaster 2300–D/2600–D Page 6 – 2 Wheels and Brakes Specifications Item Description Front tire pressure 12 to 16 PSI, (0.83 to 1.10 bar) Rear tire pressure 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) Whe[...]

Reelmaster 2300–D/2600–D Page 6 – 3 Wheels and Brakes 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. T ur[...]

Reelmaster 2300–D/2600–D Page 6 – 4 Wheels and Brakes 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.[...]

Reelmaster 2300–D/2600–D Page 6 – 5 Wheels and Brakes 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 th[...]

Reelmaster 2300–D/2600–D Page 6 – 6 Wheels and Brakes Front Wheel and Brake 17 3 6 5 9 2 15 11 7 4 10 2 8 24 11 16 30 14 27 28, 29 27 31 32 27 33 34 35 36 6 37 22 21 20 18 19 17 23 1 25 26 13 40 41 42 43 44 12, 38 39 45 46 47 47 48 49 Figure 4 1. Lock nut 2. Lock nut 3. Flat washer 4. Hex head screw 5. Flange nut 6. Adjusting rod 7. Parking b[...]

Reelmaster 2300–D/2600–D Page 6 – 7 Wheels and Brakes IMPORT ANT : 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 puller to remove the wheel hub (18) and brake drum (19). Remove the key (49) from the wheel motor shaft. 6. Remove brake extension sprin[...]

Reelmaster 2300–D/2600–D Page 6 – 8 Wheels and Brakes[...]

Reelmaster 2300–D/2600–D Page 7 – 1 Cutting Units Chapter 7 Cutting Units T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL T OOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 5 . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 7 . . . . . . . . . . [...]

Reelmaster 2300–D/2600–D Page 7 – 2 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 se[...]

Reelmaster 2300–D/2600–D Page 7 – 3 Cutting Units Special T ools Order special tools from the TORO SPECIAL TOOLS AND APPLICA TIONS GUIDE (COMMERCIAL PROD- UCTS) . 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 h[...]

Reelmaster 2300–D/2600–D Page 7 – 4 Cutting Units Bedknife Screw T ool This screwdriver–type bit is made to fit T oro 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[...]

Reelmaster 2300–D/2600–D Page 7 – 5 Cutting Units T roubleshooting There are a number of factors that can contribute to un- satisfactory quality of cut, some of which may be turf conditions. T urf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the ma[...]

Reelmaster 2300–D/2600–D Page 7 – 6 Cutting Units Factor Possible Problem/Correction 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 correct[...]

Reelmaster 2300–D/2600–D Page 7 – 7 Cutting Units Adjustments 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 Use caution when tensioning springs as they are under heavy load. Do not move lift lever , cuttin[...]

Reelmaster 2300–D/2600–D Page 7 – 8 Cutting Units 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 roll[...]

Reelmaster 2300–D/2600–D Page 7 – 9 Cutting Units Bedknife Parallel to Reel (Fig. 7 through Fig. 9) 1. Remove any reel contact by turning the bedknife ad- justment knob counterclockwise (Fig. 7). T ip cutting unit to gain access to the reel and bedknife (Fig. 8). 2. On either end of reel, insert a long strip of dry news- paper between reel an[...]

Reelmaster 2300–D/2600–D Page 7 – 10 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 (T oro Part No. 13–8199) may be obtained from your local T oro Distributor . 2. Slightly loosen (crack) nuts se[...]

Reelmaster 2300–D/2600–D Page 7 – 1 1 Cutting Units Service and Repairs Greasing Bearings, Bushings, and Pivot Points (Fig. 1 1 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 cuttin[...]

Reelmaster 2300–D/2600–D Page 7 – 12 Cutting Units Backlapping DANGER TO A VOID PERSONAL INJUR Y OR DEA TH: D Never place hands or feet in reel area while engine is running. D While backlapping, reels may stall and then restart. D Do not attempt to restart reels by hand or foot. D Do not adjust reels while engine is running. D If reel stalls,[...]

Reelmaster 2300–D/2600–D Page 7 – 13 Cutting Units Hydraulic Motor Removal and Installation Removal 1. Remove two capscrews holding the hydraulic motor to the bearing housing. 2. Remove hydraulic motor and spider coupling from the bearing housing. 3. Position the hydraulic motor away from the cutting unit prior to removing or working on the c[...]

Reelmaster 2300–D/2600–D Page 7 – 14 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. Use caution when relieving tension or tensioning springs as they ar[...]

Reelmaster 2300–D/2600–D Page 7 – 15 Cutting Units Note: On rear 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 lift tab to the c[...]

Reelmaster 2300–D/2600–D Page 7 – 16 Cutting Units Bedbar Removal and Installation (Fig. 19 through Fig. 21) Bedbar Removal 1. T urn bedknife adjusting handle to 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[...]

Reelmaster 2300–D/2600–D Page 7 – 17 Cutting Units 11 10 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 1 1. Flanged bushing 12. Bedknife screw 13. Bedknife 13 3 12 Figure 21 Cutting Units[...]

Reelmaster 2300–D/2600–D Page 7 – 18 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 bedknif[...]

Reelmaster 2300–D/2600–D Page 7 – 19 Cutting Units Roller Removal 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.[...]

Reelmaster 2300–D/2600–D Page 7 – 20 Cutting Units Roller Bearing and Seal Replacement 4 2 9 7 5 1 2 9 8 7 6 5 1 4 8 1. Adjustment nut 2. Roller shaft 3. Grease fitting 4. Full roller 5. Outer seal 6. Shim washer 7. Bearing cone 8. Bearing cup 9. Inner seal 3 3 Figure 25 Note: A rear (full) roller is shown. Bearing and seal configurations are[...]

Reelmaster 2300–D/2600–D Page 7 – 21 Cutting Units 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 [...]

Reelmaster 2300–D/2600–D Page 7 – 22 Cutting Units Reel Removal and Bearing Replacement 6 8 5 7 9 8 4 3 2 2 7 1. Cutting unit 2. Capscrew 3. Bearing cover 4. Male coupling (LH) 5. Male coupling (RH) 6. Capscrew 7. Bearing housing 8. Bearing 9. Reel Figure 26 LEFT–HAND SIDE FRONT COVER GASKET NOT SHOWN GROOVE SHOWN OUT OF POSITION Remove Ree[...]

Reelmaster 2300–D/2600–D Page 7 – 23 Cutting Units 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 b[...]

Reelmaster 2300–D/2600–D Page 7 – 24 Cutting Units Preparing a Reel for Grinding Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. 1. Remove bedbar assembly (see Bedbar Removal and Installation). 2. Remove front roller and brackets (see Roller Re- moval and Installation). Note: Most reel [...]

Reelmaster 2300–D/2600–D Page 7 – 25 Cutting Units 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 cuttin[...]

Reelmaster 2300–D/2600–D Page 7 – 26 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 a[...]

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