Part No. 96876SL Rev. A
Service Manual
ReelmasterR 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.
This safety symbol means DANGER, WARN-
ING, or CAUTION, PERSONAL SAFETY
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
Failure to obey the instructions may result in
personal injury.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE AND ADJUSTMENT INSTRUC-
TIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals are
available by sending complete Model and Serial Num-
ber to:
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company – 1996, 1998
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Table Of Contents
Chapter 1 – Safety
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 17
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 19
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 34
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 – 37
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 1
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 4
Chapter 2 – Product Records and Manuals
Chapter 5 – Electrical System
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Maintenance Interval Chart . . . . . . . . . . . . . . . . . . 2 – 4
Operation and Service History Report . . . . . . . . . 2 – 5
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 3 – Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 – 9
Perkins 100 Series Workshop Manual
Chapter 6 – Wheels and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 2
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 6 – 4
Chapter 7 – Cutting Units
Chapter 4 – Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 3
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 5
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 7 – 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . 4 – 7
Hydraulic Flow Diagrams . . . . . . . . . . . . . . . . . . . . 4 – 8
Reelmaster 2300–D/2600–D
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
Safety Instructions
The REELMASTER 2300–D/2600–D conforms to the
American National Standards Institute’s (ANSI) safety
standards for riding mowers when equipped with rear
ballast (see Operator’s Manual). Although hazard con-
trol and accident prevention are partially dependent
upon the design and configuration of the machine, these
factors are also dependent upon the awareness, con-
cern, and proper training of the personnel involved in the
operation, transport, maintenance, and storage of the
machine. Improper use or maintenance of the machine
can result in injury or death.
WARNING
To reduce the potential for injury or death,
comply with the following safety instruc-
tions.
Before Operating
Improper use or maintenance by the operator or owner
of the machine can result in injury. Reduce the potential
for any injury by complying with the following safety in-
structions.
UsetheModelandSerialNumberwhenreferringtoyour
machine. If you have questions about this Service
Manual, please contact:
The Toro Company
Commercial Service Department
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
WARNING
The engine exhaust contains carbon
monoxide, which is an odorless and
deadly poison. Carbon monoxide is also
known to the state of California to cause
birth defects. Do not run engine indoors
or in an enclosed area.
2. Only trained operators, skilled in slope operation
and who have read the Operator’s Manual, should oper-
ate the machine. Never allow children to operate the
machine or adults to operate it without proper instruc-
tions.
3. IMPORTANT: Always use proper rear ballast as
specified in the operator’s manual (see Rear Ballast of
the Operator’s Manual).
1. Read and understand the contents of the traction
unit and cutting unit operator’s manuals before operat-
ing the machine. To get replacement manuals, send
complete model and serial number to:
4. Become familiar with the controls and know how to
stop the machine and engine quickly.
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
Reelmaster 2300–D/2600–D
Safety
Page 1 – 1
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5. Do not carry passengers on the machine. Keep ev-
eryone, especially children and pets, away from the ar-
eas of operation.
9. Make sure the work area is clear of objects which
might be picked up and thrown by the reels.
10. Fill the fuel tank with diesel fuel before starting the
engine. Avoid spilling any fuel. Since fuel is highly flam-
mable, handle it carefully.
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
the machine.
A. Use an approved fuel container.
B. Do not remove the cap from the fuel tank when
engine is hot or running.
7. Always wear substantial shoes. Do not operate ma-
chine while wearing sandals, tennis shoes or sneakers.
Do not wear loose fitting clothing because it could get
caught in moving parts and possibly cause personal in-
jury.
C. Do not smoke while handling diesel fuel.
D. Fill fuel tank outdoors and not over one inch from
the top of the tank, (bottom of the filler neck). Do not
overfill.
8. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some Iocal or-
dinances and insurance regulations.
While Operating
11. Do not run the engine in a confined area without ad-
equate ventilation. Exhaust fumes are hazardous and
could be deadly.
F. Stay alert for holes in terrain and other hidden
hazards. Use extreme care when operating close to
sand traps, ditches, creeks, steep hillsides or other
hazards.
12. Sit on the seat when starting and operating the ma-
chine.
G. Reduce speed when making sharp turns. Avoid
sudden stops and starts. Use reverse pedal for
braking. The cutting units must be lowered when
going down slopes for steering control.
13. Check interlock switches daily for proper operation
(see Checking Interlock Switches of the Operator’s
Manual). Do not rely entirely on safety switches; shut off
engine before getting off the seat. If a switch fails, re-
place it before operating the machine. The interlock sys-
tem is for your protection, so do not bypass it. Replace
all interlock switches every two years.
H. Before backing up, look to the rear and assure
that no one is behind the machine. Watch out for
traffic when near or crossing roads. Always yield the
right of way.
14. When starting the engine:
A. Engage parking brake.
15. Keep hands, feet, and clothing away from moving
parts and the reel discharge area. Grass baskets, if so
equipped, must be in place during reel operation for
maximum safety.
B. Be sure traction pedal is in neutral and reel drive
is in the disengage position.
16. This product may exceed noise levels of 85 dB(A)
at the operator position. Ear protectors are recom-
mended for prolonged exposure to reduce the potential
of permanent hearing damage.
C. After the engine starts, release parking brake
and keep foot off the traction pedal. The machine
must not move. If movement is evident, the neutral
control linkage is incorrectly adjusted: therefore,
shut engine off and adjust until the machine does
not move when the traction pedal is released (see
Adjusting Transmission for Neutral of the Opera-
tor’s Manual).
17. Raise the cutting units when driving from one work
area to another.
18. Do not touch engine, muffler, exhaust pipe, or hy-
draulic tank while engine is running or soon after it has
stopped. These areas could be hot enough to cause
burns.
D. Hills over 15 degrees should be mowed up and
down, not side to side (see Slope Gauge of the Op-
erator’s Manual).
19. If a cutting unit strikes a solid object or vibrates ab-
normally, stop cutting unit immediately. Turn the engine
off, wait for all motion to stop and inspect for damage.
A damaged reeol r bedknife must be repaired or re-
placed before operation is continued.
E. Mowing hills may be dangerous. Hills over 20
degrees should not be mowed (see Slope Gauge of
the Operator’s Manual).
Safety
Reelmaster 2300–D/2600–D
Page 1 – 2
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20. Before getting off the seat:
A. Move the traction pedal to neutral.
B. Set the parking brake.
D. Stop the engine and remove the key from the ig-
nition switch.
21. Whenever the machine is left unattended, make
sure the reels are not spinning, the key is removed from
ignition switch, and the parking brake is set.
C. Disengage the cutting units and wait for the reels
to stop spinning.
Maintenance and Service
22. Before servicing or making adjustments to the ma-
chine, stop the engine and remove the key from the
switch to prevent accidental starting of the engine.
28. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be re-
lieved by stopping the engine and lowering cutting units
to the ground.
23. When changing attachments, tires or performing
other service, use the correct blocks, hoists and jacks.
Always chock or block the wheels and use jack stands
or solid wood blocks to support the raised machine. If
the traction unit is not properly supported by blocks or
jack stands, the unit may move or fall resulting in per-
sonal injury.
29. If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
30. Reduce potential fire hazards. Keep the engine
area free of excessive grease, grass, leaves, and accu-
mulation of dirt.
31. If the engine must be running to perform a mainte-
nance adjustment, keep hands, feet, clothing, and any
other parts of the body away from the cutting units and
any moving parts. Keep everyone away.
24. Check performance of all interlock switches daily.
Do not defeat interlock system. It is for your protection.
25. Ensure the entire machine is in good operating
condition. Frequently check and keep all nuts, bolts,
screws, and hydraulic fittings tight.
32. Do not overspeed the engine by changing governor
settings. To assure safety and accuracy, have an Autho-
rized Toro Distributor check maximum engine speed
with a tachometer.
26. Before applying pressure to the hydraulic system,
make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition .
33. The engine must be shut off before checking oil or
adding oil to the crankcase.
27. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for leaks.
Hydraulic fluid escaping under pressure can have suffi-
cient force to penetrate the skin and cause serious inju-
ry. 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.
34. To insure optimum performance and safety, use
genuine TORO replacement parts and accessories. Re-
placement parts and accessories made by other man-
ufacturers could be dangerous, and such use could void
the product warranty of The Toro Company.
Reelmaster 2300–D/2600–D
Safety
Rev. A
Page 1 – 3
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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 Toro Distributor.
ON LEFT SIDE OF SEAT PANEL
(Part No. 92–7270)
UNDER CONTROL PANEL
(Part No. 93–6902)
Model 03427 only
ON CARRIER FRAME
(Part No. 94–3353)
WARNING! Pinch Point between Carrier Frame and Cutting
Unit
ON FAN SHROUD
(Part No. 77–3100)
ON INSTRUMENT PANEL
(Part No. 94–4985)
Rotating Parts
ON LEFT FENDER
(Part No. 84–1650)
ON LIFT ARMS
(Part No. 93–6696)
WARNING! Spring Loaded Mechanism,
Read Disassembly Procedure
ON UNDER SEAT
(Part No. 93–6903)
ON INSIDE OF
FRONT RIGHT PANEL
(Part No. 67–5360)
ON SKIRT PANEL
(Part No. 83–9550)
Safety
Reelmaster 2300–D/2600–D
Page 1 – 4
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DANGER! Rotating Reel Will Cut Hands and Feet.
See Adjustment Procedures
ON SHIELD
(Part No. 93-8064)
Reelmaster 2300–D/2600–D
Safety
Page 1 – 5
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Safety
Reelmaster 2300–D/2600–D
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Chapter 2
Product Records and Manuals
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
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
Product Records
Record
information
about
your
Reelmaster
Insert Operator’s Manuals and Parts Catalogs for your
Reelmaster 2300–D/2600–D at the end of this section.
2300–D/2600–D on the OPERATION AND SERVICE
HISTORY REPORT form. Use this information when re-
ferring to your machine.
Reelmaster 2300–D/2600–D
Product Records and Manuals
Page 2 – 1
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Equivalents and Conversions
Product Records and Manuals
Reelmaster 2300–D/2600–D
Page 2 – 2
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Torque Specifications
Reelmaster 2300–D/2600–D
Product Records and Manuals
Page 2 – 3
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Maintenance Interval Chart
Product Records and Manuals
Reelmaster 2300–D/2600–D
Page 2 – 4
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EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
REELMASTERR 2300–D/2600–D
TORO Model and Serial Number: _____________–___________
Engine Numbers:
Transmission Numbers:
Date Purchased:
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
_________________________
Warranty Expires___________
Purchased From:
Contacts:
Parts
Phone___________________
Phone___________________
Phone___________________
Service
Sales
See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company.
Reelmaster 2300–D/2600–D
Product Records and Manuals
Page 2 – 5
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REELMASTERR 2300–D/2600–D Maintenance Schedule
Minimum Recommended Maintenance Intervals:
Maintenance Procedure
Maintenance Interval & Service
Every
Every
Every
400hrs
200hrs
100hrs
Every
50hrs
Inspect Air Filter, Dust Cup, and Baffle
Lubricate All Grease Fittings
{ Change Engine Oil
A–Level
Service
{ Check Fan and Alternator Belt Tensions
{ Change Engine Oil and Filter
{ Check Traction Belt Tension
B–Level
Service
Service Air Filter
Replace Fuel Filter/Water Separator
{ Replace Hydraulic Filter
{ Torque Wheel Lug Nuts
C–Level
Service
Replace Hydraulic Fluid
Check Battery Level/Connections
Inspect Traction Linkage Movement
*
Inspect Spider Coupling for Wear
D–Level
Service
} Torque Head Bolts and Adjust Valves
} 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
Replace Safety Switches
Cooling System – Flush/Replace Fluid
Replace Thermostat
Annual Recommendations:
Items listed are recommended every 1000 hours
or 2 years, whichever occurs first.
Fuel Tank – Drain/Flush
Hydraulic Tank – Drain/Flush
(See Operator’s and Service Manuals for specifications and procedures.)
Product Records and Manuals
Reelmaster 2300–D/2600–D
Page 2 – 6
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REELMASTERR 2300–D/2600–D Daily Maintenance Check List
Unit Designation: ____________
Daily Maintenance: (duplicate this page for routine use)
TORO ID #: ________–________
Daily Maintenance Check For Week Of ________________
Maintenance
MON
________HRS
TUES
________HRS
WED
________HRS
THURS
________HRS
FRI
________HRS
SAT
________HRS
SUN
________HRS
Check Item b
n Safety Interlock Operation
n Brake Operation
1
n Engine Oil Level
n Cooling System Fluid Level
1
Drain Water/Fuel Separator
n Air Filter, Dust Cup, and Baffle
n Radiator & Screen for Debris
2
n Unusual Engine Noises
n Unusual Operating Noises
n Hydraulic System Oil Level
1
n Hydraulic Hoses for Damage
n Fluid Leaks
1
n Fuel Level
n Tire Pressure
n Instrument Operation
n Reel–to–Bedknife Adjustment
n Height–of–Cut Adjustment
3
Lubricate All Grease Fittings
Touch–up Damaged Paint
1
= Check proper section of Operator’s Manual for fluid specifications.
2
3
= Check glow plug and injector nozzles, if hard starting, excess smoke or rough running is noted.
= Accomplish immediately after every washing, regardless of the interval listed.
Notation for areas of concern:
Inspection performed by:__________________
Item
1
Date
Information
2
3
4
5
6
7
(See Operator’s and Service Manuals for specifications and procedures.)
Reelmaster 2300–D/2600–D
Product Records and Manuals
Page 2 – 7
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Product Records and Manuals
Reelmaster 2300–D/2600–D
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Chapter 3
Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6
Fuel Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 9
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . 9
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning the Radiator and Screen . . . . . . . . . . . . . 11
Changing the Engine Oil and Filter . . . . . . . . . . . 12
Checking the Cooling System . . . . . . . . . . . . . . . . 12
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Reinstallation . . . . . . . . . . . . . . . . . . . . . . . 18
PERKINS 100 SERIES WORKSHOP MANUAL
Reelmaster 2300–D/2600–D
Page 3 – 1
Engine
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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.
ever, the cost of the test equipment and the specialized
nature of some repairs may dictate that the work be
done at an engine repair facility.
Service and repair parts for Perkins engines are sup-
plied through your local Perkins/Detroit Diesel dealer. If
no parts list is available, be sure to provide your dealer
or distributor with the Perkins model and serial number.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Special Tools section. The use
of some specialized test equipment is explained. How-
Engine
Reelmaster 2300–D/2600–D
Page 3 – 2
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Specifications
Item
Description
Make / Designation
Perkins, vertical in–line, 4–stroke, water–cooled Diesel,
103–07 KL 70275 & KL 70372
Combustion Chamber
Number of Cylinders
Bore x Stroke mm (in.)
Total Displacement cc (cu. in.)
Compression Ratio
Firing Order
IDI special swirl–combustion type
3
67 x 64 (2.64 x 2.52)
676 (41.23)
24:1
1– 2–3
Dry Weight (approximate) kg (lb.)
Fuel
64 (141)
Grade No. 2D diesel fuel (ASTM specification)
Bosch type plunger
Mechanical
Fuel Injection Pump
Governor
Idle Speed (no load)
High Idle (no load)
Fuel Injector Nozzle
1400 + 50 RPM
3200 + 50 RPM
Bosch throttle type
115 to 125 (1636 to 1778)
28.5 to 30.5_ B.T.D.C.
SAE 10W30 SF, CD
Gear driven trochoid type
2.8 (3.0) with filter
Belt driven centrifugal type
4.7 (5.0)
2
Fuel Injection Working Pressure kg/cm (psi)
Injection Timing
Engine Oil
Oil Pump
Crankcase Oil Capacity liter (U.S. qt.)
Water Pump
Cooling System Capacity liter (U.S. qt.)
Starter
12 VDC 1.2 KW
Alternator/Regulator
Glow Plug
12 VDC 14 AMP
Sheathed type
Reelmaster 2300–D/2600–D
Page 3 – 3
Engine
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Special Tools
Order special tools from TORO SPECIAL TOOLS AND
APPLICATIONS GUIDE (Commercial Products).
Some tools may be listed in the Reelmaster
2300–D/2600–D Parts Catalog. Tools may also be
available from a local supplier.
Filter Cleaner
Mix with water 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.
Figure 3
Reelmaster 2300–D/2600–D
Engine
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Nozzle Test Adapter
This adapter is required to test the fuel injection nozzles.
Figure 4
Reelmaster 2300–D/2600–D
Page 3 – 5
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General Information
Fuel Shutoff Valves
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
Reelmaster 2300–D/2600–D
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Adjustments
Alternator Belt
1. Gain access to the alternator belt (Fig 7).
8
A. Loosen top hose clamp securing the upper por-
tion of the hose connected to the air cleaner (8).
6
3
B. Remove cap screws (1) and lock flange nuts (2).
Remove hex head screws (3).
1
C. On European models, remove hex head screws
(4) from the guard (5) and air cleaner housing (6).
D. Pull air cleaner housing from the radiator top
shroud(7)andhose. Plugaircleanerhoseandhose
inlet to the air cleaner.
4
5
2. Loosen bolts securing alternator to the engine and
adjusting strap.
7
3. Adjust alternator belt to the proper tension. Tension
alternator belt so it deflects 0.20 inch with a 2 to 3 pound
load applied midway between the crankshaft and alter-
nator pulleys (Fig. 8).
2
1
3
Figure 7
1. Cap screw
5. Guard (Europe)
2. Lock flange nut
3. Hex head screw
4. Hex head screw
6. Air cleaner housing
7. Radiator top shroud
8. Air cleaner
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.
1
C. On European models, reinstall hex head screws
(4)intoguard(5)throughtheaircleanerhousing(6).
D. Secure cap screws (1) and lock flange nuts (2) to
air cleaner housing and radiator top shroud (7).
E. Secure hex head screws (3) into the air cleaner
housing and radiator assembly.
Figure 8
1. Engine belt
F. Tighten hose clamp securing the hose to the air
cleaner.
Reelmaster 2300–D/2600–D
Page 3 – 7
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Throttle Linkage
1. Verify high engine speed at 3200 ꢀ 50 RPM with
the cold start button depressed.
2. If engine speed is out of specification, loosen cap
screw, nut, and throttle cable clamp on the throttle cable
bracket enough to allow the cable to slide freely within
the bracket.
3. Move throttle lever up fully to the high speed posi-
tion.
1
4. Pullcabletowardflywheelendoftheengineuntilthe
governor lever on the engine is up against the high
speed adjustment screw. Tighten cap screw and nut se-
curing the throttle cable clamp.
2
5. Loosen capscrews (1) and nuts (2) securing the
throttle stop (3).
6. With the cold start button depressed, carefully ad-
just low engine speed to 1400 ꢀ 50 RPM with the
throttle control lever (4); adjust low speed stop screw
if necessary.
3
4
Figure 9
7. Make sure throttle control lever (4) is down so the
governor lever on the engine touches the low speed ad-
justment screw.
1. Cap screw
2. Nut
3. Throttle stop
4. Throttle control leve
8. Adjust throttle stop (3) until it contacts the bottom of
the throttle control lever (4). Tighten cap screws (1) and
nuts (2) securing the throttle stop.
9. Make sure governor lever on the engine goes
against the high speed adjustment screw when the
throttle control lever (4) is moved to the high speed posi-
tion. When the throttle control lever is moved to the low
speed position, the governor lever on the engine should
contact the low speed adjustment screw at the same
time the throttle control lever contacts the throttle stop
(3).
Engine
Reelmaster 2300–D/2600–D
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Service and Repairs
Bleeding the Fuel System
IMPORTANT: The fuel system must be primed
when a new or rebuilt engine is started for the first
time, if it runs out of fuel, or if maintenance is per-
formed on the fuel system.
1. Park machine on a level surface. Make sure fuel
tank is at least half full.
2
2. Unlatch and raise hood.
1
3
DANGER
Figure 10
Because diesel fuel is flammable, use
caution when storing or handling it. Do
not smoke while filling the fuel tank. Do
not fill the fuel tank while the engine is
hot, running, or when the in an enclosed
area. Always fill the fuel tank outside.
Wipe up any spilled diesel fuel before
starting the engine. Store fuel in a clean
safety–approved container with its cap
on. Use diesel fuel for the engine only
and no other purpose.
1. Fuel shutoff valve
2. Bleed screws
3. Bowl
6
1
5
4
3. Open fuel shutoff valve (1) located under the fuel
tank and on the fuel filter (Fig. 10).
4. Open both bleed screws (2) located on the side of
the fuel filter mounting head. Allow bowl (3) to refill with
fuel. Close bleed screws when the bowl is filled (Fig. 10).
5. On the front of the engine by the oil filter, find trans-
fer pump inlet screw location (2). Note fitting angle (5)
on the transfer pump inlet and loosen left transfer pump
screw (1) only (Fig. 11).
6
3
2
See Inset
Figure 11
1. Transfer pump screw
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 above (Fig. 11).
2. Transfer pump inlet screw location
3. Injection pump inlet screw
4. Priming lever
5. Note fitting angle
6. Injector nut
7. Loosen injection pump inlet screw (3) on the front of
the engine (Fig. 11).
9. Start engine. If engine does not run smoothly after
several minutes, crack open each injector nut (6) until
fuel (with no bubbles) comes out. Torque each injector
nut from 14.4 to 18.0 ft–lb (2.0 to 2.5 kg–m).
8. Pump priming lever (4) until a steady stream of fuel
flows out of injection pump inlet screw (3), then tighten
screw. Do not over tighten inlet screw (Fig. 11).
Reelmaster 2300–D/2600–D
Page 3 – 9
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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.
4
2. Check air cleaner body (1) for damage which could
possibly cause an air leak. Replace damaged air clean-
er body.
3
3. Make sure air cleaner cover (2) is sealing around
the air cleaner body (1).
4. Release latches (3) securing the air cleaner cover
(2) to the air cleaner body (1). Separate cover from
body. Clean inside of air cleaner cover.
1
2
5. Gently slide filter element (4) out of the air cleaner
body (1) to reduce the amount of dust dislodged. Avoid
knocking filter element against air cleaner body.
6.Inspect filter element (4) and discard if damaged. Do
not wash or reuse a damaged filter.
Figure 12
1. Air cleaner body
2. Air cleaner cover
3. Latch
4. Filter element
Washing Method
B. Keep air hose nozzle at least 2 inches from the
filter element (4). Move nozzle up and down while
rotating the filter element. Inspect for holes and
tears by looking through the filter element toward a
bright light.
A. Prepare a solution of filter cleaner and water.
Soak filter element (4) in the solution for 15 minutes.
Refer to directions on filter cleaner carton for com-
plete information.
B. After soaking filter element (4) for 15 minutes,
rinse it with clear water. Maximum water pressure
must not exceed 40 psi to prevent damage to the fil-
ter element. Rinse filter element from the clean side
to the dirty side.
7. Inspect new filter element (4) for shipping damage.
Check sealing end of new or used filter element. Do not
install a damaged filter element.
8. Insert filter element (4) properly into the air cleaner
body (1). Make sure filter element is sealed properly by
applying pressure to the outer rim of the filter element
when installing. Do not press on the flexible center of the
filter element.
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.
9. Reinstall air cleaner cover (2) and secure latches
(3). Make sure cover is positioned with top side up.
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 not exceed 100
psi to prevent damage to the filter element.
Engine
Reelmaster 2300–D/2600–D
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Cleaning the Radiator and Screen
To 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
1. Remove radiator screen (1).
2. Remove four cap screws and nuts that hold the
plastic cover to the radiator assembly. Remove plastic
cover from the radiator assembly.
3
3. Loosen both quick release knobs on the front end
of the radiator assembly. Now the oil cooler (3) can be
removed from the radiator for cleaning.
2
Figure 13
1. Radiator screen
2. Radiator
3. Oil cooler
CAUTION
Use eye protection such as goggles
when using compressed air.
4. Working from fan side of radiator (2), either spray
the radiator with a hose or blow with compressed air.
5. Thoroughly clean oil cooler (3). Clean off any other
debris that may have collected around components.
6. Reinstall the oil cooler (3). Tighten both quick re-
lease knobs on the front end of the radiator assembly.
7. Reinstall plastic cover onto the radiator assembly.
Reinstall four cap screws and nuts that hold the plastic
cover to the radiator assembly. Tighten fasteners
8. Clean radiator screen (1) and reinstall.
Reelmaster 2300–D/2600–D
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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
1. Position machine on a level surface.
2. Locate engine oil drain plug on the bottom of oil pan
and place a collecting pan below it. Remove drain plug
and let oil flow into the collecting pan. When the oil stops
draining, install drain plug.
Figure 14
1. Oil fill cap
3. Locate engine filter on the front of the engine. Re-
move oil filter. Apply a light coat of clean oil to the new
filter seal before screwing it on. DO NOT OVERTIGH-
TEN.
Note: The crankcase capacity is approximately 2.8
qts. (3.0 L) with filter. The engine uses any high–quality
10W30 detergent oil having the American Petroleum In-
stitute – API – “service classification” CD.
1
4. Add oil to the crankcase.
A. Remove oil fill cap (Fig. 14) and gradually add
small quantities of oil .
Figure 15
1. Dipstick
B. Check oil level frequently until the level reaches
the FULL mark on dipstick (Fig 15). When removing
the dipstick, wipe it with a clean rag prior to inserting
it to check the oil level.
C. Push dipstick down into dipstick tube and make
sure it is seated fully when finished (Fig 15).
Checking the Cooling System
1
e
l
CAUTION
If the engine has been running, pressur-
ized hot coolant or steam can escape
when the radiator cap is removed. Burns
may result. Do not open radiator cap
when the radiator or engine is hot.
1. Radiator cap
3.
NOT OVERFILL
r
DO
1.
2.
4.
Engine
Reelmaster 2300–D/2600–D
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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.
3
3
5
1
2. Disconnect positive (+) and then negative (–) bat-
tery cables at the battery.
3
3. Gain access to the engine.
A. Open and remove hood from the machine.
3
B. Remove right side panel to gain access to the
traction pump drive belt.
4
C. Remove left rear panel (radiator side) which
supports the instrument panel.
6
2
4
3
4. Remove left fender (1) and fender bracket (2) from
the radiator side of the frame (Fig. 17).
4
A. Remove cap screw (3) and flange nut (4) holding
the left foot rest (5) to the left fender.
Figure 17
1. Left fender
2. Left fender bracket
3. Cap screw
4. Flange nut
5. Left footrest
6. Clinch nut
B. Remove remaining cap screws (3) and flange
nuts (4) securing the fender to the fender bracket
and frame. Remove fender from the frame.
C. Remove both cap screws (3) and left fender
bracket (2) from the frame.
2
3
5. Remove cotter pin (1) from adjusting rod (2). Dis-
connect adjusting rod from brake arm (3) (Fig. 18).
1
6. Remove cap screws (3) and flange nut (4) securing
the left footrest (5) to the frame (Fig. 17). Slide the left
foot rest off the adjusting rod (2) (Fig. 18).
CAUTION
DO NOT open radiator cap or drain coolant
if the engine or radiator is hot. Pressurized
hot coolant can escape and cause burns.
Figure 18
Ethylene–gycol antifreeze is poisonous.
Dispose of it properly or store it in a proper-
ly labeled container away from children and
pets.
1. Cotter pin
2. Adjusting rod
3. Brake arm
8. Drain hydraulic reservoir.
A. Clean hydraulic oil filter and area around the fil-
ter.
7. Drain antifreeze from radiator.
A. Slowly remove radiator cap from the radiator.
B. Place clean drain pan below hydraulic oil filter to
collect the draining hydraulic oil.
B. Placedrainpanbelowtheradiatorpipeplug. Re-
move pipe plug from the bottom of the radiator. Al-
low antifreeze to drain into the container
C. Remove hydraulic oil filter from bottom of the fil-
ter housing with a bottom type filter wrench. Let oil
drain into the drain pan; install filter when drained.
Reelmaster 2300–D/2600–D
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RIGHT
39
11
1
14
2
45
3
4
36
5
32
13
6
7
CONNECTED TO
AIR FILTER HOSE
9
8
44
10
19
19
15
11
38
12
23
18
16
17
19
41
43
25
40
39
11
30
29
31
37
21
20
26
35
23
24
22 LH
46 RH
25
7
28
34
42
13
34
33
36
LEFT
27
FRONT
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 screw
11. Flat washer
12. R–clamp
13. Washer
17. U–bolt
32. Flat washer
33. Lock washer
34. Front mount bracket
35. Insert nut
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
36. Cap screw
37. Clutch spindle
38. Hose clamp
39. Cap screw
40. Electric clutch
41. Cap screw
42. Cap screw
43. Cap screw
44. Fuel hose
45. Muffler gasket
46. Right rear mount bracket
28. Throttle cable bracket
29. Clevis pin
30. Cotter pin
14. Muffler
15. Muffler tube
16. Muffler bracket
31. Throttle tab
Engine
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9. Close fuel shut–off valves under the fuel tank and
on the fuel filter.
2
10. Disconnect hoses from engine (Fig. 19).
4
A. Loosen upper hose clamp securing the air filter
hose extending from the engine to the air cleaner.
B. Loosen hose clamps (23). Disconnect upper ra-
diator hose (18) and lower radiator hose (24) from
the engine.
C. Loosen hose clamp (38) and disconnect fuel
hose (44) from the lift pump. Plug hose to prevent
leakage.
1
3
D. Loosen hose clamp and disconnect fuel hose
(return) from the injector nozzle piping. Plug hose to
prevent leakage.
Figure 20
1. Hose clamp
3. Hydraulic fitting
2. Hydraulic return hose
4. Hydraulic reservoir
CAUTION
2
The hydraulic fluid may be hot. To avoid
possible burns, allow the hydraulic sys-
tem to cool before disconnecting hoses.
1
11. Disconnect hydraulic hoses to oil cooler.
A. Loosen hose clamp (1)anddisconnecthydraulic
return hose (2) from the hydraulic fitting (3). Plug
hose and fitting to prevent leakage and contamina-
tion (Fig. 20).
B. Loosen hose clamp (1)anddisconnecthydraulic
supply hose (2) from the hydraulic elbow fitting (3).
Plug hose and fitting to prevent leakage and con-
tamination (Fig. 21).
3
4
CAUTION
Figure 21
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.
1. Hose clamp
2. Hydraulic supply hose
3. Hydraulic elbow fitting
4. Hydraulic manifold
D. Remove cap screws (39) and flat washers (11)
from the muffler and exhaust manifold. Remove
muffler and muffler gasket (53) from the engine.
12. Remove exhaust system (Fig. 19).
13. Disconnect throttle cable (Fig. 19).
A. Remove muffler clamp (19) from the muffler (14)
and muffler tube (15).
A. Loosen cap screw (43) enough to separate the
throttle cable from the throttle cable clamp (30).
B. Loosen nut (20) and U–clamp (17). Separate
muffler tube from muffler and slide muffler tube
through U–clamp.
B. Remove cotter pin (30) from clevis pin (29). Re-
move clevis pin, throttle tab (31), and throttle cable
from the engine governor lever.
C. Remove cap screws (36) and washers (13) from
the muffler and right rear mount bracket (46).
C. Secure throttle cable away from the engine.
Reelmaster 2300–D/2600–D
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14. Disconnect electrical connections (Fig. 19).
Note: Label all electrical leads for reassembly pur-
poses.
A. Disconnect connector with blue leads from the
alternator.
4
B. Disconnect connector with blue/white leads
from the traction clutch.
1
3
C. Disconnect connector from the front lift cylinder
microswitch.
D. Remove white/black lead from the temperature
sender located on the top of the water pump.
E. Remove tan lead from the high temperature shut
down switch located on the water pump behind the
fan.
2
F. Remove purple lead from the fuel valve solenoid
located above the lift pump.
Figure 22
1. Cap screws
2. Whiz nut
3. Radiator rear bracket
4. Frame
G. Remove brown lead from the oil pressure switch
located on the front of the cylinder head.
H. Remove white lead from the glow plugs located
on the front traction pump side of the cylinder head.
2
I. Remove gray, red, and white leads from the en-
gine starter solenoid located on below the exhaust
manifold.
3
J. Disconnect battery ground from the traction
clutch side of the cylinder head or the fan side of the
cylinder block.
4
K. Remove cap screw (10) and flat washer (11)
from R–clamp (12). Pull wiring harness and hydrau-
lic hoses away from the engine to keep them from
snagging the engine when it is removed. The har-
ness and hoses may be tied to the reservoir support
brackets.
1
15. Remove radiator assembly.
Figure 23
1. Carriage bolt
2. Whiz nut
3. Radiator bracket
4. Frame
A. Support the radiator assembly while removing
fasteners.
B. Remove cap screws (1) and whiz nuts (2) from
the radiator rear bracket (3) and frame (4) (Fig. 22).
C. Removecarriagebolts(1)andwhiznuts(2)from
the radiator bracket (3) and frame (4) (Fig. 23).
D. Pull radiator assembly out and then up from the
engine to prevent the engine cooling fan from catch-
ing the radiator top and bottom shrouds.
Engine
Reelmaster 2300–D/2600–D
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16. Remove traction pump drive belt as described in
Traction (Electric) Clutch of the Service and Repairs
section of Chapter 5 – Electrical System.
17. Remove engine (Fig. 19)
A. Attach short section of chain between both lift
tabs (1) located on each end of the cylinder head (2)
(Fig. 24)
1
B. Connect a hoist or chain fall at the center of the
short section of chain. Apply enough tension on the
short chain so that the engine will be supported
when the cap screws (42) securing the engine
mount brackets (22, 34, and 46) are removed.
2
C. Remove cap screws (42) and flange nuts (27)
from the engine mount brackets (22, 34, and 46)
and the frame.
Figure 24
1. Lifting tab
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 lines,
hydraulic hoses, electrical harness or other parts while
removing the engine.
D. Remove engine (25) from the frame.
E. Mount engine onto an engine rebuilding stand.
Reelmaster 2300–D/2600–D
Page 3 – 17
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Engine Reinstallation
1. Makesuremachineisparkedonalevelsurfacewith
cutting units lowered, and key removed from the start
switch. Chock wheels to keep the machine from moving.
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).
2. Make sure that all parts remove from the engine
during maintenance or rebuilding are reinstalled to the
engine.
5. Reinstall radiator assembly.
A. Place radiator assembly down and then into the
engine to prevent the engine cooling fan from catch-
ing the radiator top and bottom shrouds.
3. If mount brackets (22, 34, and 46) were removed re-
install them as follows (Fig. 19):
B. Connectairfilterhoseextendingfromtheengine
to the air cleaner. Tighten hose clamp.
A. For front mount brackets (34), secure brackets
to the engine (25) with cap screws (36), lock wash-
ers (33) and washers (13). Torque cap screws from
34 to 42 ft–lb (4.7 to 5.8 kg–m).
C. Support the radiator assembly while installing
the fasteners.
D. Install carriage bolts (1) and whiz nuts (2) to the
radiator bracket (3) and frame (4) (Fig. 23).
B. For left rear mount bracket (22), secure bracket
to the engine (25) with two cap screws (36), lock
washers (33) and washers (13) through the left
holes. Leave the right holes open for the muffler.
Torque cap screws from 34 to 42 ft–lb (4.7 to 5.8
kg–m).
E. Install cap screws (1) and whiz nuts (2) to the ra-
diator rear bracket (3) and frame (4) (Fig. 22).
6. Reconnect electrical connections (Fig. 19).
C. For right rear mount bracket (46), secure brack-
ets to the engine (25) with cap screws (36), lock
washers (33) and washers (13). Leave cap screws
loose enough so that the position of the bracket
can be adjusted after the engine is installed.
A. Untie harness and hoses from the reservoir sup-
port brackets. Pull wiring harness and hydraulic
hoses into position; keep them from contacting
moving parts. Install cap screw (10) and flat washer
(11) to R–clamp (12) and tighten to cylinder head.
4. Reinstall engine (Fig. 19)
B. Reconnect connector with blue leads to the al-
ternator.
A. Attach short section of chain between both lift
tabs (1) located on each end of the cylinder head (2)
(Fig. 24)
C. Reconnect connector with blue/white leads to
the traction clutch.
B. Connect a hoist or chain fall at the center of the
short section of chain. Apply enough tension on the
short chain so that the engine will be supported
when the engine is removed from the engine re-
building stand. Remove engine from the engine re-
building stand.
D. Reconnect connector to the front lift cylinder mi-
croswitch.
E. Reconnect white/black lead to the temperature
sender located on the top of the water pump.
F. Reconnect tan lead to the high temperature shut
down switch located on the water pump behind the
fan.
Note: One person should operate chain fall or hoist
while another person guides the engine into the frame.
Note: Be careful not to damage the engine, fuel lines,
hydraulic hoses, electrical harness or other parts while
reinstalling the engine.
G. Reconnect purple lead to the fuel valve solenoid
located above the lift pump.
H. Reconnect brown lead to the oil pressure switch
located on the front of the cylinder head.
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.
I. Reconnect white lead to the glow plugs located
on the front right side of the cylinder head.
D. Secure cap screws (42) and flange nuts (27) to
the mount brackets (22, 34, and 46) and frame.
Engine
Reelmaster 2300–D/2600–D
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J. Reconnect gray, red, and white leads to the en-
gine starter solenoid located on below the exhaust
manifold.
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.
K. Reconnect battery ground to the traction clutch
side of the cylinder head or the left side of the cylin-
der block.
13. Add antifreeze to radiator as described in Checking
the Cooling System.
7. Reconnect throttle cable (Fig. 19).
A. Run throttle cable to engine (25).
14. Slide the left foot rest (5) (Fig. 17) onto the adjusting
rod (2) (Fig. 18). Reinstall cap screws (3) and flange nut
(4) securing the left footrest (5) to the frame. Tighten cap
screws (Fig. 17).
B. Reinstall clevis pin (29), throttle tab (30), and
throttle cable to the engine governor lever. Reinstall
and lock cotter pin (31) to the clevis pin.
15. Connect adjusting rod to brake arm (3) Install and
lock cotter pin (1) to the adjusting rod (2) (Fig. 18).
C. Install throttle cable into the throttle cable clamp
(26). Tighten cap screw (43).
16. Reinstall fender bracket (2) and left fender (1) to the
radiator side of the frame (Fig. 17).
8. Reinstall exhaust system (Fig. 19).
A. Position muffler (14) and muffler gasket (45)
onto the exhaust manifold. Install capscrews (39)
and flat washers (11) to the muffler and exhaust
manifold. Tighten cap screws.
A. Secure both cap screws (3) and left fender
bracket (2) to the frame.
B. Reinstall remaining cap screws (3) and flange
nuts (4) securing the fender to the fender bracket
and frame.
B. Reinstall cap screws (36) and washers (13) into
the muffler and right rear mount bracket (46).
C. Secure cap screw (3) and flange nut (4) to the
left foot rest (5) and the left fender (1).
C. Slide muffler tube through the U–clamp (17).
Connect muffler tube to the muffler. Tighten nut (20)
and U–clamp.
17. Replace traction pump drive belt as described in
Traction (Electric) Clutch of the Service and Repairs
section of Chapter 5 – Electrical System.
D. Reinstall muffler clamp (19) to the muffler (14)
and muffler tube (15).
18. Adjust traction pump drive belt as described in the
Adjustment section of Chapter 4 – Hydraulic system.
9. Reconnect hydraulic hoses from the oil cooler.
A. Unplug hydraulic hose (2) and hydraulic elbow
fitting (3). Connect hydraulic supply hose to the hy-
draulic elbow fitting. Tighten hose clamp (1) (Fig.
21).
19. Connect negative (–) and then positive (+) battery
cables at the battery.
20. Adjust hand brake as described in the Adjustment
section of Chapter 6 – Wheels and Brakes.
B. Unplug hydraulic return hose (2) and hydraulic
fitting (3). Connect hydraulic return hose to the hy-
draulic fitting. Tighten hose clamp (1) (Fig. 20).
21. Adjust throttle linkage as described in the Adjust-
ment section of this chapter.
10. Connect hoses to the engine (Fig. 19).
22. Bleed fuel system. See Bleeding the Fuel System.
A. Connect fuel hose (return) to the injector nozzle
piping and tighten hose clamp.
23. Check oil level as described in Changing the Engine
OIl and Filter.
B. Unplug fuel hose (44). Connect fuel hose to the
lift pump and tighten hose clamp (38).
24. Replace access covers to the engine.
A. Reinstall left rear panel (radiator side) which
supports the instrument panel.
C. Connect upper radiator hose (18) and lower ra-
diator hose (24) to the engine. Tighten hose clamps
(23).
B. Reinstall right side panel which accesses the
traction pump drive belt.
D. Connect air filter hose to the engine (25).
C. Reinstall hood to the machine and close.
Reelmaster 2300–D/2600–D
Page 3 – 19
Engine
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Engine
Reelmaster 2300–D/2600–D
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Chapter 4
Hydraulic System
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 3
Checking the Hydraulic System Fluid . . . . . . . . . . 5
Changing the Hydraulic System Fluid and Filter . 6
Pushing or Towing the Traction Unit . . . . . . . . . . . 6
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . . 8
Raise Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Traction Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Traction Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 16
Hydraulic Tester – Pressure and Flow . . . . . . . . 16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic Oil Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 17
Foaming Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 17
Hydraulic System Operates Hot . . . . . . . . . . . . . . 17
Neutral Is Difficult to Find or Operates in One
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 Relief Valve Pressure . . . . 28
Test No. 6: Cross–over Relief Pressures . . . . . . 30
Test No. 7: Reel Motor Case Drain . . . . . . . . . . . 32
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Transmission for Neutral . . . . . . . . . . . . . . . . . . . . 34
Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Traction Pedal Damper . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Pump Drive Belt . . . . . . . . . . . . . . . . . . 36
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 37
Traction/Charge Pump . . . . . . . . . . . . . . . . . . . . . . 37
Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2WD/3WD Two Position Valve . . . . . . . . . . . . . . . 54
Reel Motor Drive Pump . . . . . . . . . . . . . . . . . . . . . 57
Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hydraulic Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 63
Front Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rear Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Control and Implement Relief Valves . . . . . . . . . 74
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 77
Flushing the Hydraulic System . . . . . . . . . . . . . . . 79
Hydraulic System Start–up . . . . . . . . . . . . . . . . . . 80
Direction Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Traction Response Is Sluggish . . . . . . . . . . . . . . . 17
No Traction in Either Direction . . . . . . . . . . . . . . . 17
Wheel Motor Will Not Turn . . . . . . . . . . . . . . . . . . 18
Wheel Motor Will Not Hold Load In Neutral . . . . 18
Noisy Wheel Motor Drive Pump (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
Reelmaster 2300–D/2600–D
Page 4 – 1
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Specifications
Item
Description
Traction Pump
Variable displacement piston pump
3000 PSI (207 bar)
5000 PSI (345 bar)
3600 RPM
Maximum Operating Pressure
Maximum Intermittent Pressure
Maximum Rated Speed
Rated Flow @ Maximum Rated Speed and Pressure
17 GPM (64 LPM)
Charge Pump
Maximum Operating Pressure
Maximum Rated Speed
Gerotor pump
500 PSI (34.5 bar)
3600 RPM
Rated Flow @ Maximum Rated Speed and Pressure
Charge Pressure
3.5 GPM (13.2 LPM)
100 to 150 PSI (6.9 to 10.0 bar)
Implement (Lift) Relief Valve
Implement Relief Pressure
Differential area relief valve
450 – 525 PSI (31.1 to 36.2 bar)
Wheel Motors
Orbital rotor pump (with shuttle valve on left front motor)
Maximum Operating Pressure
Maximum Intermittent Pressure
Maximum Rated Speed
2000 PSI (138 bar)
3000 PSI (207 bar)
267 RPM
Rated Flow @ Maximum Rated Speed and Pressure
15 GPM (57 LPM)
Reel Motor Drive Pump
Positive displacement gear type pump
4000 PSI (276 bar)
Maximum Operating Pressure
Maximum Intermittent Pressure
Maximum Rated Speed
4400 PSI (304 bar)
4000 RPM
Rated Flow @ Maximum Rated Speed and Pressure
8.5 GPM (32 LPM)
Hydraulic Manifold Relief Valve
Cutting Circuit Relief Pressure
Differential area relief valve
2700 to 3300 PSI (186.3 to 227.7 bar)
Reel Motor
Gear motor
1350 to 1650 PSI (93.2 to 113.9 bar)
2250 PSI (155 bar)
Cross–over Relief Pressure
Maximum Operating Pressure
Maximum Intermittent Pressure
Maximum Rated Speed
3000 PSI (207 bar)
3000 RPM
Rated Flow @ Maximum Rated Speed and Pressure
28.6 GPM (108 LPM)
Lift Control Valve
Hydraulic Filter
Hydraulic Oil
Spool type directional control valve
10 Micron spin–on cartridge type
* Mobil 424/Shell Donax TD or equivalent
Hydraulic Reservoir
Reservoir capacity 2.3 gal. U.S. (8.7 L)
Total system capacity approximately 3.3 gal. U.S. (12.5 L)
Hydraulic System
Page 4 – 2
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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.
Theseconditionscancausedamageorprematuredete-
rioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
WARNING
Before disconnecting or performing any
work on hydraulic system, all pressure in
system must be relieved by stopping the
engine and lowering or supporting the
box and/or other attachment.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings.
This can be done by observing the imprint on the hose.
Use two wrenches; hold the hose straight with one and
tighten the hose swivel nut onto the fitting with the other.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid
under high pressure. Use paper or card-
board, not hands, to search for leaks.
Hydraulic fluid escaping under pressure
can have sufficient force to penetrate the
skin and cause serious injury. If fluid is
injected into the skin, it must be surgical-
lyremovedwithinafewhoursbyadoctor
familiar with this type of injury. Gangrene
may result from such an injury.
Hydraulic Fitting Installation
O–Ring Face Seal
Nut
Body
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
Sleeve
2. Make sure the O–ring is installed and properly
seated in the groove. It is recommended that the O–ring
be replaced any time the connection is opened.
Seal
3. Lubricate the O–ring with a light coating of oil.
4. Put the tube and nut squarely into position on the
face seal end of the fitting and tighten the nut until finger
tight.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Useanotherwrenchtotightenthenuttothecor-
rect flats from finger tight (F.F.F.T.). The markings on the
nut and fitting body will verify that the connection has
been tightened.
Final
Position
Mark Nut
and Body
Size
F.F.F.T.
Initial
Position
Extend Line
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
.75 + .25
.75 + .25
.75 + .25
1.00 + .25
.75 + .25
.75 + .25
Finger Tight
After Proper Tightening
Figure 2
16 (1 in.)
Reelmaster 2300–D/2600–D
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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.
O–Ring
3. Lubricate the O–ring with a light coating of oil.
4. Install the fitting into the port and tighten it down full
length until finger tight.
5. Tighten the fitting to the correct flats from finger tight
(F.F.F.T.).
Size
F.F.F.T.
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
16 (1 in.)
SAE Straight Thread O–Ring Port – 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.
Lock Nut
3. Lubricate the O–ring with a light coating of oil.
Back–up Washer
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).
O–Ring
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
Figure 4
6. To put the fitting in the desired position, unscrew it
by the required amount, but no more than one full turn
(Step 3).
Step 1
Step 2
Step 3
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
flats from finger tight (F.F.F.T.) (Step 4).
Size
F.F.F.T.
Step 4
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
1.00 + .25
1.50 + 25
1.50 + .25
1.50 + .25
1.50 + .25
1.50 + .25
16 (1 in.)
Hydraulic System
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Checking the Hydraulic System Fluid
The hydraulic system is designed to operate on anti–
wear hydraulic fluid. The machine’s reservoir is filled at
the factory with approximately 3.3 gallons (12.5 liters) of
Mobil 424 hydraulic fluid. Check level of hydraulic
fluid before engine is first started and daily thereaf-
ter.
1
Group 1 Hydraulic Fluid (Recommended for ambi-
ent temperatures consistently below 100_ F.):
2
ISO type 46/68 anti–wear hydraulic fluid
Mobil
Mobil Fluid 424
Amoco 1000
Hy–Tran
Amoco
Figure 6
International Harvester
Texaco
1. Hydraulic reservoir cap
2. Sight gauge
TDH
Shell
Donax TD
IMPORTANT: Use only types of hydraulic fluids
specified. Other fluids could cause system damage.
Union OIl
Chevron
BP Oil
Hydraulic/Tractor Fluid
Tractor Hydraulic Fluid
BP HYD TF
Note: A red dye additive for the hydraulic system fluid
is available in 2/3 oz bottles. One bottle is sufficient for
4 to 6 gallons (15 to 22 liters) of hydraulic fluid. Order
Part No. 44–2500 from your Authorized Toro Distributor.
Boron OIl
Exxon
Eldoran UTH
Torque Fluid
Power–Tran 3
Hyken 052
Conoco
Kendall
1. Position machine on a level surface. Make sure en-
gine is off and parking brake is set.
Phillips
HG Fluid
2. Check level of the fluid by viewing into the sight
gauge. If the fluid is cold, the level should be at the bot-
tom of the gauge. If the fluid is hot, the level should be
at the center of the gauge.
Note: The fluids within this group are interchange-
able.
Group 2 Hydraulic Fluid (Biodegradable):
ISO VG 32/46 anti–wear hydraulic fluid
3. If fluid level is not at center of gauge, remove cap
from the hydraulic fluid reservoir and slowly fill reservoir
with Mobil 424 or equivalent hydraulic fluid until level
reaches center of sight gauge. DO NOT OVERFILL
Mobil
EAL 224 H
IMPORTANT: Due to the nature of biodegradable
fluids, it is critical that the fluid be changed at the
recommendedintervals or severe hydraulic compo-
nent damage may occur.
IMPORTANT: To prevent system contamination,
clean top of hydraulic fluid containers before punc-
turing. Assure pour spout and funnel are clean.
4.Install reservoir cap. Wipe up any fluid that may have
spilled.
Note: The fluid in this group is not compatible with the
fluids in group 1.
IMPORTANT: These hydraulic fluids are specified
to allow optimal operation of the machine in a wide
range of temperatures encountered. The group 1
fluids are a multi–viscosity hydraulic fluids which
allows operation at lower temperatures without the
increased viscosity that is associated with straight
viscosity fluids.
Note: When changing from one type of hydraulic fluid
to the other, be certain to remove all the old fluid from the
system, because some brands of one type are not com-
pletely compatible with some brands of the other type of
hydraulic fluid.
Reelmaster 2300–D/2600–D
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Changing the Hydraulic System Fluid and Filter
The hydraulic system filter must be changed initially, af-
ter the first five hours of operation, and thereafter every
200 hours of operation or yearly, whichever comes first.
Use a genuine Toro oil filter for replacement. The hy-
draulic fluid must be changed every 400 hours of opera-
tion or yearly, whichever comes first.
1
1. Park the machine on a level surface, lower the cut-
ting units, set parking brake and turn the engine off.
2. If only the filter is to be changed, remove reservoir
capandinsertreservoirplug(Fig. 7), toblockoutlet.This
will retain most of the fluid in reservoir when filter is re-
moved.
2
Figure 7
3. Clean the area around the hydraulic oil filter. Re-
move filter from the bottom of the filter housing andallow
the oil to flow into a drain pan. Use a bottom type filter
wrench. Dispose of the oil filter properly.
1. Reservoir plug
2. Reservoir outlet
4. Apply a film of oil on the filter gasket. Install filter by
hand until gasket contacts the mounting head; then
tighten filter an additional three–fourths turn.
5. Fill the reservoir to proper level, refer to Checking
the Hydraulic System Fluid.
6. Place all controls in neutral or disengaged position
and start engine. Run engine at lowest possible RPM to
purge the system of air.
1
Figure 8
7. Run engine until lift cylinders extend and retract and
forward and reverse wheel motion is achieved.
1. Hydraulic oil filter
8. Stop the engine and check the oil level in reservoir,
add oil if necessary.
9. Check all connections for leaks.
Pushing or Towing the Traction Unit
In case of emergency, the Reelmaster 2300–D can be
towed for a short distance. However, Toro does not rec-
ommend this as a standard procedure.
IMPORTANT: Do not tow the machine faster than
2–3 mph because drive system may be damaged. If
machine must be moved a considerable distance,
transport it on a truck or trailer.
1. Locate by–pass valve on pump and rotate it 90_
so the by–pass valve is horizontal.
1
2. Before the starting engine, close by–pass valve by
rotating it 90_ so the by–pass valve is vertical. Do not
start engine when valve is open.
Figure 9
1. By–pass valve
Hydraulic System
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Hydraulic Schematic
Reelmaster 2300–D/2600–D
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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 pump takes its suction through a fil-
ter from the reservoir.
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-
tionsoftheliftcylindersoutandthroughthecontrolvalve
to the piston pump suction. When the control valve lever
is released, spring action returns the spool to the center
position and by–passes flow back to the piston pump
suction. Lift cylinder movement is stopped. The cylinder
position is locked in place since there is no complete cir-
cuit of flow to and from the lift cylinders.
During conditions of not lifting or lowering cutting units,
flow from the charge pump goes to the control valve and
is by–passed (control valve position not shown) directly
to the suction of the piston pump and the charge relief
valve.
Circuit operation for lowering the lift cylinders is similar
to raising them. However, the control valve spool is
shifted up and flow is reversed to and from the lift cylin-
ders, thus moving the cutting units down.
When the cutting units are to be raised, the control valve
spool is positioned down and flow is directed out the top
of the control valve to the lower and outer portions of the
Hydraulic System
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Traction 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. Taking its suction directly from the return
side of the wheel motors of the traction circuit, the trac-
tion pump supplies oil flow to the wheel motors through
the supply side of the traction circuit.
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 valve and
back through the charge circuit check valves. This fil-
tered oil replaces oil losses from flow through the shuttle
valve and small amounts of leakage. The charge pump
and shuttle valve circuits allow for indirect cooling and
filtering of the traction circuit.
With the engine running, clutch engaged, and traction
pedal in the neutral position, the traction pump supplies
no flow to the wheel motors. When the traction pedal is
pressed to the forward position, the linkage from the
pedal positions the swash plate in the traction motor so
oil flows out the top port of the pump. Oil flow out of the
top port goes to the wheel motors and turns them in the
forward direction. The 2WD/3WD selector valve allows
flow to the rear wheel in the 3WD position and by–
passes the rear wheel in the 2WD position.
Intheforwarddirection, thePCflowcontrollerhasaspe-
cial function. When a unit is moving downhill, the opera-
tor will return the traction pedal to the neutral position.
In this situation, the front wheel motors act as hydraulic
pumps and reverse the oil flow through the traction cir-
cuit. The PC flow controller will restrict flow to the rear
motor sufficiently, so the reverse flow is by–passed
through the 2WD/3WD selector (check) valve around
the rear wheel motor. This action will prevent a loss of
steering control should the rear motor turn in the reverse
direction. As a result, there is no 3WD in reverse
Oil flowing out of the wheel motors returns to the bottom
port of the traction pump and is continuously pumped
out the top port. However, oil flow out of the rear wheel
motor must pass through the check valve portion of the
PC flow controller before returning to the traction pump.
Hydraulic System
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Traction Reverse
The traction circuit operates essentially the same in re-
verse as it does in the forward direction. However, the
flow through the circuit is reversed and by–passes the
rear wheel motor.
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.
With the engine running, clutch engaged, and traction
pedal in the neutral position, the traction pump supplies
no flow to the wheel motors. When the traction pedal is
pressed to the reverse position, the linkage from the
pedal positions the swash plate in the traction motor so
oil flows out the bottom port of the pump. Oil flow out of
the bottom port goes to the wheel motors and turns them
in the reverse direction. The 2WD/3WD selector valve
by–passes the rear wheel in both the 2WD and 3WD
positions.
Becauseof the by–passing of the rear wheel motor in re-
verse and the resistance to flow of the two front wheel
motors, all the traction flow is by–passed directly back
to the traction pump when the traction pedal is initially
pushed in the reverse direction. This direct by–passing
of the traction circuit causes a delay in the response of
the traction pedal in reverse until traction flow exceeds
2.1 GPM (7.9 LPM) through the PC flow controller.
Oil flowing out of the wheel motors returns to the top port
of the traction pump and is continuously pumped out the
The charge and shuttle valve circuits function the same
in reverse as they did in the forward direction.
Hydraulic System
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Mow
The reel motor drive pump is directly coupled to the the
traction pump which is driven directly by the engine
through the electric clutch. Taking its suction directly
from the reservoir, the reel motor drive pump supplies oil
flow to the hydraulic manifold block and to the reel mo-
tors.
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
speedcontrolvalveissetforisbypassedtothereservoir
through the logic cartridge valve. With the backlap valve
(MD1) in the mow position, oil flows through the valve
and reel motors which are connected in series. Oil flows
through the right, center, and then left reel motor as it
turns the motors in the mow direction. The oil then re-
turns to the reservoir.
With the engine running, the clutch engaged, and the
cutting unit switch pushed in to the OFF position, oil
flows into inlet port (P1) and through deenergized sole-
noid valve (S1) bypassing the reel motors. Oil then flows
directly back to the reservoir through the oil cooler.
Relief valve (R1) limits system pressure and is set at
3000 PSI (207 bar). When the valve opens, oil is di-
verted back to the reservoir.
When the cutting unit switch is pulled out to the ON posi-
tion with the engine running and the clutch engaged, so-
lenoid valve (S1) is energized and shut, hydraulic
system pressure builds up, and flow is diverted to the
reel motors. Oil flow from port (P1) flows through the 11
position reel speed control valve. Flow across the speed
control valve is pressure compensated by the logic car-
Backlapping operation is the same as mowing opera-
tion, except for the position of the backlap valve (MD1).
The backlap valve is in the backlap position allowing oil
flow through the left, center, and then right reel motor as
it turns the motors in the backlap direction.
Hydraulic System
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Reelmaster 2300–D/2600–D
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Special Tools
Order these tools from the TORO SPECIAL TOOLS
AND APPLICATIONS GUIDE (COMMERCIAL PROD-
UCTS).
Some tools may also be available from a local supplier.
Hydraulic Pressure Test Kit
Use to take various pressure readings for diagnostic
tests. Quick disconnect fittings provided attach directly
to mating fittings on machine test ports without tools. A
high pressure hose is provided for remote readings.
Contains one each, 1000, 5000 and 10000 PSI gauges.
Use gauges as recommended in Testing section of this
chapter.
Figure 10
Hydraulic Tester – Pressure and Flow
Figure 11
This tester requires o–ring face seal (ORFS) adapter fit-
tings for use on this machine.
A protector valve cuts out when pressure is about to
exceed the normal range for the gauge. The cutout
pressure is adjustable.
1. INLET HOSE: Hose connected from the system cir-
cuit to the inlet side of the hydraulic tester.
4. HIGH PRESSURE GAUGE: High range gauge
which accommodates pressures beyond the capacity of
the low pressure gauge, 0 to 5,000 PSI.
2. LOAD VALVE: A simulated working load is created
in the circuit by turning the valve to restrict flow.
5. FLOW METER: This meter measures actual oil flow
in the operating circuit with a gauge rated at 15 GPM.
3. LOW PRESSURE GAUGE: Low range gauge to
provide accurate reading at low pressure, 0 to 1000 PSI.
6. OUTLET HOSE: A hose from the outlet side of the
hydraulic tester connects to the hydraulic system circuit.
Hydraulic System
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Troubleshooting
The cause of an improperly functioning hydraulic sys-
tem is best diagnosed with the use of proper testing
equipment and a thorough understanding of the com-
plete hydraulic system.
Continued use of an improperly functioning hydraulic
system could lead to extensive internal component
damage.
The charts that follow contain information to assist in
troubleshooting. There may possibly be more than one
cause for a machine malfunction.
A hydraulic system with an excessive increase in heat
or noise has a potential for failure. Should either of these
conditions be noticed, immediately stop the machine,
turn off the engine, locate the cause of the trouble, and
correct it before allowing the machine to be used again.
Refer to the Testing section of this Chapter for precau-
tions and specific test procedures.
Problem
Possible Cause
Fitting(s), hose(s), or tube(s) are loose or damaged.
Hydraulic oil leaks
O–ring(s) or seal(s) are missing or damaged.
Oil level in reservoir is low.
Foaming hydraulic fluid
Hydraulic system has wrong kind of oil.
One of the pump suction lines has an air leak.
Hydraulic system operates hot
Transmission pressure is high due to load or brakes applied.
Oil level in reservoir is low, or inlet filter is loose or clogged.
Oil is contaminated or too light.
Heat exchanger is damaged or plugged. By–pass relief is stuck
open or air flow is obstructed.
Charge pressure is low.
Towing by–pass valve is open or defective.
Wheel motor(s) or reel motor(s) are worn or damaged.
Traction pump is worn or damaged.
Neutral is difficult to find or unit oper-
ates in one direction only
External control linkage is misadjusted, disconnected, binding, or
damaged.
Traction pump is worn or damaged.
Traction response is sluggish
No traction in either direction
Charge pressure is low. Hydraulic oil is very cold.
Towing by–pass valve is open or worn. Brake is not released.
Traction pump or wheel motor(s) are worn or damaged.
Brake is not released.
Oil level in reservoir is low.
Towing by–pass valve is open.
Charge pressure is low.
Traction pump or wheel motor(s) are worn or damaged.
Reelmaster 2300–D/2600–D
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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.
Make up fluid from charge pump is not available.
Wheel motor will not hold load in
neutral
Flow control setting is wrong for reverse.
Reservoir oil level is low.
Noisy reel motor drive pump (cavita-
tion)
Suction line is restricted.
Suction line has an air leak.
Reels will not turn
Cross–over relief valve(s) are stuck open. (The other reels will still
rotate.)
Valve S1 is stuck open.
An electrical problem exists. (See Chapter 5–Electrical System)
Relief valve R1 is stuck open.
LC1 logic valve is stuck open.
Reel motor drive pump is damaged.
Reel speed is erratic
Reel to bedknife adjustment is too tight.
Reel bearing(s) are damaged.
Reel motor case drain flow is exces-
sive. Flow is greater than 0.7 GPM
at 1200 PSI (2.6 LPM at 82.8 bar).
Excessive internal wear in wheel motor exists.
Reel bearing(s) are damaged.
Engine speed is too low.
Cutting units will not lift or lift slowly
Pump pulley drive belt is loose.
Charge pump is damaged.
Lift valve control linkage is binding or broken.
Lift cylinder bushings bind.
Reservoir oil level is low.
Inlet filter is loose or clogged.
Charge pump pressure or flow is insufficient.
Implement relief valve is stuck open.
Lift control valve is damaged.
Lift cylinders leak internally.
Lift cylinders leak internally.
Cutting units raise, but will not stay
up
Lift valve leaks.
Hydraulic System
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Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks. (See the Special
Tools section in this Chapter.)
1. Thoroughly clean the machine before disconnect-
ingordisassemblinganyhydrauliccomponents. 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 during testing or removal of components.
CAUTION
3. The engine must be in good operating condition.
Use a tachometer when making a hydraulic test. Engine
speed can affect the accuracy of the tester readings.
Failure to use gauges with recommended
pressure (psi) rating as listed in test pro-
cedures could result in damage to gauge
and possible personal injury from leaking
hot oil.
4. To prevent damage to tester or components, the in-
let and the outlet hoses must be properly connected,
and not reversed (tester with pressure and flow capabili-
ties).
Before Performing Hydraulic Tests
5. To minimize the possibility of damaging compo-
nents, completely open load valve in hydraulic tester
(when using tester with pressure and flow capabilities).
All obvious areas such as oil supply, filter, binding link-
age, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem being experienced.
6. Install fittings finger tight, far enough to insure that
they are not cross–threaded, before tightening with a
wrench.
7. Position the tester hoses so that rotating machine
parts will not make contact with them and result in hose
or tester damage.
WARNING
Before disconnecting or performing any
work on the hydraulic system, all pres-
sure in the system must be relieved by
stopping the engine and lowering or
supporting the cutting units or other
implements.
8. Check the oil level in the reservoir.
9. Check the control linkage for improper adjustment,
binding or broken parts.
10. Allhydraulictestsshouldbemadewiththehydraulic
oil at normal operating temperature.
Keep body and hands away from pin hole
leaks or nozzles that eject hydraulic fluid
under high pressure. Use paper or card-
board, not hands, to search for leaks.
Hydraulic fluid escaping under pressure
can have sufficient force to penetrate
skin and cause serious injury. If fluid is
injected into the skin, it must be surgical-
lyremovedwithinafewhoursbyadoctor
familiar with this type of injury. Gangrene
may result from such an injury.
Reelmaster 2300–D/2600–D
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TEST NO. 1: Traction Pump Flow
WHEEL MOTOR
RIGHT
FORWARD
REVERSE
TO REAR WHEEL MOTOR
FROM REAR WHEEL MOTOR
PC FLOW CONTROL
2.1 GPM
TESTER
TOP
BOTTOM
FROM CONTROL VALVE
TO CONTROL VALVE
FRONT
TOP
CHARGE PUMP
FROM FROM RESERVOIR
BOTTOM
TRACTION PUMP
REVERSE
(FRONT
LINE)
FORWARD
(REAR
TO RESERVOIR
FRONT
LINE)
TO HYDRAULIC MANIFOLD PORT T2
FORWARD
DISCHARGE
WHEEL MOTOR
LEFT
High Pressure
Low Pressure
Return or Suction
Flow
FRONT
Figure 12
Page 4 – 20
Hydraulic System
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Procedure for Traction Pump Flow Check:
11. Clean hose fitting and disconnect hose from the el-
bow connection on the top of the traction pump.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
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.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered and off. Make sure engine is
off.
12. Install tester in series with the motor and the discon-
nected hose. Make sure the flow control valve is fully
open.
3. Make sure the hydraulic tank is full.
13. One person should sit on the seat and operate the
machine while another person reads the tester. Start en-
gine and move the throttle to full speed (3200 " 100
RPM).
4. Make sure that traction pedal is adjusted to the neu-
tral position (see Traction Pedal in the Adjustments Sec-
tion).
5. Make sure that pump drive belt is adjusted properly.
(see Hydraulic Pump Drive belt in the Adjustments Sec-
tion).
CAUTION
6. Blockuponefronttractionwheeloffthefloortoallow
flow through the traction circuit.
Use extreme caution when taking gauge
readings. The front tire on the ground will
be trying to move the machine forward.
7. Chock remaining wheels to prevent movement of
the machine.
14. Slowly push traction pedal into fully forward posi-
tion.
8. Attach a heavy chain to the rear of the machine
frame and something solid in the shop.
15. Close flow control valve until pressure gauges read
1000 PSI. Verify pump speed of 2700 RPM with a photo-
tac.
9. Make sure parking brake is off.
10. Put 2WD/3WD selector to 2WD so the rear wheel
will not spin.
16. Observe flow gauge.
TESTER READING: minimum flow of 13 GPM
17. Release traction pedal and turn off machine.
CAUTION
18. Disconnect tester from elbow connection and hose.
Reconnect hose to elbow connection.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
19. If specifications are not met, the traction pump
needs to be repaired or replaced as necessary.
Reelmaster 2300–D/2600–D
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TEST NO. 2: Charge Pump Flow and Implement Relief Pressure
CONTROL VALVE
TO WHEEL MOTORS
VALVE TOP
TO LIFT CYLINDER
BOTTOM
IN (FRONT)
OUT (REAR)
FROM LIFT CYLINDER
BOTTOM
2
1
FRONT
TESTER
TOP
IMPLEMENT RELIEF
FILTER
CHARGE PUMP
BOTTOM
RESERVOIR
TRACTION PUMP
FRONT
REEL MOTOR
RETURN FROM MANIFOL
DRIVE PUMP
TO MANIFOLD
COOLER
High Pressure
Low Pressure
Return or Suction
Flow
DISCHARGE
FRONT
Figure 13
Hydraulic System
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Procedure for Charge Pump Flow Check:
2. Operate engine at full speed (3200 ꢀ 100 RPM).
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
3. Make sure hydraulic oil is at operating temperature.
4. Watch pressure gauge carefully. Make sure lift lever
to the cutting units is in the neutral position. Record the
pressure.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
the parking brake is engaged.
5. While holding the lift lever in the raised position,
watch the pressure gauge. Record pressure the relief
valve opens at.
3. Make sure the hydraulic tank is full.
6. Return lift lever to neutral position. Shut off engine.
CAUTION
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.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
A. If this specification is not met, adjust relief valve.
B. If this specification is met, go to step 9.
4. Disconnect outside top hose from the discharge fit-
ting of the charge pump. Connect gage end of tester to
the pump discharge fitting.
Example Calculation
PRESSURE
Relief Valve Open
(Lever to Raise)
620
5. Connect the other end of the tester to the discon-
nected hose.
Relief Valve Closed
(Lever in Neutral)
150
470
CAUTION
Open less Closed Pressure
(450 to 500 PSI)
Make sure that all hoses are free of the fly-
wheel after installation.
8. Adjusting the relief valve pressure as follows:
A. Remove the cap from the relief valve.
6. Operate engine at full speed (3200 ꢀ 100 RPM).
B. To increase the relief valve pressure set point,
use an allen wrench and turn set screw slightly
clockwise.
7. Make sure hydraulic oil is at operating temperature.
8. Make sure that traction pedal and lift valve are in
neutral and the parking brake is engaged.
C. To decrease the relief valve pressure set point,
use an allen wrench and turn set screw slightly
counterclockwise.
9. Watch flow and pressure gauges carefully while
slowly closing the flow control valve until the pressure
gauge reads 500 PSI.
D. Repeat steps 1 through 8 above until the relief
valve pressure set point is correct. Reinstall cap on
valve when valve is set properly.
10. Minimum flow gauge reading should be 2.5 GPM.
If specification is not met, repair or replace pump.
Procedure for Implement Relief Check:
E. If the relief valve pressure set point can not be
adjusted to specification, go to step 9 and replace
the relief valve.
CAUTION
Note: If the pressure and flow are within specification
but the cutting units do not lift or lift slowly, check for me-
chanical binding or internal leakage of the lift cylinder.
Do not allow charge pressure to exceed
650 PSI.
9. Disconnect tester from the pump and hose. Recon-
nect hose to the pump.
1. Fully open control valve on the tester.
Reelmaster 2300–D/2600–D
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TEST NO. 3: Charge Pump Relief Pressure
TO WHEEL MOTORS
TO LIFT CYLINDER
VALVE TOP
BOTTOM
IN (FRONT)
OUT (REAR)
FROM LIFT CYLINDER
BOTTOM
2
1
CONTROL VALVE
FRONT
IMPLEMENT RELIEF
T–CONNECTION AND GAUGE
TOP
FILTER
CHARGE PUMP
BOTTOM
RESERVOIR
TRACTION PUMP
FRONT
COOLER
REEL MOTOR
DRIVE PUMP
RETURN FROM MANIFOLD
TO MANIFOLD
High Pressure
TO CHARGE
RELIEF
Low Pressure
Return or Suction
Flow
FRONT
Figure 14
Hydraulic System
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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.
CAUTION
Make sure that all hoses are free of the fly-
wheel after installation.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
the parking brake is engaged.
5. Operate engine at full speed (3200 ꢀ 100 RPM).
3. Make sure the hydraulic tank is full.
6. Make sure hydraulic oil is at operating temperature.
7. Make sure that traction pedal and lift valve are in
neutral and the parking brake is engaged.
CAUTION
8. Pressure gauge should read from 100 to 150 PSI.
If Specification is not met, replace charge relief valve.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
9. Shut off engine.
10. Disconnect gauge and T–connection from the
pump and hose. Reconnect hose to the pump.
4. Disconnect hose from the front fitting of the charge
pump leading to the control valve. Connect T–connector
and gauge to the pump and hose fitting.
Reelmaster 2300–D/2600–D
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TEST NO. 4: Reel Drive Pump Efficiency
FILTER
TO CHARGE PUMP
BOTTOM
RESERVOIR
TO TRACTION PUMP
FRONT
COOLER
REEL DRIVE PUMP
P1
G1
M2
D1
High Pressure
Low Pressure
Return or Suction
FC1
LC1
RH
M1
M5
MD1
Flow
D3
R1
CTR
LH
S1
M6
M4
FROM LEFT
WHEEL MOTOR
D2
M3
T2
HYDRAULIC MANIFOLD
2
3
TESTER
3
1
Figure 15
1. Hose fitting
2. Reel drive pump
3. O–ring
Hydraulic System
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Procedure for Reel Drive Pump Efficiency Check:
5. Install tester in series with reel drive pump and the
disconnected hose leading to port P1 of the hydraulic
manifold. Make sure the flow control valve is fully open.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
6. Make sure backlap knob on the valve block is in the
mow position.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
the parking brake is engaged.
7. Make sure tester load valve is fully before starting
the engine.
3. Make sure the hydraulic tank is full.
8. Start engine and move throttle to full speed (3200 "
100 RPM). Do not engage the cutting units.
9. Watch pressure gauge carefully while slowly clos-
ing the flow control valve until 1500 PSI is obtained.
Verifywithaphototacthatthepumpspeedis2900RPM.
CAUTION
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
10. Flow indication should be 5.4 GPM minimum.
11. Shut off engine.
12. Disconnect tester from manifold and hose. Recon-
nect hose to the pump.
4. Clean hose connection and reel drive pump. Dis-
connect hose connection on the reel drive pump leading
port P1 on the hydraulic manifold.
13. If flow was less than 5.4 GPM or a pressure of 1500
PSIcannotbeobtained, checkforrestrictioninthepump
intake line. If line is not restricted, remove pump and re-
pair or replace as necessary.
IMPORTANT: Make sure oil flow indicator arrow on
the flow gauge is showing that the oil will flow from
the pump through the tester and into the valve
block.
Reelmaster 2300–D/2600–D
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TEST NO. 5: Manifold Relief Valve Pressure
TESTER
G1
FROM REEL
DRIVE PUMP
M2
D1
RH
MD1
M1
M5
D3
CTR
M6
M4
TO COOLER
LH
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
D2
M3
SHUTTLE VALVE
High Pressure
Low Pressure
Return or Suction
HYDRAULIC MANIFOLD
Flow
Install tester in series
between fitting and
hose at the motor (right
hand motor shown).
Figure 16
Hydraulic System
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Procedure for Manifold Relief Valve Pressure
Check:
7. Start engine and move throttle to full speed (3200 "
100 RPM). Engage the cutting units.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for approximately 10
minutes.
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.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
the parking brake is engaged.
3. Make sure the hydraulic tank is full.
10. Adjusting the relief valve pressure as follows:
A. Remove the cap from the relief valve.
CAUTION
B. To increase the relief valve pressure set point,
use an allen wrench and turn set screw slightly
clockwise.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
C. To decrease the relief valve pressure set point,
use an allen wrench and turn set screw slightly
counterclockwise.
4. Clean hose connection and right hand reel motor.
Disconnect the hose leading from the right hand reel
motor to port M2 on the hydraulic manifold.
D. Repeat steps 1 through 10 above until the relief
valve pressure set point is correct. Reinstall cap on
valve when valve is set properly.
IMPORTANT: Make sure oil flow indicator arrow on
the flow gauge is showing that the oil will flow from
the hose through the tester and into the motor.
E. If the relief valve pressure set point can not be
adjusted to specification, go to step 11 and replace
the relief valve.
5. Installtesterinserieswiththehoseandmotor. Make
sure the flow control valve is fully open.
11. Disengage cutting units. Shut off engine.
6. Make sure backlap knob on the valve block is in the
mow position. Make sure reel speed knob is set to posi-
tion 9 or greater.
12. Disconnect tester from manifold and hose. Recon-
nect hose to the pump.
CAUTION
Keep away from reels during test to pre-
vent personal injury from the rotating reel
blades.
Reelmaster 2300–D/2600–D
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TEST NO. 6: Cross–over Relief Pressures
TEST GAUGE
(TESTING IN MOW)
G1
FROM REEL
DRIVE PUMP
M2
D1
RH
MD1
M1
M5
D3
CTR
M6
M4
TO COOLER
LH
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
D2
M3
T–CONNECTION AND GAUGE
(TESTING IN BACKLAP)
HYDRAULIC MANIFOLD
High Pressure
Low Pressure
Return or Suction
Flow
Figure 17
Hydraulic System
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Procedure for Cross–over Relief Pressures Check:
9. Remove test gauge and put cap on manifold port
G1.
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.
IMPORTANT: Each reel motor has two cross over
reliefs. Test reliefs in the backlap direction only if
they are expected to be the problem. After testing
cross over reliefs in the backlap direction, make
sure the reel motor couplings are torqued (see Hy-
draulic Motor Removal and Installation of Chapter 7
– Cutting Units and Reel Motor in the Service and
Repair section).
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
parking brake is engaged. Back bedknives off all reels.
CAUTION
10. Clean left–hand reel motor and its hose connection
leading to manifold port M3. Disconnect hose connec-
tion and install pressure gauge with a T–connection be-
tween the hose connection and the motor.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
11. Make sure backlap knob on the valve block is in the
backlap position.
3. Clean manifold port G1. Remove cap and install
pressure gauge in manifold port G1.
12. One person should sit on the seat and operate the
machine while another person reads the gauge. Start
engine and move the throttle to full speed (3200 " 100
RPM).
4. Put a block of wood between the blades of the cut-
ting unit being tested to prevent the reel from rotating.
5. Make sure backlap knob on the valve block is in the
mow position.
CAUTION
6. One person should sit on the seat and operate the
machine while another person reads the tester. Start en-
gine and set throttle to full speed (3200 " 100 RPM).
Keep away from reels during test to pre-
vent personal injury from the rotating reel
blades.
CAUTION
Keep away from reels during test to pre-
vent personal injury from the rotating reel
blades.
CAUTION
Do not allow system pressure to exceed
1700 PSI. Shut off unit to prevent an over
pressure condition.
13. Engage cutting units. Observe pressure gauge.
CAUTION
Motor Position
Right Hand
Rear
Pressure Range (PSI)
1580 to 1680
Do not allow system pressure to exceed
1700 PSI. Shut off unit to prevent an over
pressure condition.
1540 to 1640
Left Hand
1500 to 1600
7. Engage cutting units. Observe pressure gauge.
14. Disengage cutting units and stop engine. If specifi-
cations are not met, the cross–over relief needs replac-
ing. Remove block of wood from cutting unit and repeat
test on other reels in the same direction of flow.
Motor Position
Right Hand
Rear
Pressure Range (PSI)
1500 to 1600
1540 to 1640
Left Hand
1580 to 1680
15. Remove test gauge and reconnect hose to motor.
Adjust bed bedknife to reel on all cutting units (see Ad-
justment section of Chapter 7 – Cutting Units.
8. Disengage cutting units and stop engine. If specifi-
cations are not met, replace cross–over relief. If specifi-
cations are met, remove block of wood from cutting unit
and repeat test on other reels in mow direction.
Reelmaster 2300–D/2600–D
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Hydraulic System
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TEST NO. 7: Reel Motor Case Drain
MEASURE CASE DRAIN
FLOW HERE
TEST CONNECTION FOR
R.H. REEL MOTOR SHOWN
G1
FROM REEL
MOTOR
DRIVE PUMP
M2
D1
RH
MD1
TESTER
M1
M5
TO COOLER
CTR
D3
M6
M4
LH
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
D2
M3
High Pressure
Low Pressure
Return or Suction
HYDRAULIC MANIFOLD
Flow
Figure 18
Hydraulic System
Page 4 – 32
Reelmaster 2300–D/2600–D
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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.
CAUTION
Keep away from reels during test to pre-
vent personal injury from the rotating reel
blades.
2. Makesuremachineisparkedonalevelsurfacewith
the cutting units lowered. Make sure engine is off and
the parking brake is engaged.
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.
CAUTION
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
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.
Motor
Position
Manifold Port
(Case Drain)
Manifold Port
(Motor Return)
10. Put case drain hose into 1 quart container gra-
duated in ounces (1 liter container graduated in millili-
ters).
Right Hand
Left Hand
Rear
D1
D2
D3
M1
M3
M6
11. One person should sit on the seat and operate the
machine while another person holds the hose and reads
the tester. Start engine and move the throttle to full
speed (3200 " 100 RPM).
3. On suspected bad motor, clean hose connection
and disconnect hose from motor that returns to the man-
ifold (see table).
12. While sitting on seat, engage cutting units by pulling
the knob on the instrument panel out. Make sure gauge
pressure still reads 1200 PSI. After 15 seconds, push
knob on the instrument panel in to disengage cutting
units. Stop the engine.
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.
13. Measuretheamountofoilcollectedinthecontainer.
Divide the number of ounces collected by 32 to get gal-
lons per minute. (Divide the number of milliliters col-
lected by 250 to get liters per minute).
4. Install tester in series with the motor and the discon-
nected return hose. Make sure the flow control valve is
fully open.
5. Make sure backlap knob on the valve block is in the
mow position.
14. Disconnect tester from motor and hose. Reconnect
hose to the pump.
6. One person should sit on the seat and operate the
machine while another person reads the tester. Start en-
gine and move the throttle to full speed (3200 " 100
RPM).
15. Remove cap from manifold fitting. Reconnect case
drain hose to the motor.
16. If flow was greater than 0.7 GPM (2.6 LPM), repair
or replace the reel motor as necessary.
Reelmaster 2300–D/2600–D
Page 4 – 33
Hydraulic System
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Adjustments
Transmission for Neutral
If the machine “creeps” when the traction control pedal
is in the neutral position, the neutral return mechanism
must be adjusted.
1
1. Block up under the frame so one of the front wheels
is off the floor. Place selector control in two wheel drive
position.
2
2. Startengine, movethrottletoSLOWandcheckfront
wheel that is off shop floor; it must not be rotating. Loos-
en pump plate nuts and rotate pump plate until creep
does not occur in either direction. When wheel stops ro-
tating, tighten nuts locking adjustment. Verify the adjust-
ment with throttle in SLOW and FAST position.
3. Should the wheel continue to rotate, check for the
following:
A. Ball bearing is loose or worn out.
B. Loose or missing fasteners.
4
C. Worn fasteners.
5
3
D. Pump lever loose on control shaft.
E. Weak or damaged Ieaf springs. Replace.
F. Internal pump component malfunction.
Figure 19
1. Pump plate nut
2. Pump
3. Neutral switch
4. Adjusting screw
5. Lock nut
4. After adjusting the pump plate, check neutral switch
operation and if necessary, adjust as follows:
A. Loosen locknut securing switch adjusting screw.
Thread away from switch until capscrew head
clears switch.
B. Rotateadjustingscrewtowardswitchuntilcircuit
through switch is made. Then, turn adjusting screw
an additional 2–1/2 turns.
C. Tighten locknut
Hydraulic System
Page 4 – 34
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Traction Pedal
If traction pedal stop cam contacts the footrest when
pushed fully forward or maximum forward traction
speed is unattainable, an adjustment to the traction ped-
al linkage is required.
2
1. To expose traction rod, remove screws securing
right fender to frame and remove fender.
4
2. Loosen jam nuts on each end of traction rod.
3
3. Rotate rod until pedal stop cam clearance is from
0.03 to 0.09 inch (0.8 to 2.3 mm) with the pedal de-
pressed.
5
4. Retighten jam nuts securing traction rod adjust-
ment.
1
IMPORTANT: Verify reverse speed with one front
wheel off the ground in 2WD and the engine at high
idle. Reverse wheel speed should be from 120 to 140
RPM. Damage may result to rear motor if this speed
is exceeded.
Figure 20
1. Traction rod
2. Damper
4. Damper bracket
5. Pedal cam stop
3. Damper pivot
5. The stop for reverse travel (under pedal) may be ad-
justed for slower travel.
PEDAL STOP CAM
0.03 to 0.09 in.
(0.8 to 2.3 mm)
FOOT PLATE
Figure 21
Traction Pedal Damper (Fig. 20)
1. Toexposetractionpedaldamper, removerighthand
panel.
4. Fully compress damper and then release it allowing
it to extend 0.08 inch (2.0 mm). Tighten locknut securing
the damper pivot to the damper bracket.
2. Loosen locknut securing damper pivot to the damp-
er bracket.
5. When traction pedal is fully depressed in reverse
direction, traction pedal must contact reverse stop so
the damper does not act as the stop in either direction.
3. Depress traction pedal fully forward and hold.
Reelmaster 2300–D/2600–D
Page 4 – 35
Hydraulic System
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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 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.
2
Note: Tighten belt to eliminate slippage (squealing
under load) but do not overtighten.
1
1. Tighten nut on adjustment rod until desired belt ten-
sion is attained.
Figure 22
1. Nut
2. Adjustment rod
Hydraulic System
Page 4 – 36
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Service and Repairs
Traction/Charge Pump
11
10
1
13
16
14
17
34
32
35
33
4
37
22
3
2
34
31
9
15
36
30
27
24
38
13
34
34
8
26
21
7
5
35
17
25
23
43
12
14
29
28
39
20
19
18
42
41
40
Figure 23
1. Cap screw
2. Reel motor drive pump
3. O–ring
4. Traction/charge pump
5. Hose
6. Hose
7. Hydraulic fitting
8. Hydraulic fitting
9. Hose connection
10. Hose connection
11. Hose connection
12. Hose connection
13. O–ring
16. Hydraulic fitting
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
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
25. Belt adjustment yoke
26. Pump drive belt
27. Pulley
28. Cap screw
14. O–ring
15. Hydraulic fitting
29. Lock washer
43. Nut
Reelmaster 2300–D/2600–D
Page 4 – 37
Hydraulic System
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Removal (Fig. 23)
Installation (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.
1. Mount the traction/charge pump (4) to the pump
mount (22). Place both cap screws (31) through the
pump mount and pump base. Install washers (33) and
lock nuts (32) onto cap screws. Tighten cap screws.
2. Place key (37) in the keyway on the pump shaft.
Slide taper lock bushing (30) into place on the pump
shaft. Tighten set screw (36).
CAUTION
Operateallhydrauliccontrolstorelievesystem
pressure and avoid injury from pressurized hy-
draulic oil.
3. Insert cap screws (28) through washers (29) and
pulley (27). Install pulley to taper lock bushing (30). Start
cap screws into bushing and leave cap screws loose.
2. Clean pump assembly and hydraulic connections.
Label all hose connections for reassembly purposes.
Put caps or plugs on any hydraulic lines or fittings left
open or exposed. Install plug into the hydraulic reser-
voir.
4. Loosen set screw (36) and adjust pulley (27) so the
gap between the pulley and pump mount is 0.20 inch.
Evenly torque cap screws from 90 to 120 in–lb. (104 to
138 kg–cm) three times each. Readjust as required.
5. Make sure mounting and O–ring sealing surfaces
on reel motor drive pump (2) and traction/charge pump
(4) are clean.
3. Remove both cap screws (1) from the pump assem-
bly. Carefully separate the reel motor drive pump (2) and
O–ring (3) from the traction/charge pump (4). Position
reel motor drive pump away from traction/charge pump.
6. Inspect O–ring (3) and replace if damaged or worn.
Apply clean hydraulic oil to O–ring. Place O–ring on reel
motor drive pump (2).
4. Remove hoses (5 and 6) from hydraulic fittings (7
and 8). Remove hose connections (9, 10, 11, and 12)
from hydraulic fittings (15, 16, and 17). Allow hoses to
drain to a suitable container.
7. Positionreelmotordrivepump(1)totraction/charge
pump (4). Secure reel motor drive pump to traction/
charge pump with cap screws (1).
5. Remove cap screw (40) and lock nut (39) from the
pump control rod (41), spacer (42), and pump lever as-
sembly (20).
8. Coat all O–rings with clean hydraulic oil. Install hy-
draulicfittings(7, 8, 15, and16)andO–rings(34)intothe
traction/charge pump (4). Torque these fittings from 23
to 27 ft–lb and as close to their original position.
6. Loosenlocknut(21)atthepumpmount(22)andnut
(43) at the belt adjustment yoke (25). Remove cotter pin
(23) and clevis pin (24) from the belt adjustment yoke.
9. Coat all O–rings with clean hydraulic oil. Install hy-
draulic fittings (17) and O–rings (35) into the traction/
charge pump (4). Tighten these fittings as close to their
original position as possible.
7. Tilt pump mount (22) and remove pump drive belt
(26) from the pulley (27).
8. Remove cap screws (28) and lock washers (29)
from the pulley (27) and taper lock bushing (30). Run
cap screws into tapped holes in the pulley, then drive
pulley off the taper lock bushing.
10. Connect hoses (5 and 6) to hydraulic fittings (7 and
8); tighten both hose clamps. Connect hose connec-
tions (9, 10, 11, and 12) to hydraulic fittings (15, 16, and
17). Tighten all hose connections.
9. Support traction/charge pump (4). Remove both
cap screws (31), lock nuts (32), and washers (33) from
the traction/charge pump and pump mount (22). Sepa-
rate traction/charge pump from the pump mount.
11. Replace cap screw (40) through the pump control
rod (41), spacer (42) and pump lever assembly (20). Se-
cure lock nut (39) to the capscrew and tighten.
12. Install pump drive belt (26) onto pulley (27). Align
the holes of the mounting plate (22) with the holes of the
belt adjustment yoke (25) and slide clevis pin (24)
through holes. Secure clevis pin with the cotter pin (23).
Note: Steps 10 and 11 may be performed depending
on the extent of the pump repair.
10. Remove fittings (7, 8, 15, 16, and 17) and O–rings
(34 and 35) from the traction/charge pump (4).
13. Adjust pump drive belt (see Adjustments section)
Tighten lock nut (21) and torque from 60 to 70 ft–lb (8.3
to 9.7 kg–m).
11. Unscrew set screw (36) enough to loosen tapered
lock bushing (30). Slide tapered lock bushing off the
pump shaft. Remove key (37) from pump shaft.
14. Remove plug from the hydraulic reservoir.
Hydraulic System
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7
8
9
10
11
12
13
14
15
5
38
39
6
4
3
13
11
2
17
18
16
7
1
19
20
KEY
23
24
22
40
21
18
25
COUPLER
OUTER RING
37
36
INNER RING
26
32
33
34
27
28
Figure 24
1. Cap screw
15. Housing assembly
28. Bearing
29. Rotating parts kit
30. Key
2. Charge pump adapter assembly
3. Gerotor assembly
4. Bearing
5. Valve assembly
6. Valve plate
7. Screw
8. Trunnion cover
9. O–ring cover
10. O–ring
16. Seal cover
17. Shaft seal
18. Dowel pin
19. Key
20. Camplate
21. Plug
22. Spring
23. Seat
24. Gasket
25. Backplate assembly
26. O–ring
31. Drive shaft
32. Retaining ring
33. Bearing race
34. Thrust bearing
35. Washer
36. Shaft seal
37. Retaining ring
38. O–ring
11. Washer
12. Inner race
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-
sembly (2). Further disassembly of the gerotor assem-
bly is not necessary.
1. Position pump into a vise with protected jaws so the
charge pump drive shaft is pointed up. Clamp onto the
mounting flange of the traction pump.
2. Remove cap screws (1 and 27) and slide charge
pump adapter assembly (2) from the backplate assem-
bly (25) clear of the shaft (31) and gerotor assembly (3).
3. Remove O–ring (26) from the charge pump adapter
assembly (2).
Reelmaster 2300–D/2600–D
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5. The charge pump adapter assembly (2) can be dis-
assembled as follows (see Fig. 25):
SPRING RETAINER
SPRING
A. Unscrew and remove spring retainer from the
charge pump adapter assembly.
B. Remove spring and cup poppet from the charge
pump adapter assembly.
CUP POPPET
6. Remove gerotor assembly (3) inner ring and cou-
pler from the shaft (31).
SUCTION PORT
BEARING
7. Lift backplate assembly (25) up and off from the
shaft (31) and housing assembly (15). Remove valve
plate (6) from the backplate assembly or rotating parts
kit (29).
CHARGE PUMP
ADAPTER ASSEMBLY
8. Remove valve assembly (5) and O–rings (38 and
39) from the backplate assembly (25). Disassembly of
the valve assembly is not necessary.
Figure 25
VALVE PLATE END
9. Remove both plugs (21), O–rings (40), spring (22),
and seats (23) from the backplate assembly (25).
WASHER
SPRING
WASHER
10. Remove gasket (24) from the housing (15) or back-
plate assembly (25).
PINS
RETAINER
RETAINING RING
PISTON BLOCK
Note: To remove the rotating parts kit (29) from the
shaft (31), a table or workbench with a hole in the work-
ing surface is required for the protruding shaft.
SPIDER
11. The rotating parts kit (29) can be removed from the
shaft (31) as follows:
SPIDER PIVOT
A. Hold rotating parts kit (29) in place and remove
the pump from the vise.
PISTON ASSEMBLIES
CAMPLATE END
Figure 26
B. Position the housing assembly (15) end of the
pump up and lower the shaft (31) through the hole in
the table or workbench. Allow rotating parts kit (29)
to rest on the table.
B. Use the following parts to disassemble the pis-
ton block:
2
1
1
5/16 in. I.D. ꢀ 15/16 in. O.D. flat washers
5/16 in. ꢀ 2–7/8 in. N.C. cap screw
5/16 in. N.C. nut
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):
C. Place cap screw through one of the flat washers.
Insert cap screw through the center of the piston
block. Install second flat washer onto the capscrew
so the washer rests on the three pins. Screw nut
onto the cap screw.
A. Removeninepistonassemblies, spider, andspi-
der pivot from the piston block.
D. Compress spring by tightening the nut onto the
cap screw. Remove the retaining ring from the pis-
ton block.
CAUTION
Be careful when removing the spring
from the piston block; the spring is highly
compressed. Safely compress the spring
before removing the retaining ring.
E. Slide washer, spring, second washer, three pins,
and retainer from the piston block.
Hydraulic System
Page 4 – 40
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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.
FLANGE
0.090 to 0.100 in.
(2.54 to 2.89 mm)
14. Remove retaining ring (32), washer (35), thrust
bearing (34), second washer (35), and second retaining
ring (32) from the shaft (31).
BEARING
DEPTH
15. Remove screws (7), trunnion cover (8), O–ring cov-
er (9), O–ring (10), washer (11), inner race (12), and
bearing (13). Remove screws (7), seal cover (16), shaft
seal (17), washer (11), and bearing (13).
GEROTOR POCKET
Figure 27
16. Position camplate (20) to one side and remove from
the housing assembly (15).
0.070 to 0.080 in.
(1.78 to 2.03 mm)
0.105 to 0.115 in.
(2.67 to 2.92 mm)
Inspection
CAUTION
BEARING
HEIGHT
ROLL PIN
HEIGHT
Use eye protection such as goggles when
using compressed air
1. Washallpartsinsolvent. Drypartswithcompressed
air.
Figure 28
FLANGE END OF HOUSING
2. Inspect charge pump adapter assembly (see Fig.
25).
0.062 to 0.078 in.
(1.57 to 1.98 mm)
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.
NUMBERED END
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.
BEARING
DEPTH
C. Make sure gerotor pocket inside the pump is not
excessively scored.
Figure 29
3. Inspect backplate assembly (25) (see Fig. 24).
5. Inspect housing assembly (15) (see Fig. 24).
A. Bearing needles must remain in bearing cage
and move freely. Verify that bearing height on the
numbered end meets the dimension in Figure 28.
A. Verify that bearing depth on the numbered end
meets the dimension in Figure 29.
B. Check that the roll pin is tight and meets the
height in Figure 28.
B. Bearing needles must move freely and remain in
their cage.
C. Replace entire assembly as a unit.
4. Inspect camplate assembly (20) (see Fig. 24).
There should be no signs of scoring on the piston shoe
surfaces.
Reelmaster 2300–D/2600–D
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Hydraulic System
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6. Inspect rotating parts kit (see Fig. 26).
9. Reassemble rotating parts kit as follows (Fig. 26):
A. Verify that piston O.D. finish shows no wear or
deep scratches. Piston shoes should fit snuggly
onto the ball end of the pistons. The shoe surface
that contacts the camplate should be smooth and
flat. Do not lap piston shoes.
A. Use the following parts to reassemble the piston
block:
2
1
1
5/16 in. I.D. ꢀ 15/16 in. O.D. flat washers
5/16 in. ꢀ 2–7/8 in. N.C. cap screw
5/16 in. N.C. nut
B. Examine the mutual contact surfaces on the spi-
der and spider pivot; both contact areas should be
smooth and free of wear.
B. Compress retainer and install into the spline of
the piston block.
C. Thepistonblocksurfacethatmakescontactwith
the valve plate should be smooth and free of deep
scratches. Do not lap piston shoes.
C. Position the head end of pins towards the inside
of the block. Install the three pins into the special
grooves in the piston block.
D. The bore areas of the piston block should be free
of scoring and contamination. Pistons should move
freely in the bore areas.
D. Install a washer, spring, and second washer into
the piston block.
E. Place cap screw through one of the flat washers.
Insert cap screw through the center of the piston
block. Install second flat washer onto the capscrew
so the washer rests on the three pins. Screw nut
onto the cap screw.
Reassembly (Fig. 24)
1. Make sure all parts are clean. Lubricate all critical
moving parts and O–rings with clean hydraulic oil.
2. If necessary, press new bearing (14) into housing
assembly (15) to the dimension shown in Figure 29.
F. Compress spring by tightening the nut onto the
cap screw. Install the retaining ring into the piston
block.
3. Insertcamplate(20)intothehousingassembly(15).
4. On the short trunnion side of the camplate (20),
install bearing (13) with numbered side to the inside of
the pump. Install inner race (12) with the chamfer to-
wards the inside of the pump. Install washer (11), O–ring
(10), O–ring cover (9), and trunnion cover (8). Secure
trunnion cover with two screws (7) torque them from 36
to 48 in–lb (42 to 55 kg–cm).
G. Unscrew the nut and remove washer and cap
screw from the piston block.
H. Install spider pivot onto the three pins and place
the spider on the spider pivot.
I. Insert piston assemblies through the spider and
into the piston block with the piston shoes resting on
the spider.
5. On the long trunnion side of the camplate (20),
install bearing (13) with numbered side to the inside of
the pump. Install washer (11) and press shaft seal (17)
into place. Secure seal cover( 16) with two screws (7)
and torque them from 36 to 48 in–lb (42 to 55 kg–cm).
10. Set rotating kit assembly (29) on a working surface
with the piston shoes facing up. Insert shaft (31) through
the rotating kit assembly with the flanged end of the
housing assembly up. Position rotating kit assembly into
the housing assembly.
6. Install retaining ring (32) towards the keyed end of
the shaft (31). Slide washer (33), thrust bearing (34), se-
cond washer (33), and second retaining ring (32) into
place over the splined end of the shaft.
11. Make sure piston block and shaft (31) splines are
aligned. Make sure piston block is engaged fully so the
pistonshoesareincontactwiththecamplate(20). Make
sure all parts are in their proper position be for pro-
ceeding to the next step.
7. Position washer (35) and shaft seal (36) onto the
shaft (31) from the keyed end.
12. Hold rotating kit assembly (29) in place, and clamp
housing assembly (15) with the flange end down into a
vise with protected jaws. Install gasket (24) and two
dowel pins (18) into the housing assembly (15).
8. Install shaft (31) into the housing assembly (15)
from the flanged end. Press shaft seal (36) into position
with a seal driver. Install retaining ring (37) into the
flanged end of the housing assembly (15).
13. If necessary, press new bearing (4) or roll pin into
backplate assembly (25) to the dimension shown in Fig-
ure 28. Bearing should be installed with numbered end
outward. Roll pin should be installed with split oriented
away from the bearing.
Hydraulic System
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14. Install seat (23) and spring (22) into backplate (25).
Install new O–ring (40) and plug (21) into the backplate
assembly. Torque plug from 95 to 105 ft–lb (13.1 to 14.5
kg–m).
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.
15. Install new O–rings (38 and 39) and valve assembly
(5) into the backplate assembly (25). Torque valve as-
sembly from 27 to 30 ft–lb (3.7 to 4.1 kg–m).
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
(3) with a light coat of petroleum jelly. Install O–ring and
outer ring onto the charge pump adapter assembly (2).
Installchargepumpadapterplateontothebackplateas-
sembly (25). Make sure O–ring and outer ring of gerotor
assembly stay in place.
16. Coat valve plate (6) with light coat of petroleum jelly
on the steel side. Align the valve plate to the roll pin on
the backplate (25). Install steel side of the valve plate to
the backplate.
17. Install backplate assembly (25) to the housing as-
sembly (15). Make sure gasket (24), valve plate (6), and
dowel pins (18) stay in place.
21. Secure charge pump adapter assembly (2) and
backplate assembly (25) to the housing assembly (15)
with cap screws (1 and 27). Torque cap screws from 17
to 20 ft–lb ( 2.3 to 22.8 kg–m).
18. Installinnerringandcouplerofgerotorassembly(3)
into the backplate assemble (25) so that the V–groove
on the coupler end enters the backplate assembly first.
Lubricate the inner ring of the gerotor.
Reelmaster 2300–D/2600–D
Page 4 – 43
Hydraulic System
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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.
9 (LH)
4
7 (LH)
17 (LH)
3
CAUTION
6
8
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
16
5
1
10
16
14
2
2. Remove wheel and brake assembly from unit (see
Repair section of Chapter 6 – Wheels and Brakes).
12
3. Clean wheel motor (1) and hydraulic connections.
Label all tube hose connections for reassembly pur-
poses. Putcapsorplugsonanyhydrauliclinesorfittings
left open or exposed.
15
13
11
4. Disconnecttubeconnections(2and3)fromhydrau-
lic fittings (5 and 6). On the left–hand wheel motor, also
disconnecthoseconnection(4)fromhydraulicfitting(7).
Allow hydraulic oil to drain from tubes and hose into a
suitable container.
Figure 30
1. Wheel motor
10. Cap screw
11. Lock nut
2. Tube connection
3. Tube connection
4. Hose connection
5. Hydraulic fitting
6. Hydraulic fitting
7. Hydraulic fitting
8. O–ring
12. Support frame
13. Brake bracket
14. Grass shield
15. Spacer
5. Support wheel motor (1). Remove four cap screws
(10) and lock nuts (11) from support frame (12). Remove
brake bracket (13), grass shield (14), and spacers (15).
Pull wheel motor from the support frame.
16. O–ring
17. O–ring
9. O–ring
4. Install tube connections (2 and 3) to hydraulic fit-
tings (5 and 6). On the left–hand motor, also ins hose
connection (4) to hydraulic fitting (7). Tighten connec-
tions.
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)
5. Install wheel and brake to unit (see Repair section
of Chapter 6 – Wheels and Brakes).
1. Place and support wheel motor (1) into the support
frame (12). Insert four cap screws (10) through the sup-
port frame and wheel motor.
2. Slide spacers (15), grass shield (14), and brake
bracket (13) onto the cap screws (10) and wheel motor
(1). Tighten lock nuts (11) onto cap screws.
3. Install hydraulic fittings (5 and 6) onto the wheel mo-
tor (1). On the left–hand wheel motor, also install hy-
draulic fitting (7) onto the wheel motor. Tighten hydraulic
fittings.
Hydraulic System
Page 4 – 44
Reelmaster 2300–D/2600–D
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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.
7
1
CAUTION
2
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
4
5
3
8
2. Clean wheel motor (1) and hydraulic connection.
Put caps or plugs on any hydraulic lines or fittings left
open or exposed.
6
Figure 31
3. Remove wheel and wheel hub from unit (see Repair
section of Chapter 6 – Wheels and Brakes).
1. Wheel motor
2. Hose connection
3. Hydraulic fitting
4. O–ring
5. Cap screw
6. Lock nut
7. Rear wheel fork
8. O–ring
4. Disconnect hose connection (2) from hydraulic fit-
tings (3). Remove O–ring (4). Allow hydraulic oil to drain
from the hose into a suitable container.
5. Support wheel motor (1). Remove four cap screws
(5) and lock nuts (6) from the rear wheel fork (7). Pull
wheel motor from the rear wheel fork.
6. Remove hydraulic fitting (3) and O–ring (8) from the
wheel motor (1).
Rear Wheel Installation (Fig. 31)
1. Place and support wheel motor (1) into the rear
wheel fork (7). Insert four cap screws (5) through the
rear wheel fork and wheel motor.
2. Tighten lock nuts (6) onto cap screws (5).
3. Install hydraulic fitting (3) and O–ring (8) onto the
wheel motor (1). Tighten hydraulic fitting.
4. Install O–ring (4) while connecting hose connec-
tions (2) onto the hydraulic fitting (8). Tighten connec-
tion.
5. Install wheel and wheel hub to unit (see Repair sec-
tion of Chapter 6 – Wheels and Brakes).
Reelmaster 2300–D/2600–D
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Hydraulic System
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13
12
11
10
PLUG
8
9
8
24*
7
6
14
5
3
4
2
1
15
16
17
25*
SHUTTLE
VALVE
24
SPRING
24*(PLUG)
25*
23
24*(PLUG)
22
21
*LEFT HAND MOTOR ONLY
20
19
18
Figure 32
1. Dirt and water seal
2. Outer bearing
3. Housing
4. Backup washer
5. Seal ring
10. Inner bearing
11. Coupling shaft
12. Thrust bearing
13. Drive link
18. Wear plate
19. Rotor
20. Vane
21. Stator
22. Manifold
14. Cap screw
6. Backup washer
7. Inner seal
8. Thrust washer
9. Thrust bearing
15. Commutator seal
16. Commutator
17. Woodruff key
23. Commutator ring
24. End cover assembly
25. O–ring
Disassembly (Fig. 32)
WARNING
If the wheel motor is not held firmly in the
vise, it could dislodge during service and
cause injury.
1. Place wheel motor in a soft jawed vice with the cou-
pling shaft (11) pointed down and the vise jaws clamping
firmly on the sides of the housing (3).
2. Scribe an alignment mark down and across the
wheel motor components from the end cover (24) to the
housing (3) for facilitating reassembly (Fig. 33). If in-
cluded in end cover, loosen both shuttle valve plugs
(left–hand motor only) for disassembly later.
Figure 33
3. Remove seven cap screws (14). Remove end cover
assembly (24) and seal ring (5).
Hydraulic System
Page 4 – 46
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Note: Bereadytocatchtheshuttlevalveorreliefvalve
componentsthatwillfalloutoftheendcovervalvecavity
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 plug in the
end cover assembly (24) must not be removed as they
are serviced as an integral part of the end cover.
4. If the end cover (24) is equipped with shuttle valve
components (left–hand motor only), remove both pre-
viously loosened plugs and O–rings (25).
5. Remove commutator ring (23).
Figure 34
CAUTION
Use eye protection such as goggles when
using compressed air
6. Remove commutator (16) and commutator seal
(15). Remove commutator seal from the commutator
using an air hose to blow air into the ring groove until the
commutator seal is lifted out (Fig. 34)
Note: The manifold (22) is constructed of plates
bonded together to form an integral component not sub-
ject to further disassembly for service. Compare config-
uration of both sides of the manifold to make sure that
same surface is reassembled against the rotor set.
Figure 35
10. Remove seal ring (5) that is between the rotor set
and wearplate.
7. Remove manifold (22). Remove seal rings (5) that
are on both sides of the manifold.
11. Remove drive link (13) from the coupling shaft (11)
if it was not removed with rotor set and wear plate (18).
Remove seal ring (5) from housing (3).
Note: The rotor set consists of the rotor (19), vanes
(20), and stator (21). Rotor set components may be-
come disassembled during service procedures.
12. Remove thrust bearing (12) from the top of the cou-
pling shaft (11).
Note: Marking all rotor components and mating spline
components for exact repositioning at assembly will
make sure maximum wear life and performance of rotor
set and wheel motor.
13. Check exposed portion of coupling shaft (11) to be
sure you have removed all signs of rust and corrosion
which might prevent its withdrawal through the dirt and
water seal (1) and outer bearing (2). Crocus cloth or fine
emery paper may be used.
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.
14. Remove coupling shaft (11); push on the output end
of the shaft. Remove seal ring (5) from housing (3).
15. Remove housing (3) from the vise and invert it. Re-
move dirt and water seal (1). A blind hole bearing or seal
puller is required.
9. Remove rotor set and wearplate (18) together, and
retain the rotor set in its assembled form with the same
vane (20) to stator (21) contact surfaces. The drive link
(13) may come away from the coupling shaft (11) with
the rotor set and wearplate. You may have to shift the ro-
tor set on the wearplate to work the drive link out of the
rotor (19) and wearplate (Fig. 35).
Reelmaster 2300–D/2600–D
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Inspection (Fig. 32)
1. Inspect bolts (14) for damaged threads and sealing
rings under the bolt head. Replace if damaged (Fig. 36).
Note: A polished pattern (not scratches) on the cover
from rotation of the commutator (16) is normal. Discolor-
ation would indicate excess fluid temperature, thermal
shock, or excess speed and require system investiga-
tion for cause and close inspection of end cover, com-
mutator, manifold, and rotor set.
Figure 36
CAUTION
Use eye protection such as goggles when
using compressed air
2. Thoroughly wash end cover (24) in proper solvent
and blow dry. Make sure the end cover valve apertures,
including the internal orifice plug, are free of contamina-
tion. Inspect end cover for cracks and the bolt head re-
cesses for good bolt head sealing surfaces. Replace
end cover as necessary (Fig. 37).
3. Inspect commutator ring (23) for cracks and burrs.
Replace commutator ring as necessary.
Figure 37
4. Inspect commutator (16) for cracks, burrs, wear,
scoring, chipping, and peening. If any of these condi-
tions exist, replace commutator and commutator ring
(23) as a matched set.
5. Inspect manifold (22) for cracks, surface scoring,
peening, chipping. Replace manifold if any of these
conditions exist. A polished pattern on the ground sur-
face from commutator or rotor rotation is normal.
Note: The rotor set consists of the rotor (19), vanes
(20), and stator (21). Rotor set components may be-
come disassembled during service procedures.
Figure 38
6. Inspect the rotor set in its assembled form for nicks,
scoring, and chipping on any surface. Inspect for broken
and worn splines. If the rotor set component requires re-
placement, the complete rotor set must be replaced as
it is a matched set.
7. Place rotor set and wear plate (18) on a flat surface
and center the rotor (19) in the stator (21) such that two
rotor lobes (180 degrees apart) and a roller vane (20)
center line are on the same stator center line. Check the
rotor lobe to roller vane clearance with a feeler gage at
this common center line. If there is more than 0.005 inch
(0.13 mm) of clearance, replace the entire rotor set (Fig.
38).
Figure 39
Hydraulic System
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8. Inspect the wearplate (18) for cracks, peening, and
scoring. A polished pattern on the wear plate from rotor
rotation is normal. Replace as necessary.
9. Inspect drive link (13) for cracks and worn or dam-
aged splines. No perceptible lash (play) should be noted
between mating spline parts of the rotor (19) or coupling
shaft (11). Replace as necessary (Fig. 39).
10. Inspect thrust bearing (12) for wear, peening, corro-
sion and a full complement of retained rollers. Replace
as necessary.
11. Inspect coupling shaft (11) internal and external
splines and keyway for damage and wear. Inspect bear-
ing and sealing surfaces of the coupling shaft for chip-
ping, nicks, grooves, severe wear, corrosion, and
discoloration. Replace coupling shaft if any of these
conditions exist. Minor shaft wear in seal area is permis-
sible. If wear exceeds 0.020 inch (0.51 mm) diametrical-
ly, replace coupling shaft. A slight ”polish” is permissible
on the shaft bearing areas (Fig. 40).
Figure 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 changing di-
mensional characteristics. Inspect tapped holes for
thread damage. If the housing is defective in these
areas, discard the housing assembly (Fig. 41).
Figure 41
13. If the housing (3) has passed inspection to this
point, inspect outer bearing (2), inner bearing (10),
thrust washers (8), and thrust bearing (9). Bearing roll-
ersmustbefirmlyretainedinthebearingcagesbutmust
rotate and orbit freely. All rollers and thrust washers
must be free of peening and corrosion. If any bearing or
thrust washer does not pass inspection, replace the
housing (3) as a complete assembly (Fig. 42).
Figure 42
Reelmaster 2300–D/2600–D
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Reassembly (Fig. 32)
1. Lubricate all seals and seal rings with clean hydrau-
lic oil before assembly.
WARNING
Since they are flammable, be extremely
careful when using any solvent. Even a
smallexplosion or fire could causeinjury
or death.
Figure 43
CAUTION
Use eye protection such as goggles when
using compressed air
2. Wash all parts in a clean petroleum–based solvent
before assembly. Blow parts dry with compressed air.
3. Press a new dirt and water seal (1) into the housing
(3) outer bearing counterbore. Press seal in with the lip
facing out and until the seal is 0.020 inch (0.51 mm) be-
low the end of housing.
4. Placehousing (3) into a soft jawed vise with the cou-
pling shaft bore down; clamp against the mounting
flange.
Figure 44
IMPORTANT: Early model wheel motors that do not
have backup washer (6) when inspected must be as-
sembled with a new backup washer (4), new backup
washer (6), and new seal (7).
5. A housing (3) that does not require replacement will
require that the two thrust washers (8) and thrust bear-
ing (9) be unseated and vertical to the counterbore and
the new backup washer (4), new backup washer (6),
and new seal (7) be worked around the thrust bearing
package and placed into their respective counterbores
(Fig. 44 and 43). The seal lip must face out of the seal
counterbore and toward the inside of wheel motor (Fig.
45). Be sure the thrust bearing package is reseated cor-
rectly after assembly of the new seal and backup wash-
ers.
Figure 45
Note: Coupling shaft (11) should be approximately
0.10 inch (2.54 mm) below the housing wear plate sur-
face to allow the assembly of thrust bearing (12). The
coupling shaft must rotate smoothly on the thrust bear-
ing (9) and thrust washer (8) (Fig. 46).
6. Apply masking tape around splines or keyway on
coupling shaft (11) to prevent damage to seal.
IMPORTANT: The outer bearing (2) is not lubricated
by the system’s hydraulic fluid. Make sure it is thor-
oughly packed with the recommended grease.
7. Make sure that a generous amount of clean corro-
sionresistantgreasehasbeenappliedtotheouterbear-
ing (2). Install the coupling shaft (11) into housing (3),
and seat shaft against the second thrust washer (8).
Hydraulic System
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8. Install thrust bearing (12) onto the end of coupling
shaft (11).
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 degrees
apart, will facilitate the assembly and alignment of com-
ponents as required in the following procedures. The
studs can be made by cutting off the heads of 3/8–24
UNF 2A bolts so they are 0.5 inch (12.7 mm) or longer
than cap screw (14).
Note: Use any alignment marks put on the coupling
shaft (11) and drive link (13) before disassembly to as-
semble the drive link splines in their original position in
the mating coupling shaft splines.
Figure 46
10. Install drive link (13) with the long splined end down
into the coupling shaft (11). Engage the drive link splines
so they mesh with the coupling shaft splines (Fig. 47).
11. Assemble wear plate (18) over the drive link (13)
and alignment studs onto the housing (3).
12. Apply a small amount of clean grease to a new seal
ring (5) and assemble it into the seal ring groove on the
wear plate side of the stator (21).
Note: The rotor set consists of the rotor (19), vanes
(20), and stator (21). Rotor set components may be-
come disassembled during service procedures.
Figure 47
Note: It may be necessary to turn one alignment stud
out of the housing (3) temporarily to assemble rotor set
over the drive link (13).
B. If assembly alignment studs are not being uti-
lized, align stator (21) bolt holes with wear plate (18)
and housing (3) bolt holes. Screw two cap screws
(14)fingertightintoboltholesapproximately180de-
grees apart to retain stator and wear plate station-
ary.
Note: The rotor set rotor counterbore side must be
down against wear plate for drive link clearance and to
maintain the original rotor–drive link spline contact. A ro-
tor set without a counterbore and that was not etched
before disassembly can be reinstalled using the drive
link spline pattern on the rotor splines if apparent, to de-
termine which side was down. The rotor set seal ring
groove faces toward the wear plate (18).
Note: If the manifold (22) side of the rotor (19) was
etched during wheel motor disassembly, this side
should be up. If the rotor is not etched and does not have
a counterbore, use the drive link spline contact pattern
apparent on the rotor splines to determine the rotor side
that must be against the wear plate.
13. Install assembled rotor set onto wear plate (18) with
rotor (19) counterbore and seal ring side down. The
splines should mesh with the drive link (13) splines.
C. Place rotor (19) with counterbore down, if appli-
cable, into stator (21), and then onto wearplate (18)
so rotor splines mesh with drive link (13) splines.
14. If disassembled rotor (19), stator (21), and vanes
(20) cannot be readily assembled by hand, assemble
with the following procedures:
IMPORTANT: Do not force rotor vanes into place,
the coating applied to stator vane pockets could
shear off.
A. Place stator (21) onto wear plate (18) with seal
ring (5) side down. Be sure the seal ring is in place.
D. Assemble six vanes (20), or as many vanes that
will readily assemble into the stator vane pockets.
Reelmaster 2300–D/2600–D
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E. Grasp the output end of coupling shaft (11) 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 assemble the seventh or re-
maining vanes. Use minimum force when
assembling the remaining vane(s).
F. Remove the two assembled bolts (14) if used to
retain stator and wear plate.
Note: The manifold (22) is made up of several plates
bonded together permanently to form an integral com-
ponent. The manifold surface that must contact the rotor
sethasit’sseriesofirregularshapedcavitiesonthelarg-
est circumference or circle around the inside diameter.
The polished impression left on the manifold by the rotor
set is another indication of which surface must contact
the rotor set.
Figure 48
15. Apply clean grease to a new seal ring (5) and as-
semble it in the seal ring groove in the rotor set contact
side of manifold (22).
16. Assemble the manifold (22) over the alignment
studs and drive link (13) and onto the rotor set. Be sure
the correct manifold surface is against the rotor set.
17. Apply grease to a new seal ring (5) and insert it in
the seal ring groove exposed on the manifold (22).
18. Assemble the commutator ring (6) over alignment
studs onto the manifold (22) (Fig. 48).
Figure 49
19. Assemble a new commutator seal (15) flat side up,
into commutator (16) and assemble commutator over
the end of drive link (13) onto manifold (22) with seal ring
side up.
20. If shuttle valve components items (left–hand motor
only) were removed from the end cover (24), screw a
plug with a new O–ring (25), loosely into one end of the
valve cavity in the end cover. Insert spring, valve, and
second spring into the other end of the valve cavity. Turn
second plug with a new O–ring (25) loosely into the end
cover valve cavity. A 3/16–inch allen wrench is required
(Fig. 49).
Note: If the end cover (24) has a valve shuttle, use line
that was previously scribed on the end cover to radially
align it into its original position.
21. Assemble new seal ring (5) into end cover (24) and
assemble end cover over the alignment studs and onto
the commutator set (Fig. 50).
Figure 50
Hydraulic System
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Note: The cap screws (14) required for use with the
shuttle valve (left–hand motor only) end cover (24) are
longer than the bolts required with standard end cover.
Refer to Toro Parts Catalog for correct service part num-
ber if replacement is required.
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 require to ro-
tate shaft should not exceed 50 ft–lb (6.9 kg–m).
22. Assemble seven cap screws (14) and screw them
in finger tight. Remove and replace the two alignment
studs with bolts after the other bolts are in place. Alter-
nately and progressively tighten the bolts to pull the end
cover and other components into place with a final
torque of 45 to 55 ft–lb (6.2 to 7.6 kg–m).
Reelmaster 2300–D/2600–D
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Hydraulic System
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2WD/3WD Two Position Valve
2
14
4
1
SKIRT ASSEMBLY
15
12
13
9
3
13
15
11
13
15
5
5
6
10
8
7
13
Figure 51
1. Two position valve
2. Nut
3. Cap screw
4. Tub clamp
5. Hydraulic tube
6. Hydraulic connection
7. Hydraulic connection
8. Hydraulic connection
9. Hydraulic connection
10. Hydraulic fitting
11. Hydraulic fitting
12. Hydraulic fitting
13. O–ring
14. Cap screw
15. O–ring
Removal (Fig. 51)
5. Disconnect hydraulic connections (6, 7, 8 and 9)
from hydraulic fittings (10, 11, and 12). Allow hydraulic
oil to drain from tubes into a suitable container.
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.
6. Remove cap screws (14) from two position valve
(1).
7. Remove fittings (10, 11, and 12) and O–rings (15)
from two position valve (1).
CAUTION
Installation (Fig. 51)
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
1. Install hydraulic fittings (10, 11, and 12) and O–rings
(15) into two position valve (1).
2. Secure cap screws (14) to two position valve (1)
through the skirt assembly.
2. Clean two position valve (1) and hydraulic fittings.
3. Put caps or plugs on any hydraulic lines or fittings
left open or exposed. Put labels on disconnected hy-
draulic lines and hoses for proper reassembly.
3. Install hydraulic connections (6, 7, 8 and 9) to hy-
draulic fittings (10, 11, and 12) and tighten fittings.
4. Tightennut(2)andcapscrew(3)sothetubeclamps
(4) will prevent movement of the hydraulic tubes (5).
4. Loosen nut (2) and cap screw (3) so the tubes
clamps (4) will allow movement of the hydraulic tubes
(5).
Hydraulic System
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1
3
5
7
9
2
4
6
7
11
8
13
8
15
10
12
14
Figure 52
1. Valve cap
2. Plug
3. O–ring
4. Ball
6. Spring pin
11. Boot
7. Back–up ring
8. O–ring
9. Valve housing
10. Boot retainer
12. Set screw
13. Valve stop
14. Lock washer
15. Knob
5. Spool
Disassembly (Fig. 52)
Inspection (Fig. 52)
1. Wash valve in solvent and thoroughly dry. Mount
valve carefully in a vise ensuring the mounting pads are
against the vise jaws.
CAUTION
2. Remove boot retainer (10) from the valve housing
(9).
Use eye protection such as goggles when
using compressed air
3. Carefully remove valve cap (1) from the valve hous-
ing (9). The valve cap is press fitted.
1. Washallpartsinsolvent. Drypartswithcompressed
air.
4. Secure valve stop (13) and remove plug (2) and O–
ring (3) from the spool (5).
2. Inspect spool (5) for bending and flatness. Signs of
wear on one side of the spool may indicate it’s bent. Re-
place a worn or damaged spool if necessary.
5. Hold knob (15) and carefully slide spool (5) out of
the valve housing (9).
3. Inspect parts for wear or damage, and replace if
necessary.
Note: The valve stop (13) and set screw are loctited
together and should remain together when removed
from the spool (5).
Reassembly (Fig. 52)
1. Coat all new O–rings and back–up rings with hy-
draulic oil. Install new O–rings (8) and new back–up
rings (7) into the bore of the valve housing (9).
6. Separate valve stop (13) and set screw (12) from
the spool (5). Carefully remove boot (11) from the valve
stop.
2. Install ball (4) and spring pin (6) into the spool (5) so
the ball is held in by the pin. Make sure both ends of the
spring pin are flush with the sides of the spool.
7. Remove spring pin (6) and ball (4) from the spool (5)
being careful no to scratch or damage the spool. Also,
be careful not to drop the ball.
3. Carefully install boot (12) onto the valve stop (13).
8. Remove back–up rings (7) and O–rings (8) from the
valve housing with a hooked scribe or thin screw driver.
Be careful not to scratch the bore surface.
Reelmaster 2300–D/2600–D
Page 4 – 55
Hydraulic System
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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.
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.
B. If the valve stop (13) and set screw (7) separated
duringdisassembly, screw the set screw completely
into the spool (5). Then loctite the exposed threads
and screw the valve stop onto the set screw and
spool. Torque valve stop from 85 to 100 in–lb.
5. Install plug (2) and new O–ring (3) into the spool (5).
Torque plug from 85 to 100 in–lb.
6. Press valve cap (1) onto valve housing (9). If the
valve cap is damaged or will not fit tightly onto the the
valve housing, replace the valve cap with a new one.
Hydraulic System
Page 4 – 56
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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.
10
INLET PORT
3
6
7
2
4
CAUTION
8
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
9
5
2. Clean reel motor drive pump (1) and hydraulic con-
nections. Install plug into the hydraulic reservoir. Label
all hose connections for reassembly purposes. Put caps
or plugs on any hydraulic lines or fittings left open or ex-
posed.
1
11
12
Figure 53
1. Reel motor drive pump
2. Hose clamp
3. Hose
4. Fitting
5. Hose
7. O–ring
8. O–ring
9. O–ring
10. Cap screw
11. O–ring
3. Loosen hose clamp (2) and remove hose (3) from
fitting (4). Allow hydraulic oil to drain from hose into a
suitable container.
6. Elbow fitting
12. Traction pump
4. Disconnecthose (5) fromelbowfitting(6).. Allowhy-
draulic oil to drain from hose into a suitable container.
4. Position reel motor drive pump (1) to traction pump
(12); the inlet port should be facing up.
5. Remove fittings (4 and 6) and O–rings (8 and 9)
from the pump.
5. Secure reel motor drive pump (1) to traction pump
(12) with cap screws (10). Torque cap screws from 27 to
31 ft–lb (3.7 to 4.3 kg–m).
6. Support reel motor drive pump (1) and remove two
cap screws (10). Separate reel motor drive pump (1)
and O–ring (11) from the traction pump (12).
6. Inspect threads and sealing surfaces of connectors.
Replace any damaged or worn connectors.
Installation (Fig. 53)
7. Install O–rings (8 and 9). Install fitting (4) and orient
to the 2 o’clock position. Install elbow connector (6) and
orient to the 45_ down.
1. Make sure mounting and O–ring sealing surfaces
on reel motor drive pump (1) and traction pump (12) are
clean.
8. Secure hose (3) to connector (4) and tighten hose
clamp(2). Securehose(5)toelbowfitting(6)andtighten
hose connector.
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).
9. Remove plug from hydraulic reservoir.
Reelmaster 2300–D/2600–D
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1
2
3
4
5
6
7
INLET PORT SIDE
10
7
6
11
14
5
4
8
12
13
9
OUTLET PORT
Figure 54
1. Retaining ring
2. Shaft seal
3. Mounting flange
4. Backup ring
5. E–seal
6. O–ring
11. Drive gear
12. Idler gear
13. Rear bearing block
14. Front bearing block
7. Dowel pin
8. End cover
9. Bolt
10. Gear housing
Disassembly (Fig. 54)
6. Remove the rear bearing block (13) from the drive
and idler gear shafts.
1. Tape the shaft end of the drive gear (11) to prevent
damaging the shaft seal when the shaft is removed or
reinstalled.
7. Remove the idler gear (12).
8. Remove the drive gear (11) shaft slowly from the
mounting flange (3). Remove the front bearing block
(14) from the drive gear (11) shaft.
2. Matchmark the inlet side of the gear housing (10)
with the mounting flange (3) and the end cover (8) with
the gear housing (10) to make sure proper orientation of
these three parts during reassembly.
Shaft Seal Replacement (Fig. 54)
1. Place the mounting flange (3) on a clean working
surface with the shaft seal up (2). Remove the retaining
ring (1).
3. Position the pump with the drive end facing down.
4. Remove the four bolts (9). Lift off the end cover (8)
and and two dowel pins (7) and them aside.
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.
5. Remove the gear housing (10) ensuring the rear
bearing block (13), front bearing block (14), drive gear
(11), andidlergear(12)remaintogether. Removethere-
maining two dowel pins from the gear housing.
Hydraulic System
Page 4 – 58
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2. Removetheshaftseal(2). Cleananycontamination
from the seal bore.
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.
3. Place a new shaft seal (2) with the part number side
up into the seal bore. Apply uniform pressure to the face
of the shaft seal while pressing it into the bore. This
method should prevent damage or misalignment of the
seal in the bore.
4. Place the shaft of the idler gear (12) into the remain-
ing position of the front bearing block (14). Apply a light
coating of oil the back face of the drive and idler gears.
4. Install new retaining ring (1) into the mounting
flange.
5. Place the rear bearing block (13) with the seal side
onthedriveandidlergearshaftends. Makesurethatthe
open side of the E–seal (5) is pointing towards the inlet
of the pump.
E–seal and Backup Ring Replacement (Fig. 54)
1. Place the front bearing block (14) on a clean sur-
face. Remove the old backup ring (4) and E–seal (5).
Clean any contamination from the E–seal groove.
6. Install the two dowel pins (7) into the mounting
flange (3).
2. Apply a light coat of petroleum jelly in the E–seal
groove of the front bearing block (14) and on the flat side
of the E–seal (5) to help keep the seals in place during
assembly.
7. Align the matchmarks on the gear housing (10) and
mounting flange (3). Place the gear housing with the
mountingflangesidedownandtheinletportontheopen
side of the E–seal (5) over the rear bearing block (13).
Slide the gear housing down over the gears and front
bearing block (14).
3. Place the E–seal (5) with its flat side up into the seal
groove on the front bearing block (14). Place the backup
ring (4) into the groove made by the E–seal and bearing
block. Make sure the notches in the center of thebackup
ring and E–seal line up so that the backup ring sits flush
with the E–seal.
8. Make sure the rear bearing block (13) face sits just
below the back face of the gear housing (3). If the rear
bearing block sits higher than the rear face of the gear
housing, remove the gear housing. Check that the E–
seal (5), backup ring (4), or O–ring (6) did not shift out
of place during assembly.
4. Repeat the above steps for the rear bearing block.
O–ring Replacement (Fig. 54)
9. Place the remaining two dowel pins (7) into the rear
of the gear housing (3). Align matchmarks and set end
cover (8) on the rear of the gear housing.
1. Remove the old O–rings (6) from the gear housing.
Clean any contamination from the O–ring groove.
2. Apply a light coat of petroleum jelly in the O–ring
groovesofthegearhousing(10). PlaceanewO–ring(6)
in each groove.
10. Insert the four bolts (9) through the bolt holes in the
end cover (8) and gear housing (3). Hand tighten each
bolt and torque to 40 ft–lb (5.5 kg–m).
Reassembly (Fig. 54)
11. Place a small amount of oil in the inlet of the pump.
rotate the drive shaft away from the inlet one revolution.
If the drive shaft binds, disassemble the pump and then
reassemble it. The pump is ready for use.
1. Place the mounting flange (3) with the shaft seal (2)
side down onto a clean working surface. Make sure that
the back side of the mounting flange is free of any con-
tamination.
2. Place the front bearing block (14) with its seal side
down onto the mounting flange (3). The open side of the
E–seal (5) must point away from the matchmark on the
inlet side of the mounting flange.
Reelmaster 2300–D/2600–D
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Reel Motor
Removal (Fig. 55)
4
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.
6
6
5
4
CAUTION
5
7
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
1
2
1
7
2. Remove reel motor from cutting unit (see Repair
section of Chapter 7 – Cutting Units).
3
3. Unscrew lock nut (1) and remove coupling (2) from
reel motor (3) using a puller.
Figure 55
1. Lock nut
2. Coupling
3. Reel motor
5. Hydraulic fittings
6. O–ring
7. O–ring
4. Clean motor, fittings, and hose connections.
4. Hose connection
Note: The position of the fittings on the reel motor is
critical to reconnecting hydraulic hoses.
5. Place O–ring (7) on face seal of hydraulic fitting (5).
Secure hydraulic fitting to the reel motor (3) ensuring
that the matchmarks are aligned. Repeat this step for
the remaining hydraulic fittings.
5. Label all hose connections (4) for reassembly pur-
poses. Matchmark reel motor and all hydraulic fittings
(5) for reassembly purposes.
6. Inspect threads and sealing surfaces of hose con-
nections (4). Replace any damaged or worn connec-
tions.
6. Remove hose connections (4) from hydraulic fit-
tings(5). Allowhydraulicoiltodrainfromhoseintoasuit-
able container. Put caps or plugs on disconnected
hoses to prevent contamination.
7. Secure hose connection (4) to the hydraulic fitting
(5). Repeat this step for the remaining hydraulic fittings.
7. Remove hydraulic fittings (5) and O–rings (7) from
reel motor (3).
8. Install reel motor to cutting unit (see Repair section
of Chapter 7 – Cutting Units).
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. Inspectthreadsandsealingsurfacesofhydraulicfit-
tings (5). Replace any damaged or worn fittings.
Hydraulic System
Page 4 – 60
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7
8
6
9
5
4
10
3
2
1
11
12
11
13
14
15
19
13
18
17
16
Figure 56
1. Plug
8. Idler gear assembly
9. Drive gear assembly
10. Key
11. O–ring
12. Body
14. Frontplate
15. Screw
16. Retaining ring
17. Oil seal
2. O–ring
3. Shim
4. Spring
5. Ball
18. Backup washer
6. Relief valve seal
7. Backplate
13. Alignment pin
19. Relief valve assembly (# 1 thru 5)
Disassembly (Fig. 56)
7. Remove body (12) from the backplate (7). Remove
O–rings (11) from the body (12) and backplate (7).
1. Make sure key (10) is removed from the drive gear
(9) shaft.
8. Remove Alignment pin (13) from the backplate (7).
2. Matchmark frontplate (14), body (12), and back-
plate (7) to assure proper reassembly.
9. Remove retaining ring (16), oil seal (17), and back-
up washer (18) from the frontplate (14).
3. Secure the motor in a vise with the drive shaft up.
4. Remove all eight screws (15).
IMPORTANT: Do not remove the relief valve assem-
bly (19) unless testing shows it to be faulty. The re-
lief valve assembly must be replaced as a complete
unit. Both relief valve seals (6) are sealed in place
with loctite; do not remove them.
5. Remove the motor from the vise. Remove the front-
plate (14) from the body (12). A wooden block or soft
face hammer might be used the gently tap the motor
when freeing the frontplate (14).
10. Remove plug (1), O–ring (2), shim (3), spring (4),
and ball (5 ) from the backplate (7).
6. Remove alignment pin (13) from the body (12). Re-
movedrivegear(9)andidlergear(8)fromthebody(12).
Reelmaster 2300–D/2600–D
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Hydraulic System
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Inspection (Fig. 56)
13. Make sure both plugs (1) are secure if they or the
backplate is not being replaced.
1. Remove all nicks and burrs from all parts with an
emery cloth
Reassembly (Fig. 56)
1. Ifreplacingthereliefvalveassembly(19), installball
(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).
CAUTION
Use eye protection such as goggles when
using compressed air
2. Coat O–ring (11) lightly with petroleum jelly and
install in groove on the front plate (14).
2. Clean all parts with solvent. Dry all parts with com-
pressed air.
3. Apply a thin coat of petroleum jelly to both gear
pockets of the body (12). Install alignment pin (13) into
body (12).
3. Inspect drive gear (9) shaft for a broken or chipped
keyway.
4. Alignmatchmarksandslipbody(12)ontofrontplate
(14) until alignment pin (13) is engaged.
4. Inspect drive gear (9) and idler gear (8) shafts at the
bushing points and seal area for rough surfaces and ex-
cessive wear.
5. Dip idler gear (8) and drive gear (9) into clean hy-
draulic oil and slip into front plate (14) bushings.
5. Replace drive gear (9) or idler gear (8) if the shaft in
the bushing area diameter measures less than 0.748 in.
(19.0 mm). A single gear may be replaced separately.
6. Coat O–ring (11) lightly with petroleum jelly and
install in groove on the back plate (7).
7. Install alignment pin (13) into back plate (7).
6. The drive gear (9) and idler gear (8) face should be
free of excessive scoring and wear.
8. Align matchmarks and slip back plate (7) over gear
shafts onto body (12) until alignment pin (13) is en-
gaged.
7. Replace drive gear (9) or idler gear (8) if gear width
is less than 1.140 in. (29.96 mm).
9. Hand tighten cap screws (15) and torque in a criss-
cross pattern from 25 to 28 ft–lb (3.46 to 3.87 kg–m).
8. Make sure that retaining rings are in the grooves on
both sides of the gear for both the drive gear (9) and idler
gear (8).
10. Place washer (18) over the drive shaft into the front
plate (14) housing. Apply a liberal coat of hydraulic oil to
the oil seal (17). Install oil seal (17) over the drive shaft
being careful not tho cut the rubber seal lips.
9. Break sharp edges of gear teeth with emery cloth.
10. Replace backplate (7) and frontplate (14) if bushing
inside diameters exceed 0.755 in. (19.2 mm). The bush-
ings are not available as replacement items.
11. Place 1–1/16 inch O.D. sleeve over the drive shaft
and press in the oil seal (17) until the retaining ring
groove appears.
11. The face of the backplate (7) and frontplate (14)
should be free of excessive scoring. Replace if scoring
a depth of 0.0015 in. (0.038 mm).
12. Press retaining ring (16) into the housing using the
sleeve until it seats in the groove.
12. Replace body (12) if the inside diameter of the gear
pockets exceeds 1.713 in. (43.5 mm).
Hydraulic System
Page 4 – 62
Reelmaster 2300–D/2600–D
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Hydraulic Manifold
Removal (Fig. 57)
1
7
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.
2
3
4
9
CAUTION
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
5
2. Raise and remove hood to get access to the man-
ifold.
8
Note: The ports on the manifold are marked for easy
identificationofcomponents. Example:R1isthereelcir-
cuitreliefvalveandG1isthetestgaugeconnectionport.
(See Hydraulic Schematics to identify the function of the
hydraulic lines and cartridge valves at each port loca-
tion).
10
Figure 57
6
1. Screw
6. Hydraulic manifold
7. Flange screw
8. Cylinder support bracket
9. Solenoid valve
10. Cap screw
2. Lock washer
3. Flat washer
4. Micro switch
5. Spacer
3. Ifnecessary, thehydraulicmanifoldcanberemoved
(Figure 57):
Installation (Fig. 57)
A. Disconnect solenoid valve (9) and micro switch
(4) electrical connectors.
1. Secure hydraulic manifold (6) to the cylinder sup-
port bracket (8) with cap screws (10) and flange screws
(7).
B. Clean manifold and hydraulic connections. Dis-
connect hydraulic lines. Label all connections for
reassembly.
2. Make sure all hydraulic connections, ports, and fit-
tings are clean.
C. Allow hydraulic lines to drain into a suitable con-
tainer. Putcapsorplugsondisconnectedhosesand
fittings to prevent contamination.
3. Connect hydraulic lines to the manifold. Tighten all
hydraulic fittings and connections.
4. Reconnect solenoid valve (9) and micro switch (4)
electrical connectors.
D. Remove cap screws (10) from the hydraulic
manifold.
E. Support hydraulic manifold (6) and remove
flange screws (7) from the hydraulic manifold. Re-
move hydraulic manifold from the cylinder support
bracket (8).
Reelmaster 2300–D/2600–D
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Hydraulic System
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11
9
25
25
26
10
26
31
28
14
7
27
28
24
23
30
23
9
29
16
29
19
8
7
3
4
18
13
12
15
7
17
3
4
6
3
5
4
4
4
3
3
2
21
12
13
21
20
20
22
4
3
1
Figure 58
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
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 directional) valve
19. Locating plate w/ pin
20. Plug
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
10. Solenoid coil
11. Nut
21. O–ring
Hydraulic System
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Solenoid Valve (Fig. 58)
Note: Usecarewhenhandlingthespoolvalve(8).
slight bending or distortion of the stem tube can
cause binding and malfunction.
1. Make sure the manifold is clean before removing
the spool valve (8).
C. Torque spool valve (8) using a deep socket to 35
ft–lb (4.8 kg–m).
2. Remove the spool valve (8):
A. Remove the nut (11) from the spool valve (8).
D. Make sure a new O–ring (9) is at each end of the
solenoid coil (10). install solenoid coil to the spool
valve (8). Apply ”Loctite 242” or equivalent to the
threads of the spool valve: torque nut (11) to 15 in–lb
(17 kg–cm).
B. Remove the solenoid coil (10) and both O–rings
(9).
Note: Use care when handling the spool valve. slight
bending or distortion of the stem tube can cause binding
and malfunction.
E. If problems still exit, remove valve and clean
again or replace valve.
C. Remove spool valve (8) with a deep socket
wrench. Remove seal kit (7).
Cartridge (Logic and Relief) Valves (Fig. 58)
1. Make sure the manifold is clean before removing
the cartridge valve (1 or 14) and seal kit (2 or 7).
3. Visually inspect the port in the manifold (22) for
damage to the sealing surfaces, damaged threads, and
contamination.
2. Remove the cartridge valve (1 or 14).
4. Visually inspect spool valve for damaged sealing
surfaces and contamination.
3. Visually inspect the port in the manifold (22) for
damage to the sealing surfaces, damaged threads, and
contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunc-
tion.
4. Visually inspect cartridge valve (1 or 14) for dam-
aged sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunc-
tion.
B. If spool valve (8) sealing surfaces appear pitted
ordamaged, thehydraulicsystemmaybeoverheat-
ing or there may be water in the system.
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be overheating or there
may be water in the system.
CAUTION
Use eye protection such as goggles when
using compressed air
CAUTION
5. Clean spool valve (8) using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out con-
tamination. Use a probe to push the internal spool in and
out 20 to 30 times to flush out contamination. Particles
as fine as talcum powder can affect the operation of high
pressure hydraulic valves. Use compressed air for
cleaning.
Use eye protection such as goggles when
using compressed air
5. Clean cartridge valve (1 of 14) using clean mineral
spirits. Submerge valve in clean mineral spirits to flush
out contamination. Particles as fine as talcum powder
can affect the operation of high pressure hydraulic
valves. Use compressed air for cleaning.
6. Reinstall the spool valve (8):
A. Lubricate new O–ring and backup ring of seal kit
(7) with clean hydraulic oil and install. The O–ring
and backup ring must be arranged properly on the
spool valve (8) for proper operation and sealing.
6. Reinstall the cartridge valve (1 or 14):
A. Lubricate new O–ring and backup ring of seal kit
(7) with clean hydraulic oil and install. The O–ring
and backup ring must be arranged properly on the
cartridge valve (1 or 14) for proper operation and
sealing.
B. Thread spool valve (8) carefully into port (S1).
The valve should go in easily without binding.
Reelmaster 2300–D/2600–D
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B. Thread cartridge valve (1 or 14) carefully into the
applicable port (LC1 or R1). The valve should go in
easily without binding. Torque the valve to 35 ft–lb
(4.8 kg–m).
A. Lubricate new O–ring and backup ring of seal kit
(7 or 17) with clean hydraulic oil and install. The O–
ring and backup ring of seal kit must be arranged
properly on the spool valve (15 or 18) for proper op-
eration and sealing.
Spool (Flow Control and Two Position Directional)
Valves (Fig. 58)
B. Thread spool valve (15 or 18) carefully into the
applicable port (FC1 or MD1). The valve should go
in easily without binding. Torque valve to 35 ft–lb
(4.8 kg–m).
1. Remove knob assembly:
A. Unscrew and remove knob (25). Remove both
jam nuts (26).
8. Reinstall knob assembly:
B. Slide off applicable indicator plate (27 or 31) be-
ing careful not to lose springs (24 or 30). Remove
spring.
A. Install applicable locating plate (16 or 19) so that
the pin seats into the locating hole.
B. Turn the threaded spool valve (15 or 18) stem
carefully clockwise until it stops.
C. Loosensetscrew(29)andslidedetentplate(28)
off the applicable spool valve (15 or 18) stem.
C. Face detent plate (28) counterbore down.
Thread detent plate (28) down onto the valve stem
until it is stopped by the locating plate (16 or 19).
Turn detent plate (28) back counterclockwise 1/4
turn.
D. Remove the applicable locating plate with pin
(16 or 19) from the spool valve (15 or 18) stem and
manifold block (22).
2. Make sure the manifold is clean before removing
the spool valve (15 or 18).
D. Center one detent plate hole over a locating
plate indentation. Drop a ball (23) into each hole,
then drop a spring (24 or 30) into each hole.
3. Remove the spool valve (15 or 18) and seal kit (7 or
17).
E. On spool (flow control) valve (15), place indica-
tor plate (27) over the detent plate (28). Make sure
the arrow points to the right at 45_.
4. Visually inspect the port in the manifold (22) for
damage to the sealing surfaces, damaged threads, and
contamination.
F. On spool (two position directional) valve (18),
place indicator plate (31) over the detent plate (28).
Make sure the arrow points directly at the number 1
on the locating plate (16).
5. Visually inspect spool valve (15 or 18) for damaged
sealing surfaces and contamination.
A. Contamination may cause valves to stick or
hang up. Contamination can become lodged in
small valve orifices or seal areas causing malfunc-
tion.
G. While pushing down on the indicator plate (27 or
31) and compressing the springs (24 or 30), thread
down a jam nut (26). While tightening the set screw
(29), tighten jam nut (26) at the same time using a
7/16 – inch wrench
B. If sealing surfaces appear pitted or damaged,
the hydraulic system may be overheating or there
may be water in the system.
H. Thread second jam nut (26) all the way down the
valve (15 or 18) stem. Apply ”Loctite 242” or equiva-
lent the valve stem threads. Screw knob (25) all the
way down until it hits the upper jam nut (26).
CAUTION
I. On spool (flow control) valve (15), turn knob (25)
counterclockwise until the arrow points at the num-
ber ”5”. Simultaneously tighten upper jam nut (26)
andturnknobsoitistightandthearrowispointingat
the number ”1” on the locating plate (16).
Use eye protection such as goggles when
using compressed air
6. If necessary, clean spool valve (15 or 18) using
clean mineral spirits. Submerge valve in clean mineral
spirits to flush out contamination. Particles as fine as tal-
cum powder can affect the operation of high pressure
hydraulic valves. Use compressed air for cleaning.
J. On spool (two position directional) valve (18),
turn knob (25) counterclockwise so the arrow is 90_
with the back of the manifold body (22). Simulta-
neously tighten upper jam nut (26) and turn knob so
it is tight and the arrow is pointing 45_ to the right in
line with the indicator plate (31).
7. Reinstall the spool valve (15 or 18):
Hydraulic System
Page 4 – 66
Reelmaster 2300–D/2600–D
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Front Lift Cylinder
INSTALL FLANGE BUSHING (18)
FROM THE INSIDE
16
FITTING SIDE
14
15
13
11
18
12
18
19
4
6
1
6
5
2
7
6
16
3
8
10
9
Figure 59
1. Hose connection
2. Hose connection
3. Hose connection
4. Hose connection
5. Hydraulic fittings
6. 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
7. O–ring
Reelmaster 2300–D/2600–D
Page 4 – 67
Hydraulic System
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Removal (Fig. 59)
9. Remove flange bushings (18) from the cylinder
support bracket (17).
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.
10. Remove lift hub (12) from the lift cylinder (8).
Installation (Fig. 59)
1. Thread lift hub (12) onto lift cylinder (8).
2. Position lift cylinder (8) inside the cylinder support
bracket (17) and valve mount bracket (19). Make sure
the inlet and outlet ports of the lift cylinder face the fitting
side of the cylinder support bracket.
CAUTION
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
3. Alignliftcylinder(8)holeswithholesatbottomofthe
valve mount bracket (18). Slide clevis pin (14) through
holes and secure pin with cotter pin (9).
2. Raise and remove hood to get access to the front lift
cylinder. Label all connections for reassembly.
4. Align lift hub (12) holes with the slots on the cylinder
support bracket (17). Install flange bushings (18) into
the cylinder support bracket slots.
3. Disconnect hose connections (1), (2), (3), and (4)
from hydraulic fittings (5). Allow hoses to drain into a
suitable container.
5. Make sure flange bushings (18) are aligned with the
lift hub (12) holes. Slide cylinder guide (16) through the
cylinder support bracket (17), flange bushings (18), and
lift hub (12).
4. Put caps or plugs on disconnected hoses and fit-
tings to prevent contamination.
5. Remove hydraulic fittings (5) and O–rings (7) from
the lift cylinder (8).
6. Secure cylinder guide (16) by screwing cap screw
(11) fully into lift hub (12).
6. Remove cotter pin (9) from the clevis pin (10). Pull
clevis pin from the lift cylinder (8).
7. Secureclevis(15)tothecylinderguide(16)withcle-
vis pin (4) and cotter pin (13).
7. Remove cap screw (11) from the lift hub (12).
Remove cotter pin (13) and clevis pin (14) from the
clevis (15) that is on the hydraulic fitting side of the
cylinder guide (15).
8. Slide clevis pin (10) through the valve mount brack-
et (19) and lift cylinder (8). Install and lock cotter pin (9)
into the clevis pin.
9. Install hydraulic fittings (5) and O–rings (7) into the
lift cylinder (8).
8. Support lift cylinder (8) and slide cylinder guide (16)
from the lift hub (12).
10. Remove caps or plugs from disconnected hoses.
Connect hose connections (1), (2), (3), and (4) to hy-
draulic fittings (5). Tighten hose connections
A. Reach up from the bottom and rotate lift cylinder
so the bottom port comes out of the slot in the frame.
B. Drop lift cylinder down and out from the frame.
Lift hub from the cylinder support bracket (17).
Hydraulic System
Page 4 – 68
Reelmaster 2300–D/2600–D
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9
11
7
5
3
10
8
1
6
4
2
12
Figure 60
1. retaining ring
2. O–ring
3. Head
5. O–ring
6. Shaft
7. O–ring
8. Piston
9. Uni–ring
10. Lock nut
11. Barrel
4. Backup washer
12. Dust seal
Disassembly (Fig. 60)
1. Remove oil from the cylinder into a drain pan by
slowly pumping the cylinder shaft (6). Plug both ports
and clean the outside of the lift cylinder.
Spanner
wrench
IMPORTANT: Prevent damage when clamping the
lift cylinder into a vise; clamp on the pivot only. Do
not close vise enough to distort barrel (11).
Retaining
ring
2. Mount lift cylinder in a vise so that the shaft (6) end
tilts up slightly. Remove and discard dust seal (12).
3. Rotate head (3) with a spanner wrench and remove
retaining ring (1) as shown in Figure 61.
Figure 61
Removing retaining ring
4. Grasp end of shaft (6); extract shaft, head (3), and
piston (8) by carefully twisting and pulling on the shaft.
6. Remove and discard O–ring (7) and uni–ring (9)
from the piston (8). Remove and discard both O–rings
(2 and 5) and backup washer (4) from the head (3).
IMPORTANT: Do not clamp vise jaws against shaft
(6) surface. Protect shaft surface before mounting
in the vise.
5. Mount shaft (6) securely in a vise by clamping vise
on the flats of the shaft. Remove locknut (10) and piston
(8) from the shaft. Slide head (3) off the shaft.
Reelmaster 2300–D/2600–D
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Hydraulic System
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Inspection (Fig. 60)
CAUTION
Spanner
wrench
Use eye protection such as goggles when
using compressed air
1. Washallpartsinsolvent. Drypartswithcompressed
air.
Retaining ring
(Offset end
against left side of
barrel groove
after installing)
2. Inspect internal surface of barrel (11) for deep
scratches, out–of–roundness, and bending. Replace if
worn or damaged.
Figure 62
Installing retaining ring
3. Inspect head (3), shaft (6), and piston (8) for exces-
sive pitting, scoring, and wear. Replace any worn or
damaged parts.
Reassembly (Fig. 60)
1. Coat all O–rings, uni–ring, and backup washer light-
ly with hydraulic oil. Install new O–ring (7) and uni–ring
(9) to the piston (8). Install O–rings (2 and 5) and backup
washer (4) to the head (3).
IMPORTANT: Do not clamp vise jaws against shaft
(6) surface. Protect shaft surface before mounting
in the vise.
2. Mount shaft (6) securely in a vise by clamping vise
on the ends of the shaft. Slide head (3) onto the shaft.
Install piston (8) and locknut (10) onto the shaft and
tighten lock nut (10).
3. Remove shaft (6) from the vise.
IMPORTANT: Prevent damage when clamping the
barrel (11) into a vise; clamp on the pivot end only.
Do not close vise enough to distort barrel.
4. Mount barrel (11) in a vise so that the shaft end tilts
up slightly.
5. Coat all internal lift cylinder parts with a light coat of
hydraulic oil. Slide piston (8), shaft (6), and head (3) as-
sembly into barrel (11) being careful not to damage the
seals.
6. Secure head (3) in barrel (11) by installing retaining
ring (1). Align key slot in head with the access groove in
the barrel. Rotate head clockwise as far as the retaining
ring will allow. The offset end of the retaining ring will be
against the left side of the barrel groove as shown in Fig-
ure 62.
Hydraulic System
Page 4 – 70
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Rear Lift Cylinder
13
12
14
11
14
ROD CLEVIS
10
15
4
9
7
3
5
15
5
2
6
1
8
Figure 63
1. Hose connection
2. Hose connection
3. Hydraulic fitting
4. Hydraulic fitting
5. O–ring
6. Cap screw
11. Cotter pin
12. Clevis pin
13. Lift arm
14. Flat washer
15. O–ring
7. Ram pivot pin
8. Pivot support
9. Lift pivot shaft
10. Lift cylinder
Removal (Fig. 63)
CAUTION
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.
The rear lift cylinder is located near the
muffler exhaust pipe. To avoid possible
burns, allow the exhaust pipe to cool be-
fore working on the rear lift cylinder.
CAUTION
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.
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
Reelmaster 2300–D/2600–D
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Hydraulic System
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3. Put caps or plugs on disconnected hoses and fit-
tings to prevent contamination.
maining flat washer and then cotter pin (11) onto the cle-
vis pin.
4. Remove cap screw (6) and ram pivot pin (7) from
pivot support (8). Slide lift pivot shaft (9) from pivot sup-
port.
4. Install hose connections (1 and 2) onto hydraulic fit-
tings (3 and 4). Tighten hose connections.
5. If rod clevis (14) has been removed, verify that the
distance between the carrier frame rollers (bumpers on
later models) and the foot step is about 1/4–inch (6 mm)
with the cutting units fully raised. Adjust rod clevis as
necessary. (Fig. 63)
5. Rotate lift cylinder (10) while swinging the lift cylin-
der down from the pivot support (8), so the hydraulic fit-
tings (3) and (4) are clear the exhaust pipe.
6. Remove cotter pin (11) from clevis pin (12). Support
lift cylinder (10) and slide clevis pin out of the lift arm (13)
removing flat washers (14).
A. Lower cutting units. Engage parking brake, stop
the engine, and remove key from the ignition switch.
7. Remove hydraulic fittings (3) and (4) and O–rings
(15) from the lift cylinder (10).
B. Remove cotter pin (11) from clevis pin (12). Slide
clevis pin out of the lift arm (13) removing flat wash-
ers (14) (Fig. 64).
Installation (Fig. 63)
C. Separate rod clevis from lift arm (13) (Fig. 63).
1. Coat new O–rings lightly with clean hydraulic oil.
Install hydraulic fittings (3) and (4) and new O–rings (15)
on the lift cylinder (10).
D. Loosen jam nut (13) and adjust rod clevis (14) as
necessary (Fig. 64).Tighten jam nut.
2. Position lift cylinder (10) inside pivot support (8).
Slide lift pivot shaft (9) through pivot support and lift cyl-
inder. Make sure lift pivot groove is aligned to accept the
ram pivot pin (7). Install ram pivot pin (7) and cap screw
(6).
E. Position rod clevis into lift arm (13) (Fig. 63).
F. Install clevis pin (12) and flat washers (14) into
the lift arm (13)androdclevis. Secureclevispinwith
cotter pin (11) (Fig. 63).
G. Checkdistancebetweenthecarrierframerollers
(bumpers on later models) and the foot step as de-
scribed above.
3. Swing the lift cylinder (10) up so its clevis is posi-
tioned between the lift arm (13) slots. Slide a flat washer
(14) onto the clevis pin (12). Slide clevis pin through the
lift arm slots and the lift cylinder (10) clevis. Install re-
14
6
11
9
7
13
5
12
3
1
10
8
6
4
2
Figure 64
1. Barrel
6. Shaft
7. O–ring
8. O–ring
9. Backup washer
10. Head
11. Retaining ring
12. Dust seal
13. Jam nut
2. Lock nut
3. Piston
4. Uni–ring
5. O–ring
14. Rod clevis
Hydraulic System
Page 4 – 72
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Disassembly (Fig. 64)
3. Inspect head (10), shaft (6), and piston (3) for ex-
cessive pitting, scoring, and wear. Replace any worn or
damaged parts.
1. Remove oil from cylinder into a drain pan by slowly
pumpingthecylindershaft(6). Plugbothportsandclean
the outside of the lift cylinder.
Reassembly (Fig. 64)
IMPORTANT: Prevent damage when clamping the
lift cylinder into a vise; clamp on the pivot end only.
Do not close vise enough to distort the barrel (1).
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).
2. Mount lift cylinder in a vise so that the shaft (6) end
tilts up slightly.
IMPORTANT: Do not clamp vise jaws against shaft
(6) surface. Protect shaft surface before mounting
in the vise.
3. Remove retaining ring (11) from the barrel (1).
4. Grasp clevis rod (14); extract shaft (6), head (10),
and piston (3) by carefully twisting and pulling on the
shaft out from the barrel (1).
2. Mount shaft (6) securely in a vise. Adjust clevis (14)
and jam nut (13) so the number of threads exposed be-
tween the jam nut (13) and the smooth surface of the
shaft is the same as noted during disassembly. The jam
nut must be tight against rod clevis for this adjustment.
IMPORTANT: Do not clamp vise jaws against shaft
surface. Protect shaft surface before mounting in
the vise.
3. Coat shaft (6) lightly with hydraulic oil. Slide head
(10) onto the shaft being careful not to damage O–ring
(7) and dust seal (12).
5. Mount shaft (6) securely in a vise. Remove locknut
(2) and piston (3) from the shaft. Slide head (10) off the
shaft.
4. Install piston (3) onto the shaft being careful not to
damage O–ring (5). Install locknut (2) onto the shaft and
tighten.
6. Remove and discard uni–ring (4) and O–ring (5)
from the piston (3). Remove and discard dust seal (12),
backup washer (9), and O–rings (7 and 8) from the head
(10).
5. Remove shaft (6) from the vise.
Note: If the rod clevis (14) is to be removed from the
shaft (6), note the number of threads exposed between
the jam nut (13) and the smooth surface of the shaft to
help reassembly.
IMPORTANT: Prevent damage when clamping the
barrel (1) into a vise; clamp on the pivot end only. Do
not close vise enough to distort barrel.
6. Mount barrel (1) in a vise so that the shaft end tilts
up slightly.
7. Loosen jam nut (13) and remove clevis if necessary.
Inspection (Fig. 64)
7. Coat all internal lift cylinder parts with a light coat of
hydraulicoil. Slidepiston(3), shaft(6), andhead(10)as-
sembly into barrel (1) being careful not to damage the
seals.
CAUTION
8. Secure head (3) in barrel (11) by installing retaining
ring (1) into barrel groove.
Use eye protection such as goggles when
using compressed air
1. Washallpartsinsolvent. Drypartswithcompressed
air.
2. Inspect internal surface of barrel (1) for deep
scratches, out–of–roundness, and bending. Replace if
worn or damaged.
Reelmaster 2300–D/2600–D
Page 4 – 73
Hydraulic System
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Control and Implement Relief Valves
7
5
6
4
8
23
9
2
1
3
24
11
24
10
23
24
24
18
12
23
24
23
2
21
20
17
19
21
13
13
22
16
22
14
15
Figure 65
1. Hose connection
2. Hydraulic fitting
3. Washer
4. Cap screw
5. Lock nut
6. Valve lever
7. Knob
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
Hydraulic System
Page 4 – 74
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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.
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 connections.
CAUTION
Operate all hydraulic controls to relieve
system pressure and avoid injury from
pressurized hydraulic oil.
Relief Valve Removal (Fig. 65)
Note: This procedure may be used if only the relief
valve needs removal from the unit.
2. Remove side panels lift hood to gain access to the
control valve and relief valve.
1. Disconnect hose connection (11) from hydraulic fit-
ting (2). Allow hose to drain to a suitable container.
Control Valve Removal (Fig. 65)
2. Disconnect tube (18) from hydraulic fitting (2). Allow
fitting to drain to a suitable container.
1. Disconnect hose connections (1, 11, 14, and 15)
from hydraulic fittings (2 and 13). Allow hoses to drain
to a suitable container.
3. Remove relief valve body (19) and hydraulic fitting
(2) from tube (12).
2. Remove lock nuts (5 and 16). Slide cap screw (4)
and washer (3) from the control valve (9).
4. Remove hydraulic fitting (2), tube (18) and both O–
rings (23) from the relief valve body (19).
3. Slide control valve (9) from the support bracket (17)
and remove from the unit.
Relief Valve Installation (Fig. 65)
Note: This procedure may be used if only the relief
4. Unsnap and remove connecting link assembly (8).
Remove valve lever (6) from the control valve (9).
valve has been removed from the unit.
1. Install hydraulic fitting (2) and O–ring (23) to the re-
lief valve body (19).
5. Disconnect tube (18) from hydraulic fitting (2). Dis-
connect tube (12) from hydraulic fitting (10).
2. Install tube (18) and O–ring (23) to the relief valve
body (19).
6. Remove hydraulic fittings (2, 10, and 13) and O–
rings (21 and 23) from the control valve (9).
3. Set relief valve body (19) and attachments into the
unit.
Control Valve Installation (Fig. 65)
1. Install O–rings (21 and 23) and hydraulic fittings (2,
10, and 13) to the control valve (9).
4. Connect tube (18) to hydraulic fitting (2).
5. Connect tube (12) to hydraulic fitting (2).
2. Install tube (12) to hydraulic fitting (10). Connect
tube (18) to hydraulic fitting (24).
6. Connect hose connection (11) to hydraulic fitting
(2).
3. Install valve lever (6) to the control valve (9) by
snapping the connecting link assembly (8) to the valve
lever and control valve.
Reelmaster 2300–D/2600–D
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Control Valve Disassembly (Fig. 66)
1. Wash control valve in solvent and dry it thoroughly.
2. Mountcontrolvalveintoavisesothemountingpads
are against the jaws of the vice and snap ring (14) faces
up.
8
Note: Remove check valve seat (5) only if it needs re-
placement; it is press fitted in.
3. Remove plug (1) and O–ring (2) from the valve body
(7). Remove spring (3), ball (4), cam pin (6).
4. Repeat step 3 for the other plug (1).
9
7
5. Remove snap ring (14) from the bottom of the valve
body (7). Remove spool snap ring (13), spring retainer
(10), spacer (12), and spring (11).
5
3
6. Push and twist spool (8) carefully out of the valve
body (7). Set spool aside.
1
7. Remove O–rings (9) using a soft hooked scribe or
a thin screwdriver and being careful not to scratch the
valve bore finish.
6
Control Valve Inspection (Fig. 66)
9
10
4
11
CAUTION
2
12
13
Use eye protection such as goggles when
using compressed air
10
14
Figure 66
1. Washallpartsinsolvent. Drypartswithcompressed
air.
1. Plug
8. Spool
9. O–ring
10. Spring retainer
11. Spring
12. Spacer
13. Spool snap ring
14. Snap ring
2. O–ring
3. Spring
4. Ball
5. Check valve seat
6. Cam pin
2. Inspect spool (8) for bending and flatness. Signs of
wear on one side of the spool may indicate it’s bent. Re-
place a worn or damaged spool if necessary.
7. Body
3. Inspect parts for wear or damage, and replace if
necessary.
3. Install spring retainer (10), spring (11), spacer (12),
other spring retainer (10), and spool snap ring (13) onto
the spool (8). Install snap ring (14) into the valve body
(7).
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).
4. If check valve seat (5) was damaged and removed,
press fit it into the valve body (7).
2. Coat spool (8) lightly with hydraulic oil. Push and
twist spool carefully into the valve body (7). Avoid dam-
aging O–rings (9).
5. Installcampin(6), ball(4), andspring(3). Placenew
O–ring (2) on plug (1) and install them into the valve
body (7). Tighten plug (1).
6. Repeat steps 4 and 5 for the other plug (1) and valve
assembly.
Hydraulic System
Page 4 – 76
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Hydraulic Reservoir
1
6
7
2
26
8
9
15
14
10
11
26
12
22
26
5
23
25
13
27
14
14
3
20
21
4
15
3
24
26
16
5
14
17
19
12
18
11
13
10
5
Figure 67
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. Tank bracket
10. Grommet
19. Hydraulic hose
20. Oil filter element
21. Oil filter head
22. 90_ fitting
11. Flat washer
12. Cap screw
13. Carriage screw
14. Hose clamp
15. Hydraulic hose
16. Hydraulic fitting
17. U–bracket support
18. Cap screw
23. Hydraulic hose
24. Hydraulic hose
25. Hydraulic hose
26. O–ring
27. Hydraulic fitting
Reelmaster 2300–D/2600–D
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Hydraulic System
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Inspecting Reservoir Parts (Fig. 67)
4. Make sure cap screws (12) are secure. If loose, re-
move and reinstall cap screws with loctite.
1. Clean tank (1) and filler screen (7) with solvent.
2. Inspect tank (1) for leaks, cracks, or other damage.
3. Replace hydraulic hoses if worn or leaking.
5. Make sure all bracket fasteners are tight.
Hydraulic System
Page 4 – 78
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Flushing the Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or the system is
contaminated (oil appears milky or black or con-
tains metal particles).
1
IMPORTANT: Flush hydraulic system when chang-
Ing from petroleum base hydraulic fluid, such as
Mobil 424, to biodegradable fluid, such as Mobil
EAL 224H. Operate machine under normal operat-
ing conditions for at least four (4) hours before
draining.
2
1. Park machine on a level surface. Lower cutting
units, stop engine, engage parking brake and remove
key from ignition switch.
Figure 68
2. Clean area around filter mounting area. Remove fil-
ter and drain reservoir into a suitable container. Drain
hydraulic system, Make sure lift cylinders, hoses, and
tube lines are drained while the system is warm. Discard
filter.
1. Hydraulic reservoir cap
2. Sight gauge
3. Inspect and clean reservoir (see Inspecting Reser-
voir Parts).
4. Make sure filter mounting surface is clean. Apply
hydraulic oil to gasket on the new filter. Screw filter on
until gasket contacts mounting plate, then tighten filter
half a turn.
1
Note: Use biodegradable fluid, such as Mobil EAL
224H, forthisstepifyouarechangingtothistypeoffluid.
Use only hydraulic fluids specified in Checking Hydrau-
lic System Fluid (see General section of this chapter).
Other fluids could cause system damage.
Figure 69
1. Hydraulic filter
11. Raise and lower cutting units several times.
5. Fill hydraulic reservoir.
12. Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic reservoir and add correct oil
if necessary.
6. Disconnect electrical connector to the fuel stop so-
lenoid to prevent engine from starting.
13. Operate the machine for two (2) hours under normal
operating conditions.
7. Turn ignition key switch; engage starter for ten (10)
seconds to the prime pump. Repeat this step again.
14. Check condition of hydraulic oil. If the flushing fluid
showsanysignsofcontamination, orifyouarechanging
to biodegradable fluid, repeat steps 1 through 14 again.
8. Connect electrical connector to the fuel stop sole-
noid.
9. Start engine and let it idle at low speed for a mini-
mum of two (2) minutes.
15. Assume normal operation and follow recom-
mended maintenance intervals.
10. Increase engine speed to high idle for minimum of
one (1) minute under no load.
Reelmaster 2300–D/2600–D
Page 4 – 79
Hydraulic System
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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 not purging the
system of air.
CAUTION
Becarefulwhenoperatingthecuttingunit
reels. Contact with the reel or other mov-
ing parts can result in personal injury.
1. After the hydraulic system components have been
properly installed and if the traction pump was rebuilt or
replaced, make sure traction pump housing is at least
half full of clean hydraulic oil.
9. After the hydraulic system starts to show signs of fill,
accomplish the following:
2. Make sure all hydraulic connections and lines are
secured tightly.
A. If a reel motor was replaced or rebuilt, run the
cutting units at the minimum speed setting (under
no load) for 10 minutes in both directions.
3. Make sure hydraulic reservoir is full. Add correct oil
if necessary (see Checking the Hydraulic System Fluid).
Drain, flush, and refill hydraulic system reservoir and
change oil filter if component failure was severe or sys-
tem is contaminated.
B. If a reel motor drive pump was replaced or re-
built, run the cutting units at the minimum speed set-
ting (under no load) for 10 minutes.
C. If a traction pump or a wheel motor was replaced
or rebuilt, run the traction unit so the wheels slowly
turn for 10 minutes.
4. Disconnect electrical connector to the fuel stop so-
lenoid to prevent engine from starting.
5. After repairs, check control linkage for proper ad-
justment, binding, or broken parts.
10. Operate the traction unit and cutting unit by gradual-
ly increasing their work load to full over a 10 minute peri-
od.
6. Make sure traction pedal is in neutral and the cut-
ting unit switch is off. Turn ignition key switch; engage
starter for fifteen (15) seconds to the prime pump.
11. Stop the machine. Check reservoir and fill if neces-
sary. Check hydraulic components for leaks and tighten
any loose connections.
7. Connect electrical connector to the fuel stop sole-
noid.
8. Make sure traction pedal is in neutral and the cut-
ting unit switch is off. Start engine and run it at low idle.
The charge pump should pick up oil and fill the hydraulic
system. If there is no indication of fill in 30 seconds, stop
the engine and determine the cause.
Hydraulic System
Page 4 – 80
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Chapter 5
Electrical System
Table of Contents
WIRING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 2
Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Run/Mow Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Run/Backlap Circuits . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Indication and Safety Circuits . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 10
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Run and Transport Problems . . . . . . . . . 12
Cutting Unit Operating Problems . . . . . . . . . . . . . 13
Verify Interlock System Operation . . . . . . . . . . . . 14
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . 15
Battery Test (Open Circuit) . . . . . . . . . . . . . . . . . . 15
Charging System Test . . . . . . . . . . . . . . . . . . . . . . 15
Glow Plug System 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
Traction (Neutral) Interlock Switch . . . . . . . . . . . . 24
Seat Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . 25
Cutting Unit Interlock Switch . . . . . . . . . . . . . . . . . 26
Backlap Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 27
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cutting Unit Solenoid Valve Coil . . . . . . . . . . . . . . 30
Traction (Electric) Clutch . . . . . . . . . . . . . . . . . . . . 31
Reelmaster 2300–D/2600–D
Electrical System
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Wiring Schematics
W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
D 2
W H I T E
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Electrical System
Reelmaster 2300–D/2600–D
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
D 2
W H I T E
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Reelmaster 2300–D/2600–D
Electrical System
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
W H I T E
D 2
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Electrical System
Reelmaster 2300–D/2600–D
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
D 2
W H I T E
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Reelmaster 2300–D/2600–D
Electrical System
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
D 2
W H I T E
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Electrical System
Reelmaster 2300–D/2600–D
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
W H I T E
D 2
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Reelmaster 2300–D/2600–D
Electrical System
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W H I T E
Y
G R A
W H I T E
D 4
D 2
D 3
D 1
D 1
D 3
D 4
W H I T E
D 2
B L U E / W H I T E
P U R P L E / W H I T E
W H I T E / B L A C K
B L A C K
O R A N G E / W H I T E
B L A C K
O R A N G E / W H I T E
B R O W N / W H I T E
Electrical System
Reelmaster 2300–D/2600–D
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Special Tools
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS 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: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
Thehighimpedance(internalresistance)ofadigitalme-
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 electrical switches
and contacts.
Figure 2
Reelmaster 2300–D/2600–D
Electrical System
Page 5 – 9
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Troubleshooting
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this machine (see Wiring Sche-
matics section of this chapter).
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.
If the machine has any interlock switches by–passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank
(if solenoid clicks, problem is not in safety interlock
system).
Battery charge is low.
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.
Cutting unit switch is ON (pulled out) or faulty.
Battery is dead.
Nothing happens when start attempt is made.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Fusible link is open.
Wiring to the start circuit (see Wiring Schematics)
components is loose, corroded, or damaged.
Ignition switch is faulty.
Starter relay is faulty.
Starter solenoid is faulty.
Engine fuse (10 amp) is open.
Fuse block is faulty.
High temperature shutdown relay and/or switch are
faulty.
Traction (neutral) interlock switch out of adjustment or
faulty.
Electrical System
Reelmaster 2300–D/2600–D
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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 faulty.
Glow plugs are faulty.
Engine or fuel system is malfunctioning (see Chapter
6 – Engine).
Engine and fuel may be to cold.
Engine cranks (but should not) with the traction pedal
out of the neutral position.
Traction (neutral) interlock switch is out of adjustment,
faulty, or short circuited.
Diode (D1) circuit board/connector housing is short
circuited.
Engine cranks (but should not) with the cutting unit
switch ON (pulled out).
Backlap/mow switch is in the backlap position.
Cutting unit switch is faulty or short circuited.
Reelmaster 2300–D/2600–D
Electrical System
Page 5 – 11
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General Run and Transport 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.
Traction (neutral) interlock switch is out of adjustment,
faulty, or short circuited.
Engine kills when the traction pedal is depressed or
Operator is sitting too far forward on the seat (seat
the cutting unit switch is pulled ON with the operator in switch not depressed).
the seat.
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.
Battery is dead .
Engine kills during operation (operator sitting on seat). Operator moved too far forward on the seat (seat
switch not depressed).
Engine overheated.
Wiring to the run circuits (see Wiring Schematics)
components became broken or disconnected.
Electrical System
Reelmaster 2300–D/2600–D
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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 circuits (see Wiring
Schematics) components is loose, corroded, or
damaged.
Seat switch is faulty, out of adjustment, or short
circuited.
Cutting units run (but should not) when raised.
However, they shut off with the cutting unit switch
Cutting unit interlock switch is faulty.
Cutting units shut off when raised. However, they do
not shut off with the cutting unit switch.
Cutting unit switch is faulty or short circuited.
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 open.
Fuse block is faulty.
Cutting units are not lowered.
Cutting unit switch is faulty.
Cutting unit interlock switch is faulty.
Cutting solenoid valve is faulty.
Reelmaster 2300–D/2600–D
Electrical System
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Verify Interlock System Operation
CAUTION
stop, there may be a malfunction in the interlock system.
Repairtheproblemimmediately. Iftheenginedoesstop,
proceed to step 4.
4. Make sure the mow/backlap knob is in the mow
position (turned counterclockwise), the traction pedal is
in neutral, and the cutting unit switch is pushed to the
OFF position. With the operator off the seat, start the en-
gine. Pull the cutting unit switch to the ON position, the
engine should stop. If the engine does not stop, there
may be a malfunction in the interlock system. Repair the
problem immediately. If the engine does stop, proceed
to step 5.
The interlock switches are for the opera-
tor’s protection; do not disconnect them.
Check the operation of the switches daily
to assure the interlock system is operat-
ing. If a switch is defective, replace it be-
fore operating the machine. Regardless if
switches are operating properly or not,
replace them every two years to assure
maximum safety.
5. Make sure the mow/backlap knob is in the backlap
position (turned clockwise), the traction pedal is in neu-
tral, and the cutting unit switch is pushed to the OFF
position. With the operator off the seat, start the engine.
Pull the cutting unit switch to the ON position, the engine
should not stop. If the engine does stop, there may be
a malfunction in the interlock system. Repair the prob-
lem immediately. If the engine does not stop, proceed to
step 6.
1. Movethemachinetoawideopenareafreeofdebris
and bystanders. Raise the cutting units and stop the en-
gine. Engage the parking brake. Keep hands and feet
away from cutting units.
2. Make sure the mow/backlap knob is in the mow
position (turned counterclockwise). Sit on the seat. Pull
the cutting unit switch to the ON position. Try to start the
engine. If the engine cranks, there may be a malfunction
in the interlock system. Repair the problem immediately.
If the engine does not crank, proceed to step 3.
6. Withthecuttingunitsintheraisedposition, sitonthe
seat and start the engine. Pull the cutting unit switch to
the ON position. Lower the cutting units to the ground.
The cutting unit reels should turn and the reels turning
light should glow when the cutting units are lowered.
Raise the cutting units and verify that the reels stop and
the reels turning light is out. If the reels do not stop, there
may be a malfunction in the interlock system. Repair the
problem immediately.
3. Make sure the mow/backlap knob is in the mow
position (turned counterclockwise), the traction pedal is
in neutral, and the cutting unit switch is pushed to the
OFF position. With the operator off the seat, start the en-
gine. Depress the traction pedal with the operator out of
the seat, the engine should stop. If the engine does not
Electrical System
Reelmaster 2300–D/2600–D
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Electrical System Quick Checks
Battery Test (Open Circuit Test)
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
Battery Charge Level
Fully charged (100%)
75% charged
12.68 V (or higher)
12.45 V
Set the multimeter to the DC volts setting. The battery
should be at a temperature of 60_ to 100_ F. The ignition
keyshouldbeoffandallaccessoriesturnedoff. Connect
the positive (+) meter lead to the positive battery post
and the negative (–) meter lead the the negative battery
post.
12.24 V
50% charged
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the bat-
tery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if a charging sys-
tem is functioning. It will tell you if a charging system has
an output, but not its capacity.
Start the engine and run at 3200 RPM. Allow the battery
to charge for at least 3 minutes. Record the battery volt-
age.
Tool required: Digital multimeter set to DC volts.
Test results should be (example):
Test instructions: Connect the positive (+) meter lead to
the positive battery post, and the negative (–) meterlead
to the negative battery post. Leave the test leads con-
nected and record the battery voltage.
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
Battery Voltage after 3 Minute Charge
Difference
= 12.30v
= 12.80v
= +0.50 v
Note: Upon starting the engine, the battery voltage
will drop and then increase once the engine is running.
Note: Depending upon the condition of the battery
charge and battery temperature, the charging system
voltage will increase at different rates as the battery
charges.
Glow Plug System Test
This is a fast, simple test that can help you determine a
glow plug system’s integrity and operation. The test
should be run anytime hard starting (cold) is encoun-
tered on a diesel engine equipped with a glow plug sys-
tem.
instructions). Set the multimeter on the volts scale. With
the key off (or Glow Switch in the OFF position), place
the current transducer around the main glow plug power
supply wire(s) and read the meter prior to activating
glow plug system. Adjust the transducer to read zero (if
applicable). Cycle the glow plug system at least two
times (per instructions in Operator’s Manual) and record
the final results.
Tool(s) required: Digital multimeter and/or AC/DC
current transducer (Hall Effect).
Testinstructions:Properlyconnectthecurrenttransduc-
er to the digital multimeter (refer to manufacturer’s
The Reelmaster 2300–D glow plug system should have
a reading of about 21 Amps.
Reelmaster 2300–D/2600–D
Electrical System
Page 5 – 15
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Starting System Test
This is an excellent test to use when a “slow crank/no
start” problem is encountered. It will tell you if the prob-
lem is due to an electrical open, short or high resistance
in the starter circuit.
tions). Setthemultimeteronvoltsscale. Withthekeyoff,
place the current transducer around the main negative
(–) battery cable and read the meter prior to activating
the starter system. Adjust the transducer to read zero (if
applicable). Crank the engine for at least 3 seconds and
record the results. Typical starter system draw for the
RM 2300–D is about 155 Amps at 65_F.
NOTE: The Battery condition and state of charge must
checked before testing the starter system.
Tool(s) required: Digital multimeter and/or AC/DC
current transducer (Hall Effect).
If current draw is significantly higher than listed, check
for a shorted condition. If current draw is significantly
lower than listed, check for high resistance.
Testinstructions:Properlyconnectcurrenttransducerto
the digital multimeter (refer to manufacturers instruc-
Electrical System
Reelmaster 2300–D/2600–D
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check).
CAUTION
When testing electrical components for
continuity with a multimeter (ohms set-
ting), make sure that power to the circuit
has been disconnected.
NOTE: Electrical troubleshooting of any 12 Volt power
connection can also be performed through voltage drop
tests without disconnecting the component.
NOTE: See the Perkins 100 Series Workshop Manual
for more component testing information.
Ignition Key Switch
The ignition (key) switch has four positions (GLOW,
OFF, ON, and START). The terminals are marked as
shown. The circuitry of the ignition switch is shown in the
chart. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether all
circuits are being completed while the key is moved to
each position. Verify continuity between switch termi-
nals.
CONTINUITY
AMONG
TERMINALS
POSITION
GLOW (3)
50
19
17
30+19+AC
AC
30
50
50
50
19
17
OFF (0)
ON (1)
NONE
AC
AC
AC
30
30
19
17
30+AC
19
17
START (2)
30+17+50+AC
30
Figure 3
Reelmaster 2300–D/2600–D
Electrical System
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Starter and High Temperature Shut Down Relays
1. Verify coil resistance between terminals 86 and 85
with a multimeter (ohms setting). Resistance should be
from 80 to 90 ohms.
87
86
85
87A
87
87A
2. Connect multimeter (ohms setting) leads to relay
terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuitybetweenterminals30and87as12VDCisap-
plied and removed from terminal 85.
86
85
30
30
Figure 4
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
4. Connect multimeter (ohms setting) lead to relay ter-
minal 30 and 87A. Apply +12 VDC to terminal 85. The
relay should break and make continuity between termi-
nals 30 and 87A as 12 VDC is applied and removed from
terminal 85.
5. Disconnect voltage from and multimeter leads from
relay terminals.
High Temperature Shutdown Switch
The switch is located on top of the water pump. The
pump is on the left end of the engine inside of the fan
pulley assembly. There is a tan wire attached to the
switch.
1
1. Lower the coolant level in the engine and remove
the high temperature shutdown switch.
2. Put the switch in a container of oil with a thermome-
ter and slowly heat the oil (Fig. 6).
CAUTION
Handle the hot oil with extreme care to
prevent personal injury or fire.
Figure 5
1. High temperature shutdown switch
3. Check the continuity of the switch with a multimeter
(ohms setting). The switch is normally open and should
close at 206 to 218_F (97 to 103_C).
4. Allow the oil to cool. The switch should open at
194_F (90_C).
Figure 6
Electrical System
Reelmaster 2300–D/2600–D
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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/cm2 ).
1
Testing with the engine off
1. TurntheignitionswitchtoON. Theoilpressurelamp
should be on.
2. If the lamp is not on, disconnect the brown wire from
the switch and ground it to the engine block.
3. If the lamp comes on the switch is bad.
Figure 7
4. If the lamp does not come on after step 2, check the
indicating circuit (see Indicating and Safety Circuits).
1. Oil pressure switch
Testing with the engine on
6. Remove switch and install test gauge in the oil pres-
sure switch port.
1. If the lamp is on with the engine running, shut off the
engine immediately.
7. Start the engine and check for a minimum of 30 psi
at 1400 RPM. If the engine oil pressure is low, shut off
the engine immediately.
2. Disconnect the brown wire from the switch.
3. TurntheignitionswitchtoON. Theoilpressurelamp
should go out.
8. Shut off the engine and remove the test gauge.
9. Iftheengineoilpressureisgood, replacetheswitch.
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.
Hour Meter
1. Connect the positive (+) terminal of a 12 VDC
source to the positive terminal of the hour meter.
Hobbs
QUARTZ
1
2. Connect the negative (–) terminal of the voltage
source to the other terminal of the hour meter.
0 0 0 0 1
10
HOURS
3. The hour meter should move a 1/10 of an hour in six
minutes.
4. Disconnect the voltage source from the hour meter.
+
BACK
Figure 8
Reelmaster 2300–D/2600–D
Electrical System
Page 5 – 19
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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.
Battery Light
The battery light should come on when the ignition
switch is in ON with the engine not running or with an im-
properly operating charging circuit while the engine is
running.
Oil Pressure Light
The oil pressure light should come on when the ignition
switch is in the ON position with the engine not running.
Also, it should light with the engine running when the oil
pressure drops below 4 PSI (0.3 kg/cm2).
1. Turn ignition switch to ON; the light should come on.
2. Turn ignition switch to OFF.
1. Disconnect the brown wire from the oil pressure
switch.
FRONT
OIL
(RED)
WATER
(RED)
2. Ground the brown wire to the engine block.
3. Turn the ignition switch to ON; the light should come
on.
4. Turn the ignition switch to OFF and connect the
brown wire to the oil pressure switch.
BATT
(AMBER)
GLOW
(AMBER)
High Temperature (Water) Shutdown Light
The temperature light should come on only if the high
temperature shutdown switch and relay have stopped
the engine when the coolant temperature is above
206_F (97_C). The ignition switch must be in either the
ON or START position for the light to come on.
1
2
6
5
1. Disconnect the tan wire from the high temperature
shutdown switch.
1 2 3 4 5 6
BACK
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.
Figure 9
4. Turn the ignition switch to OFF and connect the tan
wire to the high temperature shutdown switch.
GLOW
BATT
OIL
3
2
5
6
1
Glow Light
The glow light should come on with the ignition in the
GLOW or START position.
1. Turn the ignition switch to GLOW or START; the light
should come on.
4
2. Turn the ignition switch to OFF.
WATER
Figure 10
Electrical System
Reelmaster 2300–D/2600–D
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Temperature 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
1. Lower the coolant level in the engine and remove
the high temperature sending unit.
2. Put the switch in a container of oil with a thermome-
ter and slowly heat the oil (Fig. 12).
CAUTION
Handle the hot oil with extreme care to
prevent personal injury or fire.
Figure 11
1. Temperature sending
unit
3. Check the resistance of the sender with a multime-
ter(ohmssetting)asthetemperatureincreases. Thefol-
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.
63 TO 79 OHMS
G
VARIABLE
S I
RESISTANCE
12 VDC
1. Connect the temperature gauge to the variable re-
sistance and DC voltage source (Fig. 13).
+
–
BACK
2. Adjust the resistance until the gauge needle points
to the 180_F tic mark; the resistance setting should be
from 63 to 79 ohms.
Figure 13
180_F (82_C) TIC MARK
3. Disconnect the voltage source, gauge, and variable
resistance.
FRONT
Figure 14
Reelmaster 2300–D/2600–D
Electrical System
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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.
H
G
F
Diode D1
E
D
C
B
A
This diode allows a current path through the traction in-
terlock switch when the seat interlock switch is open.
The engine can be started and run with no operator in
theseatwhenthetractionpedalisintheneutralposition.
Possible indications of diode failure may be: The engine
will crank but not start with the operator out of the seat
with the traction pedal in neutral, the engine will shut
down when the operator leaves the seat with the cutting
unit switch in the off position and the traction pedal in
neutral, or the engine cranks with the traction pedal not
in neutral.
DIODE
DIAGRAM
Figure 15
H
Diode D2
G
F
This diode protects the cutting unit switch, interlock
switch, and indicator light from inductive voltage spikes
caused by the cutting unit solenoid valve.
E
D
C
B
A
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
Diode D3
CIRCUIT BOARD
Figure 16
This diode protects the ignition switch and starter relay
contacts from induction voltage spikes caused by the
starter solenoid.
Possible indications of diode failure may be the failure
or repeated failure of those components above
associated with the starter solenoid circuit.
Red Lead (+)
on
Terminal
Black Lead (–)
on
Continuity
Terminal
H
A
G
B
F
A
H
B
G
C
F
YES
NO
Diode D4
This diode protects the seat interlock switch and cutting
unit switch from induction voltage spikes caused by the
fuel valve solenoid.
YES
NO
Possible indications of diode failure may be the failure
or repeated failure seat interlock switch.
YES
NO
C
E
D
Testing
D
E
YES
NO
The diodes can be individually tested using a digital
multimeter (ohms setting) and the table to the right.
Electrical System
Reelmaster 2300–D/2600–D
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Fuel Valve Solenoid
The fuel valve solenoid must be energized for the en-
gine to run. It is mounted on the engine block next to the
injection pump and has a purple wire attached to it.
In Place Testing
1
1
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
1. Disconnect the wire from the solenoid.
Figure 17
( !) u0l C-lC0 98l0n83.
2. Using a digital multimeter, ground one lead to the
engine block and connect the other to the solenoid ter-
minal.
PLUNGER
TERMINAL
3. The resistance should be about 11.5 ohms.
4. Connect the wire to the solenoid.
Live testing
1. Disconnect the wire from the solenoid.
Note: The solenoid may be removed from the engine
or tested in place.
Figure 18
2. Connect a positive (+) test lead from a 12 VDC
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 Unit Solenoid Valve Coil
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
1. Disconnect solenoid valve electrical connector.
1
2. Measure resistance between the two connector ter-
minals. The resistance should be about 7.2 ohms.
Figure 19
1. Solenoid Valve Coil
3. Connect solenoid valve electrical connector.
Reelmaster 2300–D/2600–D
Electrical System
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Traction (Electric) Clutch
Note: When disconnecting the clutch, use the electri-
cal connector that connects the clutch directly to the wir-
ing harness. Do not use the connector attached to the
traction clutch switch. This connector contains a diode
in the circuit which will give incorrect resistance read-
ings
3. Connect the clutch electrical connector to the wiring
harness.
Note: Low resistance may be accompanied by the 10
amp engine fuse blowing from drawing high current.
High resistance may be accompanied by the clutch not
engaging from drawing insufficient current.
Live Testing
Deenergized Testing
1. Disconnect the clutch electrical connector from the
wiring harness.
Note: Prior to taking small resistance readings with a
digital multimeter, short the test leads together. The me-
ter will display a small resistance value (usually 0.5
ohms or less). This resistance is due to the internal re-
sistance of the meter and test leads. Subtract this value
from from the measured value of the component you are
testing.
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.
1. Disconnect the clutch electrical connector from the
wiring harness.
4. Connect the clutch electrical connector to the wiring
harness.
2. Using a digital multimeter, measure the resistance
between the connector terminals. The resistance
should be from 3.0 to 4.0 ohms.
Traction (Neutral) Interlock Switch
Thetractioninterlockswitchisnormallyopenandcloses
when the traction pedal in in the neutral position.
1. Disconnect the electrical connector to the switch.
2. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
1
3. With the engine off, slowly push the traction pedal
in the forward and reverse direction while watching the
multimeter. Continuity should be broken in the forward
and reverse directions.
4. Allow the traction pedal to return to the neutral posi-
tion. There should be continuity across the terminals.
5. Reconnect the electrical connector to the switch.
2
Figure 20
1. Connector leads
2. Interlock switch
Electrical System
Reelmaster 2300–D/2600–D
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Seat Interlock Switch
This switch is a normally open switch that closes when
the operator is on the seat. If the cutting unit switch or
traction interlock switch is open and the operator raises
out of the seat, the engine will stop. The switch and its
electrical connector are located under the skirt below
the seat.
1
1. Disconnect switch electrical connector.
2. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
Note: Make sure the compression spring and pin hold
the seat off the switch when there is no operator in the
seat.
Figure 21
1. Seat interlock switch
3. With the seat lowered and no operator in the seat,
there should be no continuity between the terminals.
4. Haveanoperatorslowlysitintheseat. Thereshould
be continuity as the seat approaches the bottom of its
travel.
5. Connect switch electrical connector.
1
Figure 22
1. Seat interlock switch
Reelmaster 2300–D/2600–D
Electrical System
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Cutting Unit Interlock Switch
This switch is normally open and closes when the lift cyl-
inder is retraced (cutting units lowered). The switch and
its electrical connector are located behind and below the
hydraulic manifold on the cylinder support bracket.
1. Disconnect switch electrical connector.
2. With the cutting units lowered, check the continuity
of the switch by connecting a multimeter (ohms setting)
across the connector terminals. There should be conti-
nuity across the switch.
1
3. Raise the cutting units and check the continuity of
the switch. There should be no continuity across the
switch with the lift cylinder extended.
4. Connect switch electrical connector.
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.
3
1. Disconnect the electrical connector.
1
2. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
3. With the engine off, turn the backlap knob clockwise
to the backlap position while watching the multimeter.
Continuity should be made as the switch closes.
2
4. Turnthebacklapknobcounterclockwisetothemow
position while watching the multimeter. Continuity
should be broken as the switch opens.
Figure 24
1. Backlap switch
2. Connector
3. Backlap knob
5. Reconnect the electrical connector.
Electrical System
Reelmaster 2300–D/2600–D
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Service and Repairs
NOTE: See the Perkins 100 Series Workshop Manual
for more component repair information.
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extend.
Additionally, battery and electrical component failure
can be prevented.
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.
CAUTION
FILLER CAPS
CAP TUBES
When working with batteries, use ex-
treme caution to avoid slashing or spil-
ling electrolyte. Electrolyte can destroy
clothing and burn skin or eyes. Always
wear safety goggles and a face shield
when working with batteries.
CORRECT
WATER
LEVEL
COVER SEAL
Electrolyte Specific Gravity
Fully charged: 1.265 corrected to 80_F (26.7_C)
Discharged: less than 1.240
Figure 25
Battery Specifications
C. Check for signs of wetness or leakage on the top
of the battery which might indicate a loose or mis-
sing filler cap, overcharging, loose terminal post, or
overfilling. Also, check the battery case for dirt and
oil. Clean the battery with a solution of baking soda
and water, then rinse it with clean water.
BCI Group 55 Battery:
450 Amp Cranking Performance at 0_ F (–17.8_ C)
60 Minute Reserve Capacity at 80_F (26.7_C)
Removal
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the bat-
tery cables.
D. Check that the cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
1. Removethebatteryhold–downclamp. Slidebattery
forward.
E. Check the electrolyte level in each cell. If the lev-
el is below the tops of the plates in any cell, fill all
cells with distilled water to the bottom of the cap
tubes. Charge at 15 to 25 amps for 15 minutes to al-
low sufficient mixing of the electrolyte.
2. Disconnect the ground cable (–) first to prevent
short circuiting the battery, other components, or the op-
erators hands. Disconnect the positive (+) cable.
2. Conductahydrometertestofthebatteryelectrolyte.
3. Make sure that the filler caps are on tightly.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
4. Remove battery from the battery compartment to a
service area. This will minimize possible battery dam-
age and allow better access for inspection and service.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm–
up the hydrometer. At the same time take the tem-
perature of the cell.
Inspection, Maintenance , and Testing
1. Perform the following inspection and maintenance
tasks:
A. Check for cracks caused by overly tight or loose
hold–down clamp. Replace battery if cracked and
leaking.
Reelmaster 2300–D/2600–D
Electrical System
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B. Temperature correct each cell reading. For each
10_F (5.5_C) above 80_F (26.7_C) add 0.004 to the
specific gravity reading. For each 10_F (5.5_C) be-
low 80_F (26.7_C) subtract 0.004 from the specific
gravity reading.
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Minimum
Voltage
Battery Electrolyte
Temperature
Example: Cell Temperature 100_F
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
70_F (and up)
21.1_C (and up)
15.6_C
Cell Gravity
1.245
0.008
60_F
50_F
40_F
30_F
20_F
10_F
0_F
ADD (20_ above 80_F)
10.0_C
Correction to 80_F 1.253
4.4_C
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the
battery. Charge at the recommended rate and time
given in Charging or until all cells specific gravity is
1.225 or greater with the difference in specific grav-
ity between the highest and lowest cell less than
0.050. If these charging conditions can not be met,
replace the battery.
–1.1_C
–6.7_C
–12.2_C
–17.8_C
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the mini-
mum, return the battery to service.
3. Perform a high–discharge test with an adjustable
load tester.
Installation
Thisisoneofthemostreliablemeansoftestingabattery
asitsimulatesthecold–crankingtest. Acommercialbat-
tery load tester is required to perform this test.
IMPORTANT: To prevent possible electrical prob-
lems, install only a fully charged battery.
1. Make sure the ignition switch and all accessories
are off.
CAUTION
2. Make sure the battery compartment is clean and re-
painted if necessary.
Follow the manufacturer’s instructions
when using a battery tester.
3. Make sure all battery cables and connection are in
goodconditionandthatthebatteryholddownclamphas
been repaired or replaced.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.0 VDC, recharge the battery.
4. Lift seat and place the battery near its compartment.
Push the positive cable connector onto positive battery
post. Do not hammer; this will damage the battery. Tight-
en bolts with two wrenches.
B. Ifthebatteryhasbeencharged, applya150amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufactur-
er’s instructions.
5. Place the battery in its compartment and make sure
it is level and flat. Tighten the battery hold–down bolts
uniformly to prevent cracking or distorting the battery
case.
C. Makesurethebatteryterminalsarefreeofcorro-
sion.
6. Apply a light coat of grease on all battery posts and
cable connectors to reduce corrosion after connections
are made.
D. Measure the temperature of the center cell.
E. Connect a battery load tester to the battery ter-
minals following the manufacturer’s instruc-
tions. Connect a digital multimeter to the battery
terminals.
7. Connect a digital multimeter (set to amps) between
the negative battery post and the negative (ground)
cable connector. The reading should be less than 0.1
amp. If the reading is 0.1 amp or more, the unit’s electri-
cal system should be tested and repaired.
F. Apply a test load of one half the Cranking Perfor-
mance rating (see Fig. 25) of the battery for 15 se-
conds.
8. Connect the negative (ground) cable connector to
the negative battery post.
G. Take a voltage reading at 15 seconds, then re-
move the load.
Electrical System
Reelmaster 2300–D/2600–D
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Charging
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac-
complished with a constant current battery charger
which is available in most shops.
CAUTION
Do not charge a frozen battery because it
can explode and cause injury. Let the bat-
tery warm to 60_F (15.5_ C) before con-
necting to a charger.
Charge the battery in a well–ventilated
place to dissipate gases produced from
charging. These gases are explosive;
keep open flame and electrical spark
away from the battery. Do not smoke.
Nausea may result if the gases are in-
haled. Unplug the charger from the elec-
trical outlet before connecting or discon-
nectingthechargerleadsfromthebattery
posts.
CAUTION
Follow the manufacturer’s instructions
when using a battery charging.
1. Determine the battery charge level from either its
open circuit voltage or specific gravity.
Battery Charge Open Circuit
Specific
Gravity
Level
100%
75%
50%
25%
0%
Voltage
12.68
12.45
12.24
12.06
11.89
3. Following the manufacturer’s instructions, con-
nect the charger cables to the battery. Make sure a good
connection is made.
1.265
1.225
1.190
1.155
1.120
4. Charge the battery following the manufacturer’s
instructions.
5. Occasionally check the temperature of the battery
electrolyte. If the temperature exceeds 125_F (51.6_C)
or the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
2. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
6. Three hours prior to the end of the charging, mea-
sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three consecutive
readings.
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less 3.8 hrs
@
7.5 hrs 11.3 hrs 15 hrs
@
@
@
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
4 amps 4 amps 4 amps 4 amps
126 to
170
5.5 hrs
@
11 hrs
@
16.5 hrs 22 hrs
@
@
5 amps 5 amps 5 amps 5 amps
171 to
250
5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
@
@
@
@
6 amps 6 amps 6 amps 6 amps
above
250
6 hrs
@
12 hrs
@
18 hrs
@
24 hrs
@
10 amps 10 amps 10 amps 10 amps
Reelmaster 2300–D/2600–D
Electrical System
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Cutting Unit Solenoid Valve Coil
The solenoid valve coil can be easily replaced without
opening the hydraulic system.
3
1
Removal
1. Disconnect the electrical connector.
2. Remove the nut from the spool assembly.
2
3
3. Slide the coil assembly and O–rings from the spool
assembly. Discard the coil assembly and O–rings.
4
4. Clean any corrosion or dirt from the spool assembly.
Loctite 242
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.
Figure 26
3. Connect the electrical connector.
1. Nut
2. Coil assembly
3. O–ring
4. Spool assembly
Electrical System
Reelmaster 2300–D/2600–D
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Traction (Electric) Clutch (Fig. 27 through 31)
Theclutchcircuitisnormallyenergizedwhentheengine
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.
2
1
Failure to engage the clutch is likely caused by too large
of a clutch air gap, a circuit fault in the clutchelectromag-
net, or another electrical problem (see Wiring Schemat-
ics).
3
4
Note: The air gap is not adjustable. The clutch must
be serviced as a whole and individual parts can not be
replaced.
Figure 27
1. Flanged nut
2. Dampener
3. Traction arm
4. U–bracket support
Removal
2
5
1. Make sure the engine is off and the fuel solenoid is
disconnected.
4
1
2. Lift the hood and disconnect the clutch electrical
connection. Make sure the connection is free of the
cable harness and the R–bracket holding it to the engine
block.
2
3. Remove the right and left front panels to access the
clutch and U–bracket support.
Figure 28
1. Nut
4. Adjusting yoke
2. Cotter pin
3. Clevis pin
5. Pump mount
4. Remove the flanged nut securing the dampener to
the traction arm. Remove nut, lock washer and flat
washer securing the dampener to the U–bracket sup-
port. Remove the dampener (Fig 27).
5. Remove the two bolts, flat washers, and grommets
holding the tank to the U–bracket support. Remove the
nuts, carriage bolts, and U–bracket support from the
frame (Fig. 29).
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).
4
5
3
6
7. Remove long capscrew with the jam nut from en-
gine block. Retain the position of the jam nut on the
capscrew (Fig. 30).
6
8. Remove the spindle with the clutch attached by al-
ternately loosening all spindle capscrews and then pull-
ing on the clutch (Fig. 30). When the spindle is free of the
fly wheel, slide it up along the flywheel and rotate it out
to clear the traction pedal and foot rest.
2
5
1
9. Remove the capscrews, lock washers, and pulley
from the clutch (Fig. 30).
Figure 29
1. Capscrew
2. Flat washer
3. Grommet
4. Hydraulic tank 6. Carriage bolt
5. Nut
10. Remove the capscrew, lockwasher, and flat washer
from the spindle. Slide the clutch and key from the clutch
spindle (Fig. 30).
Reelmaster 2300–D/2600–D
Electrical System
Page 5 – 31
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Installation
through the flat washers and grommets; apply loctite to
capscrew threads. Secure the hydraulic tank to the U–
bracket support with the two capscrews (Fig. 29).
1. When installing an new clutch, remove the wire
bracket from the old clutch and install it with the flat
washers and new pop rivets on the new clutch. Run the
wires through the bracket and tie wrap to them to the
bracket as on the original clutch. Make sure wires are
tight against the clutch wire bracket or they will
catch in the spindle bolts (Fig. 30).
11. Attach the dampener to the traction pedal and U–
bracket support (Fig. 27). Adjust the traction pedal (see
Adjustments section of Chapter 4 – Hydraulic System).
12. Replace and secure panels to the unit. Reconnect
the fuel solenoid.
2. Make sure the spindle is free of dirt and rust. Insert
the capscrews with flat washers through the spindle
base from the shaft side (Fig. 30).
11
1
12
15
2
13
3. Apply never seize to the spindle shaft and keyway.
Slide the clutch rotor (Fig. 31) onto the spindle shaft with
the bracket side towards the spindle base (Fig. 30).
Make sure that the capscrews with the flat washers stay
in the spindle holes.
14
16
7
4
4. Apply never seize to the key. Insert the key into the
keyway. Slide the armature (Fig. 31) onto the shaft and
key (Fig. 30).
8
10
17
9
5. Place the the capscrews through the lock washers
and secure the pulley to the clutch. Place the lock wash-
er and large flat washer onto the capscrew and secure
them to the shaft; torque from 40 to 50 ft–lb (Fig. 30).
5
6
3
6. Place the clutch and spindle up to the flywheel.
Screw one of the capscrews into the flywheel to support
the spindle during alignment. Secure all the capscrews
while pushing the spindle into the flywheel; tighten in a
crisscross pattern (Fig. 30).
Figure 30
1. Long capscrew 7. Clutch
2. Jam nut 8. Capscrew
3. Clutch spindle 9. Lock washer
13. Flat washer
14. Key
15. Wire bracket
16. Pop rivet
17. Flat washer
4. Flywheel
5. Capscrew
6. Flat washer
10. Pulley
11. Capscrew
12. Lock washer
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).
1
2
8. Run the electrical connector through the R–bracket
with the cable harness and reconnect. Make sure the
wires do not make contact with moving parts of the
clutch and that the R–bracket capscrew is tight.
9. Tilt the pump mount and install the belt to the clutch
and pump pulleys. Align the adjusting yoke with the
pump mount holes and secure with the clevis and cotter
pins (Fig. 28). Adjust the belt (see Adjustments section
of Chapter 4 – Hydraulic System).
Figure 31
1. Rotor
2. Armature
10. Secure the U–bracket support to the frame using
the carriage bolts and nuts. Place the two capscrews
Electrical System
Reelmaster 2300–D/2600–D
Page 5 – 32
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Chapter 6
Wheels and Brakes
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hand Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel (3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . . 6
Reelmaster 2300–D/2600–D
Wheels and Brakes
Page 6 – 1
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Specifications
Item
Description
Front tire pressure
12 to 16 PSI, (0.83 to 1.10 bar)
Rear tire pressure
2 ply (Older models)
4 ply (Newer models)
8 to 10 PSI, (0.55 to 0.69 bar)
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)
250 to 400 ft–lb, (34.6 to 55.3 kg–m)
Wheel planetary mounting cap screw torque
Wheels and Brakes
Reelmaster 2300–D/2600–D
Page 6 – 2
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Adjustments
Hand Brake
1. Ensure machine is parked on a level surface with
the cutting units lowered. Ensure engine is off.
3
2. Jack up the front of the machine and support it from
under the frame with jack stands. Remove both front
wheels.
4
1
2
3. Make sure brake is in the OFF position.
Brake Arm
4. Turnby–passvalveontractionpumptotheby–pass
position as described in the General Information section
of Chapter 4 – Hydraulic System.
Lever Distance
5
5. Loosen jam nut (1) on the clevis (2).
6. Adjust brake arm lever distance.
A. Remove cotter pin (3) securing the clevis (2) to
the upper brake arm lever (4). Disconnect clevis
from the upper brake arm lever.
Figure 1
1. Jam nut
2. Clevis
3. Cotter pin
4. Upper brake arm lever
5. Lower brake arm lever
B. Rotateclevisoneturnatatime(clockwise)tode-
crease the distance between the upper brake arm
lever and lower brake arm lever (5).
11. Turn by–pass valve on traction pump to the closed
position as described in the General Information section
of Chapter 4 – Hydraulic System.
C. Install clevis to upper brake arm lever. Install cot-
ter pin to clevis.
12. After any brake adjustment, operate the vehicle at
a low speed (one mph or less) and check that brakes en-
gage equally on both wheels. Readjust as necessary.
D. Repeat steps 6.A. through 6.C. until the brake
shoes firmly contact the brake drums (the wheel will
not turn by hand).
E. When the wheel will not turn by hand, back the
brake shoes off the brake drum. Remove cotter pin
securing top of the clevis to the upper brake arm le-
ver. Disconnect clevis from the 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 (2) to the upper brake arm lever (4).
Install and lock cotter pin (3) into the clevis. Tighten jam
nut (1).
8. Repeat procedure for the other wheel.
9. Checkbrakeadjustmentandadjustagainasneces-
sary.
10. Install wheels.
Reelmaster 2300–D/2600–D
Wheels and Brakes
Page 6 – 3
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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.
7
2
2. Lift rear wheel off the ground using a jack. Secure
back of the frame.
3
3. Remove lug nuts from the wheel hub studs. Slide off
wheel assembly.
8
4. Remove lock nut from the wheel motor shaft.
5
IMPORTANT: DO NOT hit wheel hub with a hammer
during removal or installation. Hammering may
cause damage to the wheel motor.
6
4
5. Mount a wheel puller to the wheel hub studs and re-
move the wheel hub off the wheel motor shaft. Remove
the woodruff key.
1
Figure 2
1. Lug nut
2. Wheel hub stud
3. Wheel assembly
4. Lock nut
5. Wheel motor shaft
6. Wheel hub
7. Woodruff key
8. Wheel motor
6. Remove rust from all parts with a wire brush prior to
installation. Clean all parts. Replace any worn or dam-
aged parts.
Installation
1. Install woodruff key and wheel hub onto the wheel
motor shaft.
2. Install lock nut to wheel motor shaft and tighten to
a torque of 250 to 400 ft–lb (34.6 to 55.3 kg–m).
3. Install wheel assembly and secure the lug nuts to
the wheel hub studs.
4. Tighten lug nuts evenly in a crossing pattern to a
torque of 45 to 65 ft–lb (6.22 to 8.98 kg–m).
Wheels and Brakes
Reelmaster 2300–D/2600–D
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Rear Wheel (2WD)
Removal
1
1. Park machine on a level surface. Ensure engine is
off. Set hand brake and block front wheels.
7
2. Lift rear wheel off the ground using a jack. Secure
back of the frame.
4
2
3. Remove lock nut (1) and flat washer (2) from the
castor axle (3). Slide castor axle from the castor fork (4)
and remove wheel.
3
6
5
4. If the wheel was removed because of bad bearings,
proceed as follows:
7
A. Remove spacer (5) from the rim (6).
B. Pull bearings (7) from the rim.
Installation
Figure 3
1. Lock nut
5. Spacer
6. Rim
7. Bearing
2. Flat washer
3. Castor axle
4. Castor fork
1. Ifthebearings(7)wereremovedfromtherim(6), re-
place with new bearings as follows:
A. Press a new bearing into one side of the rim until
the flange of outer race is flush with the rim.
B. Slidespacer(5)throughthebearinguntiltheend
of the spacer is flush with the outside of the bearing
inner race.
C. Presstheremainingnewbearing(7)intotheoth-
er side of the rim and over the spacer so the flange
of outer race is flush with the rim.
D. The spacer must not extend beyond the inner
race of either bearing.
2. Install wheel and slide castor axle (3) through the
castor fork (4) and wheel.
3. Secure flat washer (2) and lock nut (1) to the castor
axle (3). Torque lock nut from 45 to 65 ft–lb (6.2 to 9.0
kg–m).
Reelmaster 2300–D/2600–D
Wheels and Brakes
Page 6 – 5
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Front Wheel and Brake
7
8
6
5
4
3
9
2
2
45
24
10
46
11
47
48
12, 38
13
11
37
6
49
14
17
16
15
42
47
19
36
18
27
39
35
34
28, 29
26
20
25
1
27
30
33
27
32
21
22
44
23
43
31
17
40
41
LEFT WHEEL SHOWN
Figure 4
1. Lock nut
18. Wheel hub
34. Hex nut
2. Lock nut
19. Brake drum
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
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–ring
3. Flat washer
4. Hex head screw
5. Flange nut
6. Adjusting rod
7. Parking brake assembly
8. Flanged screw
9. Spring
10. Hydraulic fitting
11. Elbow fitting
12. Wheel motor (RH)
13. Lock nut
14. Flat washer
46. O–ring
47. O–ring
48. O–ring
49. Key
31. Clevis pin
32. Brake lever assembly
33. Clevis
15. Grass brake shield
16. Hex head screw
17. Brake shoe
Removal
3. Lift front wheel off the ground using a jack. Block
front and rear of other wheels.
1. Park machine on a level surface. Ensure engine is
off.
4. Remove lug nuts (22) and tire and rim assembly (20
and 21). Remove lock nut (40) from wheel hub (18).
2. Make sure brake is in the OFF position.
Wheels and Brakes
Reelmaster 2300–D/2600–D
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IMPORTANT: DO NOT hit wheel hub (18) with a ham-
mer during removal or installation. Hammering may
cause damage to the wheel motor (12 or 38).
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). Tightenfasten-
ers.
5. Useapullertoremovethewheelhub(18)andbrake
drum (19). Remove the key (49) from the wheel motor
shaft.
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).
6. Remove brake extension springs (42) from brake
shoes (17). Remove brake shoes from brake plate (44).
7. Remove cotter pin (27) from the clevis pin (31). Re-
move clevis pin from the brake lever assembly (32).
Separate brake lever assembly from the clevis (33).
3. Install brake shoes (17) onto the brake plate (44).
Install extension springs (42) into the holes on each end
of the brake shoes. Springs should be installed in oppo-
site directions of each other.
8. Remove hex head screws (16) and lock nuts (13)
holding the brake plate (44) and grass brake shield (15)
to the brake bracket (25).
4. Mount key (49) in the wheel motor shaft, then install
the wheel hub (18) and the brake drum (19) onto the
wheel motor shaft.
IMPORTANT: DO NOT remove brake lever assembly
(32) from the brake plate (44)..
5. Install the lock nut (40) onto the wheel motor shaft
and tighten to torque of 250 to 400 ft–lb (34.6 to 55.3
kg–m).
9. Remove brake plate (44), flat washers (14), and
grass brake shield (15) from the brake bracket (25).
10. Remove rust from all parts with a wire brush prior to
installation. Clean all parts. Inspect brake shoe contact
surfaces of the brake drum for excessive wear. Replace
any worn or damaged parts.
6. Adjust and check brakes.
7. Install tire and wheel assembly (items 20 and 21)
and secure the lug nuts (22) to the wheel hub studs (23).
Tighten lug nuts evenly in a crossing pattern to a torque
of 45 to 65 ft–lb (6.22 to 8.98 kg–m).
Reelmaster 2300–D/2600–D
Wheels and Brakes
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Wheels and Brakes
Reelmaster 2300–D/2600–D
Page 6 – 8
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Chapter 7
Cutting Units
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lift Arm Counterbalance Spring . . . . . . . . . . . . . . . 7
Height–of–Cut and Leveling both Rollers . . . . . . . 8
Bedknife Parallel to Reel . . . . . . . . . . . . . . . . . . . . . 9
Height–of–Cut and Front Roller Level . . . . . . . . . 10
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 11
Greasing 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 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reelmaster 2300–D/2600–D
Page 7 – 1
Cutting Units
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Specifications
Figure 1
MOUNTING: All cutting units are supported by equal
length independent lift arms and are interchangeable to
all three cutting unit positions.
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.
REEL CONSTRUCTION: 5 or 8 blades of 7” (18 cm) di-
ameter welded to 5 stamped steel spiders. Reels are
mounted on greaseable self–aligning ball bearings. The
RM2300–D reel is 27 inches long and the RM2600–D
reel is 32 inches long.
8 blade at 880 reel rpm moving 5 mph (8 km/h)
.75” (19.1 mm) clip.
RM2300–D OPTIONAL EQUIPMENT:
Full Roller Kit
Sectional Roller Kit
Wiehle Roller Kit
Anti–Scalp Roller Kit
Grass Basket Kit
Roller Scraper Kit
Comb Kit
Model No. 03440
Model No. 03445
Model No. 03450
Model No. 03447
Model No. 03443
Part No. 60–9560
Part No. 67–9400
Part No. 93–6915
Part No. 94–3664
HEIGHT OF CUT RANGE:
Floating Cutting Unit – 1/4” to 1–3/4”
(6.4mm to 44.4mm)
Fixed Cutting Unit – 1/2” to 2–5/8”
(12.7 mm to 65.6 mm)
Fixed Kit
Skid Kit
POWER:Reelmotorsalloweasyremovalfromorinstal-
lation onto the cutting unit. Cutting units can be driven
from either end.
RM2600–D OPTIONAL EQUIPMENT:
Sectional Roller Kit
Wiehle Roller Kit
Anti–Scalp Roller Kit
Roller Scraper Kit
Fixed Kit
Model No. 03476
HEIGHT–OF–CUT
&
ROLLER ADJUSTMENT:
Model No. 03475
Model No. 03477
Model No. 03478
Part No. 93–6915
Part No. 94–3664
Height–of–cut adjustment is made with the rear roller by
a quick locating pin and/or threaded micro–adjustment.
Frontrollerpositionisadjustableto3locationstosetcut-
ting unit attitude.
Skid Kit
BEDKNIFE AND BEDBAR ADJUSTMENT: A single
knob screw adjustment for bedknife to reel is located at
the center of the bedbar. The adjustment knob detent al-
lows 0.001 inch bedknife movement for each indexed
position.
CUTTING UNIT LIFT: Hydraulic lift has an automatic
reel shut off. All units are controlled from one lever.
SUSPENSION SYSTEM: Adjustable counterbalance
spring provide for a fully floating suspension. L–I–N–
K–ST cutting unit suspension system provides fore and
aft oscillation. Main center pivot allows side–to–side os-
cillation. With optional Fixed Kit (Part No. 93–6915), cut-
ting units can be locked into fixed (fore/aft) position for
use with skids or anti–scalp rollers.
CLIP FREQUENCY: With variable speed set to maxi-
mum rpm:
5 blade at 880 reel rpm moving 4 mph (6.4 km/h)
.96” (24.4 mm) clip.
Cutting Units
Page 7 – 2
Reelmaster 2300–D/2600–D
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Special Tools
Order special tools from the TORO SPECIAL TOOLS
AND APPLICATIONS 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 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
Reelmaster 2300–D/2600–D
Page 7 – 3
Cutting Units
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Bedknife Screw Tool
This screwdriver–type bit is made to fit Toro bedknife at-
taching screws. Use this bit with a torque wrench to se-
cure the bedknife to the bedbar.
DO NOT use and air or manual impact wrench with this
tool.
Figure 4
Cutting Units
Page 7 – 4
Reelmaster 2300–D/2600–D
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Troubleshooting
There are a number of factors that can contribute to un-
satisfactory quality of cut, some of which may be turf
conditions. Turf conditions such as excessive thatch,
“sponginess” or attempting to cut off too much grass
height may not always be overcome by adjusting the
machine. It is important to remember that the lower the
height of cut, the more critical these factors are.
Remember that the “effective” or actual height of cut de-
pends on cutting unit weight and turf conditions. Effec-
tive height of cut will be different than the bench set
height of cut.
Factors That Can Affect Quality of Cut
Factor
Possible Problem/Correction
1. Engine maximum governed speed.
Check maximum governed engine speed. Adjust
speed to specifications if necessary. If engine is not
running at specified maximum governed RPM, reel
speed settings may not match ground speed.
2. Reel speed and ground speed.
Adjust reel speed to setting shown on REEL SPEED
SETTINGS graph for the number of reel blades (5 or 8)
and the desired ground speed (see Operator”s
Manual).
All reels should rotate at about the same speed. All
cutting units should have equal bedknife to reel
contact. If checking RPM, do not run reel too long
without cutting grass, or bedknife and/or reel may
overheat and “rifle”.
See other items in Troubleshooting 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 compensate for different turf
conditions. Decreased counter balance tension will
help keep the cutting units on the ground when
mowing at higher speeds, and it helps maintain a
uniform height of cut in rough conditions or in areas of
thatch build up. Increased counterbalance tension will
improve traction by increasing weight on the front tires.
Also, the spring may be adjusted at the cutting unit
pivot point. Raising the spring at the lift tab decreases
the cutting unit weight at the outboard end. Lowering
the spring at the lift tab increases the cutting unit
weight at the outboard end.
NOTE: Decreased counter balance tension may lower
the actual or ”effective” height of cut.
4. Tire pressure.
Check each tire’s pressure. Adjust to pressures
specified in Specifications section of Chapter 6 –
Wheels and Brakes.
Reelmaster 2300–D/2600–D
Page 7 – 5
Cutting Units
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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 corrected by tightening bedknife to
reel contact. Grind reel to remove taper and/or rifling
(grooved or wavy appearance). Grind bedknife to
sharpen and/or remove rifling. (Most common cause of
rifling is bedknife to reel contact that is too tight.)
NOTE: New bedknife must be ground or backlapped
after installing on bedbar.
7. Bedknife to reel adjustment.
Check bedknife to reel contact daily. Bedknife must
have light contact all across reel. No contact will cause
cutting edges to become dull. Excessive contact
accelerates wear; quality of cut may be adversely
affected.
Slightly dull cutting edges may be corrected by
backlapping, Excessively dull cutting edges must be
corrected by grinding the reel and bedknife.
8. Front roller position.
9. Rear roller parallel to reel.
10. Height of cut.
Make sure front rollers on all cutting units are in the
same position.
Rear roller must be set so that it is parallel with the reel
before setting height of cut.
Make sure all cutting units are set at the same height
of cut. Set units as specified in the Operator’s Manual.
11. Bedbar stability.
Check bedbar end bushings, adjuster pivot bushings
and nylon flanged bushings for wear or damage.
Check adjustment knob to make sure detent holds
adjustment.
12. Number of reel blades.
Use cutting unit model with correct number of blades
for clip frequency and optimum quality of cut range
(see Specifications).
13. Cutting unit alignment and ground following.
14. Roller condition.
Check lift arms and cutting unit pivot linkages for wear,
damage, binding, or bent pivot pins.
All rollers should rotate freely. Make sure bearings are
properly lubricated. Replace bearings if worn
damaged.
Cutting Units
Page 7 – 6
Reelmaster 2300–D/2600–D
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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
WARNING
DO NOT REMOVE THESE PINS
Use caution when tensioning springs as
they are under heavy load. Do not move
lift lever, cutting units can lower without
the engine running.
3
2
1. Raise cutting units to relieve tension on the counter-
balance springs.
2. Makesuremachineisshutoffandparkingbrake
is set.
3. Removecotterpinandclevispinsecuringthespring
shackle to the counterbalance arm. Do not remove the
other clevis pin .
4
1
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
2. Spring Shackle
3. Counterbalance arm
4. Counterbalance spring
Counterbalance Arm
Hole Position
Application
Middle Hole
Second Hole from Top
Top Hole
for 5 blade reels
for 8 blade reels without
baskets
for 8 blade reels with
baskets
IMPORTANT: These are recommended settings.
Readjust spring positions to attain optimum per-
formance. By raising spring locations on counter-
balance arms, cutting unit weight on ground is
reduced and traction is increased.
5. Reinstall clevis pin through the desired hole, then
attach cotter pin.
Reelmaster 2300–D/2600–D
Page 7 – 7
Cutting Units
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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.
6
1. Position cutting unit on a flat level table or board.
5/8”
2. Slightly loosen (crack) nut securing each roller
bracket to the angle bracket.
8
3. For the rear roller, adjust support cap screw to
achieve 5/8” +1/16 (15.9 mm "1.6) dimension between
both Height–of–Cut supports and rear roller brackets.
5
4
2
1”
4. For the front roller, adjust support cap screw to
achieve 1” + 1/16 (25.4 mm "1.6) dimension between
both Height–of–Cut supports and front roller brackets.
7
5. For the rear roller, remove hairpin cotters securing
rear Height–of–Cut pins and reinstall in the 1/2” setting
as indicated on the rear Height–of–Cut plate.
1
4
6. For the front roller, remove hairpin cotters securing
front Height–of–Cut pins and reinstall in the 1/4” setting
as indicated on the front Height–of–Cut plate to allow
clearance between front roller and table.
3
Figure 6
1. Nut
5. Support capscrew
6. Height–of–Cut support
7. Height–of–Cut pins
8. Height–of Cut plate
2. Rear roller bracket
3. Front roller bracket
4. Angle bracket
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 of roller. The paper
should not fit between the roller and the table.
9. Level rear roller by adjusting the appropriate sup-
port cap screw on rear roller supports until the roller is
parallel and the entire length of roller contacts the table.
A piece of paper inserted between the roller and the
table should not fit.
10. When roller is level, adjust both rollers to desired
Height–of–Cut with pins. Tighten nuts securing roller
brackets and replace hairpin cotters to the Height of
cut pins.
Cutting Units
Page 7 – 8
Reelmaster 2300–D/2600–D
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Bedknife Parallel to Reel (Fig. 7 through Fig. 9)
1. Removeanyreelcontactbyturningthebedknifead-
justment knob counterclockwise (Fig. 7). Tip 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 and bedknife. While slowly rotating
reel into bedknife, turn bedknife adjusting knob clock-
wise, one click at a time until paper is pinched lightly,
which results in a slight drag when paper is pulled.
3. 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 than
two clicks beyond first contact of reel bedknife (Fig.9).
Figure 8
6. Tighten nuts and carriage bolts and verify adjust-
ment.
1
3
2
1
Figure 7
1. Bedknife adjusting screw
Figure 9
1. Carriage bolts
3. Adjustment nuts
2. Bedbar adjuster
Reelmaster 2300–D/2600–D
Page 7 – 9
Cutting Units
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Height–of–Cut and Front Roller Level
1. On gauge bar, set head of screw to desired Height–
of–Cut. This measurement is from bar face to underside
of screw head. Gauge bar (Toro Part No. 13–8199) may
be obtained from your local Toro Distributor.
2
4
3
2. Slightly loosen (crack) nuts securing each front roll-
er bracket to the angle bracket.
5
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.
1
6
Figure 10
1. Gauge bar
5. Front roller support cap
screw
6. Bedknife
2. Front roller bracket nut
3. Front roller bracket
4. Angle bracket
Cutting Units
Page 7 – 10
Reelmaster 2300–D/2600–D
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Service and Repairs
Greasing Bearings, Bushings, and Pivot Points (Fig. 11 and Fig. 12)
Note: Each cutting unit has (8) grease fittings (with
optional front roller installed) that must be lubricated
regularly with No. 2 General Purpose Lithium Base
EARLIER UNITS
Grease.
Note: On earlier production cutting units the grease
fittings for the reels are locate on the inside of the cutting
unit. Later production 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.
LATER UNITS
Figure 12
B. Reel bearings (inside sideplate), (2) and front
and rear rollers (2 ea.) (Fig. 12). Grease these fit-
tings every 8 hours.
IMPORTANT: Lubricating cutting units immediately af-
ter washing helps purge water out of bearings and in-
creases bearing life.
2. Wipe each grease fitting with a clean rag.
3. Apply grease until pressure is felt against the han-
dle.
4. Wipe excess grease away.
Figure 11
Reelmaster 2300–D/2600–D
Page 7 – 11
Cutting Units
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Backlapping
2
1
DANGER
TO AVOID PERSONAL INJURY OR
DEATH:
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, stop engine before
Figure 13
attempting to clear reel.
1. Backlap knob
2. Reel speed knob
D Reel motors are connected in series,
moving one motor moves the other two.
7. To make an adjustment to the cutting units while
backlapping, turn reels OFF by pushing in on the knob
on instrument panel and turning the engine OFF. After
adjustments have been completed, repeat steps 4–6.
1. Position machine on a clean, level surface, lower
the cutting units, stop the engine, engage parking brake
and remove key from the ignition switch.
8. When backlap operation is completed, rotate back-
lap knob counter–clockwise to the MOW position, set
reel speed controls to the desired mowing setting and
wash all lapping compound off the cutting units.
2. Unlatch and raise hood to expose the controls.
3. Rotate backlap knob, on valve block, clockwise to
backlap position. Rotate reel speed knob to position 1.
Note: Additional instructions and procedures on
Backlapping are available in the TORO Sharpening
Reel & Rotary Mowers Manual Form No. 80–300SC.
4. Make initial reel to bedknife adjustments appropri-
ate for backlapping on all cutting units. Start engine and
set engine to low idle speed.
Note: For a better cutting edge, run a file across the
front face of the bedknife when the lapping operation is
completed. This will remove any burrs or rough edges
that may have built up on the cutting edge.
5. Engage reels by 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.
Cutting Units
Page 7 – 12
Reelmaster 2300–D/2600–D
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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.
HOUSING
FACE
3. Position the hydraulic motor away from the cutting
unit prior to removing or working on the cutting unit.
2
Inspection
1. Inspect spider coupling for wear. Replace worn cou-
pling with new one.
2. Check coupling inside bearing housing. If coupling
is loose remove and check for worn threads. Replace
coupling if threads are worn. Reinstall coupling (see
Reel Removal and Bearing Replacement, Install Reel).
3
4
5
1
Installation
Figure 14
1. Capscrew
2. Hydraulic motor
3. Bearing housing
4. Spider couping
5. O–ring
Note: The cutting unit can be installed with the hy-
draulic motor driving the 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 of the housing to form a seal. Mount hydraulic
motor to the bearing housing. Secure motor with the
two capscrews.
B. On models with O–rings, replace if necessary.
Make sure O–ring is on the front plate of the motor.
Mount hydraulic motor to the bearing housing. Se-
cure motor with the two capscrews.
3. Grease bearing housing sufficiently to fill housing
with grease (see Greasing Bearings, Bushings, and Piv-
ot Points).
Reelmaster 2300–D/2600–D
Page 7 – 13
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Cutting Unit Removal and Installation (Fig. 15 through Fig. 18)
Remove Cutting Unit
3
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.
2
4
WARNING
INSERT
BREAKER BAR
1
Use caution when relieving tension or
tensioning springs as they are under
heavy load. Do not move lift lever, cutting
Figure 15
1. Bottom capscrew
2. Top capscrew
3. Counterbalance arm
4. Counterbalance spring
units can lower without the engine run-
ning.
3. Loosen top cap screw. Put breaker bar in the square
2
hole and hold tension of spring (Fig. 15).
3
4. Removebottomcapscrewandslowlyrelievethere-
maining tension on the spring (Fig. 15).
5. Remove capscrews, lock washers, and lift tab se-
curing the spring to the carrier frame. Remove spring
from the carrier frame (Fig. 16).
1
4
6. Note from which hole on the lift tab the spring is re-
moved from.
Note: On rear cutting unit, also remove the thrust
washer. The thrust washer is located between the rear
of the carrier frame and the flat washer.
Figure 16
1. Capscrew and lock washer 3. Spring
2. Lift tab
4. Carrier frame
7. Remove flange head cap screw and flat washer
from the pivot rod (Fig. 17).
8. Disconnect tipper chain on front carrier frame (Fig.
18). Slide carrier frame off the pivot rod.
Install Cutting Unit
1. Place thrust washer on pivot rod (front cutting units
only), and slide carrier frame onto pivot rod (Fig. 17).
3
Note: On rear cutting unit, reinstall thrust washer be-
tween the rear of the carrier frame and the flat washer.
4
1
2. Secure flat washer and flange head cap screw onto
pivot rod (Fig. 17).
3. Connect tipper chain to the front carrier frame (Fig.
18).
2
Figure 17
1. Flange head capscrew
2. Flat washer
3. Pivot rod
4. Thrust washer
Cutting Units
Page 7 – 14
Reelmaster 2300–D/2600–D
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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.
1
RM2600 TIPPER CHAIN
IS CONNECTED TO THE
BOTTOM OF THE FRAME
5. Secure counterbalance spring and lift tab to the car-
rier frame with the capscrews and lock washers (Fig.
16).
2
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).
7. Secure bottom of counter balance arm to frame with
the bottom capscrew. Tighten top cap screw (Fig. 15)
Figure 18
1. Tipper chain
2. Carrier frame
Reelmaster 2300–D/2600–D
Page 7 – 15
Cutting Units
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Bedbar Removal and Installation (Fig. 19 through Fig. 21)
Bedbar Removal
2
1. Turn bedknife adjusting handle to loosen bedknife
to reel contact (Fig. 19).
3
2. Remove both jam nuts and hex socket set screws
from the bedbar yoke (Fig. 19)
3. Unscrew adjusting handle (left–hand threaded) un-
til it is removed from the cutting unit (Fig. 19).
6
4. Loosen both adjusting lock nuts on the adjusting
housing (Fig. 20).
1
4
5. Remove both carriage bolts and nuts from the ad-
justing housing (Fig. 20).
5
6. Remove both carriage bolts and nuts from the bed-
bar housing. Remove bedbar from the cutting unit (Fig.
21).
Figure 19
7. Remove capscrew, lock washer, flat washer, and
spacer from the end of the bedbar (Fig. 21).
1. Adjusting handle
2. Jam nut
3. Hex socket set screw
4. Bedbar yoke
5. Cutting unit
6. Pivot hub
8. Remove adjusting housing and bedbar housing
from the bed bar. Remove bedbar washer (Fig. 21).
9. Sharpen or replace bedknife as necessary (see
Bedknife Replacement and Grinding).
Bedbar Installation
1. Inspect flanged bushings and bushing assemblies
for wear; replace if necessary (Fig. 21).
2. Clean and apply anti–seize lubricant to both bedbar
pivots. Install bedbar washer on the bedbar (Fig. 21)
1
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).
2
3
4. Install bedbar assembly on the cutting unit.
5. Secure bedbar housing to the cutting unit with both
carriage bolts and nuts (Fig. 21). Secure adjusting hous-
ing to the cutting unit with both carriage bolts and nuts
(Fig. 20).
Figure 20
1. Adjusting lock nut
2. Adjusting housing
3. Carriage bolt and nut
9. Tighten jam nuts onto the hex socket set screws.
The handle should be centered within the bedbar yoke.
The handle should turn freely with a good solid clicking
action.
6. Tighten both adjusting lock nuts on the adjusting
housing (Fig. 20).
7. Install adjusting handle on the cutting unit by screw-
ing it in (Fig. 19).
10. Adjust bedknife to reel (see Bedknife to Parallel to
Reel Adjustment).
8. Apply Never Seize to both hex socket set screws.
Seat both hex socket set screws into the bedbar yoke
and tapered seats of the pivot hub with a slight preload
(Fig. 19).
Cutting Units
Page 7 – 16
Reelmaster 2300–D/2600–D
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3
5
6
13
7
1
10
4
12
2
9
8
10
11
9
Figure 21
1. Carriage bolt and nut
2. Bedbar housing
3. Bedbar
6. Flat washer
7. Spacer
8. Bedbar washer
9. Adjusting housing
10. Bushing assembly
11. Flanged bushing
12. Bedknife screw
13. Bedknife
4. Capscrew
5. Lock washer
Reelmaster 2300–D/2600–D
Page 7 – 17
Cutting Units
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Bedknife Replacement and Grinding (Fig. 22 and Fig. 23)
1. Remove bedbar from cutting unit (see Bedbar Re-
moval and Installation).
Use a torque wrench
and bedknife screw tool
2. Remove bedknife screws and remove bedknife.
3. Remove all rust, scale and corrosion from bedbar
surface before installing new bedknife.
4. Install new bedknife:
A. Make sure bedbar threads are clean.
B. Use new screws. Apply anti–seize lubricant to
screw threads before installing.
IMPORTANT: DO NOT use an impact wrench .
C. Tighten screws to a torque of 250 to 300 in–lb
(288 to 345 kg–cm) working from the center toward
each end of the bedbar (Fig. 22).
9
7
5
3
1
2
4
6
8
10
5. Since there can be variations in the mounting sur-
face of the bedbar, a new bedknife will not be perfectly
flat after it is installed. Because of this, it is necessary to
backlap or grind a new bedknife after installing it to the
bedbar. Follow the existing angle that was ground into
the bedknife and grind only enough to make sure the top
surface is true.
Tighten screws to a torque of 250 to 300 in–lb
(288 to 345 kg–cm) starting in the middle of the
bedknife.
Figure 22
Regrinding Bedknife
Remove bedbar / bedknife assembly from cutting unit
before attempting to regrind a used bedknife (see Bed-
bar Removal and Installation).
Top Face
Relief Angle
Note: When grinding, be careful to not overheat the
bedknife. Remove small amounts of material with each
pass of the grinder.
Front
Face
Front Angle
Figure 23
Note: If the height of cut is 1/2–inch or lower on the
cutting unit, the front angle can be increased to 30_ for
improved performance.
Bedknife Regrinding Specifications
Relief Angle
5_
3_ to 6_
15_ (see Note above)
13_ to 17_
Relief Angle Range
Front Angle
Front Angle Range
Cutting Units
Page 7 – 18
Reelmaster 2300–D/2600–D
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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
2. Removebothlocknutsfromthecapscrewssecuring
each angle bracket to the cutting unit.
1
3. Remove capscrews from both angle brackets and
the cutting unit.
5
4. Separate roller assembly, roller brackets, and angle
brackets from the cutting unit.
6
7
4
5. Remove roller brackets from the roller assembly.
10
3
Roller Installation
8
11
9
1. Inspect flanged bushing and bushings for wear; re-
place if necessary.
Figure 24
1. Height–of–cut pin
2. Hairpin cotter
3. Roller bracket
4. Lock nut
7. Front roller assembly
8. Flanged bushing
9. Bushing
10. Carriage bolt
11. Lock nut
Note: The flanged end of the flanged bushing must
face inside toward the roller when the roller bracket is
installed onto the cutting unit.
5. Capscrew
6. Angle bracket
Note: A soft hammer may be needed to tap the roller
bracket into position on the hex adjustment nut of the
roller.
6. Mount roller, roller brackets, and angle brackets to
the cutting unit. Secure roller brackets and angle brack-
ets to the cutting unit with capscrews.
2. Insert smaller diameter roller shaft into the flanged
bushing, bushing, and roller bracket. Make sure hex of
the roller bracket mates with the hex adjustment nut
on the roller.
7. Install both height–of–cut pins and hairpin cotters.
8. Install both locknuts to the capscrews, and secure
each angle bracket to the cutting unit.
3. Insert the other end of the roller shaft into the other
bushing and roller bracket. Make sure hex of the roller
bracket mates with the hex adjustment nut on the
roller.
9. Adjust roller level (see Height–of–Cut and Leveling
Both Rollers).
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 instal-
ling them onto the cutting unit. If necessary after bearing
adjustment, align roller brackets as follows:
A. Remove roller bracket on the side with the
flanged bushing.
B. Replace roller bracket so it is aligned to within
" one hex flat of the roller adjustment nut.
C. Align both roller brackets.
Reelmaster 2300–D/2600–D
Page 7 – 19
Cutting Units
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Roller Bearing and Seal Replacement
1
5
7
8
9
2
4
3
4
3
6
2
5
9
1
8
7
Figure 25
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
Note: A rear (full) roller is shown. Bearing and seal
configurations are the same for full and wiehle rollers.
The wiehle roller does not have the a inner seal and
shim washer. The shim washer is not used on all full roll-
ers.
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 seals and shim washers (if installed).
7. Remove both bearing cones
Remove Seals and Bearings
1. Clean inside roller around both adjusting nuts and
roller shaft ends. Both areas should be free of dirt and
debris.
Note: An electric arc welder can be used to shrink the
bearing cup to simplify its removal. Only a small arc in
one location on the cup is required.
2. Remove an adjusting nut from one end of the roller
shaft.
8. Remove both bearing cups from the roller. Remove
both inner seals (if installed).
3. Keep roller level and slide the shaft with the remain-
ing adjusting nut out of the roller.
9. Discard seals and bearings.
Cutting Units
Page 7 – 20 Reelmaster 2300–D/2600–D
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Install New Seals and Bearings
7. Install a bearing cone into the bearing cup at each
end of the roller shaft. Then install shim washer if it was
previously installed.
1. Make sure all parts are clean prior to installing bear-
ings and seals.
8. Install outer seal onto each end of the roller shaft.
Make sure hard surface of seal faces out.
2. Install inner seals onto both ends of the roller shaft
(if previously installed).
9. Slide the roller shaft through the roller.
3. Press both bearing cups into the roller. Make sure
narrow end of taper faces inside of the roller.
10. Install remaining adjustment nut and tighten it to
seat both bearings. Roller should be rotated to seat both
bearings.
4. Keep roller level and secured roller in a vise.
5. If assembling a full roller, fill the inside of roller tube
with 6 oz. of SAE 90 oil.
11. Back off both adjustment nuts to allow the roller to
spinfreely. Tightenbothadjustmentnutsagaintoamax-
imum of 5 in–lb (5.8 kg–cm) rolling torque with no bear-
ing end play.
6. Pack both bearing cones with No. 2 general pur-
pose lithium base grease.
12. Grease both bearings (see Greasing Bearings,
Bushings, and Pivot Points ).
Reelmaster 2300–D/2600–D
Page 7 – 21
Cutting Units
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Reel Removal and Bearing Replacement
8
7
2
5
COVER GASKET
NOT SHOWN
6
8
GROOVE SHOWN
OUT OF POSITION
2
9
LEFT–HAND SIDE
7
3
4
FRONT
Figure 26
4. Male coupling (LH)
5. Male coupling (RH)
6. Capscrew
1. Cutting unit
2. Capscrew
3. Bearing cover
7. Bearing housing
8. Bearing
9. Reel
Remove Reel
6. Remove capscrews from both bearing housings.
Pull bearing housings and bearings from reel.
1. Remove bedbar assembly from cutting unit (see
Bedbar Removal and Installation).
7. Rotate bearings within the bearing housings, and
remove bearings from both bearing housings through
the loading grooves.
2. Remove front roller from cutting unit (see Roller Re-
moval and Installation).
8. Remove reel from cutting unit.
3. Remove capscrews, bearing cover, and cover gas-
ket from the bearing housing.
Inspect Reel
Note: A 3/8–inch drive ratchet with an extension will
fit into the square hole of the coupling.
1. Replace reel if the diameter has decreased to the
service limit (see Reel Grinding Specification in Prepar-
ing Reel For Grinding)
4. Unscrew male coupling (LH) from the reel. This
coupling is left hand threaded.
2. Replace reel if blades are bent or cracked.
5. Unscrew male coupling (RH) from the reel. This
coupling is right hand threaded.
3. Check for a bent reel shaft by placing the reel shaft
ends in V–blocks. Replace reel if the reel shaft is bent.
IMPORTANT: Support reel to prevent it from dropping
when the bearing housings are removed.
Cutting Units
Page 7 – 22
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Install Reel
1. Inspect bearings and replace if worn or damaged.
8. Secure bearing housings and bearings on the reel
shaftendsandcuttingunitwiththecapscrews. Alternate
evenly between capscrews when when tightening.
2. Make sure bearing seating surfaces and threads on
reel shaft ends are clean. Apply anti–seize lubricant to
both bearing seating surfaces.
9. Degrease threaded end of male couplings and reel
shaft. Make sure grease is completely removed
3. Align reel inside the cutting unit with the bearing
housing holes. The reel must be positioned so that the
grooved end of the shaft (left–hand threads) is on the left
side of the cutting unit (Fig. 26).
A. Apply removable Loctite 242 or equivalent to the
threads.
B. Do not get Loctite on the bearing seal.
4. Clean inside of the bearing housing before instal-
ling.
10. Screw male coupling (RH) from the reel. This cou-
pling is right hand threaded.
5. Install bearing into bearing housing as follows:
A. Load bearing through loading grooves.
11. Screw male coupling (LH) from the reel. This cou-
pling is left hand threaded.
B. Position bearing so its outer grease holes will be
90_ to the loading grooves.
12. Torque both couplings from 55 to 65 ft–lb
(7.6 to 9.0 kg–m).
13. Install front roller to cutting unit (see Roller Removal
and Installation).
C. Rotate bearing inside of the housing so the ex-
tended part of the inner race is facing the inside of
the housing.
14. Install bedbar assembly to cutting unit (see Bedbar
Removal and Installation).
6. Side the bearings and bearing housings onto the
reel shaft.
15. Complete cutting unit set–up and adjustment se-
quence (see Adjustments section).
7. On earlier production models, make sure bearing
housings are installed with the grease fittings pointing to
the front of the cutting unit.
16. Grease both bearings (see Greasing Bearings,
Bushings, and Pivot Points ).
Reelmaster 2300–D/2600–D
Page 7 – 23
Cutting Units
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Preparing a Reel for Grinding
Note: Check to make sure reel bearings are in good
3. After completing grinding process:
condition and properly adjusted before grinding reel.
A. Install front roller and brackets (see Roller Re-
moval and Installation).
1. Remove bedbar assembly (see Bedbar Removal
and Installation).
B. Install bedbar assembly (see Bedbar Removal
and Installation).
2. Remove front roller and brackets (see Roller Re-
moval and Installation).
C. Complete cutting unit set–up and adjustment se-
quence (see Adjustments section).
Note: Most reel grinders require that the rear roller
assembly be mounted to the cutting unit for proper sup-
port in the reel grinder. The rear roller must be parallel
to the reel shaft to remove taper when grinding, or the
cutting unit must be aligned so the grinding wheel will
travel parallel to the reel shaft. This will result in the the
reel being ground to the desired cylinder shape.
Reel Grinding Specifications
Nominal Reel Diameter
Service Limit Reel Diameter
Blade Relief Angle
Relief Angle Range
Blade Land Width
7I (178 mm)
6.2I (158 mm)
30_
20_ to 40_
Note: When grinding, be careful to not overheat the
reel blades. Remove small amounts of material with
each pass of the grinder.
.060I (1.5 mm)
.050I to .090I (1.3 to 2.3 mm)
.060I (1.5 mm)
Land Width Range
Max. Reel Taper
BLADE RELIEF ANGLE
REEL DIAMETER
BLADE
LAND
WIDTH
D
2
D
1
REEL DIAMETER TAPER = D – D
1
2
Figure 27
Cutting Units
Page 7 – 24
Reelmaster 2300–D/2600–D
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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
6
4
2. Remove lock nuts, capscrews, washers, and both
links from the cutting unit (Fig. 28).
3. Align fixed side plate with holes on the cutting unit
(Fig. 29).
1
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
3
6. Fasten new height–of–cut plate to the cutting unit
with new pop rivets (Fig. 29).
5
Figure 28
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
5
1
6
3
4
2
Figure 29
1. Fixed side plate
2. Capscrews
3. Washers
4. Flanged lock nut
5. Height–of–cut plate
6. Pop rivet
Reelmaster 2300–D/2600–D
Page 7 – 25
Cutting Units
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Skid Kit Installation
1. Remove front roller from the cutting unit (see Roller
Removal and Installation).
2. Align skid slots with the angle bracket holes on the
cutting unit.
3. Secure skid to the cutting unit with both flange head
screws, flat washers, and lock nuts.
4. Adjust skid height as necessary by loosening lock
nuts and flange head screws, then retighten fasteners.
5
4
2
3
1
Figure 30
1. Skid
2. Angle bracket holes
3. Flange head screw
4. Flat washer
5. Lock nut
Cutting Units
Page 7 – 26
Reelmaster 2300–D/2600–D
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