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Toro 2600D, 2300-D service manual This page is blank

Models: 2600D 2300-D

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Toro 2600D, 2300-D service manual This page is blank

Contents

Reelmaster 2300±D/2600±D Service ManualPreface The Toro Company ± 1996This page is blank Chapter 1 ± Safety Table Of ContentsSafety Chapter 2 ± Product Records and ManualsThis page is blank Table of Contents SafetySafety Instructions ChapterSafety While OperatingPage 1 ± Reelmaster 2300±D/2600±DSafety Maintenance and ServiceSafety Page 1 ± 3 Rev. AWARNING! Spring Loaded Mechanism Read Disassembly Procedure Safety and Instruction DecalsSafety ON INSTRUMENT PANEL Part No. 94±4985 ON UNDER SEAT Part No. 93±6903Safety SafetyA &!% # !## * % % A*$% Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D SafetyPage 1 ± Product Records Product Records and ManualsTable of Contents ChapterProduct Records and Manuals Equivalents and ConversionsPage 2 ± Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Torque SpecificationsPage 2 ± Product Records and ManualsProduct Records and Manuals Maintenance Interval ChartPage 2 ± Reelmaster 2300±D/2600±DREELMASTER 2300±D/2600±D EQUIPMENT OPERATION AND SERVICE HISTORY REPORT forMaintenance Procedure REELMASTERR 2300±D/2600±D Maintenance ScheduleMaintenance Interval & Service Minimum Recommended Maintenance IntervalsDaily Maintenance duplicate this page for routine use REELMASTERR2300±D/2600±D Daily Maintenance Check ListMaintenance Daily Maintenance Check For Week OfA± Service every 50 hours A B C D OtherD ± Service every 400 hours B ± Service every 100 hoursTable of Contents EngineChapter EngineEngine IntroductionPage 3 ± Reelmaster 2300±D/2600±DEngine SpecificationsReelmaster 2300±D/2600±D Page 3 ±Special Tools Filter CleanerDiesel Engine Compression Test Kit Nozzle TesterEngine Nozzle Test AdapterReelmaster 2300±D/2600±D Page 3 ±Fuel Shutoff Valves General InformationEngine Page 3 ±Alternator Belt AdjustmentsEngine Reelmaster 2300±D/2600±DEngine Throttle LinkagePage 3 ± Reelmaster 2300±D/2600±DBleeding the Fuel System Service and RepairsDANGER Reelmaster 2300±D/2600±DUse eye protection such as goggles when using compressed air Air CleanerWashing Method Compressed Air MethodUse eye protection such as goggles when using compressed air Cleaning the Radiator and ScreenEngine Reelmaster 2300±D/2600±DChecking the Cooling System Changing the Engine Oil and Filterwhen the radiator cap is removed. Burns when the radiator or engine is hotEngine Engine RemovalReelmaster 2300±D/2600±D Page 3 ±CONNECTED TO RIGHTAIR FILTER HOSE 22 LHEngine 10. Disconnect hoses from engine FigReelmaster 2300±D/2600±D Page 3 ±Engine 14. Disconnect electrical connections FigPage 3 ± Reelmaster 2300±D/2600±DEngine 17. Remove engine FigReelmaster 2300±D/2600±D Page 3 ±Engine Engine ReinstallationPage 3 ± Reelmaster 2300±D/2600±DEngine 7. Reconnect throttle cable Fig A. Run throttle cable to engineReelmaster 2300±D/2600±D Page 3 ±Reelmaster 2300±D/2600±D EnginePage 3 ± Table of Contents Hydraulic SystemChapter Reelmaster 2300±D/2600±DHydraulic System SpecificationsPage 4 ± Reelmaster 2300±D/2600±DHydraulic Hoses Hydraulic Fitting InstallationGeneral Information O±Ring Face SealSAE Straight Thread O±Ring Port ± Adjustable SAE Straight Thread O±Ring Port ± Non±adjustableHydraulic System Page 4 ±ISO type 46/68 anti±wear hydraulic fluid Checking the Hydraulic System FluidGroup 2 Hydraulic Fluid Biodegradable ISO VG 32/46 anti±wear hydraulic fluidPushing or Towing the Traction Unit Changing the Hydraulic System Fluid and FilterHydraulic System Page 4 ±Hydraulic Schematic Hydraulic SchematicReelmaster 2300±D/2600±D Page 4 ±Raise Cutting Units Hydraulic Flow DiagramsHydraulic System Page 4 ±Reelmaster 2300±D/2600±D Raise Cutting UnitsPage 4 ± Hydraulic SystemHydraulic System Traction ForwardPage 4 ± Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D WHEEL MOTOR Traction ForwardPage 4 ± Hydraulic System Solenoid S1 is shownHydraulic System Traction ReversePage 4 ± Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Traction ReversePage 4 ± Hydraulic System Solenoid S1 is shownReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Page 4 ± Hydraulic System Reelmaster 2300±D/2600±DSolenoid S1 is shown energized Valve MD1 is selected to mowHydraulic Tester ± Pressure and Flow Hydraulic Pressure Test KitSpecial Tools Hydraulic SystemProblem TroubleshootingPossible Cause Reelmaster 2300±D/2600±DPossible Cause ProblemHydraulic System Page 4 ±Before Performing Hydraulic Tests TestingReelmaster 2300±D/2600±D Page 4 ±Hydraulic System TEST NO. 1 Traction Pump FlowPage 4 ± Reelmaster 2300±D/2600±DUse extreme caution when taking gauge Procedure for Traction Pump Flow Checkreadings. The front tire on the ground will be trying to move the machine forwardHydraulic System TEST NO. 2 Charge Pump Flow and Implement Relief PressurePage 4 ± Reelmaster 2300±D/2600±DProcedure for Implement Relief Check Procedure for Charge Pump Flow CheckDo not allow charge pressure to exceed 650 PSI Example CalculationHydraulic System TEST NO. 3 Charge Pump Relief PressurePage 4 ± Reelmaster 2300±D/2600±DSystem Procedure for Charge Pump Relief CheckReelmaster 2300±D/2600±D Page 4 ±Hydraulic System TEST NO. 4 Reel Drive Pump EfficiencyPage 4 ± Reelmaster 2300±D/2600±D100 RPM. Do not engage the cutting units Procedure for Reel Drive Pump Efficiency CheckSystem Reelmaster 2300±D/2600±DHigh Pressure Low Pressure Return or Suction Flow TEST NO. 5 Manifold Relief Valve PressureHydraulic System Page 4 ±Reelmaster 2300±D/2600±D Procedure for Manifold Relief Valve Pressure CheckPage 4 ± Hydraulic SystemHydraulic System TEST NO. 6 Cross±over Relief PressuresPage 4 ± Reelmaster 2300±D/2600±D± Cutting Units and Reel Motor in the Service and Repair section Procedure for Cross±over Relief Pressures CheckMotor Position Pressure Range PSIHydraulic System TEST NO. 7 Reel Motor Case DrainPage 4 ± Reelmaster 2300±D/2600±DMotor Procedure for Reel Motor Case Drain CheckManifold Port Manifold PortAdjustments Transmission for NeutralHydraulic System Page 4 ±Traction Pedal Damper Fig Traction PedalReelmaster 2300±D/2600±D Page 4 ±Hydraulic System Hydraulic Pump Drive BeltPage 4 ± Reelmaster 2300±D/2600±DService and Repairs Traction/Charge PumpReelmaster 2300±D/2600±D Page 4 ±Removal Fig Installation FigHydraulic System Page 4 ±3. Remove O±ring 26 from the charge pump adapter assembly Disassembly FigReelmaster 2300±D/2600±D Page 4 ±Hydraulic System B. Remove spring and cup poppet from the charge pump adapter assemblyPage 4 ± Reelmaster 2300±D/2600±DInspection Use eye protection such as goggles when using compressed airReelmaster 2300±D/2600±D Page 4 ±Hydraulic System Reassembly FigPage 4 ± Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D 15. Install new O±rings 38 and 39 and valve assemblyPage 4 ± Hydraulic SystemFront Wheel Installation Fig Wheel MotorFront Wheel Removal Fig Hydraulic System3WD Rear Wheel Removal Fig Rear Wheel Installation FigSystem Reelmaster 2300±D/2600±DLEFT HAND MOTOR ONLY Disassembly FigHydraulic System Page 4 ±5. Remove commutator ring Use eye protection such as goggles when using compressed airReelmaster 2300±D/2600±D Page 4 ±Inspection Fig Use eye protection such as goggles when using compressed airHydraulic System Page 4 ±Reelmaster 2300±D/2600±D 8. Inspect the wearplate 18 for cracks, peening, and scoring. A polished pattern on the wear plate from rotor rotation is normal. Replace as necessaryPage 4 ± Hydraulic SystemUse eye protection such as goggles when using compressed air Reassembly FigHydraulic System Page 4 ±Reelmaster 2300±D/2600±D 9. Apply a small amount of clean grease to a new seal ring 5 and insert it into the housing 3 seal ring groovePage 4 ± Hydraulic SystemHydraulic System Reelmaster 2300±D/2600±D Note The cap screws 14 required for use with the shuttle valve left±hand motor only end cover 24 are longer than the bolts required with standard end cover. Refer to Toro Parts Catalog for correct service part num- ber if replacement is requiredPage 4 ± Hydraulic SystemSKIRT ASSEMBLY 2WD/3WD Two Position ValveInstallation Fig Removal FigUse eye protection such as goggles when using compressed air Disassembly FigReassembly Fig Inspection FigHydraulic System A. If the valve stop 13 and set screw 7 did not separate during disassembly, screw them into the spool 5 and torque valve stop from 85 to 100 in±lbPage 4 ± Reelmaster 2300±D/2600±DInstallation Fig Reel Motor Drive PumpRemoval Fig Reelmaster 2300±D/2600±DShaft Seal Replacement Fig Disassembly FigHydraulic System Page 4 ±O±ring Replacement Fig E±seal and Backup Ring Replacement FigReassembly Fig Reelmaster 2300±D/2600±DInstallation Fig Reel MotorRemoval Fig Hydraulic System1. Make sure key 10 is removed from the drive gear 9 shaft Disassembly FigReelmaster 2300±D/2600±D Page 4 ±Reassembly Fig Use eye protection such as goggles when using compressed airInspection Fig Hydraulic SystemInstallation Fig Hydraulic ManifoldRemoval Fig Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Use eye protection such as goggles when using compressed air Use eye protection such as goggles when using compressed airSolenoid Valve Fig Cartridge Logic and Relief Valves FigSpool Flow Control and Two Position Directional Valves Fig Use eye protection such as goggles when using compressed airHydraulic System Page 4 ±Reelmaster 2300±D/2600±D Front Lift CylinderPage 4 ± Hydraulic SystemRemoval Fig Installation FigHydraulic System Page 4 ±IMPORTANT Do not clamp vise jaws against shaft Disassembly Fig6 surface. Protect shaft surface before mounting in the vise Spanner wrench Retaining ringReassembly Fig Use eye protection such as goggles when using compressed airInspection Fig IMPORTANT Do not clamp vise jaws against shaftRemoval Fig Rear Lift CylinderReelmaster 2300±D/2600±D Page 4 ±maining flat washer and then cotter pin 11 onto the cle- vis pin Installation FigHydraulic System Page 4 ±Use eye protection such as goggles when using compressed air Disassembly FigReassembly Fig Inspection FigHydraulic System Control and Implement Relief ValvesPage 4 ± Reelmaster 2300±D/2600±DRelief Valve Installation Fig Control Valve Installation FigControl Valve Removal Fig Relief Valve Removal FigUse eye protection such as goggles when using compressed air Control Valve Disassembly FigControl Valve Reassembly Fig Control Valve Inspection FigReelmaster 2300±D/2600±D Hydraulic ReservoirPage 4 ± Hydraulic SystemInspecting Reservoir Parts Fig 1. Clean tank 1 and filler screen 7 with solvent2. Inspect tank 1 for leaks, cracks, or other damage 3. Replace hydraulic hoses if worn or leakingReelmaster 2300±D/2600±D Flushing the Hydraulic SystemPage 4 ± Hydraulic SystemHydraulic System Hydraulic System Start±upPage 4 ± Reelmaster 2300±D/2600±DTable of Contents Electrical SystemChapter SystemElectrical Schematic Wiring SchematicsReelmaster 2300±D Electrical System Page 5 ±Start Circuits Reelmaster 2300±DPage 5 ± Electrical SystemReelmaster 2300±D Run CircuitsElectrical System Page 5 ±Page 5 ± Electrical System Reelmaster 2300±DElectrical System Run/Mow CircuitsReelmaster 2300±D Run/Backlap CircuitsElectrical System Page 5 ±Reelmaster 2300±D Charging CircuitsPage 5 ± Electrical SystemReelmaster 2300±D Indication and Safety CircuitsElectrical System Page 5 ±Skin±Over Grease MultimeterSpecial Tools Electrical SystemTroubleshooting Starting ProblemsProblem Possible CausesProblem Starting Problems continuedPossible Causes SystemProblem General Run and Transport ProblemsPossible Causes Electrical SystemProblem Cutting Unit Operating ProblemsPossible Causes SystemElectrical System Verify Interlock System OperationPage 5 ± Reelmaster 2300±D/2600±DElectrical System Quick Checks Battery Test Open Circuit TestCharging System Test Glow Plug System TestElectrical System Starting System TestPage 5 ± Reelmaster 2300±D/2600±DIgnition Key Switch Component TestingElectrical System Reelmaster 2300±D/2600±DHigh Temperature Shutdown Switch Starter and High Temperature Shut Down RelaysElectrical System Page 5 ±0 0 0 0 Oil Pressure SwitchHour Meter Testing with the engine offHigh Temperature Water Shutdown Light Indicator Lights and CircuitsBattery Light Oil Pressure LightTemperature Gauge Temperature Sending UnitReelmaster 2300±D/2600±D Page 5 ±Testing Diode Circuit BoardDiode D1 Diode D2Cutting Unit Solenoid Valve Coil Fuel Valve SolenoidIn Place Testing Live testingTraction Electric Clutch Traction Neutral Interlock SwitchDeenergized Testing Live TestingSystem Seat Interlock SwitchReelmaster 2300±D/2600±D Page 5 ±Backlap Switch Cutting Unit Interlock SwitchElectrical System Page 5 ±Service and Repairs Battery ServiceInspection, Maintenance , and Testing RemovalBattery Electrolyte Follow the manufacturers instructions when using a battery testerInstallation MinimumBattery Charge Follow the manufacturers instructions when using a battery chargingBattery Charge Level 4. Charge the battery following the manufacturers instructionsCutting Unit Solenoid Valve Coil InstallationRemoval LoctiteRemoval Traction Electric Clutch Fig. 27 throughElectrical System Reelmaster 2300±D/2600±DWire bracket InstallationElectrical System Page 5 ±Table of Contents Wheels and BrakesSPECIFICATIONS SERVICE AND REPAIRSWheels and Brakes SpecificationsPage 6 ± Reelmaster 2300±D/2600±DAdjustments Hand BrakeBrake Arm Lever DistanceService and Repairs Rear Wheel 3WDInstallation RemovalInstallation Rear Wheel 2WDRemoval BrakesLEFT WHEEL SHOWN Front Wheel and BrakeRemoval Wheels and BrakesInstallation IMPORTANT DO NOT remove brake lever assembly 32 from the brake plateWheels and Brakes Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Wheels and BrakesPage 6 ± Table of Contents Cutting UnitsChapter Cutting UnitsHEIGHT OF CUT RANGE SpecificationsFloating Cutting Unit ± 1/4º to 1±3/4º 6.4mm to 44.4mm Fixed Cutting Unit ± 1/2º to 2±5/8º 12.7 mm to 65.6 mmHandle Assembly Gauge Bar AssemblySpecial Tools Reelmaster 2300±D/2600±DDO NOT use and air or manual impact wrench with this tool Bedknife Screw ToolCutting Units Page 7 ±Troubleshooting Factors That Can Affect Quality of CutPossible Problem/Correction FactorFactor Possible Problem/CorrectionCutting Units Page 7 ±Adjustments Lift Arm Counterbalance Spring2. Make sure machine is shut off and parking brake is set Counterbalance Arm5/8º Height±of±Cut and Leveling Rear RollerCutting Units Page 7 ±Cutting Units Bedknife Parallel to Reel Fig. 7 through FigReelmaster 2300±D/2600±D Page 7 ±Cutting Units Height±of±Cut and Front Roller LevelPage 7 ± Reelmaster 2300±D/2600±DService and Repairs Greasing Bearings, Bushings, and Pivot Points Fig. 11 and Fig4. Wipe excess grease away Reelmaster 2300±D/2600±DD Do not adjust reels while engine is running Backlapping DANGERTO AVOID PERSONAL INJURY OR DEATH D Never place hands or feet in reel area while engine is runningInstallation Hydraulic Motor Removal and InstallationHOUSING RemovalInstall Cutting Unit Cutting Unit Removal and Installation Fig. 15 through FigRemove Cutting Unit 2. Make sure traction unit is shut off and parking brake is setReelmaster 2300±D/2600±D Cutting UnitsPage 7 ± Cutting UnitsBedbar Installation Bedbar Removal and Installation Fig. 19 through FigBedbar Removal Cutting UnitsCutting Units Bushing assemblyReelmaster 2300±D/2600±D Page 7 ±Regrinding Bedknife Bedknife Replacement and Grinding Fig. 22 and FigCutting Units Page 7 ±Roller Installation Roller Removal and InstallationRoller Removal Cutting UnitsRemove Seals and Bearings Roller Bearing and Seal ReplacementCutting Units Page 7 ±Cutting Units Install New Seals and BearingsReelmaster 2300±D/2600±D Page 7 ±COVER GASKET Reel Removal and Bearing ReplacementNOT SHOWN GROOVE SHOWNB. Do not get Loctite on the bearing seal Install ReelCutting Units Reelmaster 2300±D/2600±DReel Grinding Specifications Preparing a Reel for GrindingCutting Units Page 7 ±Cutting Units Fixed Side Plate Installation Fig. 28 and FigReelmaster 2300±D/2600±D Page 7 ±Cutting Units Skid Kit InstallationPage 7 ± Reelmaster 2300±D/2600±DThis page is blank The Toro Company Commercial Products