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

Models: 2600D 2300-D

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

Contents

Preface Service ManualReelmaster 2300±D/2600±D The Toro Company ± 1996This page is blank Safety Table Of ContentsChapter 1 ± Safety Chapter 2 ± Product Records and ManualsThis page is blank Safety Instructions SafetyTable of Contents ChapterPage 1 ± While OperatingSafety Reelmaster 2300±D/2600±DSafety Maintenance and ServiceSafety Page 1 ± 3 Rev. ASafety Safety and Instruction DecalsWARNING! Spring Loaded Mechanism Read Disassembly Procedure ON INSTRUMENT PANEL Part No. 94±4985 ON UNDER SEAT Part No. 93±6903A &!% # !## * % % A*$% SafetySafety Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D SafetyPage 1 ± Table of Contents Product Records and ManualsProduct Records ChapterPage 2 ± Equivalents and ConversionsProduct Records and Manuals Reelmaster 2300±D/2600±DPage 2 ± Torque SpecificationsReelmaster 2300±D/2600±D Product Records and ManualsPage 2 ± Maintenance Interval ChartProduct Records and Manuals Reelmaster 2300±D/2600±DEQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTER 2300±D/2600±DMaintenance Interval & Service REELMASTERR 2300±D/2600±D Maintenance ScheduleMaintenance Procedure Minimum Recommended Maintenance IntervalsMaintenance REELMASTERR2300±D/2600±D Daily Maintenance Check ListDaily Maintenance duplicate this page for routine use Daily Maintenance Check For Week OfD ± Service every 400 hours A B C D OtherA± Service every 50 hours B ± Service every 100 hoursChapter EngineTable of Contents EnginePage 3 ± IntroductionEngine Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D SpecificationsEngine Page 3 ±Diesel Engine Compression Test Kit Filter CleanerSpecial Tools Nozzle TesterReelmaster 2300±D/2600±D Nozzle Test AdapterEngine Page 3 ±Engine General InformationFuel Shutoff Valves Page 3 ±Engine AdjustmentsAlternator Belt Reelmaster 2300±D/2600±DPage 3 ± Throttle LinkageEngine Reelmaster 2300±D/2600±DDANGER Service and RepairsBleeding the Fuel System Reelmaster 2300±D/2600±DWashing Method Air CleanerUse eye protection such as goggles when using compressed air Compressed Air MethodEngine Cleaning the Radiator and ScreenUse eye protection such as goggles when using compressed air Reelmaster 2300±D/2600±Dwhen the radiator cap is removed. Burns Changing the Engine Oil and FilterChecking the Cooling System when the radiator or engine is hotReelmaster 2300±D/2600±D Engine RemovalEngine Page 3 ±AIR FILTER HOSE RIGHTCONNECTED TO 22 LHReelmaster 2300±D/2600±D 10. Disconnect hoses from engine FigEngine Page 3 ±Page 3 ± 14. Disconnect electrical connections FigEngine Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D 17. Remove engine FigEngine Page 3 ±Page 3 ± Engine ReinstallationEngine Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D 7. Reconnect throttle cable Fig A. Run throttle cable to engineEngine Page 3 ±Reelmaster 2300±D/2600±D EnginePage 3 ± Chapter Hydraulic SystemTable of Contents Reelmaster 2300±D/2600±DPage 4 ± SpecificationsHydraulic System Reelmaster 2300±D/2600±DGeneral Information Hydraulic Fitting InstallationHydraulic Hoses O±Ring Face SealHydraulic System SAE Straight Thread O±Ring Port ± Non±adjustableSAE Straight Thread O±Ring Port ± Adjustable Page 4 ±Group 2 Hydraulic Fluid Biodegradable Checking the Hydraulic System FluidISO type 46/68 anti±wear hydraulic fluid ISO VG 32/46 anti±wear hydraulic fluidHydraulic System Changing the Hydraulic System Fluid and FilterPushing or Towing the Traction Unit Page 4 ±Reelmaster 2300±D/2600±D Hydraulic SchematicHydraulic Schematic Page 4 ±Hydraulic System Hydraulic Flow DiagramsRaise Cutting Units Page 4 ±Page 4 ± Raise Cutting UnitsReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Traction ForwardHydraulic System Reelmaster 2300±D/2600±DPage 4 ± Hydraulic System Traction ForwardReelmaster 2300±D/2600±D WHEEL MOTOR Solenoid S1 is shownPage 4 ± Traction ReverseHydraulic System Reelmaster 2300±D/2600±DPage 4 ± Hydraulic System Traction ReverseReelmaster 2300±D/2600±D Solenoid S1 is shownReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Solenoid S1 is shown energized Reelmaster 2300±D/2600±DPage 4 ± Hydraulic System Valve MD1 is selected to mowSpecial Tools Hydraulic Pressure Test KitHydraulic Tester ± Pressure and Flow Hydraulic SystemPossible Cause TroubleshootingProblem Reelmaster 2300±D/2600±DHydraulic System ProblemPossible Cause Page 4 ±Reelmaster 2300±D/2600±D TestingBefore Performing Hydraulic Tests Page 4 ±Page 4 ± TEST NO. 1 Traction Pump FlowHydraulic System Reelmaster 2300±D/2600±Dreadings. The front tire on the ground will Procedure for Traction Pump Flow CheckUse extreme caution when taking gauge be trying to move the machine forwardPage 4 ± TEST NO. 2 Charge Pump Flow and Implement Relief PressureHydraulic System Reelmaster 2300±D/2600±DDo not allow charge pressure to exceed 650 PSI Procedure for Charge Pump Flow CheckProcedure for Implement Relief Check Example CalculationPage 4 ± TEST NO. 3 Charge Pump Relief PressureHydraulic System Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Procedure for Charge Pump Relief CheckSystem Page 4 ±Page 4 ± TEST NO. 4 Reel Drive Pump EfficiencyHydraulic System Reelmaster 2300±D/2600±DSystem Procedure for Reel Drive Pump Efficiency Check100 RPM. Do not engage the cutting units Reelmaster 2300±D/2600±DHydraulic System TEST NO. 5 Manifold Relief Valve PressureHigh Pressure Low Pressure Return or Suction Flow Page 4 ±Page 4 ± Procedure for Manifold Relief Valve Pressure CheckReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± TEST NO. 6 Cross±over Relief PressuresHydraulic System Reelmaster 2300±D/2600±DMotor Position Procedure for Cross±over Relief Pressures Check± Cutting Units and Reel Motor in the Service and Repair section Pressure Range PSIPage 4 ± TEST NO. 7 Reel Motor Case DrainHydraulic System Reelmaster 2300±D/2600±DManifold Port Procedure for Reel Motor Case Drain CheckMotor Manifold PortHydraulic System Transmission for NeutralAdjustments Page 4 ±Reelmaster 2300±D/2600±D Traction PedalTraction Pedal Damper Fig Page 4 ±Page 4 ± Hydraulic Pump Drive BeltHydraulic System Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Traction/Charge PumpService and Repairs Page 4 ±Hydraulic System Installation FigRemoval Fig Page 4 ±Reelmaster 2300±D/2600±D Disassembly Fig3. Remove O±ring 26 from the charge pump adapter assembly Page 4 ±Page 4 ± B. Remove spring and cup poppet from the charge pump adapter assemblyHydraulic System Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Use eye protection such as goggles when using compressed airInspection Page 4 ±Page 4 ± Reassembly FigHydraulic System Reelmaster 2300±D/2600±DPage 4 ± 15. Install new O±rings 38 and 39 and valve assemblyReelmaster 2300±D/2600±D Hydraulic SystemFront Wheel Removal Fig Wheel MotorFront Wheel Installation Fig Hydraulic SystemSystem Rear Wheel Installation Fig3WD Rear Wheel Removal Fig Reelmaster 2300±D/2600±DHydraulic System Disassembly FigLEFT HAND MOTOR ONLY Page 4 ±Reelmaster 2300±D/2600±D Use eye protection such as goggles when using compressed air5. Remove commutator ring Page 4 ±Hydraulic System Use eye protection such as goggles when using compressed airInspection Fig Page 4 ±Page 4 ± 8. Inspect the wearplate 18 for cracks, peening, and scoring. A polished pattern on the wear plate from rotor rotation is normal. Replace as necessaryReelmaster 2300±D/2600±D Hydraulic SystemHydraulic System Reassembly FigUse eye protection such as goggles when using compressed air Page 4 ±Page 4 ± 9. Apply a small amount of clean grease to a new seal ring 5 and insert it into the housing 3 seal ring grooveReelmaster 2300±D/2600±D Hydraulic SystemHydraulic System Page 4 ± 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 requiredReelmaster 2300±D/2600±D Hydraulic SystemInstallation Fig 2WD/3WD Two Position ValveSKIRT ASSEMBLY Removal FigReassembly Fig Disassembly FigUse eye protection such as goggles when using compressed air Inspection FigPage 4 ± 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±lbHydraulic System Reelmaster 2300±D/2600±DRemoval Fig Reel Motor Drive PumpInstallation Fig Reelmaster 2300±D/2600±DHydraulic System Disassembly FigShaft Seal Replacement Fig Page 4 ±Reassembly Fig E±seal and Backup Ring Replacement FigO±ring Replacement Fig Reelmaster 2300±D/2600±DRemoval Fig Reel MotorInstallation Fig Hydraulic SystemReelmaster 2300±D/2600±D Disassembly Fig1. Make sure key 10 is removed from the drive gear 9 shaft Page 4 ±Inspection Fig Use eye protection such as goggles when using compressed airReassembly Fig Hydraulic SystemRemoval Fig Hydraulic ManifoldInstallation Fig Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Solenoid Valve Fig Use eye protection such as goggles when using compressed airUse eye protection such as goggles when using compressed air Cartridge Logic and Relief Valves FigHydraulic System Use eye protection such as goggles when using compressed airSpool Flow Control and Two Position Directional Valves Fig Page 4 ±Page 4 ± Front Lift CylinderReelmaster 2300±D/2600±D Hydraulic SystemHydraulic System Installation FigRemoval Fig Page 4 ±6 surface. Protect shaft surface before mounting in the vise Disassembly FigIMPORTANT Do not clamp vise jaws against shaft Spanner wrench Retaining ringInspection Fig Use eye protection such as goggles when using compressed airReassembly Fig IMPORTANT Do not clamp vise jaws against shaftReelmaster 2300±D/2600±D Rear Lift CylinderRemoval Fig Page 4 ±Hydraulic System Installation Figmaining flat washer and then cotter pin 11 onto the cle- vis pin Page 4 ±Reassembly Fig Disassembly FigUse eye protection such as goggles when using compressed air Inspection FigPage 4 ± Control and Implement Relief ValvesHydraulic System Reelmaster 2300±D/2600±DControl Valve Removal Fig Control Valve Installation FigRelief Valve Installation Fig Relief Valve Removal FigControl Valve Reassembly Fig Control Valve Disassembly FigUse eye protection such as goggles when using compressed air Control Valve Inspection FigPage 4 ± Hydraulic ReservoirReelmaster 2300±D/2600±D Hydraulic System2. Inspect tank 1 for leaks, cracks, or other damage 1. Clean tank 1 and filler screen 7 with solventInspecting Reservoir Parts Fig 3. Replace hydraulic hoses if worn or leakingPage 4 ± Flushing the Hydraulic SystemReelmaster 2300±D/2600±D Hydraulic SystemPage 4 ± Hydraulic System Start±upHydraulic System Reelmaster 2300±D/2600±DChapter Electrical SystemTable of Contents SystemReelmaster 2300±D Wiring SchematicsElectrical Schematic Electrical System Page 5 ±Page 5 ± Reelmaster 2300±DStart Circuits Electrical SystemElectrical System Run CircuitsReelmaster 2300±D Page 5 ±Electrical System Reelmaster 2300±DPage 5 ± Electrical System Run/Mow CircuitsElectrical System Run/Backlap CircuitsReelmaster 2300±D Page 5 ±Page 5 ± Charging CircuitsReelmaster 2300±D Electrical SystemElectrical System Indication and Safety CircuitsReelmaster 2300±D Page 5 ±Special Tools MultimeterSkin±Over Grease Electrical SystemProblem Starting ProblemsTroubleshooting Possible CausesPossible Causes Starting Problems continuedProblem SystemPossible Causes General Run and Transport ProblemsProblem Electrical SystemPossible Causes Cutting Unit Operating ProblemsProblem SystemPage 5 ± Verify Interlock System OperationElectrical System Reelmaster 2300±D/2600±DCharging System Test Battery Test Open Circuit TestElectrical System Quick Checks Glow Plug System TestPage 5 ± Starting System TestElectrical System Reelmaster 2300±D/2600±DElectrical System Component TestingIgnition Key Switch Reelmaster 2300±D/2600±DElectrical System Starter and High Temperature Shut Down RelaysHigh Temperature Shutdown Switch Page 5 ±Hour Meter Oil Pressure Switch0 0 0 0 Testing with the engine offBattery Light Indicator Lights and CircuitsHigh Temperature Water Shutdown Light Oil Pressure LightReelmaster 2300±D/2600±D Temperature Sending UnitTemperature Gauge Page 5 ±Diode D1 Diode Circuit BoardTesting Diode D2In Place Testing Fuel Valve SolenoidCutting Unit Solenoid Valve Coil Live testingDeenergized Testing Traction Neutral Interlock SwitchTraction Electric Clutch Live TestingReelmaster 2300±D/2600±D Seat Interlock SwitchSystem Page 5 ±Electrical System Cutting Unit Interlock SwitchBacklap Switch Page 5 ±Inspection, Maintenance , and Testing Battery ServiceService and Repairs RemovalInstallation Follow the manufacturers instructions when using a battery testerBattery Electrolyte MinimumBattery Charge Level Follow the manufacturers instructions when using a battery chargingBattery Charge 4. Charge the battery following the manufacturers instructionsRemoval InstallationCutting Unit Solenoid Valve Coil LoctiteElectrical System Traction Electric Clutch Fig. 27 throughRemoval Reelmaster 2300±D/2600±DElectrical System InstallationWire bracket Page 5 ±SPECIFICATIONS Wheels and BrakesTable of Contents SERVICE AND REPAIRSPage 6 ± SpecificationsWheels and Brakes Reelmaster 2300±D/2600±DBrake Arm Hand BrakeAdjustments Lever DistanceInstallation Rear Wheel 3WDService and Repairs RemovalRemoval Rear Wheel 2WDInstallation BrakesRemoval Front Wheel and BrakeLEFT WHEEL SHOWN Wheels and BrakesWheels and Brakes IMPORTANT DO NOT remove brake lever assembly 32 from the brake plateInstallation Reelmaster 2300±D/2600±DReelmaster 2300±D/2600±D Wheels and BrakesPage 6 ± Chapter Cutting UnitsTable of Contents Cutting UnitsFloating Cutting Unit ± 1/4º to 1±3/4º 6.4mm to 44.4mm SpecificationsHEIGHT OF CUT RANGE Fixed Cutting Unit ± 1/2º to 2±5/8º 12.7 mm to 65.6 mmSpecial Tools Gauge Bar AssemblyHandle Assembly Reelmaster 2300±D/2600±DCutting Units Bedknife Screw ToolDO NOT use and air or manual impact wrench with this tool Page 7 ±Possible Problem/Correction Factors That Can Affect Quality of CutTroubleshooting FactorCutting Units Possible Problem/CorrectionFactor Page 7 ±2. Make sure machine is shut off and parking brake is set Lift Arm Counterbalance SpringAdjustments Counterbalance ArmCutting Units Height±of±Cut and Leveling Rear Roller5/8º Page 7 ±Reelmaster 2300±D/2600±D Bedknife Parallel to Reel Fig. 7 through FigCutting Units Page 7 ±Page 7 ± Height±of±Cut and Front Roller LevelCutting Units Reelmaster 2300±D/2600±D4. Wipe excess grease away Greasing Bearings, Bushings, and Pivot Points Fig. 11 and FigService and Repairs Reelmaster 2300±D/2600±DTO AVOID PERSONAL INJURY OR DEATH Backlapping DANGERD Do not adjust reels while engine is running D Never place hands or feet in reel area while engine is runningHOUSING Hydraulic Motor Removal and InstallationInstallation RemovalRemove Cutting Unit Cutting Unit Removal and Installation Fig. 15 through FigInstall Cutting Unit 2. Make sure traction unit is shut off and parking brake is setPage 7 ± Cutting UnitsReelmaster 2300±D/2600±D Cutting UnitsBedbar Removal Bedbar Removal and Installation Fig. 19 through FigBedbar Installation Cutting UnitsReelmaster 2300±D/2600±D Bushing assemblyCutting Units Page 7 ±Cutting Units Bedknife Replacement and Grinding Fig. 22 and FigRegrinding Bedknife Page 7 ±Roller Removal Roller Removal and InstallationRoller Installation Cutting UnitsCutting Units Roller Bearing and Seal ReplacementRemove Seals and Bearings Page 7 ±Reelmaster 2300±D/2600±D Install New Seals and BearingsCutting Units Page 7 ±NOT SHOWN Reel Removal and Bearing ReplacementCOVER GASKET GROOVE SHOWNCutting Units Install ReelB. Do not get Loctite on the bearing seal Reelmaster 2300±D/2600±DCutting Units Preparing a Reel for GrindingReel Grinding Specifications Page 7 ±Reelmaster 2300±D/2600±D Fixed Side Plate Installation Fig. 28 and FigCutting Units Page 7 ±Page 7 ± Skid Kit InstallationCutting Units Reelmaster 2300±D/2600±DThis page is blank Commercial Products The Toro Company