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. REFER TO THE TRACTION UNIT AND CUTTING UNIT OPERATOR’S MANUALS FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Chapter 2 – Product Records and Manuals Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Maintenance Interval Chart . . . . . . . . . . . . . . . . . . Operation and Service History Report . . . . . . . . . 2–1 2–2 2–3 2–4 2–5 Chapter 3 – Engine Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . .
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Chapter 1 Safety Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 1 Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3 SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
5. Do not carry passengers on the machine. Keep everyone, especially children and pets, away from the areas of operation. 6. Keep all shields, safety devices and decals in place. lf a shield, safety device or decal is damaged, malfunctioning or illegible, repair or replace it before operating the machine. 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.
20. Before getting off the seat: D. Stop the engine and remove the key from the ignition switch. A. Move the traction pedal to neutral. B. Set the parking brake. Safety C. Disengage the cutting units and wait for the reels to stop spinning. 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. Maintenance and Service 22.
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. UNDER CONTROL PANEL (Part No. 93–6902) ON LEFT SIDE OF SEAT PANEL (Part No. 92–7270) Model 03427 only ON CARRIER FRAME (Part No.
DANGER! Rotating Reel Will Cut Hands and Feet. See Adjustment Procedures Reelmaster 2300–D/2600–D Page 1 – 5 Safety ON SHIELD (Part No.
Safety Page 1 – 6 Reelmaster 2300–D/2600–D
Chapter 2 Product Records and Manuals PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Capscrew Markings and Torque Values – U.S. . . Capscrew Markings and Torque Values – Metric MAINTENANCE INTERVAL CHART . . . . . . . . . . . . .
Equivalents and Conversions Product Records and Manuals Page 2 – 2 Reelmaster 2300–D/2600–D
Product Records and Manuals Torque Specifications Reelmaster 2300–D/2600–D Page 2 – 3 Product Records and Manuals
Maintenance Interval Chart Product Records and Manuals Page 2 – 4 Reelmaster 2300–D/2600–D
Product Records and Manuals EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for REELMASTERR 2300–D/2600–D TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transmission Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service ______
REELMASTERR 2300–D/2600–D Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Inspect Air Filter, Dust Cup, and Baffle Lubricate All Grease Fittings { Change Engine Oil { Check Fan and Alternator Belt Tensions Maintenance Interval & Service Every 100hrs Every 50hrs Every 200hrs Every 400hrs A–Level Service { Change Engine Oil and Filter B–Level Service { Check Traction Belt Tension Service Air Filter Replace Fuel Filter/Water Separator { Replace Hydraulic Filter
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 ________________ n Safety Interlock Operation n Brake Operation n Engine Oil Level1 n Cooling System Fluid Level1 MON TUES WED THURS FRI SAT SUN ________HRS ________HRS ________HRS ________HRS ________HRS ________HRS ________HRS Product Records and Manuals Maintenance Check It
Product Records and Manuals Page 2 – 8 Reelmaster 2300–D/2600–D R A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Chapter 3 Engine Table of Contents 2 3 4 6 6 7 7 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 . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 2300–D/2600–D mower. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained.
Specifications Item Description Make / Designation Perkins, vertical in–line, 4–stroke, water–cooled Diesel, 103–07 KL 70275 & KL 70372 Combustion Chamber IDI special swirl–combustion type Number of Cylinders 3 Bore x Stroke mm (in.) 67 x 64 (2.64 x 2.52) Total Displacement cc (cu. in.) 676 (41.23) Compression Ratio 24:1 Firing Order 1– 2–3 64 (141) Fuel Grade No.
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 engines for checking the general operating condition of the engine.
Nozzle Test Adapter This adapter is required to test the fuel injection nozzles.
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.
Adjustments Alternator Belt 1. Gain access to the alternator belt (Fig 7). A. Loosen top hose clamp securing the upper portion of the hose connected to the air cleaner (8). 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) and hose. Plug air cleaner hose and hose inlet to the air cleaner. 4 2.
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 position. 1 4. Pull cable toward flywheel end of the engine until the governor lever on the engine is up against the high speed adjustment screw.
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 performed 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 1. Fuel shutoff valve 2. Bleed screws 3. Bowl 6 Engine Because diesel fuel is flammable, use caution when storing or handling it.
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 cleaner body. 3 ÇÇ ÇÇ ÇÇ 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.
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.
Changing the Engine Oil and Filter Change oil and filter initially after the first 20 hours of operation. 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 3. Locate engine filter on the front of the engine. Remove oil filter.
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 (–) battery 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. A.
RIGHT 39 11 1 2 4 36 5 32 13 6 7 9 8 44 10 CONNECTED TO AIR FILTER HOSE 19 11 38 19 12 41 14 45 3 15 23 18 19 25 16 17 40 39 29 11 31 30 37 20 21 43 26 35 23 25 7 28 34 42 34 36 FRONT 22 LH 46 RH 24 33 13 LEFT 27 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Cap screw Lock washer Clutch washer Engine pulley Cap screw Wire bracket Nut Pop rivet Key Cap screw Flat washer R–clamp Washer Muffler Muffler tube Muffler bracket Engine 17. 18. 19. 20. 21. 22.
9. Close fuel shut–off valves under the fuel tank and on the fuel filter. 10. Disconnect hoses from engine (Fig. 19). 2 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 radiator 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.
14. Disconnect electrical connections (Fig. 19). Note: Label all electrical leads for reassembly purposes. A. Disconnect connector with blue leads from the alternator. 4 B. Disconnect connector with blue/white leads from the traction clutch. 1 C. Disconnect connector from the front lift cylinder microswitch. 3 D. Remove white/black lead from the temperature sender located on the top of the water pump. E.
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.
Engine Reinstallation 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). 1. Make sure machine is parked on a level surface with cutting units lowered, and key removed from the start switch. Chock wheels to keep the machine from moving. 2. Make sure that all parts remove from the engine during maintenance or rebuilding are reinstalled to the engine. 5. Reinstall radiator assembly. A.
J. Reconnect gray, red, and white leads to the engine starter solenoid located on below the exhaust manifold. K. Reconnect battery ground to the traction clutch side of the cylinder head or the left side of the cylinder block. 11. Open fuel shut–off valves under the fuel tank and on the fuel filter. 12. Fill hydraulic reservoir with hydraulic fluid as described in the General Information section of Chapter 4 – Hydraulic System. Check reservoir for leaks. 13.
Engine Page 3 – 20 Reelmaster 2300–D/2600–D
Chapter 4 Hydraulic System Table of Contents Reelmaster 2300–D/2600–D TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1: Traction Pump Flow . . . . . . . . . . . . . . Test No. 2: Charge Pump Flow and Implement Relief Pressure . . . . . . . . . . . . . . . . . Test No. 3: Charge Relief Pressure . . . . . . . . . . . Test No. 4: Real Drive Pump Efficiency . . . . . . . Test No. 5: Manifold Relief Valve Pressure . . . . Test No. 6: Cross–over Relief Pressures . . . .
Specifications Item Description Traction Pump Maximum Operating Pressure Maximum Intermittent Pressure Maximum Rated Speed Rated Flow @ Maximum Rated Speed and Pressure Variable displacement piston pump 3000 PSI (207 bar) 5000 PSI (345 bar) 3600 RPM 17 GPM (64 LPM) Charge Pump Maximum Operating Pressure Maximum Rated Speed Rated Flow @ Maximum Rated Speed and Pressure Charge Pressure Gerotor pump 500 PSI (34.5 bar) 3600 RPM 3.5 GPM (13.2 LPM) 100 to 150 PSI (6.9 to 10.
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 conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
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 fitting 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. Figure 3 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
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 thereafter. 1 Group 1 Hydraulic Fluid (Recommended for ambient temperatures consistently below 100_ F.): 2 ISO type 46/68 anti–wear hydraulic fluid Note: able.
Changing the Hydraulic System Fluid and Filter The hydraulic system filter must be changed initially, after 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 hydraulic fluid must be changed every 400 hours of operation or yearly, whichever comes first. 1 1. Park the machine on a level surface, lower the cutting units, set parking brake and turn the engine off. 2.
Reelmaster 2300–D/2600–D Page 4 – 7 WHEEL MOTOR LEFT REVERSE (FRONT LINE) OUTER 12 in3 [197cc] FORWARD (REAR LINE) REAR WHEELDRIVE CIRCUIT IS NOT USED ON 2WD UNITS Solenoid S1 is shown de–energized Hydraulic Schematic Reelmaster 2300–D/2600–D LIFT CYL REAR INNER LIFT CYL FRONT B–UPPER A–LOWER 12 in3 [197cc] T2 WHEEL MOTOR RIGHT P1 REEL RELIEF 3000 psi R1 .49 in3 GEAR PUMP [8.
Hydraulic Flow Diagrams Raise Cutting Units The charge pump is part of the traction pump and is directly 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 filter from the reservoir.
Reelmaster 2300–D/2600–D Page 4 – 9 Hydraulic System REVERSE (FRONT LINE) OUTER FORWARD (REAR LINE) 12 in3 [197cc] WHEEL MOTOR LEFT T2 MD1 BACKLAPPING VALVE FRONT G1 Solenoid S1 is shown de–energized Control valve is positioned up REEL RELIEF 3000 psi FLOW CONTROL VALVE Hydraulic System REEL ON–OFF VALVE 1 M5 M1 D1 M2 D3 M3 D2 LIFT RELIEF 475 psi COOLER RESERVOIR 2.3 GALLON [8.
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 traction pump supplies oil flow to the wheel motors through the supply side of the traction circuit.
Reelmaster 2300–D/2600–D Page 4 – 11 Hydraulic System REVERSE (FRONT LINE) OUTER FORWARD (REAR LINE) Solenoid S1 is shown de–energized High Pressure Low Pressure (Charge) Return or Suction Flow Traction Forward 12 in3 [197cc] MOTOR Reelmaster 2300–D/2600–D WHEELLEFT LIFT CYL REAR INNER LIFT CYL FRONT B–UPPER A–LOWER 12 in3 [197cc] WHEEL MOTOR RIGHT T2 P1 CHARGE PUMP .42 IN3 [6.9CC] REEL RELIEF 3000 psi R1 .49 in3 GEAR PUMP [8.
Traction Reverse The traction circuit operates essentially the same in reverse as it does in the forward direction. However, the flow through the circuit is reversed and by–passes the rear wheel motor. With the engine running, clutch engaged, and traction pedal in the neutral position, the traction pump supplies no flow to the wheel motors.
Reelmaster 2300–D/2600–D Page 4 – 13 Hydraulic System REVERSE (FRONT LINE) OUTER FORWARD (REAR LINE) Solenoid S1 is shown de–energized High Pressure Low (Charge) Pressure Return or Suction Flow Traction Reverse 12 in3 [197cc] MOTOR Reelmaster 2300–D/2600–D WHEELLEFT LIFT CYL REAR INNER LIFT CYL FRONT B–UPPER A–LOWER 12 in3 [197cc] WHEEL MOTOR RIGHT T2 P1 CHARGE PUMP .42 IN3 [6.9CC] REEL RELIEF 3000 psi R1 .49 in3 GEAR PUMP [8.
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 motors. 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 solenoid valve (S1) bypassing the reel motors.
Reelmaster 2300–D/2600–D Page 4 – 15 Hydraulic System REVERSE (FRONT LINE) OUTER FORWARD (REAR LINE) Flow High Pressure Low Pressure (Charge) Return or Suction Solenoid S1 is shown energized Valve MD1 is selected to mow Mow 12 in3 [197cc] MOTOR Reelmaster 2300–D/2600–D WHEELLEFT LIFT CYL REAR INNER LIFT CYL FRONT B–UPPER A–LOWER 12 in3 [197cc] WHEEL MOTOR RIGHT T2 P1 REEL RELIEF 3000 psi R1 .49 in3 GEAR PUMP [8.0cc] S1 CHARGE PUMP .42 IN3 [6.
Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). 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.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. 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.
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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 disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of components. 2.
TEST NO. 1: Traction Pump Flow WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR REVERSE FROM REAR WHEEL MOTOR PC FLOW CONTROL 2.
Procedure for Traction Pump Flow Check: 11. Clean hose fitting and disconnect hose from the elbow connection on the top of the traction pump. 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered and off. Make sure engine is off.
TEST NO.
Procedure for Charge Pump Flow Check: 2. Operate engine at full speed (3200 100 RPM). 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 3. Make sure hydraulic oil is at operating temperature. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Make sure the hydraulic tank is full. 4. Watch pressure gauge carefully.
TEST NO.
Procedure for Charge Pump Relief Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 3. Make sure the hydraulic tank is full. CAUTION Make sure that all hoses are free of the flywheel after installation. 5. Operate engine at full speed (3200 100 RPM). 6.
TEST NO. 4: Reel Drive Pump Efficiency FILTER TO CHARGE PUMP BOTTOM RESERVOIR TO TRACTION PUMP FRONT COOLER REEL DRIVE PUMP P1 G1 M2 High Pressure FC1 D1 RH MD1 M5 LC1 Flow D3 R1 Low Pressure Return or Suction M1 CTR S1 M6 FROM LEFT WHEEL MOTOR M4 LH D2 M3 T2 HYDRAULIC MANIFOLD 2 3 TESTER 3 1 Figure 15 1. Hose fitting Hydraulic System 2. Reel drive pump Page 4 – 26 3.
Procedure for Reel Drive Pump Efficiency Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 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. 6.
TEST NO. 5: Manifold Relief Valve Pressure TESTER G1 FROM REEL DRIVE PUMP M2 D1 RH MD1 M1 M5 D3 CTR M6 TO COOLER M4 LH FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR SHUTTLE VALVE D2 M3 High Pressure Low Pressure Return or Suction Flow HYDRAULIC MANIFOLD Install tester in series between fitting and hose at the motor (right hand motor shown).
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 temperature by operating the machine for approximately 10 minutes. 8. Watch pressure gauge carefully while slowly closing the flow control valve until the manifold relief opens. 9. System pressure should be from 2700 to 3300 PSI. 2. Make sure machine is parked on a level surface with the cutting units lowered.
TEST NO.
Procedure for Cross–over Relief Pressures Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and parking brake is engaged. Back bedknives off all reels. CAUTION 9. Remove test gauge and put cap on manifold port G1. IMPORTANT: Each reel motor has two cross over reliefs.
TEST NO. 7: Reel Motor Case Drain MEASURE CASE DRAIN FLOW HERE TEST CONNECTION FOR R.H.
Procedure for Reel Motor Case Drain Check: 1. Make sure hydraulic oil is at normal operating temperature by operating the machine for approximately 10 minutes. Make sure the hydraulic tank is full. CAUTION Keep away from reels during test to prevent personal injury from the rotating reel blades. 2. Make sure machine is parked on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged. 7. Engage reels by pulling the knob on the instrument panel out.
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. Start engine, move throttle to SLOW and check front wheel that is off shop floor; it must not be rotating. Loosen pump plate nuts and rotate pump plate until creep does not occur in either direction.
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 pedal 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 depressed. 5 4.
Hydraulic Pump Drive Belt Make sure pump belt is properly tensioned to assure proper operation of the machine and prevent unnecessary wear. On new belts, check tension after 8 hours operation. A new hydraulic pump belt should tensioned so it deflects 0.120 inch with a 15 to 17 pound load applied midway 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.
Service and Repairs Traction/Charge Pump 11 10 1 13 16 14 34 17 32 35 33 4 37 15 22 3 2 34 31 9 36 38 13 27 24 30 34 8 26 21 7 5 35 25 23 12 17 29 43 14 28 39 20 42 19 41 18 40 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Cap screw Reel motor drive pump O–ring Traction/charge pump Hose Hose Hydraulic fitting Hydraulic fitting Hose connection Hose connection Hose connection Hose connection O–ring O–ring Hydraulic fitting Reelmaster 2300–D/2600–D 16.
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.
7 9 10 8 11 12 13 14 15 5 38 ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ 6 39 4 3 2 1 KEY 18 18 13 11 19 17 16 7 20 23 22 40 21 24 25 COUPLER OUTER RING 29 INNER RING 26 37 36 35 32 33 34 33 32 30 Hydraulic System 31 27 28 Figure 24 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Cap screw Charge pump adapter assembly Gerotor assembly Bearing Valve assembly Valve plate Screw Trunnion cover O–ring cover O–ring Washer Inner race Bearing Bearing 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
5. The charge pump adapter assembly (2) can be disassembled 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 coupler from the shaft (31). 7. Lift backplate assembly (25) up and off from the shaft (31) and housing assembly (15).
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 cover (9), O–ring (10), washer (11), inner race (12), and bearing (13).
9. Reassemble rotating parts kit as follows (Fig. 26): 6. Inspect rotating parts kit (see 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. B. Examine the mutual contact surfaces on the spider and spider pivot; both contact areas should be smooth and free of wear. C.
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 assembly from 27 to 30 ft–lb (3.7 to 4.1 kg–m). 16.
Wheel Motor Front Wheel Removal (Fig. 30) 1. Before removing any parts from the hydraulic system, 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. 9 (LH) 4 7 (LH) 3 17 (LH) CAUTION 6 16 8 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 5 10 1 16 14 2 2.
3WD Rear Wheel Removal (Fig. 31) 1. Before removing any parts from the hydraulic system, 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. 7 1 CAUTION 2 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 5 3 4 8 2. Clean wheel motor (1) and hydraulic connection. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3.
12 13 11 10 3 1 6 4 5 7 8 PLUG 9 8 24* 14 2 15 16 17 25* SHUTTLE VALVE 24 25* SPRING 24* (PLUG) 23 24* (PLUG) 22 21 19 *LEFT HAND MOTOR ONLY 20 18 Figure 32 1. 2. 3. 4. 5. 6. 7. 8. 9. Dirt and water seal Outer bearing Housing Backup washer Seal ring Backup washer Inner seal Thrust washer Thrust bearing 10. 11. 12. 13. 14. 15. 16. 17. Inner bearing Coupling shaft Thrust bearing Drive link Cap screw Commutator seal Commutator Woodruff key 18. 19. 20. 21. 22. 23. 24. 25.
Note: Be ready to catch the shuttle valve or relief valve components that will fall out of the end cover valve cavity when the plugs are removed. Note: O–ring (25) is not included in the seal kit, but can be serviced separately if required. Note: The insert and ,if included, the orifice plug in the end cover assembly (24) must not be removed as they are serviced as an integral part of the end cover. 4.
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. Discoloration would indicate excess fluid temperature, thermal shock, or excess speed and require system investigation for cause and close inspection of end cover, commutator, manifold, and rotor set.
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 damaged 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, corrosion and a full complement of retained rollers. Replace as necessary. 11.
Reassembly (Fig. 32) 1. Lubricate all seals and seal rings with clean hydraulic oil before assembly. WARNING Since they are flammable, be extremely careful when using any solvent. Even a small explosion or fire could cause injury 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.
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 components 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.
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 necessary clearance to assemble the seventh or remaining 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 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 number 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 rotate shaft should not exceed 50 ft–lb (6.9 kg–m). Hydraulic System 22.
2WD/3WD Two Position Valve 2 14 4 1 SKIRT ASSEMBLY 15 12 13 9 13 3 15 11 13 8 15 5 5 6 10 13 7 Figure 51 1. 2. 3. 4. 5. Two position valve Nut Cap screw Tub clamp Hydraulic tube 6. 7. 8. 9. 10. Hydraulic connection Hydraulic connection Hydraulic connection Hydraulic connection Hydraulic fitting Removal (Fig. 51) 1. Before removing any parts from the hydraulic manifold, park the machine on a level surface, engage the parking brake, lower the cutting units and stop the engine.
1 3 5 7 9 2 4 6 7 11 8 13 8 15 10 12 14 Figure 52 Valve cap Plug O–ring Ball Spool 6. 7. 8. 9. 10. Spring pin Back–up ring O–ring Valve housing Boot retainer 11. 12. 13. 14. 15. Boot Set screw Valve stop Lock washer Knob Inspection (Fig. 52) Disassembly (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). 3.
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 during disassembly, 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.
Reel Motor Drive Pump Removal (Fig. 53) 1. Before removing any parts from the hydraulic manifold, 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. 10 6 INLET PORT 3 7 2 4 CAUTION 8 Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. 9 3. Loosen hose clamp (2) and remove hose (3) from fitting (4).
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. 2. 3. 4. 5. Retaining ring Shaft seal Mounting flange Backup ring E–seal 6. 7. 8. 9. 10. O–ring Dowel pin End cover Bolt Gear housing Drive gear Idler gear Rear bearing block Front bearing block 6. Remove the rear bearing block (13) from the drive and idler gear shafts. Disassembly (Fig. 54) 1. Tape the shaft end of the drive gear (11) to prevent damaging the shaft seal when the shaft is removed or reinstalled.
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. Install new retaining ring (1) into the mounting flange. E–seal and Backup Ring Replacement (Fig. 54) 1. Place the front bearing block (14) on a clean surface. Remove the old backup ring (4) and E–seal (5). Clean any contamination from the E–seal groove. 2.
Reel Motor Removal (Fig. 55) 4 1. Before removing any parts from the hydraulic manifold, 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. 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.
7 5 3 4 2 1 8 6 9 10 11 12 11 13 14 15 19 13 18 17 16 1. 2. 3. 4. 5. 6. 7. Plug O–ring Shim Spring Ball Relief valve seal Backplate 8. 9. 10. 11. 12. 13. Idler gear assembly Drive gear assembly Key O–ring Body Alignment pin 14. 15. 16. 17. 18. 19. Frontplate Screw Retaining ring Oil seal Backup washer Relief valve assembly (# 1 thru 5) 7. Remove body (12) from the backplate (7). Remove O–rings (11) from the body (12) and backplate (7). Disassembly (Fig. 56) 1.
13. Make sure both plugs (1) are secure if they or the backplate is not being replaced. Inspection (Fig. 56) 1. Remove all nicks and burrs from all parts with an emery cloth Reassembly (Fig. 56) 1. If replacing the relief valve assembly (19), install ball (5), spring (4), shim (3), O–ring (2), and plug (1) into the backplate (7). Hand tighten plug (1) and then torque from 10 to 12 ft–lb (1.38 to 1.66 kg–m). CAUTION Use eye protection such as goggles when using compressed air 2.
Hydraulic Manifold Removal (Fig. 57) 1 1. Before removing any parts from the hydraulic manifold, 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. 7 2 3 9 4 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 manifold. 3. If necessary, the hydraulic manifold can be removed (Figure 57): A.
11 25 25 26 26 9 10 14 24 9 27 31 30 28 23 7 8 29 28 23 29 16 19 15 18 7 17 3 4 13 7 12 3 4 6 3 5 4 4 4 3 3 2 13 21 12 20 21 22 20 4 1 3 Figure 58 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cartridge (logic) valve Seal kit Plug O–ring O–ring Plug Seal kit Spool valve O–ring Solenoid coil Nut Hydraulic System 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Note: Use care when handling the spool valve (8). slight bending or distortion of the stem tube can cause binding and malfunction. Solenoid Valve (Fig. 58) 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).
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 operation and sealing. 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). Spool (Flow Control and Two Position Directional) Valves (Fig. 58) B.
Front Lift Cylinder INSTALL FLANGE BUSHING (18) FROM THE INSIDE 16 FITTING SIDE 14 15 11 18 12 18 4 1 6 19 6 5 2 7 6 16 3 8 10 9 Figure 59 1. 2. 3. 4. 5. 6. 7. Hose connection Hose connection Hose connection Hose connection Hydraulic fittings O–ring O–ring Reelmaster 2300–D/2600–D 8. 9. 10. 11. 12. 13. 14. Lift cylinder Cotter pin Clevis pin Cap screw Lift hub Cotter pin Clevis pin Page 4 – 67 15. 16. 17. 18. 19. 20.
9. Remove flange bushings (18) from the cylinder support bracket (17). Removal (Fig. 59) 1. Before removing any parts from the hydraulic manifold, 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. 10. Remove lift hub (12) from the lift cylinder (8). Installation (Fig. 59) 1. Thread lift hub (12) onto lift cylinder (8). CAUTION 2.
9 11 7 5 3 10 8 1 6 4 2 Hydraulic System 12 Figure 60 1. 2. 3. 4. retaining ring O–ring Head Backup washer 5. 6. 7. 8. O–ring Shaft O–ring Piston 9. 10. 11. 12. Uni–ring Lock nut Barrel 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.
Inspection (Fig. 60) CAUTION Spanner wrench Use eye protection such as goggles when using compressed air 1. Wash all parts in solvent. Dry parts with compressed air. 2. Inspect internal surface of barrel (11) for deep scratches, out–of–roundness, and bending. Replace if worn or damaged. Retaining ring (Offset end against left side of barrel groove after installing) Figure 62 Installing retaining ring 3. Inspect head (3), shaft (6), and piston (8) for excessive pitting, scoring, and wear.
Rear Lift Cylinder 13 12 14 11 14 ROD CLEVIS 10 15 4 9 3 5 5 15 2 6 1 Hydraulic System 7 8 Figure 63 1. 2. 3. 4. 5. Hose connection Hose connection Hydraulic fitting Hydraulic fitting O–ring 6. 7. 8. 9. 10. Cap screw Ram pivot pin Pivot support Lift pivot shaft Lift cylinder 11. 12. 13. 14. 15. Cotter pin Clevis pin Lift arm Flat washer O–ring Removal (Fig. 63) CAUTION 1.
3. Put caps or plugs on disconnected hoses and fittings to prevent contamination. maining flat washer and then cotter pin (11) onto the clevis pin. 4. Remove cap screw (6) and ram pivot pin (7) from pivot support (8). Slide lift pivot shaft (9) from pivot support. 4. Install hose connections (1 and 2) onto hydraulic fittings (3 and 4). Tighten hose connections. 5.
1. Remove oil from cylinder into a drain pan by slowly pumping the cylinder shaft (6). Plug both ports and clean the outside of the lift cylinder. 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). 2. Mount lift cylinder in a vise so that the shaft (6) end tilts up slightly. 3. Remove retaining ring (11) from the barrel (1). 4.
Control and Implement Relief Valves 7 5 6 4 1 24 2 8 23 9 3 11 24 10 23 24 24 18 12 23 23 20 2 24 21 19 17 16 21 13 13 22 22 14 15 Figure 65 1. 2. 3. 4. 5. 6. 7. 8. Hose connection Hydraulic fitting Washer Cap screw Lock nut Valve lever Knob Connecting link assembly Hydraulic System 9. 10. 11. 12. 13. 14. 15. 16. Control valve Hydraulic fitting Hose connection Tube Hydraulic fitting Hose connection Hose connection Lock nut Page 4 – 74 17. 18. 19. 20. 21. 22. 23. 24.
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 hydraulic fittings (2 and 13) and tighten connections.
Control Valve Disassembly (Fig. 66) 1. Wash control valve in solvent and dry it thoroughly. 2. Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring (14) faces up. 8 Note: Remove check valve seat (5) only if it needs replacement; 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 5. Remove snap ring (14) from the bottom of the valve body (7).
Hydraulic Reservoir 1 6 7 2 26 8 26 9 15 10 11 14 12 22 5 23 26 13 25 27 20 14 Hydraulic System 14 3 21 4 3 24 15 26 5 16 14 17 19 12 5 11 10 18 13 Figure 67 1. 2. 3. 4. 5. 6. 7. 8. 9. Shoulder screw Sight glass Hose clamp Barb fitting Flange nut Cap assembly Filler screen Hydraulic tank Tank bracket Reelmaster 2300–D/2600–D 10. 11. 12. 13. 14. 15. 16. 17. 18.
4. Make sure cap screws (12) are secure. If loose, remove and reinstall cap screws with loctite. Inspecting Reservoir Parts (Fig. 67) 1. Clean tank (1) and filler screen (7) with solvent. 5. Make sure all bracket fasteners are tight. 2. Inspect tank (1) for leaks, cracks, or other damage. 3. Replace hydraulic hoses if worn or leaking.
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 contains metal particles). 1 IMPORTANT: Flush hydraulic system when changIng from petroleum base hydraulic fluid, such as Mobil 424, to biodegradable fluid, such as Mobil EAL 224H. Operate machine under normal operating conditions for at least four (4) hours before draining. 2 1. Park machine on a level surface.
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 damaging the system or its components from not purging the system of air. 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.
Chapter 5 Electrical System Table of Contents COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . Starter and High Temperature Shutdown Relays High Temperature Shut Down Switch . . . . . . . . . Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Lights and Circuits . . . . . . . . . . . . . . . . . Temperature Sending Unit . .
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN INDICATOR LIGHT CUTTING UNIT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE YELLOW OFF ON TEMP SENDING UNIT I G S 85 86 BLACK RED/BLACK RED/BLACK GREEN ORANGE TEMP GAUGE AC AC ALTERNATOR WHITE/BLACK Page 5 – 2 + – 30 87 BLACK HOUR METER
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN REELS TURNING INDICATOR LIGHT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE 85 86 + – 30 87 BLACK HOUR METER PINK 1 2 3 4 5 6 A B CD E F GREEN INDICATOR LIGHT CLUSTER ENGINE COOLANT GLOW PLUG HIGH TEMP SHUTDOWN RELAY RED/BLACK GREEN 87A TA
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN REELS TURNING INDICATOR LIGHT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE I G S 85 86 BLACK RED/BLACK TEMP SENDING UNIT TEMP GAUGE OFF ON RED/BLACK GREEN ORANGE ALTERNATOR AC AC + – 30 87 BLACK HOUR METER PINK INDICATOR LIGHT CLUSTER
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN INDICATOR LIGHT REELS TURNING CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE YELLOW OFF ON TEMP SENDING UNIT I G S 85 86 + – 30 87 BLACK HOUR METER PINK 1 2 3 4 5 6 A B CD E F GREEN INDICATOR LIGHT CLUSTER ENGINE COOLANT GLOW PLUG HIGH TEM
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN REELS TURNING INDICATOR LIGHT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE YELLOW OFF ON TEMP SENDING UNIT I G S 85 86 BLACK RED/BLACK RED/BLACK GREEN ORANGE TEMP GAUGE AC AC ALTERNATOR WHITE/BLACK + – 30 87 BLACK HOUR METER PINK INDI
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN REELS TURNING INDICATOR LIGHT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE I G S 85 86 + – 30 87 HOUR METER BLACK PINK 1 2 3 4 5 6 A B CD E F GREEN INDICATOR LIGHT CLUSTER ENGINE COOLANT GLOW PLUG HIGH TEMP SHUTDOWN RELAY RED/BLACK GREEN 8
BLUE GREEN BROWN/WHITE ORANGE ORANGE/WHITE ORANGE/WHITE YELLOW GREEN REELS TURNING INDICATOR LIGHT CUTTING UNIT INTERLOCK SWITCH NORMALLY OPEN CLOSED WHEN CYLINDER IS RETRACTED BLACK CUTTING UNIT SOLENOID VALVE BLACK BLACK BLACK BLACK VOLTAGE REGULATOR/RECTIFIER BLACK BLACK BLACK BLUE ORANGE/WHITE ORANGE/WHITE I G S 85 86 BLACK RED/BLACK TEMP SENDING UNIT TEMP GAUGE OFF ON RED/BLACK GREEN ORANGE ALTERNATOR AC AC + – 30 87 BLACK HOUR METER PINK INDICATOR LIGHT CLUSTER
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). 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.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting 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 (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.
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. Engine kills when the traction pedal is depressed or the cutting unit switch is pulled ON with the operator in the seat. Operator is sitting too far forward on the seat (seat switch not depressed).
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.
Verify Interlock System Operation stop, there may be a malfunction in the interlock system. Repair the problem immediately. If the engine does stop, proceed to step 4. CAUTION 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 engine. Pull the cutting unit switch to the ON position, the engine should stop.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60_ to 100_ F. The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–) meter lead the the negative battery post. Voltage Measured Battery Charge Level 12.
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 problem is due to an electrical open, short or high resistance in the starter circuit. 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).
Component Testing For accurate resistance and/or continuity checks, electrically 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 setting), make sure that power to the circuit has been disconnected.
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 30 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 continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85. 3.
Oil Pressure Switch The switch is located on the front cylinder head above the injection pump and governor assembly. It is a normally closed switch and opens with pressure. The operating range for the switch is 2.8 to 5.7 PSI (0.2 to 04 kg/cm2 ). 1 Testing with the engine off 1. Turn the ignition switch to ON. The oil pressure lamp 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.
Indicator Lights and Circuits Note: Individual light bulbs can be tested by removing them from the lighting cluster and applying 12 VDC to their wiring terminals. Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running when the oil pressure drops below 4 PSI (0.3 kg/cm2).
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 thermometer 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.
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 D D1 D3 D2 D4 E This diode allows a current path through the traction interlock switch when the seat interlock switch is open. The engine can be started and run with no operator in the seat when the traction pedal is in the neutral position.
Fuel Valve Solenoid The fuel valve solenoid must be energized for the engine 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 11 Note: Prior to taking small resistance readings with a digital multimeter, short the test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads.
Traction (Electric) Clutch Note: When disconnecting the clutch, use the electrical connector that connects the clutch directly to the wiring 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 readings 3. Connect the clutch electrical connector to the wiring harness.
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 terminals.
Cutting Unit Interlock Switch This switch is normally open and closes when the lift cylinder 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 continuity across the switch. 1 3.
Service and Repairs NOTE: See the Perkins 100 Series Workshop Manual for more component repair information. Battery Service B. Check battery terminal posts for corrosion. Use a terminal brush or steel wool to clean corrosion from the battery terminal posts. 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. 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) below 80_F (26.7_C) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100_F Cell Gravity ADD (20_ above 80_F) Correction to 80_F 1.253 H. Using the table below, determine the minimum voltage for the cell temperature reading. Minimum Voltage 1.245 0.008 C. If the difference between the highest and lowest cell specific gravity is 0.
Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished 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 battery warm to 60_F (15.5_ C) before connecting to a charger. Charge the battery in a well–ventilated place to dissipate gases produced from charging.
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. 3. Slide the coil assembly and O–rings from the spool assembly. Discard the coil assembly and O–rings. 2 3 4 4. Clean any corrosion or dirt from the spool assembly. Loctite 242 Installation 1. Coat new O–rings lightly with petroleum jelly.
Traction (Electric) Clutch (Fig. 27 through 31) The clutch circuit is normally energized when the engine is starting or running. When energized, an electromagnet pulls the armature into contact with the rotor to drive the pulley and the traction motor through a fan belt. 2 Failure to engage the clutch is likely caused by too large of a clutch air gap, a circuit fault in the clutch electromagnet, or another electrical problem (see Wiring Schematics). Note: The air gap is not adjustable.
Installation 1. When installing an new clutch, remove the wire bracket from the old clutch and install it with the flat washers and new pop rivets on the new clutch. Run the wires through the bracket and tie wrap to them to the bracket as on the original clutch. Make sure wires are tight against the clutch wire bracket or they will catch in the spindle bolts (Fig. 30). through the flat washers and grommets; apply loctite to capscrew threads.
Chapter 6 Wheels and Brakes Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Rear Wheel (3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel and Brake . . . . . . . . . . . . . . . . . . . . . . 4 4 5 6 Wheels and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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) Wheel planetary mounting cap screw torque Wheels and Brakes 250 to 400 ft–lb, (34.6 to 55.
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 Lever Distance 4. Turn by–pass valve on traction pump to the by–pass position as described in the General Information section of Chapter 4 – Hydraulic System. 5 5. Loosen jam nut (1) on the clevis (2).
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. Remove lug nuts from the wheel hub studs. Slide off wheel assembly. 3 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.
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.
Front Wheel and Brake 5 7 6 8 4 3 9 2 2 45 10 46 11 47 24 48 11 12, 38 37 49 13 14 6 15 16 17 42 47 19 36 27 35 28, 29 18 39 26 20 25 34 27 1 33 30 27 32 21 44 23 43 31 22 17 40 LEFT WHEEL SHOWN 41 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
IMPORTANT: DO NOT hit wheel hub (18) with a hammer during removal or installation. Hammering may cause damage to the wheel motor (12 or 38). 5. Use a puller to remove the wheel hub (18) and brake drum (19). Remove the key (49) from the wheel motor shaft. 6. Remove brake extension springs (42) from brake shoes (17). Remove brake shoes from brake plate (44). 7. Remove cotter pin (27) from the clevis pin (31). Remove clevis pin from the brake lever assembly (32).
Wheels and Brakes Page 6 – 8 Reelmaster 2300–D/2600–D
Chapter 7 Cutting Units Table of Contents 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 . . . . . .
Specifications Figure 1 MOUNTING: All cutting units are supported by equal length independent lift arms and are interchangeable to all three cutting unit positions. REEL CONSTRUCTION: 5 or 8 blades of 7” (18 cm) diameter 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. HEIGHT OF CUT RANGE: Floating Cutting Unit – 1/4” to 1–3/4” (6.4mm to 44.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). 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.
Bedknife Screw Tool This screwdriver–type bit is made to fit Toro bedknife attaching screws. Use this bit with a torque wrench to secure the bedknife to the bedbar. DO NOT use and air or manual impact wrench with this tool.
Troubleshooting There are a number of factors that can contribute to unsatisfactory 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 depends on cutting unit weight and turf conditions.
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.
Adjustments CAUTION Never install or work on the cutting units or lift arms with the traction unit engine running. Always stop the engine and remove 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 counterbalance springs. 2. Make sure machine is shut off and parking brake is set.
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 leveling 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 1” 4.
Bedknife Parallel to Reel (Fig. 7 through Fig. 9) 1. Remove any reel contact by turning the bedknife adjustment 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 newspaper between reel and bedknife. While slowly rotating reel into bedknife, turn bedknife adjusting knob clockwise, one click at a time until paper is pinched lightly, which results in a slight drag when paper is pulled. 3.
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. Slightly loosen (crack) nuts securing each front roller bracket to the angle bracket. 4 2 3 5 3.
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 Grease. EARLIER UNITS 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 located on the outside portion of the bearing housing. 1.
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 attempting to clear reel. D Reel motors are connected in series, moving one motor moves the other two. Figure 13 1. Backlap knob 1.
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 coupling with new one. 2. Check coupling inside bearing housing. If coupling is loose remove and check for worn threads.
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 units can lower without the engine running. Figure 15 1. Bottom capscrew 2. Top capscrew 3. Loosen top cap screw.
Note: On rear counterbalance spring, make sure that the vinyl cover is on prior to reinstalling the spring. 4. Make sure one end of spring is secured to the spring shackle and the other end is hooked into the lift tab hole noted in step 6. 5. Secure counterbalance spring and lift tab to the carrier frame with the capscrews and lock washers (Fig. 16). 1 RM2600 TIPPER CHAIN IS CONNECTED TO THE BOTTOM OF THE FRAME 2 6.
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) until 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 adjusting housing (Fig. 20). 5 6.
3 5 6 7 13 1 10 4 12 2 9 8 10 11 9 Figure 21 Carriage bolt and nut Bedbar housing Bedbar Capscrew Lock washer 6. 7. 8. 9. Flat washer Spacer Bedbar washer Adjusting housing 10. 11. 12. 13. Bushing assembly Flanged bushing Bedknife screw Bedknife Cutting Units 1. 2. 3. 4. 5.
Bedknife Replacement and Grinding (Fig. 22 and Fig. 23) 1. Remove bedbar from cutting unit (see Bedbar Removal 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.
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. Remove both locknuts from the capscrews securing 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.
Roller Bearing and Seal Replacement 1 5 7 9 2 4 3 8 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 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 rollers. Remove Seals and Bearings 4.
Install New Seals and Bearings 1. Make sure all parts are clean prior to installing bearings and seals. 2. Install inner seals onto both ends of the roller shaft (if previously installed). 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. 8. Install outer seal onto each end of the roller shaft. Make sure hard surface of seal faces out. 9. Slide the roller shaft through the roller. 3.
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 4 FRONT 3 Figure 26 1. Cutting unit 2. Capscrew 3. Bearing cover 4. Male coupling (LH) 5. Male coupling (RH) 6. Capscrew 7. Bearing housing 8. Bearing 9. Reel 6. Remove capscrews from both bearing housings. Pull bearing housings and bearings from reel. Remove Reel 1. Remove bedbar assembly from cutting unit (see Bedbar Removal and Installation). 2.
Install Reel 1. Inspect bearings and replace if worn or damaged. 2. Make sure bearing seating surfaces and threads on reel shaft ends are clean. Apply anti–seize lubricant to both bearing seating surfaces. 8. Secure bearing housings and bearings on the reel shaft ends and cutting unit with the capscrews. Alternate evenly between capscrews when when tightening. 9. Degrease threaded end of male couplings and reel shaft. Make sure grease is completely removed 3.
Preparing a Reel for Grinding Note: Check to make sure reel bearings are in good condition and properly adjusted before grinding reel. 3. After completing grinding process: A. Install front roller and brackets (see Roller Removal 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 Removal and Installation).
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.
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. 4 3 5 2 1 Figure 30 1. Skid 2. Angle bracket holes 3. Flange head screw Cutting Units Page 7 – 26 4. Flat washer 5.
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