Toro 2600D User Manual

Reelmaster 2300–D/2600–D

Preface

The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Reelmaster 2300–D/2600–D.
REFER TO THE TRACTION UNIT AND CUTTING UNIT 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. Replacement Operator’s Manuals are available by sending complete Model and Serial Num­ber to:
The Toro Company 8111 Lyndale Avenue South Minneapolis, MN 55420
The T oro Company reserves the right to change product specifications or this publication without notice.
Part No. 96876SL Rev. A
Service Manual
This safety symbol means DANGER, WARN­ING, or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read the instructions that follow. Failure to obey the instructions may result in personal injury.
IMPORTANT: The IMPORTANT notice will give im­portant instructions which must be followed to pre­vent damage to systems or components on the machine.
The Toro Company – 1996, 1998
This page is blank.

Table Of Contents

Chapter 1 – Safety
Safety Instructions 1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 – 4. . . . . . . . . . . . . . . .
Chapter 2 – Product Records and Manuals
Product Records 2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 – 2. . . . . . . . . . . . . . . .
Torque Specifications 2 – 3. . . . . . . . . . . . . . . . . . . . . . .
Maintenance Interval Chart 2 – 4. . . . . . . . . . . . . . . . . .
Operation and Service History Report 2 – 5. . . . . . . . .
Chapter 3 – Engine
Introduction 3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 3 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 3 – 9. . . . . . . . . . . . . . . . . . . . . . . .
Perkins 100 Series Workshop Manual
Chapter 4 – Hydraulic System
Specifications 4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4 – 3. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 4 – 7. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Diagrams 4 – 8. . . . . . . . . . . . . . . . . . . .
Special Tools 4 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 4 – 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 4 – 37. . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 – Electrical System
Wiring Schematics 5 – 2. . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Checks 5 – 15. . . . . . . . . . . . .
Component Testing 5 – 17. . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 5 – 27. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 – Wheels and Brakes
Specifications 6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 6 – 4. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7 – Cutting Units
Specifications 7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble Shooting 7 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 7 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 7 – 11. . . . . . . . . . . . . . . . . . . . . . .
SafetyProduct Records
and Manuals
Engine
System
Hydraulic
Reelmaster 2300–D/2600–D
System
Electrical
Brakes
Wheels andCutting Units
This page is blank.
Table of Contents
SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . .
Before Operating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions
The REELMASTER 2300–D/2600–D conforms to the American National Standards Institute’s (ANSI) safety standards for riding mowers when equipped with rear ballast (see Operator’s Manual). Although hazard con­trol and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, con­cern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
Chapter 1
Safety
Safety
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 4. . . . . . . . . .
WARNING
To reduce the potential for injury or death, comply with the following safety instruc­tions.
Before Operating
Improper use or maintenance by the operator or owner of the machine can result in injury . Reduce the potential for any injury by complying with the following safety in­structions.
WARNING
The engine exhaust contains carbon monoxide, which is an odorless and deadly poison. Carbon monoxide is also known to the state of California to cause birth defects. Do not run engine indoors or in an enclosed area.
1. Read and understand the contents of the traction unit and cutting unit operator’s manuals before operat­ing the machine. To get replacement manuals, send complete model and serial number to:
The Toro Company 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196
Use the Model and Serial Number when referring to your machine. If you have questions about this Service Manual, please contact:
The Toro Company Commercial Service Department 8111 Lyndale Avenue South Minneapolis, Minnesota 55420–1196
2. Only trained operators, skilled in slope operation and who have read the Operator’s Manual, should oper­ate the machine. Never allow children to operate the machine or adults to operate it without proper instruc­tions.
3. IMPORTANT: Always use proper rear ballast as specified in the operator’s manual (see Rear Ballast of the Operator’s Manual).
4. Become familiar with the controls and know how to stop the machine and engine quickly.
Reelmaster 2300–D/2600–D
Page 1 – 1
Safety
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. Since fuel is highly flam­mable, handle it carefully.
A. Use an approved fuel container.
7. Always wear substantial shoes. Do not operate ma­chine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing because it could get caught in moving parts and possibly cause personal in­jury .
8. Wearing safety glasses, safety shoes, long pants and a helmet is advisable and required by some Iocal or­dinances and insurance regulations.
While Operating
12. Sit on the seat when starting and operating the ma­chine.
13. Check interlock switches daily for proper operation (see Checking Interlock Switches of the Operator’s Manual). Do not rely entirely on safety switches; shut off engine before getting off the seat. If a switch fails, re­place it before operating the machine. The interlock sys­tem is for your protection, so do not bypass it. Replace all interlock switches every two years.
B. Do not remove the cap from the fuel tank when engine is hot or running.
C. Do not smoke while handling diesel fuel. D. Fill fuel tank outdoors and not over one inch from
the top of the tank, (bottom of the filler neck). Do not overfill.
F. Stay alert for holes in terrain and other hidden hazards. Use extreme care when operating close to sand traps, ditches, creeks, steep hillsides or other hazards.
G. Reduce speed when making sharp turns. Avoid sudden stops and starts. Use reverse pedal for braking. The cutting units must be lowered when going down slopes for steering control.
H. Before backing up, look to the rear and assure that no one is behind the machine. Watch out for traffic when near or crossing roads. Always yield the right of way.
14. When starting the engine: A. Engage parking brake. B. Be sure traction pedal is in neutral and reel drive
is in the disengage position. C. After the engine starts, release parking brake
and keep foot off the traction pedal. The machine must not move. If movement is evident, the neutral control linkage is incorrectly adjusted: therefore, shut engine off and adjust until the machine does not move when the traction pedal is released (see Adjusting Transmission for Neutral of the Opera­tor’s Manual).
D. Hills over 15 degrees should be mowed up and down, not side to side (see Slope Gauge of the Op­erator’s Manual).
E. Mowing hills may be dangerous. Hills over 20 degrees should not be mowed (see Slope Gauge of the Operator’s Manual).
15. Keep hands, feet, and clothing away from moving parts and the reel discharge area. Grass baskets, if so equipped, must be in place during reel operation for maximum safety.
16. This product may exceed noise levels of 85 dB(A) at the operator position. Ear protectors are recom­mended for prolonged exposure to reduce the potential of permanent hearing damage.
17. Raise the cutting units when driving from one work area to another.
18. Do not touch engine, muffler, exhaust pipe, or hy­draulic tank while engine is running or soon after it has stopped. These areas could be hot enough to cause burns.
19. If a cutting unit strikes a solid object or vibrates ab­normally , stop cutting unit immediately . T urn the engine off, wait for all motion to stop and inspect for damage. A damaged  or bedknife must be repaired or re- placed before operation is continued.
Safety
Page 1 – 2
Reelmaster 2300–D/2600–D
20. Before getting off the seat: A. Move the traction pedal to neutral. B. Set the parking brake. C. Disengage the cutting units and wait for the reels
to stop spinning.
Maintenance and Service
chine, stop the engine and remove the key from the switch to prevent accidental starting of the engine.
23. When changing attachments, tires or performing
other service, use the correct blocks, hoists and jacks. Always chock or block the wheels and use jack stands or solid wood blocks to support the raised machine. If the traction unit is not properly supported by blocks or jack stands, the unit may move or fall resulting in per­sonal injury.
D. Stop the engine and remove the key from the ig­nition switch.
21. Whenever the machine is left unattended, make sure the reels are not spinning, the key is removed from ignition switch, and the parking brake is set.
Safety
28. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be re­lieved by stopping the engine and lowering cutting units to the ground.
29. If major repairs are ever needed or if assistance is desired, contact an Authorized Toro Distributor.
30. Reduce potential fire hazards. Keep the engine area free of excessive grease, grass, leaves, and accu­mulation of dirt.
24. Check performance of all interlock switches daily.
Do not defeat interlock system. It is for your protection.
25. Ensure the entire machine is in good operating
condition. Frequently check and keep all nuts, bolts, screws, and hydraulic fittings tight.
26. Before applying pressure to the hydraulic system,
make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition .
27. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have suffi­cient force to penetrate the skin and cause serious inju­ry. lf fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
31. If the engine must be running to perform a mainte­nance adjustment, keep hands, feet, clothing, and any other parts of the body away from the cutting units and any moving parts. Keep everyone away.
32. Do not overspeed the engine by changing governor settings. T o assure safety and accuracy , have an Autho­rized Toro Distributor check maximum engine speed with a tachometer.
33. The engine must be shut off before checking oil or adding oil to the crankcase.
34. To insure optimum performance and safety, use genuine TORO replacement parts and accessories. Re­placement parts and accessories made by other man­ufacturers could be dangerous, and such use could void the product warranty of The Toro Company.
Reelmaster 2300–D/2600–D
Page 1 – 3
Rev . A
Safety
Safety and Instruction Decals
The following safety and instruction decals are affixed to the traction unit. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed
UNDER CONTROL P ANEL
(Part No. 93–6902)
WARNING! Pinch Point between Carrier Frame and Cutting
ON INSTRUMENT P ANEL
(Part No. 94–4985)
below and in your Parts Catalog. Order replacements from your Authorized Toro Distributor.
ON LEFT SIDE OF SEAT PANEL
(Part No. 92–7270)
Model 03427 only
ON CARRIER FRAME
(Part No. 94–3353)
Unit
ON FAN SHROUD
(Part No. 77–3100)
Rotating Parts
Safety
ON UNDER SEA T
(Part No. 93–6903)
ON INSIDE OF
FRONT RIGHT PANEL
(Part No. 67–5360)
Page 1 – 4
ON LEFT FENDER (Part No. 84–1650)
ON LIFT ARMS
(Part No. 93–6696)
WARNING! Spring Loaded Mechanism,
Read Disassembly Procedure
ON SKIRT PANEL
(Part No. 83–9550)
Reelmaster 2300–D/2600–D
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Safety
Reelmaster 2300–D/2600–D
Page 1 – 5
Safety
Safety
Page 1 – 6
Reelmaster 2300–D/2600–D
Table of Contents
Chapter 2
Product Records and Manuals
PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
Product Records
Record information about your Reelmaster 2300–D/2600–D on the OPERATION AND SERVICE HISTORY REPOR T form. Use this information when re­ferring to your machine.
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Capscrew Markings and Torque Values – U.S. 3. .
Capscrew Markings and Torque Values – Metric 3
MAINTENANCE INTERV AL CHAR T 4. . . . . . . . . . . . .
OPERATION AND SERVICE HISTOR Y REPORT 5.
and Manuals
Product Records
Insert Operator’s Manuals and Parts Catalogs for your Reelmaster 2300–D/2600–D at the end of this section.
Reelmaster 2300–D/2600–D
Page 2 – 1
Product Records and Manuals
Equivalents and Conversions
Product Records and Manuals
Page 2 – 2
Reelmaster 2300–D/2600–D
Torque Specifications
and Manuals
Product Records
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
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
REELMASTER 2300–D/2600–D
TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transmission Numbers: _________________________ Date Purchased: _________________________ Warranty Expires___________ Purchased From: _________________________
_________________________ _________________________
Contacts: Parts _________________________ Phone___________________
and Manuals
Product Records
Service _________________________ Phone___________________ Sales _________________________ Phone___________________
See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company.
Reelmaster 2300–D/2600–D
Page 2 – 5
Product Records and Manuals
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
{ Change Engine Oil and Filter { Check Traction Belt Tension
Service Air Filter Replace Fuel Filter/Water Separator
{ Replace Hydraulic Filter { Torque Wheel Lug Nuts
Replace Hydraulic Fluid Check Battery Level/Connections Inspect Traction Linkage Movement
* Inspect Spider Coupling for Wear
} Torque Head Bolts and Adjust Valves } Check Engine RPM (idle and full throttle)
Every 50hrs
A–Level
Service
Maintenance Interval & Service
Every
100hrs
B–Level
Service
Every
200hrs
C–Level
Service
Every
400hrs
D–Level
Service
{ Initial break in at 10 hours * Every 400 hours or annually, whichever occurs first } Initial break in at 50 hours
Replace all Moving Hoses Replace Safety Switches Cooling System – Flush/Replace Fluid Replace Thermostat Fuel Tank – Drain/Flush Hydraulic Tank – Drain/Flush
(See Operator’s and Service Manuals for specifications and procedures.)
Items listed are recommended every 1000 hours
Annual Recommendations:
or 2 years, whichever occurs first.
Product Records and Manuals
Page 2 – 6
Reelmaster 2300–D/2600–D
REELMASTERR 2300–D/2600–D Daily Maintenance Check List
Daily Maintenance: (duplicate this page for routine use)
Daily Maintenance Check For Week Of ________________ Maintenance Check Item b
n Safety Interlock Operation n Brake Operation n Engine Oil Level n Cooling System Fluid Level
Drain Water/Fuel Separator
n Air Filter, Dust Cup, and Baffle n Radiator & Screen for Debris n Unusual Engine Noises n Unusual Operating Noises n Hydraulic System Oil Level n Hydraulic Hoses for Damage n Fluid Leaks n Fuel Level
1
1
2
1
1
MON
________HRS
TUES
________HRS
WED
________HRS
Unit Designation: ____________ TORO ID #: ________–________
THURS
________HRS
FRI
________HRS
SAT
________HRS
SUN
________HRS
and Manuals
and Manuals
Product Records
Product Records
n Tire Pressure n Instrument Operation n Reel–to–Bedknife Adjustment n Height–of–Cut Adjustment
Lubricate All Grease Fittings
3
Touch–up Damaged Paint
1
= Check proper section of Operator’s Manual for fluid specifications.
2
= Check glow plug and injector nozzles, if hard starting, excess smoke or rough running is noted.
3
= Accomplish immediately after every washing, regardless of the interval listed.
Notation for areas of concern: Inspection performed by:__________________
Item
Date Information 1 2 3 4 5 6 7
(See Operator’s and Service Manuals for specifications and procedures.)
Reelmaster 2300–D/2600–D
Page 2 – 7
Product Records and Manuals
Date: ________________
Service Air Filter
Replace Fuel Filter/Water Separator
Replace Hydraulic Filter
Torque Wheel Lug Nuts
A and B – Sevice required
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Form No. 95–872–SL(See Operator’s and Service Manual for specifications and procedures.)
Remarks:
R
TORO I.D. #:
__________________–__________________
A B C D Other
Service to perform (circle):
REELMASTER 2300–D/2600–D Supervisor Maintenance Work Order
Unit Designation:
(Duplicate this page for routine use.)
Hours:
Technician:
Change Engine Oil Filter
Check Traction Belt Tension
A – Service required
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
Inspect Air Filter, Dust Cup, and Baffle
Lubricate All Grease Fittings
Change Engine Oil
Check Fan and Alternator Belt Tension
________________________________
________________________________
________________________________
A– Service (every 50 hours) B – Service (every 100 hours) C – Service (every 200 hours)
________________________________
_______________________________
________________________________
Replace Moving Hoses
Replace Safety Switches (Every 2 yrs)
Coolant System – Flush/Replace Fluid
Replace Thermostat
Fuel Tank – Drain/Flush
Hydraulic Tank – Drain/Flush
Replace Hydraulic Fluid
Check Battery Level/Connections
D – Service (every 400 hours) Other – Annual Service and Specials Additional Service Items
Inspect Traction Linkage Movement
Inspect Spider Coupling for Wear
Torque Head Bolts and Adjust Valves
Check Engine RPM (Idle & Full Throttle)
_______________________________
A, B, and C – Sevice required
_______________________________
_______________________________
________________________________
________________________________
Product Records and Manuals
Page 2 – 8
Reelmaster 2300–D/2600–D
Table of Contents
Chapter 3
Engine
INTRODUCTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICA TIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 6. . . . . . . . . . . . . . . . . . . . .
Fuel Shutoff Valves 6. . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Belt 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Linkage 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 9. . . . . . . . . . . . . . . . . . . . . .
Bleeding the Fuel System 9. . . . . . . . . . . . . . . . . . . .
Air Cleaner 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Radiator and Screen 11. . . . . . . . . . . . .
Changing the Engine Oil and Filter 12. . . . . . . . . . .
Checking the Cooling System 12. . . . . . . . . . . . . . . .
Engine Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Reinstallation 18. . . . . . . . . . . . . . . . . . . . . . .
PERKINS 100 SERIES WORKSHOP MANUAL
Engine
Reelmaster 2300–D/2600–D Page 3 – 1 Engine

Introduction

This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the diesel engine used in the Reelmaster 2300–D/2600–D mower.
Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special T ools section. The use of some specialized test equipment is explained. How-
ever, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility.
Service and repair parts for Perkins engines are sup­plied through your local Perkins/Detroit Diesel dealer. If no parts list is available, be sure to provide your dealer or distributor with the Perkins model and serial number.
Engine
Page 3 – 2
Reelmaster 2300–D/2600–D

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
Dry Weight (approximate) kg (lb.) 64 (141)
Fuel Grade No. 2D diesel fuel (ASTM specification)
Fuel Injection Pump Bosch type plunger
Governor Mechanical
Idle Speed (no load) 1400 + 50 RPM
High Idle (no load) 3200 + 50 RPM
Engine
Fuel Injector Nozzle Bosch throttle type
Fuel Injection Working Pressure kg/cm2 (psi) 115 to 125 (1636 to 1778)
Injection Timing 28.5 to 30.5 B.T.D.C.
Engine Oil SAE 10W30 SF, CD
Oil Pump Gear driven trochoid type
Crankcase Oil Capacity liter (U.S. qt.) 2.8 (3.0) with filter
Water Pump Belt driven centrifugal type
Cooling System Capacity liter (U.S. qt.) 4.7 (5.0)
Starter 12 VDC 1.2 KW
Alternator/Regulator 12 VDC 14 AMP
Glow Plug Sheathed type
Reelmaster 2300–D/2600–D Page 3 – 3 Engine

Special Tools

Order special tools from
APPLICATIONS GUIDE (Commercial Products
TORO SPECIAL TOOLS AND
).
Filter Cleaner
Mix with water and use solution to wash the Donaldson air cleaner element.
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. The kit includes a case, gauge with hose, glow plug hole adapters, and instructions.
Some tools may be listed in the Reelmaster 2300–D/2600–D Parts Catalog. Tools may also be available from a local supplier.
Figure 1
Nozzle Tester
This tests the condition and opening pressure of fuel in­jection nozzles.
Engine
Page 3 – 4
Figure 2
Figure 3
Reelmaster 2300–D/2600–D
Nozzle Test Adapter
This adapter is required to test the fuel injection nozzles.
Figure 4
Engine
Reelmaster 2300–D/2600–D Page 3 – 5 Engine

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)
Figure 6
1. Fuel shut off valve (on the fuel filter)
1
Engine
Page 3 – 6
Reelmaster 2300–D/2600–D

Adjustments

Alternator Belt
1. Gain access to the alternator belt (Fig 7). A. Loosen top hose clamp securing the upper por-
tion of the hose connected to the air cleaner (8). B. Remove cap screws (1) and lock flange nuts (2).
Remove hex head screws (3). C. On European models, remove hex head screws
(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.
2. Loosen bolts securing alternator to the engine and
adjusting strap.
3. Adjust alternator belt to the proper tension. T ension
alternator belt so it deflects 0.20 inch with a 2 to 3 pound load applied midway between the crankshaft and alter­nator pulleys (Fig. 8).
4. Tighten bolts securing the alternator to the engine.
5. Reinstall air cleaner housing (Fig 7). A. Unplug air cleaner hose and hose inlet to the air
cleaner.
8
4
3
1. Cap screw
2. Lock flange nut
3. Hex head screw
4. Hex head screw
1
Figure 7
6
3
1
5
7
2
5. Guard (Europe)
6. Air cleaner housing
7. Radiator top shroud
8. Air cleaner
Engine
B. Place air cleaner housing (6) on the radiator top shroud (7). Reconnect upper end of the air cleaner hose to the air cleaner (8). Align holes to receive fasteners.
C. On European models, reinstall hex head screws (4) into guard (5) through the air cleaner housing (6).
D. Secure cap screws (1) and lock flange nuts (2) to air cleaner housing and radiator top shroud (7).
E. Secure hex head screws (3) into the air cleaner housing and radiator assembly.
F . Tighten hose clamp securing the hose to the air cleaner.
1
Figure 8
1. Engine belt
Reelmaster 2300–D/2600–D Page 3 – 7 Engine
Throttle Linkage
e
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.
4. Pull cable toward flywheel end of the engine until the governor lever on the engine is up against the high speed adjustment screw. T ighten cap screw and nut se­curing the throttle cable clamp.
5. Loosen capscrews (1) and nuts (2) securing the throttle stop (3).
6. With the cold start button depressed, carefully ad­just low engine speed to 1400 50 RPM with the throttle control lever (4); adjust low speed stop screw if necessary.
7. Make sure throttle control lever (4) is down so the governor lever on the engine touches the low speed ad­justment screw.
8. Adjust throttle stop (3) until it contacts the bottom of the throttle control lever (4). Tighten cap screws (1) and nuts (2) securing the throttle stop.
9. Make sure governor lever on the engine goes against the high speed adjustment screw when the throttle control lever (4) is moved to the high speed posi­tion. When the throttle control lever is moved to the low speed position, the governor lever on the engine should contact the low speed adjustment screw at the same time the throttle control lever contacts the throttle stop (3).
2
1. Cap screw
2. Nut
4
Figure 9
1
3
3. Throttle stop
4. Throttle control lev
Engine
Page 3 – 8
Reelmaster 2300–D/2600–D

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. Unlatch and raise hood.
2
DANGER
Because diesel fuel is flammable, use caution when storing or handling it. Do not smoke while filling the fuel tank. Do not fill the fuel tank while the engine is hot, running, or when the in an enclosed area. Always fill the fuel tank outside. Wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean safety–approved container with its cap on. Use diesel fuel for the engine only and no other purpose.
3. Open fuel shutoff valve (1) located under the fuel
tank and on the fuel filter (Fig. 10).
4. Open both bleed screws (2) located on the side of
the fuel filter mounting head. Allow bowl (3) to refill with fuel. Close bleed screws when the bowl is filled (Fig. 10).
5. On the front of the engine by the oil filter, find trans-
fer pump inlet screw location (2). Note fitting angle (5) on the transfer pump inlet and loosen left transfer pump screw (1) only (Fig. 11).
6. When a steady stream of fuel flows out of the trans-
fer pump screw (1), tighten screw and retain noted fitting angle (5) from step 5 above (Fig. 11).
7. Loosen injection pump inlet screw (3) on the front of
the engine (Fig. 11).
flows out of injection pump inlet screw (3), then tighten screw. Do not over tighten inlet screw (Fig. 11).
3
1
Figure 10
1. Fuel shutoff valve
2. Bleed screws
6
3. Bowl
5
1
4
6
2
 
3
Figure 11
1. Transfer pump screw
2. Transfer pump inlet screw location
3. Injection pump inlet screw
4. Priming lever
5. Note fitting angle
6. Injector nut
9. Start engine. If engine does not run smoothly after several minutes, crack open each injector nut (6) until fuel (with no bubbles) comes out. Torque each injector nut from 14.4 to 18.0 ft–lb (2.0 to 2.5 kg–m).
Engine
Reelmaster 2300–D/2600–D Page 3 – 9 Engine
Air Cleaner
1. Service the air cleaner filter every 400 hours (more frequently in extreme dusty or dirty conditions). Do not over service air filter.
4
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.
5. Gently slide filter element (4) out of the air cleaner body (1) to reduce the amount of dust dislodged. Avoid knocking filter element against air cleaner body.
Washing Method
A. Prepare a solution of filter cleaner and water. Soak filter element (4) in the solution for 15 minutes. Refer to directions on filter cleaner carton for com­plete information.
B. After soaking filter element (4) for 15 minutes, rinse it with clear water. Maximum water pressure must not exceed 40 psi to prevent damage to the fil­ter element. Rinse filter element from the clean side to the dirty side.
C. Dry filter element (4) using warm flowing air (160F maximum), or allow element to air–dry. Do not use a light bulb to dry the filter element because damage could result.
3
1
2
Figure 12
1. Air cleaner body
2. Air cleaner cover
3. Latch
4. Filter element
B. Keep air hose nozzle at least 2 inches from the filter element (4). Move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter element toward a bright light.
8. Insert filter element (4) properly into the air cleaner body (1). Make sure filter element is sealed properly by applying pressure to the outer rim of the filter element when installing. Do not press on the flexible center of the filter element.
Compressed Air Method
CAUTION
Use eye protection such as goggles when using compressed air.
A. Blow compressed air from the inside to the out­side of the dry filter element (4). Do not exceed 100 psi to prevent damage to the filter element.
Engine
9. Reinstall air cleaner cover (2) and secure latches (3). Make sure cover is positioned with top side up.
Page 3 – 10
Reelmaster 2300–D/2600–D
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. Remove radiator screen (1).
1
2. Remove four cap screws and nuts that hold the
3. Loosen both quick release knobs on the front end
of the radiator assembly. Now the oil cooler (3) can be removed from the radiator for cleaning.
CAUTION
Use eye protection such as goggles when using compressed air.
4. Working from fan side of radiator (2), either spray
the radiator with a hose or blow with compressed air.
5. Thoroughly clean oil cooler (3). Clean off any other
debris that may have collected around components.
6. Reinstall the oil cooler (3). Tighten both quick re-
lease knobs on the front end of the radiator assembly.
7. Reinstall plastic cover onto the radiator assembly.
Reinstall four cap screws and nuts that hold the plastic cover to the radiator assembly. Tighten fasteners
3
1. Radiator screen
2. Radiator
2
Figure 13
3. Oil cooler
Engine
8. Clean radiator screen (1) and reinstall.
Reelmaster 2300–D/2600–D Page 3 – 11 Engine
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. 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.
3. Locate engine filter on the front of the engine. Re­move oil filter. Apply a light coat of clean oil to the new filter seal before screwing it on. DO NOT OVERTIGH-
TEN. Note: The crankcase capacity is approximately 2.8
qts. (3.0 L) with filter. The engine uses any high–quality 10W30 detergent oil having the American Petroleum In­stitute – API – “service classification” CD.
4. Add oil to the crankcase. A. Remove oil fill cap (Fig. 14) and gradually add
small quantities of oil . B. Check oil level frequently until the level reaches
the FULL mark on dipstick (Fig 15). When removing the dipstick, wipe it with a clean rag prior to inserting it to check the oil level.
1
Figure 14
1. Oil fill cap
1
Figure 15
1. Dipstick
C. Push dipstick down into dipstick tube and make sure it is seated fully when finished (Fig 15).
Checking the Cooling System
  "("# "  &#   "$#  &* #!  !# #( ( #!)  %  # # #    ( ! "#!# #   #(  #  "("# " !'#(  $!#"  
CAUTION
If the engine has been running, pressur­ized hot coolant or steam can escape when the radiator cap is removed. Burns may result. Do not open radiator cap when the radiator or engine is hot.
1. !$( !% !#! 
2.  %  #  # !#!  !#! #
#   # !)# ! 
1
Figure 16
1. Radiator cap
3.  # # % " & !" # "("# DO
NOT OVERFILL
4. "# !#!   ##
Engine
Page 3 – 12
Reelmaster 2300–D/2600–D
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
2. Disconnect positive (+) and then negative (–) bat­tery cables at the battery.
3. Gain access to the engine. A. Open and remove hood from the machine. B. Remove right side panel to gain access to the
traction pump drive belt. C. Remove left rear panel (radiator side) which
supports the instrument panel.
4. Remove left fender (1) and fender bracket (2) from
the radiator side of the frame (Fig. 17).
A. Remove cap screw (3) and flange nut (4) holding the left foot rest (5) to the left fender.
B. Remove remaining cap screws (3) and flange nuts (4) securing the fender to the fender bracket and frame. Remove fender from the frame.
C. Remove both cap screws (3) and left fender bracket (2) from the frame.
5. Remove cotter pin (1) from adjusting rod (2). Dis-
connect adjusting rod from brake arm (3) (Fig. 18).
6. Remove cap screws (3) and flange nut (4) securing
the left footrest (5) to the frame (Fig. 17). Slide the left foot rest off the adjusting rod (2) (Fig. 18).
2
6
4
3
1. Left fender
2. Left fender bracket
3. Cap screw
2
4
Figure 17
3
4
4. Flange nut
5. Left footrest
6. Clinch nut
3
1
3
Engine
1
CAUTION
DO NOT open radiator cap or drain coolant if the engine or radiator is hot. Pressurized hot coolant can escape and cause burns.
Ethylene–gycol antifreeze is poisonous. Dispose of it properly or store it in a proper­ly labeled container away from children and pets.
7. Drain antifreeze from radiator.
1. Cotter pin
2. Adjusting rod
8. Drain hydraulic reservoir. A. Clean hydraulic oil filter and area around the fil-
ter.
A. Slowly remove radiator cap from the radiator.
B. Place clean drain pan below hydraulic oil filter to
B. Place drain pan below the radiator pipe plug. Re-
collect the draining hydraulic oil.
move pipe plug from the bottom of the radiator. Al­low antifreeze to drain into the container
C. Remove hydraulic oil filter from bottom of the fil­ter housing with a bottom type filter wrench. Let oil drain into the drain pan; install filter when drained.
Reelmaster 2300–D/2600–D Page 3 – 13 Engine
Figure 18
3. Brake arm
41
25
43
26
FRONT
40
35
RIGHT
39 11
1
2
3
4
5
32
6
7
9
8
44
10
CONNECTED TO AIR FILTER HOSE
11
13
45
36
38
12
23
18
19
14
19 19
15 16
17
39
31
11
30
37
20
21
29
23
7
28
42
34
36
33
34
13
25
24
27
22 LH 46 RH
LEFT
1. Cap screw
2. Lock washer
3. Clutch washer
4. Engine pulley
5. Cap screw
6. Wire bracket
7. Nut
8. Pop rivet
9. Key
10. Cap screw
11. Flat washer
12. R–clamp
13. Washer
14. Muffler
15. Muffler tube
16. Muffler bracket
Figure 19
17. U–bolt
18. Upper radiator hose
19. Muffler clamp
20. Nut
21. Lock washer
22. Left rear mount bracket
23. Hose clamp
24. Lower radiator hose
25. Engine
26. Throttle cable clamp
27. Flange nut
28. Throttle cable bracket
29. Clevis pin
30. Cotter pin
31. Throttle tab
32. Flat washer
33. Lock washer
34. Front mount bracket
35. Insert nut
36. Cap screw
37. Clutch spindle
38. Hose clamp
39. Cap screw
40. Electric clutch
41. Cap screw
42. Cap screw
43. Cap screw
44. Fuel hose
45. Muffler gasket
46. Right rear mount bracket
Engine
Page 3 – 14
Reelmaster 2300–D/2600–D
9. Close fuel shut–off valves under the fuel tank and on the fuel filter.
10. Disconnect hoses from engine (Fig. 19). A. Loosen upper hose clamp securing the air filter
hose extending from the engine to the air cleaner. B. Loosen hose clamps (23). Disconnect upper ra-
diator hose (18) and lower 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.
D. Loosen hose clamp and disconnect fuel hose (return) from the injector nozzle piping. Plug hose to prevent leakage.
CAUTION
2
4
1. Hose clamp
2. Hydraulic return hose
1
3
Figure 20
3. Hydraulic fitting
4. Hydraulic reservoir
The hydraulic fluid may be hot. To avoid possible burns, allow the hydraulic sys­tem to cool before disconnecting hoses.
11. Disconnect hydraulic hoses to oil cooler. A. Loosen hose clamp (1) and disconnect hydraulic
return hose (2) from the hydraulic fitting (3). Plug hose and fitting to prevent leakage and contamina­tion (Fig. 20).
B. Loosen hose clamp (1) and disconnect hydraulic supply hose (2) from the hydraulic elbow fitting (3). Plug hose and fitting to prevent leakage and con­tamination (Fig. 21).
CAUTION
The muffler and muffler tube may be hot. To avoid possible burns, allow the ex­haust system to cool before working on the muffler and muffler tube.
12. Remove exhaust system (Fig. 19).
2
1
4
3
Figure 21
1. Hose clamp
2. Hydraulic supply hose
3. Hydraulic elbow fitting
4. Hydraulic manifold
D. Remove cap screws (39) and flat washers (11) from the muffler and exhaust manifold. Remove muffler and muffler gasket (53) from the engine.
Engine
A. Remove muffler clamp (19) from the muffler (14) and muffler tube (15).
B. Loosen nut (20) and U–clamp (17). Separate muffler tube from muffler and slide muffler tube through U–clamp.
C. Remove cap screws (36) and washers (13) from the muffler and right rear mount bracket (46).
13. Disconnect throttle cable (Fig. 19). A. Loosen cap screw (43) enough to separate the
throttle cable from the throttle cable clamp (30). B. Remove cotter pin (30) from clevis pin (29). Re-
move clevis pin, throttle tab (31), and throttle cable from the engine governor lever.
C. Secure throttle cable away from the engine.
Reelmaster 2300–D/2600–D Page 3 – 15 Engine
14. Disconnect electrical connections (Fig. 19). Note: Label all electrical leads for reassembly pur-
poses.
A. Disconnect connector with blue leads from the alternator.
B. Disconnect connector with blue/white leads from the traction clutch.
C. Disconnect connector from the front lift cylinder microswitch.
D. Remove white/black lead from the temperature sender located on the top of the water pump.
E. Remove tan lead from the high temperature shut down switch located on the water pump behind the fan.
F . Remove purple lead from the fuel valve solenoid located above the lift pump.
G. Remove brown lead from the oil pressure switch located on the front of the cylinder head.
4
2
1. Cap screws
2. Whiz nut
1
3
Figure 22
3. Radiator rear bracket
4. Frame
H. Remove white lead from the glow plugs located on the front traction pump side of the cylinder head.
I. Remove gray , red, and white leads from the en­gine starter solenoid located on below the exhaust manifold.
J. Disconnect battery ground from the traction clutch side of the cylinder head or the fan side of the cylinder block.
K. Remove cap screw (10) and flat washer (11) from R–clamp (12). Pull wiring harness and hydrau­lic hoses away from the engine to keep them from snagging the engine when it is removed. The har­ness and hoses may be tied to the reservoir support brackets.
15. Remove radiator assembly. A. Support the radiator assembly while removing
fasteners. B. Remove cap screws (1) and whiz nuts (2) from
the radiator rear bracket (3) and frame (4) (Fig. 22).
3
1
1. Carriage bolt
2. Whiz nut
2
4
Figure 23
3. Radiator bracket
4. Frame
C. Remove carriage bolts (1) and whiz nuts (2) from the radiator bracket (3) and frame (4) (Fig. 23).
D. Pull radiator assembly out and then up from the engine to prevent the engine cooling fan from catch­ing the radiator top and bottom shrouds.
Engine
Page 3 – 16
Reelmaster 2300–D/2600–D
17. Remove engine (Fig. 19) A. Attach short section of chain between both lift
tabs (1) located on each end of the cylinder head (2) (Fig. 24)
B. Connect a hoist or chain fall at the center of the short section of chain. Apply enough tension on the short chain so that the engine will be supported when the cap screws (42) securing the engine mount brackets (22, 34, and 46) are removed.
1
2
C. Remove cap screws (42) and flange nuts (27) from the engine mount brackets (22, 34, and 46) and the frame.
Note: One person should operate the chain fall or hoist while another person guides the engine out of the frame.
Note: Be careful not to damage the engine, fuel lines, hydraulic hoses, electrical harness or other parts while removing the engine.
D. Remove engine (25) from the frame. E. Mount engine onto an engine rebuilding stand.
Figure 24
1. Lifting tab 2. Cylinder head
Engine
Reelmaster 2300–D/2600–D Page 3 – 17 Engine
Engine Reinstallation
3. If mount brackets (22, 34, and 46) were removed re­install them as follows (Fig. 19):
A. For front mount brackets (34), secure brackets to the engine (25) with cap screws (36), lock wash­ers (33) and washers (13). T orque cap screws from 34 to 42 ft–lb (4.7 to 5.8 kg–m).
B. For left rear mount bracket (22), secure bracket to the engine (25) with two cap screws (36), lock washers (33) and washers (13) through the left holes. Leave the right holes open for the muffler. Torque cap screws from 34 to 42 ft–lb (4.7 to 5.8 kg–m).
C. For right rear mount bracket (46), secure brack­ets to the engine (25) with cap screws (36), lock washers (33) and washers (13). Leave cap screws
loose enough so that the position of the bracket can be adjusted after the engine is installed.
4. Reinstall engine (Fig. 19) A. Attach short section of chain between both lift
tabs (1) located on each end of the cylinder head (2) (Fig. 24)
B. Connect a hoist or chain fall at the center of the short section of chain. Apply enough tension on the short chain so that the engine will be supported when the engine is removed from the engine re­building stand. Remove engine from the engine re­building stand.
Note: One person should operate chain fall or hoist while another person guides the engine into the frame.
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).
5. Reinstall radiator assembly. A. Place radiator assembly down and then into the
engine to prevent the engine cooling fan from catch­ing the radiator top and bottom shrouds.
B. Connect air filter hose extending from the engine to the air cleaner. Tighten hose clamp.
C. Support the radiator assembly while installing the fasteners.
D. Install carriage bolts (1) and whiz nuts (2) to the radiator bracket (3) and frame (4) (Fig. 23).
E. Install cap screws (1) and whiz nuts (2) to the ra­diator rear bracket (3) and frame (4) (Fig. 22).
6. Reconnect electrical connections (Fig. 19). A. Untie harness and hoses from the reservoir sup-
port brackets. Pull wiring harness and hydraulic hoses into position; keep them from contacting moving parts. Install cap screw (10) and flat washer (11) to R–clamp (12) and tighten to cylinder head.
B. Reconnect connector with blue leads to the al­ternator.
C. Reconnect connector with blue/white leads to the traction clutch.
D. Reconnect connector to the front lift cylinder mi­croswitch.
E. Reconnect white/black lead to the temperature sender located on the top of the water pump.
F . Reconnect tan lead to the high temperature shut down switch located on the water pump behind the fan.
Note: Be careful not to damage the engine, fuel lines, hydraulic hoses, electrical harness or other parts while reinstalling the engine.
C. Reinstall engine (25) onto the frame. Make sure fastener holes of the mount brackets (22, 34, and
46) are aligned with the holes on the frame. D. Secure cap screws (42) and flange nuts (27) to
the mount brackets (22, 34, and 46) and frame.
Engine
Page 3 – 18
G. Reconnect purple lead to the fuel valve solenoid located above the lift pump.
H. Reconnect brown lead to the oil pressure switch located on the front of the cylinder head.
I. Reconnect white lead to the glow plugs located on the front right side of the cylinder head.
Reelmaster 2300–D/2600–D
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.
7. Reconnect throttle cable (Fig. 19).
1 1. 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. Add antifreeze to radiator as described in Checking
the Cooling System. A. Run throttle cable to engine (25). B. Reinstall clevis pin (29), throttle tab (30), and
throttle cable to the engine governor lever. Reinstall and lock cotter pin (31) to the clevis pin.
C. Install throttle cable into the throttle cable clamp (26). Tighten cap screw (43).
8. Reinstall exhaust system (Fig. 19). A. Position muffler (14) and muffler gasket (45)
onto the exhaust manifold. Install capscrews (39) and flat washers (11) to the muffler and exhaust manifold. Tighten cap screws.
B. Reinstall cap screws (36) and washers (13) into the muffler and right rear mount bracket (46).
C. Slide muffler tube through the U–clamp (17). Connect muffler tube to the muffler . Tighten nut (20) and U–clamp.
D. Reinstall muffler clamp (19) to the muffler (14) and muffler tube (15).
9. Reconnect hydraulic hoses from the oil cooler.
14. Slide the left foot rest (5) (Fig. 17) onto the adjusting rod (2) (Fig. 18). Reinstall cap screws (3) and flange nut (4) securing the left footrest (5) to the frame. Tighten cap screws (Fig. 17).
15. Connect adjusting rod to brake arm (3) Install and lock cotter pin (1) to the adjusting rod (2) (Fig. 18).
16. Reinstall fender bracket (2) and left fender (1) to the radiator side of the frame (Fig. 17).
A. Secure both cap screws (3) and left fender bracket (2) to the frame.
B. Reinstall remaining cap screws (3) and flange nuts (4) securing the fender to the fender bracket and frame.
C. Secure cap screw (3) and flange nut (4) to the left foot rest (5) and the left fender (1).
17. Replace traction pump drive belt as described in Traction (Electric) Clutch of the Service and Repairs section of Chapter 5 – Electrical System.
18. Adjust traction pump drive belt as described in the Adjustment section of Chapter 4 – Hydraulic system.
Engine
A. Unplug hydraulic hose (2) and hydraulic elbow fitting (3). Connect hydraulic supply hose to the hy­draulic elbow fitting. Tighten hose clamp (1) (Fig.
21). B. Unplug hydraulic return hose (2) and hydraulic
fitting (3). Connect hydraulic return hose to the hy­draulic fitting. Tighten hose clamp (1) (Fig. 20).
10. Connect hoses to the engine (Fig. 19). A. Connect fuel hose (return) to the injector nozzle
piping and tighten hose clamp. B. Unplug fuel hose (44). Connect fuel hose to the
lift pump and tighten hose clamp (38). C. Connect upper radiator hose (18) and lower ra-
diator hose (24) to the engine. Tighten hose clamps (23).
D. Connect air filter hose to the engine (25).
Reelmaster 2300–D/2600–D Page 3 – 19 Engine
19. Connect negative (–) and then positive (+) battery cables at the battery.
20. Adjust hand brake as described in the Adjustment section of Chapter 6 – Wheels and Brakes.
21. Adjust throttle linkage as described in the Adjust­ment section of this chapter.
22. Bleed fuel system. See Bleeding the Fuel System.
23. Check oil level as described in Changing the Engine OIl and Filter.
24. Replace access covers to the engine. A. Reinstall left rear panel (radiator side) which
supports the instrument panel. B. Reinstall right side panel which accesses the
traction pump drive belt. C. Reinstall hood to the machine and close.
Engine
Page 3 – 20
Reelmaster 2300–D/2600–D
Table of Contents
Chapter 4
Hydraulic System
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .
Hydraulic Hoses 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fitting Installation 3. . . . . . . . . . . . . . . . . .
Checking the Hydraulic System Fluid 5. . . . . . . . . .
Changing the Hydraulic System Fluid and Filter 6.
Pushing or Towing the Traction Unit 6. . . . . . . . . . .
HYDRAULIC SCHEMATIC 7. . . . . . . . . . . . . . . . . . . . .
HYDRAULIC FLOW DIAGRAMS 8. . . . . . . . . . . . . . . .
Raise Cutting Units 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Forward 10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Reverse 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mow 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Test Kit 16. . . . . . . . . . . . . . . . . .
Hydraulic Tester – Pressure and Flow 16. . . . . . . .
TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Oil Leaks 17. . . . . . . . . . . . . . . . . . . . . . . . .
Foaming Hydraulic Fluid 17. . . . . . . . . . . . . . . . . . . .
Hydraulic System Operates Hot 17. . . . . . . . . . . . . .
Neutral Is Difficult to Find or Operates in One
Direction Only 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Response Is Sluggish 17. . . . . . . . . . . . . . .
No Traction in Either Direction 17. . . . . . . . . . . . . . .
Wheel Motor Will Not Turn 18. . . . . . . . . . . . . . . . . .
Wheel Motor Will Not Hold Load In Neutral 18. . . .
Noisy Wheel Motor Drive Pump (Cavitation) 18. . .
Reels Will Not Turn 18. . . . . . . . . . . . . . . . . . . . . . . . .
Reel Speed Is Erratic 18. . . . . . . . . . . . . . . . . . . . . . .
Reel Motor Case Drain Flow Is Excessive 18. . . . .
Cutting Units Will Not Lift or Lift Slowly 18. . . . . . . .
Cutting Units Raise, but Will Not Stay Up 18. . . . . .
TESTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test No. 1: Traction Pump Flow 20. . . . . . . . . . . . . .
Test No. 2: Charge Pump Flow and
Implement Relief Pressure 22. . . . . . . . . . . . . . . . .
Test No. 3: Charge Relief Pressure 24. . . . . . . . . . .
Test No. 4: Real Drive Pump Efficiency 26. . . . . . .
Test No. 5: Manifold Relief Valve Pressure 28. . . .
Test No. 6: Cross–over Relief Pressures 30. . . . . .
Test No. 7: Reel Motor Case Drain 32. . . . . . . . . . .
ADJUSTMENTS 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission for Neutral 34. . . . . . . . . . . . . . . . . . . .
Traction Pedal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traction Pedal Damper 35. . . . . . . . . . . . . . . . . . . . .
Hydraulic Pump Drive Belt 36. . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 37. . . . . . . . . . . . . . . . . . . . .
Traction/Charge Pump 37. . . . . . . . . . . . . . . . . . . . . .
Wheel Motor 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2WD/3WD Two Position Valve 54. . . . . . . . . . . . . . .
Reel Motor Drive Pump 57. . . . . . . . . . . . . . . . . . . . .
Reel Motor 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Manifold 63. . . . . . . . . . . . . . . . . . . . . . . . .
Front Lift Cylinder 67. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Lift Cylinder 71. . . . . . . . . . . . . . . . . . . . . . . . . .
Control and Implement Relief Valves 74. . . . . . . . .
Hydraulic Reservoir 77. . . . . . . . . . . . . . . . . . . . . . . .
Flushing the Hydraulic System 79. . . . . . . . . . . . . . .
Hydraulic System Start–up 80. . . . . . . . . . . . . . . . . .

System

Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 1

Specifications

Item Description
Traction Pump Variable displacement piston pump
Maximum Operating Pressure 3000 PSI (207 bar) Maximum Intermittent Pressure 5000 PSI (345 bar) Maximum Rated Speed 3600 RPM Rated Flow @ Maximum Rated Speed and Pressure 17 GPM (64 LPM)
Charge Pump Gerotor pump
Maximum Operating Pressure 500 PSI (34.5 bar) Maximum Rated Speed 3600 RPM Rated Flow @ Maximum Rated Speed and Pressure 3.5 GPM (13.2 LPM) Charge Pressure 100 to 150 PSI (6.9 to 10.0 bar)
Implement (Lift) Relief Valve Differential area relief valve
Implement Relief Pressure 450 – 525 PSI (31.1 to 36.2 bar)
Wheel Motors Orbital rotor pump (with shuttle valve on left front motor)
Maximum Operating Pressure 2000 PSI (138 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Rated Speed 267 RPM Rated Flow @ Maximum Rated Speed and Pressure 15 GPM (57 LPM)
Reel Motor Drive Pump Positive displacement gear type pump
Maximum Operating Pressure 4000 PSI (276 bar) Maximum Intermittent Pressure 4400 PSI (304 bar) Maximum Rated Speed 4000 RPM Rated Flow @ Maximum Rated Speed and Pressure 8.5 GPM (32 LPM)
Hydraulic Manifold Relief Valve Differential area relief valve
Cutting Circuit Relief Pressure 2700 to 3300 PSI (186.3 to 227.7 bar)
Reel Motor Gear motor Cross–over Relief Pressure 1350 to 1650 PSI (93.2 to 113.9 bar)
Maximum Operating Pressure 2250 PSI (155 bar) Maximum Intermittent Pressure 3000 PSI (207 bar) Maximum Rated Speed 3000 RPM Rated Flow @ Maximum Rated Speed and Pressure 28.6 GPM (108 LPM)
Lift Control Valve Spool type directional control valve
Hydraulic Filter 10 Micron spin–on cartridge type
Hydraulic Oil * Mobil 424/Shell Donax TD or equivalent
Hydraulic Reservoir Reservoir capacity 2.3 gal. U.S. (8.7 L)
Total system capacity approximately 3.3 gal. U.S. (12.5 L)
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 2

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.
When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint on the hose. Use two wrenches; hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other.
W ARNING
Before disconnecting or performing any work on hydraulic system, all pressure in system must be relieved by stopping the engine and lowering or supporting the box and/or other attachment.
Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or card­board, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury. If fluid is injected into the skin, it must be surgical­ly removed within a few hours by a doctor familiar with this type of injury . Gangrene may result from such an injury.
Hydraulic Fitting Installation
O–Ring Face Seal
1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.
2. Make sure the O–ring is installed and properly seated in the groove. It is recommended that the O–ring be replaced any time the connection is opened.
3. Lubricate the O–ring with a light coating of oil.
4. Put the tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight.
5. Mark the nut and fitting body. Hold the body with a wrench. Use another wrench to tighten the nut to the cor­rect flats from finger tight (F .F.F .T .). The markings on the nut and fitting body will verify that the connection has been tightened.
Size F.F.F.T .
4 (1/4 in. nominal hose or tubing) .75 + 6 (3/8 in.) .75 + 8 (1/2 in.) .75 + 10 (5/8 in.) 1.00 + 12 (3/4 in.) .75 + 16 (1 in.) .75 +
.25 .25 .25 .25 .25 .25
Nut
Sleeve
Seal
Body
Figure 1
Final Position
Mark Nut and Body
Extend Line
Initial Position
Finger Tight After Proper Tightening
Figure 2
System
System
Hydraulic
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 3
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.
3. Lubricate the O–ring with a light coating of oil.
O–Ring
4. Install the fitting into the port and tighten it down full length until finger tight.
5. Tighten the fitting to the correct flats from finger tight (F .F .F .T .).
Size F .F .F .T .
4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 8 (1/2 in.) 1.50 + 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +
.25 .25 .25 .25 .25 .25
SAE Straight Thread O–Ring Port – Adjustable
1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material.
2. Always replace the O–ring seal when this type of fit­ting shows signs of leakage.
3. Lubricate the O–ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure the back up washer is not loose and is pushed up as far as possible (Step 1).
Figure 3
Lock Nut
Back–up Washer
O–Ring
5. Install the fitting into the port and tighten finger tight until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by the required amount, but no more than one full turn (Step 3).
7. Hold the fitting in the desired position with a wrench and turn the jam nut with another wrench to the correct flats from finger tight (F.F.F.T.) (Step 4).
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 + 6 (3/8 in.) 1.50 + 8 (1/2 in.) 1.50 + 10 (5/8 in.) 1.50 + 12 (3/4 in.) 1.50 + 16 (1 in.) 1.50 +
.25
25 .25 .25 .25 .25
Figure 4
Step 3Step 1
Step 2 Step 4
Figure 5
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 4
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.
Group 1 Hydraulic Fluid (Recommended for ambi­ent temperatures consistently below 100 F.):
ISO type 46/68 anti–wear hydraulic fluid Mobil Mobil Fluid 424
Amoco Amoco 1000 International Harvester Hy–Tran Texaco TDH Shell Donax TD Union OIl Hydraulic/T ractor Fluid Chevron Tractor Hydraulic Fluid BP Oil BP HYD TF Boron OIl Eldoran UTH Exxon Torque Fluid Conoco Power–Tran 3 Kendall Hyken 052 Phillips HG Fluid
Note: The fluids within this group are interchange­able.
Group 2 Hydraulic Fluid (Biodegradable):
1
2
Figure 6
1. Hydraulic reservoir cap 2. Sight gauge
IMPORTANT: Use only types of hydraulic fluids specified. Other fluids could cause system damage.
Note: A red dye additive for the hydraulic system fluid
is available in 2/3 oz bottles. One bottle is sufficient for 4 to 6 gallons (15 to 22 liters) of hydraulic fluid. Order Part No. 44–2500 from your Authorized T oro Distributor .
1. Position machine on a level surface. Make sure en­gine is off and parking brake is set.
System
Hydraulic
ISO VG 32/46 anti–wear hydraulic fluid
Mobil EAL 224 H
IMPORTANT: Due to the nature of biodegradable fluids, it is critical that the fluid be changed at the recommended intervals or severe hydraulic compo­nent damage may occur.
Note: The fluid in this group is not compatible with the
fluids in group 1.
IMPORTANT: These hydraulic fluids are specified to allow optimal operation of the machine in a wide range of temperatures encountered. The group 1 fluids are a multi–viscosity hydraulic fluids which allows operation at lower temperatures without the increased viscosity that is associated with straight viscosity fluids.
Note: When changing from one type of hydraulic fluid
to the other, be certain to remove all the old fluid from the system, because some brands of one type are not com­pletely compatible with some brands of the other type of hydraulic fluid.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 5
IMPORTANT: To prevent system contamination, clean top of hydraulic fluid containers before punc­turing. Assure pour spout and funnel are clean.
4.Install reservoir cap. Wipe up any fluid that may have spilled.
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. Park the machine on a level surface, lower the cut­ting units, set parking brake and turn the engine off.
2. If only the filter is to be changed, remove reservoir cap and insert reservoir plug (Fig. 7), to block outlet. This will retain most of the fluid in reservoir when filter is re­moved.
3. Clean the area around the hydraulic oil filter. Re­move filter from the bottom of the filter housing and allow the oil to flow into a drain pan. Use a bottom type filter wrench. Dispose of the oil filter properly.
4. Apply a film of oil on the filter gasket. Install filter by hand until gasket contacts the mounting head; then tighten filter an additional three–fourths turn.
1
2
Figure 7
1. Reservoir plug 2. Reservoir outlet
5. Fill the reservoir to proper level, refer to Checking the Hydraulic System Fluid.
6. Place all controls in neutral or disengaged position and start engine. Run engine at lowest possible RPM to purge the system of air.
7. Run engine until lift cylinders extend and retract and forward and reverse wheel motion is achieved.
9. Check all connections for leaks.
Pushing or Towing the Traction Unit
IMPORTANT: Do not tow the machine faster than 2–3 mph because drive system may be damaged. If machine must be moved a considerable distance, transport it on a truck or trailer.
1
Figure 8
1. Hydraulic oil filter
1. Locate by–pass valve on pump and rotate it 90_ so the by–pass valve is horizontal.
2. Before the starting engine, close by–pass valve by rotating it 90_ so the by–pass valve is vertical. Do not start engine when valve is open.
1
Figure 9
1. By–pass valve
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 6

Hydraulic Schematic

(SHOWN IN 3WD)
2WD/3WD SELECTOR
BOTTOM
TOP
WHEEL MOTOR
12 in3
REAR
[197cc]
LEFT WHEEL MOTOR SCHEMATIC
REEL MOTOR SCHEMATIC
CROSS–OVER RELIEF
1500 PSI
[25.2cc]
1.54 in3
REEL MOTORS
FORWARD
REVERSE
IN (FRONT)
VAL VE TOP A
2.1 GPM
PC FLOW CONTROL
BOTTOM B
OUT (REAR)
TOW VALVE
TOP
BOTTOM
2
475 psi
REEL LIFT
CONTROL VALVE
CHARGE RELIEF
LIFT RELIEF
FRONT
100–150 psi
FILTER
10 MICRON NOM
TOP
2.3 GALLON
RESERVOIR
LOW PRESSURE
BOTTOM
.42 IN3
[6.9CC]
CHARGE PUMP
[8.7 LITER]
1.24 in3
[20.3 cc)
TRACTION PUMP
COOLER
FRONT
.49 in3
[8.0cc]
GEAR PUMP
G1
REEL SPEED CONTROLLER
P1
1
RH
M2
D1
FCI
M1
M5
MD1
BACKLAPPING
LC1
D3
VALVE
LOGIC
VALVE
R1
CTR
LH
M6
M4
M3
D2
System
Hydraulic
FLOW CONTROL VALVE
REEL
REEL
VALVE
ON–OFF
RELIEF
3000 psi
S1
RIGHT
WHEEL MOTOR
12 in3
[197cc]
OUTER
A–LOWER
LIFT CYL
FRONT
B–UPPER
INNER
LIFT CYL
REAR
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 7
LINE)
(REAR
FORWARD
LINE)
(FRONT
REVERSE
12 in3
[197cc]
LEFT
WHEEL MOTOR
REAR WHEELDRIVE CIRCUIT IS
de–energized
Solenoid S1 is shown
Hydraulic Schematic
Reelmaster 2300–D/2600–D
T2
NOT USED ON 2WD UNITS

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.
During conditions of not lifting or lowering cutting units, flow from the charge pump goes to the control valve and is by–passed (control valve position not shown) directly to the suction of the piston pump and the charge relief valve.
When the cutting units are to be raised, the control valve spool is positioned down and flow is directed out the top of the control valve to the lower and outer portions of the
lift cylinders. Hydraulic pressure against the cylinder pistons pushes the shafts out. At the same time, the pis­tons push the hydraulic fluid in the upper and inner por­tions of the lift cylinders out and through the control valve to the piston pump suction. When the control valve lever is released, spring action returns the spool to the center position and by–passes flow back to the piston pump suction. Lift cylinder movement is stopped. The cylinder position is locked in place since there is no complete cir­cuit of flow to and from the lift cylinders.
Circuit operation for lowering the lift cylinders is similar to raising them. However, the control valve spool is shifted up and flow is reversed to and from the lift cylin­ders, thus moving the cutting units down.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 8
(SHOWN IN 3WD)
2WD/3WD SELECTOR
BOTTOM
TOP
WHEEL MOTOR
12 in3
REAR
[197cc]
LEFT WHEEL MOTOR SCHEMATIC
REEL MOTOR SCHEMATIC
CROSS–OVER RELIEF
1500 PSI
[25.2cc]
1.54 in3
REEL MOTORS
FORWARD
REVERSE
IN (FRONT)
REEL LIFT
CONTROL VALVE
VAL VE TOP A
2.1 GPM
PC FLOW CONTROL
BOTTOM B
OUT (REAR)
TOW VALVE
TOP
BOTTOM
2
475 psi
1
LIFT RELIEF
FRONT
FILTER
TOP
100–150 psi
CHARGE RELIEF
RESERVOIR
10 MICRON NOM
LOW PRESSURE
BOTTOM
.42 IN3
[6.9CC]
CHARGE PUMP
[8.7 LITER]
2.3 GALLON
1.24 in3
TRACTION PUMP
(20.3 cc)
COOLER
FRONT
.49 in3
[8.0cc]
GEAR PUMP
G1
REEL SPEED CONTROLLER
P1
RH
M2
D1
FCI
M1
M5
MD1
BACKLAPPING
LC1
D3
VALVE
LOGIC
VALVE
R1
CTR
LH
M6
M4
M3
D2
FLOW CONTROL VALVE
REEL
REEL
VALVE
ON–OFF
RELIEF
3000 psi
S1
System
Hydraulic
12 in3
[197cc]
RIGHT
WHEEL MOTOR
OUTER
A–LOWER
LIFT CYL
FRONT
B–UPPER
INNER
LIFT CYL
REAR
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 9
LINE)
(REAR
FORWARD
LINE)
(FRONT
REVERSE
WHEEL MOTOR
LEFT
12 in3
[197cc]
T2
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Solenoid S1 is shown de–energized
Raise Cutting Units
Reelmaster 2300–D/2600–D
Control valve is positioned up
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.
With the engine running, clutch engaged, and traction pedal in the neutral position, the traction pump supplies no flow to the wheel motors. When the traction pedal is pressed to the forward position, the linkage from the pedal positions the swash plate in the traction motor so oil flows out the top port of the pump. Oil flow out of the top port goes to the wheel motors and turns them in the forward direction. The 2WD/3WD selector valve allows flow to the rear wheel in the 3WD position and by– passes the rear wheel in the 2WD position.
Oil flowing out of the wheel motors returns to the bottom port of the traction pump and is continuously pumped out the top port. However, oil flow out of the rear wheel motor must pass through the check valve portion of the PC flow controller before returning to the traction pump.
A small amount of hydraulic oil leaves the traction circuit through the bi–directional shuttle valve in the front left wheel motor. This oil is cooled as it flows through the cooler and returned to the reservoir.
Filtered hydraulic oil is supplied to the traction circuit from the charge pump though the lift control valve and back through the charge circuit check valves. This fil­tered oil replaces oil losses from flow through the shuttle valve and small amounts of leakage. The charge pump and shuttle valve circuits allow for indirect cooling and filtering of the traction circuit.
In the forward direction, the PC flow controller has a spe­cial function. When a unit is moving downhill, the opera­tor will return the traction pedal to the neutral position. In this situation, the front wheel motors act as hydraulic pumps and reverse the oil flow through the traction cir­cuit. The PC flow controller will restrict flow to the rear motor sufficiently, so the reverse flow is by–passed through the 2WD/3WD selector (check) valve around the rear wheel motor. This action will prevent a loss of steering control should the rear motor turn in the reverse direction. As a result, there is no 3WD in reverse
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 10
(SHOWN IN 3WD)
2WD/3WD SELECTOR
BOTTOM
TOP
WHEEL MOTOR
12 in3
REAR
[197cc]
LEFT WHEEL MOTOR SCHEMATIC
REEL MOTOR SCHEMATIC
CROSS–OVER RELIEF
1500 PSI
[25.2cc]
1.54 in3
REEL MOTORS
FORWARD
REVERSE
IN (FRONT)
VAL VE TOP A
2.1 GPM
PC FLOW CONTROL
BOTTOM B
OUT (REAR)
TOW VALVE
TOP
BOTTOM
2
475 psi
REEL LIFT
CONTROL VALVE
LIFT RELIEF
FRONT
CHARGE RELIEF
TOP
100–150 psi
FILTER
10 MICRON NOM
LOW PRESSURE
.42 IN3
[6.9CC]
CHARGE PUMP
RESERVOIR
BOTTOM
2.3 GALLON
[8.7 LITER]
1.24 in3
[20.3 cc)
TRACTION PUMP
COOLER
FRONT
.49 in3
[8.0cc]
GEAR PUMP
G1
REEL SPEED CONTROLLER
P1
1
RH
M2
D1
FCI
M1
M5
MD1
BACKLAPPING
LC1
D3
VALVE
LOGIC
VALVE
R1
CTR
LH
M6
M4
M3
D2
FLOW CONTROL VALVE
System
REEL
REEL
VALVE
ON–OFF
RELIEF
3000 psi
S1
Hydraulic
12 in3
[197cc]
RIGHT
WHEEL MOTOR
OUTER
A–LOWER
LIFT CYL
FRONT
B–UPPER
INNER
LIFT CYL
REAR
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 11
LINE)
(REAR
FORWARD
LINE)
(FRONT
REVERSE
T2
12 in3
[197cc]
LEFT
WHEEL MOTOR
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Solenoid S1 is shown
Traction Forward
Reelmaster 2300–D/2600–D
de–energized
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. When the traction pedal is pressed to the reverse position, the linkage from the pedal positions the swash plate in the traction motor so oil flows out the bottom port of the pump. Oil flow out of the bottom port goes to the wheel motors and turns them in the reverse direction. The 2WD/3WD selector valve by–passes the rear wheel in both the 2WD and 3WD positions.
Oil flowing out of the wheel motors returns to the top port of the traction pump and is continuously pumped out the
bottom port. However, oil flow to the rear wheel motor is blocked by the check valve portion of the PC flow con­troller and forced through the restriction before going to the motor. Flow is limited to 2.1 GPM to the rear wheel motor. This flow is suf ficient to prevent cavitation on the rear motor in reverse.
Because of the by–passing of the rear wheel motor in re­verse and the resistance to flow of the two front wheel motors, all the traction flow is by–passed directly back to the traction pump when the traction pedal is initially pushed in the reverse direction. This direct by–passing of the traction circuit causes a delay in the response of the traction pedal in reverse until traction flow exceeds
2.1 GPM (7.9 LPM) through the PC flow controller. The charge and shuttle valve circuits function the same
in reverse as they did in the forward direction.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 12
(SHOWN IN 3WD)
2WD/3WD SELECTOR
BOTTOM
TOP
WHEEL MOTOR
12 in3
REAR
[197cc]
LEFT WHEEL MOTOR SCHEMATIC
REEL MOTOR SCHEMATIC
CROSS–OVER RELIEF
1500 PSI
[25.2cc]
1.54 in3
REEL MOTORS
FORWARD
REVERSE
IN (FRONT)
VAL VE TOP A
2.1 GPM
PC FLOW CONTROL
OUT (REAR)
BOTTOM B
TOW VALVE
BOTTOM
2
425 psi
REEL LIFT
CONTROL VALVE
LIFT RELIEF
FRONT
CHARGE RELIEF
TOP
100–150 psi
FILTER
10 MICRON NOM
LOW PRESSURE
.42 IN3
[6.9CC]
CHARGE PUMP
RESERVOIR
BOTTOM
2.3 GALLON
[8.7 LITER]
1.24 in3
[20.3 cc)
TRACTION PUMP
COOLER
FRONT
.49 in3
[8.0cc]
GEAR PUMP
G1
REEL SPEED CONTROLLER
P1
1
TOP
RH
M2
D1
FCI
M1
M5
MD1
BACKLAPPING
LC1
D3
VALVE
LOGIC
VALVE
R1
CTR
LH
M6
M4
M3
D2
FLOW CONTROL VALVE
REEL
REEL
VALVE
ON–OFF
RELIEF
3000 psi
S1
System
Hydraulic
12 in3
[197cc]
RIGHT
WHEEL MOTOR
OUTER
A–LOWER
LIFT CYL
FRONT
B–UPPER
INNER
LIFT CYL
REAR
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 13
LINE)
(REAR
FORWARD
LINE)
(FRONT
REVERSE
T2
12 in3
[197cc]
LEFT
WHEEL MOTOR
High Pressure
Low (Charge) Pressure
Return or Suction
Flow
Solenoid S1 is shown
Reelmaster 2300–D/2600–D
Traction Reverse
de–energized
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. Oil then flows directly back to the reservoir through the oil cooler.
When the cutting unit switch is pulled out to the ON posi­tion with the engine running and the clutch engaged, so­lenoid valve (S1) is energized and shut, hydraulic system pressure builds up, and flow is diverted to the reel motors. Oil flow from port (P1) flows through the 1 1 position reel speed control valve. Flow across the speed control valve is pressure compensated by the logic car-
tridge valve (LC1). The logic cartridge valve maintains a pressure differential of 75 PSI (5.2 bar) across the speed control valve. Any excess flow above what the speed control valve is set for is bypassed to the reservoir through the logic cartridge valve. With the backlap valve (MD1) in the mow position, oil flows through the valve and reel motors which are connected in series. Oil flows through the right, center, and then left reel motor as it turns the motors in the mow direction. The oil then re­turns to the reservoir.
Relief valve (R1) limits system pressure and is set at 3000 PSI (207 bar). When the valve opens, oil is di­verted back to the reservoir.
Backlapping operation is the same as mowing opera­tion, except for the position of the backlap valve (MD1). The backlap valve is in the backlap position allowing oil flow through the left, center, and then right reel motor as it turns the motors in the backlap direction.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 14
(SHOWN IN 3WD)
2WD/3WD SELECTOR
BOTTOM
TOP
WHEEL MOTOR
12 in3
REAR
[197cc]
LEFT WHEEL MOTOR SCHEMATIC
REEL MOTOR SCHEMATIC
CROSS–OVER RELIEF
1500 PSI
[25.2cc]
1.54 in3
REEL MOTORS
FORWARD
REVERSE
IN (FRONT)
VAL VE TOP A
2.1 GPM
PC FLOW CONTROL
OUT (REAR)
BOTTOM B
TOW VALVE
BOTTOM
2
425 psi
REEL LIFT
CONTROL VALVE
LIFT RELIEF
FRONT
CHARGE RELIEF
TOP
100–150 psi
FILTER
10 MICRON NOM
LOW PRESSURE
.42 IN3
[6.9CC]
CHARGE PUMP
RESERVOIR
BOTTOM
2.3 GALLON
[8.7 LITER]
1.24 in3
[20.3 cc)
TRACTION PUMP
COOLER
FRONT
.49 in3
[8.0cc]
GEAR PUMP
G1
REEL SPEED CONTROLLER
P1
1
TOP
RH
M2
D1
FCI
M1
M5
MD1
BACKLAPPING
LC1
D3
VALVE
LOGIC
VALVE
R1
CTR
LH
M6
M4
M3
D2
FLOW CONTROL VALVE
REEL
VALVE
ON–OFF
S1
REEL
RELIEF
3000 psi
System
System
Hydraulic
Hydraulic
12 in3
[197cc]
RIGHT
WHEEL MOTOR
OUTER
A–LOWER
LIFT CYL
FRONT
B–UPPER
INNER
LIFT CYL
REAR
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 15
LINE)
(REAR
FORWARD
LINE)
(FRONT
REVERSE
T2
12 in3
[197cc]
LEFT
WHEEL MOTOR
High Pressure
Low Pressure (Charge)
Return or Suction
Flow
Solenoid S1 is shown energized
Mow
Reelmaster 2300–D/2600–D
Valve MD1 is selected to mow

Special Tools

Order these tools from the
AND APPLICATIONS GUIDE (COMMERCIAL PROD­UCTS)
.
TORO SPECIAL TOOLS
Hydraulic Pressure Test Kit
Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each, 1000, 5000 and 10000 PSI gauges. Use gauges as recommended in Testing section of this chapter.
Hydraulic Tester – Pressure and Flow
Figure 10
Figure 11
This tester requires o–ring face seal (ORFS) adapter fit­tings for use on this machine.
1. INLET HOSE: Hose connected from the system cir­cuit to the inlet side of the hydraulic tester.
2. LOAD V ALVE: A simulated working load is created in the circuit by turning the valve to restrict flow.
3. LOW PRESSURE GAUGE: Low range gauge to provide accurate reading at low pressure, 0 to 1000 PSI.
A protector valve cuts out when pressure is about to exceed the normal range for the gauge. The cutout pressure is adjustable.
4. HIGH PRESSURE GAUGE: High range gauge which accommodates pressures beyond the capacity of the low pressure gauge, 0 to 5,000 PSI.
5. FLOW METER: This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM.
6. OUTLET HOSE: A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 16

Troubleshooting

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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.
Problem
Hydraulic oil leaks
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БББББББББББ
Foaming hydraulic fluid
БББББББББББ
БББББББББББ
БББББББББББ
Hydraulic system operates hot
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
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Possible Cause
Fitting(s), hose(s), or tube(s) are loose or damaged.
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O–ring(s) or seal(s) are missing or damaged.
ББББББББББББББББББББ
Oil level in reservoir is low.
ББББББББББББББББББББ
Hydraulic system has wrong kind of oil.
ББББББББББББББББББББ
One of the pump suction lines has an air leak.
ББББББББББББББББББББ
Transmission pressure is high due to load or brakes applied.
ББББББББББББББББББББ
Oil level in reservoir is low, or inlet filter is loose or clogged.
ББББББББББББББББББББ
ББББББББББББББББББББ
Oil is contaminated or too light.
ББББББББББББББББББББ
Heat exchanger is damaged or plugged. By–pass relief is stuck
ББББББББББББББББББББ
open or air flow is obstructed.
ББББББББББББББББББББ
Charge pressure is low.
ББББББББББББББББББББ
ББББББББББББББББББББ
Towing by–pass valve is open or defective.
ББББББББББББББББББББ
Wheel motor(s) or reel motor(s) are worn or damaged.
ББББББББББББББББББББ
Traction pump is worn or damaged.
ББББББББББББББББББББ
Continued use of an improperly functioning hydraulic system could lead to extensive internal component damage.
The charts that follow contain information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction.
Refer to the Testing section of this Chapter for precau­tions and specific test procedures.
System
Hydraulic
Neutral is difficult to find or unit oper-
БББББББББББ
ates in one direction only
БББББББББББ
Traction response is sluggish
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
No traction in either direction
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 17
External control linkage is misadjusted, disconnected, binding, or
ББББББББББББББББББББ
damaged.
ББББББББББББББББББББ
Traction pump is worn or damaged. Charge pressure is low. Hydraulic oil is very cold.
ББББББББББББББББББББ
ББББББББББББББББББББ
Towing by–pass valve is open or worn. Brake is not released.
ББББББББББББББББББББ
Traction pump or wheel motor(s) are worn or damaged.
ББББББББББББББББББББ
Brake is not released.
ББББББББББББББББББББ
ББББББББББББББББББББ
Oil level in reservoir is low.
ББББББББББББББББББББ
Towing by–pass valve is open.
ББББББББББББББББББББ
ББББББББББББББББББББ
Charge pressure is low.
ББББББББББББББББББББ
Traction pump or wheel motor(s) are worn or damaged.
ББББББББББББББББББББ
Problem
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Possible Cause
Wheel motor will not turn
БББББББББББ
БББББББББББ
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Wheel motor will not hold load in
БББББББББББ
neutral
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Noisy reel motor drive pump (cavita-
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tion)
БББББББББББ
БББББББББББ
Reels will not turn
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
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Internal parts in wheel motor are damaged.
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Brakes are binding.
ББББББББББББББББББББ
ББББББББББББББББББББ
Key on wheel motor shaft is sheared or missing. Make up fluid from charge pump is not available.
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ББББББББББББББББББББ
Flow control setting is wrong for reverse. Reservoir oil level is low.
ББББББББББББББББББББ
Suction line is restricted.
ББББББББББББББББББББ
ББББББББББББББББББББ
Suction line has an air leak. Cross–over relief valve(s) are stuck open. (The other reels will still
ББББББББББББББББББББ
rotate.)
ББББББББББББББББББББ
Valve S1 is stuck open.
ББББББББББББББББББББ
ББББББББББББББББББББ
An electrical problem exists. (See Chapter 5–Electrical System)
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Relief valve R1 is stuck open.
ББББББББББББББББББББ
ББББББББББББББББББББ
LC1 logic valve is stuck open.
ББББББББББББББББББББ
Reel motor drive pump is damaged.
Reel speed is erratic
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БББББББББББ
Reel motor case drain flow is exces-
БББББББББББ
sive. Flow is greater than 0.7 GPM
БББББББББББ
at 1200 PSI (2.6 LPM at 82.8 bar). Cutting units will not lift or lift slowly
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
БББББББББББ
Cutting units raise, but will not stay
БББББББББББ
up
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Reel to bedknife adjustment is too tight.
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ББББББББББББББББББББ
Reel bearing(s) are damaged. Excessive internal wear in wheel motor exists.
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Reel bearing(s) are damaged.
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Engine speed is too low.
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Pump pulley drive belt is loose.
ББББББББББББББББББББ
ББББББББББББББББББББ
Charge pump is damaged.
ББББББББББББББББББББ
Lift valve control linkage is binding or broken.
ББББББББББББББББББББ
ББББББББББББББББББББ
Lift cylinder bushings bind.
ББББББББББББББББББББ
Reservoir oil level is low.
ББББББББББББББББББББ
Inlet filter is loose or clogged.
ББББББББББББББББББББ
ББББББББББББББББББББ
Charge pump pressure or flow is insufficient.
ББББББББББББББББББББ
Implement relief valve is stuck open.
ББББББББББББББББББББ
ББББББББББББББББББББ
Lift control valve is damaged.
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Lift cylinders leak internally.
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Lift cylinders leak internally.
ББББББББББББББББББББ
ББББББББББББББББББББ
Lift valve leaks.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 18

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.)
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test pro­cedures could result in damage to gauge and possible personal injury from leaking hot oil.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding link­age, loose fasteners, or improper adjustments must be checked before assuming that a hydraulic component is the source of the problem being experienced.
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. Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components.
3. The engine must be in good operating condition. Use a tachometer when making a hydraulic test. Engine speed can affect the accuracy of the tester readings.
4. T o prevent damage to tester or components, the in­let and the outlet hoses must be properly connected, and not reversed (tester with pressure and flow capabili­ties).
5. To minimize the possibility of damaging compo­nents, completely open load valve in hydraulic tester (when using tester with pressure and flow capabilities).
6. Install fittings finger tight, far enough to insure that they are not cross–threaded, before tightening with a wrench.
W ARNING
Before disconnecting or performing any work on the hydraulic system, all pres­sure in the system must be relieved by stopping the engine and lowering or supporting the cutting units or other implements.
Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or card­board, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and cause serious injury. If fluid is injected into the skin, it must be surgical­ly removed within a few hours by a doctor familiar with this type of injury . Gangrene may result from such an injury.
7. Position the tester hoses so that rotating machine parts will not make contact with them and result in hose or tester damage.
8. Check the oil level in the reservoir.
9. Check the control linkage for improper adjustment, binding or broken parts.
10. All hydraulic tests should be made with the hydraulic oil at normal operating temperature.
System
System
Hydraulic
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 19
TEST NO. 1: Traction Pump Flow
WHEEL MOTOR
RIGHT
FORWARD
TO REAR WHEEL MOTOR
REVERSE
BOTTOM
CHARGE PUMP
TRACTION PUMP
FROM REAR WHEEL MOTOR
PC FLOW CONTROL
2.1 GPM
TESTER
TOP
FROM CONTROL VALVE
FRONT
TO CONTROL VALVE
TOP
FROM FROM RESERVOIR
BOTTOM
REVERSE (FRONT LINE)
FORWARD (REAR LINE)
WHEEL MOTOR
LEFT
High Pressure Low Pressure Return or Suction
Flow
TO HYDRAULIC MANIFOLD PORT T2
FRONT
Figure 12
FRONT
TO RESERVOIR
FORWARD DISCHARGE
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 20
Procedure for Traction Pump Flow
1. Make sure hydraulic oil is at normal operating tem­perature by operating the machine for approximately 10 minutes.
3. Make sure the hydraulic tank is full.
4. Make sure that traction pedal is adjusted to the neu­tral position (see Traction Pedal in the Adjustments Sec­tion).
5. Make sure that pump drive belt is adjusted properly . (see Hydraulic Pump Drive belt in the Adjustments Sec­tion).
Check:
IMPORT ANT: Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose.
12. Install tester in series with the motor and the discon­nected hose. Make sure the flow control valve is fully open.
13. One person should sit on the seat and operate the machine while another person reads the tester. Start en­gine and move the throttle to full speed (3200 100 RPM).
CAUTION
6. Block up one front traction wheel off the floor to allow flow through the traction circuit.
7. Chock remaining wheels to prevent movement of the machine.
8. Attach a heavy chain to the rear of the machine frame and something solid in the shop.
9. Make sure parking brake is off.
10. Put 2WD/3WD selector to 2WD so the rear wheel will not spin.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Use extreme caution when taking gauge readings. The front tire on the ground will be trying to move the machine forward.
14. Slowly push traction pedal into fully forward posi­tion.
15. Close flow control valve until pressure gauges read 1000 PSI. Verify pump speed of 2700 RPM with a photo­tac.
16. Observe flow gauge. TESTER READING: minimum flow of 13 GPM
17. Release traction pedal and turn off machine.
18. Disconnect tester from elbow connection and hose.
Reconnect hose to elbow connection.
19. If specifications are not met, the traction pump
needs to be repaired or replaced as necessary.
System
System
Hydraulic
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 21
TEST NO. 2: Charge Pump Flow and Implement Relief Pressure
CONTROL VALVE TO WHEEL MOTORS
TO LIFT CYLINDER
FROM LIFT CYLINDER
BOTTOM
VALVE TOP
BOTTOM
IN (FRONT)
OUT (REAR)
2
1
CHARGE PUMP
TRACTION PUMP
TO MANIFOLD
High Pressure Low Pressure Return or Suction
Flow
REEL MOTOR DRIVE PUMP
FRONT
TOP
BOTTOM
IMPLEMENT RELIEF
TESTER
FILTER
RESERVOIR
FRONT
RETURN FROM MANIFOL
COOLER
DISCHARGE
FRONT
Figure 13
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 22
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 the hydraulic tank is full.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
4. Disconnect outside top hose from the discharge fit­ting of the charge pump. Connect gage end of tester to the pump discharge fitting.
5. Connect the other end of the tester to the discon­nected hose.
3. Make sure hydraulic oil is at operating temperature.
4. Watch pressure gauge carefully . Make sure lift lever to the cutting units is in the neutral position. Record the pressure.
5. While holding the lift lever in the raised position, watch the pressure gauge. Record pressure the relief valve opens at.
6. Return lift lever to neutral position. Shut off engine.
7. Subtract the relief valve closed pressure from the relief valve open pressure (see example below). The dif­ference should be from 450 to 500 PSI.
A. If this specification is not met, adjust relief valve. B. If this specification is met, go to step 9.
Example Calculation
Relief V alve Open
(Lever to Raise)
PRESSURE
620
CAUTION
Make sure that all hoses are free of the fly­wheel after installation.
6. Operate engine at full speed (3200 100 RPM).
7. Make sure hydraulic oil is at operating temperature.
8. Make sure that traction pedal and lift valve are in neutral and the parking brake is engaged.
9. Watch flow and pressure gauges carefully while slowly closing the flow control valve until the pressure gauge reads 500 PSI.
10. Minimum flow gauge reading should be 2.5 GPM. If specification is not met, repair or replace pump.
Procedure for Implement Relief
Check:
Relief V alve Closed
(Lever in Neutral)
Open less Closed Pressure
(450 to 500 PSI)
8. Adjusting the relief valve pressure as follows: A. Remove the cap from the relief valve. B. To increase the relief valve pressure set point,
use an allen wrench and turn set screw slightly clockwise.
C. To decrease the relief valve pressure set point, use an allen wrench and turn set screw slightly counterclockwise.
D. Repeat steps 1 through 8 above until the relief valve pressure set point is correct. Reinstall cap on valve when valve is set properly.
E. If the relief valve pressure set point can not be adjusted to specification, go to step 9 and replace the relief valve.
150
470
System
Hydraulic
CAUTION
Do not allow charge pressure to exceed 650 PSI.
1. Fully open control valve on the tester.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 23
Note: If the pressure and flow are within specification but the cutting units do not lift or lift slowly , check for me­chanical binding or internal leakage of the lift cylinder.
9. Disconnect tester from the pump and hose. Recon-
nect hose to the pump.
TEST NO. 3: Charge Pump Relief Pressure
TO WHEEL MOTORS
TO LIFT CYLINDER
FROM LIFT CYLINDER
BOTTOM
CHARGE PUMP
TRACTION PUMP
VALVE TOP
BOTTOM
FRONT
T–CONNECTION AND GAUGE
TOP
BOTTOM
IN (FRONT)
OUT (REAR)
2
1
CONTROL VALVE
IMPLEMENT RELIEF
FILTER
RESERVOIR
TO MANIFOLD
High Pressure Low Pressure Return or Suction
Flow
REEL MOTOR DRIVE PUMP
FRONT
COOLER
RETURN FROM MANIFOLD
TO CHARGE RELIEF
FRONT
Figure 14
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 24
Procedure for Charge Pump Relief
Check:
1. Make sure hydraulic oil is at normal operating tem­perature by operating the machine for approximately 10 minutes.
3. Make sure the hydraulic tank is full.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
4. Disconnect hose from the front fitting of the charge pump leading to the control valve. Connect T–connector and gauge to the pump and hose fitting.
CAUTION
Make sure that all hoses are free of the fly­wheel after installation.
5. Operate engine at full speed (3200 100 RPM).
6. Make sure hydraulic oil is at operating temperature.
7. Make sure that traction pedal and lift valve are in
neutral and the parking brake is engaged.
8. Pressure gauge should read from 100 to 150 PSI.
If Specification is not met, replace charge relief valve.
9. Shut off engine.
10. Disconnect gauge and T–connection from the
pump and hose. Reconnect hose to the pump.
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 25
TEST NO. 4: Reel Drive Pump Efficiency
TO CHARGE PUMP
FILTER
BOTTOM
RESERVOIR
FROM LEFT
WHEEL MOTOR
TO TRACTION PUMP
REEL DRIVE PUMP
P1
FC1
LC1
R1
S1
T2
HYDRAULIC MANIFOLD
FRONT
MD1
G1
M2
D1
M1 M5
D3
M6
M4
D2 M3
COOLER
RH
CTR
LH
High Pressure Low Pressure Return or Suction
Flow
2
3
TESTER
3
1
Figure 15
1. Hose fitting 2. Reel drive pump 3. O–ring
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 26
Procedure for Reel Drive Pump Efficiency
1. Make sure hydraulic oil is at normal operating tem­perature by operating the machine for approximately 10 minutes.
Check:
5. Install tester in series with reel drive pump and the
6. Make sure backlap knob on the valve block is in the
mow position.
7. Make sure tester load valve is fully before starting
the engine.
3. Make sure the hydraulic tank is full.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
4. Clean hose connection and reel drive pump. Dis­connect hose connection on the reel drive pump leading port P1 on the hydraulic manifold.
IMPORT ANT: Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the pump through the tester and into the valve block.
8. Start engine and move throttle to full speed (3200
100 RPM). Do not engage the cutting units.
9. Watch pressure gauge carefully while slowly clos-
ing the flow control valve until 1500 PSI is obtained. Verify with a phototac that the pump speed is 2900 RPM.
10. Flow indication should be 5.4 GPM minimum.
11. Shut off engine.
12. Disconnect tester from manifold and hose. Recon-
nect hose to the pump.
13. If flow was less than 5.4 GPM or a pressure of 1500
PSI cannot be obtained, check for restriction in the pump intake line. If line is not restricted, remove pump and re­pair or replace as necessary.
System
System
Hydraulic
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 27
TEST NO. 5: Manifold Relief Valve Pressure
G1
FROM REEL
DRIVE PUMP
TESTER
M2
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
SHUTTLE VALVE
MD1
HYDRAULIC MANIFOLD
D1
M1
M5
D3
M6
M4
D2
M3
RH
CTR
TO COOLER
LH
High Pressure Low Pressure Return or Suction
Flow
Install tester in series between fitting and hose at the motor (right hand motor shown).
Figure 16
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 28
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.
3. Make sure the hydraulic tank is full.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
4. Clean hose connection and right hand reel motor. Disconnect the hose leading from the right hand reel motor to port M2 on the hydraulic manifold.
IMPORT ANT: Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the hose through the tester and into the motor.
5. Install tester in series with the hose and motor. Make sure the flow control valve is fully open.
6. Make sure backlap knob on the valve block is in the mow position. Make sure reel speed knob is set to posi­tion 9 or greater.
8. Watch pressure gauge carefully while slowly clos-
ing the flow control valve until the manifold relief opens.
9. System pressure should be from 2700 to 3300 PSI. A. If specification is not met, adjust relief valve. B. If this specification is met, go to step 11.
10. Adjusting the relief valve pressure as follows: A. Remove the cap from the relief valve. B. To increase the relief valve pressure set point,
use an allen wrench and turn set screw slightly clockwise.
C. To decrease the relief valve pressure set point, use an allen wrench and turn set screw slightly counterclockwise.
D. Repeat steps 1 through 10 above until the relief valve pressure set point is correct. Reinstall cap on valve when valve is set properly.
E. If the relief valve pressure set point can not be adjusted to specification, go to step 1 1 and replace the relief valve.
11. Disengage cutting units. Shut off engine.
12. Disconnect tester from manifold and hose. Recon-
nect hose to the pump.
System
Hydraulic
CAUTION
Keep away from reels during test to pre­vent personal injury from the rotating reel blades.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 29
TEST NO. 6: Cross–over Relief Pressures
TEST GAUGE (TESTING IN MOW)
G1
FROM REEL
DRIVE PUMP
M2
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
MD1
D1
M1
M5
D3
M6
M4
D2
M3
RH
CTR
TO COOLER
LH
HYDRAULIC MANIFOLD
Figure 17
T–CONNECTION AND GAUGE (TESTING IN BACKLAP)
High Pressure Low Pressure Return or Suction
Flow
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 30
Procedure for Cross–over Relief Pressures
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.
Check:
G1.
IMPORTANT: Each reel motor has two cross over reliefs. Test reliefs in the backlap direction only if they are expected to be the problem. After testing cross over reliefs in the backlap direction, make sure the reel motor couplings are torqued (see Hy­draulic Motor Removal and Installation of Chapter 7 – Cutting Units and Reel Motor in the Service and Repair section).
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
3. Clean manifold port G1. Remove cap and install pressure gauge in manifold port G1.
4. Put a block of wood between the blades of the cut­ting unit being tested to prevent the reel from rotating.
5. Make sure backlap knob on the valve block is in the mow position.
6. One person should sit on the seat and operate the machine while another person reads the tester. Start en­gine and set throttle to full speed (3200 100 RPM).
CAUTION
Keep away from reels during test to pre­vent personal injury from the rotating reel blades.
10. Clean left–hand reel motor and its hose connection
1 1. Make sure backlap knob on the valve block is in the backlap position.
12. One person should sit on the seat and operate the
machine while another person reads the gauge. Start engine and move the throttle to full speed (3200 100
RPM).
CAUTION
Keep away from reels during test to pre­vent personal injury from the rotating reel blades.
CAUTION
Do not allow system pressure to exceed 1700 PSI. Shut off unit to prevent an over pressure condition.
System
Hydraulic
CAUTION
Do not allow system pressure to exceed 1700 PSI. Shut off unit to prevent an over pressure condition.
7. Engage cutting units. Observe pressure gauge.
Motor Position
Right Hand 1500 to 1600
Rear 1540 to 1640
Left Hand 1580 to 1680
8. Disengage cutting units and stop engine. If specifi­cations are not met, replace cross–over relief. If specifi­cations are met, remove block of wood from cutting unit and repeat test on other reels in mow direction.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 31
Pressure Range (PSI)
13. Engage cutting units. Observe pressure gauge.
14. Disengage cutting units and stop engine. If specifi-
cations are not met, the cross–over relief needs replac­ing. Remove block of wood from cutting unit and repeat test on other reels in the same direction of flow.
15. Remove test gauge and reconnect hose to motor.
Adjust bed bedknife to reel on all cutting units (see Ad­justment section of Chapter 7 – Cutting Units.
Motor Position
Right Hand 1580 to 1680
Rear 1540 to 1640
Left Hand 1500 to 1600
Pressure Range (PSI)
TEST NO. 7: Reel Motor Case Drain
R
MEASURE CASE DRAIN FLOW HERE
G1
FROM REEL
MOTOR
DRIVE PUMP
TEST CONNECTION FOR R.H. REEL MOTOR SHOWN
M2
FROM CARTRIDGE
VALVES AND LEFT
WHEEL MOTOR
MD1
HYDRAULIC MANIFOLD
D1
M1
M5
D3
M6
M4
D2
M3
RH
TESTER
TO COOLE
CTR
LH
High Pressure Low Pressure Return or Suction
Flow
Figure 18
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 32
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
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
Motor
Position
Right Hand D1 M1
Left Hand D2 M3
Rear D3 M6
3. On suspected bad motor, clean hose connection and disconnect hose from motor that returns to the man­ifold (see table).
IMPORT ANT: Make sure oil flow indicator arrow on the flow gauge is showing that the oil will flow from the motor through the tester and into the hose.
Manifold Port
(Case Drain)
Manifold Port
(Motor Return)
CAUTION
Keep away from reels during test to pre­vent personal injury from the rotating reel blades.
7. Engage reels by pulling the knob on the instrument
panel out. While watching pressure gauges, slowly close flow control valve until a pressure of 1200 PSI is obtained.
8. Disengage cutting units and stop engine.
9. Clean hose fitting and disconnect hose from case
drain on the manifold block (see table). Plug the man­ifold port.
10. Put case drain hose into 1 quart container gra-
duated in ounces (1 liter container graduated in millili­ters).
11. One person should sit on the seat and operate the
machine while another person holds the hose and reads the tester. Start engine and move the throttle to full speed (3200 100 RPM).
12. While sitting on seat, engage cutting units by pulling
the knob on the instrument panel out. Make sure gauge pressure still reads 1200 PSI. After 15 seconds, push knob on the instrument panel in to disengage cutting units. Stop the engine.
System
Hydraulic
4. Install tester in series with the motor and the discon­nected return hose. Make sure the flow control valve is fully open.
5. Make sure backlap knob on the valve block is in the mow position.
6. One person should sit on the seat and operate the machine while another person reads the tester. Start en­gine and move the throttle to full speed (3200 100 RPM).
13. Measure the amount of oil collected in the container.
Divide the number of ounces collected by 32 to get gal­lons per minute. (Divide the number of milliliters col­lected by 250 to get liters per minute).
14. Disconnect tester from motor and hose. Reconnect
hose to the pump.
15. Remove cap from manifold fitting. Reconnect case
drain hose to the motor.
16. If flow was greater than 0.7 GPM (2.6 LPM), repair
or replace the reel motor as necessary.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 33

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. Block up under the frame so one of the front wheels is off the floor . Place selector control in two wheel drive position.
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. When wheel stops ro­tating, tighten nuts locking adjustment. Verify the adjust­ment with throttle in SLOW and FAST position.
3. Should the wheel continue to rotate, check for the following:
A. Ball bearing is loose or worn out.
1
2
B. Loose or missing fasteners. C. Worn fasteners. D. Pump lever loose on control shaft. E. Weak or damaged Ieaf springs. Replace. F. Internal pump component malfunction.
4. After adjusting the pump plate, check neutral switch operation and if necessary, adjust as follows:
A. Loosen locknut securing switch adjusting screw. Thread away from switch until capscrew head clears switch.
B. Rotate adjusting screw toward switch until circuit through switch is made. Then, turn adjusting screw an additional 2–1/2 turns.
C. Tighten locknut
5
1. Pump plate nut
2. Pump
3. Neutral switch
4
3
Figure 19
4. Adjusting screw
5. Lock nut
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 34
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.
1. To expose traction rod, remove screws securing right fender to frame and remove fender.
2
2. Loosen jam nuts on each end of traction rod.
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.
4. Retighten jam nuts securing traction rod adjust­ment.
IMPORTANT: Verify reverse speed with one front wheel off the ground in 2WD and the engine at high idle. Reverse wheel speed should be from 120 to 140 RPM. Damage may result to rear motor if this speed is exceeded.
5. The stop for reverse travel (under pedal) may be ad­justed for slower travel.
4
3
1
1. Traction rod
2. Damper
3. Damper pivot
PEDAL ST OP CAM
5
Figure 20
4. Damper bracket
5. Pedal cam stop
0.03 to 0.09 in. (0.8 to 2.3 mm)
System
Hydraulic
Traction Pedal Damper (Fig. 20)
1. T o expose traction pedal damper, remove right hand panel.
2. Loosen locknut securing damper pivot to the damp­er bracket.
3. Depress traction pedal fully forward and hold.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 35
4. Fully compress damper and then release it allowing
it to extend 0.08 inch (2.0 mm). Tighten locknut securing the damper pivot to the damper bracket.
5. When traction pedal is fully depressed in reverse
direction, traction pedal must contact reverse stop so the damper does not act as the stop in either direction.
FOOT PLATE
Figure 21
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 1 1 to 13 pound load applied midway in span of belt.
2
1
1
Figure 22
1. Nut 2. Adjustment rod
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 36

Service and Repairs

Traction/Charge Pump
15
10
1
13
16
11
14
34
17
35
32
33
4
37
22
31
34
3
2
9
36
27
13
38
24
30
34
34
8
21
7
5
35
26
System
Hydraulic
1. Cap screw
2. Reel motor drive pump
3. O–ring
4. Traction/charge pump
5. Hose
6. Hose
7. Hydraulic fitting
8. Hydraulic fitting
9. Hose connection
10. Hose connection
11. Hose connection
12. Hose connection
13. O–ring
14. O–ring
15. Hydraulic fitting
17
20 19
18
16. Hydraulic fitting
17. Hydraulic fitting
18. Cap screw
19. Flat washer
20. Pump lever assembly
21. Lock nut
22. Pump mount
23. Cotter pin
24. Clevis pin
25. Belt adjustment yoke
26. Pump drive belt
27. Pulley
28. Cap screw
29. Lock washer
25
12
14
39
42
Figure 23
40
43
23
29
28
41
30. T apered lock bushing
31. Cap screw
32. Lock nut
33. Washer
34. O–ring
35. O–ring
36. Set screw
37. Key
38. Key
39. Lock nut
40. Cap screw
41. Pump control rod
42. Spacer
43. Nut
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 37
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.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy­draulic oil.
2. Clean pump assembly and hydraulic connections. Label all hose connections for reassembly purposes. Put caps or plugs on any hydraulic lines or fittings left open or exposed. Install plug into the hydraulic reser­voir.
4. Remove hoses (5 and 6) from hydraulic fittings (7 and 8). Remove hose connections (9, 10, 11, and 12) from hydraulic fittings (15, 16, and 17). Allow hoses to drain to a suitable container.
5. Remove cap screw (40) and lock nut (39) from the pump control rod (41), spacer (42), and pump lever as­sembly (20).
6. Loosen lock nut (21) at the pump mount (22) and nut (43) at the belt adjustment yoke (25). Remove cotter pin (23) and clevis pin (24) from the belt adjustment yoke.
7. Tilt pump mount (22) and remove pump drive belt (26) from the pulley (27).
9. Support traction/charge pump (4). Remove both cap screws (31), lock nuts (32), and washers (33) from the traction/charge pump and pump mount (22). Sepa­rate traction/charge pump from the pump mount.
1. Mount the traction/charge pump (4) to the pump mount (22). Place both cap screws (31) through the pump mount and pump base. Install washers (33) and lock nuts (32) onto cap screws. Tighten cap screws.
2. Place key (37) in the keyway on the pump shaft. Slide taper lock bushing (30) into place on the pump shaft. Tighten set screw (36).
3. Insert cap screws (28) through washers (29) and pulley (27). Install pulley to taper lock bushing (30). Start cap screws into bushing and leave cap screws loose.
4. Loosen set screw (36) and adjust pulley (27) so the gap between the pulley and pump mount is 0.20 inch. Evenly torque cap screws from 90 to 120 in–lb. (104 to 138 kg–cm) three times each. Readjust as required.
5. Make sure mounting and O–ring sealing surfaces on reel motor drive pump (2) and traction/charge pump (4) are clean.
6. Inspect O–ring (3) and replace if damaged or worn. Apply clean hydraulic oil to O–ring. Place O–ring on reel motor drive pump (2).
7. Position reel motor drive pump (1) to traction/charge pump (4). Secure reel motor drive pump to traction/ charge pump with cap screws (1).
8. Coat all O–rings with clean hydraulic oil. Install hy­draulic fittings (7, 8, 15, and 16) and O–rings (34) into the traction/charge pump (4). Torque these fittings from 23 to 27 ft–lb and as close to their original position.
9. Coat all O–rings with clean hydraulic oil. Install hy­draulic fittings (17) and O–rings (35) into the traction/ charge pump (4). Tighten these fittings as close to their original position as possible.
10. Connect hoses (5 and 6) to hydraulic fittings (7 and
8); tighten both hose clamps. Connect hose connec­tions (9, 10, 1 1, and 12) to hydraulic fittings (15, 16, and
17). Tighten all hose connections.
11. Replace cap screw (40) through the pump control rod (41), spacer (42) and pump lever assembly (20). Se­cure lock nut (39) to the capscrew and tighten.
Note: Steps 10 and 11 may be performed depending on the extent of the pump repair.
10. Remove fittings (7, 8, 15, 16, and 17) and O–rings (34 and 35) from the traction/charge pump (4).
11. Unscrew set screw (36) enough to loosen tapered lock bushing (30). Slide tapered lock bushing off the pump shaft. Remove key (37) from pump shaft.
12. Install pump drive belt (26) onto pulley (27). Align the holes of the mounting plate (22) with the holes of the belt adjustment yoke (25) and slide clevis pin (24) through holes. Secure clevis pin with the cotter pin (23).
13. Adjust pump drive belt (see Adjustments section) Tighten lock nut (21) and torque from 60 to 70 ft–lb (8.3 to 9.7 kg–m).
14. Remove plug from the hydraulic reservoir. Reelmaster 2300–D/2600–DHydraulic System Page 4 – 38
78
9
10
11
12
13
14
5
38
15
6
39
4
3
13
2
1
18
19
11
17
16
7
20
27
28
1. Cap screw
2. Charge pump adapter assembly
3. Gerotor assembly
4. Bearing
5. Valve assembly
6. Valve plate
7. Screw
8. Trunnion cover
9. O–ring cover
10. O–ring
11. Washer
12. Inner race
13. Bearing
14. Bearing
KEY
COUPLER
OUTER RING
INNER RING
26
Figure 24
15. Housing assembly
16. Seal cover
17. Shaft seal
18. Dowel pin
19. Key
20. Camplate
21. Plug
22. Spring
23. Seat
24. Gasket
25. Backplate assembly
26. O–ring
27. Cap screw
25
18
24
23
22
40
21
30
31
28. Bearing
29. Rotating parts kit
30. Key
31. Drive shaft
32. Retaining ring
33. Bearing race
34. Thrust bearing
35. Washer
36. Shaft seal
37. Retaining ring
38. O–ring
39. O–ring
40. O–ring
29
32
33
34
33
32
35
37 36
System
Hydraulic
Disassembly (Fig. 24)
4. Remove outer ring from either the inner ring of the gerotor assembly (3) or the charge pump adapter as-
1. Position pump into a vise with protected jaws so the charge pump drive shaft is pointed up. Clamp onto the
sembly (2). Further disassembly of the gerotor assem­bly is not necessary.
mounting flange of the traction pump.
2. Remove cap screws (1 and 27) and slide charge pump adapter assembly (2) from the backplate assem­bly (25) clear of the shaft (31) and gerotor assembly (3).
3. Remove O–ring (26) from the charge pump adapter assembly (2).
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 39
5. The charge pump adapter assembly (2) can be dis­assembled as follows (see Fig. 25):
A. Unscrew and remove spring retainer from the charge pump adapter assembly.
B. Remove spring and cup poppet from the charge pump adapter assembly.
SPRING RETAINER
SPRING
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). Remove valve plate (6) from the backplate assembly or rotating parts kit (29).
8. Remove valve assembly (5) and O–rings (38 and
39) from the backplate assembly (25). Disassembly of the valve assembly is not necessary.
9. Remove both plugs (21), O–rings (40), spring (22), and seats (23) from the backplate assembly (25).
10. Remove gasket (24) from the housing (15) or back­plate assembly (25).
Note: To remove the rotating parts kit (29) from the shaft (31), a table or workbench with a hole in the work­ing surface is required for the protruding shaft.
1 1. The rotating parts kit (29) can be removed from the shaft (31) as follows:
A. Hold rotating parts kit (29) in place and remove the pump from the vise.
B. Position the housing assembly (15) end of the pump up and lower the shaft (31) through the hole in the table or workbench. Allow rotating parts kit (29) to rest on the table.
C. Remove rotating parts kit (29) by lifting away the housing assembly (15) and shaft (31).
12. The rotating parts kit (29) can be disassembled as follows (see Fig. 26):
A. Remove nine piston assemblies, spider, and spi­der pivot from the piston block.
SUCTION PORT
BEARING
CHARGE PUMP
ADAPTER ASSEMBLY
Figure 25
VALVE PLATE END
WASHER
SPRING
PINS
RETAINER
SPIDER
CAMPLATE END
WASHER
RETAINING RING
PISTON BLOCK
SPIDER PIVOT
PISTON ASSEMBLIES
Figure 26
B. Use the following parts to disassemble the pis­ton block:
2 5/16 in. I.D. 15/16 in. O.D. flat washers 1 5/16 in. 2–7/8 in. N.C. cap screw 1 5/16 in. N.C. nut
C. Place cap screw through one of the flat washers. Insert cap screw through the center of the piston block. Install second flat washer onto the capscrew so the washer rests on the three pins. Screw nut onto the cap screw.
CAUTION
Be careful when removing the spring from the piston block; the spring is highly compressed. Safely compress the spring before removing the retaining ring.
D. Compress spring by tightening the nut onto the cap screw. Remove the retaining ring from the pis­ton block.
E. Slide washer, spring, second washer , three pins, and retainer from the piston block.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 40
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 .
15. Remove screws (7), trunnion cover (8), O–ring cov­er (9), O–ring (10), washer (11), inner race (12), and bearing (13). Remove screws (7), seal cover (16), shaft seal (17), washer (11), and bearing (13).
16. Position camplate (20) to one side and remove from the housing assembly (15).
Inspection
FLANGE
GEROTOR POCKET
0.070 to 0.080 in. (1.78 to 2.03 mm)
Figure 27
0.090 to 0.100 in. (2.54 to 2.89 mm)
BEARING
DEPTH
0.105 to 0.115 in. (2.67 to 2.92 mm)
CAUTION
Use eye protection such as goggles when using compressed air
1. Wash all parts in solvent. Dry parts with compressed air.
2. Inspect charge pump adapter assembly (see Fig.
25). A. Check relief valve seat inside suction port. Make
sure that seat is smooth and free of burrs or other defects. Relief valve spring must not be damaged.
B. Bearing needles must remain in bearing cage and move freely. Verify that bearing depth on the flange side meets the dimension in Figure 27.
C. Make sure gerotor pocket inside the pump is not excessively scored.
3. Inspect backplate assembly (25) (see Fig. 24). A. Bearing needles must remain in bearing cage
and move freely. Verify that bearing height on the numbered end meets the dimension in Figure 28.
BEARING
HEIGHT
ROLL PIN
HEIGHT
Figure 28
FLANGE END OF HOUSING
0.062 to 0.078 in. (1.57 to 1.98 mm)
BEARING
DEPTH
NUMBERED END
Figure 29
5. Inspect housing assembly (15) (see Fig. 24). A. Verify that bearing depth on the numbered end
meets the dimension in Figure 29.
System
System
Hydraulic
Hydraulic
B. Check that the roll pin is tight and meets the height in Figure 28.
C. Replace entire assembly as a unit.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 41
B. Bearing needles must move freely and remain in their cage.
6. Inspect rotating parts kit (see Fig. 26).
9. Reassemble rotating parts kit as follows (Fig. 26):
A. Verify that piston O.D. finish shows no wear or deep scratches. Piston shoes should fit snuggly onto the ball end of the pistons. The shoe surface that contacts the camplate should be smooth and flat. Do not lap piston shoes.
B. Examine the mutual contact surfaces on the spi­der and spider pivot; both contact areas should be smooth and free of wear.
C. The piston block surface that makes contact with the valve plate should be smooth and free of deep scratches. Do not lap piston shoes.
D. The bore areas of the piston block should be free of scoring and contamination. Pistons should move freely in the bore areas.
Reassembly (Fig. 24)
1. Make sure all parts are clean. Lubricate all critical moving parts and O–rings with clean hydraulic oil.
2. If necessary, press new bearing (14) into housing assembly (15) to the dimension shown in Figure 29.
3. Insert camplate (20) into the housing assembly (15).
A. Use the following parts to reassemble the piston block:
2 5/16 in. I.D. 15/16 in. O.D. flat washers 1 5/16 in. 2–7/8 in. N.C. cap screw 1 5/16 in. N.C. nut
B. Compress retainer and install into the spline of the piston block.
C. Position the head end of pins towards the inside of the block. Install the three pins into the special grooves in the piston block.
D. Install a washer, spring, and second washer into the piston block.
E. Place cap screw through one of the flat washers. Insert cap screw through the center of the piston block. Install second flat washer onto the capscrew so the washer rests on the three pins. Screw nut onto the cap screw.
F. Compress spring by tightening the nut onto the cap screw. Install the retaining ring into the piston block.
4. On the short trunnion side of the camplate (20), install bearing (13) with numbered side to the inside of the pump. Install inner race (12) with the chamfer to­wards the inside of the pump. Install washer (1 1), O–ring (10), O–ring cover (9), and trunnion cover (8). Secure trunnion cover with two screws (7) torque them from 36 to 48 in–lb (42 to 55 kg–cm).
5. On the long trunnion side of the camplate (20), install bearing (13) with numbered side to the inside of the pump. Install washer (1 1) and press shaft seal (17) into place. Secure seal cover( 16) with two screws (7) and torque them from 36 to 48 in–lb (42 to 55 kg–cm).
6. Install retaining ring (32) towards the keyed end of the shaft (31). Slide washer (33), thrust bearing (34), se­cond washer (33), and second retaining ring (32) into place over the splined end of the shaft.
7. Position washer (35) and shaft seal (36) onto the shaft (31) from the keyed end.
8. Install shaft (31) into the housing assembly (15) from the flanged end. Press shaft seal (36) into position with a seal driver. Install retaining ring (37) into the flanged end of the housing assembly (15).
G. Unscrew the nut and remove washer and cap screw from the piston block.
H. Install spider pivot onto the three pins and place the spider on the spider pivot.
I. Insert piston assemblies through the spider and into the piston block with the piston shoes resting on the spider.
10. Set rotating kit assembly (29) on a working surface with the piston shoes facing up. Insert shaft (31) through the rotating kit assembly with the flanged end of the housing assembly up. Position rotating kit assembly into the housing assembly.
11. Make sure piston block and shaft (31) splines are aligned. Make sure piston block is engaged fully so the piston shoes are in contact with the camplate (20). Make
sure all parts are in their proper position be for pro­ceeding to the next step.
12. Hold rotating kit assembly (29) in place, and clamp housing assembly (15) with the flange end down into a vise with protected jaws. Install gasket (24) and two dowel pins (18) into the housing assembly (15).
13. If necessary, press new bearing (4) or roll pin into backplate assembly (25) to the dimension shown in Fig­ure 28. Bearing should be installed with numbered end outward. Roll pin should be installed with split oriented away from the bearing.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 42
14. Install seat (23) and spring (22) into backplate (25). Install new O–ring (40) and plug (21) into the backplate assembly . T orque plug from 95 to 105 ft–lb (13.1 to 14.5 kg–m).
15. Install new O–rings (38 and 39) and valve assembly (5) into the backplate assembly (25). Torque valve as­sembly from 27 to 30 ft–lb (3.7 to 4.1 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.
B. Torque retainer from 5 to 7 ft–lb (0.7 to 1.0 kg–m).
16. Coat valve plate (6) with light coat of petroleum jelly on the steel side. Align the valve plate to the roll pin on the backplate (25). Install steel side of the valve plate to the backplate.
17. Install backplate assembly (25) to the housing as­sembly (15). Make sure gasket (24), valve plate (6), and dowel pins (18) stay in place.
18. Install inner ring and coupler of gerotor assembly (3) into the backplate assemble (25) so that the V–groove on the coupler end enters the backplate assembly first. Lubricate the inner ring of the gerotor.
20. Coat O–ring (26) and outer ring of gerotor assembly
(3) with a light coat of petroleum jelly . Install O–ring and outer ring onto the charge pump adapter assembly (2). Install charge pump adapter plate onto the backplate as­sembly (25). Make sure O–ring and outer ring of gerotor assembly stay in place.
21. Secure charge pump adapter assembly (2) and
backplate assembly (25) to the housing assembly (15) with cap screws (1 and 27). Torque cap screws from 17 to 20 ft–lb ( 2.3 to 22.8 kg–m).
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 43
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.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
2. Remove wheel and brake assembly from unit (see Repair section of Chapter 6 – Wheels and Brakes).
10
9 (LH)
4
3
7 (LH)
17 (LH)
6
8
16
5
16
2
1
14
12
4. Disconnect tube connections (2 and 3) from hydrau­lic fittings (5 and 6). On the left–hand wheel motor, also disconnect hose connection (4) from hydraulic fitting (7). Allow hydraulic oil to drain from tubes and hose into a suitable container.
5. Support wheel motor (1). Remove four cap screws (10) and lock nuts (1 1) from support frame (12). Remove brake bracket (13), grass shield (14), and spacers (15). Pull wheel motor from the support frame.
6. Remove hydraulic fittings (5 and 6) and O–ring from the wheel motor (1). On the left–hand wheel motor, also remove hydraulic fitting (7) from the wheel motor.
Front Wheel Installation (Fig. 30)
1. Place and support wheel motor (1) into the support frame (12). Insert four cap screws (10) through the sup­port frame and wheel motor.
15
13
11
Figure 30
1. Wheel motor
2. Tube connection
3. Tube connection
4. Hose connection
5. Hydraulic fitting
6. Hydraulic fitting
7. Hydraulic fitting
8. O–ring
9. O–ring
10. Cap screw
11. Lock nut
12. Support frame
13. Brake bracket
14. Grass shield
15. Spacer
16. O–ring
17. O–ring
4. Install tube connections (2 and 3) to hydraulic fit­tings (5 and 6). On the left–hand motor, also ins hose connection (4) to hydraulic fitting (7). Tighten connec­tions.
5. Install wheel and brake to unit (see Repair section of Chapter 6 – Wheels and Brakes).
2. Slide spacers (15), grass shield (14), and brake bracket (13) onto the cap screws (10) and wheel motor (1). Tighten lock nuts (11) onto cap screws.
3. Install hydraulic fittings (5 and 6) onto the wheel mo­tor (1). On the left–hand wheel motor, also install hy­draulic fitting (7) onto the wheel motor. T ighten hydraulic fittings.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 44
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.
CAUTION
7
1
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
2. Clean wheel motor (1) and hydraulic connection. Put caps or plugs on any hydraulic lines or fittings left open or exposed.
3. Remove wheel and wheel hub from unit (see Repair section of Chapter 6 – Wheels and Brakes).
4. Disconnect hose connection (2) from hydraulic fit­tings (3). Remove O–ring (4). Allow hydraulic oil to drain from the hose into a suitable container.
5. Support wheel motor (1). Remove four cap screws (5) and lock nuts (6) from the rear wheel fork (7). Pull wheel motor from the rear wheel fork.
6. Remove hydraulic fitting (3) and O–ring (8) from the wheel motor (1).
Rear Wheel Installation (Fig. 31)
5
1. Wheel motor
2. Hose connection
3. Hydraulic fitting
4. O–ring
6
Figure 31
8
5. Cap screw
6. Lock nut
7. Rear wheel fork
8. O–ring
2
4
3
System
Hydraulic
1. Place and support wheel motor (1) into the rear wheel fork (7). Insert four cap screws (5) through the rear wheel fork and wheel motor.
2. Tighten lock nuts (6) onto cap screws (5).
3. Install hydraulic fitting (3) and O–ring (8) onto the wheel motor (1). Tighten hydraulic fitting.
4. Install O–ring (4) while connecting hose connec­tions (2) onto the hydraulic fitting (8). Tighten connec­tion.
5. Install wheel and wheel hub to unit (see Repair sec­tion of Chapter 6 – Wheels and Brakes).
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 45
11
12
13
10
8
9
8
7
6
3
2
1
5
4
15
17
16
14
24*
SHUTTLE
VALVE
24
24*(PLUG)
25*
PLUG
25*
SPRING
23
24*
(PLUG)
20
21
22
*LEFT HAND MOTOR ONLY
19
Figure 32
1. Dirt and water seal
2. Outer bearing
3. Housing
4. Backup washer
5. Seal ring
6. Backup washer
7. Inner seal
8. Thrust washer
9. Thrust bearing
10. Inner bearing
11. Coupling shaft
12. Thrust bearing
13. Drive link
14. Cap screw
15. Commutator seal
16. Commutator
17. Woodruff key
Disassembly (Fig. 32)
W ARNING
If the wheel motor is not held firmly in the vise, it could dislodge during service and cause injury.
1. Place wheel motor in a soft jawed vice with the cou­pling shaft (1 1) pointed down and the vise jaws clamping firmly on the sides of the housing (3).
18
18. Wear plate
19. Rotor
20. Vane
21. Stator
22. Manifold
23. Commutator ring
24. End cover assembly
25. O–ring
2. Scribe an alignment mark down and across the wheel motor components from the end cover (24) to the housing (3) for facilitating reassembly (Fig. 33). If in­cluded in end cover, loosen both shuttle valve plugs (left–hand motor only) for disassembly later.
Figure 33
3. Remove seven cap screws (14). Remove end cover assembly (24) and seal ring (5).
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 46
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: The insert and ,if included, the orifice plug in the end cover assembly (24) must not be removed as they are serviced as an integral part of the end cover.
4. If the end cover (24) is equipped with shuttle valve components (left–hand motor only), remove both pre­viously loosened plugs and O–rings (25).
5. Remove commutator ring (23).
CAUTION
Use eye protection such as goggles when using compressed air
6. Remove commutator (16) and commutator seal (15). Remove commutator seal from the commutator using an air hose to blow air into the ring groove until the commutator seal is lifted out (Fig. 34)
Note: The manifold (22) is constructed of plates bonded together to form an integral component not sub­ject to further disassembly for service. Compare config­uration of both sides of the manifold to make sure that same surface is reassembled against the rotor set.
7. Remove manifold (22). Remove seal rings (5) that are on both sides of the manifold.
Note: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may be­come disassembled during service procedures.
Note: Marking all rotor components and mating spline components for exact repositioning at assembly will make sure maximum wear life and performance of rotor set and wheel motor.
8. Mark surface of rotor (19) and stator (21) that is fac­ing up with etching ink or a grease pencil before remov­ing from the wheel motor. This will make sure correct reassembly of the rotor into the stator and the rotor set into wheel motor.
9. Remove rotor set and wearplate (18) together, and retain the rotor set in its assembled form with the same vane (20) to stator (21) contact surfaces. The drive link (13) may come away from the coupling shaft (11) with the rotor set and wearplate. Y ou may have to shift the ro­tor set on the wearplate to work the drive link out of the rotor (19) and wearplate (Fig. 35).
Figure 34
Figure 35
10. Remove seal ring (5) that is between the rotor set
and wearplate. 1 1. Remove drive link (13) from the coupling shaft (11)
if it was not removed with rotor set and wear plate (18). Remove seal ring (5) from housing (3).
12. Remove thrust bearing (12) from the top of the cou-
pling shaft (11).
sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the dirt and water seal (1) and outer bearing (2). Crocus cloth or fine emery paper may be used.
14. Remove coupling shaft (1 1); push on the output end
of the shaft. Remove seal ring (5) from housing (3).
move dirt and water seal (1). A blind hole bearing or seal puller is required.
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 47
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.
CAUTION
Use eye protection such as goggles when using compressed air
2. Thoroughly wash end cover (24) in proper solvent and blow dry . Make sure the end cover valve apertures, including the internal orifice plug, are free of contamina­tion. Inspect end cover for cracks and the bolt head re­cesses for good bolt head sealing surfaces. Replace end cover as necessary (Fig. 37).
3. Inspect commutator ring (23) for cracks and burrs. Replace commutator ring as necessary.
5. Inspect manifold (22) for cracks, surface scoring, peening, chipping. Replace manifold if any of these conditions exist. A polished pattern on the ground sur­face from commutator or rotor rotation is normal.
Figure 36
Figure 37
Note: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may be­come disassembled during service procedures.
6. Inspect the rotor set in its assembled form for nicks, scoring, and chipping on any surface. Inspect for broken and worn splines. If the rotor set component requires re­placement, the complete rotor set must be replaced as it is a matched set.
7. Place rotor set and wear plate (18) on a flat surface and center the rotor (19) in the stator (21) such that two rotor lobes (180 degrees apart) and a roller vane (20) center line are on the same stator center line. Check the rotor lobe to roller vane clearance with a feeler gage at this common center line. If there is more than 0.005 inch (0.13 mm) of clearance, replace the entire rotor set (Fig.
38).
Figure 38
Figure 39
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 48
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. Inspect coupling shaft (11) internal and external splines and keyway for damage and wear. Inspect bear­ing and sealing surfaces of the coupling shaft for chip­ping, nicks, grooves, severe wear, corrosion, and discoloration. Replace coupling shaft if any of these conditions exist. Minor shaft wear in seal area is permis­sible. If wear exceeds 0.020 inch (0.51 mm) diametrical­ly , replace coupling shaft. A slight ”polish” is permissible on the shaft bearing areas (Fig. 40).
Note: Do not remove inner bearing (10), thrust wash­ers (8), thrust bearing (9), inner seal (7), backup wash­ers (6 and 4), and outer bearing (2) from the housing (3). These parts should be inspected in place.
Figure 40
12. Inspect housing (3) for cracks. Inspect machined surfaces for nicks, burrs, peening, and corrosion. Re­move burrs that can be removed without changing di­mensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly (Fig. 41).
13. If the housing (3) has passed inspection to this point, inspect outer bearing (2), inner bearing (10), thrust washers (8), and thrust bearing (9). Bearing roll­ers must be firmly retained in the bearing cages but must rotate and orbit freely. All rollers and thrust washers must be free of peening and corrosion. If any bearing or thrust washer does not pass inspection, replace the housing (3) as a complete assembly (Fig. 42).
Figure 41
Figure 42
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 49
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.
CAUTION
Use eye protection such as goggles when using compressed air
2. Wash all parts in a clean petroleum–based solvent before assembly. Blow parts dry with compressed air.
3. Press a new dirt and water seal (1) into the housing (3) outer bearing counterbore. Press seal in with the lip facing out and until the seal is 0.020 inch (0.51 mm) be­low the end of housing.
Figure 43
4. Place housing (3) into a soft jawed vise with the cou­pling shaft bore down; clamp against the mounting flange.
IMPORT ANT: Early model wheel motors that do not have backup washer (6) when inspected must be as­sembled with a new backup washer (4), new backup washer (6), and new seal (7).
5. A housing (3) that does not require replacement will require that the two thrust washers (8) and thrust bear­ing (9) be unseated and vertical to the counterbore and the new backup washer (4), new backup washer (6), and new seal (7) be worked around the thrust bearing package and placed into their respective counterbores (Fig. 44 and 43). The seal lip must face out of the seal counterbore and toward the inside of wheel motor (Fig.
45). Be sure the thrust bearing package is reseated cor­rectly after assembly of the new seal and backup wash­ers.
6. Apply masking tape around splines or keyway on coupling shaft (11) to prevent damage to seal.
IMPORT ANT : The outer bearing (2) is not lubricated by the system’s hydraulic fluid. Make sure it is thor­oughly packed with the recommended grease.
Figure 44
Figure 45
Note: Coupling shaft (11) should be approximately
0.10 inch (2.54 mm) below the housing wear plate sur­face to allow the assembly of thrust bearing (12). The coupling shaft must rotate smoothly on the thrust bear­ing (9) and thrust washer (8) (Fig. 46).
7. Make sure that a generous amount of clean corro­sion resistant grease has been applied to the outer bear­ing (2). Install the coupling shaft (11) into housing (3), and seat shaft against the second thrust washer (8).
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 50
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 (12.7 mm) or longer than cap screw (14).
Note: Use any alignment marks put on the coupling shaft (11) and drive link (13) before disassembly to as­semble the drive link splines in their original position in the mating coupling shaft splines.
10. Install drive link (13) with the long splined end down into the coupling shaft (1 1). Engage the drive link splines so they mesh with the coupling shaft splines (Fig. 47).
11. Assemble wear plate (18) over the drive link (13) and alignment studs onto the housing (3).
Figure 46
12. Apply a small amount of clean grease to a new seal ring (5) and assemble it into the seal ring groove on the wear plate side of the stator (21).
Note: The rotor set consists of the rotor (19), vanes (20), and stator (21). Rotor set components may be­come disassembled during service procedures.
Note: It may be necessary to turn one alignment stud out of the housing (3) temporarily to assemble rotor set over the drive link (13).
Note: The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor–drive link spline contact. A ro­tor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to de­termine which side was down. The rotor set seal ring groove faces toward the wear plate (18).
13. Install assembled rotor set onto wear plate (18) with rotor (19) counterbore and seal ring side down. The splines should mesh with the drive link (13) splines.
14. If disassembled rotor (19), stator (21), and vanes (20) cannot be readily assembled by hand, assemble with the following procedures:
A. Place stator (21) onto wear plate (18) with seal ring (5) side down. Be sure the seal ring is in place.
Figure 47
B. If assembly alignment studs are not being uti­lized, align stator (21) bolt holes with wear plate (18) and housing (3) bolt holes. Screw two cap screws (14) finger tight into bolt holes approximately180 de­grees apart to retain stator and wear plate station­ary.
Note: If the manifold (22) side of the rotor (19) was etched during wheel motor disassembly, this side should be up. If the rotor is not etched and does not have a counterbore, use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate.
C. Place rotor (19) with counterbore down, if appli­cable, into stator (21), and then onto wearplate (18) so rotor splines mesh with drive link (13) splines.
IMPORTANT: Do not force rotor vanes into place, the coating applied to stator vane pockets could shear off.
D. Assemble six vanes (20), or as many vanes that will readily assemble into the stator vane pockets.
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 51
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 manifold (22) is made up of several plates bonded together permanently to form an integral com­ponent. The manifold surface that must contact the rotor set has it’s series of irregular shaped cavities on the larg­est circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set.
15. Apply clean grease to a new seal ring (5) and as­semble it in the seal ring groove in the rotor set contact side of manifold (22).
Figure 48
16. Assemble the manifold (22) over the alignment studs and drive link (13) and onto the rotor set. Be sure the correct manifold surface is against the rotor set.
17. Apply grease to a new seal ring (5) and insert it in the seal ring groove exposed on the manifold (22).
18. Assemble the commutator ring (6) over alignment studs onto the manifold (22) (Fig. 48).
19. Assemble a new commutator seal (15) flat side up, into commutator (16) and assemble commutator over the end of drive link (13) onto manifold (22) with seal ring side up.
20. If shuttle valve components items (left–hand motor only) were removed from the end cover (24), screw a plug with a new O–ring (25), loosely into one end of the valve cavity in the end cover. Insert spring, valve, and second spring into the other end of the valve cavity . Turn second plug with a new O–ring (25) loosely into the end cover valve cavity . A 3/16–inch allen wrench is required (Fig. 49).
Note: If the end cover (24) has a valve shuttle, use line that was previously scribed on the end cover to radially align it into its original position.
Figure 49
21. Assemble new seal ring (5) into end cover (24) and assemble end cover over the alignment studs and onto the commutator set (Fig. 50).
Figure 50
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 52
Note: The cap screws (14) required for use with the shuttle valve (left–hand motor only) end cover (24) are longer than the bolts required with standard end cover. Refer to T oro Parts Catalog for correct service part num­ber if replacement is required.
22. Assemble seven cap screws (14) and screw them in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alter­nately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 45 to 55 ft–lb (6.2 to 7.6 kg–m).
23. Torque the two shuttle valve plugs in the end cover
24. Check motor shaft for rotation. T orque require to ro-
tate shaft should not exceed 50 ft–lb (6.9 kg–m).
System
Hydraulic
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 53
2WD/3WD Two Position Valve
13
14
2
4
1
SKIRT ASSEMBLY
15
12
13
9
15
11
13
8
7
10
15
5
13
3
5
6
Figure 51
1. Two position valve
2. Nut
3. Cap screw
4. Tub clamp
5. Hydraulic tube
6. Hydraulic connection
7. Hydraulic connection
8. Hydraulic connection
9. Hydraulic connection
10. Hydraulic fitting
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. Remove the key from the ignition switch.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
2. Clean two position valve (1) and hydraulic fittings.
3. Put caps or plugs on any hydraulic lines or fittings left open or exposed. Put labels on disconnected hy­draulic lines and hoses for proper reassembly.
4. Loosen nut (2) and cap screw (3) so the tubes clamps (4) will allow movement of the hydraulic tubes (5).
11. Hydraulic fitting
12. Hydraulic fitting
13. O–ring
14. Cap screw
15. O–ring
5. Disconnect hydraulic connections (6, 7, 8 and 9) from hydraulic fittings (10, 11, and 12). Allow hydraulic oil to drain from tubes into a suitable container.
6. Remove cap screws (14) from two position valve (1).
7. Remove fittings (10, 11, and 12) and O–rings (15) from two position valve (1).
Installation (Fig. 51)
1. Install hydraulic fittings (10, 1 1, and 12) and O–rings (15) into two position valve (1).
2. Secure cap screws (14) to two position valve (1) through the skirt assembly.
3. Install hydraulic connections (6, 7, 8 and 9) to hy­draulic fittings (10, 11, and 12) and tighten fittings.
4. Tighten nut (2) and cap screw (3) so the tube clamps (4) will prevent movement of the hydraulic tubes (5).
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 54
1
3
5
7
2
4
6
8
8
Figure 52
1. Valve cap
2. Plug
3. O–ring
4. Ball
5. Spool
6. Spring pin
7. Back–up ring
8. O–ring
9. Valve housing
10. Boot retainer
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.
9
10
12
Inspection (Fig. 52)
14
7
11
11. Boot
12. Set screw
13. Valve stop
14. Lock washer
15. Knob
CAUTION
13
15
System
Hydraulic
2. Remove boot retainer (10) from the valve housing (9).
3. Carefully remove valve cap (1) from the valve hous­ing (9). The valve cap is press fitted.
4. Secure valve stop (13) and remove plug (2) and O– ring (3) from the spool (5).
5. Hold knob (15) and carefully slide spool (5) out of the valve housing (9).
Note: The valve stop (13) and set screw are loctited together and should remain together when removed from the spool (5).
6. Separate valve stop (13) and set screw (12) from the spool (5). Carefully remove boot (1 1) from the valve stop.
7. Remove spring pin (6) and ball (4) from the spool (5) being careful no to scratch or damage the spool. Also, be careful not to drop the ball.
8. Remove back–up rings (7) and O–rings (8) from the valve housing with a hooked scribe or thin screw driver. Be careful not to scratch the bore surface.
Use eye protection such as goggles when using compressed air
1. Wash all parts in solvent. Dry parts with compressed
air.
2. Inspect spool (5) for bending and flatness. Signs of
wear on one side of the spool may indicate it’s bent. Re­place a worn or damaged spool if necessary.
3. Inspect parts for wear or damage, and replace if
necessary.
Reassembly (Fig. 52)
1. Coat all new O–rings and back–up rings with hy-
2. Install ball (4) and spring pin (6) into the spool (5) so
the ball is held in by the pin. Make sure both ends of the spring pin are flush with the sides of the spool.
3. Carefully install boot (12) onto the valve stop (13).
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 55
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. Torque valve stop from 85 to 100 in–lb.
5. Install plug (2) and new O–ring (3) into the spool (5). Torque plug from 85 to 100 in–lb.
6. Press valve cap (1) onto valve housing (9). If the valve cap is damaged or will not fit tightly onto the the valve housing, replace the valve cap with a new one.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 56
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
7
3
2
4
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
2. Clean reel motor drive pump (1) and hydraulic con­nections. Install plug into the hydraulic reservoir. Label all hose connections for reassembly purposes. Put caps or plugs on any hydraulic lines or fittings left open or ex­posed.
3. Loosen hose clamp (2) and remove hose (3) from fitting (4). Allow hydraulic oil to drain from hose into a suitable container.
4. Disconnect hose (5) from elbow fitting (6).. Allow hy­draulic oil to drain from hose into a suitable container.
5. Remove fittings (4 and 6) and O–rings (8 and 9) from the pump.
6. Support reel motor drive pump (1) and remove two cap screws (10). Separate reel motor drive pump (1) and O–ring (11) from the traction pump (12).
Installation (Fig. 53)
1. Make sure mounting and O–ring sealing surfaces on reel motor drive pump (1) and traction pump (12) are clean.
2. Replace all O–rings with new ones. Apply clean hy­draulic oil to all O–rings.
8
9
5
1
11
12
Figure 53
1. Reel motor drive pump
2. Hose clamp
3. Hose
4. Fitting
5. Hose
6. Elbow fitting
7. O–ring
8. O–ring
9. O–ring
10. Cap screw
11. O–ring
12. Traction pump
4. Position reel motor drive pump (1) to traction pump
(12); the inlet port should be facing up.
(12) with cap screws (10). T orque cap screws from 27 to 31 ft–lb (3.7 to 4.3 kg–m).
6. Inspect threads and sealing surfaces of connectors.
Replace any damaged or worn connectors.
7. Install O–rings (8 and 9). Install fitting (4) and orient
to the 2 o’clock position. Install elbow connector (6) and orient to the 45 down.
8. Secure hose (3) to connector (4) and tighten hose
clamp (2). Secure hose (5) to elbow fitting (6) and tighten hose connector.
System
Hydraulic
3. Place O–ring (11) on reel motor drive pump (1).
9. Remove plug from hydraulic reservoir.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 57
1
2
3
4
5
6
7
10
INLET PORT SIDE
7
6
11
14
5
4
8
12
Figure 54
1. Retaining ring
2. Shaft seal
3. Mounting flange
4. Backup ring
5. E–seal
6. O–ring
7. Dowel pin
8. End cover
9. Bolt
10. Gear housing
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.
2. Matchmark the inlet side of the gear housing (10) with the mounting flange (3) and the end cover (8) with the gear housing (10) to make sure proper orientation of these three parts during reassembly.
3. Position the pump with the drive end facing down.
4. Remove the four bolts (9). Lift off the end cover (8) and and two dowel pins (7) and them aside.
5. Remove the gear housing (10) ensuring the rear bearing block (13), front bearing block (14), drive gear (1 1), and idler gear (12) remain together. Remove the re­maining two dowel pins from the gear housing.
13
9
OUTLET PORT
11. Drive gear
12. Idler gear
13. Rear bearing block
14. Front bearing block
7. Remove the idler gear (12).
8. Remove the drive gear (11) shaft slowly from the mounting flange (3). Remove the front bearing block (14) from the drive gear (11) shaft.
Shaft Seal Replacement (Fig. 54)
1. Place the mounting flange (3) on a clean working surface with the shaft seal up (2). Remove the retaining ring (1).
Note: Avoid scratching or marring the shaft seal bore in the mounting flange (3). Large scratches may cause the shaft seal (2) to leak around the outer diameter of the seal.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 58
2. Remove the shaft seal (2). Clean any contamination from the seal bore.
3. Place a new shaft seal (2) with the part number side up into the seal bore. Apply uniform pressure to the face of the shaft seal while pressing it into the bore. This method should prevent damage or misalignment 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. Apply a light coat of petroleum jelly in the E–seal groove of the front bearing block (14) and on the flat side of the E–seal (5) to help keep the seals in place during assembly.
3. Place the E–seal (5) with its flat side up into the seal groove on the front bearing block (14). Place the backup ring (4) into the groove made by the E–seal and bearing block. Make sure the notches in the center of the backup ring and E–seal line up so that the backup ring sits flush with the E–seal.
4. Repeat the above steps for the rear bearing block.
O–ring Replacement (Fig. 54)
1. Remove the old O–rings (6) from the gear housing. Clean any contamination from the O–ring groove.
2. Apply a light coat of petroleum jelly in the O–ring grooves of the gear housing (10). Place a new O–ring (6) in each groove.
Reassembly (Fig. 54)
1. Place the mounting flange (3) with the shaft seal (2) side down onto a clean working surface. Make sure that the back side of the mounting flange is free of any con­tamination.
3. Apply a light coating of oil to the exposed face of the
front bearing block (14). Make sure the tape is on the shaft end of the drive gear (10). Insert the shaft end of the drive gear (1 1) slowly through the front bearing block (14) and the shaft seal (2) being careful not to damage the shaft seal.
4. Place the shaft of the idler gear (12) into the remain-
ing position of the front bearing block (14). Apply a light coating of oil the back face of the drive and idler gears.
5. Place the rear bearing block (13) with the seal side
on the drive and idler gear shaft ends. Make sure that the open side of the E–seal (5) is pointing towards the inlet of the pump.
6. Install the two dowel pins (7) into the mounting
flange (3).
7. Align the matchmarks on the gear housing (10) and
mounting flange (3). Place the gear housing with the mounting flange side down and the inlet port on the open side of the E–seal (5) over the rear bearing block (13). Slide the gear housing down over the gears and front bearing block (14).
8. Make sure the rear bearing block (13) face sits just
below the back face of the gear housing (3). If the rear bearing block sits higher than the rear face of the gear housing, remove the gear housing. Check that the E– seal (5), backup ring (4), or O–ring (6) did not shift out of place during assembly.
9. Place the remaining two dowel pins (7) into the rear
of the gear housing (3). Align matchmarks and set end cover (8) on the rear of the gear housing.
10. Insert the four bolts (9) through the bolt holes in the
end cover (8) and gear housing (3). Hand tighten each bolt and torque to 40 ft–lb (5.5 kg–m).
1 1. Place a small amount of oil in the inlet of the pump. rotate the drive shaft away from the inlet one revolution. If the drive shaft binds, disassemble the pump and then reassemble it. The pump is ready for use.
System
Hydraulic
2. Place the front bearing block (14) with its seal side down onto the mounting flange (3). The open side of the E–seal (5) must point away from the matchmark on the inlet side of the mounting flange.
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 59
Reel Motor
Removal (Fig. 55)
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.
CAUTION
Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil.
2. Remove reel motor from cutting unit (see Repair section of Chapter 7 – Cutting Units).
3. Unscrew lock nut (1) and remove coupling (2) from reel motor (3) using a puller.
4. Clean motor, fittings, and hose connections. Note: The position of the fittings on the reel motor is
critical to reconnecting hydraulic hoses.
5. Label all hose connections (4) for reassembly pur­poses. Matchmark reel motor and all hydraulic fittings (5) for reassembly purposes.
6. Remove hose connections (4) from hydraulic fit­tings (5). Allow hydraulic oil to drain from hose into a suit­able container. Put caps or plugs on disconnected hoses to prevent contamination.
7. Remove hydraulic fittings (5) and O–rings (7) from reel motor (3).
Installation (Fig. 55)
4
6
5
6
4
5
7
1
2
7
1
3
Figure 55
1. Lock nut
2. Coupling
3. Reel motor
4. Hose connection
5. Hydraulic fittings
6. O–ring
7. O–ring
5. Place O–ring (7) on face seal of hydraulic fitting (5). Secure hydraulic fitting to the reel motor (3) ensuring that the matchmarks are aligned. Repeat this step for the remaining hydraulic fittings.
6. Inspect threads and sealing surfaces of hose con­nections (4). Replace any damaged or worn connec­tions.
7. Secure hose connection (4) to the hydraulic fitting (5). Repeat this step for the remaining hydraulic fittings.
8. Install reel motor to cutting unit (see Repair section of Chapter 7 – Cutting Units).
1. Install coupling (2) and secure lock nut (1) to the reel motor (3) and torque to 35 ft–lb (4.8 kg–m).
2. Make sure hydraulic fitting ports and O–ring sealing surfaces on the reel motor (3) are clean.
3. Apply clean hydraulic oil to all O–rings.
4. Inspect threads and sealing surfaces of hydraulic fit­tings (5). Replace any damaged or worn fittings.
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 60
7
6
5
4
3
2
1
8
9
10
11
12
11
13
14
19
1. Plug
2. O–ring
3. Shim
4. Spring
5. Ball
6. Relief valve seal
7. Backplate
13
Figure 56
8. Idler gear assembly
9. Drive gear assembly
10. Key
11. O–ring
12. Body
13. Alignment pin
15
18
17
16
14. Frontplate
15. Screw
16. Retaining ring
17. Oil seal
18. Backup washer
19. Relief valve assembly (# 1 thru 5)
System
Hydraulic
Disassembly (Fig. 56)
7. Remove body (12) from the backplate (7). Remove
O–rings (11) from the body (12) and backplate (7).
1. Make sure key (10) is removed from the drive gear (9) shaft.
2. Matchmark frontplate (14), body (12), and back­plate (7) to assure proper reassembly.
3. Secure the motor in a vise with the drive shaft up.
8. Remove Alignment pin (13) from the backplate (7).
9. Remove retaining ring (16), oil seal (17), and back-
up washer (18) from the frontplate (14).
IMPORT ANT : Do not remove the relief valve assem­bly (19) unless testing shows it to be faulty . The re-
4. Remove all eight screws (15).
lief valve assembly must be replaced as a complete unit. Both relief valve seals (6) are sealed in place
5. Remove the motor from the vise. Remove the front-
with loctite; do not remove them.
plate (14) from the body (12). A wooden block or soft face hammer might be used the gently tap the motor when freeing the frontplate (14).
10. Remove plug (1), O–ring (2), shim (3), spring (4),
and ball (5 ) from the backplate (7).
6. Remove alignment pin (13) from the body (12). Re­move drive gear (9) and idler gear (8) from the body (12).
Reelmaster 2300–D/2600–D Hydraulic SystemPage 4 – 61
Inspection (Fig. 56)
1. Remove all nicks and burrs from all parts with an emery cloth
CAUTION
Use eye protection such as goggles when using compressed air
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).
2. Coat O–ring (11) lightly with petroleum jelly and install in groove on the front plate (14).
2. Clean all parts with solvent. Dry all parts with com­pressed air.
3. Inspect drive gear (9) shaft for a broken or chipped keyway .
4. Inspect drive gear (9) and idler gear (8) shafts at the bushing points and seal area for rough surfaces and ex­cessive wear.
5. Replace drive gear (9) or idler gear (8) if the shaft in the bushing area diameter measures less than 0.748 in. (19.0 mm). A single gear may be replaced separately.
6. The drive gear (9) and idler gear (8) face should be free of excessive scoring and wear.
7. Replace drive gear (9) or idler gear (8) if gear width is less than 1.140 in. (29.96 mm).
9. Break sharp edges of gear teeth with emery cloth.
10. Replace backplate (7) and frontplate (14) if bushing inside diameters exceed 0.755 in. (19.2 mm). The bush­ings are not available as replacement items.
11. The face of the backplate (7) and frontplate (14) should be free of excessive scoring. Replace if scoring a depth of 0.0015 in. (0.038 mm).
3. Apply a thin coat of petroleum jelly to both gear pockets of the body (12). Install alignment pin (13) into body (12).
4. Align matchmarks and slip body (12) onto front plate (14) until alignment pin (13) is engaged.
5. Dip idler gear (8) and drive gear (9) into clean hy­draulic oil and slip into front plate (14) bushings.
6. Coat O–ring (11) lightly with petroleum jelly and install in groove on the back plate (7).
7. Install alignment pin (13) into back plate (7).
8. Align matchmarks and slip back plate (7) over gear shafts onto body (12) until alignment pin (13) is en­gaged.
9. Hand tighten cap screws (15) and torque in a criss­cross pattern from 25 to 28 ft–lb (3.46 to 3.87 kg–m).
10. Place washer (18) over the drive shaft into the front plate (14) housing. Apply a liberal coat of hydraulic oil to the oil seal (17). Install oil seal (17) over the drive shaft being careful not tho cut the rubber seal lips.
11. Place 1–1/16 inch O.D. sleeve over the drive shaft and press in the oil seal (17) until the retaining ring groove appears.
12. Press retaining ring (16) into the housing using the sleeve until it seats in the groove.
12. Replace body (12) if the inside diameter of the gear pockets exceeds 1.713 in. (43.5 mm).
Reelmaster 2300–D/2600–DHydraulic System Page 4 – 62
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