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.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or repair of the machine.
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
1 1. Do not run the engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could be deadly.
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
22. Before servicing or making adjustments to the ma-
chine, stop the engine and remove the key from the
switch to prevent accidental starting of the engine.
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
&))!% # !## *) %( % )
"*()$%) '&*'(
') &
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).
8. Pump priming lever (4) until a steady stream of fuel
flows out of injection pump inlet screw (3), then tighten
screw. Do not over tighten inlet screw (Fig. 11).
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
2. Check air cleaner body (1) for damage which could
possibly cause an air leak. Replace damaged air cleaner body.
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.
6.Inspect filter element (4) and discard if damaged. Do
not wash or reuse a damaged filter.
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.
7. Inspect new filter element (4) for shipping damage.
Check sealing end of new or used filter element. Do not
install a damaged filter element.
8. Insert filter element (4) properly into the air cleaner
body (1). Make sure filter element is sealed properly by
applying pressure to the outer rim of the filter element
when installing. Do not press on the flexible center of the
filter element.
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
plastic cover to the radiator assembly. Remove plastic
cover from the radiator assembly.
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
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