Toro REELMASTER 2300-D User manual

Part No. 96876SL Rev. A
Service Manual
ReelmasterR2300–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 INSTRUC-
TIONS. 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 Num-
ber to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, MN 55420
TheToroCompanyreservestherighttochangeproduct
specifications or this publication without notice.
ING, or CAUTION, PERSONAL SAFETY
Failure to obey the instructions may result in
This safety symbol means DANGER, WARN-
INSTRUCTION. When you see this symbol,
carefully read the instructions that follow.
personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe 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
SafetyProductRecords
and Manuals
Engine
Hydraulic
System
Electrical
System
Wheels andCutting Units Brakes
Reelmaster 2300–D/2600–D

This page is blank.

Chapter 1
Safety
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 con-
trol and accident prevention are partially dependent
uponthedesignandconfigurationofthemachine,these
factors are also dependent upon the awareness, con-
cern,andpropertrainingofthepersonnelinvolvedinthe
operation, transport, maintenance, and storage of the
machine. Improper use or maintenance of the machine
can result in injury or death.
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 4
comply with the following safety instruc-
tions.
WARNING
To reduce the potential for injury or death,
Safety
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 in-
structions.
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.
WARNING
1. Read and understand the contents of the traction
unit and cutting unit operator’s manuals before operat-
ing the machine. To get replacement manuals, send
complete model and serial number to:
The Toro Company
8111 Lyndale Avenue South
Minneapolis, Minnesota 55420–1196
UsetheModelandSerialNumberwhenreferringtoyour
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
andwhohavereadtheOperator’sManual,shouldoper-
ate the machine. Never allow children to operate the
machine or adults to operate it without proper instruc-
tions.
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 ev-
eryone, especially children and pets, away from the ar-
eas of operation.
6. Keepallshields,safetydevicesanddecalsinplace.
lf a shield, safety device or decal is damaged, malfunc-
tioning or illegible, repair or replace it before operating
the machine.
7. Alwayswearsubstantial shoes.Do notoperatema-
chine 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 in-
jury.
8. Wearing safety glasses, safety shoes, long pants
andahelmetisadvisableandrequiredbysomeIocalor-
dinances and insurance regulations.
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 flam-
mable, handle it carefully.
A. Use an approved fuel container.
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. Fillfueltankoutdoorsandnotoveroneinchfrom
thetop ofthe tank,(bottom ofthe fillerneck). Donot
overfill.
While Operating
11. Donot runtheengineina confinedarea withoutad-
equate ventilation. Exhaust fumes are hazardous and
could be deadly.
12. Sit on the seat when starting and operating the ma-
chine.
13. Check interlock switches daily for proper operation
(see Checking Interlock Switches of the Operator’s
Manual).Donotrelyentirely onsafetyswitches;shutoff
engine before getting off the seat. If a switch fails, re-
placeitbeforeoperatingthemachine.Theinterlocksys-
tem is for your protection, so do not bypass it. Replace
all interlock switches every two years.
14. When starting the engine:
A. Engage parking brake.
B. Besure tractionpedal isinneutral andreel 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 Opera-
tor’s Manual).
D. Hills over 15 degrees should be mowed up and
down, not side to side (see Slope Gauge of the Op-
erator’s Manual).
E. Mowing hills may be dangerous. Hills over 20
degreesshould notbemowed(seeSlope Gaugeof
the Operator’s Manual).
F. Stay alert for holes in terrain and other hidden
hazards.Useextremecarewhen operatingcloseto
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
trafficwhennearorcrossingroads.Alwaysyieldthe
right of way.
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 recom-
mended 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 hy-
draulic 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 ab-
normally, stop cutting unit immediately. Turn the engine
off, wait for all motion to stop and inspect for damage.
A damaged reel 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: D. Stopthe engineand remove the keyfrom the ig-
nition switch.
A. Move the traction pedal to neutral. 21. Whenever the machine is left unattended, make
B. Set the parking brake. sure the reels are not spinning, the key is removed from
ignition switch, and the parking brake is set.
C. Disengagethecuttingunitsandwaitforthereels
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 per-
sonal injury.
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 suffi-
cient force to penetrate the skin and cause serious inju-
ry. lf fluid is injected into the skin, it must be surgically
removedwithin afew hoursby adoctorfamiliarwiththis
form of injury or gangrene may result.
28. Beforedisconnectingorperforminganyworkonthe
hydraulic system, all pressure in system must be re-
lieved 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 accu-
mulation of dirt.
31. If the engine must be running to perform a mainte-
nance 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. Donot overspeed theengine bychanging governor
settings.Toassuresafetyandaccuracy,haveanAutho-
rized 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
genuineTOROreplacementpartsandaccessories.Re-
placement parts and accessories made by other man-
ufacturerscouldbedangerous,andsuchusecouldvoid
the product warranty of The Toro Company.
Safety
Reelmaster 2300–D/2600–D Page 1 – 3 Rev. A Safety

Safety and Instruction Decals
The following safety and instruction decals are affixed below and in your Parts Catalog. Order replacements
to the traction unit. If any decal becomes illegible or from your Authorized Toro Distributor.
damaged, install a new decal. Part numbers are listed
ON CARRIER FRAME
(Part No. 94–3353)
WARNING! Pinch Point between Carrier Frame and Cutting
Unit
ON FAN SHROUD
ON INSTRUMENT PANEL (Part No. 77–3100)
(Part No. 94–4985)
UNDER CONTROL PANEL
(Part No. 93–6902)
ON LEFT SIDE OF SEAT PANEL
(Part No. 92–7270)
Model 03427 only
ON LEFT FENDER
(Part No. 84–1650)
ON LIFT ARMS
(Part No. 93–6696)
Rotating Parts
ON UNDER SEAT WARNING! Spring Loaded Mechanism,
(Part No. 93–6903) Read Disassembly Procedure
ON INSIDE OF
FRONT RIGHT PANEL
(Part No. 67–5360) ON SKIRT PANEL
(Part No. 83–9550)
Safety Page 1 – 4 Reelmaster 2300–D/2600–D

DANGER! Rotatin  Reel Will Cut Hands and Feet.
See Adjustment Procedures
ON SHIELD
(Part No. 93-8064)
Safety
Reelmaster 2300–D/2600–D Page 1 – 5 Safety

Safety Page 1 – 6 Reelmaster 2300–D/2600–D

Chapter 2
Product Records and Manuals
Table of Contents
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
HISTORYREPORTform.Usethisinformationwhenre-
ferring to your machine.
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Capscrew Markings and Torque Values – U.S. . . 3
Capscrew Markings and Torque Values – Metric 3
MAINTENANCE INTERVAL CHART . . . . . . . . . . . . . 4
OPERATION AND SERVICE HISTORY REPORT . 5
Insert Operator’s Manuals and Parts Catalogs for your
Reelmaster 2300–D/2600–D at the end of this section.
ProductRecords
and Manuals
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

ProductRecords
and Manuals
Reelmaster 2300–D/2600–D Page 2 – 3 Product Records and Manuals
Torque Specifications

Maintenance Interval Chart
Product Records and Manuals Page 2 – 4 Reelmaster 2300–D/2600–D

_________________________
_________________________
_________________________
_________________________
_________________________
EQUIPMENT OPERATION AND SERVICE HISTORY REPORT
for
REELMASTERR2300–D/2600–D
TORO Model and Serial Number: _____________–___________
Engine Numbers: _________________________
Transmission Numbers: _________________________
Date Purchased: _________________________ Warranty Expires___________
Purchased From: _________________________
Contacts: Parts Phone___________________
Service Phone___________________
Sales Phone___________________
ProductRecords
and Manuals
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 Maintenance Interval & Service
Inspect Air Filter, Dust Cup, and Baffle Every
50hrs Every
100hrs Every
200hrs Every
400hrs
Lubricate All Grease Fittings
{ Change Engine Oil
A–Level
{ Check Fan and Alternator Belt Tensions
Service
{ Change Engine Oil and Filter
B–Level
{ Check Traction Belt Tension
Service
Service Air Filter
Replace Fuel Filter/Water Separator
{ Replace Hydraulic Filter
C–Level
{ Torque Wheel Lug Nuts
Service
Replace Hydraulic Fluid
Check Battery Level/Connections
Inspect Traction Linkage Movement
* Inspect Spider Coupling for Wear
D–Level
} Torque Head Bolts and Adjust Valves
Service
} Check Engine RPM (idle and full throttle)
{ Initial break in at 10 hours
* Every 400 hours or annually, whichever occurs first
} Initial break in at 50 hours
Replace all Moving Hoses Annual Recommendations:
Replace Safety Switches
Items listed are recommended every 1000 hours
or 2 years, whichever occurs first.
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.)
Product Records and Manuals Page 2 – 6 Reelmaster 2300–D/2600–D

ProductRecords
and Manuals
REELMASTERR 2300–D/2600–D Daily Maintenance Check List
Daily Maintenance: (duplicate this page for routine use) Unit Designation: ____________
TORO ID #: ________–________
Maintenance
Maintenance
Check Item b
Daily Maintenance Check For Week Of ________________
MON
________HRS TUES ________HRS WED ________HRS THURS ________HRS FRI ________HRS SAT ________HRS SUN ________HRS
n Safety Interlock Operation
n Brake Operation
n Engine Oil Level1
n Cooling System Fluid Level1
Drain Water/Fuel Separator
n Air Filter, Dust Cup, and Baffle
n Radiator & Screen for Debris
n Unusual Engine Noises2
n Unusual Operating Noises
n Hydraulic System Oil Level1
n Hydraulic Hoses for Damage
n Fluid Leaks
n Fuel Level1
n Tire Pressure
n Instrument Operation
n Reel–to–Bedknife Adjustment
n Height–of–Cut Adjustment
Lubricate All Grease Fittings3
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
ProductRecords
and Manuals
(See Operator’s and Service Manuals for specifications and procedures.)
Reelmaster 2300–D/2600–D Page 2 – 7 Product Records and Manuals

________________________________ ________________________________ ________________________________ ________________________________ ________________________________
_______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________
________________________________ ________________________________
_______________________________ _______________________________ _______________________________
________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________ ________________________________
Product Records and Manuals Page 2 – 8 Reelmaster 2300–D/2600–D
REELMASTER R 2300–D/2600–D Supervisor Maintenance Work Order Date: ________________
(Duplicate this page for routine use.)
Unit Designation: Hours:
__________________–__________________
Service to perform (circle):
A B C D Other
Remarks:
Technician:
TORO I.D. #:
A– Service (every 50 hours)
Inspect Air Filter, Dust Cup, and Baffle Lubricate All Grease Fittings Change Engine Oil Check Fan and Alternator Belt Tension
B – Service (every 100 hours)
Change Engine Oil Filter Check Traction Belt Tension A – Service required
D – Service (every 400 hours)
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 & Full Throttle) A, B, and C – Sevice required
Other – Annual Service and Specials
Replace Moving Hoses Replace Safety Switches (Every 2 yrs) Coolant System – Flush/Replace Fluid Replace Thermostat Fuel Tank – Drain/Flush Hydraulic Tank – Drain/Flush
C – Service (every 200 hours)
Service Air Filter Replace Fuel Filter/Water Separator Replace Hydraulic Filter Torque Wheel Lug Nuts A and B – Sevice required
Additional Service Items
(See Operator’s and Service Manual for specifications and procedures.) Form No. 95–872–SL

Chapter 3
Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE AND REPAIRS 9. . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bleeding the Fuel System 9. . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Cleaner 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6 Cleaning the Radiator and Screen . . . . . . . . . . . . . 11
Fuel Shutoff Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Changing the Engine Oil and Filter 12. . . . . . . . . . .
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Checking the Cooling System 12. . . . . . . . . . . . . . . .
Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine Reinstallation 18. . . . . . . . . . . . . . . . . . . . . . .
PERKINS 100 SERIES WORKSHOP MANUAL
Reelmaster 2300–D/2600–D Page 3 – 1 Engine
Engine

Introduction
This Chapter gives information about specifications,
maintenance,troubleshooting, testing, andrepair 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
toolsaredescribedintheSpecialToolssection.Theuse
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 sup-
plied 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