Page 1 The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
Page 2 This page is intentionally blank. Reelmaster 2000–D...
Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System Safety Instructions ......1 -- 2 Electrical Schematics and Electrical Harness Jacking Instructions...
Page 4 This page is intentionally blank. Reelmaster 2000–D...
Page 5: Safety Instructions 1
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . 2 JACKING INSTRUCTIONS ..... 4 Before Operating .
Page 6: Safety Instructions
The Reelmaster 2000--D has been tested and certified or death. To reduce the potential for injury or death, by TORO for compliance with existing safety standards comply with the following safety instructions. and specifications as specified in the Traction Unit Op- erator’s Manual.
Page 7: Maintenance And Service
Toro replacement parts and 6. Before disconnecting or performing any work on the accessories. Replacement parts and accessories made...
Page 8: Jacking Instructions
Part numbers are listed in your Parts the traction unit and the cutting units of the Reelmaster Catalog. Order replacement decals from your Autho- 2000–D. If any decal becomes illegible or damaged, in- rized Toro Distributor. Safety Reelmaster 2000–D Page 1 – 4...
Page 9: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......Standard Torque for Dry, Zinc Plated, and MAINTENANCE .
Page 10: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Rev. A Reelmaster 2000--D...
Page 11: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 12 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 13: Standard Torque For Dry, Zinc Plated, And
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 14: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...
Page 15 Maintenance Maintenance procedures and recommended service in- tion when performing regular equipment maintenance. tervals for the Reelmaster 2000–D are covered in the Refer to the Engine Operator’s Manual for additional en- Traction Unit Operator’s Manual. Refer to that publica- gine specific maintenance procedures. Reelmaster 2000–D Product Records and Maintenance Page 2 –...
Page 16 Product Records and Maintenance Reelmaster 2000–D Page 2 – 8...
Page 17: Introduction 3
Chapter 3 Engine Table of Contents INTRODUCTION ......2 SERVICE AND REPAIRS ..... . 6 SPECIFICATIONS .
Page 18: Introduction
Service and repair parts for Briggs & Stratton/Daihatsu Most repairs and adjustments require tools which are diesel engines are supplied through your local Toro Dis- commonly available in many service shops. Special tributor. If no parts list is available, be sure to provide tools are described in the Special Tools section.
Page 19: Specifications
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Diesel Number of Cylinders Bore x Stroke mm (in.) 68 x 78 (2.68 x 3.07) Total Displacement cc (cu. in.) 850 (51.9) Compression Ratio 24.5:1 Firing Order 1 –...
Page 20: General Information
General Information Fuel Shutoff Valve This valve (Fig. 1) should be shut when removing the fuel tank or engine from the machine or when placing the unit in long term storage. Figure 1 1. Fuel shutoff valve (under the fuel tank) Adding Oil to Engine When adding oil to the engine, maintain clearance be- tween the oil fill device and the oil fill opening in the valve...
Page 21: Adjustments
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper ad- justment of throttle control. Make sure throttle control is operating properly. 1. Move remote throttle control lever to FAST position. 2. Check position of speed control lever on fuel injec- tion pump.
Page 22: Service And Repairs
Service and Repairs Fuel System Thread–locking Compound 30 to 60 in–lb (3.4 to 6.8 N–m) RIGHT FRONT Figure 6 1. Fuel tank 6. Fuel shut off 11. Washer 2. Fuel cap 7. Hose clamp 12. Cap screw 3. Hose clamp 8.
Page 23 Fuel Tank Removal DANGER 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Because diesel fuel is highly flammable, use caution when storing or handling it. Do not 2.
Page 24: Air Cleaner
Air Cleaner Ç Ç Ç Ç RIGHT FRONT Figure 7 1. Air cleaner assembly 6. Hose clamp 11. Air cleaner cover 2. Mounting bracket 7. Air cleaner bracket 12. Vacuator valve 3. Flange head screw 8. Cap screw 13. Plug 4.
Page 25 This page is intentionally blank. Reelmaster 2000–D Page 3 – 9 Engine...
Page 26: Exhaust System
Exhaust System 200 in–lb (22.6 N–m) RIGHT FRONT Figure 8 1. Muffler 6. Rubber isolator 11. Flat washer 2. Exhaust gasket 7. Clamp 12. Spacer 3. Muffler header 8. Coupler spring 13. Cap screw 4. Tailpipe 9. Flange nut 14. Carriage screw 5.
Page 27: Manual
Removal (Fig. 8) Installation (Fig. 8) NOTE: Make sure exhaust manifold and muffler head- CAUTION er sealing surfaces are free of debris or damage that may prevent a tight seal. The muffler and exhaust pipe may be hot. To 1. If muffler header was removed, place exhaust gas- avoid possible burns, allow the engine and ex- ket on the exhaust manifold.
Page 28: Radiator
Radiator RIGHT FRONT Figure 9 1. Radiator surge tank 14. Screen 26. Warning decal 2. Surge tank bracket 15. Bottom radiator shield 27. Radiator hose 3. Top radiator shroud 16. Screw 28. Bulb seal 4. Flange head screw 17. Hose clamp 29.
Page 29 Removal (Fig. 9) Installation 1. Park machine on a level surface, lower cutting units, 1. Install any removed brackets or shrouds to radiator stop engine, engage parking brake, and remove key using Figure 9 as a guide. from the ignition switch. 2.
Page 30: Engine Removal
Engine Removal 1. Park machine on a level surface, lower cutting units, stop engine, and remove key from the ignition switch. Chock wheels to keep the machine from moving. 2. Disconnect positive (+) and then negative (–) battery cables at the battery. 3.
Page 31 12.Close fuel tank shut–off valve. 13.Disconnect hoses from engine. A. Loosen clamps and disconnect upper and lower radiator hoses from the engine. B. At injector pump, loosen hose clamp and discon- nect fuel hose from the fuel filter/water separator (Fig. 12). Plug hose to prevent leakage and contami- nation.
Page 32 Lift Tab Lift Tab RIGHT FRONT Figure 15 1. Engine 11. Rear engine frame 21. Lock nut 2. Flywheel stub shaft 12. Engine channel 22. Snubbing washer 3. Cap screw 13. Flange head screw 23. Engine mount 4. Flat washer 14.
Page 33: Engine Installation
Engine Installation 1. Locate machine on a level surface with cutting units 5. Reconnect electrical connections. lowered and key removed from the ignition switch. A. Pull wiring harness and hoses into position keep- Chock wheels to keep the machine from moving. ing them from contacting moving parts.
Page 34 6. Install hydraulic pump assembly (see Service and 16.Fill hydraulic reservoir with hydraulic fluid (see Trac- Repairs section of Chapter 4 – Hydraulic System). tion Unit Operator’s Manual). Check reservoir for leaks. 7. After engine and pump installation, verify pulley 17.Slide the left foot rest onto the brake rod.
Page 35: Engine Pto
Engine PTO Disassembly 1. Remove three cap screws and lock washers that se- cure bushing to pulley. IMPORTANT: Excessive or unequal pressure on the cap screws can break the bushing flange. 2. Insert cap screws into threaded removal holes of the bushing.
Page 36 This page is intentionally blank. Engine Reelmaster 2000–D Page 3 – 20...
Page 37: Hydraulic Schematic 4
Chapter 4 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE AND REPAIRS .
Page 38: Specifications
Specifications Item Description Traction Pump Variable displacement piston pump Maximum Operating Pressure 3000 PSI (207 bar) Wheel Motors Orbital rotor motor (with shuttle valve on left front motor) Maximum Operating Pressure 2000 PSI (138 bar) Charge Pump Gerotor pump integral in traction pump Charge Pressure 100 to 150 PSI (6.9 to 10.0 bar) Implement (Lift) Relief Valve...
Page 39 This page is intentionally blank. Reelmaster 2000–D Page 4 – 3 Hydraulic System...
Page 40: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation and mainte- Before disconnecting or performing any work nance.
Page 41 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 fit- ting shows signs of leakage. O–Ring 3.
Page 42: Towing Traction Unit
Towing Traction Unit IMPORTANT: If towing limits are exceeded, severe damage to the piston pump may occur. If it becomes necessary to tow (or push) the machine, tow (or push) at a speed below 3 mph (4.8 kph), and for a distance less than 1/4 mile (0.4 km).
Page 43: Hydraulic Schematic
Hydraulic Schematic Reelmaster 2000–D Page 4 – 7 Hydraulic System...
Page 44: Hydraulic Flow Diagrams
Hydraulic Flow Diagrams Hydraulic System Page 4 – 8 Reelmaster 2000–D...
Page 45: Traction Circuit
Traction Circuit Forward Direction Reverse Direction The traction pump is driven by the engine through the The traction circuit operates essentially the same in re- pulleys and pump drive belt. The traction circuit of the verse as it does in the forward direction. However, the hydraulic system acts essentially as a closed loop.
Page 46 Hydraulic System Page 4 – 10 Reelmaster 2000–D...
Page 47: Lift Circuit
Lift Circuit The charge pump is part of the traction pump and is di- of the control valve to the lower and outer portions of the rectly coupled to it. It supplies hydraulic pressure for lift cylinders. Hydraulic pressure against the cylinder raising and lowering cutting units and maintaining 100 pistons pushes the shafts out.
Page 48 Hydraulic System Page 4 – 12 Reelmaster 2000–D...
Page 49: Mow Circuit
Mow Circuit The reel motor drive pump is directly coupled to the trac- compensated by the logic cartridge valve (LC1). Any ex- tion pump which is belt driven by the engine. Taking its cess flow above what the speed control valve is set for suction directly from the reservoir, the reel motor drive is bypassed to the reservoir through the logic cartridge pump supplies oil flow to the hydraulic manifold block...
Page 50: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 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.
Page 51: Hydraulic Test Fitting Kit
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of O–ring Face Seal fittings to enable connection of test gauges to the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 11...
Page 52: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic sys- Continued use of an improperly functioning hydraulic tem is best diagnosed with the use of proper testing system could lead to extensive internal component equipment and a thorough understanding of the com- damage.
Page 53 Problem Possible Cause No traction in either direction Brake is not released. Oil level in reservoir is low. Traction pump by--pass valve is open. Charge pressure is low. Traction pump or wheel motor(s) are worn or damaged. Wheel motor will not turn Internal parts in wheel motor are damaged.
Page 54 Problem Possible Cause Cutting units will not lift or lift slowly Engine speed is too low. Pump pulley drive belt is loose. Charge pump is damaged. Lift valve control linkage is binding or broken. Lift cylinder bushings are binding. Reservoir oil level is low. Inlet filter is loose or clogged.
Page 55: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 56: Test No. 1: Traction Circuit Working Pressure
TEST NO. 1: Traction Circuit Working Pressure (Using Pressure Gauge) WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REVERSE FROM REAR WHEEL MOTOR (OPTIONAL 3WD KIT) BOTTOM TEST GAUGE (FORWARD) CHARGE RELIEF FROM LIFT CONTROL VALVE FRONT TO LIFT CONTROL VALVE TEST GAUGE (REVERSE)
Page 57 Procedure for Traction Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 3.
Page 58: Test No. 2: Mow Circuit Working Pressure
TEST NO. 2: Mow Circuit Working Pressure (Using Pressure Gauge) FILTER TO CHARGE PUMP RESERVOIR TO TRACTION PUMP COOLER GEAR PUMP TEST GAUGE FROM LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 17 Hydraulic System Page 4 –...
Page 59 Procedure for Mow Circuit Working Pressure Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered and off. Make sure engine is off. 3.
Page 60: Test No. 3: Traction Pump Flow
TEST NO. 3: Traction Pump Flow (Using Tester With Pressure Gauges and Flow Meter) WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REVERSE FROM REAR WHEEL MOTOR (OPTIONAL 3WD KIT) TESTER BOTTOM CHARGE RELIEF FROM LIFT CONTROL VALVE FRONT TO LIFT CONTROL VALVE CHARGE PUMP...
Page 61 Procedure for Traction Pump Flow Test: CAUTION 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 Use extreme caution when taking gauge read- minutes. ings. The front tire on the ground will be trying 2.
Page 62: Test No. 4: Charge Pump Flow And Lift Relief Pressure
TEST NO. 4: Charge Pump Flow and Lift Relief Pressure (Using Tester With Pressure Gauges and Flow Meter) REEL LIFT TO WHEEL MOTORS TO WHEEL MOTORS CONTROL VALVE TO LIFT CYLINDER VALVE TOP BOTTOM IN (FRONT) FROM LIFT CYLINDER OUT (REAR) BOTTOM CHARGE RELIEF LIFT RELIEF...
Page 63 Procedure for Charge Pump Flow Test: 3. Operate engine at full speed (3200 + 50 RPM). 1. Make sure hydraulic oil is at normal operating tem- 4. Watch pressure gauge carefully. Make sure lift lever perature by operating the machine for approximately 10 is in the neutral position.
Page 64: Test No. 5: Charge Pump Relief Pressure
TEST NO. 5: Charge Pump Relief Pressure (Using Pressure Gauge) TO WHEEL MOTORS TO WHEEL MOTORS VALVE TOP TO LIFT CYLINDER IN (FRONT) BOTTOM FROM LIFT CYLINDER OUT (REAR) BOTTOM REEL LIFT CONTROL VALVE LIFT RELIEF CHARGE RELIEF FRONT T–CONNECTION AND GAUGE FILTER CHARGE PUMP BOTTOM...
Page 65 Procedure for Charge Pump Relief Pressure Test: 9. Shut off engine. 1. Make sure hydraulic oil is at normal operating tem- 10.Disconnect gauge and T–connection from the pump perature by operating the machine for approximately 10 and hose. Reconnect hose to the pump. minutes.
Page 66: Test No. 6: Reel Gear Pump Flow
TEST NO. 6: Reel Gear Pump Flow (Using Tester With Pressure Gauges and Flow Meter) FILTER TO CHARGE PUMP RESERVOIR TO TRACTION PUMP COOLER GEAR PUMP TESTER FROM LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 24 Hydraulic System...
Page 67 Procedure for Reel Gear Pump Flow Test: 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 minutes. 2. Park machine on a level surface with the cutting units lowered. Make sure engine is off and the parking brake is engaged.
Page 68: Test No. 7: Manifold Relief Valve Pressure
TEST NO. 7: Manifold Relief Valve Pressure (Using Tester With Pressure Gauges and Flow Meter) TESTER FROM REEL DRIVE PUMP TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure Low Pressure (Charge) Return or Suction Flow Install tester in series between fitting...
Page 69 Procedure for Manifold Relief Valve Pressure Test: NOTE: Do not remove relief valve from the hydraulic manifold for adjustment. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 10.Adjust the relief valve pressure as follows: minutes.
Page 70: Test No. 8: Cross--Over Relief Pressures
TEST NO. 8: Cross–over Relief Pressures (Using Pressure Gauge) TEST GAUGE LOCATION (TESTING IN MOW) FROM REEL DRIVE PUMP TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR T–CONNECTION AND GAUGE LOCATION HYDRAULIC MANIFOLD (TESTING IN BACKLAP) Working Pressure Low Pressure (Charge) Return or Suction Flow Figure 29...
Page 71 Procedure for Cross–over Relief Pressures Test: 9. Remove test gauge and put cap on manifold port G1. 1. Make sure hydraulic oil is at normal operating tem- IMPORTANT: Each reel motor has two cross–over perature by operating the machine for approximately 10 reliefs.
Page 72: Test No. 9: Reel Motor Case Drain
TEST NO. 9: Reel Motor Case Drain (Using Tester With Pressure Gauges and Flow Meter) MEASURE RH CASE DRAIN FLOW HERE TEST CONNECTION FOR R.H. REEL MOTOR SHOWN FROM REEL MOTOR GEAR PUMP TESTER TO COOLER FROM CARTRIDGE VALVES AND LEFT WHEEL MOTOR HYDRAULIC MANIFOLD Working Pressure...
Page 73 Procedure for Reel Motor Case Drain Test: 5. Install flow tester with pressure gauges in series with the motor and the disconnected return hose. Make sure NOTE: Over a period of time, a reel motor can wear in- the flow control valve on the tester is fully open. ternally.
Page 74: Test No. 10: Wheel Motor Case Drain
TEST NO. 10: Wheel Motor Case Drain (Using Tester With Pressure Gauges and Flow Meter) WHEEL MOTOR RIGHT FORWARD TO REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REVERSE FROM REAR WHEEL MOTOR (OPTIONAL 3WD KIT) REELS DISENGAGED TO PREVENT FLOW TO REAR WHEEL TESTER BOTTOM TEST CONNECTION FOR...
Page 75 Procedure for Wheel Motor Case Drain Test: 14.If specifications are not met, the tested wheel motor needs to be repaired or replaced as necessary. 1. Make sure hydraulic oil is at normal operating tem- perature by operating the machine for approximately 10 15.If remaining front wheel motor requires testing, com- minutes.
Page 76: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the hydraulic reservoir and add cor- tem, park machine on a level surface, engage parking rect oil if necessary.
Page 77: Flush Hydraulic System
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or the system is contaminated (oil appears milky or black or con- tains metal particles). IMPORTANT: Flush hydraulic system when chang- Ing from petroleum base hydraulic fluid, such as Mobil DTE 15M, to biodegradable fluid, such as Mo- bil EAL 224H.
Page 78: Hydraulic System Start-Up
Hydraulic System Start–up NOTE: When initially starting the hydraulic system with new or rebuilt components such as motors, pumps, or CAUTION lift cylinders, it is important that this start–up procedure be used. This procedure reduces the chance of damag- ing the system or its components from not purging the Be careful when operating the cutting unit reels.
Page 79: Hydraulic Pump Drive Belt
Hydraulic Pump Drive Belt 60 to 70 ft–lb (81 to 95 N–m) RIGHT FRONT Figure 34 1. Hydraulic pump drive belt 6. Adjusting bolt (full thread) 11. Cap screw 2. Pump pulley 7. Jam nut 12. Thrust washer 3. Engine pulley 8.
Page 80: Traction/Charge Pump
Traction/Charge Pump 90 to 120 in–lb (10.2 to 13.6 N–m) Anti–seize lubricant Thread–locking Compound RIGHT FRONT Figure 35 1. Taper lock bushing 16. 90 hydraulic fitting 31. Cap screw 2. Hydraulic pump drive belt 17. 90 hydraulic fitting 32. Protective sleeve 3.
Page 81 Neutral Arm Assembly Figure 36 1. Extension spring 11. Thrust washer 20. Flange nut 2. Hose 12. Traction stud 21. Flat washer 3. Neutral bracket 13. Grease fitting 22. Lock nut 4. Pump lever 14. Cap screw 23. Screw 5. Screw 15.
Page 82 4. Remove pulley from the taper lock bushing on the 8. Remove reel drive pump from the piston pump (see piston pump: Reel Drive Pump Removal). A. Remove cap screws and lock washers securing 9. Remove hydraulic fittings and O–rings from the pulley to the taper lock bushing.
Page 83 9. Install drive belt to the pulleys (see Hydraulic Pump Drive Belt). CAUTION 10.Check traction drive for neutral and neutral switch The extension spring is under tension and may adjustment (see Traction Unit Operator’s Manual). cause personal injury during installation. Use caution when installing the spring to the neutral 11.
Page 84: Traction/Charge Pump Service
Traction/Charge Pump Service Figure 37 1. Drive shaft 13. Camplate insert 25. Washer 2. End cover 14. Washer 26. Dowel pin 3. Housing 15. Bearing 27. Cap screw 4. Rotating kit 16. Camplate shaft seal 28. Cap screw 5. Camplate 17.
Page 85: Reel Gear Pump
Reel Gear Pump Removal (Fig. 38) 27 to 33 ft–lb (37 to 44 N–m) 1. Park the machine on a level surface, engage the PUMP parking brake, lower the cutting units, and stop the en- INLET gine. Remove the key from the ignition switch. PORT CAUTION Operate all hydraulic controls to relieve system...
Page 86: Reel Gear Pump Service (Barnes)
Reel Gear Pump Service (Barnes) INLET PORT SIDE OUTLET PORT 40 ft- -lb (54 N- -m) Figure 39 1. Retaining ring 6. O- -ring 11. Drive gear 2. Shaft seal 7. Dowel pin 12. Idler gear 3. Mounting flange 8. End cover 13.
Page 87 Shaft Seal Replacement (Fig. 39) 2. Place the front bearing block with its seal side down onto the mounting flange. The open side of the E–seal 1. Place the mounting flange on a clean working sur- should point toward the matchmark on the inlet side of face with the shaft seal (2) up.
Page 88: Reel Gear Pump Service (Casappa)
Reel Gear Pump Service (Casappa) 33 ft- -lb (45 N- -m) Figure 39.1 1. Retaining ring 6. Back- -up gasket 11. Dowel pin 2. Shaft seal 7. Front wear plate 12. Body 3. Front flange 8. Drive shaft 13. Washer (4 used) 4.
Page 89 4. Loosen the four (4) cap screws that secure pump as- 10.Clean all parts. Check all components for burrs, sembly. scoring, nicks and other damage. 5. Remove pump from vise and remove fasteners. 11. Replace the entire pump assembly if parts are ex- cessively worn or scored.
Page 90: Wheel Motor
Wheel Motor Front Wheel Motor Removal (Fig. 40) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en- gine. Remove the key from the ignition switch. 9 (LH) 7 (LH) CAUTION 6 (LH) Operate all hydraulic controls to relieve system...
Page 91 3WD Rear Wheel Motor Removal (Fig. 41) If the optional 3 Wheel Drive Kit has been installed, rear wheel motor removal procedure is as follows. 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en- gine.
Page 92: Wheel Motor Service
Wheel Motor Service LEFT WHEEL MOTOR SHOWN Figure 42 1. Coupling shaft 11. Manifold 21. Inner seal 2. Thrust bearing 12. Stator 22. Back–up washer 3. Drive link 13. Vane 23. Seal ring 4. Cap screw 14. Rotor 24. Back–up washer 5.
Page 93: Cutting Reel Motor
Cutting Reel Motor Removal (Fig. 43) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en- gine. Remove the key from the ignition switch. CAUTION 35 ft–lb Operate all hydraulic controls to relieve system (47 N–m) pressure and avoid injury from pressurized hy- draulic oil.
Page 94: Cutting Reel Motor Service (Serial Number Below 290000000)
Cutting Reel Motor Service (Serial Number Below 290000000) 10 to 12 ft- -lb (14 to 16 N- -m) 25 to 28 ft- -lb (34 to 38 N- -m) Figure 44 1. Relief valve plug 8. Idler gear assembly 14. Frontplate 2.
Page 95 IMPORTANT: Do not remove the relief valve assem- 11. The face of the backplate and frontplate should be bly (19) unless testing shows it to be faulty. The re- free of excessive scoring. Replace if any scoring exists lief valve assembly must be replaced as a complete to a depth of 0.0015 in.
Page 96: Cutting Reel Motor Service (Serial Number Above 290000000)
Cutting Reel Motor Service (Serial Number Above 290000000) 33 ft- -lb (45 N- -m) Figure 44.1 1. Dust seal 7. Back- -up gasket 13. O- -ring 2. Retaining ring 8. Front wear plate 14. Relief valve 3. Flange washer 9. Dowel pin 15.
Page 97 4. Loosen cap screws from the rear cover. 4. Inspect wear plates for the following: 5. Remove motor from the vise. Turn motor so that the A. Bearing areas should not have excessive wear or shaft end is facing down. Remove cap screws. scoring.
Page 98 1. Lubricate O--rings, pressure seals, back--up gaskets 8. Install rear wear plate with pressure seal side up and and wear plate grooves with a thin coat of petroleum jel- open side of the pressure seal pointing to the inlet side ly.
Page 99 This page is intentionally blank. 57.4 Rev. A Reelmaster 2000--D Page 4 - - Hydraulic System...
Page 100: Hydraulic Manifold
Hydraulic Manifold Removal (Fig. 45) 1. Park the machine on a level surface, engage the parking brake, lower the cutting units, and stop the en- gine. Remove the key from the ignition switch. CAUTION Operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hy- draulic oil.
Page 101 This page is intentionally blank. Reelmaster 2000–D Page 4 – 59 Hydraulic System...
Page 102: Hydraulic Manifold Service (Serial Number Below 290000000)
Hydraulic Manifold Service (Serial Number Below 290000000) 35 ft- -lb 15 in- -lb (47 N- -m) (1.7 N- -m) Thread- -locking Compound 35 ft- -lb Thread- -locking (47 N- -m) Compound 35 ft- -lb (47 N- -m) 35 ft- -lb (47 N- -m) 35 ft- -lb (47 N- -m)
Page 103: Hydraulic Manifold Service
Hydraulic Manifold Service 8. Reinstall the cartridge valve: 1. Make sure the manifold is clean before removing the A. Lubricate new seal kit components with clean hy- cartridge valve. draulic oil and install on valve. The o–rings, sealing rings, and backup rings must be arranged properly 2.
Page 104 H. On backlap valve, turn knob counterclockwise so the arrow is 90 with the back of the manifold body. Simultaneously tighten upper jam nut and turn knob so it is tight and the arrow is pointing 45 to the right in line with the indicator plate.
Page 105 This page is intentionally blank. Reelmaster 2000–D Page 4 – 63 Hydraulic System...
Page 106 Hydraulic Manifold Service (Serial Number Above 290000000) 15 ft- -lb (20 N- -m) 40 ft- -lb 5 ft- -lb (54 N- -m) (6.7 N- -m) 50 ft- -lb (67 N- -m) FRONT 25 ft- -lb 25 ft- -lb (34 N- -m) (34 N- -m) 20 ft- -lb 20 ft- -lb...
Page 107 Hydraulic Manifold Service C. Push spool down until O--ring and back--up ring are exposed on bottom of mow manifold. Remove 1. Make sure the manifold is thoroughly cleaned before lower O--ring and back--up ring from spool. removing any cartridge valve. D.
Page 108 B. Lubricate threads of cartridge valve with clean CAUTION hydraulic oil. Thread cartridge valve carefully into correct manifold port. The valve should go in easily without binding. Abrupt movement of internal spools can cause C. Torque cartridge valve using a deep well socket stored fluid to be released suddenly.
Page 109 This page is intentionally blank. 63.4 Rev. A Reelmaster 2000--D Page 4 - - Hydraulic System...
Page 110: Wheel Drive Selector Valve
3 Wheel Drive Selector Valve RIGHT FRONT 6 12 Figure 47 1. Forward hydraulic tube 6. 90 hydraulic fitting 11. O–ring 2. Reverse hydraulic tube 7. Cap screw 12. O–ring 3. Lock nut 8. Flat washer 13. Hydraulic hose 4. 3WD selector valve 9.
Page 111 If the optional 3 Wheel Drive Kit has been installed, the Installation (Fig. 47) 3WD selector valve removal and installation procedure 1. Install hydraulic fittings and new O–rings into selec- is as follows. tor valve. Removal (Fig. 47) 2. Position selector valve to the machine. Secure se- 1.
Page 112: Wheel Drive Selector Valve Service
3 Wheel Drive Selector Valve Service 4 to 6 ft–lb (5.4 to 8.1 N–m) Thread–locking Compound 35 to 40 ft–lb 35 to 40 ft–lb (47 to 54 N–m) (47 to 54 N–m) Figure 48 1. Selector Valve manifold 3. Pilot operated directional valve 5.
Page 113 If the optional 3 Wheel Drive Kit has been installed, the 7. Reinstall the cartridge valve: 3WD selector valve service procedure is as follows. A. Lubricate new seal kit components with clean hy- Selector Valve Service draulic oil and install on valve. The o–rings, sealing rings, and backup rings must be arranged properly 1.
Page 114: Front Lift Cylinder
Front Lift Cylinder INSTALL FLANGE BUSHINGS (18) FROM THE INSIDE HYDRAULIC FITTING SIDE Figure 49 1. Hydraulic hose 8. Lift cylinder 14. Clevis pin 2. Hydraulic hose 9. Cotter pin 15. Lift chain clevis 3. Hydraulic hose 10. Clevis pin 16.
Page 115 Removal (Fig. 49) Installation (Fig. 49) 1. Park the machine on a level surface, engage the 1. Thread lift hub onto lift cylinder and tighten fully. parking brake, lower the cutting units, and stop the en- 2. Position lift cylinder inside the cylinder support gine.
Page 116: Front Lift Cylinder Service
Front Lift Cylinder Service Figure 50 1. Retaining ring 5. O–ring 9. Uni–ring 2. O–ring 6. Shaft 10. Lock nut 3. Head 7. O–ring 11. Barrel 4. Backup washer 8. Piston 12. Dust seal Disassembly (Fig. 50) 5. Mount shaft securely in a vise by clamping vise on the flats of the shaft.
Page 117 Inspection CAUTION Spanner wrench Use eye protection such as goggles when using compressed air Retaining ring 1. Wash all parts in solvent. Dry parts with compressed (Offset end air. against left side of barrel groove 2. Inspect internal surface of barrel for deep scratches, after installing) out–of–roundness, and bending.
Page 118: Rear Lift Cylinder
Rear Lift Cylinder FRONT RIGHT 28 11 Figure 53 1. Cotter pin 11. 45 hydraulic fitting 21. Thrust washer 2. Tension spring arm 12. Hydraulic fitting 22. Cutting unit pivot shaft 3. Cap screw 13. Rear lift cylinder 23. Flat washer 4.
Page 119 Removal (Fig. 53) Installation (Fig. 53) 1. Park the machine on a level surface, engage the 1. Coat new O–rings lightly with clean hydraulic oil. parking brake, lower the cutting units, and stop the en- Install hydraulic fittings with new O–rings to the lift cylin- gine.
Page 120: Rear Lift Cylinder Service
Rear Lift Cylinder Service Figure 54 1. Barrel 6. Shaft 11. Retaining ring 2. Lock nut 7. O–ring 12. Dust seal 3. Piston 8. O–ring 13. Jam nut 4. Uni–ring 9. Backup washer 14. Clevis rod 5. O–ring 10. Head 15.
Page 121 Reassembly (Fig. 54) 4. Install piston onto the shaft being careful not to dam- age O–ring. Install locknut onto the shaft and tighten. 1. Coat new dust seal, uni–ring, backup washer, and all O–rings lightly with hydraulic oil. Install new O–ring and 5.
Page 122: Control And Lift Relief Valves
Control and Lift Relief Valves RETURN Figure 55 1. Control valve 11. Hydraulic hose 20. Relief valve cartridge 2. Lock nut 12. O–ring 21. Hydraulic tube 3. Hydraulic hose 13. Lock nut 22. Hydraulic adapter 4. Cap screw 14. Sponge 23.
Page 123 5. Unsnap and remove connecting link assembly (28). 1. Disconnect hose connection (9) from hydraulic tee Remove valve lever (5) from the control valve (1). fitting (7). Allow hose to drain hydraulic oil into a suitable container. 6. Disconnect tube (21) from hydraulic fitting (7). Dis- connect tube (18) from 90 hydraulic fitting (8).
Page 124 Control Valve Disassembly (Fig. 56) 1. Wash control valve in solvent and dry it thoroughly. 2. Mount control valve into a vise so the mounting pads are against the jaws of the vice and snap ring faces up. NOTE: Remove check valve seat only if it needs re- placement;...
Page 125: Hydraulic Reservoir
Hydraulic Reservoir Thread–locking Compound 30 to 60 in–lb (3.4 to 6.8 N–m) RIGHT FRONT 30 to 60 in–lb (3.4 to 6.8 N–m) Thread–locking Compound Figure 57 1. Shoulder screw 10. Tank mount grommet 19. Suction hose 2. Sight glass 11. Washer 20.
Page 126: Oil Cooler
Oil Cooler Hydraulic Sealant RIGHT FRONT 12 13 Figure 58 1. Oil cooler 7. Hydraulic hose (from manifold) 13. Front screen bracket 2. Hydraulic connector 8. Knob 14. Flat washer 3. O–ring 9. Lock nut 15. Lock nut 4. Bulkhead nut 10.
Page 127: Electrical Schematics And Electrical Harness And Connector Drawings
Chapter 5 Electrical System Table of Contents ELECTRICAL SCHEMATICS and ELECTRICAL Reels On Indicator Light ....13 HARNESS and CONNECTOR DRAWINGS .
Page 128 Electrical Schematics and Electrical Harness and Connectors Drawings The electrical schematics and other electrical drawings for the Reelmaster 2000–D are located in Chapter 8 – Electrical Diagrams. Electrical System Reelmaster 2000–D Page 5 – 2...
Page 129: Special Tools
Multimeter The multimeter can test electrical components and cir- cuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 130: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and CAUTION components used on this machine (see Chapter 8 – Electrical Diagrams). Remove all jewelry, especially rings and If the machine has any interlock switches by–passed, watches, before doing any electrical trouble- shooting or testing.
Page 131 Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. Engine run solenoid is faulty. Glow plugs are faulty. Engine or fuel system is malfunctioning (see Chapter 3 – Engine). Engine and/or fuel may be too cold. Standard Control Module is faulty. Engine cranks (but should not) with the traction pedal Traction neutral switch is out of adjustment or faulty.
Page 132: General Run And Transport Problems
General Run and Transport Problems Problem Possible Causes Engine continues to run (but should not) when the Seat switch is faulty, out of adjustment, or short traction pedal is depressed with no operator on the circuited. seat. Traction neutral switch is out of adjustment, faulty, or short circuited.
Page 133: Cutting Unit Operating Problems
Cutting Unit Operating Problems Problem Possible Causes Engine Continues to run (but should not) when the reel Backlap switch is in the backlap position. engage switch is ON with no operator in the seat. Backlap switch is faulty or out of adjustment. Wiring to the mow/backlap circuit components is loose, corroded, or damaged (see Wiring Schematics).
Page 134: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery 12.45 v 75% charged should be at a temperature of 60...
Page 135: Starting System Test
Starting System Test This is an excellent test to use when a “slow crank/no Set the multimeter to the correct scale. With the key in start” problem is encountered. It will determine if the the OFF position, place the ammeter pickup around the problem is due to an electrical open, short, or high resis- main negative (--) battery cable and read the meter prior tance in the starter circuit.
Page 136: Adjustments
Adjustments Neutral Switch 1. Adjust the neutral switch so that the switch opens when the traction pedal is moved forward 1 inch (2.5 cm), measured at the top of pedal. Figure 3 1. Traction pedal 3. Traction arm 2. Neutral switch Parking Brake Switch 1.
Page 137: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- NOTE: See the Briggs & Stratton/Daihatsu Engine Re- trically disconnect the component being tested from the pair Manual for more component testing information. circuit (e.g. unplug the ignition switch connector before doing a continuity check).
Page 138: Indicator Lights
Indicator Lights Engine Oil Pressure Light The oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should light with the engine running if the engine oil pressure drops below 4.3 PSI (0.3 kg/cm To test the oil pressure light and circuit wiring, ground the gray wire attached to oil pressure switch located on the front side of engine near the oil dipstick.
Page 139: Hour Meter
Hour Meter 1. Connect the positive (+) terminal of a 12 VDC source to the positive (+) terminal of the hour meter. Hobbs 2. Connect the negative (–) terminal of the voltage QUARTZ source to the other terminal of the hour meter. 0 0 0 0 HOURS 3.
Page 140: Glow Relay
Glow Relay The glow relay is attached to the instrument panel. When energized, the glow relay allows electrical current to the glow plugs. NOTE: Prior to taking small resistance readings with a digital multi meter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less).
Page 141: High Temperature Shutdown Switch
High Temperature Shutdown Switch The high temperature shutdown switch is located on the top of the water pump housing. The water pump is on the left end of the engine inside the fan pulley assembly. There is a blue/white wire attached to the shutdown switch.
Page 142: Oil Pressure Switch
Oil Pressure Switch The engine oil pressure switch is located on the cylinder near the dipstick and oil filter. It is a normally closed switch and opens with pressure. The operating range for the switch is 2.9 to 5.7 PSI (0.2 to 0.4 kg/cm Testing with the engine off 1.
Page 143: Solenoid Valve Coil
Solenoid Valve Coil The hydraulic system on the Reelmaster 2000–D uses a solenoid valve coil on the reel drive manifold and, when equipped with the optional 3WD kit, a second sole- noid coil on the 3WD manifold. NOTE: Prior to taking small resistance readings with a digital multimeter, short the test leads together.
Page 144: Standard Control Module
Standard Control Module The Reelmaster 2000–D is equipped with a Standard Control Module to monitor and control electrical compo- nents required for safe operation. This Module is at- tached to the back of the instrument panel (Fig. 19). Inputs from the neutral, parking brake, PTO, start (igni- tion), backlap, and high temperature switches are moni- tored by the Module.
Page 145: Traction Neutral Switch
Traction Neutral Switch The traction neutral switch is a normally open proximity switch that closes when the traction pedal is in the neu- tral position. The traction arm that is pinned to the trac- tion lever acts as the sensing plate for the switch. The Standard Control Module monitors the operation of the traction neutral switch.
Page 146: Seat Switch
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If either the neutral switch or parking brake switch is open when the operator raises out of the seat, the engine will stop. The standard seat uses a switch that is fastened to the underside of the seat (Fig.
Page 147: Parking Brake Switch
Parking Brake Switch The parking brake switch is a normally open proximity switch that is mounted on a bracket at the base of the parking brake lever (Fig. 23). The parking brake lever is used as the sensing plate. When the parking brake is engaged, the brake lever is moved away from the brake switch and the switch opens.
Page 148: Cutting Unit Interlock Switch
Cutting Unit Interlock Switch This switch is normally open and closes when the cutting units are lowered. The switch and its electrical connec- tor are located behind and below the hydraulic manifold on the cylinder support bracket. 1. Disconnect switch electrical connector. 2.
Page 149: Fuses
Fuses The fuse block is located on the back of the instrument panel (Fig. 26). Identification, Function, and Wiring The fuses are held in the fuse block. Use Figure 27 to identify each individual fuse and its correct amperage. Each fuse holder has the following functions and wire connected to it.
Page 150: Diode Assembly
Diode Assembly Diode D3 is used for circuit protection from voltage spikes when the hydraulic valve solenoid is de–ener- gized. The diode plugs into the wiring harness (see Wire Harness Drawings in Chapter 8 – Electrical Diagrams). Diode Test The diode (Fig. 28) can be tested using a digital multime- ter (diode test or ohms setting) and the table below.
Page 151: Service And Repairs
A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with skin–over grease (Toro Part No. 505-47) or petro- leum jelly to prevent corrosion. Reelmaster 2000–D Electrical System Page 5 –...
Page 152: Specifications 6
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes.
Page 153 B. Temperature correct each cell reading. For each G. Take a voltage reading at 15 seconds, then re- F (5.5 C) above 80 F (26.7 C) add 0.004 to the move the load. specific gravity reading. For each 10 F (5.5 C) be- H.
Page 154 2. Determine the charging time and rate using the 3. Following the manufacturer’s instructions, con- manufacturer’s battery charger instructions or the nect the charger cables to the battery. Make sure a good following table. connection is made. 4. Charge the battery following the manufacturer’s Battery Battery Charge Level instructions.
Page 155: Solenoid Valve Coil
Solenoid Valve Coil The solenoid valve coil on the reel drive (Fig. 30) and 3WD hydraulic manifold, if equipped, (Fig. 31) can be easily replaced without opening the hydraulic system. Removal 2 to 5 ft–lb 1. Disconnect the electrical connector. (2.7 to 6.8 N–m) 2.
Page 156 This page is intentionally blank. Electrical System Reelmaster 2000–D Page 5 – 30...
Page 157: Service And Repairs 6
Chapter 6 Chassis Table of Contents SPECIFICATIONS ......2 Standard Seat ......10 SERVICE AND REPAIRS .
Page 158: Specifications
Specifications Item Description Front tire pressure 16 to 20 PSI (1.1 to 1.38 bar) (20 x 10–8, 4 ply, tubeless) Rear tire pressure 16 to 20 PSI (1.1 to 1.38 bar) (20 x 8–8, 4 ply, tube type) Front and rear wheel lug nut torque 45 to 65 ft–lb (61 to 88 N–m) Front hub nut torque 250 to 400 ft–lb (339 to 542 N–m)
Page 159 This page is intentionally blank. Reelmaster 2000–D Page 6 – 3 Chassis...
Page 160: Service And Repairs
Service and Repairs Rear Wheel (Standard 2 Wheel Drive) 60 to 80 ft–lb (81 to 108 N–m) 45 to 65 ft–lb (61 to 88 N–m) 11 7 RIGHT FRONT 15 to 20 ft–lb (20 to 27 N–m) (See text for tightening procedure) Figure 1 1.
Page 161 Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, lower cutting units, 1. If seal and inner bearing were removed from the stop engine, engage parking brake, and remove key wheel hub, place greased bearing cone into inner bear- from the ignition switch.
Page 162: Rear Wheel (Optional 3 Wheel Drive)
Rear Wheel (Optional 3 Wheel Drive) 250 to 400 ft–lb (339 to 542 N–m) 45 to 65 ft–lb (61 to 88 N–m) Figure 2 1. Rear wheel fork 4. Key 7. Wheel assembly 2. Steering tube assembly 5. Drive stud 8.
Page 163 Removal (Fig. 2) Installation (Fig. 2) 1. Park machine on a level surface, lower cutting units, 1. Install key and wheel hub onto the wheel motor shaft. stop engine, engage parking brake, and remove key 2. Install lock nut to wheel motor shaft and tighten to a from the ignition switch.
Page 164: Front Wheels And Brakes
Front Wheels and Brakes 45 to 65 ft–lb (61 to 88 N–m) RIGHT FRONT Anti–seize lubricant 250 to 400 ft–lb (339 to 542 N–m) Figure 3 1. Flange nut 13. Lug nut 24. Nut 2. Brake rod 14. Lock nut 25.
Page 165 7. Remove cotter pin (28) from the yoke pin (21). Re- move yoke pin from the brake lever (22) and separate yoke (23) from the brake lever (Fig. 4). 8. Remove cap screws (9) and lock nuts (6) holding the backing plate (36) and brake grass shield (8) to the brake bracket.
Page 166: Standard Seat
Standard Seat Figure 5 1. Seat (incl. 2 thru 7) 6. Seat cushion 11. Cap screw 2. Seat switch 7. Seat shell 12. Lock washer 3. Cap screw 8. Seat adjuster 13. Seat stop 4. Edging clip 9. Seat adjuster with latch 14.
Page 167: Suspension Seat
Suspension Seat 39 40 Figure 6 1. Plate 16. Adjusting rail (LH) 31. Washer 2. Rivet 17. Screw 32. Backrest trim 3. Screw 18. Washer 33. Tension spring set 4. Wear parts kit (incl. 8 thru 11) 19. Nut 34. Spindle adjuster (incl. 29 thru 5.
Page 168: Steering Assembly
Steering Assembly 60 to 80 ft–lb (81 to 108 N–m) RIGHT FRONT Figure 7 1. Steering wheel 11. Cap screw 20. Thrust washer 2. Steering wheel cover 12. Grease fitting 21. Lock washer 3. Lock nut 13. Sector gear 22. Flange bushing 4.
Page 169 Disassembly Assembly 1. Park machine on a level surface, lower cutting units, 1. Assemble steering assembly using Figure 7 as a stop engine, engage parking brake, and remove key guide. from the ignition switch. A. Shim steering shaft (with gear) and sector gear 2.
Page 170: Front Lift Arms
Front Lift Arms 17 13 RIGHT FRONT Figure 8 1. Lift arm (LH shown) 11. Chain 21. Cap screw 2. Lock washer 12. Shackle 22. Reinforcement plate 3. Cap screw 13. Clevis pin 23. Lift arm pivot shaft 4. Thrust washer 14.
Page 171: Rear Lift Arm
Rear Lift Arm FRONT RIGHT Figure 9 1. Lift arm 9. Thrust washer 17. Spacer 2. Bushing 10. Flat washer 18. Spring tension arm 3. Grease fitting 11. Flange head screw 19. Lock nut 4. Cap screw 12. Lift arm pivot shaft 20.
Page 172 This page is intentionally blank. Chassis Page 6 – 16 Reelmaster 2000–D...
Page 173: Special Tools 7
Chapter 7 Cutting Units Table of Contents SPECIFICATIONS ......2 SPECIAL TOOLS ......4 TROUBLESHOOTING .
Page 174: Specifications
Specifications Figure 1 MOUNTING: All cutting units are supported by equal SUSPENSION SYSTEM: A fully floating suspension length, independent lift arms and are interchangeable to with hydraulic counterbalance. L–I–N–K–S cutting all three cutting unit positions. unit suspension system provides fore and aft oscillation. Main center pivot allows side–to–side oscillation.
Page 175 This page is intentionally blank. Reelmaster 2000–D Page 7 – 3 Cutting Units...
Page 176: Special Tools
Toro Part Number: TOR299100 Figure 3 Bedknife Screw Tool This screwdriver type bit is made to fit Toro bedknife at- taching screws. Use this bit with a torque wrench to se- cure the bedknife to the bedbar. IMPORTANT: Do not use an air or manual impact wrench with this tool.
Page 177 This tool should be used with the Toro Guide to Evaluation Reel Mower Performance and Using the TurfEvaluator (Toro part no. 97931SL)
Page 178: Troubleshooting
For additional information regarding cutting unit trouble- machine. It is important to remember that the lower the shooting, see Aftercut Appearance Troubleshooting Aid height–of–cut, the more critical these factors are. (Toro part no. 00076SL). Factors That Can Affect Quality Of Cut Factor Possible Problem/Correction 1.
Page 179 Factor Possible Problem/Correction 6. Bedknife to reel adjustment. Check bedknife to reel contact daily. Bedknife must have light contact all across the reel. No contact will cause cutting edges to become dull. Excessive contact accelerates wear; quality of cut may be adversely affected.
Page 180: Adjustments
Adjustments CAUTION Never install or work on the cutting units or lift arms with the engine running. Always stop en- gine and remove key first. See Cutting Unit Operator’s Manual for adjustment pro - cedures for the cutting units on the Reelmaster 2000–D. Characteristics The single knob bedknife–to–reel adjustment system in- If a cutting unit is determined to be out of adjustment,...
Page 181: Service And Repairs
Service and Repairs Hydraulic Reel Motor Removal (Fig. 7) 1. Remove two cap screws holding the hydraulic motor to the bearing housing. 2. Remove hydraulic motor, o–ring, and spider coupler from the bearing housing. Position hydraulic motor away from the cutting unit prior to removing or working on the cutting unit.
Page 182: Bedbar
Bedbar ANTI–SEIZE LUBRICANT PERMANENT THREAD–LOCKING COMPOUND ANTI–SEIZE LUBRICANT ANTI–SEIZE LUBRICANT RIGHT FRONT 250 to 300 in–lb (28 to 34 N–m) Figure 8 1. Rubber bushing 12. Flange bushing 23. Flat washer 2. Flanged bushing 13. Bushing 24. Lock washer 3. Jam nut 14.
Page 183 Installation 1. Inspect flanged bushings and bushing for wear; re- place if necessary. 2. Clean and apply anti–seize lubricant to both bedbar pivots. Install bedbar washer on the bedbar. 3. Install bedbar adjusting housing and bedbar housing on the bedbar. Reinstall spacer, flat washer, lock wash- er, and cap screw to the right end of the bedbar.
Page 184: Bedknife Replacement And Grinding
Bedknife Replacement and Grinding 1. Remove bedbar from the cutting unit (see Bedbar Removal). 2. Remove bedknife screws and bedknife. 3. Remove all rust, scale and corrosion from the bedbar surface before installing new bedknife. NOTE: Use a torque wrench and a bedknife screw tool to install bedknife screws.
Page 185: Front And Rear Rollers
Front and Rear Rollers NOTE: This section can be used for both the front and rear rollers. Roller Removal 1. Remove both height–of–cut pins and hairpin cotters from each roller bracket. 2. Remove both locknuts from the cap screws securing each angle bracket to the cutting unit.
Page 186: Roller Service
Roller Service See assembly process for tightening procedure Figure 13 1. Full roller 5. Bearing cone (outer) 9. Wiehle roller 2. Roller shaft 6. Outer seal 10. Sectional roller shaft 3. Grease seal 7. Adjustment nut 11. Bearing cone (inner) 4.
Page 187 Full or Wiehle Roller Assembly Sectional Roller Assembly 1. Make sure all parts are clean prior to installing bear- 1. Make sure all parts are clean prior to installing bear- ings and seals. ings and seals. 2. On a full roller, grease inner seal lips and install inner 2.
Page 188: Cutting Reel
Cutting Reel 55 to 65 ft–lb (75 to 88 N–m) THREAD–LOCKING COMPOUND RIGHT ANTI–SEIZE LUBRICANT FRONT 27 28 55 to 65 ft–lb (75 to 88 N–m) THREAD–LOCKING COMPOUND Figure 14 1. Hydraulic motor 13. Cutting reel 25. Grease fitting 2. Cap screw 14.
Page 189 Inspect Cutting Reel (Fig. 14) 12.Install bedbar assembly to cutting unit (see Bedbar Installation). 1. Replace reel if the diameter has decreased to the service limit (see Reel Grinding Specification in Prepar- 13.Complete cutting unit set–up and adjustment se- ing Reel For Grinding). quence (see Cutting Unit Operator’s Manual).
Page 190: Prepare Reel For Grinding
Prepare Reel for Grinding NOTE: Check to make sure reel bearings are in good 3. After completing grinding process: condition and properly adjusted before grinding reel. A. Install front roller and brackets (see Roller Re- 1. Remove bedbar assembly (see Bedbar Removal moval and Installation).
Page 191: Fixed Side Plate Installation
Fixed Side Plate Installation 1. Remove pop rivets and rear height–of–cut plates from both sides of the cutting unit (Fig. 16). 2. Remove lock nuts, cap screws, washers, and both links from the cutting unit (Fig. 16). 3. Align fixed side plate with holes on the cutting unit (Fig.
Page 192: Skid Kit Installation
Skid Kit Installation 1. Remove front roller from the cutting unit (see Roller Removal). 2. Align skid slots with the angle bracket holes on the cutting unit. 3. Secure skid to the cutting unit with both flange head screws, flat washers, and lock nuts. 4.
Page 193: Electrical Schematics
Chapter 8 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATICS ....Serial Number Below 230000000 ....Serial Number Above 230000000 .
Page 194 This page is intentionally blank. Electrical Diagrams Page 8 – 2 Reelmaster 2000–D...
Page 195 (IN OFF) (UNOCCUPIED) (IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Electrical Schematic Serial Number Below 230000000 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 8 - - 3 Rev.
Page 196 Reelmaster 2000--D Electrical Schematic Serial Number Above 230000000 All relays and solenoids are shown as de- - energized. All ground wires are black. Page 8 - - 4 Rev. A...
Page 197 (IN OFF) (IN NEUTRAL) (UNOCCUPIED) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Glow Plug Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 - - 5 Rev. A...
Page 198 (IN OFF) (UNOCCUPIED) (IN NEUTRAL) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) NOTE: The engine will crank with either the parking brake engaged or the seat occupied. Reelmaster 2000--D Crank Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 - - 6...
Page 199 (DISENGAGED) (IN OFF) (NOT IN NEUTRAL) (OCCUPIED) 3 WD SOLENOID (IF EQUIPPED) (IN OFF) Reelmaster 2000--D Run (Transport) Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 - - 7 Rev. A...
Page 200 (DISENGAGED) (REELS LOWERED) (IN OFF) (NOT IN NEUTRAL) (OCCUPIED) 3 WD SOLENOID (IF EQUIPPED) (IN ON) Reelmaster 2000--D Run (Mow) Circuit (Serial Number Below 230000000 Shown) Power Current Control Current Indicator/Gauge Current Logic Direction Page 8 - - 8 Rev. A...
Page 201 This page is intentionally blank. Page 8 - - 9 Rev. A...
Page 202 GREEN BLACK ORANGE ORANGE BLUE YELLOW BLACK PINK GRAY PINK PINK BLACK BLACK WHITE BLACK PINK BLACK PINK GRAY WHITE WHITE PINK PINK BLACK BLUE/WHITE PINK BLACK BROWN VIOLET VIOLET ORANGE Reelmaster 2000--D Main Wire Harness Serial Number Below 230000000 Page 8 - - 10 Rev.
Page 203 Reelmaster 2000--D Main Wire Harness Serial Number Below 230000000 Page 8 - - 11 Rev. A...
Page 204 GREEN BLACK ORANGE ORANGE BLUE YELLOW BLACK PINK GRAY PINK PINK BLACK WHITE BLACK BLACK PINK PINK BLACK GRAY WHITE WHITE PINK PINK BLACK BLUE/WHITE PINK BLACK BROWN VIOLET VIOLET ORANGE Reelmaster 2000--D Main Wire Harness Serial Number Above 230000000 Page 8 - - 12 Rev.
Page 205 Reelmaster 2000--D Main Wire Harness Serial Number Above 230000000 Page 8 - - 13 Rev. A...
Page 206 BLACK YELLOW BLACK ORANGE WHITE BROWN GREEN Reelmaster 2000--D Engine Wire Harness Page 8 - - 14 Rev. A...
Page 207 Reelmaster 2000--D Engine Wire Harness Page 8 - - 15 Rev. A...
Page 208 This page is intentionally blank. Page 8 - - 16 Rev. A...

Toro Reelmaster 2000-D Service Manual

Table of Contents

Chapter 1 -- Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Engine

Chapter 4 Hydraulic System

Electrical System

Chapter 5 -- Electrical System

Section 6

Chapter 6 -- Chassis

Section 7

Chapter 7 -- Cutting Units

Chapter 8 -- Electrical Diagrams

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Reelmaster 2000-D

Summary of Contents for Toro Reelmaster 2000-D

Table of Contents