Excell Xr2600 Replacement Pump For Firewood Processors (5 Pro Tips)

Okay, let’s dive into the world of firewood processors and the crucial role of the hydraulic pump, specifically focusing on replacing the pump on an Excell XR2600. We’ll cover not just the “how,” but also the “why,” and equip you with some pro tips to ensure a successful and long-lasting repair.

Future-Proofing Your Firewood Processor: The Heart of the Matter

Firewood processors are the unsung heroes of efficient firewood production. They take the back-breaking labor out of cutting and splitting, allowing you to process a significant amount of wood in a fraction of the time. However, like any machine, they rely on their components to function correctly. The hydraulic pump is arguably the most critical component, the heart that drives the entire splitting operation. A failing or inadequate pump can bring your production to a screeching halt. Replacing the pump on an Excell XR2600 isn’t just a repair; it’s an investment in the future of your firewood operation. A well-chosen, properly installed pump can boost performance, improve reliability, and extend the life of your processor.

I’ve seen firsthand the frustration of a malfunctioning firewood processor. I remember back when I first started seriously processing firewood for my family and some neighbors. I was using a borrowed processor that had seen better days. The hydraulic pump was weak, causing slow splitting cycles and frequent stalls. It turned what should have been a few hours of work into an all-day ordeal. That experience taught me the importance of a robust and reliable hydraulic system and the value of knowing how to maintain and repair it.

1. Understanding the Excell XR2600 and Its Hydraulics

Before we get our hands dirty, let’s establish a foundation. The Excell XR2600 is a popular entry-level firewood processor known for its affordability and compact size. It’s typically powered by a gasoline engine that drives a hydraulic pump, which in turn powers the splitting cylinder.

Key Components of the Hydraulic System:
- Hydraulic Pump: The heart of the system, converting mechanical energy from the engine into hydraulic power (pressure and flow).
- Hydraulic Cylinder: Converts hydraulic power into linear motion, driving the splitting wedge.
- Hydraulic Valve: Controls the direction of hydraulic fluid flow, allowing you to extend and retract the cylinder.
- Hydraulic Reservoir (Tank): Stores the hydraulic fluid.
- Hydraulic Hoses and Fittings: Connect all the components and carry the hydraulic fluid.
- Hydraulic Fluid: The lifeblood of the system, transmitting power from the pump to the cylinder.
Understanding Hydraulic Pressure and Flow (GPM):
- Pressure (PSI – Pounds per Square Inch): The force exerted by the hydraulic fluid. Higher pressure means more splitting force. The XR2600 typically operates at a pressure range between 2500-3000 PSI.
- Flow (GPM – Gallons Per Minute): The volume of hydraulic fluid delivered by the pump per minute. Higher flow means faster splitting cycles. The XR2600 pump usually delivers around 8-11 GPM, depending on the engine RPM.
Why Pumps Fail:
- Contamination: The most common cause of pump failure. Dirt, debris, and water in the hydraulic fluid can damage the internal components of the pump.
- Cavitation: Occurs when air bubbles form in the hydraulic fluid due to low pressure or high fluid temperature. These bubbles collapse violently, damaging the pump.
- Overheating: Excessive heat can break down the hydraulic fluid and damage the pump seals.
- Wear and Tear: Over time, the internal components of the pump will wear out due to friction.

Pro Tip #1: Diagnose the Problem Accurately

Don’t assume the pump is the culprit immediately. A proper diagnosis will save you time and money. Here are some common symptoms of a failing hydraulic pump and what they might indicate:

Slow Splitting Cycle: Could be a weak pump, low hydraulic fluid level, a clogged filter, or a leak in the system.
Pump Whining or Squealing: Often indicates cavitation due to low fluid level, a clogged filter, or a faulty pump.
No Splitting Power: Could be a completely failed pump, a stuck valve, or a broken cylinder.
Milky or Foamy Hydraulic Fluid: Indicates water contamination.
Excessive Heat in the Pump: Indicates internal friction or a clogged filter.

Troubleshooting Steps:

Check the Hydraulic Fluid Level: Ensure the reservoir is filled to the correct level. Low fluid is a common cause of pump problems.
Inspect the Hydraulic Fluid: Look for signs of contamination (milky appearance, debris). If the fluid is contaminated, you’ll need to flush the entire system.
Check the Hydraulic Filter: A clogged filter restricts fluid flow and can cause cavitation. Replace the filter if it’s dirty.
Inspect the Hoses and Fittings: Look for leaks. Even a small leak can reduce system pressure.
Use a Hydraulic Pressure Gauge: Connect a pressure gauge to the hydraulic system (usually at the valve) to measure the pressure. Compare the reading to the XR2600’s specifications (typically 2500-3000 PSI). If the pressure is significantly lower than specified, the pump is likely the problem.

2. Selecting the Right Replacement Pump

Choosing the correct replacement pump is crucial for optimal performance and longevity. Don’t just grab the cheapest pump you can find.

Matching Specifications: The replacement pump must meet or exceed the specifications of the original pump. Pay close attention to:
- Flow Rate (GPM): Match the GPM of the original pump to maintain the same splitting speed. A slightly higher GPM is acceptable, but a significantly higher GPM could overload the engine.
- Pressure Rating (PSI): The pump must be rated for at least the same pressure as the original pump. A higher pressure rating is generally better for durability.
- Shaft Size and Type: The pump shaft must match the engine’s shaft size and type (e.g., keyed, tapered).
- Mounting Configuration: The pump’s mounting holes must align with the existing mounting points on the XR2600.
- Port Size and Type: The pump’s inlet and outlet ports must match the size and type of the hydraulic hoses.
Pump Types:
- Gear Pumps: The most common type of pump used in firewood processors. They are relatively inexpensive and durable.
- Piston Pumps: More expensive than gear pumps but offer higher efficiency and pressure capabilities.
- Vane Pumps: Less common in firewood processors, but they offer a good balance of performance and cost.
Brands and Quality: Stick with reputable brands known for quality and reliability. Some popular brands include:
- Prince Hydraulics: A well-known and trusted brand.
- Barnes Hydraulics: Another reputable brand with a wide range of pumps.
- Husco: Known for their high-performance pumps and valves.
- Northern Tool: Offers a selection of pumps at competitive prices.
Where to Buy:
- Online Retailers: Amazon, eBay, and Northern Tool are good sources for hydraulic pumps.
- Hydraulic Supply Stores: Local hydraulic supply stores can offer expert advice and a wider selection of pumps.
- Small Engine Repair Shops: Some small engine repair shops also carry hydraulic pumps.

Pro Tip #2: Consider a Two-Stage Pump

For a performance upgrade, consider installing a two-stage hydraulic pump. A two-stage pump delivers high flow at low pressure for fast cylinder extension and retraction, and then automatically switches to low flow at high pressure for maximum splitting force.

Benefits of a Two-Stage Pump:
- Faster Splitting Cycles: Significantly reduces the time it takes to split each log.
- Increased Efficiency: Reduces engine load and fuel consumption.
- Improved Performance: Provides more splitting force when needed.
Installation Considerations:
- Valve Compatibility: Ensure your hydraulic valve is compatible with a two-stage pump. You may need to upgrade the valve.
- Hose Size: You may need to upgrade the hydraulic hoses to handle the increased flow.
- Reservoir Size: A larger hydraulic reservoir may be required to accommodate the increased fluid volume.

I once upgraded a customer’s firewood processor with a two-stage pump, and the difference was remarkable. He was able to process twice as much wood in the same amount of time. The initial investment in the pump and valve was quickly offset by the increased productivity.

3. The Replacement Process: Step-by-Step Guide

Now, let’s get to the actual replacement process. This is where attention to detail and safety are paramount.

Safety First!

Disconnect the Spark Plug: Before working on any part of the engine or hydraulic system, disconnect the spark plug wire to prevent accidental starting.
Wear Safety Glasses: Hydraulic fluid can be under high pressure and can cause serious eye injury.
Wear Gloves: Hydraulic fluid can irritate the skin.
Work in a Well-Ventilated Area: Hydraulic fluid fumes can be harmful.
Use Proper Tools: Using the wrong tools can damage the components.

Tools You’ll Need:

Wrenches: A set of open-end and box-end wrenches. Metric sizes are common.
Socket Set: A socket set with various sizes.
Screwdrivers: A Phillips head and a flathead screwdriver.
Pliers: A pair of pliers or channel locks.
Hydraulic Hose Wrenches (Flare Nut Wrenches): These wrenches are designed to grip hydraulic fittings without damaging them.
Drain Pan: To catch any spilled hydraulic fluid.
Clean Rags: To wipe up spills and keep things clean.
Hydraulic Fluid: The correct type of hydraulic fluid for your XR2600 (check your owner’s manual). AW32 or AW46 are common choices.
Hydraulic Filter: A new hydraulic filter.
Thread Sealant (Teflon Tape or Pipe Dope): To seal the hydraulic fittings.
Torque Wrench: To tighten the bolts and fittings to the correct torque specifications.
Camera or Phone: To take pictures of the hose and fitting connections before disconnecting them. This will help you reassemble everything correctly.

Step-by-Step Instructions:

Prepare the Work Area: Park the XR2600 on a level surface and engage the parking brake.
Drain the Hydraulic Fluid:
- Locate the drain plug on the hydraulic reservoir.
- Place a drain pan under the drain plug.
- Remove the drain plug and allow the hydraulic fluid to drain completely.
- Reinstall the drain plug and tighten it securely.
Disconnect the Hydraulic Hoses:
- Use hydraulic hose wrenches to loosen the hydraulic fittings at the pump.
- Important: Before disconnecting any hoses, take pictures of the connections so you can remember how they go back together.
- Carefully disconnect the hoses and cap them off to prevent dirt and debris from entering the system. Use clean rags to wipe up any spilled fluid.
Remove the Old Pump:
- Locate the bolts that secure the pump to the engine or mounting bracket.
- Remove the bolts and carefully remove the old pump.
Install the New Pump:
- Align the new pump with the mounting holes.
- Install the mounting bolts and tighten them to the correct torque specifications.
Reconnect the Hydraulic Hoses:
- Remove the caps from the hoses and the pump ports.
- Apply thread sealant (Teflon tape or pipe dope) to the threads of the fittings.
- Reconnect the hoses to the pump, making sure to match the original connections (refer to the pictures you took earlier).
- Tighten the fittings securely using hydraulic hose wrenches.
Replace the Hydraulic Filter:
- Locate the hydraulic filter.
- Unscrew the old filter and discard it.
- Lubricate the rubber gasket on the new filter with hydraulic fluid.
- Screw the new filter onto the filter housing and tighten it hand-tight, plus an additional half-turn.
Refill the Hydraulic Fluid:
- Remove the fill cap from the hydraulic reservoir.
- Pour in the correct type and amount of hydraulic fluid (check your owner’s manual).
- Reinstall the fill cap.
Bleed the Hydraulic System:
- Start the engine and let it idle for a few minutes.
- Slowly operate the hydraulic cylinder back and forth several times to bleed any air from the system.
- Check the hydraulic fluid level and add more fluid if necessary.
Check for Leaks:
- Inspect all the hose connections and fittings for leaks.
- Tighten any fittings that are leaking.

Pro Tip #3: Use Hydraulic Hose Wrenches (Flare Nut Wrenches)

Using standard wrenches on hydraulic fittings can easily damage the soft brass or steel, leading to leaks. Hydraulic hose wrenches, also known as flare nut wrenches, are specifically designed to grip these fittings without rounding them off. They have a box-end design with a small opening that allows you to slip the wrench over the hose while still providing a secure grip on the fitting. This is a small investment that will save you headaches in the long run.

4. Fine-Tuning and Testing

Once the pump is installed and the system is bled, it’s time to fine-tune and test the XR2600.

Adjust Engine Speed: Adjust the engine speed to the manufacturer’s specifications. This will ensure the pump is operating at the correct RPM.
Check Hydraulic Pressure: Use a hydraulic pressure gauge to verify that the system is operating at the correct pressure. Adjust the pressure relief valve if necessary. (Consult your XR2600’s manual for the proper adjustment procedure.)
Test Splitting Performance: Split a few logs to ensure the XR2600 is operating smoothly and efficiently.
Listen for Unusual Noises: Pay attention to any unusual noises coming from the pump or hydraulic system. These noises could indicate a problem.
Monitor Fluid Temperature: Check the hydraulic fluid temperature after running the XR2600 for a while. Overheating can damage the pump and other components.

Pro Tip #4: Flush the Hydraulic System After a Pump Failure

If the old pump failed due to contamination, it’s essential to flush the entire hydraulic system to remove any remaining debris. This will prevent the new pump from being damaged.

Flushing Procedure:
1. Drain the hydraulic fluid from the reservoir.
2. Remove the hydraulic hoses from the pump and cylinder.
3. Use compressed air to blow out the hoses and cylinder.
4. Fill the reservoir with a flushing oil (a light-weight hydraulic oil or kerosene).
5. Start the engine and run the XR2600 for a few minutes.
6. Drain the flushing oil.
7. Replace the hydraulic filter.
8. Refill the reservoir with the correct type of hydraulic fluid.

I had a situation where a customer’s pump failed catastrophically, sending metal shavings throughout the entire system. We had to completely disassemble the hydraulic system, clean every component, and replace all the hoses and fittings to ensure the new pump wouldn’t be damaged. It was a time-consuming process, but it saved the customer from having to replace the pump again in a few months.

5. Maintenance and Prevention

Replacing the pump is just the first step. Proper maintenance is essential to keep your XR2600 running smoothly for years to come.

Regular Hydraulic Fluid Changes: Change the hydraulic fluid at the intervals recommended in your owner’s manual (typically every 100-200 hours of operation).
Replace the Hydraulic Filter Regularly: Replace the hydraulic filter every time you change the hydraulic fluid.
Keep the Hydraulic System Clean: Prevent dirt and debris from entering the hydraulic system.
Inspect Hoses and Fittings Regularly: Check for leaks and replace any damaged hoses or fittings.
Store the XR2600 Properly: When storing the XR2600 for extended periods, drain the hydraulic fluid and cover the machine to protect it from the elements.
Monitor Hydraulic Fluid Level: Always keep the hydraulic fluid level at the optimal level.

Pro Tip #5: Use a Magnetic Drain Plug

Install a magnetic drain plug in the hydraulic reservoir. The magnet will attract any metal particles in the hydraulic fluid, helping to keep the system clean and prevent wear. This is a simple and inexpensive way to extend the life of your hydraulic pump and other components.

I always recommend using a magnetic drain plug, especially in older machines. It’s amazing how much metal debris can accumulate in the hydraulic fluid over time. The magnetic drain plug acts like a filter, trapping these particles and preventing them from circulating through the system.

Case Study: Reviving a Neglected Excell XR2600

I once worked on an Excell XR2600 that had been neglected for years. The hydraulic pump was completely shot, the hoses were cracked and leaking, and the hydraulic fluid was thick and black. The owner had given up on it, but I saw potential.

Here’s what I did:

Complete Disassembly and Cleaning: I disassembled the entire hydraulic system, cleaned every component with solvent, and replaced all the hoses and fittings.
Pump Replacement: I installed a new two-stage hydraulic pump.
Reservoir Cleaning: I thoroughly cleaned the hydraulic reservoir and installed a magnetic drain plug.
Filter Replacement: I replaced the hydraulic filter with a high-quality filter.
Fluid Replacement: I filled the system with new, high-quality hydraulic fluid.
Engine Tune-Up: I tuned up the engine, replacing the spark plug, air filter, and fuel filter.

The result was a firewood processor that ran like new. The splitting cycles were faster, the engine ran smoother, and the owner was thrilled. This case study highlights the importance of proper maintenance and the potential for reviving even the most neglected machines.

Strategic Insights for Firewood Processing

Beyond the technical aspects of pump replacement, let’s consider some strategic insights to maximize your firewood processing efficiency:

Wood Selection: Choosing the right wood species can significantly impact your processing speed and the quality of your firewood. Hardwoods like oak, maple, and ash are dense and provide excellent heat, but they can be more difficult to split. Softwoods like pine and fir are easier to split but burn faster and produce less heat. I prefer to split a mix of hardwoods and softwoods to provide a balance of heat and ease of use.
Wood Seasoning: Properly seasoned firewood burns more efficiently and produces less smoke. Green wood can be difficult to split and can take a long time to dry. Aim for a moisture content of 20% or less before burning. The best way to season firewood is to stack it in a well-ventilated area and allow it to dry for at least six months.
Ergonomics: Firewood processing can be physically demanding. Pay attention to ergonomics to prevent injuries. Use proper lifting techniques, take frequent breaks, and consider using a log lift to reduce strain on your back.
Safety Gear: Always wear appropriate safety gear when processing firewood, including safety glasses, gloves, hearing protection, and steel-toed boots.
Stacking Techniques: Proper firewood stacking is essential for efficient drying and storage. Stack the wood in rows with gaps between the rows to allow for air circulation. Cover the top of the stack to protect it from rain and snow. I like to use a crisscross stacking pattern to create a stable and visually appealing stack.
Tool Maintenance: Regularly maintain your firewood processing tools, including your chainsaw, axe, and log splitter. Keep your chainsaw chain sharp, sharpen your axe, and lubricate your log splitter.
Chain Saw Sharpening: A sharp chain saw is essential for efficient bucking of logs. I use a chain saw file and a depth gauge to keep my chain sharp. I sharpen my chain every time I refuel the saw.
Axe Selection: A good axe is essential for splitting smaller logs and kindling. I prefer a splitting axe with a heavy head and a long handle.
Log Splitting Techniques: Use proper log splitting techniques to reduce the risk of injury. Position the log securely on the splitter, keep your hands away from the splitting wedge, and use a pushing motion rather than a swinging motion.
Drying Methods: Understanding different drying methods ensures efficient firewood preparation. Air drying is common, but kiln drying accelerates the process. Aim for a moisture content below 20% for optimal burning.
Timber Handling: Use appropriate timber handling techniques to minimize physical strain. Log tongs, cant hooks, and skidding winches can significantly reduce the effort required to move logs.

Next Steps: Putting Knowledge into Action

Assess Your XR2600: Evaluate the condition of your existing hydraulic pump and determine if replacement is necessary.
Diagnose the Problem: Use the troubleshooting steps outlined in this guide to pinpoint the exact cause of the problem.
Select the Right Pump: Choose a replacement pump that meets or exceeds the specifications of the original pump. Consider upgrading to a two-stage pump for improved performance.
Gather Your Tools and Materials: Assemble all the necessary tools and materials before starting the replacement process.
Follow the Step-by-Step Instructions: Carefully follow the step-by-step instructions to replace the pump.
Fine-Tune and Test: Fine-tune and test the XR2600 to ensure it’s operating smoothly and efficiently.
Implement a Maintenance Plan: Develop a regular maintenance plan to keep your XR2600 running smoothly for years to come.

By following these pro tips and taking a proactive approach to maintenance, you can ensure that your Excell XR2600 firewood processor remains a reliable and efficient workhorse for many years to come. Remember, a well-maintained machine is a safe and productive machine. Now, get out there and start processing that firewood!