Toro Reelmaster 2000-D, Service Manual

Page: 95 / 208

IMPORTANT: Do not remove the relief valve assem-
bly (19) unless testing shows it to be faulty. The re-
lief valve assembly must be replaced as a complete
unit. Both relief valve seats (6) are sealed in place
with locking compound; do not remove them.
10.If necessary, remove relief valve plug, O–ring, shim,
spring, and ball from the backplate.
Inspection (Fig. 44)
1. Remove all nicks and burrs from all parts with an
emery cloth
CAUTION
Use eye protection such as goggles when using
compressed air
2. Clean all parts with solvent. Dry all parts with com-
pressed air.
3. Inspect drive gear (9) shaft for a broken or chipped
keyway.
4. Inspect drive gear and idler gear (8) shafts at the
bushing points and seal area for rough surfaces and ex-
cessive wear.
5. Replace drive gear or idler gear if the shaft in the
bushing area diameter measures less than 0.748 in.
(19.0 mm). A single gear may be replaced separately.
6. The drive gear and idler gear face should be free of
excessive scoring and wear.
7. Replace drive gear or idler gear if gear width is less
than 1.140 in. (29.96 mm).
8. Make sure that retaining rings are in the grooves on
both sides of the gear for both the drive gear and idler
gear.
9. Break sharp edges of gear teeth with emery cloth.
10.Replace backplate (7) and frontplate (14) if bushing
inside diameters exceed 0.755 in. (19.2 mm). The bush-
ings are not available as replacement items.
11. The face of the backplate and frontplate should be
free of excessive scoring. Replace if any scoring exists
to a depth of 0.0015 in. (0.038 mm).
12.Replace body (12) if the inside diameter of the gear
pockets exceeds 1.713 in. (43.5 mm).
13.Make sure that both relief valve plugs are secure if
they or the backplate are not being replaced.
Reassembly (Fig. 44)
1. If replacing the relief valve assembly (19), install ball,
spring, shim, O–ring, and plug into the backplate. Hand
tighten plug and then torque from 10 to 12 ft–lb (14 to 16
N–m).
2. Coat new O–ring lightly with petroleum jelly and
install in groove on the frontplate.
3. Apply a thin coat of petroleum jelly to both gear pock-
ets of the body. Install alignment pin into body.
4. Align matchmarks and slip body onto frontplate until
alignment pin is engaged.
5. Dip idler gear and drive gear into clean hydraulic oil
and slip into frontplate bushings.
6. Coat new O–ring lightly with petroleum jelly and
install in groove on the backplate.
7. Install alignment pin into backplate.
8. Align matchmarks and slip backplate over gear
shafts onto body until alignment pin is engaged.
9. Install and hand tighten cap screws. Torque in a
crisscross pattern from 25 to 28 ft–lb (34 to 38 N–m).
10.Place washer (18) over the drive shaft into the front-
plate housing. Apply a liberal coat of hydraulic oil to the
oil seal. Install oil seal over the drive shaft being careful
not to cut the rubber seal lips.
11. Place a 1–1/16 inch O.D. sleeve over the drive shaft
and press the oil seal into the frontplate housing until the
retaining ring groove appears.
12.Install retaining ring into the frontplate housing using
the sleeve until the ring seats in the groove.
Hydraulic System
Reelmaster 2000–D Page 4 – 57 Hydraulic System