Toro 133-0157 User manual

FormNo.3399-460RevC
RearRollerBrushMVPKit
Reelmaster®3555,3575,5010,and5010-HSeriesCuttingUnitwith
5-inchor7-inchReel
ModelNo.133-0157
ModelNo.133-0158
InstallationInstructions
ThisproductcomplieswithallrelevantEuropeandirectives.Fordetails,pleaseseetheDeclarationof
Incorporation(DOI)atthebackofthispublication.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
DescriptionQty.Use
Nopartsrequired–Determinetherollerbrushorientation.
Roller-brushhousing1
Hex-socketbolt(3/8x1inch)2
Greasetting(90°)1
Shoulderbolt(angehexsocket)1
Roller-brushassembly1
Shoulderbolt1
Beltcover/plateassembly1
Bolt(5/16x1/2inch)4
Spacer1
Drivepulley1
Flange-headbolt(3/8x2inches)1
Belt1
Shimwasher(asrequiredforbeltalignment)1
Driveshaft(right-handthreads)1
Driveshaft(left-handthreads)1
Installtherollerbrush.
Highheight-of-cutbrush(optional)–Installthehighheight-of-cutbrush—forHOCgreaterthan
2.5cm(1inch).
Important:Fora5-inchcuttingunitdrivebyan
electricreelmotor,youmustorder1weight(Part
No.127-4259-03)and2bolts(PartNo.322-7).
Note:Determinetheleftandrightsidesofthecutting
unitfrombehindthecuttingunit.
Important:UsetheRearRollerBrushKitonly
whencuttingintheheight-of-cutrangeof6to
25mm(1/4to1inch).Usethehighheight-of-cut
brushwhencuttingabove25mm(1inch).Referto
InstallingtheHighHeight-of-CutBrush(page8).
©2019—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3399-460*C

DeterminingtheRoller
BrushOrientation
RefertoFigure1todeterminethepositionoftheroller
brushandreelmotors.
g027187
Figure1
1.Cuttingunit15.Cuttingunit5
2.Cuttingunit26.Reelmotor
3.Cuttingunit37.Rightroller-brushdrive
assembly
4.Cuttingunit48.Leftroller-brushdrive
assembly
Important:Theseinstructionsandillustrations
showtheinstallationofthekitoncuttingunits
withtherearrollerbrushmountedontheleftend
ofthecuttingunit.
InstallingtheRollerBrush
InstallingtheDriveshaft
1.Restrainthereelforremoval;refertoRestraining
theReelforRemovingThreadedInserts(page
11).
2.Removeanddiscardthecutting-unitthreaded
insertfortherear-roller-brushdrive(Figure2).
g032009
Figure2
1.Threadedinsert(insert
withleft-handthreads
shown)
3.Driveshaft
2.Agrooveonthefaceof
theinsertordriveshaft
indicatesleft-hand
threads.
4.Applythread-locking
compoundhere.
Note:Cuttingunits1,3,and5useinsertsand
driveshaftswithleft-handthreads(Figure1).
3.Restrainthereelforinstallation;referto
RestrainingtheReelforInstallingThreaded
Inserts(page12).
4.Applythread-lockingcompoundtothedriveshaft
threads(Figure2)andinstalleithertheleftor
rightdriveshaft,torquingitto115to128N∙m(85
to95ft-lb).
Note:Discardtheother(unused)driveshaft
includedinthekit.
MountingtheRoller-Brush
Housing
1.LightlygreasetheO-ringandensurethatthe
O-ringisinstalledontheroller-brushhousing
(Figure3).
2

g020371
Figure3
1.Roller-brushhousing2.O-ring
2.ForModel133-0158kitforReelmaster
5010machineswith7-inchcuttingunits
only:Mounttheroller-brushhousingtothe
reel-bearinghousingwith2hex-socketbolts(3/8
x1inch);refertoFigure4.
Note:Positiontheroller-brushhousingsothat
thethreadedholeistowardthefrontofthe
cuttingunit.
g037640
Figure4
1.Roller-brushhousing3.Hex-socketbolt
2.Threadedhole4.Frontofthemachine
3.ForModel133-0157kitforReelmaster5010
machineswith5-inchcuttingunitsonly:
•Forahydraulic-driverreelmotor:Install
2bolts(5/16x1/2inch)onthetopofthe
rollerbrushhousingasshowninFigure5
(hydraulic5-inchreelmotorsonly).
g028040
Figure5
1.Order1weight(PartNo.
127-4259-03)and2bolts
(PartNo.322-7)forthe
electricreelmotor.
3.Roller-brushhousing
2.Bolts(5/16x1/2inch)for
thehydraulicreelmotor
•Foranelectric-drivenreelmotor:Order
andinstall1weight(PartNo.127-4259-03)
and2bolts(PartNo.322-7)asshownin
Figure5.
Note:The2bolts(5/16x1/2inch)fromthe
kitarenotused.
Note:FortheReelmaster5010-H
machinewitha5-inchor7-inchcutting
unitwithanelectric-drivenreelmotor:On
thereelmotorsideplate,replacethefront
sideplateshoulderboltwithaangehex
socketshoulderboltasshowninFigure6.
g035933
Figure6
ReelMotorSideofCuttingUnit
1.Frontsideplateshoulder
bolt(removeanddiscard)
2.Flangehexsocket
shoulderbolt(new)
3

InstallingtheRollerBrush
Assembly
1.Removethegreasettingfortherollerfromthe
sideofthecuttingunitthathastheroller-brush
housing(Figure7).
g031872
Figure7
1.Greasetting
2.Installthe90°greasettingsothatitfaces
rearward(Figure8).
g031873
Figure8
1.Spacer3.Greasetting(90°)
2.Side-platemountingange4.Flangelocknutsand
washers(removethem)
3.Removethe2angelocknutsandwashers
securingeachrollerbrackettothesideplates
(Figure8).
Note:Donotremovethebolts.Also,remove
anyspacerspositionedonthetopsideofthe
side-platemountingange.
4.Positiontheleftorrightroller-brushassembly
mountingbracketsontotheroller-bracketbolts
(Figure9).
g037641
Figure9
1.Leftroller-brushassembly3.Washer(4)
2.Roller-brushmounting
bracket
4.Flangelocknut(4)
Important:Mounttheroller-brushassembly
mountingbracketsdirectlytothetopsurface
ofthecutting-unitside-platemounting
ange.Donotputspacersbetweenthe
roller-brushmountingbracketsandthe
side-platemountinganges.Savethe
additionalspacersforpotentiallateruse.
5.Securethebrush-assemblymountingbrackets
tothecutting-unitsideplateswiththenutsand
washersthatyoupreviouslyremoved.
4

InstallingtheRollerBrushPlate
1.Slideeachexcludersealoutwarduntilthelip
sealsareinlightcontactwitheachbearing
housing(Figure10).
g027192
Figure10
1.Bearinghousing2.Excluderseal
2.Applyacoatingofgreasetotheinnerdiameter
ofthegrommetintheroller-brushhousing
(Figure11).
g037642
Figure11
1.Bolt(5/16x1/2inch)4.Cleanoutanypaint
fromthethreadsusing
a5/16–18tapbefore
screwingintheshoulder
bolt.
2.Shoulderbolt5.Roller-brushhousing
3.Grommet6.Brush-plateassembly
3.Installtheleftorrightroller-brushplate(Figure
11).
Note:Whenyouinserttheprotrusionon
theplateintothegrommetintheroller-brush
housing,ensurethatthegrommetstaysproperly
seatedinthehousing.Theroller-brushplate
isproperlyseatedwhenthereisnoresistance
fromtherubbergrommetanditpivotsfreely.
Note:Ensurethattheidler-pulleyassemblyis
installedonthebottomasshowninFigure12.
g035650
Figure12
Left(top)andRight(bottom)Idler-PulleyAssemblies
1.Leftbrushplate4.Idler-armassembly
2.Rightbrushplate5.Spring
3.Idlerpulley
4.Applythread-lockingcompoundtothe2bolts
(5/16x1/2inch)andusethemtomountthe
brushplatetotheroller-brushbearinghousing
(Figure11).
Note:T orquetheboltsto20to25N∙m(15to
19ft-lb).
5.Cleanoutanypaintfromthethreadsinthe
roller-brushhousing,usinga5/16–18tap,before
screwingintheshoulderbolt(Figure11).
Important:Ifthethreadsarenotcleaned
beforetheshoulderboltisscrewedin,the
boltcouldbreak.
6.Applythread-lockingcompoundtotheshoulder
bolt(Figure11).
5

7.Securethebrushplatetotheroller-brush
housingwiththeshoulderbolt(Figure11).
Note:Torquetheboltto20to25N∙m(15to
19ft-lb).
Note:Theshoulderboltshouldnotclampthe
platetothehousing.
8.Checktoensurethattheroller-brushplateis
paralleltothecutting-unitsideplate.Ifitisnot
parallel,proceedasfollows:
A.Loosenthe2angelocknutssecuring
theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure13).
g027194
Figure13
1.Loosentheseboltsforpositioningtherollerbrush.
2.Loosentheseangelocknutsformakingtheroller-brush
plateparallel.
B.Rotatetheroller-brushbearinghousinguntil
thebrushplateisparalleltothecutting-unit
sideplate(Figure13).
C.Tightenthe2angelocknutssecuring
theroller-brushmountingbrackettothe
cutting-unitsideplate(Figure13).
PositioningtheRollerBrush
1.Loosenthe2boltssecuringeachroller-brush
bearinghousingtotheroller-brushmounting
bracket(Figure13).
Note:Theboltsshouldbeloose.
2.Positiontherollerbrushsothatitisjusttouching
orrestingontherearroller(Figure14).
Important:Theroller-brushshaftmustnot
contactthecutting-unitsideplate.
Important:Heavybrushcontactonthe
rollerwillcauseprematurebrushwear.
g027303
Figure14
1.Bearinghousing(some
partsnotshown)
5.Lightcontact
2.Sideplate6.Rearroller
3.Rollerbrush7.Greasetting
4.Ensurethatthereis
clearancehere.
Note:Theroller-brushshaftmustbeparallel
totherearroller.
Important:Positionbothroller-brush
bearinghousingssothattheyareparallel
tothegroundtoensureclearanceforthe
rear-rollergreasetting.
3.Tightenthe2boltssecuringeachroller-brush
bearinghousingtotheroller-brushmounting
brackets.
6

InstallingtheDrivePulley
1.Insertthespacerontotheshaftinthebearing
housing(Figure15).
g027195
Figure15
1.Driveshaft3.Drivepulley
2.Spacer4.Flange-headbolt(3/8x2
inches)—torqueitto47to
54N∙m(35to40ft-lb)
2.Insertthedrivepulleyintothespacerandonto
thedriveshaft(Figure15).
Note:Ensurethatthepulleytabsarepositioned
intheslotinthedriveshaft.
3.Securethepulleyandspacertothedriveshaft
withaange-headbolt(3/8x2inches);refer
toFigure15.
Note:Torquetheboltto47to54N∙m(35to
40ft-lb).
Important:Iftheboltisnotproperly
torqued,theboltwillcomeloose.
InstallingtheBelt
1.Installthebeltontothepulleysasfollows:
•Loopthebeltaroundthedrivepulleyand
thenoverthetopoftheidlerpulley(Figure
16).
g027196
Figure16
1.Drivepulley3.Belt
2.Idler-pulleyassembly4.Drivenpulley
•Startthebeltonthedrivenpulley(Figure
17).
•Useadeep-wellsocket(9/16inch)torotate
thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure17).
g020390
Figure17
1.Belt2.Deep-wellsocket(9/16
inch)
Important:Ensurethattheribsonthebelt
areproperlyseatedinthegroovesineach
pulleyandthatthebeltisinthecenterofthe
idlerpulley.
7

2.Pushdownontheidlerpulleytoensurethatthe
idler-pulleyassemblypivotsfreely.
CompletingtheInstallation
1.Checkthealignmentofthebeltandpulleys;
refertoCheckingthePulleyAlignment(page9).
2.Slidethebeltcoverontothemountingboltsand
securethecoverwith2angenuts(Figure18).
Important:Donotovertightenthenutsto
preventdamagingthecover.
g037643
Figure18
1.Beltcover3.Flangenuts
2.Setscrewinstalled4.Setscrewremoved
3.Ensurethatthetopsetscrewisinstalled;remove
anddiscardthebottomsetscrewfordrainage
(Figure18).
4.Lubricatethegreasettingsoneachofthe
roller-brushbearinghousingswithNo.2lithium
grease(Figure19).Wipeoffanyexcessgrease,
especiallyaroundtheexcluderseals.
g032011
Figure19
InstallingtheHigh
Height-of-CutBrush
Optional
Installthehighheight-of-cutbrush(soldseparately)
whentheheightofcutis2.5cm(1inch)ormore(5or
morespacersinstalledbelowthesideplatepad).
1.Ifarollerbrushisinstalledonthecutting
unit,removethe2bolts,washers,andnuts
securingthenon-drivebearinghousingtothe
bearing-housingmountingbracket(Figure20
andFigure21).
g037644
Figure20
1.Non-drivebearinghousing4.Washer(2)
2.Flangenuts5.Bolt(2)
3.Mountingbracket
2.Slidethenon-drivebearinghousingandthe
excludersealoffthebrushshaft(Figure21).
g027201
Figure21
1.Non-drivebearinghousing3.Brushshaft
2.Excluderseal
3.Removethe2J-boltsandthenuts(Figure22).
4.Slidetheexistingbrushoffthebrushshaft
(Figure22).
8

5.Loosenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket(Figure22).
6.Slidethehighheight-of-cutbrushontothebrush
shaft(Figure22).
7.Clampthebrushontotheshaftwiththe2J-bolts
andnutspreviouslyremoved(Figure22).
Important:Insertthethreadedendofthe
J-boltsthroughtheouterholesofthebrush
shaftwhilehookingthecurvedendsofthe
J-boltsintotheinnerholes.
8.TorquetheJ-boltlocknutsto2to3N∙m(20to
25in-lb).
g037645
Figure22
1.Highheight-of-cutbrush3.Loosenthesebolts.
2.J-bolts4.Nuts
9.Installtheexcludersealandthenon-drive
bearinghousingontothebrushshaft(Figure21).
10.Mountthenon-drivebearinghousingtothe
bearing-housingmountingbracketwiththe2
bolts,washers,andnutspreviouslyremoved.
Note:Becarefulnottoknockthesealspring
off.
11.Tightenthe2bolts,washers,andnutssecuring
thedrive-bearinghousingtothebearing-housing
mountingbracket.
Maintenance
•Ensurethatthebrushisparalleltotherollerwith
1.5mm(0.060inch)clearancetolightcontact.
•Greasethettingsevery50hoursandafterevery
washing.
•Whenreplacingarollerbrush,torquetheJ-bolts
to2to3N∙m(20to25in-lb).
•Whenreplacingthebrush-shaft-drivenpulley,
torquethenutto36to45N∙m(27to33ft-lb).
•Whenreplacingthebrush-drivepulley,apply242
Loctite(blue)andtorquetheboltto47to54N∙m
(35to40ft-lb).
Note:Therollerbrush,theidlerbearing,andthebelt
areconsideredconsumableitems.
CheckingthePulley
Alignment
Important:Ensurethatthebeltisproperly
tensionedpriortocheckingthealignment.
1.Layastraightedgealongtheouterfaceofthe
drivepulley(Figure23).
Important:Onlylaythestraightedgeacross
thedrivepulley,donotlayitacrossthedrive
andthedrivenpulley.
2.Ensurethattheouterfacesofthedrivepulley
andthedrivenpulleyareinlinewithin0.76mm
(0.030inch).
Important:Donotusetheidlerpulleyto
checkthealignment.
3.Ifthepulleysarenotaligned,refertoAdjusting
thePulleyAlignment(page10).
Important:Thebeltmayfailprematurelyif
thepulleysarenotproperlyaligned.
g027197
Figure23
9

AdjustingthePulley
Alignment
1.Thedrivenpulley(attheroller-brushshaft)can
moveinorout(Figure24).
Note:Makenoteofwhichwaythepulleyneeds
tomovewhencheckingthebeltalignment;refer
toCheckingthePulleyAlignment(page9).
g037639
Figure24
1.Drivenpulley3.Driven-pulleynut
2.Idlerpulley
2.Whilerotatingthereel,whichrotatesthedrive
pulley,prythebeltoffthedrivepulley(Figure
24).
Note:Wearapaddedgloveoruseaheavyrag
torotatethereel.
3.Removethelocknutsecuringthedrivenpulley
tothebrushshaft(Figure24orFigure25).
Note:Usea1/2-inchwrenchontheroller-brush
shaftatstokeepitfromrotating.
4.Removethedrivenpulleyfromtheshaft(Figure
25).
5.Ifthepulleyneedstomoveout,adda0.8mm
(0.032inch)thickwasher(Figure25).
Important:Ifthepulleyneedstomovein,
removetheexisting0.8mm(0.032inch)thick
washer.
6.InstallthepulleyasshowninFigure25.
g009077
Figure25
1.Locknut3.Washer—0.8mm(0.032
inch)thick
2.Drivenpulley4.Brush-shaftats
7.Whileholdingtheatsoftheroller-brushshaft,
securethedrivenpulleyontheshaftwiththe
angenut(3/8–16)previouslyremoved.
Note:Seatthelocknut;thentorqueitto36to
45N∙m(27to33ft-lb).
8.Installthebeltontothepulleysasfollows:
A.Loopthebeltaroundthedrivepulleyand
thenoverthetopoftheidlerpulley(Figure
26).
g031875
Figure26
1.Drivenpulley3.Drivepulley
2.Idler-pulleyassembly4.Belt
B.Startthebeltonthedrivenpulley(Figure
26).
C.Usea9/16-inchdeep-wellsockettorotate
thebrushassemblyandguidethebeltonto
thedrivenpulley(Figure27).
10