Gear Case And Frame Assembly - Toro Reelmaster 5 Blade Operator's Manual

Gear Case And Frame
Assembly
1. Apply Permatex #2 to serrations on drive tube studs and
press into gear case.
2. Apply Never Seez to threads and mount stub axles to
gear cases and secure with locknuts. Tighten locknuts to
40–55 ft. lb.
3. Press seal and bearing cup into right hand gear case.
Make sure plastic seal guard is installed over seal boss.
4. Slide gear case onto right hand end of reel shaft (key
slot end).
Note: Use caution not to damage seal in gear case when
inserting reel shaft.
5. Tap bearing cone onto reel shaft just far enough to
allow insertion of woodruff key and pinion gear.
Important Right hand bearing must be pressed onto
reel shaft by tightening pinion gear nut. DO NOT PRESS
ON OTHERWISE.
6. Install woodruff key, pinion gear, and nut and tighten
until gear bottoms out on reel shaft (left hand thread).
7. Remove nut, pinion gear and woodruff key before
continuing assembly.
8. Mount cross tube to right hand gear case and secure
finger tight with (3) lockwashers and nuts.
9. Press seal and bearing cup into left hand gear case.
Make sure plastic seal guard is installed over seal boss.
10. Slide gear case onto left hand end of reel shaft and gear
case studs into mounting holes in cross tube.
Note: Use caution not to damage seal in gear case when
inserting reel shaft.
11. Secure gear case to cross tube with (3) lockwashers and
nuts. Tighten nuts on both ends of cross tube to
80–90 ft.–lb.
12. Slide bearing cone onto left hand end of reel shaft and
into gear case.
13. Assemble the right hand ratchet gear ring over the shaft
and insert two (2) compression springs.
14. Assemble right hand ratchet ring over ratchet gear ring
and seat with a driver and hammer. Secure entire
assembly with (3) three stop nuts. Nuts should be drawn
up evenly and gradually to 14–22 ft. lb.
(19.04–29.8 N–m) to prevent breaking the ratchet ring.
Note: Ensure that assembly will ratchet. If assembly does
not ratchet, back nuts off slightly.
15. Place O–ring into groove on right hand throwout finger,
coat ring with heavy oil or grease, and slide through
sideplate, making sure that O–ring does not get
damaged. Install throwout sleeve over throwout finger
and tighten securely in gear case.
16. Slide throwout handle over finger and secure in place
with drive lock pin.
17. Position woodruff key in key slot in reel shaft and slide
on pinion gear.
18. Secure nut (left hand thread) on right hand reel shaft.
19. Assemble the ratchet gear and bearing assembly to right
hand, ratchet gear ring and secure with right hand
ratchet gear stud.
20. On the left side, assemble ratchet gear ring over the reel
shaft and insert (2) compression springs.
21. Assemble left hand ratchet ring over the ratchet gear
ring and seat with a driver and hammer. Secure entire
assembly with three (3) stop nuts. Nuts should be drawn
up evenly and gradually to 14–22 ft. lb.
(19.04–29.8 N.m) to prevent breakage of the ratchet
ring.
Note: Ensure that assembly will ratchet. If assembly does
not ratchet, back nuts off slightly.
22. Place O–ring into groove on left hand throwout finger,
coat ring with heavy oil or grease, and slide through
sideplate, making sure that O–ring does not get
damaged. Install throwout sleeve over throwout finger
and tighten securely in gear case.
23. Slide throwout handle over finger and secure in place
with a drive lock pin.
24. Aligning mark on pinion gear with mark on reel shaft
slide gear onto spline shaft.
25. Instal new nut (right hand thread) on left hand reel shaft
but do not tighten. When mower is completely
reassembled adjust reel bearing, refer to Adjusting Reel
Bearing, page 7.
26. Assemble the ratchet gear and bearing assembly to the
left hand reel ratchet gear ring and secure with the left
hand ratchet gear stud.
27. Mount bedbar to gear cases with shoulder bolts, rubber
spacers, plastic washers and locknuts. Use bottom
mounting hole in bedbar for 1 1 blade reels and top
mounting hole for 5 and 7 blade reels. When installing
left hand shoulder bolt (offset thread) thread the bolt in
until it touches rubber spacer, then back it out one
complete turn and tighten nut. Do not back out right
hand bolt. This will allow bedbar adjustment. Refer to
Parallel Bedknife to Reel, page 6.
28. Position roller bracket assembly in slots of gear case.
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