Wednesday, November 18, 2015

Toro MH 400 belt replacement

Our new material handler developed a tear . I did a temporary stitch job to make it last till a new belt came . Surprisingly it lasted a few weeks getting the remaining fall work and new tee decks near completion . Great machine and saved the crew loads of man hours .
Yes it is a big job to change since the belt comes as one complete piece . 
They can be taken somewhere to get a joint installed saving on disassembling the machine .    

One of the guys cleaned it all up for me . 

Originally I was going to lift it out as per instruction using the shop over head beam . 
After much thinking and planning I decided to go a different route . Same route the guys at Veseys used a few years back . 

Disassemble all the hardware in rear of hopper . I also flipped the tailgate up .

Front adjusters ...bearing case slides in grooves .

Hydraulic driven chain . Pump can just stay on .

These bearing collars lock bearing to shaft . They actually turn on bearing and set screw holds it in place .

Chain tensioner removed .

Lots of torque here .The idler gear is actually pushed down and held in place with an Allan head set screw . You will need to heat it up to get it to turn . ( left in picture )

Remove the driven gear . This machine is new an older model will need a puller .

Removed the collar on bearings and slide them off the drive roller shaft . The drive rollers are pretty heavy . ON REASSEMBLY THE LEFT SIDE (direction of travel )THE BOLTS NEED TO BE INSTALLED BEFORE ASSEMBLING THE DRIVE ROLLER. If you forget will have to come back out to install them . 

Because I am sliding the roller tray out the back the rear roller and brackets had to be removed .The large nut on the left was removed ..the one on the right I moved over to pinch the centre one in place . That way I'm not changing the factory setting . 

Front was the same removed adjusters trying to keep the original setting on both sides . The front is awkward to work from but managed to loosen everything off .

Bearing housing are grooved and slide in the track the point where it drops out  I slid the shaft off one end to slide the bearing out the rest of the way . Reinstalling the the bracket made for a good resting area for the end of the shaft so you can get the other side apart. This roller is also very heavy . 

The fenders make good shelves for parts . 

I like to install things back the same way so marking one end of shaft with an R or L for reference . 

Remove all the rubber shields and plates on side and front . The extra room will be needed for the belt to fold up on top . 

Front panel . On reassembly you will need to re silicon to help keep sand / material out .  

A good thing about a scissor lift is that they are mobile . I get a chuckle now because originally I didn't know what I was going to use it for . Use it everyday . Sliding it over I could raise it and push it in under the rear section to pick up the end of the roller tray . 

24 bolts later and it's ready to drag out . 

Both my magnetic trays are loaded up with nuts and bolts . 

the roller just pop out easily . Wrapping a strap around the frame I was able to grab a hold and walk backwards on the scissor lift . Actually drug back easily .  

and out . 

 The roll top from Lawsons came in pretty handy to hold tools . 

 Remove the remaining rollers . No tools just lift up and out . 

Directional arrow faces rear of machine . 

Flip the roller tray on end .

I was just able to muscle the belt over the frame and flip back down onto scissor lift . Scissor lift was on the floor for belt install . Slide the rollers back in under the belt 

Lining everything up .

Right side panel floats and I was able to put a piece of re-bar in to spread the opening a couple inches wider .  

Pushed it in as far I could almost half way .Using straps I was able to get it the rest of the way fairly easy . 

Lining up the holes for bolts to go back in . Going to the back end first I dropped the scissor lift and placed a 6x6 under the roller tray frame .This way I'm able to raise and lower one end to get it started . An alignment tool to push in a bolt hole help greatly . 

Loosely tighten 2 bolts and moved to the front . To raise the front I move the strap to the top centre .

Perfect !! the worse is over .

Getting ready to install rear drive roller .

Man power 1 about 5.5 to 6 hours into it now  , Might need a guy tomorrow to shove the bolts through and hold for the rubber shields , 

Getting ready to install the front roller .Clean everything up well . I set one bearing in place and started the adjuster to hold it in place .

Slide the roller on belt . tapping the bearing casing a bit to get the angle needed to start the shaft in the bearing .  

Leaving these plates in place gave the roller shaft a place to sit

Now I was ready to put bearing on and raise shaft up to slide in place .

Straighten the belt out before adjusting

Keep them roughly even . Later on will run the belt for final adjustments .

Greased all the bearings etc. 

Putting duct tape over the bolts made easy to installation the nuts by yourself .

End panel next.

All done ....looks great .

With good planning it wasn't as huge a job I had thought it would be .

P.S. This is a new machine and it came apart very easily . If it was 20 years old I would have replaced all 4 bearings and used the cutting torch to cut off any troublesome bolts  to speed things up .