Plastic Winder Tensioner Bushing Replacement

These instructions are for the replacement of the Tilmor Plastic Winder Tensioner Bushing.

Tools

Personal Protective Equipment

7/16" Wrench

9/16" Wrench

9/16" Socket

Ratchet

3/4" Wrench

3/4" Socket

Torque Wrench

7/16" Socket

Estimated Time

1 hrs

Before You Begin

WARNING: Before making repairs or adjustments set the parking brake, turn off engine, and remove ignition key. Always disconnect the negative battery cable from the battery when working with electrical components. Always work in a manner that does not put safety at risk!

WARNING: Safety glasses must be worn during installation. Ear (hearing) protection must be worn when using air or power tools.

Installation Notes: Right and left hand orientation referred to in these instructions is determined as if facing forward from the operator station.

Adjust the Belt Tension

Remove the tension from the belt by adjusting the tensioner (A) to the lowest position (B).

Remove the Pulley Cover

Remove the seven 1/4” bolts (D) and the seven 1/4” flat washers around the outside perimeter and remove the pulley cover (C).

Remove the Belt

Remove the belt from the pulleys.

Remove the Tensioner Pulley

To remove the tensioner pulley (F) remove the 3/8” bolt (E), secured in place by a 3/8” locking flange nut.

Remove the Tensioner Assembly

Remove the tensioner assembly by removing the 1/2” locking nut (G) that secures the tensioner to the top cover.

Disassemble the Tensioner Assembly

Remove the 1/2” lock nut (J), 1/2” bolt (H), and 1/2” washer (I) from the tensioner assembly.

Remove the bushings (K) from the tensioner assembly.

Assemble the Tensioner Assembly

Install the new bushings into the tensioner assembly.

Install the 1/2” bolt with the flat washer installed through the tensioner assembly. Secure the 1/2” bolt in place with a 1/2” lock nut (L). Tighten the nut down until it is snug and then loosen the nut one thread. The assembly should rotate freely on the 1/2” bolt.

Install the Tensioner Assembly

Position tensioner assembly in the top cover. Insert the tensioner mounting bolt through the upper mounting hole (M).

Ensure that the torsion spring adjustment handle (N) is placed through the top cover (O).

Secure the tensioner in place with the 1/2” locking flange nut (G). Torque the flange nut to 85 ft-lbs (115 Nm).

Install the Tensioner Pulley

Place a 3/8” washer on the 3/8” bolt, followed by the tensioner pulley and another 3/8” washer as shown below.

Install the pulley onto the tensioner pulley mount in the center mounting hole (P).

Secure the tensioner pulley in place using a 3/8” locking flange nut. Torque the 3/8” bolt to 35 ft-lbs (47 Nm).

Verify the Pulley Alignment

Ensure that the tensioner pulley is in line with the idler pulley and the reel drive pulley.

Install the Belt

Install the belt, by routing the belt around the pulleys.

NOTE: The V portion of the belt must be on the plastic winder reel drive pulley (Q).

Adjust the Belt Tension

Set the belt tension as required by adjusting the tension adjustment lever.

Reinstall the pulley cover. Torque the seven 1/4” bolts (D) with 1/4" washers to 100 in-lbs (11 Nm).