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Toro Brake Kit, TX 1000 Compact Tool Carrier Installation guide

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FormNo.3422-159RevA
BrakeKit
TX1000CompactToolCarrier
ModelNo.136-4799
InstallationInstructions
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Removetheaccesspanels.
2
Nopartsrequired
–
Removetheexistingbrakeassembly.
3
Brakebracketassembly1
Assemblethecablestothebrake-mount
plate.
Bolt(5/16x1inch)
2
Nut(5/16inch)
2
4
Spring
1
Installthebrakebracketassembly.
Brakemount2
Bolt(3/8x1-1/4inches)
4
5
Cabletie
1
Installthebrakemounts.
6
Nopartsrequired
–
Adjustthebrakecables.
7
Cabletie
1
Completetheinstallation.
8
Nopartsrequired
–
Installthecoverplates.
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved
*3422-159*A
1
RemovingtheCoverPlates
NoPartsRequired
RotatingtheSideandFrontPads
1.Removethebottom2bolts(5/16x3/4inch)that
securetheleftandrightsidepadstotheframe
plates(Figure1).
g247039
Figure1
1.Bolts(5/16x3/4inch)3.Sidepad
2.Frameplate
2.Rotatethepadsup(Figure1).
3.Loosenthecaptiveboltthatsecuresthefront
padtothescreenframe(Figure2)
g247038
Figure2
1.Captivebolt
4.Rotatethepadup(Figure2).
2
RemovingtheScreen
1.Removethe4bolts(3/8x7/8inch)thatsecure
thescreenframetotheframeplates(Figure3)
g247037
Figure3
1.Bolts(3/8x7/8inch)2.Screenframe
2.Removethescreenframefromthemachine
(Figure3).
RemovingtheRear-CoverPlate
1.Removethe2ange-headbolts(1/4x1/2inch)
and2clampsthatsecurethefuelhosetothe
rear-coverplate(Figure4).
g247035
Figure4
1.Rear-coverplate
4.Flange-headbolt(1/4x
1/2inch)
2.Fuelhose
5.Flange-headbolt(5/16x
5/8inch)
3.Clamp
2.Removethe3ange-headbolts(5/16x5/8
inch)thatsecuretherear-coverplatetothe
rear-frameplate(Figure4).
3.Removetherear-coverplatefromthemachine
(Figure5).
g247036
Figure5
3
RemovingtheBottom-Access
Plate
1.Removethe2capscrews(3/8x1inch)that
securethebottomcoverplatetotheframeplate
(Figure6).
g247034
Figure6
1.Capscrew(3/8x1inch)
2.Bottomcoverplate
2.Removethebottomcoverplatefromthe
machine(Figure6).
2
RemovingtheExisting
BrakeAssembly
NoPartsRequired
Procedure
1.Beneaththeoperator’splatform,unplugthe
auxiliary-switchwireharnessfromthemainwire
harnessofthemachine(Figure7).
g037830
Figure7
1.Mainwireharness
3.Operator’splatform
2.Auxiliary-switchharness
2.Disconnectthewireharnessfromthebrake
switch.
3.Removethe2bolts,2nuts,andbrakelever
assembly(Figure8).
4
g242415
Figure8
1.Nut(2)3.Bolt(2)
2.Brakeleverassembly
4.Removeandretainthebrakeswitchand
fastenersfromtheassembly(Figure9).
g241737
Figure9
1.Screw(2)3.Jamnut(2)
2.Brakeswitch
5.Removethebrakemountassemblyfromboth
sidesofthemachineasfollows:
A.Removethe2boltssecuringthebrake
mounttothetrackmotorcasting(Figure
10).
g240461
Figure10
1.Trackmotorcasting
4.Bolt(2)
2.Brake-shaftpin
5.Brakemount
3.Compressionspring
6.Brakecable
B.Removeandretainthecompressionspring
andbrake-shaftpin(Figure10).
C.Loosenthenutssecuringthebrakecableto
thebrakemount(Figure10).Removethe
brakecables.
3
AssemblingtheCablesto
theBrake-MountPlate
Partsneededforthisprocedure:
1Brakebracketassembly
Procedure
1.Slidethecablewiperoffthethreadedconduit
ttingandthreadtheendjamnutoffthetting
(Figure11).
5
g247370
Figure11
1.Cablewiper4.Cable
2.Jamnut5.Brake-mountplate
3.Threadedconduittting
2.Alignthecablethroughslotinthebrake-mount
plateandslidethethreadedconduittting
throughthebracket(Figure11).
3.Threadtheendjamnutontothettingthreaded
conduittting(Figure12).
g247371
Figure12
1.Cablewiper
3.Brake-mountplate
2.Jamnut
4.Adjustthepositionofthejamnutstocenter
thethreaded-conduitttingtothebrake-mount
plate,andtightenthejamnuts(Figure12).
5.Slidethecablewiperovertheendofthe
threaded-conduittting(Figure12).
6.Repeatsteps1through5fortheotherbrake
cable(Figure11andFigure12).
4
InstallingtheBrakeBracket
Assembly
Partsneededforthisprocedure:
2
Bolt(5/16x1inch)
2
Nut(5/16inch)
1
Spring
Procedure
1.Installthebrakeswitchtothenewbrakebracket
assembly(Figure9).
Note:Ensurethattheplungerhousingisush
withorslightlyinsidetheedgeofthebrake
bracket.
6
2.Frominsidethemachine,insertthebrake
handlethroughtheholeintherearplatesothat
thehandlepointsupward.
3.Securethebrakebracketassemblyusing2
bolts(5/16x1inch)and2nuts(5/16inch)as
showninFigure13.
g242428
Figure13
1.Nut—5/16inch(2)2.Bolt—5/16x1inch(2)
5
InstallingtheBrakeMounts
Partsneededforthisprocedure:
2Brakemount
4
Bolt(3/8x1-1/4inches)
1
Cabletie
Procedure
1.Loosenthenutsontheendofthebrakecable
withthebarreltting.Insertthecablethrough
thebrakemountandspring,andinsertthe
barrelttingintotheslotofthebrake-shaftpin
(Figure14).
g242891
Figure14
1.Brake-shaftpin
4.Brakecable
2.Compressionspring
5.Nut
3.Brakemount
6.Barreltting
2.Insertthebrake-shaftpinintothespringand
thenintothebrakemount(Figure14).Pushin
thepintocompressthespring,insertthebarrel
ttingofthebrakecableintotheslotinthepin,
slidethecableintothenotchinthebrakemount,
andslowlyreleasethepinandspring.
3.Tightenthenutsonthebrakecable.
4.Securethebrakemounttothemotormount,
withtheopensidefacingtowardtheoperator’s
platform,using2bolts(3/8x1-1/4inches)as
showninFigure15andFigure16.
Note:Ensuretoroutethecablestotheinside
oftheoilcoolerandradiatorhoses(Figure16).
g234347
Figure15
1.Brakemount
2.Bolt—3/8x1-1/4inches
(2)
g242491
Figure16
1.Hose2.Brakecable
5.Repeattheprocedurefortheotherbrakemount
ontheothersideofthemachine.
7
6.Routethemachinewireharnessandthebrake
switchharnessasshowninFigure17.Connect
thebrakeswitchtothemachinewireharness.
g242890
Figure17
1.Brakeswitchconnector
3.Cabletie
2.Machinewireharness
(ConnectorP42)
7.Securethemachinewireharnesstotheupper
brakecableusingacabletie(Figure17).
6
AdjustingtheBrakeCables
NoPartsRequired
Procedure
1.Movetheparking-brakelevertotheONposition.
2.Loosenthe2nutsonthepinsideofeachbrake
cableandadjustthecablesothatitistautand
thepinisushagainstthetrackmotorcasting
(Figure10).
Note:Adjustthenutstowardthepintomove
thepinfurtherinward;adjustthenutsawayfrom
thepintomovethepinfurtheroutward.
3.Movetheparking-brakelevertotheOFFposition.
4.Adjustthespringsideofeachbrakecableso
thatthecableistaut,butthepinisushwiththe
outsideofthetrackmotorcasting(Figure18).
g240527
Figure18
1.Trackmotorcasting2.Pin
5.Cycletheparkingbrakestoensurethey
consistentlyengageanddisengage.
7
ConnectingtheWire
Harness
Partsneededforthisprocedure:
1
Cabletie
Procedure
1.Plugtheauxiliary-switchwireharnesstothe
mainwireharnessofthemachine(Figure19).
g037848
Figure19
1.Mainwireharness
3.Operator’splatform
2.Auxiliary-switchharness
8
2.Useacabletietosecuretheauxiliary-switch
wireharnesstotherightbrakecablesothat
theharnessdoesnotrubagainstorbecome
pinchedbetweenparts.
8
InstallingtheCoverPlates
NoPartsRequired
InstallingtheBottom-AccessPlate
1.Alignthetabofthebottomcoverplatewiththe
frameplateofthemachine(Figure20).
g247051
Figure20
1.Bottomcoverplate
2.Capscrew(3/8x1inch)
2.Aligntheholesinthebottomcoverplatewiththe
frameplate(Figure20).
3.Assemblethebottomcoverplatetotheframe
plate(Figure20)withthe2capscrews(3/8
x1inch)thatyouremovedinRemovingthe
Bottom-AccessPlate(page4).
4.Torquethecapscrewsto37to45N∙m(27to33
ft-lb).
InstallingtheRear-CoverPlate
1.Aligntheholesintherear-coverplatetothe
holesintherear-frameplate(Figure21).
g247052
Figure21
1.Rear-coverplate
2.Rear-frameplate
2.Assembletherear-coverplatetotherear-frame
plate(Figure22)withthe3ange-headbolts
(5/16x5/8inch)thatyouremovedinRemoving
theRear-CoverPlate(page3).
g247054
Figure22
1.Rear-coverplate
4.Clamp
2.Flange-headbolt(5/16x
5/8inch)
5.Flange-headbolt(1/4x
1/2inch)
3.Fuelhose
9
3.Torquethe3ange-headboltto1978to2542
N∙cm(175to225in-lb).
4.Securethefuelhosetotherear-coverplatewith
the2clampsand2ange-headbolt(1/4x1/2
inch),andtightentheboltsbyhand(Figure22).
InstallingtheScreen
1.Aligntheholesinthemountingtabsofthe
screenframewiththeholesontheframeplates
(Figure23).
g247055
Figure23
1.Screenframe3.Mountingtab(screen
frame)
2.Bolts(3/8x7/8inch)
2.Assemblethescreenframetotheframeplates
(Figure23)withthe4bolts(3/8x7/8inch)that
youremovedinRemovingtheScreen(page3).
3.Torquetheboltsto7to45N∙m(27to33ft-lb).
AssemblingthePads
1.Rotatethefrontpaddown(Figure24).
g247057
Figure24
1.Frontpad
2.Captivebolt
2.Assemblethefrontpadtothescreenframewith
thecaptivebolt,andtightentheboltbyhand
(Figure24).
3.Rotatetheleftandrightsidepadsdown,and
alignthelowerholesinthepadswiththeholes
intheframeplates(Figure25).
4.Assemblethesidepadstotheframeplates
(Figure25)atthebottomholeswiththe2bolts
(5/16x3/4inch)thatyouremovedinRotating
theSideandFrontPads(page2).
10
g247058
Figure25
1.Frameplate
3.Bolts(5/16x3/4inch)
2.Sidepads
4.Topbolts
5.Torquethe2boltsthatsecurethesidepadsto
theframeplatesto1978to2542N∙cm(175to
225in-lb).
11
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