Toro 136-1199 Installation Instructions Manual

Installation

LooseParts

FormNo.3407-721RevA

BrakeReplacementKit

Twister

ModelNo.136-1199

®

orWorkman

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

®

UtilityVehicle

InstallationInstructions

WARNING

CALIFORNIA

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1
2

3

4
5

Nopartsrequired

Nopartsrequired

Rightspindle1
Leftspindle
Brake-caliperassembly2
Flange-headbolt(3/8x1inch)
Rotor2
Hex-socketbolt(5/16x3/4inch)
Frontbrake-lineassembly1
Banjowasher4
Banjobolt2
Clip
Bleedscrew2

Nopartsrequired

Nopartsrequired

Qty.

Use

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1

4

8

2

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Preparethemachine.

Removetheexistingbrakeassembly.

Installthenewbrakeassembly.

Bleedthebrakecalipers.

Installthewheels.

6
7

©2016—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Nopartsrequired

Nopartsrequired

Registeratwww.T oro.com.

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–

Adjustthefrontwheeltoe-in.

Burnish(break-in)thebrakes.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3407-721*A

1

PreparingtheMachine

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekeyfromthekeyswitch.

2

Figure1

3.Removethebanjoboltandwasherfromthe
brake-caliperassembly ,andremovethefrontbrakeline
fromthebrake-caliperassembly(Figure3).

RemovingtheExistingBrake
Assembly

NoPartsRequired

Procedure

1.Liftthefrontofthemachineandsupportitwithjack
stands.

2.Removethelugnutsthatsecurethewheeltothehub
(Figure2).

Figure3

1.Banjobolt3.Frontbrakeline

2.Banjowasher4.Brake-caliperassembly

Figure2

1.Hub3.Lugnut

2.Wheel

2

4.Removetheange-headbolts(3/8x1inch)that
securethebracketforthebrake-caliperassemblytothe
spindleandremovethebrake-caliperassemblyfrom
thespindle(Figure4).

6.Removethedustcap,hairpincotter,nutretainer,and
jamnut,andremovethehubandrotorfromthe
spindle(Figure6).

Note:Retainthehub,dustcap,jamnut,nutretainer,
andhairpincotter.

Figure4

1.Flange-headbolt(3/8x1
inch)

2.Spindle

3.Caliperbracket
(brake-caliperassembly)

5.Removethefrontbrakelinefromthemastercylinder
(Figure5).

Note:Discardthefrontbrakeline.

Figure6

1.Spindle

2.Rotor6.Dustcap

3.Hub7.Hairpincotter

4.Jamnut

5.Nutretainer

7.Removethe4hex-socketbolts(5/16x3/4inch),and
removetherotorfromthehub(Figure7).

Note:Discardtherotorand4hex-socketbolts(5/16
x3/4inch).

Figure5

1.Frontbrakeline2.Mastercylinder

1.Hex-socketbolt(5/16x3/4
inch)

2.Rotor

3

Figure7

3.Hub

8.Removethehairpincotterandslottedhexnutfrom
thetierodballjoint,anddisconnectthetierodfrom
thespindle(Figure8).

Note:Retainthehairpincotterandslottedhexnut.

Figure8

1.Tierod

2.Hairpincotter

3.Balljoint

9.Removethehex-headbolt(1/2x6inches),clip,and
locknut(1/2inch)fromthecontrolarm,andremove
thespindle(Figure9).

4.Spindle

5.Slottedhexnut

3

InstallingtheNewBrake
Assembly

Partsneededforthisprocedure:

1Rightspindle

1

Leftspindle

2Brake-caliperassembly

4

Flange-headbolt(3/8x1inch)

2Rotor

8

Hex-socketbolt(5/16x3/4inch)

1Frontbrake-lineassembly

4Banjowasher

2Banjobolt

2

Clip

2Bleedscrew

Note:Retainthehex-headbolt(1/2x6inches)and
locknut(1/2inch).

Note:Discardthespindle.

Figure9

1.Hex-headbolt(1/2x6
inches)

2.Clip4.Locknut(1/2inch)

3.Spindle

Procedure

1.Installthefrontbrakelinetothemastercylinder
(Figure5).

2.Installthespindleassemblytothecontrolarmusing
thehex-headbolt(1/2x6inches),clip,andlocknut
(1/2inch)asshowninFigure9.

3.Torquethelocknut(1/2inch)to102to136N∙m(75
to100ft-lb).

4.Installthetierodtothespindleassemblyusingthe
slottedhexnutandhairpincotter(Figure8).

Note:Iftheholedoesnotaligntoinstallthecotter
key,tightenonlytoaligntheslottednuttoensurethat
theholeforthehairpincotterisvisible,theninstall
thehairpincotter.

5.Torquetheslottedhexnutto27to34N∙m(20to25
ft-lb).

6.Installtherotortothehubusing4hex-socketbolts
(5/16x3/4inch)asshowninFigure7.

7.Torquethe4hex-socketbolts(5/16x3/4inch)to12
to15N∙m(9to11ft-lb).

10.Repeatsteps2through9ontheothersideofthe
machine.

4

8.Installtherotorandhubassemblytothespindleby
performingthefollowing:

A.Tightenthejamnutwhileturningthehubtoseat

thebearings,andtorquethejamnutto16to20
N∙m(12to15ft-lb)asshowninFigure6.

B.Loosenthejamnutuntilitisawayfromthetab

washerandhub,andtorquethejamnutto169to
226N∙cm(15to20in-lb)whilerotatingthehub
(Figure6).

C.Installthenutretaineroverthejamnut,ensure

thattheholeforthehairpincotterisvisible,and
installthehairpincotter(Figure6).

D.Installthedustcap(Figure6).

9.Installthenewbrake-caliperassemblytothespindle
using2ange-headbolts(3/8x1inch)asshownin

Figure4.

10.Torquethe2ange-headbolts(3/8x1inch)to47to
54N∙m(35to40ft-lb).

11.Installthebleedscrewintothetopholeofthe
brake-caliperassembly(Figure10).

4

BleedingtheBrakeCalipers

NoPartsRequired

Procedure

Important:Y ouwillneed2peopletoperformthis

procedure.

1.Pushdownthebrakepedalfully.

2.Withbrakepedalpusheddownfully,loosenthebleed
screw1/4turn(Figure11).

3.Withbrakepedalpusheddownfully,tightenthebleed
screw1/4turn(Figure11).

Figure10

1.Bleedscrew

12.Torquethebleedscrewto6to7.5N∙m(4.5to5.5ft-lb).

13.Installthefrontbrakelinetothebrake-caliperassembly
usingabanjoboltand2banjowashers(Figure3).

14.Torquethebanjoboltto12to15N∙m(9to11ft-lb).

2.Topholeofthe
brake-caliperassembly

Figure11

4.Repeatthisprocessuntilairnolongerreleasesfrom
thecalipers.

Note:Whenairnolongerreleases,youshouldnotsee
anymoreairbubblesinthebrakeuid.

5.Fillthemastercylinderwithbrakeuid;refertoyour
Operator’sManual.

5

5

G009235

1

2

3

InstallingtheWheels

NoPartsRequired

Procedure

1.Installthewheelontothehubusingthepreviously
removedlugnuts(Figure2).

1.Measurethedistancebetweenbothofthefronttiresat
theaxleheightatboththefrontandrearofthefront
tires(Figure12).

2.Torquethelugnutsinastarpatternto102to129N∙m
(75to95ft-lb).

6

AdjustingtheFrontWheel
Toe-in

NoPartsRequired

Procedure

Thetoe-inshouldbe0to6mm(0to1/4inch).

•Checkthetirepressuretoensurethatthefronttiresare

inatedto82kPa(12psi).

•Either,addweighttothedriver'sseatequaltotheaverage

operatorwhowillrunthemachine,orhaveanoperator
sitontheseat.Theweightoroperatormustremainon
theseatforthedurationoftheprocedure.

Figure12

1.Tirecenterline—back3.Axlecenterline

2.Tirecenterline—front

2.Ifthemeasurementdoesnotfallwithin0to6mm(0
to1/4inch),loosenthejamnutsattheouterendof
thetierods(Figure13).

Figure13

1.Tierod2.Jamnut

•Onalevelsurface,rollthemachinestraightback2to3

m(6to10ft)andthenstraightforwardtotheoriginal
startingposition.Thisallowsthesuspensiontosettleinto
theoperatingposition.

•Measurethetoe-inwiththewheelsfacingstraightahead.

3.Rotatebothtierodstomovethefrontofthetire
inwardoroutward.

4.Tightenthetierodjamnutswhentheadjustmentis
correct.

5.Ensurethatthereisfulltravelofthesteeringwheelin
bothdirections.

6

7

BurnishingtheBrakes

NoPartsRequired

Procedure

Toensureoptimumperformanceofthebrakesystem,burnish
(break-in)thebrakesbeforeuse.

1.Bringthemachineuptofullspeed,applythebrakesto
rapidlystopthemachinewithoutlockingupthetires.

2.Repeatthisprocedure10times,waiting1minute
betweenstops,toavoidoverheatingthebrakes.

Important:Thisprocedureismosteffectiveifthe
machineisloadedwith227kg(500lb).

7