Toro 136-4840 Installation Instructions

FormNo.3422-409RevB

TrackCompletionKit

TX1000NarrowTrackCompactToolCarrier

ModelNo.136-4840

InstallationInstructions

Installation

2

RemovingtheCovers

1

PreparingtheMachine

NoPartsRequired

Procedure

WARNING

Mechanicalorhydraulicjacksmayfailto
supportthemachineandcauseseriousinjury.

Usejackstandswhensupportingthe
machine.

1.Removeanyattachmentsfromthemachine.

2.Parkthemachineonalevelsurface.

3.Engagetheparkingbrake.

4.Raisetheloaderarmsandsecurethemwiththe
cylinderlocks.

5.Shutofftheengine,removethekey,andwait
forthemachinetocool.

NoPartsRequired

RemovingtheFrontScreen

1.Openthehoodandsecurethehoodprop.

2.Loosenthe2topboltsandremovethe2front
bolts.

6.Raisethemachineoffthegroundsothatyou
canaccessunderneaththemachine.Support
themachineusingjackstands.

Note:Usejackstandsratedforyourmachine.

RefertotheOperator’sManualforyourmachine
todeterminetheweight.

©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

Figure1

1.Topbolt2.Frontbolt

3.Removethescreen.

RemovingtheFrontCover

1.Removethe2upperbolts(3/8x1inch),2
washers,and2lowerbolts(5/16x5/8inch)from
thefrontcover.

2.Removethefrontcover(Figure2).

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3422-409*B

g262277

3

RemovingtheExisting TrackAssemblies

NoPartsRequired

Procedure

1.Placeragsoracontainerunderthetrack
motorhydraulicportstocatchanyuidasyou
completethisprocedure(Figure4).

Figure2

1.Upperbolt—3/8x1inch
(2)

2.Frontcover

3.Washer(2)

4.Lowerbolt—5/16x5/8
inch(2)

RemovingtheBottomCoverPlate

1.Removethe2bolts(3/8x1inch)thatsecurethe
bottomcoverplatetotheframeplate(Figure3).

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2.Markthehosesconnectedtothemotorswith
theirportlocations(i.e.,leftfront,leftrear,right
front,rightrear).

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Figure4

1.Hose(4)3.Port(4)

2.Trackmotor(2)

3.Removethehosefrom1trackmotorandinstall
protectivecoversoverthehoseopenings.

4.Removethehydraulicttingsfromthemotor.

Figure3

1.Bolts(3/8x1inch)

2.Removethebottomcoverplatefromthe
machine(Figure3).

2.Bottomcover

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2

5.Removethenutfromthefronttrackpinshown
inFigure5.

Note:Donotremovethepinatthistime.

Figure5

1.Trackpin2.Nut

6.Loosentherearboltsecuringthereartrack
frametothemachine(Figure6).

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Figure7

1.Trackassembly

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8.Removethebrakemountassemblyfromthe
motorasfollows:

A.Removeandretainthe2boltssecuring

thebrakemounttothetrackmotorcasting
(Figure8).

Figure6

1.Rearbolt

7.Usingahoistorforkliftcapableoflifting181kg
(400lb),slidethetrackassemblyfromtheframe
about15cm(6inches)asshowninFigure7.

Important:Ensurethatthehydrauliclines

areoutoftheway.

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Figure8

1.Trackmotorcasting4.Brakemount

2.Brake-shaftpin5.Bolt—3/8x1-1/4inches

3.Compressionspring

(2)

6.Brakecable

B.Loosenthenutssecuringthebrakecableto

thebrakemount(Figure8).Removethe
brakecables.

C.Removeandretainthecompressionspring

(Figure8).

9.Completelyremovethetrackassemblyfromthe
machine.

10.Repeattheprocedurefortheothertrack.

3

4

InstallingtheNewTrack Assemblies

barrelttingofthebrakecableintotheslot
inthepin,slidethecableintothemount
notchsothatthenotchisbetweenthe2
cablenuts,andslowlyreleasethepinand
spring.

C.Adjustthenutsonthebrakecablesothat

only2threadsshowtowardthecable
(Figure9).

Partsneededforthisprocedure:

2

Trackassembly(soldseparately)

2Brakemount

2

Brake-shaftpin

1

Brakekit(soldseparately)

Procedure

1.Usingahoistorforkliftcapableoflifting181kg
(400lb),liftthetrackassemblytoapproximately
15cm(6inches)awayfromthemachine.

2.Ifyouareinstallingaseparatebrakekit,refer
totheInstallationInstructionsforthekit(see
ServiceBulletin110),thencontinuetostep3.

Important:Usethebrakemountsandpins

providedinthistrackkit.Donotusethe
brakemountsandpinsprovidedintheBrake
Kit.

Ifyouarenotinstallingaseparatebrakekit,
continueasfollows.

A.Insertthebrakecablethroughthebrake

mountandspring,andinsertthebarrel
ttingintotheslotofthebrake-shaftpin
(Figure9).

D.Tightenthenuts.

E.Securethebrakemounttothemotor

mount,withtheopensidefacingtowardthe
trackmotor,usingthe2boltsyouremoved
previously(Figure10).

Figure10

1.Brakemount

3.Installthetrackassemblyandsecureittothe
mainframeusingthebolt,washer,pin,andnut
removedfromthetrackassemblies(Figure11).

2.Bolt—3/8x1-1/4inches
(2)

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Figure9

1.Brake-shaftpin

2.Compressionspring

3.Brakemount

B.Insertthebrake-shaftpinintothespringand

thenintothebrakemount(Figure9).Push
inthepintocompressthespring,insertthe

4.Brakecable

5.Nut

6.Barreltting

g261347

Figure11

1.Nut4.Washer

2.Pin5.Trackassembly

3.Bolt

4.Torquethefrontnutto244to298N∙m(180to
220ft-lb)andtorquetherearboltto305to373
N∙m(225to275ft-lb).

4

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5.Placeragsoracontainerunderthetrackmotor
hydraulicportstocatchanyuid.Removethe
plugsfromtrackmotor.

6.InspectandreplaceanydamagedO-ringson
thehydraulicttings.

7.Installthehydraulicttingsintothenewtrack
motors(Figure12).T orquethemto136to163
N∙m(100to120ft-lb).

Figure12

1.Hose(4)3.Trackmotor(2)

2.Fittinginstalledintothe

port(4)

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Figure13

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1.Hoses

8.Installthehosestotheportsthatyoumarked
(Figure12).

9.Torquethehosesto50to64N∙m(37to47ft-lb).

10.Repeattheprocedurefortheothertrack.

11.Inthefrontofthemachine,removethe2hoses
onthetandempumpandinstallthemtothe
oppositeports(Figure13).T orquethettingsto
24to30N∙m(18to22ft-lb).

5

5

ReplacingtheReliefValves

Partsneededforthisprocedure:

4

Reliefvalve

Procedure

3.Install2newreliefvalvesintheirplaceand
torquethemto34to39N∙m(25to29ft-lb).

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Figure15

1.Usepressurizedairtocleanthecavitiesofeach
reliefvalvebeforeremovingthem.

2.Usea15mmsockettoremovetheexistingtop
reliefvalvesfromthetandempump(Figure14).

4.Placeragsortowelsunderthetandempumpto
catchuidfromthehosesandtting.

5.Loosenthe2hoseclampsandremovethe
hosesfromthetting(Figure16).

Figure16

1.Nut

2.Hoseclamp(2)

3.Hose(2)

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1.Tandempump

6.Cleantheareaaroundthetting.

7.Usea1-1/4inchcrowfootoropen-endwrenchto
loosenthenutonthettingshowninFigure16.

g257481

Figure14

2.Topreliefvalve(2)

6

8.Rotatethettingcounterclockwisesothatthe
atsideofthettingalignswiththereliefvalve
portopening(Figure17).

Figure17

6

InstallingtheCovers

NoPartsRequired

InstallingtheBottomCoverPlate

1.Alignthetabofthebottomcoverplatewiththe
frameplateofthemachine(Figure18).

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1.Fitting

9.Removethe2lowerreliefvalves(Figure17).

10.Install2newvalvesintheirplaceandtorque
themto34to39N∙m(25to29ft-lb).

11.Rotatethettingtotheoriginalorientation
(Figure16).Torquethenutto182to222N∙m
(134to164ft-lb).

12.Installthehosesandhoseclamps(Figure16).

2.Lowerreliefvalve(2)

Figure18

1.Bottomcoverplate

2.Aligntheholesinthebottomcoverplatewiththe
frameplate(Figure18).

3.Assemblethebottomcoverplatetotheframe
plate(Figure18)withthe2capscrews(3/8x1
inch)thatyouremovedpreviously.

2.Capscrew(3/8x1inch)

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7

InstallingtheFrontCover

InstallingtheFrontScreen

Installthefrontcoverusingthe2bolts(3/8x1inch),
2washers,and2bolts(5/16x5/8inch)thatyou
removedpreviously(Figure19).

Figure19

1.Upperbolt—3/8x1inch
(2)

2.Frontcover

3.Washer(2)

4.Lowerbolt—5/16x5/8
inch(2)

1.Installthefrontscreenusingthe4bolts(3/8x1
inch)youremovedpreviously(Figure20).

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1.Bolt—3/8x1inch(2)

Figure20

2.Lowerthemachinetotheground.

8

7

InstallingtheHandle

Partsneededforthisprocedure:

1Handle

2Bolt

2Nut

Procedure

4.Installthenewhandleusing2boltsand2nuts
(Figure23).

1.Opentherear-accesscover.

2.Removeandretainthe4boltsandnutssecuring
thecontrolpanelcovertothemachine(Figure

21).

Figure21

1.Boltandnut(4)

3.Liftupthecontrolpanelcoverandremovethe
fronthandle(Figure22).

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Figure23

1.Bolt(2)3.Nut(2)

2.Handle

5.Securethecontrolpanelcoverusingthe4bolts
and4nutsyouremovedpreviously.

6.Closetherear-accesscover.

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Figure22

1.Handle2.Bolt

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9

Maintenance

5.Usinga1/2inchdriveratchet,turnthetensioning
screwuntilthetrackgapis13mm(1/2inch)as
showninFigure24.

AdjustingtheTrackTension

Lift/support1sideofthemachineandusingtheweight
ofthetrack,verifythatthegapbetweenthebottom
ofthelipoftheroadwheelandthetrackis13mm
(1/2inch)asshowninFigure24.Ifitisnot,adjustthe
tracktensionusingthefollowingprocedure.

Figure24

1.Roadwheel

1.Parkthemachineonalevelsurface,engagethe
parkingbrake,andlowertheloaderarms.

Note:Turningthescrewcounter-clockwise

tightensthetrack;turningthescrewclockwise
loosensthetrack.

6.Aligntheclosestnotchinthetensionscrewto
thelocking-boltholeandsecurethescrewwith
thelockingboltandnut(Figure25).

7.Repeattheprocedurefortheothertrack.

8.Drivethemachine,thenparkthemachineona
levelsurface,engagetheparkingbrake,shutoff
theengine,andremovethekey.

9.Verifythatthetrackdeectionis13mm(1/2
inch)asshowninFigure24.Adjustifnecessary.

ReplacingtheTracks

Replacethetrackswhentheyarebadlyworn.

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RemovingtheTracks

1.Removeanyattachments.

2.Parkthemachineonalevelsurface,ensuring
thatonly1sprockethalfisengagedwiththe
track(Figure26).

2.Shutofftheengineandremovethekey.

3.Raisethesideofthemachinethatyouare
adjustingsothatthetrackisofftheground.

4.Removethelockingbolt,spacer,andnut(Figure

25).

Figure25

1.Lockingbolt

2.Tensioningscrew4.Nut

3.Spacer

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Figure26

1.Sprockethalf

3.Engagetheparkingbrake.

4.Lowertheloaderarmssothattheyare

g257903

approximately20to25cm(8to10inches)
abovetheframe.

5.Shutofftheengineandremovethekey.

6.Liftthesideofthemachinewiththetrackyou
arereplacing.Supportthemachineusingjack
stands.

Note:Usejackstandsratedforyourmachine.

10

WARNING

Mechanicalorhydraulicjacksmayfailto
supportthemachineandcauseserious
injury.

Usejackstandswhensupportingthe
machine.

7.Removethelockingbolt,spacer,andnut(Figure

25).

8.Usinga1/2-inchdriveratchet,releasethe
drivetensionbyturningthetensioningscrew
clockwise(Figure25andFigure27).

11.Movethetractioncontrolforwarduntiltheother
halfofthedrivesprocketisnotengagedwith
thetrack(Figure29).

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Figure29

12.Engagetheparkingbrake,shutofftheengine,
andremovethekey.

13.Removethetrackfromthetrackframe,drive
hub,thenfrontwheel.

Figure27

1.Sprocket4.Ratchet(1/2inch)

2.Track

3.Frontwheel

5.Roadwheel(5)

9.Removethe3boltssecuringthesprockethalf
thatisnotengagedwiththetrack(Figure28).

InstallingtheTracks

1.Wrapthenewtrackaroundthefrontwheel,then
wrapthetrackaroundthedrivehubontheside
withoutthesprocket(Figure27).

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2.Pushthetrackunderandbetweentheroad
wheelsandwrapitaroundthelowerframe
(Figure27).

Note:Ensurethattheroadwheelsarecentered

onthetrack.

3.Starttheengineanddisengagetheparking
brake.

4.Movethetractioncontrolforwarduntilthedrive
sprockethalfengageswiththetrack(Figure30).

Figure28

1.Bolt(3)2.Sprockethalf

10.Startthemachineanddisengagetheparking
brake.

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Figure30

5.Engagetheparkingbrake,shutofftheengine,
andremovethekey.

6.Applythread-lockingcompoundtotheboltsof
thedrivesprockethalfthatyouremovedand

11

installthesprockethalf(Figure28).Torquethe
boltsto95to115N∙m(70to85ft-lb).

7.Usinga1/2inchdriveratchet,turnthetensioning
screwcounter-clockwiseuntilthetrackdeection
is13mm(1/2inch)asshowninFigure24.

8.Aligntheclosestnotchinthetensionscrewto
thelockingboltholeandsecurethescrewwith
thelockingbolt,spacer,andnut.

9.Lowerthemachinetotheground.

10.Repeattheproceduretoreplacetheothertrack.

11.Drivethemachine,thenparkthemachineona
levelsurface,engagetheparkingbrake,shutoff
theengine,andremovethekey.

12.Verifythatthetrackdeectionis13mm(1/2
inch)asshowninFigure24.

12