Toro 133-0575 User manual

FormNo.3399-376RevA
AlternatorKit
Workman®HDX-AutoUtilityVehicle
ModelNo.133-0575
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Disconnectthehydraulicpumpand
removethecouplerassembly.
3Nopartsrequired–Removetheadapterplate.
Alternatorpulley1
Alternatorbelt1
4Hexsocketatheadscrew(M8x20
mm)2
Installthealternatorpulleyandbelt.
5Nopartsrequired–Installthecouplerassembly.
6Alternator-brackettemplate1Drillholesforthealternatorbracket.
Alternatorbracket1
Alternator1
Spacer1
Hex-headscrew(3/8x2-3/4inches)1
Flatwasher(7/16inch)1
Flangenut(3/8inch)1
Hex-headangescrew(M8x20mm)1
Hex-headangescrew(1/4x3/4inch)6
7
Flangenut(1/4inch)6
Installthealternator.
8Nopartsrequired–Connectthehydraulicpump.
9Alternatorwireharness1Connectthekitandenginewire
harnessestothealternator.
©2016—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3399-376*A

ProcedureDescriptionQty.Use
10Nopartsrequired–Connectthebattery.
11Nopartsrequired–Testthealternator.
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface,settheparking
brake,shutofftheengine,andremovethekey.
2.Disconnectthenegativebatterycable;refertoyour
Operator’sManual.
2
DisconnectingtheHydraulic
PumpandRemovingthe
CouplerAssembly
NoPartsRequired
Procedure
1.Loosenthe2setscrewsonthehydraulic-pumphub
(Figure1).
Figure1
1.Hydraulic-pumphub2.Setscrews
2.Removethe4boltsandnutsfromthehydraulicpump
(Figure2).
Figure2
1.Boltandnut
3.Separatethehydraulicpumpfromthecouplerand
movethehydraulicpumpoutoftheway.
Note:Retainthehardware.
4.Removethe2angenutsfromthehydraulic-pump
hub(Figure3).
Figure3
1.Flangenuts
5.Removethe2boltsand2washersfromthecoupler
assembly(Figure4).
2

Figure4
1.Bolt3.Couplerassembly
2.Washer
6.Removethecouplerassembly.
3
RemovingtheAdapterPlate
NoPartsRequired
Procedure
1.Removethehexsocketatheadscrewsfromthe
adapterplate(Figure5).
Figure5
1.Hexsocketathead
screws
2.Adapterplate
2.Removetheadapterplate(Figure5).
Note:Discardtheadapterplateandscrews.
4
InstallingtheAlternatorPulley
andBelt
Partsneededforthisprocedure:
1Alternatorpulley
1Alternatorbelt
2Hexsocketatheadscrew(M8x20mm)
Procedure
1.Installthealternatorbeltontothealternatorpulley
(Figure6).
Figure6
1.Alternatorpulley2.Alternatorbelt
2.Installthealternatorpulleytothemotorwiththe2
hexsocketatheadscrews(M8x20mm)asshown
inFigure7.
3

Figure7
1.Alternatorpulley2.Hexsocketathead
screws(M8x20mm)
3.Applythread-lockingcompoundtothe2hexsocket
atheadscrews(M8x20mm)andtorquethemto26
to31N∙m(19to23ft-lb).
5
InstallingtheCoupler
Assembly
NoPartsRequired
Procedure
1.Applythread-lockingcompoundtothe2bolts
removedin2DisconnectingtheHydraulicPumpand
RemovingtheCouplerAssembly(page2).
2.Installthe2boltsandwashers,andtorquetheboltsto
1,483to1,907N∙cm(131to169in-lb).
3.Installthe2nutsremovedin2Disconnectingthe
HydraulicPumpandRemovingtheCouplerAssembly
(page2)andtorquethenutsto1,483to1,907N∙cm
(131to169in-lb).
6
DrillingHolesfortheAlternator
Bracket
Partsneededforthisprocedure:
1Alternator-brackettemplate
Procedure
Usingthealternator-brackettemplate,drill2holes(5/16
inch)intothehydraulic-pumpbracket(Figure8).
Figure8
1.Alternator-bracket
template
2.Hydraulic-pumpbracket
4

7
InstallingtheAlternator
Partsneededforthisprocedure:
1Alternatorbracket
1Alternator
1Spacer
1Hex-headscrew(3/8x2-3/4inches)
1Flatwasher(7/16inch)
1Flangenut(3/8inch)
1Hex-headangescrew(M8x20mm)
6Hex-headangescrew(1/4x3/4inch)
6Flangenut(1/4inch)
Procedure
1.Movethecarboncanistertotherightsideofthe
machineandusecabletiestosecureittothehydraulic
hardlinesawayfrommovingorhotparts(Figure9).
Figure9
1.Carboncanister2.Hydraulichardlines
2.Installthealternatorbrackettothehydraulic-pump
bracketwiththe6hex-headangescrews(1/4x3/4
inch)and6angenuts(1/4inch)asshowninFigure
10.
Figure10
1.Hydraulic-pumpbracket3.Flangenut(1/4inch)
2.Alternatorbracket4.Hex-headangescrew
(1/4x3/4inch)
3.Installthealternatortothealternatorbracketwiththe
hex-headscrew(3/8x2-3/4inches),atwasher(7/16
inch),spacer,andangenut(3/8inch)asshownin
Figure11.
Note:WheninstallingwiththeCabHeaterKit,the
‘T’inthecoolantlineneedstobeturnedtodirectthe
hoseawayfromthealternator.
5

Figure11
1.Hex-headscrew(3/8x
2-3/4inches)
4.Spacer
2.Flatwasher(7/16inch)5.Flangenut(3/8inch)
3.Alternatorbracket6.Alternator
4.Usingcableties,securetheenginecrossovertubeand
enginewireharnessawayfromthealternatorbelt
(Figure12).
Figure12
1.Enginewireharness2.Crossovertube
5.Looselyinstallthehex-headangescrew(M8x20
mm)throughtheslotinthealternatorbracketandthe
holeinthealternator(Figure13).
Figure13
1.Holeinthealternator3.Hex-headangescrew
(M8x20mm)
2.Slotinthealternator
bracket
6.Slidethealternatorbeltoverthepulleyonthealternator
(Figure14).
Figure14
1.Pulley2.Alternatorbelt
7.Tensionthealternatorbeltandensurethatithas1.25
cm(1/2inch)ofexwhenapplying4.5kg(10lb)of
forceatmid-span.
8.Tightenthehex-headangescrew(M8x20mm).
6

8
ConnectingtheHydraulic
Pump
NoPartsRequired
Procedure
1.Installthehydraulicpumpwiththe4boltsandnuts
removedin2DisconnectingtheHydraulicPumpand
RemovingtheCouplerAssembly(page2).
2.Tightenthe2setscrewsonthehydraulic-pumphub
(Figure1).
9
ConnectingtheKitand
EngineWireHarnessestothe
Alternator
Partsneededforthisprocedure:
1Alternatorwireharness
Procedure
1.Connectthekitwireharnesstothealternator(Figure
15).
Figure15
2.Connectthealternatorwireharnesstotheenginewire
harness(Figure16).
Figure16
1.Connectthealternatorwireharnesstotheenginewire
harnesshere.
3.Disconnectthepurplewirewiththeterminalringon
thestarter,andsecureitwithelectricaltape.
4.Connectthepositiveterminalringtothepositive
terminalonthestarter(Figure15).
7

10
ConnectingtheBattery
NoPartsRequired
Procedure
Connectthenegativebatterycable;refertoyourOperator’s
Manual.
11
TestingtheAlternator
NoPartsRequired
Procedure
1.Shutofftheengineandcheckthebatteryvoltage.
2.Starttheengineandcheckthebatteryvoltage.
Note:Afterstartingtheengine,thevoltageshouldbe
13.5to14.5V .
8