FACTORY CAT RPS TOMCAT CORPORATION Artificial Turf and Carpet Sweeping Install Kit #349-641 & #349-642 1. Detach batteries so that there is no power running through the machine before starting. 2. Start removing the side brooms by pulling the pins out of the side broom motors to drop the brooms off (SEE 1). Save these brooms off to the side, upside-down as to not bend the brushes. 3. Once the side brooms are removed you will have easier access to the four bolts that are holding the drive onto the drive plate. These need to be loosened (SEE 2-5). Using a 1/2 socket, loosen these bolts. Remove the positive and negative terminal wires from the drive. Note: You may need to spin the wheel around to access certain bolts better. 4. Now that the bolts are loosened, you will need to finish taking it off by lifting the front of the machine either by a hoist or a floor jack. Make sure to use a piece of wood or cardboard to not scratch up the paint on the frame from the lift point. 1 of 10
6. Once the screws of the parking brake casing are removed, the casing can easily come off (SEE 8-9). You don t need to take it off completely, just enough to get access to the four screws underneath the casing. These can be taken off with a 1/4 size socket (SEE 10-11). 5. Now that the drive is detached from the drive shaft, it s best to work on a table of some sort for the next steps (SEE 6). Turn the drive motor so that the parking brake is facing you, and remove the four screws that are holding the parking brake casing on (SEE 7). 2 of 10
7. Once the four screws are removed that are holding the parking brake on, the parking brake will come right off (SEE 12). Note: Make note of the position of the parking brake are at this time. During the reinstall you will need to know this. Normally it will (if you are facing it) be at around the 1 o clock position. 8. Now that you have removed the parking brake, you have access to a star knob which will need to be removed. To remove, use an 1.5 sized allen wrench to loosen (SEE 13). To loosen, two full turns usually is enough. 9. Once you have loosen the allen key, pop the star knob off (SEE 14). A screw driver or two is an easy solution. 10. With the star knob removed (save for re-install) you will have access now to the motor key (SEE 15). This is a very small crescent key. To remove, use a small flat head screw driver and a mallet and tap it lightly till it comes out and save to the side for re-install (SEE 16). 3 of 10
11. Now with the entire parking brake side removed, you are going to want to turn the drive around and locate the two main bolts holding the motor casing on (SEE 17). 12. Once you have located the bolts, remove them with a 7/16 socket (SEE 18). Pull them out and set them to the side. 13. With the bolts removed, grab hold of the back motor casing. In a quick motion, push the motor forward a tad and then quickly pull back. The magnets inside of the motor casing make it a little difficult for the casing to come off. To make it easier, have someone hold the wheel in place while the casing is being removed (SEE 19). Note: You want to make sure you make note of where the positive and negative terminal connections are facing before you fully remove the casing as to re-installing the new one has to match. 14. Now that the casing is removed, remove the motor by using a mallet and tapping the backside where the motor key was to pop the motor out. Sometimes this is harder than others and you may need a hoist to pull the motor out (SEE 20). 4 of 10
15. Now that the entire motor assembly has been removed off of the standard drive, the new motor needs to be reinstalled. Locate your motor #349-8311 that was sent to you and preform steps 11-14 on it so that you have the motor, the black cylindrical casing, as well as the back motor casing apart along with the two large bolts. 16. Now before we reassemble the upgraded motor into the regular drive, we have to reset all of the magnets in the back of the cylindrical casing (SEE 21). This should already be apart, if not using a mallet knock it out gently. Note: You may see a circular inner ring come loose or fall out. Keep this (SEE 25-26). 17. Each of the magnets need to be pushed back (SEE 22) and while being held back, a pin inserted into the hole on the top and the bottom of the magnet bracket (SEE 23). 18. Do this for all four of the magnets on the back casing (SEE 24). 5 of 10
19. Now that all the magnets are in place, you have room to place the ring mentioned in step 16 s Note (SEE 25). 20. When placing this ring back into the center of the back motor casing in between all of the magnet brackets, you must make sure that the rings ends are bent up (SEE 26-27). 21. Now that the ring is in place you can lightly set the motor into the motor case backing. You will feel this go into place. Give it a couple light taps with a mallet on the top of it to make sure it is snug in there (SEE 28). 22. All of the pins that are holding the magnets in place need to be removed now. Remove them gently and let the magnets snap into place. Easiest removal with another pin or needle nose pliers. 6 of 10
23. With all of the pins out of the magnet brackets and the motor fully in place on the back of the motor casing, you can now install the main black cylindrical casing. Before placing over motor, make sure to find the casing markings and line them up for the most part (SEE 29-30). Note: Before doing the next step make sure to wear gloves as the magnets inside the motor are very strong and you could pinch your hand. 25. Now that the motor is all assembled its time to load it into the wheel drive assembly. Before you load it in, mark with a black marker where the main motor bolt holes go on the outside rim of the wheel. This helps you locate the bolt holes later as when loading in the motor you can no longer see the holes (SEE 34). Note: Make sure your positive and negative terminals are the same as before. 24. With gloves on (SEE Note Above) slowly lower the casing over the motor. The magnets will grab on very fast. Slide the casing down over the motor (SEE 31) and make sure that the casing markings are lined up (SEE 32). If they aren t, turn the casing to re-align them. Once they are, tape the case in place (SEE 33). 7 of 10
26. Once the rim of the wheel is marked, place the motor into the drive assembly (SEE 35). You will feel it lock in and you will notice that the back of the motor will stick out of the other end of the assembly (SEE 36). 8 of 10 27. With the motor all the way in place, now you can install the long bolts to attach the motor onto the drive assembly (SEE 37). In order to find these holes, use your black markings on the inner wheel rim. Once you get one slightly threaded, do the same for the other one. You want to tighten them both at about the same speed so that the motor sits level onto the drive assembly. 28. Once the motor is completely tightened, you can remove the tape that was holding the casing in place. Turn the motor around and re-install the crescent motor key into the back of the motor. Once that is in place, also reinstall the star knob on top of the key (SEE Steps 8-10). 29. Now with the key and star knob fastened in place, we can install the parking brake. Before installing, make sure that the inner ring as the ability to move around (SEE 38). 30. If the inner ring moves, skip this. Otherwise you need to disengage the parking brake by pulling one or the other way on the lever (SEE 39).
31. Refer back to Steps 6 and 7 on the rest of the parking break install. You might need to move the parking brake around a little bit for the star knob to fit inside of the star inner ring in the brake. Install the four bolts as well as the four screws for the parking brake cover and your motor has been successfully upgraded to a 2HP motor. 32. Install the drive back onto the machine the same way you took it off. Tighten the bolts on as much as you can before you lower the machine down onto the ground. You want to tighten them all at the same rate so that the drive sits square and flat on the drive plate. Reattach the positive and negative terminal connectors for the drive. 33. Lower the machine all the way onto the ground and now that there is weight on the tire, it won t move as much while you try to tighten it as much as possible. Your upgraded drive is now installed. 34. Remove your hopper and flip it over (SEE 40). We are going to be removing and installing a new seal on the bottom of the hopper. Using a 3/8 socket or wrench, remove all of the nuts and bolts and replace the curtain #349-5710 with the #8-571L 1/32 Thick seal (SEE 41). If You Ordered #349-642 (Carpet Sweeping Package) All That Is Left To Do Is To Install The Broom #8-401NN And Reattach the batteries. You Do Not Need To Continue With This Guide. If You Ordered #349-641 (Artificial Turf Grooming Package) Continue On With This Install Guide. 9 of 10
35. Remove the Left Hand Side Door Curtain #349-9509 (SEE 42). Remove the Inner Side Wiper #349-5750 behind the Right Hand Side Door (SEE 43). Both can be removed with a 3/8 socket or wrench. 36. Find the Vertical Main Broom Curtain #349-1165 (SEE 44-46; 45 is view from directly in back of the machine) and loosen all of the nuts. Normally this curtain is set as see in PICTURE 45, with the curtain being as low as it can go. We want to loosen the nuts and bolts and move it up all the way it can go and retighten all of the nuts and bolts. 37. All that is left to do is to replace the current broom with the Carpet Broom 8-401NN. Then reattach the batteries. 10 of 10