Toro 131-2814 Installation Instructions

FormNo.3395-583RevA

ExhaustKit

RT1200TractionUnit

ModelNo.131-2814

InstallationInstructions

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

Installation

1

PreparingtoInstallthe
ExhaustKit

NoPartsRequired

Procedure

1.Parkthemachineonalevelsurface.

2.Lowerallattachments,stoptheengine,andremovethe
keyfromtheKEYSWITCH.

3.Removetheright-sidepanel;refertoOperator’sManual
forthemachine.

4.Allowtheexhaustsystemtocoolcompletely.

2

Note:Thebatterycoverislocatedbetweenthe

operatorseatandtherearROPSbulkhead.

Figure1

1.Operatorseat4.Flange-headbolts(5/16x
1inch)

2.Finger-pullcover5.Nutclip

3.Hole(batterycover)6.ROPSbulkhead

RemovingtheRight-Cowl
Panel

NoPartsRequired

DisconnectingtheBattery

1.RotatetheBATTERY-DISCONNECTswitchtotheOff
position;refertoOperator’ sManualforthemachine.

2.Removethe2nger-pullcoversfromtheholesinthe
batterycover(Figure1).

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Registeratwww.T oro.com.

3.Removethe4ange-headbolts(5/16x1inch)that
securethebatterycovertotheROPSplatform(Figure

1).

4.Usingthengerpulls,liftthebatterycoverupto
removeitfromtheROPSplatform(Figure1).

5.Removethelock-washernut(3/8inch)securingthe
negative-batterycableandringterminaltothenegative
studofthebatteryandremovethecablesfromthe
battery(Figure2).

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3395-583*A

2.Atthebattery-disconnectswitch,removethescrewthat
securestheknobtotheshaftoftheswitch(Figure4).

Figure2

1.Positive-batterycable

2.Negative-batterycable

3.Ringterminal

4.Lock-washernut(3/8inch)

5.Negativestud(battery)

6.Positivestud(battery)

6.Movebacktheinsulatorbootandremovethe
lock-washernut(3/8inch)securingthepositive-battery
cabletothepositivestudofthebatteryandremovethe
cablefromthebattery(Figure2).

DisconnectingtheBattery-Disconnect
Switch

1.Attheinboardsideofthejumppost,movebackthe
insulatorboot,removethenut,andremovethecable
formthethreadedstud(Figure3).

Figure4

1.Right-cowlpanel4.Jamnut

2.Shaft(battery-disconnect
switch)

3.Lockwasher

5.Knob

6.Screw

3.Removethejamnutandlockwasherthatsecurethe
disconnectswitchtotheright-cowlpanel(Figure4).

4.Pushtheshaftofthebattery-disconnectswitch
rearwardtoseparatetheswitchfromthecowlpanel
(Figure4).

Figure3

1.Jumppost

2.Right-cowlpanel5.Insulatorboot

3.Threadedstud6.Locknut

4.Cableterminal

2

RemovingtheSide-CowlPanel

1.Removetheange-headbolt(12x40mm)thatsecures
theright-cowlpaneltotheROPS-mountingplate
(Figure5).

Figure6

Figure5

1.Flange-headbolt(12
x40mm)—upper
ROPS-mountingplate

2.Right-cowlpanel

3.Clamp(hydraulic-tank
breather)

4.Flange-headbolt(8x35
mm)—rewall

2.Removetheange-headbolt(8x35mm)thatsecures
theclampforthehydraulic-tankbreatherandthe
right-cowlpaneltotherewall(Figure5)

3.Removetheright-cowlpanelfromthemachine(Figure

6).

Note:Rotatethepanelasneededtocleartheexhaust
systemcomponents.

3

3

RemovingtheExhaustSystem

NoPartsRequired

RemovingtheMuferandHeatShield

Note:Exhaustsystemweight:approximately39.5kg(88

lb).

1.Supporttheexhaustsystemwithliftingequipment
(Figure7).

Figure8

1.Flangenut4.Turbocharger-exhaust
pipe

2.Guillotineclamp5.Muferinletpipe

3.Bandclamp

3.Removethe4angelocknuts(8mm),4bolts(8x
120mm),andrearmountingplatethatsecurethe
exhaust-systemmounttothefrontrightROPStube
(Figure9).

Note:Retainthelocknuts,bolts,andmountingplate
forinstallationinAssemblingtheMufertothe

TurbochargerOutletPipe(page7).

Figure7

2.Removethebandclampandthelowerguillotineclamp
thatsecuresthemufertotheturbocharger-exhaust
pipe(Figure8).

Note:RetaintheclampsforinstallationinInstalling

theBellows-AlignmentJig(page5)andInstallingthe
GuillotineClampandtheBandClamp(page8).

Figure9

1.Bolts(8x120mm)

2.Rearmountingplate

3.ROPStube

4.Separatethemuferfromtheturbocharger-exhaust
pipeandremovethemuferfromthemachine(Figure

10).

Note:Donotremovetheheatshieldfromthemufer.

4.Exhaust-systemmount

5.Flangelocknuts(8mm)

4

Figure10

5.Removetheangeclampthatsecurestheangeofthe
turbocharger-exhaustpipetotheoutletangeofthe
turbochargerandremovetheexhaustpipefromthe
machine(Figure11).

Note:Retaintheangeclampforinstallation
inInstallingtheTurbocharger-ExhaustPipeand

Pipe-AlignmentJig(page6);discardtheold

turbocharger-exhaustpipe.

4

Preparingthe
Turbocharger-ExhaustPipe

NoPartsRequired

PreparingtheMufer

1.Cleantheexteriorsurfaceoftheinletpipeforthe
mufer(Figure12).

Figure12

1.Flange
(turbocharger-exhaust
pipe)

2.Nut(angeclamp)

Figure11

1.Inletpipe(mufer)

2.Applyalightcoatofhigh-temperature,anti-galling
compoundtotheexteriorsurfaceofthemufer-inlet
pipe.

5

Installingthe
Turbocharger-ExhaustPipe

Partsneededforthisprocedure:

1Bellows-alignmentjig

1Turbocharger-exhaustpipe

3.Flange(turbocharger
outlet)

1Pipe-alignmentjig

InstallingtheBellows-AlignmentJig

1.Alignthebellows-alignmentjigtothenew
turbocharger-exhaustpipewiththeshorttabofthejig
belowthebellows(Figure13).

5

Figure13

1.Guillotineclamp5.Leftleg(bellows-alignment

2.Flangenut

3.Bellows
(turbocharger-exhaust
pipe)

4.Insideradius
(turbocharger-exhaust
pipe)

jig)

6.Shorttab
(bellows-alignmentjig)

7.Rightleg
(bellows-alignmentjig)

2.Assembletheguillotineclampthatyouremovedinstep

2ofRemovingtheMuferandHeatShield(page4)to

thebellows-alignmentjig(Figure13).

3.Aligntheleftlegofthejigtotheoutsideradiusofthe
bendinthepipeandtherightlegtotheinsideradius
ofthebendasshowninFigure13.

4.Tightentheangenutsoftheguillotineclampto19
to25N-m(14to18ft-lb).

InstallingtheTurbocharger-Exhaust
PipeandPipe-AlignmentJig

Figure14

1.Turbocharger-exhaust
pipe(withthebellowjig
installed)

2.Flangeclamp

3.Turbocharger-outletange

2.Loosenthe2ange-headbolts(10x20mm)that
securetheupper-rearheatshieldtothestandoffsofthe
exhaustmanifold(AofFigure15).

Note:Youwillhavetoloosentheboltssothatyou
have5mm(3/16)ormoreclearancebetweenthehead
oftheboltandtheheatshield.

1.Assemblethenewturbocharger-exhaustpipetothe
outletangeoftheturbochargerwiththeangeclamp
thatyouremovedinstep5ofRemovingtheMufer

andHeatShield(page4)andtightentheangenutonly

enoughtokeepthepipealignedtotheturbocharger
(Figure14).

6

6

InstallingtheMuferandHeat
Shield

Partsneededforthisprocedure:

3

Shim1.5mm(0.06inch)

1

Shim0.8mm(0.03inch)

AssemblingtheMufertothe
TurbochargerOutletPipe

1.Alignthebandclamparoundtheturbocharger-exhaust
pipe

2.Aligntheinletpipeofthemuferwiththe
turbocharger-exhaustpipe(Figure16).

Note:Ensurethatthealignmentpinsofthe
muferinletpipearealignedwiththeslotsinthe
turbocharger-exhaustpipeange.

Figure15

1.Turbocharger-exhaust
pipe

2.Flange-headbolts(10x
20mm)

3.Flangeclamp

4.Upper-rearheatshield

3.Assemblethepipe-alignmentjigontotheheatshield
andundertheange-headbolts(AofFigure15)and
tightentheboltsto17to21N-m(47to57ft-lb).

Note:Ensurethatthealignmentjigispushedinward
sothattheboltsarefullyseatedintheslotsofthejig.

4.Rotatetheexhaustpipesothatthesurfaceofthepipe
isushtothesmallangeofthepipe-alignmentjig
(BofFigure15).

Note:Thesmallangeofthepipe-alignmentjig
shouldalignbetweenthe2legsofthebellows-alignment
jig.Ifthebracketsarenotaligned,loosentheguillotine
clamp,positionthebellowsjig,andtightentheange
nutsoftheguillotineclampto19to25N-m(14to
18ft-lb).

5.Tightenthenutoftheangeclampsecurely.

5.Pipe-alignmentjig

6.Standoff(exhaust
manifold)

7.Smallange
(pipe-alignmentjig)

8.Pipesurface
(turbocharger-exhaust
pipe)

Figure16

1.Alignmentpin(muferinlet
pipe)

2.Bandclamp

3.Inserttheinletpipeintotheexhaustpipeintotheinlet
pipeisfullyseated(Figure16)

Note:Youshouldalignthepinatthemuferinletpipe
nearthebottomoftheslotintheturbocharger-exhaust
pipe.

Note:Donottwistthemuferwhileassemblingit
totheturbocharger-exhaustpipeoryoumaydamage
thebellows.

3.Slot
(turbocharger-exhaust
pipeange)

7

4.Aligntheexhaust-systemmounttothefront,right
ROPStube(Figure17).

Figure17

InstallingtheGuillotineClampandthe
BandClamp

1.Removethe2ange-headboltsthatsecure
theguillotineclamp,bellows-alignmentjig,and
turbocharger-exhaustpipe,andremovethejig(Figure

18).

1.Rearmountingplate

2.Flange-headbolts(8x120
mm)

3.ROPStube7.Shim1.5mm(0.06inch)

4.Exhaust-systemmount

5.Flangelocknut(8mm)

6.Shim0.8mm(0.03inch)

5.Looselyassembletherearmountingplatetotheto
theexhaust-systemmount(Figure17)withthe4
ange-headbolts(8x120mm)and4angelocknuts
(8mm)thatyouremovedinstep3of3Removingthe

ExhaustSystem(page4).

6.Checkthegapbetweentheexhaust-systemmountand
theROPStube(Figure17).

Note:Ifneeded,addshimsbetweenthe
exhaust-systemmountandtheROPStubetomaintain
theaxialalignmentbetweenthemuferinletpipeand
theturbocharger-exhaustpipe.

7.Torquetheange-headboltsandangelocknutsto17
to21N-m(23to29ft-lb).

Figure18

1.Bellows-alignmentjig3.Bandclamp

2.Guillotineclamp

4.Turbocharger-exhaust
pipe

2.Assemblethebandclampjustbelowthealignmentpin
ofthemuferinletpipe(Figure16andFigure18).

3.Assembletheguillotineclampbetweenthealignment
pinandtheendoftheturbocharger-exhaustpipe
(Figure18).

4.Tightentheangenutsoftheguillotineclampand
tightentheboltandnutofthebandclamp.

5.Loosenthe2ange-headboltssecuringthe
pipe-alignmentjigtotheheatshieldandremovethe
alignmentjig(Figure19).

8

Figure20

Figure19

1.Flange-headbolt2.Pipe-alignmentjig

6.Torquetheange-headboltsto34to42N-m(47to
57ft-lb).

7.Lookattheturbocharger-exhaustpipefromtheside
andconrmthatthebellowsisstraight.

Note:Ifthebellowsisnotalignedstraight,perform
thefollowing:

A.Loosentheange-headboltsandangelocknuts

thatsecuretheexhaust-systemmounttothe
ROPStube(Figure17).

B.Addorremoveshimstotheexhaust-system

mountasneededtoalignthebellows;refertostep

6inAssemblingtheMufertotheTurbocharger
OutletPipe(page7).

C.Torquetheange-headboltsandangelocknuts

fortheexhaust-systemmountto17to21N-m
(23to29ft-lb).

1.Flange-headbolts(6x16
mm)

2.Clipnut(6mm)

3.Flange-headbolts(6x30
mm)

4.Muferstrap

5.Heatshield

B.Loosentheange-headbolts(6x30mm)that

securethemuferstrapstotheexhaust-system
mount(Figure20).

C.Loosenthe2ange-headbolts(1/2x1inch)

andserratedangenuts(1/2inch)thatsecure
thelower-mufersupporttotheexhaust-system
mount(Figure21).

8.Lookattheturbocharger-exhaustpipefromthefront
andconrmthatthebellowsisstraight.

Note:Ifthebellowsisnotalignedstraight,perform
thefollowing:

A.Removethe6ange-headbolts(6x16mm)that

securetheheatshieldtotheexhaust-systemmount
andremovetheheatshield(Figure20).

9

Figure21

1.Exhaust-systemmount

2.Flange-headbolts(1/2
x1inch)—lowermufer
support

D.Movethemuferleftorrighttoalignthebellows

(Figure21).

E.Tightenthe2ange-headbolts(1/2x1inch)

andserratedangenuts(1/2inch)thatsecure
thelower-mufersupporttotheexhaust-system
mountto91to113N-m(67to83ft-lb).

F.Tightentheange-headbolts(6x30mm)that

securethemuferstrapsto972to1198N-cm
(86to106in-lb).

G.Assembletheheatshieldtoexhaust-systemmount

withthe6ange-headbolts(6x16mm)and
torquetheboltsto972to1198N-cm(86to106
in-lb).

3.Lower-mufersupport

4.Serratedangenuts(1/2
inch)

7

InstallingtheRightSideCowl
Panel

NoPartsRequired

InstallingtheCowlPanel

1.Aligntheholesintherightside-cowlpanelwiththe
holesintheROPSplateandtherewall;refertoFigure

5inRemovingtheSide-CowlPanel(page3).

2.AssemblethecowlpaneltotheROPSplatewiththe
ange-headbolt(12x40mm)thatyouremovedin
step1ofRemovingtheSide-CowlPanel(page3).

3.Assembletheclampforthehydraulic-tankbreatherand
side-cowlpaneltotherewallwiththeange-headbolt
(8x35mm)thatyouremovedinstep2inRemoving

theSide-CowlPanel(page3).

Note:Ensurethatthebreatherisverticallyaligned.

4.Tightenthe12mmboltattheROPSplateto80to100
N-cm(59to73ft-lb)andtightenthe10mmboltatthe
rewallto44to57N-cm(34to42ft-lb).

AssemblingtheBattery-Disconnect
Switch

1.Assembletheelectricalcablethatyouremovedinstep

1ofDisconnectingtheBattery-DisconnectSwitch
(page2)ontothreadedstudofthejumppost(Figure

3)withthelocknut.

2.Aligntheelectricalcableatthestudofthejumppost
upward,tightenthelocknut,andaligntheinsulator
bootoverthenutandstud.

3.Assemblethebattery-disconnectswitchintothe
openingatthemountingangeoftherightside-cowl
panel(Figure4)withthelockwasherandjamnutthat
youremovedinstepof3andtightenthejamnut.

Note:Ensurethatthealignmentpinofthedisconnect
switchisalignedwiththeslotinthemountingange
ofthepanelandtheswitchisushtotheange.

4.Installtheknobontotheshaftofthedisconnect
switchwiththescrewthatyouremovedinstep2of

DisconnectingtheBattery-DisconnectSwitch(page2).

10

ConnectingtheBattery

1.Assemblethepositive-batterycableintothepositive
studofthebattery(Figure2)withthelock-washernut
(3/8inch)thatyouremovedinstep6ofDisconnecting

theBattery(page1).

2.Torquethelock-washernutto(10to15ft-lb)andalign
theinsulatorbootoverthenutandstud.

3.Assemblethenegative-batterycableintothenegative
studofthebattery(Figure2)withthelock-washernut
(3/8inch)thatyouremovedinstep5ofDisconnecting

theBattery(page1).

4.Aligntheholesinthebatterycoverwiththeclipnuts
atthemountingangeforthecover(Figure1).

5.Securethebatterycovertothemachinewiththe4
ange-headbolts(5/16x1inch)thatyouremovedin
step3ofDisconnectingtheBattery(page1).

6.Installthenger-pullcoverintotheholesinthebattery
cover.

8

CompletingtheInstallationof
theKit

NoPartsRequired

Procedure

1.Rotatethebattery-disconnectswitchtotheOn
position;refertoOperator’ sManualforthemachine.

2.Starttheengineandcheckforexhaustleaksatthe
turbocharger-exhaustpipeandthemufer.

Note:Repairallleaksbeforeinstallingthesidepanel.

3.Installtheright-sidepanel;refertoOperator’sManual
forthemachine.

11