Toro 131-2858 Installation Instructions

FormNo.3396-283RevA

ColdStartKit

RT1200TractionUnit

ModelNo.131-2859

InstallationInstructions

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

Installation

1

PreparingtoInstalltheCold
StartKit

NoPartsRequired

PreparingtheMachine

1.Movethemachinetoalevelsurface,shutoffthe
engine,andremovethekeyfromthekeyswitch.

2.Allowtheengineandhydraulicsystemtocool.

RemovingtheSidePanelsand
DisconnectingtheBattery

1.Pressinthebuttonportionofeachlatch—thepartof
thelatchincludingthelockcylinder(Figure1).

Figure1

1.Latchlever

2.Latchbutton

2.Liftthepanelupandawayfromthemachine(Figure2).

3.Side-panellatch

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8111LyndaleAvenueSouth
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Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3396-283*A

Figure2

Figure4

1.Latch

2.Sidepanel

3.Repeatsteps1and2forthesidepanelattheotherside
ofthemachine.

4.RotatetheBATTERYDISCONNECTswitch
counterclockwisetotheOFFposition(Figure3).

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

2.Traction-pedalassembly4.6-socketconnector

3.6-pinconnector
(traction-pedalsensor)

(machineharness)

2.Removethecabletiesecuringthetraction-pedal
harness.

3.Disconnectthe6-socketconnectorofthemachine
harnessfromthe6-pinconnectorofthetraction-pedal
sensor(Figure4).

4.Removethetraction-pedalassemblyfromthemachine
(Figure4).

RemovingtheConsolePanel

1.Removethe4ange-headbolts(5/16x1inch)that
securetheconsolepaneltotheframeoftheconsole
(Figure5).

Figure3

1.BATTERYONposition2.BATTERYOFFposition

RemovingtheTraction-PedalAssembly

Removethetraction-pedalassemblyasfollows:

1.Removethe4ange-headbolts(5/16x1inch)that
securethattraction-pedalassemblytothechassisofthe
machine(Figure4).

Figure5

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

2.Consolepanel

3.Consoleframe

2.Removetheconsolepanelfromthemachine(Figure5).

2

RemovingtheTransmissionShield

1.Removethe4angedlocknuts(1/2inch)from4
carriagebolts(1/2x1-1/2inch)thatsecurethe
transmissionshieldtotheframeofthemachine(Figure

6).

2

Assemblingthe2-Way
SolenoidValve

Partsneededforthisprocedure:

12-waysolenoidvalve

2

O-ring

2

90ºhydraulicttings

1Valve-mountplate

2

Carriagebolt(1/4x1-3/4inch)

2

Locknut(1/4inch)

2

Hose(1/4x16-1/4inch)

Procedure

1.Installthe2hydraulicttings(90°)andO-ringsinto
port1andport2ofthe2-waysolenoidvalveasshown
inFigure7.

Figure6

1.Frontofthemachine

2.Flangedlocknuts(1/2
inch)

2.Removethetransmissionshieldfromthemachine
(Figure6).

Note:Donotremovethecarriageboltsfromthe
frame.

3.Transmissionshield

4.Carriagebolts(1/2x1-1/2
inch)

Figure7

1.90ºhydraulicttings3.Port2(2-waysolenoid
valve)

2.O-ring4.Port1(2-waysolenoid
valve)

2.Assemblethe2-waysolenoidvalvetothevalve-mount
plate(Figure8)withthe2carriagebolts(1/4x1-3/4
inch)and2locknuts(1/4inch).

3

Figure8

1.90ºhydraulictting(port2)

2.Hoses(1/4x16-1/4inch)6.Locknut(1/4inch)

3.Carriagebolt(1/4x1-3/4
inch)

4.Valve-mountplate

3.Assemblethestraightttingsofthehoses(1/4x
16-1/4inch)ontothe90ºhydraulicttingsandtighten
thettingsbyhand(Figure8).

5.2-waysolenoidvalve

7.90ºhydraulictting(port1)

3

InstallingtheOriceInsertinto
theHIC-FanValve

Partsneededforthisprocedure:

1

Oriceinsert

Procedure

1.Loosenthebolt(5/16x1-1/2inch)thatsecuresthe
tubeforthefanmotorandtheclampblocks(Figure9).

Figure9

1.Frontofthemachine5.Straight-hydraulictting

2.Hydraulichose(signalport
XtoLShydraulicpump)

3.90°hydraulic
adapter—long(LS-pump
port)

4.Bolt(5/16x1-1/2inch)8.Clampblock

2.Removethetubenutforthefan-motortubeandthe
straight-hydraulicttingatportM2oftheHIC-fan
valve(Figure9).

Note:Packtheareaaroundthettingwithragsto
absorbthehydraulicuid.

3.Removethehydraulichosefromthe90ºhydraulic
adapterattheLS-pumpportoftheHIC-fanvalve
(Figure9).

4.Removethe90ºhydraulicadapterattheLS-pumpport
(Figure9).

Note:ChecktheO-ringforthe90ºhydraulicadapter,
replacetheO-ringifitisdamagedorworn

(M2port)

6.HIC-fanvalve

7.Tube(hydraulic—fan
motor)

5.ThreadtheoriceinsertintotheLS-pumpportofthe
HIC-fanvalveandtightenbyhand(Figure10).

4

Figure10

1.Frontofthemachine3.Oriceinsert

2.LS-pumpport4.90ºhydraulic
adapter—long(LS-pump
port)

6.Threadthe90ºhydraulicadapterintotheLS-pump
portoftheHIC-fanvalve(Figure10).

Note:Youwilltightenthejamnutforthe90º
hydraulicadapter,installstraight-hydraulictting,and
installthefan-motortubeinlatersteps.

Figure11

1.Frontofthemachine

2.90°swiveltting5.Hose(hydraulicreturn)

3.90°hydraulictting(T-port)

4.Flow-dividervalve

4

Installingthe2-WaySolenoid
ValveandHoses

Partsneededforthisprocedure:

2

Bolt(8x100mm)

2

Flangelocknut(8mm)

2

Washer(8mm)

2

T-tting

Assemblingthe2-WayValvetothe
Machine

1.Removethehydraulic-returnhosefromthe90°swivel
ttingthatisinstalledtothe90°hydraulicttingin
portToftheow-dividervalve(Figure11).

Note:Discardthe90°swiveltting.

2.Removetheswivelttingfromthe90°hydraulictting
inportToftheow-dividervalve(Figure11).

3.Removethe2angelocknuts(8mm),2bolts(8x90
mm),and2washersthatsecuretheow-dividervalve
totheleft,framechannelofthemachine(Figure12).

Note:Discardthebolts,nuts,andwashers.

1.Bolt(8x90mm)

2.Washer

3.Leftframechannel

5

Figure12

4.Flow-dividervalve

5.Flangelocknuts(8mm)

4.Aligntheholesinthevalve-mountplateforthe2-way
solenoidvalve,theow-dividervalve,andtheleft
framechannel(Figure13).

Figure13

1.Flangelocknuts(8mm)4.Leftframechannel

2.Valve-mountplate(2-way
solenoidvalve)

3.Flow-dividervalve

5.Washer

6.Bolt(8x100mm)

InstallingtheSignalPort-XHose

1.AssembletheT-ttingontothe90ºhydraulicadapter
attheLS-pumpportoftheHIC-fanvalve(Figure14).

5.Assemblethemountplateand2-wayvalvetotheframe
with2bolts(8x100mm),2angelocknuts(8mm),
and2washersfromthekit(Figure13).

6.Torquetheboltsandnutsto23to29N-m(17to21
ft-lb).

Figure14

1.Frontofthemachine4.90ºhydraulicadapter

2.Hydraulichose(from
signalportXoftheLS
hydraulicpump)

3.T-tting

(LS-pumpportofthe
HIC-fanvalve)

5.HIC-fanvalve

2.InstallthehydraulichosefromsignalportXoftheLS
hydraulicpumptotheT-ttingattheHIC-fanvalve
asshownin(Figure14).

Note:Ifthe90°ttingofthehydraulichosedoesnot
alignwiththeT-ttingattheHIC-fanvalve,loosenthe
swivelttingatthe90°ttinginsignalportXofthe
LShydraulicpump(Figure15).

6

1.Swiveltting(hydraulic
hose—signalportX)

Figure15

2.LShydraulicpump

Figure16

1.Frontofthemachine3.HIC-fanvalve

2.Hoses(1/4x16-1/4
inch)—Port1ofthe2-way
solenoidvalve

4.T-tting

InstallingtheLS-PumpHose

1.Installthehosethatisconnectedtothe90ºhydraulic
ttinginport1ofthe2-wayvalvetotheTttingat
LS-pumpportoftheHIC-fanvalve(Figure16).

2.Torquethehydraulicttings(Figure16)asspeciedin
thefollowingtablebelow:

Jamnutforthe90ºhydraulic
adapter—LS-pumpportofthe

HIC-fanvalve(Figure10)

T-tting—swivelnut(Figure

16)

Hydraulichose—fromsignal
portXoftheLShydraulic
pump(Figure14)

Hydraulichose—fromthe
90ºhydraulicttingatport1of
the2-wayvalve(Figure8)

47to58N-m(35to43ft-lb)

20to28N-m(15to21ft-lb)

20to28N-m(15to21ft-lb)

20to28N-m(15to21ft-lb)

7

ConnectingtheFan-MotorTube

ConnectingtheHydraulicReturnHose

1.Installthestraight-hydraulicttingthatyouremoved
instep2of3InstallingtheOriceInsertintothe

HIC-FanValve(page4)andtorquethettingto47

to58N-m(35to43ft-lb).

1.AssembleaT-ttingontothe90°hydraulicttingin
portToftheow-dividervalve(Figure19).

Figure17

1.Frontofthemachine3.Straight-hydraulictting

2.LS-pumpport

4.Fan-motortube

2.Installthefan-motortubetothestraight-hydraulic
tting(Figure17)andtorquetheswivelnutforthe
tubeto45to55N-m(33to41ft-lb).

3.Alignthe2fan-motortubestotheclampblocks
(Figure18)andtightenthebolt(5/16x1-1/2inch)to
1978to2542N-cm(175to225in-lb).

Figure18

Figure19

1.Hoses(1/4x16-1/4
inch)—fromport2of
2-waysolenoidvalve

2.2-waysolenoidvalve6.Hydraulic-returnhose

3.Frontofthemachine

4.90°hydraulictting(port
T)

5.T-tting

7.Flow-dividervalve

2.Assemblethehydraulic-returnhosetotheT-ttingas
showninFigure19.

3.Assemblethehosefromthe90°hydraulicttingin
port2ofthe2-waysolenoidvalveontotheT-ttingas
showninFigure19.

4.TorquetheswivelnutoftheT-ttingto20to28N-m
(15to21ft-lb),andthehydraulic-returnhoseandthe
port2hoseofthe2-waysolenoidvalveto20to28
N-m(15to21ft-lb).

1.Fan-motortubes

2.Bolt(5/16x1-1/2inch

3.Clampblock

8

5

InstallingtheWiringHarness

Partsneededforthisprocedure:

1Timerrelayandmountingtab

1

Self-adhesivecover

1

Wiringharness(cold-startkit)

2

Flangeheadbolt(#10–32x3./4inch)

2

Flangelocknut(#10–32)

PreparingtheTimerRelay

1.Insertthenarrowlegofthemountingtabintotheslot
inthecaseofthetimerrelaywiththeoffsetlegaway
fromthecase(Figure20).

2.Atthetopofthetimerrelay ,setswitch1totheON
(up)position(Figure20).

RemovingtheDashPanel

1.Disconnectthe23-pinconnectorofthedashwiring
harnessfromthe23-socketconnectorforthemachine
wiringharness(Figure21)

Figure21

1.23-pinconnector(dash
wiringharness)

2.23-socketconnector
(machinewiringharness)

Figure20

1.Clockwise(untilyoufeel
lightcontact)

2.Counterclockwise30°4.Mountingtab(part

3.Self-adhesivecover

includedwiththetimer
relay)

2.Removethe4angebolts(8x30mm)and2ange
locknuts(8mm)thatsecurethedashassemblytothe
frameoftheconsole(Figure22).

3.Setswitch2totheOFF(down)position(Figure20).

4.Rotatetheslotofthetimercontrolcounterclockwise
untilyoufeellightcontact(Figure20).

5.Rotatetheslotofthetimercontrolclockwise30°
(Figure20).

1.Flangebolt(8x30mm)

2.Flangelocknut(8mm)

9

Figure22

3.Dashassembly

3.Removethedashfromtheconsole(Figure22).

ConnectingtheWiringHarnessofthe
Cold-StartKittotheDashPanel

1.Atthebackofthedash,removethe6-socketconnector
ofthedashharnessfromthebladeterminalofthe
starterswitch(Figure23).

2.Attheauxiliary-powerport,removethesocketterminal
fortheblack(ground)wireofthedashharness(Figure

23).

Figure24

Figure23

1.6-socketconnector(dash
harness)

2.Starterswitch

3.Socketterminal—black
(ground)wire

4.Bladeterminal
(auxiliary-powerport)

3.Connectthesocketterminalfortheblackwireofthe
dashharnessontothepiggybackterminalofthewiring
harnessforthecold-startkit(Figure24).

1.Bluewire(dashharness)3.Piggybackterminal(wiring

2.Socketterminal—black
(ground)wire(dash
harness)

harnessforthecold-start
kit)

4.Bladeterminal
(auxiliary-powerport)

4.Connectthepiggybackterminalofthewiringharness
forthecold-startkitontotheopenbladeterminalof
theauxiliary-powerport(Figure24).

5.Connectthe6-socketconnectorofthewiringharness
forthecold-startkitontotheconnectorforthestarter
switch(Figure25).

Figure25

1.6-pinconnector(wiring
harnessforthecold-start
kit)

2.6-socketconnector(dash
harness)

3.Starter-switchconnector

4.6-socketconnector(wiring
harnessforthecold-start
kit)

6.Connectthe6-pinconnectorofthewiringharnessfor
thecold-startkitintothe6-socketconnectorofthe
dashharness(Figure25).

10

RoutingtheWiringHarnessand

G030030

InstallingtheDashPanel

1.Routethelegsofthewiringharnesswiththe2-socket
connectorand5-socketconnectordownthrough
theconsoleandlongthemainwiringharnessofthe
machine(Figure26).

4.Routethelegofthewiringharnesswiththe2-socket
connectordownthroughthegrommetoftheoor
plate(Figure27).

Figure27

Figure26

1.2-socketconnector

2.5-socketconnector4.6-pinconnector,

3.Grommet

6-socketconnector,and
uninsulatedterminal

2.Securethedashpaneltotheconsolewiththe4ange
bolts(8x30mm)and2angelocknuts(8mm)that
youremovedinstep2ofRemovingtheConsolePanel

(page2).

1.Frontofthemachine

2.Wiringharness(cold-start
kit)

3.Hydraulicpump

5.Routethelegofthewiringharnesswiththe2-socket
connectordownrearwardalongthemainwiring
harnessforthemachine(Figure27).

6.Routethelegofthewiringharnesswiththe2-socket
connectordowntothe2-wayvalve(Figure28).

3.Connectthe23-pinconnectorofthedashwiring
harnesstothe23-socketconnectorofthemachine
wiringharness;refertoFigure21inRemovingthe

DashPanel(page9).

11

Figure28

DrillingtheMountingHolesforthe
5-socketConnectorandTimerRelay

1.Attheleft,rearsideoftherewall,measurefromthe
oorplatevertically197mm(7-3/4inches)andmark
therewall(Figure30).

1.Wiringharness(cold-start
kit)

2.2-wayvalve

3.Frontofthemachine

7.Connectthe2-socketconnectorofthewiringharness
forthecold-startkitontothe2-pinconnectorofthe
2-wayvalve.

Figure30

1.Innersideofconsoleto
centerofhole103mm
(4-1/16inches)

2.5mm(3/16inch)drillbit7.Flange-headbolt(#10–32

3.Floorplatetocenter
ofhole197mm(7-3/4
inches)

4.Frontofthemachine9.Hole(rewall)

5.Wiringlegwiththe
6-pinconnector,
6-socketconnector,and
uninsulatedterminal

6.Wiringlegwiththe
2-socketconnector

x3/4inch)

8.5-socketconnector

1.2-socketconnector(wiring
harnessforthecold-start
kit)

Figure29

2.2-pinconnector(2-way
valve)

2.Fromtheinboardsideoftheleft-consolepanel,
measurehorizontally103mm(4-1/16inches)and
marktherewall(Figure30).

3.Centerpunchtherewallattheintersectionofthe2
marks.

12

4.Atthecenterpunchmark,drilla5mm(3/16inch)
holethroughtherewall(Figure30).

Important:Coverthefuseblocktopreventmetal
shavingsfromtouchingtheblock.

5.Assemblethe5-socketconnectortotherewall(Figure

30)withaange-headbolt(#10-32x3/4inch).

6.Assemblethetimerrelaytothe5-socketconnector
(Figure31).

Figure31

1.5-socketconnector2.Timerrelay

8.Removethetimerrelayfromthe5-socketconnector,
removethe5-socketconnectorfromtherewall,and
centerpunchthemarkthatyoumadeinstep7.

9.Atthecenterpunchmark,drilla5mm(3/16inch)
holethroughtherewall(Figure32).

Important:Coverthefuseblockand5-socket
connectortopreventmetalshavingsfromtouching
theblockandconnector.

Assemblingthe5-socketConnector
andTimerRelaytotheFirewall

1.Securethe5-socketconnectortothelowerholeinthe
rewallwithaange-headbolt(#10-32x3/4inch)
andangelocknut(#10–32);refertoBinFigure30
andFigure33

7.Aligntherelayand5-socketconnectorverticallyand
marktheholeinthemountingtabforthetimerrelay
ontotherewall(AofFigure32).

Figure33

1.Frontofthemachine3.Flange-headbolt(#10-32

2.Locknut(#10-32)

x3/4inch)

4.Firewall

2.Assemblethetimerrelaytothe5-socketconnector
(Figure31).

1.Pencil

2.Mountingtab(timerrelay)

Figure32

3.5mm(3/16inch)drillbit

13

Figure34

InstallingtheSidePanels

1.RotatethebatterydisconnectswitchtotheOn
position;refertoFigure3inRemovingtheSidePanels

andDisconnectingtheBattery(page1).

2.Alignthesidepanelwiththemachineframe.

3.Alignthemountingboltatthetopofthesidepanel
withtheholeinthesupportangeofthehoodpanel
(Figure35).

1.Flange-headbolt(#10-32
x3/4inch)

3.Securethemountingtabforthetimerrelaytothe
upperholeintherewallwithaange-headbolt
(#10-32x3/4inch)andangelocknut(#10–32);refer
toFigure33andFigure34.

2.Mountingtab(timerrelay)

6

FinishingtheInstallationthe
ColdStartKit

NoPartsRequired

InstallingtheTransmissionShield

1.Aligntheholesintheangeofthetransmissionshield
withthe4carriageboltsintheframeofthemachine
thatyoudisassembledinstep1ofRemovingthe

TransmissionShield(page3).

Figure35

4.Applylightinwardpressureagainstthepanelat1of
thelatches.

5.Setthelatchbypushinginthelatchlever;refertoFigure

1inRemovingtheSidePanelsandDisconnectingthe
Battery(page1).

6.Repeatsteps4and5attheotherlatch.

7.Repeatsteps2through6forthesidepanelattheother
sideofthemachine.

2.Securethetransmissionshieldtotheframeofthe
machinewiththe4angelocknutsthatyouremoved
in1ofRemovingtheTransmissionShield(page3).

3.Torquethenutsto91to113N-m(67to83ft-lb).

InstallingtheTraction-pedalAssembly

1.Connectthe6-socketconnectorofthemachineharness
tothe6-pinconnectorofthetraction-pedalsensor;
refertoFigure4inRemovingtheTraction-Pedal

Assembly(page2).

2.Aligntheholesintheplateofthetraction-pedal
assemblywiththeholesinthechassisofthemachine;
(Figure4).

3.Securethetraction-pedalassemblytothechassisof
themachinewiththe4hex-angedheadbolts(6x25
mm);refertoFigure4.

7

CheckingtheOperationofthe
Machine

NoPartsRequired

CheckingtheOperationoftheKit

Note:Youwillneedanotherpersontocheckthefunctionof

themachine.

1.Starttheengine.

Note:Lettheenginerunfor1to2minutes.

14

2.Ensurethatthefanforthecoolingsystemstarts
running5secondsaftertheenginestarts.

ServicingtheHydraulicSystem

•Ifthefanstartsearlierthat5secondsafterthe

enginestarts,rotatetheslotofthetimerclockwise
toincreasethetimerdelay(Figure36).

Figure36

1.Clockwise—moretimer
delay

2.Counterclockwise—less
timerdelay

3.Self-adhesivecover

WARNING

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

Ifhydraulicuidisinjectedintotheskinitmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththistypeofinjury.Gangrenemay
resultifthisisnotdone.

•Keepbodyandhandsawayfrompin-holeleaks
ornozzlesthatejecthigh-pressurehydraulic
uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic
system.

•Makesurethatallhydraulic-uidhosesand
linesareingoodconditionandthatallhydraulic
connectionsandttingsaretightbefore
applyingpressuretothehydraulicsystem.

Hydraulic-uidspecication:T oroPremiumAll-season

HydraulicFluid

IfToroPremiumAll-seasonHydraulicFluidisnotavailable,
youmayuseMobilDTE15MSpecial(MobilDTE15Muid
withspecialantiwearadditivepackage).

1.Checkthemachineforhydraulicleaks.

•Ifthefanstartslaterthat5secondsaftertheengine

starts,rotatetheslotofthetimercontrolclockwise
todecreasethetimerdelay(Figure36).

3.Ensurethescreenofthecommandcenterisdisplaying
themachineandengineinformation.

4.Shutofftheengineandremovethekeyfromthekey
switch.

5.Removethereleasebackingfromtheself-adhesive
cover,alignitovertheswitchesandtimercontrol,and
pressthecovertothecaseofthetimerrelay(Figure36).

Note:Repairallhydraulicleaksbeforeoperatingthe
machine.

2.Checkthelevelofthehydraulicuidinthetankand
addthespeciedhydraulicuidasneeded;refertothe
Operator’sManualforthemachine.

Note:Youshouldseethatthehydraulic-uidlevelis
atthemidpointofthesightglassatthesideofthetank.

InstallingtheConsolePanel

1.Applymedium-gradethread-lockingcompoundtothe
4ange-headbolts(5/16x1inch)thatyouremovedin
step1ofRemovingtheConsolePanel(page2).

2.Aligntheholesintheconsolepanelwiththeholesin
theframeoftheconsole;refertoFigure5inRemoving

theConsolePanel(page2).

3.Assemblethepaneltotheconsolewiththe4
ange-headbolts(5/16x1inch).

4.Torquetheboltsto1978to2542N-cm(175to225
in-lb).

15