Toro 131-2883 Installation Instructions

InternationalShipKit

G009027

1

2

RT1200Trencher

ModelNo.131-2883

Introduction

ReadtheOperator’sManualforyourmachineandthe
attachmentscarefullytolearnhowtooperateandmaintain
yourproductproperlyandtoavoidinjuryandproduct
damage.Youareresponsibleforoperatingtheproduct
properlyandsafely.

YoumaycontactTorodirectlyatwww.Toro.comforproduct
safetyandoperationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedToroServiceDealer
orToroCustomerServiceandhavethemodelandserial
numbersofyourproductready.

Important:Thismachinewasmanufacturedaccording
totheappropriateregulatorystandardsineffectatthe
timeofmanufacture.Modifyingthismachineinany
waymaycauseittobeoutofcompliancewiththose
standardsandwiththeinstructionsinthis

Man ual.

onlybyanAuthorizedToroServiceDealer.

Modicationstothismachineshouldbemade

Operator’ s

FormNo.3396-716RevA

InstallationInstructions

CAUTION

Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.

Figure2

1.Wearsafetyglasses.

2.Wearhearingprotection.

Contents

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure1),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Figure1

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Introduction..................................................................1

ConguringtheMachineforShipping...............................2

PreparingtheMachine.............................................2

PreparingtoRemovetheROPS.................................2

RemovingtheROPS................................................7

AssemblingtheMachineforShipping........................9

PreparingtoMovetheMachine................................11

PreparingtheMachinefortheCustomer...........................12

PreparingtoMovetheMachine................................12

PreparingtheMachine............................................13

RemovingtheShippingConguration

Components......................................................13

InstallingtheROPS................................................16

InstallingtheRearFendersandtheRearControl

Cover................................................................18

InstallingtheDashPanelandConsole

Panel.................................................................19

InstallingtheTurbocharger-ExhaustPipe..................21

InstallingtheMuferExtensionandRain

Cap...................................................................25

SwitchingntheBatteryandInstallingtheSide

Panels...............................................................25

©2015—TheT oro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3396-716*A

Conguringthe
MachineforShipping

LooseParts

Description

Shippingplate

Hearingprotector1Wearpersonalprotectiveequipment.

Quantity

1Installtheshippingplate.

PreparingtheMachine

Lifting-equipmentcapacity:408kg(900lb)minimum

1.Ensurethatthemachinetiltislevelandthetilt-lockout
pinisinstalled;refertotheOperator’sManualforthe
machine.

2.Movethemachinetoalevelsurfacethatisbelowthe
liftingequipmentwiththespeciedliftcapacity.

3.Lowerallattachments,stoptheengine,andremove
thekeyfromtheKEYSWITCH;refertotheOperator’ s
Manualforthemachine.

4.Allowtheexhaustsystemtocoolcompletely.

PreparingtoRemovethe ROPS

Use

RemovingtheSidePanelsand
DisconnectingtheBattery

1.Pressinthebuttonportionofeachlatch—thepartof
thelatchincludingthelockcylinder(Figure3).

Figure3

1.Latchlever

2.Latchbutton

2.Liftthepanelupandawayfromthemachine(Figure4).

3.Side-panellatch

Figure4

1.Latch

2

2.Sidepanel

3.Repeatsteps1and2forthesidepanelattheotherside
ofthemachine.

4.Placebothsidepanelsintotheshippingcontainer.

5.RotatetheBATTERYDISCONNECTswitch
counterclockwisetotheOFFposition(Figure5).

Figure5

2.Removetheextension,raincap,andclampfromthe
mufer(Figure6).

3.Placeextension,raincap,andclampintotheshipping
container.

RemovingtheTurbocharger-Exhaust
Pipe

1.Removethebandclampandthelowerguillotineclamp
thatsecurethemufertotheturbocharger-exhaust
pipe(Figure7).

1.BATTERYONposition2.BATTERYOFFposition

RemovingtheMuferExtensionand
RainCap

1.Loosentheclampthatsecuresthemuferextension
andraincaptotheoutletpipeofthemufer(Figure6).

Figure7

1.Guillotineclamp

2.Bandclamp4.Turbocharger-exhaust

3.Flangeclamp

pipe

2.Removetheangeclampthatsecurestheangeofthe
turbocharger-exhaustpipetotheoutletangeofthe
turbocharger(Figure7).

3.Movetheturbocharger-exhaustpipedownuntilthe
alignmentpinsofthemufer-inletpipecleartheslots
intheturbocharger-exhaustpipe(Figure8).

Important:Donotbendordamagethepleated
sectionoftheturbocharger-exhaustpipewhile
removingthepipetothemachine.

Figure6

1.Mufer-outletpipe4.Inboardofthemachine

2.Clamp5.Pivot(raincap)

3.Muferextensionandrain
cap

3

Figure8

RemovingtheConsolePanelandthe
DashPanel

RemovingtheConsolePanel

1.Removethe4ange-headbolts(5/16x1inch)that
securetheconsolepaneltotheframeoftheconsole
(Figure10).

1.Alignmentpin(mufer-inlet
pipe)

2.Slots
(turbocharger-exhaust
pipe)

4.Removetheturbocharger-exhaustpipefromthe
machine(Figure9).

Figure10

1.Consoleframe3.Flange-headbolts(5/16x
1inch)

2.Consolepanel

2.Removethepanelfromthemachine(Figure10).

RemovingtheDashPanel

1.Disconnectthe23-pinconnectorofthedashwiring
harnessfromthe23-socketconnectorforthemachine
wiringharness(Figure11)

Figure9

5.Placetheturbocharger-exhaustpipe,bandclamp,
guillotineclamp,andangeclampintotheshipping
container.

Figure11

1.23-pinconnector(dash
wiringharness)

2.23-socketconnector
(machinewiringharness)

2.Removethe4angebolts(8x30mm)and2ange
locknuts(8mm)thatsecurethedashpaneltotheframe
oftheconsole(Figure12).

4

5.Removethe6-socketconnectorofthewiringharness
forthemachinefromtheconnectorforthestarter
switch(Figure14).

Figure14

Figure12

1.Flangebolt(8x30mm)

2.Flangelocknut(8mm)

3.Dashassembly

3.Removethepiggybackterminalofthewiringharness
forthemachinefromthebladeterminalofthe
auxiliary-powerport(Figure13).

1.6-pinconnector(wiring
harnessforthemachine)

2.6-socketconnector(dash
harness)

3.Starter-switchconnector

4.6-socketconnector(wiring
harnessforthemachine)

6.Removethe6-pinconnectorofthewiringharnessfor
themachinefromthe6-socketconnectorofthedash
harness(Figure14).

7.Carefullyremovethedashpanelfromtheconsole
(Figure12).

Note:Setasidethedashpanel,angebolts,and
locknutsforassemblyinAssemblingtheMachinefor

Shipping(page9).

Figure13

1.Bluewire(dashharness)3.Piggybackterminal(wiring

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

harnessforthemachine)

4.Bladeterminal
(auxiliary-powerport)

4.Removethesocketterminalfortheblackwireofthe
dashharnessfromthepiggybackterminalofthewiring
harnessforthemachine(Figure13)

5

RemovingtheRearControlCoverand
RearFenders

RemovingtheRearControlCover

1.Removethe6ange-headbolt(12x30mm)that
securetherearcontrolcovertotherearbulkheadof
themachine(Figure15).

Figure16

Figure15

1.Bulkhead

2.Rearcoverplate

3.Flange-headbolt(12x30
mm)

2.Removethecontrolcoverfromthemachine.

Note:Setasidethecontrolcoverandange-head
boltsforassemblyinAssemblingtheMachinefor

Shipping(page9).

RemovingtheRearFenders

1.Removethe5ange-headbolts(10x30mm)and2
reinforcementplates(withtheattachednutclips)that
securethefendertothechassisofthemachine(Figure

16).

Note:Haveanotherpersonsupporttherearfender
whileyouremovethemountinghardware.

1.Flange-headbolts(10x
30mm)

2.Curvedreinforcement
plateandclipnuts

3.Fendermount

4.Straightreinforcement
plateandclipnuts

5.Fender

6.Frontofthemachine

2.Removethefenderfromthemachine.

3.Repeatsteps1and2fortherearfenderattheother
sideofthemachine.

Note:Setasidethefenders,reinforcementplates
(withtheattachedclipnuts),andange-headbolts
forassemblyinAssemblingtheMachineforShipping

(page9).

6

DisconnectingtheAuxiliary-Control
PanelWiring

1.Attheauxiliary-controlpanel,removethe10-socket
connectorattheendofthemain-wiringharnessfrom
the10-pinconnectorforthetiltswitch(Figure17).

Figure18

2.Removethe2ange-headbolts(12x40mm)that
securethehoodplate,ROPS-mountingplate,leftcowl
panel,andrightcowlpanel(Figure19)

Figure17

1.Plugs3.Auxiliary-controlpanel

2.Tiltswitch4.10-socketconnectors
(main-wiringharness)

2.Removethe7remaining10-socketconnectorsofthe
main-wiringharnessfromthe7rocker-switchplugsin
theauxiliary-controlpanel(Figure17).

RemovingtheROPS

Lifting-equipmentcapacity:408kg(900lb)minimum

AdditionalEquipment:hand-operatedwinch

1.SupporttheROPSframeandmuferwithlifting
equipmenthavingaminimumliftcapacityof408kg
(900lb)asshowninFigure18.

Note:TheROPSframeandmuferisweighted
towardtherear.YouwillneedtotilttheROPSframe
andmufertoremovetheROPS.Wheneverpossible,
use2piecesofliftingequipmenttolifttheROPSframe
andmufer.

Figure19

1.Leftcowlpanel3.Hood-plateange

2.Flange-headbolt(12x40
mm)

4.ROPS-mountingplate

3.Removethe2ange-headbolts(16x50mm)
and2angelocknuts(16mm)thatsecurethe
ROPS-mountingplatetotheframeoftheconsole
(Figure20).

Note:Ifyouhavedifcultyremovingthebolts,
theROPSframetubesareundertension.Usea
hand-operatedwinchtopullthefrontROPStube(s)
towardthereartube(s)torelievesheeringpressure
fromthebolts.

Note:Discardthe2ange-headbolts(16x50mm)
and2angelocknuts(16mm).

7

Figure20

1.ROPS-mountingplate3.Flange-headbolts(16x
50mm)

2.Flangelocknuts(16mm)4.Consoleframe

4.AttherearframetubesfortheROPS,removethe8
ange-headbolts(16x70mm)and8angelocknuts
(16mm)thatsecuretheROPStubestothechassisof
themachine(Figure21).

Figure21

1.Flangelocknuts(16mm)3.ROPStube

2.Flange-headbolts(16x
70mm)

5.Usingtheliftingequipment,raisethebackoftheROPS
slightly.

6.Usingtheliftingequipment,movetheROPSrearward
andupuntiltheROPS-mountingplateclearsthehood
plateandcowlpanels(Figure19).

Note:PayattentiontotheROPS-mountingplateasit
separatesfromthehoodplateandcowlpanels,andas
themountingplateclearsthesteeringwheel.

7.LifttheROPSandmuferandremovetheROPSfrom
themachine(Figure22).

Note:Ifyouhavedifcultyremovingthebolts,
theROPSframetubesareundertension.Usea
hand-operatedwinchtopulltheROPStubestogether
torelievesheeringpressurefromthebolts.

Note:Discardthe8ange-headbolts(16x70mm)
and8angelocknuts(16mm).

Figure22

8.MovetheROPSandmufertotheshippingcontainer.

8

AssemblingtheMachinefor Shipping

InstallingtheShippingPlate

1.Aligntheshippingplatebetweentheangeofthehood
plate,leftcowlpanel,andrightcowlpanel(Figure23).

AssemblingtheDashPaneland
ConsolePaneltotheMachine

AssemblingtheDashPanel

1.Alignthedashpaneltotheconsole(Figure24).

Figure24

1.Dashwiringharness3.Machinewiringharness

2.Dashpanel

Figure23

1.Hood-plateange3.Cowlpanel

2.Shippingplate4.Flange-headbolt(12x40
mm)

2.Assembletheshippingplate,hoodplateandcowl
panels(Figure23)withthe2ange-headbolt(12x
40mm)thatyouremovedinstep2inRemovingthe

ROPS(page7).

3.Tightentheange-headbolttoashippingtorqueof40
to50N-m(30to37ft-lb).

2.Connectthesocketterminalfortheblackwireof
thedashharnessontothepiggybackterminalofthe
wiringharnessforthemachine;refertoFigure13in

RemovingtheDashPanel(page4).

3.Connectthepiggybackterminalofthewiringharness
forthemachineontotheopenbladeterminalofthe
auxiliary-powerport;refertoFigure13inRemoving

theDashPanel(page4).

4.Connectthe6-socketconnectorofthewiringharness
forthemachineontotheconnectorforthestarter
switch;refertoFigure14inRemovingtheDashPanel

(page4).

5.Connectthe6-pinconnectorofthewiringharness
forthemachineintothe6-socketconnectorofthe
dashharness;refertoFigure14inRemovingtheDash

Panel(page4).

6.Aligntheholesinthedashpanelwithholesinthe
consoleframeandtheshippingplate(Figure25).

9

Figure25

AssemblingtheRearFendersandRear
ControlCovertotheMachine

AssemblingtheRearFenders

1.Aligntheholesinthestraightreinforcementplate(with
theattachedclipnuts)thatyouremovedinstep1of

RemovingtheRearFenders(page6)withtherear2

holesintherearfender(Figure26).

1.Flangebolts(8x30mm)

2.Flangelocknuts(8mm)4.Consoleframe

3.Dashpanel

7.Assemblethedashpaneltotheconsoleandthe
shippingplate(Figure25)withthe4angebolts(8x
30mm)and2angelocknuts(8mm)thatyouremoved
instep2ofRemovingtheDashPanel(page4)

8.Tightentheange-headboltsandlocknutsatthefront
ofthedashuntiltheendoftheboltisushwiththe
lockingportionofthelocknut(Figure25)

9.Tightentheange-headboltsatthesideofthedash
paneltoashippingtorqueof120to140N-cm(108
to132in-lb).

10.Connectthe23-pinconnectorofthedashwiring
harnesstothe23-socketconnectorofthemachine
wiringharness;refertoFigure11inRemovingthe

DashPanel(page4).

AssemblingtheConsolePanel

1.Aligntheholesintheconsolepanelwiththeholes
intheframeoftheconsole;refertoFigure10in

RemovingtheDashPanel(page4).

Figure26

1.Fendermount

2.Frontofthemachine5.Straightreinforcement

3.Curvedreinforcement
plateandclipnuts

4.Rearfender

plateandclipnuts

6.Flange-headbolts(10x
30mm)

2.Assemblethestraightreinforcementplate(withthe
attachedclipnuts)tothefenderwiththe2ange-head
bolts(10x30mm)thatyouremovedinstep1of

RemovingtheRearFenders(page6)andtightenthe

boltssecurely(Figure26).

3.Alignthecurvedreinforcementplate(withtheattached
clipnuts)thatyouremovedinstep1ofRemovingthe

RearFenders(page6)withtheforward,insideholesof

therearfender(Figure26).

2.Assemblethepaneltotheconsolewiththe4
ange-headbolts(5/16x1inch)thatyouremovedin
step1ofRemovingtheDashPanel(page4).

3.Tightentheange-headboltstoashippingtorqueof
989to2540N-cm(88to123in-lb).

4.Alignthefender,plate,andclipnutwiththeholeinthe
fendermountoftheoperator’splatform(Figure26).

Note:Haveanotherpersonsupporttherearfender
whileyouinstallthemountinghardware.

5.Assemblethefender,plate,andclipnuttothefender
mountwith3ange-headbolts(10x30mm)thatyou
removedinstep1ofRemovingtheRearFenders(page

6).

6.Tightentheange-headboltstoashippingtorqueof
24to29N-cm(17to21ft-lb).

10

7.Repeatsteps1through6fortherearfenderatthe

G009027

1

2

othersideofthemachine.

AssemblingtheRearControlCover

1.Assemble3ange-headbolts(12x30mm)thatyou
removedinstep1inRemovingtheRearFenders(page

6)intothetop3clipnutsattheholesintherearcontrol

coverandtightensecurely(Figure27).

Figure28

1.BATTERYONposition2.BATTERYOFFposition

WearingPersonalProtectiveEquipment

Figure27

1.Flange-headbolts(12x
30mm)

2.Rearcontrolcover

2.Aligntheholesintherearcontrolcoverwiththeholes
intherearplatformframe(Figure27).

3.Assembletherearcontrolcovertotherearplatform
frame(Figure27)withthe3ange-headbolts(12x30
mm)thatyouremovedinstep1inDisconnectingthe

Auxiliary-ControlPanelWiring(page7).

4.Tightenthe3ange-headboltstoashippingtorqueof
40to50N-m(30to36in-lb).

3.Rearplatformframe

PreparingtoMovetheMachine

ConnectingtheBattery

RotatetheBATTERYDISCONNECTswitchtotheONposition
(Figure28).

CAUTION

Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.

Figure29

1.Wearsafetyglasses.

1.Wearthesuppliedhearingprotectorwhenmovingthe
machineintotheshippingcontainer.

2.Whennishedmovingthemachineintotheshipping
container,attachthehearingprotectortothesteering
wheelofthemachine.

2.Wearhearingprotection.

DisconnectingtheBattery

RotatetheBATTERYDISCONNECTswitchtotheOFFposition
(Figure28).

11

PreparingtheMachine

G009027

1

2

fortheCustomer

LooseParts

Description

Hearingprotector1Wearpersonalprotectiveequipment.

ROPSandmuferassembly

Flange-headbolt(16x50mm)

Flangelocknut(16mm)

Flange-headbolts(16x70mm)

Shim1.52mm(0.06inch)

Shim0.76mm(0.03inch)

Muferextensionandraincap

Clamp

Sidepanel(left)

Sidepanel(right)

PreparingtoMovetheMachine

ConnectingtheBattery

RotatetheBATTERYDISCONNECTswitchtotheONposition
(Figure30).

Quantity

1

2

10

8

3Aligntheturbocharger-exhaustpipe.

1Aligntheturbocharger-exhaustpipe.

1

1

1Installthesidepanels.

1Installthesidepanels.

AligntheROPStothemachine.

AssembletheROPStothemachine.

AssembletheROPStothemachine.

AssembletheROPStothemachine.

Installthemuferextensionandraincap.

Installthemuferextensionandraincap.

WearingPersonalProtectiveEquipment

CAUTION

Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Use

Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.

Figure31

1.Wearsafetyglasses.

2.Wearhearingprotection.

1.Removethehearingprotectorfromthesteeringwheel.

Figure30

1.BATTERYONposition2.BATTERYOFFposition

2.Wearthesuppliedhearingprotectorwhenmovingthe
machinefromtheshippingcontainer.

12

PreparingtheMachine

Lifting-equipmentcapacity:408kg(900lb)minimum

1.Ensurethatthemachinetiltislevelandthetilt-lockout
pinisinstalled;refertotheOperator’sManualforthe
machine.

2.Movethemachinetoalevelsurfacethatisbelowthe
liftingequipmentwiththespeciedliftcapacity.

3.Lowerallattachments,stoptheengine,andremove
thekeyfromtheKEYSWITCH;refertotheOperator’ s
Manualforthemachine.

4.Allowtheenginetocoolcompletely .

RemovingtheShipping
CongurationComponents

RemovingtheRearControlCoverand
RearFenders

RemovingtheRearControlCover

RemovingtheRearFenders

1.Removethe3ange-headbolts(10x30mm)that
securetherearfenderandcurvedreinforcementplate
(withtheattachedclipnuts)tothefendermount,and
removethefender(Figure33).

Note:Haveanotherpersonsupporttherearfender
whileyouremovethemountinghardware.

1.Removethe3ange-headbolts(12x30mm)fromthe
clipnutsatthetop3holesintherearcontrolcover
(Figure32).

Figure32

Figure33

1.Fendermount

2.Frontofthemachine5.Straightreinforcement

3.Curvedreinforcement
plateandclipnuts

4.Rearfender

plateandclipnuts

6.Flange-headbolts(10x
30mm)

2.Removethe2ange-headbolts(10x30mm)and
straightreinforcementplate(withtheattachedclip
nuts)fromtherear2holesintherearfender(Figure

33).

3.Repeatsteps1and2fortherearfenderattheother
sideofthemachine.

4.Settheange-headbolts,reinforcementplates(with
theattachedclipnuts),andfendersforinstallationin

InstallingtheRearFenders(page18).

1.Flange-headbolts(12x
30mm)

2.Rearcontrolcover

3.Rearplatformframe

2.Removethe3ange-headbolts(12x30mm)that
securetherearcontrolcovertotherearplatformframe,
andremovethecoverfromthemachine(Figure32).

3.Setasidethecoverandange-headboltsforinstallation
inInstallingtheRearControlCover(page19).

13

RemovingtheConsolePanelandthe
DashPanel

RemovingtheConsolePanel

1.Removethe4ange-headbolts(5/16x1inch)that
securetheconsolepaneltotheframeoftheconsole
(Figure34).

Figure34

2.Removethe4angebolts(8x30mm)and2ange
locknuts(8mm)thatsecurethedashpaneltotheframe
oftheconsole(Figure36).

1.Consoleframe3.Flange-headbolts(5/16x
1inch)

2.Consolepanel

2.Removethepanelfromthemachine(Figure34).

3.Setasidethepanelandange-headboltsforinstallation
inInstallingtheConsolePanel(page21).

RemovingtheDashPanel

1.Disconnectthe23-pinconnectorofthedashwiring
harnessfromthe23-socketconnectorforthemachine
wiringharness(Figure35)

Figure36

1.Flangebolts(8x30mm)

2.Flangelocknuts(8mm)4.Consoleframe

3.Dashpanel

3.Liftupthedashpaneluntilyoucanaccesstheelectrical
connectorsattheforwardsideofthepanel.

4.Removethepiggybackterminalofthewiringharness
forthemachinefromthebladeterminalofthe
auxiliary-powerport(Figure37).

1.23-pinconnector(dash
wiringharness)

Figure35

2.23-socketconnector
(machinewiringharness)

Figure37

1.Bluewire(dashharness)3.Piggybackterminal(wiring

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

14

harnessforthemachine)

4.Bladeterminal
(auxiliary-powerport)

5.Removethesocketterminalfortheblackwireofthe
dashharnessfromthepiggybackterminalofthewiring
harnessforthemachine(Figure37)

6.Removethe6-socketconnectorofthewiringharness
forthemachinefromtheconnectorforthestarter
switch(Figure38).

Figure38

RemovingtheShippingPlate

1.Removethe2ange-headbolt(12x40mm)that
securetheshippingplate,hoodplate,leftcowlpanel,
andrightcowlpanel(Figure40).

1.6-pinconnector(wiring
harnessforthemachine)

2.6-socketconnector(dash
harness)

3.Starter-switchconnector

4.6-socketconnector(wiring
harnessforthemachine)

7.Removethe6-pinconnectorofthewiringharnessfor
themachinefromthe6-socketconnectorofthedash
harness(Figure38).

8.Carefullyremovethedashpanelfromtheconsole
(Figure39).

Figure40

1.Flange-headbolt(12x40
mm)

2.Hood-plateange4.Shippingplate

3.Shippingplate

2.Movetheshippingplateoutwarduntiltheplateclears
theangeofthehoodplate,andremovetheshipping
platefromthemachine(Figure40).

Note:Retaintheange-headboltsforinstallation
inAssemblingtheROPStotheMachine(page17).
Discardtheshippingplate.

Figure39

1.Dashwiringharness3.Machinewiringharness

2.Dashpanel

9.Settheange-headbolts,locknuts,anddashpanelfor
installationinInstallingtheDashPanel(page19).

15

InstallingtheROPS

AligningtheROPStotheMachine

Lifting-equipmentcapacity:408kg(900lb)minimum

Customerprovidedtool:hand-operatedwinch.

1.SupporttheROPSframeandmuferwithlifting
equipmenthavingaminimumliftcapacityof408kg
(900lb)asshowninFigure41.

Note:TheROPSframeandmuferisweighted
towardtherear.YouwillneedtotilttheROPSframe
andmufertoinstalltheROPS.Wheneverpossible,
use2piecesofliftingequipmenttolifttheROPSframe
andmufer.

Figure42

4.TipthefrontoftheROPSdowntoaligntheforward
ROPSplatebetweentheangeofthehoodplate,left
cowlpanel,andrightcowlpanel(Figure42andFigure

43).

Figure41

2.Usingtheliftingequipment,carefullyremovethe
ROPSandmuferfromtheshippingcontainerand
aligntheROPSabovethemachine(Figure41).

3.MovetheROPSforwardanddownuntilthe
ROPS-mountingplatetheclearssteeringwheel(Figure

42).

Figure43

1.Flange(hoodplate)3.ROPSplate

2.Leftandrightcowlpanels

16

5.Atthebackofthemachine,checktheclearance
betweentherearbulkheadpaneloftheROPSandthe
wiringharnessofthemachine(Figure44)

Figure44

1.Flangefortherearframe
tube(ROPS)

2.ROPSmounts(chassis)4.Wiringharness(machine)

3.Rearbulkheadpanel
(ROPS)

6.Usingtheliftingequipment,carefullymovetheROPS
forwardanddownuntiltheholesinthehoodplate
andcowlsarealignedwiththeholesintheROPSplate
(Figure43).

7.AligntheangesattherearframetubesfortheROPS
withtheROPSmountsforthechassisofthemachine
(Figure44).

AssemblingtheROPStotheMachine

1.AssembletheROPSplatetotheframeoftheconsole
withthe2ange-headbolts(16x50mm)and2ange
locknuts(16mm)fromtheshippingkit,andtighten
theboltsandnutsbyhand(Figure45).

Figure45

1.ROPS-mountingplate3.Flange-headbolts(16x
50mm)

2.Flangelocknuts(16mm)4.Consoleframe

2.Applyacoatofmedium-grade,thread-locking
compoundtothethreadsofthe2ange-headbolts(12
x40mm)thatyouremovedinstep1inRemovingthe

ShippingPlate(page15).

3.Assemblethe2ange-headbolts(12x40mm)through
theholesintheangeofthehoodpanel,ROPSplate,
leftcowlpanel,andrightcowlpanel,andtightenthe
boltsandnutsbyhand(Figure46).

17

Figure46

1.Leftcowlpanel3.Hood-plateange

2.Flange-headbolt(12x40
mm)

4.ROPS-mountingplate

4.Aligntheholesintheangeattherearframetubefor
theROPSwiththeholesintheROPSmountforthe
chassisofthemachine(Figure47).

Note:Ifyouhavedifcultyaligningtheholes,usea
hand-operatedwinchbetweentherearROPStubeand
afrontROPStubetopulltherearROPStubeforward
andaligntheholes.Usethehand-operatedwinch
betweentherearROPStubestopullthetubesinward
toaligntheholes(Figure47).

DescriptionTorquevalue

Flange-headbolts(16x50
mm)andangelocknuts
(16mm)—ROPSplateand
consoleframe(Figure45)

Flange-headbolts(12x40
mm)—hoodplate,ROPS
plate,leftandrightcowlpanel
(Figure46)

Flange-headbolts(16x70
mm)andangelocknuts(16
mm)—rearROPStubesand
chassis(Figure47)

319to400N-m(235to295
ft-lb)

80to10N-m(59to73ft-lb)

319to400N-m(235to295
ft-lb)

InstallingtheRearFenders andtheRearControlCover

InstallingtheRearFenders

1.Applyacoatofmedium-grade,thread-locking
compoundtothethreadsofthe10ange-headbolts
(10x30mm)thatyouremovedinsteps1and3of

RemovingtheRearFenders(page13).

2.Aligntheholesintherearfenderwiththeholesinthe
fendermountofthechassisandangeoftheROPS
tube(Figure48).

Note:Haveanotherpersonsupporttherearfender
whileyouinstallthemountinghardware.

Figure47

1.Flangelocknuts(16mm)3.ROPStube

2.Flange-headbolts(16x
70mm)

5.AssembletherearROPStubetothechassiswith4
ange-headbolts(16x70mm)and4angelocknuts
(16mm),andtightenbyhand(Figure47).

6.Repeatsteps4and5totherearROPStubeattheother
sideofthemachine.

7.Torquetheboltsandnutsasindicatedinthetablethat
follows:

1.Flange-headbolts(10x
30mm)

2.Curvedreinforcement
plateandclipnuts

3.Fendermount

18

Figure48

4.Straightreinforcement
plateandclipnuts

5.Fender

6.Frontofthemachine

3.Alignthenutclipsonthereinforcementplateswiththe
holesinthefender(Figure48).

4.Assemblethefender,reinforcementplates,andnut
clipstothemachine(Figure48)withthe5ange-head
bolts(10x30mm).

5.Torquetheange-headboltsto47to57N-m(34to
42ft-lb).

6.Repeatsteps2through5fortherearfenderatthe
othersideofthemachine.

InstallingtheRearControlCover

1.Atthebackofthemachine,connectthe10-socket
connectorattheendofthemain-wiringharnessinto
the10-pinconnectorofthetiltswitch(Figure49).

Figure50

1.Bulkhead

2.Rearcoverplate

3.Flange-headbolt(12x30
mm)

5.Assembletherearcontrolcoverwiththeholesinthe
rearbulkhead(Figure50)withthe6ange-headbolt
(12x30mm).

Figure49

1.Plugs3.Auxiliary-controlpanel

2.Tiltswitch4.10-socketconnector
(main-wiringharness)

2.Assemblethe7remaining10-socketconnectorsinto
the7rocker-switchplugsintheauxiliary-controlpanel
(Figure49)

3.Applyacoatofmedium-grade,thread-locking
compoundtothethreadsofthe6ange-headbolts
(12x30mm)thatyouremovedinsteps1and2in

RemovingtheRearControlCover(page13).

4.Aligntheholesintherearcontrolcoverwiththeholes
intherearbulkheadofthemachine(Figure50).

6.Torquetheange-headboltto80to10N-m(59to
73ft-lb).

InstallingtheDashPaneland ConsolePanel

InstallingtheDashPanel

1.Alignthedashpaneltotheconsole(Figure48).

Figure51

1.Dashwiringharness3.Machinewiringharness

2.Dashpanel

2.Connectthesocketterminalfortheblackwireofthe
dashharnessontothepiggybackterminalofthewiring
harnessforthemachine(Figure52).

19

Figure52

G030030

7.Aligntheholesinthedashpanelwithholesinthe
consoleframe(Figure54).

1.Bluewire(dashharness)3.Piggybackterminal(wiring

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

harnessforthemachine)

4.Bladeterminal
(auxiliary-powerport)

3.Connectthepiggybackterminalofthewiringharness
forthemachineontotheopenbladeterminalofthe
auxiliary-powerport(Figure52).

4.Connectthe6-socketconnectorofthewiringharness
forthemachineontotheconnectorforthestarter
switch(Figure53).

Figure54

8.Assemblethedashpaneltotheconsole(Figure55)
withthe4angebolts(8x30mm)and2ange
locknuts(8mm).

Figure53

1.6-pinconnector(wiring
harnessforthemachine)

2.6-socketconnector(dash
harness)

3.Starter-switchconnector

4.6-socketconnector(wiring
harnessforthemachine)

5.Connectthe6-pinconnectorofthewiringharnessfor
themachineintothe6-socketconnectorofthedash
harness(Figure53).

6.Applyacoatofmedium-grade,thread-locking
compoundtothethreadsofthe4angebolts(8x30
mm)thatyouremovedinstep2ofRemovingtheDash

Panel(page14).

Figure55

1.Flangebolt(8x30mm)

2.Flangelocknut(8mm)

3.Dashassembly

9.Tightentheange-headboltsandlocknutstoanal
torqueof120to140N-cm(108to132in-lb).

20

InstallingtheConsolePanel

1.Connectthe23-pinconnectorofthedashwiring
harnesstothe23-socketconnectorofthemachine
wiringharness(Figure56).

Figure56

Installingthe Turbocharger-ExhaustPipe

AssemblingtheTurbocharger-Exhaust
PipeontotheMachine

1.Aligntheturbocharger-exhaustpipe(fromtheshipping
kit)throughthenotchesintherightcowlpaneland
hoodpanelofthemachine(Figure58).

Important:Donotbendordamagethepleated
sectionoftheturbocharger-exhaustpipewhile
assemblingthepipetothemachine.

1.23-pinconnector(dash
wiringharness)

2.Applymedium-grade,thread-lockingcompoundtothe
4ange-headbolts(5/16x1inch)thatyouremovedin
step1ofRemovingtheConsolePanel(page14).

3.Aligntheholesintheconsolepanelwiththeholesin
theframeoftheconsole(Figure57).

2.23-socketconnector
(machinewiringharness)

Figure57

Figure58

2.Aligntheslotsintheturbocharger-exhaustpipewith
thealignmentpinsofthemufer-inletpipeand
assembletheexhaustpipeontothemufer(Figure59).

1.Consoleframe3.Flange-headbolts(5/16x
1inch)

2.Consolepanel

4.Assemblethepaneltotheconsole(Figure57)withthe
4ange-headbolts(5/16x1inch).

5.Tightentheboltstoanaltorqueof1978to2542
N-cm(175to225in-lb).

21

Figure59

1.Alignmentpins
(mufer-inletpipe)

2.Slots
(turbocharger-exhaust
pipe)

3.Aligntheangesoftheturbocharger-exhaustpipeand
theoutletangeoftheturbocharger,assemblethe
angeclampovertheanges,andtightentheclampto
closet(Figure60).

Note:Whentheangesoftheturbochargeroutlet
andtheturbocharger-exhaustpipearealigned,the2
alignmentpinsforthemufer-inletpipeshouldhave

3.2mm(1/8inch)orgreaterclearancefromtheclosed
endofthe2slotsintheturbocharger-exhaustpipe.

4.Assemblethebandclamp(fromtheshippingkit)
belowthe2alignmentpinsofthemufer-inletpipe
andtightentheclamptocloset(Figure61).

Figure61

1.Guillotineclamp3.Alignmentpin(mufer-inlet
pipe)

2.Bandclamp

5.Assembletheguillotineclamp(fromtheshippingkit)
abovethe2alignmentpinsofthemufer-inletpipe
andtightentheclamptocloset(Figure61).

AligningtheTurbocharger-Exhaust
Pipe

MeasuringtheBellows

1.Turbocharger-exhaust

2.Flangeclamp

1.Atthefrontsideofthebellowsofthe
turbocharger-exhaustpipe,measurethedistancefrom
theupperedgeoftheupper-weldseamtothelower
edgeofthelower-weldseam.

Recordyourmeasurementhere:

Note:Ifyourfront-sidemeasurementislessthanor
greaterthan152.4mm(6inches)andthepleatsofthe
bellowsarenotverticallyaligned,performthestepsin

AligningtheMuferFronttoBack(page23).

Figure60

3.Turbochargeroutlet

pipe

22

Figure62

AligningtheMuferFronttoBack

1.Loosenthe4ange-headbolts(8x120mm)and
angelocknuts(8mm)thatsecuretheexhaust-system
mounttotheROPStube(Figure63).

1.Upperedgeofthe
upper-weldseam

2.152.4mm(6inches)

3.Loweredgeofthe
lower-weldseam

2.Attherightsideofthebellows,measurethedistance
fromtheupperedgeoftheupper-weldseamtothe
loweredgeofthelower-weldseam.

Recordyourmeasurementhere:

Note:Ifyourrightsidemeasurementislessthanor
greaterthan152.4mm(6inches)andthepleatsofthe
bellowsarenotverticallyaligned,performthestepsin

AligningtheMuferLefttoRight(page24).

3.Ifthefrontandsidemeasurementsofweldseamsfor
thebellowsare152.4mm(6inches)andthepleatsof
thebellowsareverticallyaligned,skiptoSecuringthe

Turbocharger-ExhaustPipe(page24).

Figure63

1.ROPStube4.Shim0.76mm(0.03inch)

2.Exhaust-systemmount

3.Flange-headbolts(8x120
mm)—lowerpositions

5.Shim1.52mm(0.06inch)

2.Addshim(s)—fromtheshippingkitorremovethe
shim(s)totheexhaust-systemmountatthelower2
ange-headboltsasneededtoalignthepleatsofthe
bellows(Figure63).

Note:Changethetotalshimthicknessin0.76mm
(0.03inch)increments.

3.Torquetheange-headboltsandangelocknutsfor
theexhaust-systemmountto17to21N-m(23to29
ft-lb).

4.Measurethebellowsweld-seamdimensionandconrm
thatthepleatsofthebellowsarealignedstraight
(Figure62).

Note:Ifbellowsisnotaligned,repeatsteps1through

3untiltheweld-seamsmeasurementforthebellowsis

152.4mm(6inches)fronttobackandthepleatsofthe
bellowsarealignedstraight.

5.Iftheturbocharger-exhaustpipeisalignedlefttoright,
skiptoSecuringtheTurbocharger-ExhaustPipe(page

24).

23

AligningtheMuferLefttoRight

1.Removethe6ange-headbolts(6x16mm)that
securetheheatshieldtotheexhaust-systemmountand
removetheheatshield(Figure64).

Figure64

1.Flange-headbolts(6x16
mm)

2.Clipnut(6mm)

3.Flange-headbolts(6x30
mm)

4.Muferstrap

5.Heatshield

2.Loosentheange-headbolts(6x30mm)thatsecure
themuferstrapstotheexhaust-systemmount(Figure

64).

3.Loosenthe2ange-headbolts(1/2x1inch)
andserratedangenuts(1/2inch)thatsecurethe
lower-mufersupporttotheexhaust-systemmount
(Figure65).

Figure65

1.Exhaust-systemmount

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

3.Lower-mufersupport

4.Serratedangenuts(1/2
inch)

4.Movethemuferleftorrighttoalignthebellowsso
thattheweld-seammeasurementattheleftandright
sidesare152.4mm(6inches)andpleatsofthebellows
arealignedstraight(Figure65).

5.Tightenthe2ange-headbolts(1/2x1inch)
andserratedangenuts(1/2inch)thatsecurethe
lower-mufersupporttotheexhaust-systemmountto
91to113N-m(67to83ft-lb).

6.Tightentheange-headbolts(6x30mm)thatsecure
themuferstrapsto972to1198N-cm(86to106
in-lb).

7.Applyacoatofmedium-grade,thread-locking
compoundtothe6ange-headbolts(6x16mm)that
youremovedinstep1.

8.Assembletheheatshieldtoexhaust-systemmountwith
the6ange-headbolts(6x16mm)andtorquethe
boltsto972to1198N-cm(86to106in-lb).

9.Iftheturbocharger-exhaustpipeisalignedfrontto
back,skiptoSecuringtheTurbocharger-ExhaustPipe

(page24).

SecuringtheT urbocharger-ExhaustPipe

1.Tightenthenutoftheangeclampsecurely.

2.Tightentheangenutsoftheguillotineclampand
tightentheboltandnutofthebandclampsecurely.

24

InstallingtheMuferExtension

SwitchingntheBatteryand

andRainCap

1.Aligntheraincapofthemuferextension(fromthe
shippingkit)totheoutletpipeofthemufersothat
thepivotfortheraincapisinboard(Figure66).

Note:Whentheraincapiscorrectlyalignedtothe
outletpipeofthemufer,exhaustfromthemufer
willblowoutwardandawayfromthemachine.

InstallingtheSidePanels

1.RotatetheBATTERYDISCONNECTswitchtotheON
position(Figure67).

Figure67

1.BATTERYONposition2.BATTERYOFFposition

Figure66

1.Mufer-outletpipe4.Inboardofthemachine

2.Clamp5.Pivot(raincap)

3.Muferextensionandrain
cap

2.Assemblethemuferextensionandraincaptothe
outletpipeofthemufer(Figure66).

Note:Ensurethattheendofthemufer-outletpipe
extendspasttheslotsinthemuferextension

3.Securethemuferextensionandraincap(Figure66)
withtheclamp76mm(3inch)fromtheshippingkit.

2.Alignthesidepanel(fromtheshippingkit)withthe
machineframe.

3.Alignthemountingboltatthetopofthesidepanel
withtheholeinthesupportangeofthehoodpanel
(Figure68).

Figure68

4.Applylightinwardpressureagainstthepanelat1of
thelatches.

5.Setthelatchbypushinginthelatchlever—thepartof
thelatchtotheleftofthelockcylinder(Figure69).

25

Figure69

1.Latchlever

2.Latchbutton

3.Side-panellatch

6.Repeatsteps4and5attheotherlatch.

7.Repeatsteps2through6forthesidepanelattheother
sideofthemachine.

26

Notes:

27