Toro 131-2883 Installation Instructions

Page 1
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
Page 2
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
Page 3
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
Page 4
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
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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
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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
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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
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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
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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).
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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).
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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).
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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
Page 13

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).
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Page 14
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)
Page 15
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).
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Page 16

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
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Page 17
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).
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Page 18
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
Page 19
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).
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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).
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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).
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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
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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).
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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.
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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).
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Figure69
1.Latchlever
2.Latchbutton
3.Side-panellatch
6.Repeatsteps4and5attheotherlatch.
7.Repeatsteps2through6forthesidepanelattheother sideofthemachine.
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Notes:
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