2. Toro
  3. International Ship Kit, RT1200 Trencher

Toro International Ship Kit, RT1200 Trencher Installation guide

  • Hello! I am an AI chatbot trained to assist you with the Toro International Ship Kit, RT1200 Trencher Installation guide. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
FormNo.3396-716RevA
InternationalShipKit
RT1200Trencher
ModelNo.131-2883
InstallationInstructions
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
Operator’ s
Man ual.
Modicationstothismachineshouldbemade
onlybyanAuthorizedToroServiceDealer.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure1),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure1
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
CAUTION
Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.
G009027
1
2
Figure2
1.Wearsafetyglasses.
2.Wearhearingprotection.
Contents
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—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved
*3396-716*A
Conguringthe
MachineforShipping
LooseParts
Description
Quantity
Use
Shippingplate
1Installtheshippingplate.
Hearingprotector1Wearpersonalprotectiveequipment.
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
RemovingtheSidePanelsand
DisconnectingtheBattery
1.Pressinthebuttonportionofeachlatch—thepartof
thelatchincludingthelockcylinder(Figure3).
Figure3
1.Latchlever
3.Side-panellatch
2.Latchbutton
2.Liftthepanelupandawayfromthemachine(Figure4).
Figure4
1.Latch
2.Sidepanel
2
3.Repeatsteps1and2forthesidepanelattheotherside
ofthemachine.
4.Placebothsidepanelsintotheshippingcontainer.
5.RotatetheBATTERYDISCONNECTswitch
counterclockwisetotheOFFposition(Figure5).
Figure5
1.BATTERYONposition2.BATTERYOFFposition
RemovingtheMuferExtensionand
RainCap
1.Loosentheclampthatsecuresthemuferextension
andraincaptotheoutletpipeofthemufer(Figure6).
Figure6
1.Mufer-outletpipe4.Inboardofthemachine
2.Clamp5.Pivot(raincap)
3.Muferextensionandrain
cap
2.Removetheextension,raincap,andclampfromthe
mufer(Figure6).
3.Placeextension,raincap,andclampintotheshipping
container.
RemovingtheTurbocharger-Exhaust
Pipe
1.Removethebandclampandthelowerguillotineclamp
thatsecurethemufertotheturbocharger-exhaust
pipe(Figure7).
Figure7
1.Guillotineclamp
3.Flangeclamp
2.Bandclamp4.Turbocharger-exhaust
pipe
2.Removetheangeclampthatsecurestheangeofthe
turbocharger-exhaustpipetotheoutletangeofthe
turbocharger(Figure7).
3.Movetheturbocharger-exhaustpipedownuntilthe
alignmentpinsofthemufer-inletpipecleartheslots
intheturbocharger-exhaustpipe(Figure8).
Important:Donotbendordamagethepleated
sectionoftheturbocharger-exhaustpipewhile
removingthepipetothemachine.
3
Figure8
1.Alignmentpin(mufer-inlet
pipe)
2.Slots
(turbocharger-exhaust
pipe)
4.Removetheturbocharger-exhaustpipefromthe
machine(Figure9).
Figure9
5.Placetheturbocharger-exhaustpipe,bandclamp,
guillotineclamp,andangeclampintotheshipping
container.
RemovingtheConsolePanelandthe
DashPanel
RemovingtheConsolePanel
1.Removethe4ange-headbolts(5/16x1inch)that
securetheconsolepaneltotheframeoftheconsole
(Figure10).
Figure10
1.Consoleframe3.Flange-headbolts(5/16x
1inch)
2.Consolepanel
2.Removethepanelfromthemachine(Figure10).
RemovingtheDashPanel
1.Disconnectthe23-pinconnectorofthedashwiring
harnessfromthe23-socketconnectorforthemachine
wiringharness(Figure11)
Figure11
1.23-pinconnector(dash
wiringharness)
2.23-socketconnector
(machinewiringharness)
2.Removethe4angebolts(8x30mm)and2ange
locknuts(8mm)thatsecurethedashpaneltotheframe
oftheconsole(Figure12).
4
Figure12
1.Flangebolt(8x30mm)
3.Dashassembly
2.Flangelocknut(8mm)
3.Removethepiggybackterminalofthewiringharness
forthemachinefromthebladeterminalofthe
auxiliary-powerport(Figure13).
Figure13
1.Bluewire(dashharness)3.Piggybackterminal(wiring
harnessforthemachine)
2.Socketterminal—black
(ground)wire(dash
harness)
4.Bladeterminal
(auxiliary-powerport)
4.Removethesocketterminalfortheblackwireofthe
dashharnessfromthepiggybackterminalofthewiring
harnessforthemachine(Figure13)
5.Removethe6-socketconnectorofthewiringharness
forthemachinefromtheconnectorforthestarter
switch(Figure14).
Figure14
1.6-pinconnector(wiring
harnessforthemachine)
3.Starter-switchconnector
2.6-socketconnector(dash
harness)
4.6-socketconnector(wiring
harnessforthemachine)
6.Removethe6-pinconnectorofthewiringharnessfor
themachinefromthe6-socketconnectorofthedash
harness(Figure14).
7.Carefullyremovethedashpanelfromtheconsole
(Figure12).
Note:Setasidethedashpanel,angebolts,and
locknutsforassemblyinAssemblingtheMachinefor
Shipping(page9).
5
RemovingtheRearControlCoverand
RearFenders
RemovingtheRearControlCover
1.Removethe6ange-headbolt(12x30mm)that
securetherearcontrolcovertotherearbulkheadof
themachine(Figure15).
Figure15
1.Bulkhead
3.Flange-headbolt(12x30
mm)
2.Rearcoverplate
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.
Figure16
1.Flange-headbolts(10x
30mm)
4.Straightreinforcement
plateandclipnuts
2.Curvedreinforcement
plateandclipnuts
5.Fender
3.Fendermount
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).
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.
Figure18
2.Removethe2ange-headbolts(12x40mm)that
securethehoodplate,ROPS-mountingplate,leftcowl
panel,andrightcowlpanel(Figure19)
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).
Note:Ifyouhavedifcultyremovingthebolts,
theROPSframetubesareundertension.Usea
hand-operatedwinchtopulltheROPStubestogether
torelievesheeringpressurefromthebolts.
Note:Discardthe8ange-headbolts(16x70mm)
and8angelocknuts(16mm).
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).
Figure22
8.MovetheROPSandmufertotheshippingcontainer.
8
AssemblingtheMachinefor
Shipping
InstallingtheShippingPlate
1.Aligntheshippingplatebetweentheangeofthehood
plate,leftcowlpanel,andrightcowlpanel(Figure23).
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).
AssemblingtheDashPaneland
ConsolePaneltotheMachine
AssemblingtheDashPanel
1.Alignthedashpaneltotheconsole(Figure24).
Figure24
1.Dashwiringharness3.Machinewiringharness
2.Dashpanel
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
1.Flangebolts(8x30mm)
3.Dashpanel
2.Flangelocknuts(8mm)4.Consoleframe
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).
2.Assemblethepaneltotheconsolewiththe4
ange-headbolts(5/16x1inch)thatyouremovedin
step1ofRemovingtheDashPanel(page4).
3.Tightentheange-headboltstoashippingtorqueof
989to2540N-cm(88to123in-lb).
AssemblingtheRearFendersandRear
ControlCovertotheMachine
AssemblingtheRearFenders
1.Aligntheholesinthestraightreinforcementplate(with
theattachedclipnuts)thatyouremovedinstep1of
RemovingtheRearFenders(page6)withtherear2
holesintherearfender(Figure26).
Figure26
1.Fendermount
4.Rearfender
2.Frontofthemachine5.Straightreinforcement
plateandclipnuts
3.Curvedreinforcement
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).
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
othersideofthemachine.
AssemblingtheRearControlCover
1.Assemble3ange-headbolts(12x30mm)thatyou
removedinstep1inRemovingtheRearFenders(page
6)intothetop3clipnutsattheholesintherearcontrol
coverandtightensecurely(Figure27).
Figure27
1.Flange-headbolts(12x
30mm)
3.Rearplatformframe
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).
PreparingtoMovetheMachine
ConnectingtheBattery
RotatetheBATTERYDISCONNECTswitchtotheONposition
(Figure28).
Figure28
1.BATTERYONposition2.BATTERYOFFposition
WearingPersonalProtectiveEquipment
CAUTION
Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.
G009027
1
2
Figure29
1.Wearsafetyglasses.
2.Wearhearingprotection.
1.Wearthesuppliedhearingprotectorwhenmovingthe
machineintotheshippingcontainer.
2.Whennishedmovingthemachineintotheshipping
container,attachthehearingprotectortothesteering
wheelofthemachine.
DisconnectingtheBattery
RotatetheBATTERYDISCONNECTswitchtotheOFFposition
(Figure28).
11
PreparingtheMachine
fortheCustomer
LooseParts
Description
Quantity
Use
Hearingprotector1Wearpersonalprotectiveequipment.
ROPSandmuferassembly
1
AligntheROPStothemachine.
Flange-headbolt(16x50mm)
2
AssembletheROPStothemachine.
Flangelocknut(16mm)
10
AssembletheROPStothemachine.
Flange-headbolts(16x70mm)
8
AssembletheROPStothemachine.
Shim1.52mm(0.06inch)
3Aligntheturbocharger-exhaustpipe.
Shim0.76mm(0.03inch)
1Aligntheturbocharger-exhaustpipe.
Muferextensionandraincap
1
Installthemuferextensionandraincap.
Clamp
1
Installthemuferextensionandraincap.
Sidepanel(left)
1Installthesidepanels.
Sidepanel(right)
1Installthesidepanels.
PreparingtoMovetheMachine
ConnectingtheBattery
RotatetheBATTERYDISCONNECTswitchtotheONposition
(Figure30).
Figure30
1.BATTERYONposition2.BATTERYOFFposition
WearingPersonalProtectiveEquipment
CAUTION
Thismachineproducessoundlevelsthatcancause
hearinglossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis
machine.
Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.
G009027
1
2
Figure31
1.Wearsafetyglasses.
2.Wearhearingprotection.
1.Removethehearingprotectorfromthesteeringwheel.
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
1.Removethe3ange-headbolts(12x30mm)fromthe
clipnutsatthetop3holesintherearcontrolcover
(Figure32).
Figure32
1.Flange-headbolts(12x
30mm)
3.Rearplatformframe
2.Rearcontrolcover
2.Removethe3ange-headbolts(12x30mm)that
securetherearcontrolcovertotherearplatformframe,
andremovethecoverfromthemachine(Figure32).
3.Setasidethecoverandange-headboltsforinstallation
inInstallingtheRearControlCover(page19).
RemovingtheRearFenders
1.Removethe3ange-headbolts(10x30mm)that
securetherearfenderandcurvedreinforcementplate
(withtheattachedclipnuts)tothefendermount,and
removethefender(Figure33).
Note:Haveanotherpersonsupporttherearfender
whileyouremovethemountinghardware.
Figure33
1.Fendermount
4.Rearfender
2.Frontofthemachine5.Straightreinforcement
plateandclipnuts
3.Curvedreinforcement
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).
13
RemovingtheConsolePanelandthe
DashPanel
RemovingtheConsolePanel
1.Removethe4ange-headbolts(5/16x1inch)that
securetheconsolepaneltotheframeoftheconsole
(Figure34).
Figure34
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)
Figure35
1.23-pinconnector(dash
wiringharness)
2.23-socketconnector
(machinewiringharness)
2.Removethe4angebolts(8x30mm)and2ange
locknuts(8mm)thatsecurethedashpaneltotheframe
oftheconsole(Figure36).
Figure36
1.Flangebolts(8x30mm)
3.Dashpanel
2.Flangelocknuts(8mm)4.Consoleframe
3.Liftupthedashpaneluntilyoucanaccesstheelectrical
connectorsattheforwardsideofthepanel.
4.Removethepiggybackterminalofthewiringharness
forthemachinefromthebladeterminalofthe
auxiliary-powerport(Figure37).
Figure37
1.Bluewire(dashharness)3.Piggybackterminal(wiring
harnessforthemachine)
2.Socketterminal—black
(ground)wire(dash
harness)
4.Bladeterminal
(auxiliary-powerport)
14
5.Removethesocketterminalfortheblackwireofthe
dashharnessfromthepiggybackterminalofthewiring
harnessforthemachine(Figure37)
6.Removethe6-socketconnectorofthewiringharness
forthemachinefromtheconnectorforthestarter
switch(Figure38).
Figure38
1.6-pinconnector(wiring
harnessforthemachine)
3.Starter-switchconnector
2.6-socketconnector(dash
harness)
4.6-socketconnector(wiring
harnessforthemachine)
7.Removethe6-pinconnectorofthewiringharnessfor
themachinefromthe6-socketconnectorofthedash
harness(Figure38).
8.Carefullyremovethedashpanelfromtheconsole
(Figure39).
Figure39
1.Dashwiringharness3.Machinewiringharness
2.Dashpanel
9.Settheange-headbolts,locknuts,anddashpanelfor
installationinInstallingtheDashPanel(page19).
RemovingtheShippingPlate
1.Removethe2ange-headbolt(12x40mm)that
securetheshippingplate,hoodplate,leftcowlpanel,
andrightcowlpanel(Figure40).
Figure40
1.Flange-headbolt(12x40
mm)
3.Shippingplate
2.Hood-plateange4.Shippingplate
2.Movetheshippingplateoutwarduntiltheplateclears
theangeofthehoodplate,andremovetheshipping
platefromthemachine(Figure40).
Note:Retaintheange-headboltsforinstallation
inAssemblingtheROPStotheMachine(page17).
Discardtheshippingplate.
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.
Figure41
2.Usingtheliftingequipment,carefullyremovethe
ROPSandmuferfromtheshippingcontainerand
aligntheROPSabovethemachine(Figure41).
3.MovetheROPSforwardanddownuntilthe
ROPS-mountingplatetheclearssteeringwheel(Figure
42).
Figure42
4.TipthefrontoftheROPSdowntoaligntheforward
ROPSplatebetweentheangeofthehoodplate,left
cowlpanel,andrightcowlpanel(Figure42andFigure
43).
Figure43
1.Flange(hoodplate)3.ROPSplate
2.Leftandrightcowlpanels
16
5.Atthebackofthemachine,checktheclearance
betweentherearbulkheadpaneloftheROPSandthe
wiringharnessofthemachine(Figure44)
Figure44
1.Flangefortherearframe
tube(ROPS)
3.Rearbulkheadpanel
(ROPS)
2.ROPSmounts(chassis)4.Wiringharness(machine)
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).
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:
DescriptionTorquevalue
Flange-headbolts(16x50
mm)andangelocknuts
(16mm)—ROPSplateand
consoleframe(Figure45)
319to400N-m(235to295
ft-lb)
Flange-headbolts(12x40
mm)—hoodplate,ROPS
plate,leftandrightcowlpanel
(Figure46)
80to10N-m(59to73ft-lb)
Flange-headbolts(16x70
mm)andangelocknuts(16
mm)—rearROPStubesand
chassis(Figure47)
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.
Figure48
1.Flange-headbolts(10x
30mm)
4.Straightreinforcement
plateandclipnuts
2.Curvedreinforcement
plateandclipnuts
5.Fender
3.Fendermount
6.Frontofthemachine
18
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).
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).
Figure50
1.Bulkhead
3.Flange-headbolt(12x30
mm)
2.Rearcoverplate
5.Assembletherearcontrolcoverwiththeholesinthe
rearbulkhead(Figure50)withthe6ange-headbolt
(12x30mm).
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
1.Bluewire(dashharness)3.Piggybackterminal(wiring
harnessforthemachine)
2.Socketterminal—black
(ground)wire(dash
harness)
4.Bladeterminal
(auxiliary-powerport)
3.Connectthepiggybackterminalofthewiringharness
forthemachineontotheopenbladeterminalofthe
auxiliary-powerport(Figure52).
4.Connectthe6-socketconnectorofthewiringharness
forthemachineontotheconnectorforthestarter
switch(Figure53).
Figure53
1.6-pinconnector(wiring
harnessforthemachine)
3.Starter-switchconnector
2.6-socketconnector(dash
harness)
4.6-socketconnector(wiring
harnessforthemachine)
5.Connectthe6-pinconnectorofthewiringharnessfor
themachineintothe6-socketconnectorofthedash
harness(Figure53).
6.Applyacoatofmedium-grade,thread-locking
compoundtothethreadsofthe4angebolts(8x30
mm)thatyouremovedinstep2ofRemovingtheDash
Panel(page14).
7.Aligntheholesinthedashpanelwithholesinthe
consoleframe(Figure54).
G030030
Figure54
8.Assemblethedashpaneltotheconsole(Figure55)
withthe4angebolts(8x30mm)and2ange
locknuts(8mm).
Figure55
1.Flangebolt(8x30mm)
3.Dashassembly
2.Flangelocknut(8mm)
9.Tightentheange-headboltsandlocknutstoanal
torqueof120to140N-cm(108to132in-lb).
20
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/