Toro International Ship Kit, RT1200 Trencher Installation guide

Toro
Brand
Toro
Model
International Ship Kit, RT1200 Trencher
Type
Installation guide
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
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Toro International Ship Kit, RT1200 Trencher Installation guide

Toro
Brand
Toro
Model
International Ship Kit, RT1200 Trencher
Type
Installation guide
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