Installation Instructions

ManualsBrandsToro ManualsTrenchersToro 131-2883

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

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

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3396-716*A

Summary of content (28 pages)

PAGE 1
Form No. 3396-716 Rev A International Ship Kit RT1200 Trencher Model No. 131-2883 Installation Instructions CAUTION Introduction Read the Operator’s Manual for your machine and the attachments carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely. You may contact Toro directly at www.Toro.
PAGE 2
Configuring the Machine for Shipping Loose Parts Description Quantity Use Shipping plate 1 Install the shipping plate. Hearing protector 1 Wear personal protective equipment. Preparing the Machine Lifting-equipment capacity: 408 kg (900 lb) minimum 1. Ensure that the machine tilt is level and the tilt-lockout pin is installed; refer to the Operator’s Manual for the machine. 2. Move the machine to a level surface that is below the lifting equipment with the specified lift capacity. 3.
PAGE 3
. Repeat steps 1 and 2 for the side panel at the other side of the machine. 4. Place both side panels into the shipping container. 5. Rotate the BATTERY DISCONNECT switch counterclockwise to the OFF position (Figure 5). 2. Remove the extension, rain cap, and clamp from the muffler (Figure 6). 3. Place extension, rain cap, and clamp into the shipping container. Removing the Turbocharger-Exhaust Pipe 1.
PAGE 4
Removing the Console Panel and the Dash Panel Removing the Console Panel 1. Remove the 4 flange-head bolts (5/16 x 1 inch) that secure the console panel to the frame of the console (Figure 10). Figure 8 1. Alignment pin (muffler-inlet 2. Slots pipe) (turbocharger-exhaust pipe) Figure 10 1. Console frame 3. Flange-head bolts (5/16 x 1 inch) 2. Console panel 4. Remove the turbocharger-exhaust pipe from the machine (Figure 9). 2. Remove the panel from the machine (Figure 10). Removing the Dash Panel 1.
PAGE 5
. Remove the 6-socket connector of the wiring harness for the machine from the connector for the starter switch (Figure 14). Figure 14 Figure 12 1. Flange bolt (8 x 30 mm) 3. Dash assembly 1. 6-pin connector (wiring harness for the machine) 3. Starter-switch connector 2. 6-socket connector (dash harness) 4. 6-socket connector (wiring harness for the machine) 6. Remove the 6-pin connector of the wiring harness for the machine from the 6-socket connector of the dash harness (Figure 14). 2.
PAGE 6
Removing the Rear Control Cover and Rear Fenders Removing the Rear Control Cover 1. Remove the 6 flange-head bolt (12 x 30 mm) that secure the rear control cover to the rear bulkhead of the machine (Figure 15). Figure 16 Figure 15 1. Bulkhead 3. Flange-head bolt (12 x 30 mm) 1. Flange-head bolts (10 x 30 mm) 4. Straight reinforcement plate and clip nuts 2. Curved reinforcement plate and clip nuts 5. Fender 3. Fender mount 6. Front of the machine 2. Rear cover plate 2.
PAGE 7
Disconnecting the Auxiliary-Control Panel Wiring 1. At the auxiliary-control panel, remove the 10-socket connector at the end of the main-wiring harness from the 10-pin connector for the tilt switch (Figure 17). Figure 18 2. Remove the 2 flange-head bolts (12 x 40 mm) that secure the hood plate, ROPS-mounting plate, left cowl panel, and right cowl panel (Figure 19) Figure 17 1. Plugs 3. Auxiliary-control panel 2. Tilt switch 4. 10-socket connectors (main-wiring harness) 2.
PAGE 8
Figure 21 1. Flange locknuts (16 mm) 3. ROPS tube 2. Flange-head bolts (16 x 70 mm) 5. Using the lifting equipment, raise the back of the ROPS slightly. 6. Using the lifting equipment, move the ROPS rearward and up until the ROPS-mounting plate clears the hood plate and cowl panels (Figure 19). Note: Pay attention to the ROPS-mounting plate as it separates from the hood plate and cowl panels, and as the mounting plate clears the steering wheel. Figure 20 1. ROPS-mounting plate 3.
PAGE 9
Assembling the Dash Panel and Console Panel to the Machine Assembling the Machine for Shipping Assembling the Dash Panel Installing the Shipping Plate 1. Align the dash panel to the console (Figure 24). 1. Align the shipping plate between the flange of the hood plate, left cowl panel, and right cowl panel (Figure 23). Figure 24 1. Dash wiring harness 3. Machine wiring harness 2. Dash panel 2.
PAGE 10
Assembling the Rear Fenders and Rear Control Cover to the Machine Assembling the Rear Fenders 1. Align the holes in the straight reinforcement plate (with the attached clip nuts) that you removed in step 1 of Removing the Rear Fenders (page 6) with the rear 2 holes in the rear fender (Figure 26). Figure 25 1. Flange bolts (8 x 30 mm) 3. Dash panel 2. Flange locknuts (8 mm) 4. Console frame 7.
PAGE 11
7. Repeat steps 1 through 6 for the rear fender at the other side of the machine. Assembling the Rear Control Cover 1. Assemble 3 flange-head bolts (12 x 30 mm) that you removed in step 1 in Removing the Rear Fenders (page 6) into the top 3 clip nuts at the holes in the rear control cover and tighten securely (Figure 27). Figure 28 1. BATTERY ON position 2.
PAGE 12
Preparing the Machine for the Customer Loose Parts Description Quantity Use Hearing protector 1 Wear personal protective equipment. ROPS and muffler assembly 1 Align the ROPS to the machine. Flange-head bolt (16 x 50 mm) 2 Assemble the ROPS to the machine. Flange locknut (16 mm) 10 Assemble the ROPS to the machine. Flange-head bolts (16 x 70 mm) 8 Assemble the ROPS to the machine. Shim 1.52 mm (0.06 inch) 3 Align the turbocharger-exhaust pipe. Shim 0.76 mm (0.
PAGE 13
Preparing the Machine Removing the Rear Fenders 1. Remove the 3 flange-head bolts (10 x 30 mm) that secure the rear fender and curved reinforcement plate (with the attached clip nuts) to the fender mount, and remove the fender (Figure 33). Lifting-equipment capacity: 408 kg (900 lb) minimum 1. Ensure that the machine tilt is level and the tilt-lockout pin is installed; refer to the Operator’s Manual for the machine.
PAGE 14
Removing the Console Panel and the Dash Panel 2. Remove the 4 flange bolts (8 x 30 mm) and 2 flange locknuts (8 mm) that secure the dash panel to the frame of the console (Figure 36). Removing the Console Panel 1. Remove the 4 flange-head bolts (5/16 x 1 inch) that secure the console panel to the frame of the console (Figure 34). Figure 34 1. Console frame 3. Flange-head bolts (5/16 x 1 inch) Figure 36 2. Console panel 1. Flange bolts (8 x 30 mm) 3. Dash panel 2. Flange locknuts (8 mm) 4.
PAGE 15
Removing the Shipping Plate 5. Remove the socket terminal for the black wire of the dash harness from the piggyback terminal of the wiring harness for the machine (Figure 37) 1. Remove the 2 flange-head bolt (12 x 40 mm) that secure the shipping plate, hood plate, left cowl panel, and right cowl panel (Figure 40). 6. Remove the 6-socket connector of the wiring harness for the machine from the connector for the starter switch (Figure 38). Figure 38 1. 6-pin connector (wiring harness for the machine) 3.
PAGE 16
Installing the ROPS Aligning the ROPS to the Machine Lifting-equipment capacity: 408 kg (900 lb) minimum Customer provided tool: hand-operated winch. 1. Support the ROPS frame and muffler with lifting equipment having a minimum lift capacity of 408 kg (900 lb) as shown in Figure 41. Note: The ROPS frame and muffler is weighted toward the rear. You will need to tilt the ROPS frame and muffler to install the ROPS. Whenever possible, use 2 pieces of lifting equipment to lift the ROPS frame and muffler.
PAGE 17
5. At the back of the machine, check the clearance between the rear bulkhead panel of the ROPS and the wiring harness of the machine (Figure 44) Figure 44 1. Flange for the rear frame tube (ROPS) 3. Rear bulkhead panel (ROPS) 2. ROPS mounts (chassis) 4. Wiring harness (machine) 6. Using the lifting equipment, carefully move the ROPS forward and down until the holes in the hood plate and cowls are aligned with the holes in the ROPS plate (Figure 43). Figure 45 7.
PAGE 18
Figure 46 1. Left cowl panel 3. Hood-plate flange 2. Flange-head bolt (12 x 40 mm) 4.
PAGE 19
3. Align the nut clips on the reinforcement plates with the holes in the fender (Figure 48). 4. Assemble the fender, reinforcement plates, and nut clips to the machine (Figure 48) with the 5 flange-head bolts (10 x 30 mm). 5. Torque the flange-head bolts to 47 to 57 N-m (34 to 42 ft-lb). 6. Repeat steps 2 through 5 for the rear fender at the other side of the machine. Installing the Rear Control Cover 1.
PAGE 20
7. Align the holes in the dash panel with holes in the console frame (Figure 54). Figure 52 1. Blue wire (dash harness) 3. Piggyback terminal (wiring harness for the machine) 2. Socket terminal—black (ground) wire (dash harness) 4. Blade terminal (auxiliary-power port) G030030 Figure 54 3. Connect the piggyback terminal of the wiring harness for the machine onto the open blade terminal of the auxiliary-power port (Figure 52). 8.
PAGE 21
Installing the Turbocharger-Exhaust Pipe Installing the Console Panel 1. Connect the 23-pin connector of the dash wiring harness to the 23-socket connector of the machine wiring harness (Figure 56). Assembling the Turbocharger-Exhaust Pipe onto the Machine 1. Align the turbocharger-exhaust pipe (from the shipping kit) through the notches in the right cowl panel and hood panel of the machine (Figure 58).
PAGE 22
4. Assemble the band clamp (from the shipping kit) below the 2 alignment pins of the muffler-inlet pipe and tighten the clamp to close fit (Figure 61). Figure 59 1. Alignment pins (muffler-inlet pipe) Figure 61 2. Slots (turbocharger-exhaust pipe) 1. Guillotine clamp 3. Alignment pin (muffler-inlet pipe) 2. Band clamp 3.
PAGE 23
Aligning the Muffler Front to Back 1. Loosen the 4 flange-head bolts (8 x 120 mm) and flange locknuts (8 mm) that secure the exhaust-system mount to the ROPS tube (Figure 63). Figure 62 1. Upper edge of the upper-weld seam 3. Lower edge of the lower-weld seam 2. 152.4 mm (6 inches) Figure 63 2. At the right side of the bellows, measure the distance from the upper edge of the upper-weld seam to the lower edge of the lower-weld seam. Record your measurement here: 1. ROPS tube 4. Shim 0.76 mm (0.
PAGE 24
Aligning the Muffler Left to Right 1. Remove the 6 flange-head bolts (6 x 16 mm) that secure the heatshield to the exhaust-system mount and remove the heatshield (Figure 64). Figure 65 Figure 64 1. Flange-head bolts (6 x 16 mm) 4. Muffler strap 2. Clip nut (6 mm) 5. Heatshield 1. Exhaust-system mount 3. Lower-muffler support 2. Flange-head bolts (1/2 x 1 inch)—lower muffler support 4. Serrated flange nuts (1/2 inch) 3. Flange-head bolts (6 x 30 mm) 4.
PAGE 25
Installing the Muffler Extension Switching n the Battery and Installing the Side Panels and Rain Cap 1. Rotate the BATTERY DISCONNECT switch to the ON position (Figure 67). 1. Align the rain cap of the muffler extension (from the shipping kit) to the outlet pipe of the muffler so that the pivot for the rain cap is inboard (Figure 66). Note: When the rain cap is correctly aligned to the outlet pipe of the muffler, exhaust from the muffler will blow outward and away from the machine. Figure 67 1.
PAGE 26
Figure 69 1. Latch lever 3. Side-panel latch 2. Latch button 6. Repeat steps 4 and 5 at the other latch. 7. Repeat steps 2 through 6 for the side panel at the other side of the machine.
PAGE 27
Notes: 27
PAGE 28