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General Information
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GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.3
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VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2013 BRUTUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2013 BRUTUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2013 BRUTUS HD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2013 BRUTUS HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GENERAL: 2013 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2013 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 FUEL INFORMATION / RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 BIO-DIESEL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 B5 DIESEL FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 BIO-FUEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 B6 TO B20 BIO-DIESEL FUEL BLEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 ENGINE WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 COLD WEATHER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 BLOCK HEATER USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
FUEL INFORMATION, USAGE AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1.12
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Example: D131D9JDJ
GROUP 1st digit MODEL YEAR 2/3rd digit CHASSIS 4th digit* DRIVELINE 5th digit* ENGINE 6th digit* 7th digit* CATEGORY 8th digit OPTION REGION
A = ATV D = BRUTUS R = RANGER
11 12 13
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
3TNM72-APB13-Cylinder, Liquid Cooled, Diesel, Electric Start
Vehicle Identification Number (VIN) Designation
Example: 4XA1D9JD3D2000000
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Engine Designation Number
Vehicle Descriptors Engine Modifier Mfg. Location Model Year * Engine Size
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C = Sportsman 6x6 D = Sportsman Tour Displacement in cc divided A = 2x4 Chain E = Trail Boss by 10 and rounded to two B = 2x4 Shaft F = Sportsman Youth digits C = 4x4 AC Drive G = Sport (i.e. 50 = 498cc) D = 4x4 Shaft, DeDion H = RANGER 6x6 -----------E = 4x4 Shaft / IRS J = RZR XP For electric vehicles G = 4x4 Chain rear / K = Sport Youth 08 = 48 Volt shaft front M = Sportsman 12 = 72 Volt H = 4x4 Shaft / IRS N = Trail Blazer J = 2x4 Swing arm Manual P = Phoenix L = DeDion w/Non Powered - - OR - R = RANGER Midsize Attach - "Lifter" S = RZR M = DeDion w/Powered T = Sportsman X2 Attach - "Mower" 5 = 550 E = EPS U = RANGER Fullsize N = 4x4 Shaft ADC 6 = 570 D = Diesel V = RZR P = 2x4 / IRS Manual 7 = 760 F = D + E W = Multi-pass RGR R = 6x6 Shaft / IRS 8 = 850 G = Gauge X = Multi-pass RZR T = 4x4 Shaft / Trailing Arm 9 = 875 Option #1 Z = Sportsman XP X = 4x4 Shaft EBS or 904 J=F+G 1 = BRUTUS (No Cab) 2 = BRUTUS (w/Cab)
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Vehicle Identifiers
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Category
World Mfg. ID
Check Digit
1 4
2
3
4 1
Driveline
Chassis
5 D
6 9
7 J
8 D
9 3
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A = ORV D = Diesel E = EU On-road F = INT'L G = EV L = LSV M = Military S = Scandinavian V = EU On-road C = Calif.
Individual Serial No.
14
15 0
X
A
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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9th digit** 10th digit
16 0
17 0
GENERAL INFORMATION
Vehicle and Engine Serial Number Locations
Whenever corresponding about a Polaris BRUTUS utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle. Refer to Figure 1-1. Figure 1-1
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The engine model and serial number can be found on a nameplate located on top of the engine. These numbers are also stamped on flat pads on the left side of the crankcase. Refer to Figure 1-2.
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VIN
Figure 1-2
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Engine Numbers
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GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model 2013 BRUTUS 2013 BRUTUS HD 2013 BRUTUS HDPTO D131D9JDJ D131L9JDJ D132M9JDJ Model No. Owner's Manual 9924341 9924341 9924341 Parts Manual 9924343 9924343
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Series# 20 21 22 23 27 28 31 32 67 68 Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278
KEY COVER P/N 5533534
Key Series Number
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NOTE: When ordering service parts be sure to use the correct parts manual.
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GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris' official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/
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Select "SPX Website - Tools, diagnostics" from the "Service and Warranty" drop down menu
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GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2013 BRUTUS
MODEL NUMBER: D131D9JDJ ENGINE NUMBER: 3TNM72-APB
Category Length Width (tires) Height Wheel Base Ground Clearance Min. Turning Radius (Unlocked "Turf Mode") Cargo Box Dimensions (inside dimensions) Dry Weight Curb Weight Operator / Passenger Capacity Cargo Box Capacity Hitch Tongue Capacity Rated Vehicle Payload (includes weight of operator, passenger and cargo) Rated Vehicle Capacity (GVWR) Hitch Towing Capacity Dimension / Capacity 123.5 in. / 310.4 cm 63.2 in. / 160.5 cm 73 in. / 185.4 cm 84 in. / 213.4 cm 10 in. / 25.4 cm 90 in. / 229 cm 43.5 x 54 x 11.5 in. (108 x 137 x 29 cm) 1643 lbs. / 745.3 kg 1741 lbs. / 790 kg 500 lbs. / 227 kg 1250 lbs. / 567 kg 150 lbs. / 68 kg 1750 lbs. / 794 kg
3450 lbs. / 1565 kg 2000 lbs. / 907 kg
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GENERAL INFORMATION
MODEL: 2013 BRUTUS
STD MODELS: D131D9JDJ ENGINE NUMBER: 3TNM72-APB
Engine Platform Engine Number Engine Displacement Number of Cylinders Bore & Stroke Compression Ratio Compression Pressure High Idle Low Idle Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Starting Aid Fuel Injection Unit (non-serviceable) Fuel Transfer System Fuel Pump Pressure Fuel Tank Capacity Fuel Requirement Transmission Type Shift Type Travel Control Fuel System Yanmar MC Fuel Injection Pump Indirect Injection Electronic Fuel Pump (in-line) 1-5 psi (7-34 kPa) 10 gal. (37.8 L) Yanmar 3-Cylinder, Liquid Cooled, Diesel 3TNM72-APB1 904 cc 3 72 x 74 mm 23.5:1 470 ± 15 PSI 3700 ± 100 RPM 1350 ± 100 RPM Pressurized Wet Sump Polaris DIESEL Oil 2.75 qts. (2.6 L) 6.6 qts. (6.2 L) Instrument Cluster Indicator Canister Style Glow Plugs / Opt. Block Heater Relays DC Outlets Alternator Rated Output Headlights Tail Lights Brake Lights Starting System Battery Electrical 90A / 1215 Watts @ 3000 RPM Halogen: Low 55W / High 60W x 2 L.E.D. (10): 0.2 Watts x 2 L.E.D. (10): 2.9 Watts x 2 Electric Start Flooded-Filled / 32 Amp Hr. 575 CCA / 12 Volt (2) - Standard 12 Volt Located in Fuse/Relay Boxes: Chassis - ECM - Fuel Hold - Fuel Pull - Glow Plug - Starter Externally Mounted Relays: - Rear Differential - Cooling Fan 40 Amp: - Cooling Fan Motor
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Circuit Breakers
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Fuses Steering Type Toe Out Front Travel Rear Travel Front Suspension Rear Suspension Shock Preload Adjustment Front Wheel Size / Type Rear Wheel Size / Type Front Tire Make / Model / Size Rear Tire Make / Model / Size Tire Air Pressure Brake System Brake Fluid
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Low Sulfur or Ultra Low Sulfer
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Hydrostatic Drive / Hydraulics / Drivetrain
Hydrostatic Driven
In Line Shift - H / L / N / P
Hydraulic Pump Steering Flow
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Pedal Drive Hydrostatic Drive Forward / Reverse Engine Driven Gear Type
Hydraulic Pump Capacity Steering Relief Valve Charge Relief Valve Hydraulic Filtration
7.6 gpm (28.8 L) @ 3600 RPM 2.2 gpm (8.3 L) @ 3600 RPM 850 psi (58.6 bar) 87 psi (6 bar) Full flow with 50 psi (3.4 bar) cold weather bypass valve 2.75 qts. (2.6 L) 7.2 qts. (6.8 L) Demand Drive 6.75 oz. (200 ml) AGL 41 oz. (1200 ml)
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Hydraulic Fluid Capacity (Reservoir Only) Hydraulic Fluid Capacity (Full System) Front Gearcase Lubricant Requirements Transmission Lubricant Requirements
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Steering / Suspension Wheels / Brakes DOT 4
20 Amp: - Accessory - Drive - ECU - Fuel Hold Solenoid - Hydro - Lights 30 Amp: - Chassis - Fuel Pull Solenoid Glow Plug Hydraulic Power Steering 1/8 - 1/4 in. (3.2 - 6.35 mm) Dual A-arm 6 in. (15.2 cm) Multi-Link Coil Over De-Dion 6 in. (15.2 cm) Cam Adjustment 12 x 6 / Steel 12 x 8 / Steel Carlisle / AT489 / 25 x 10 R12 Carlisle / AT489 / 25 x 11 R12 Front: 10 psi (69 kPa) Rear: 20 psi (138 kPa) 4 Wheel Hydraulic Disc
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HD
MODEL NUMBER: D131L9JDJ ENGINE NUMBER: 3TNM72-APB
Category Length (with bucket) Width (tires) Height Wheel Base Ground Clearance Min. Turning Radius (Unlocked "Turf Mode") Cargo Box Dimensions (inside dimensions) Dry Weight Curb Weight Operator / Passenger Capacity Cargo Box Capacity Attachment Arm Rated Operating Capacity Hitch Tongue Capacity Rated Vehicle Payload (includes weight of operator, passenger, cargo and attachment) Rated Vehicle Capacity (GVWR) Hitch Towing Capacity Dimension / Capacity 157.9 in. / 401 cm 63.2 in. / 160.5 cm 73 in. / 185.4 cm 84 in. / 213.4 cm 10 in. / 25.4 cm 90 in. / 229 cm 43.5 x 54 x 11.5 in. (108 x 137 x 29 cm) 1830 lbs. / 830.1 kg 1919 lbs. / 870 kg 500 lbs. / 227 kg 1250 lbs. / 567 kg 500 lbs. / 227 kg 150 lbs. / 68 kg 2000 lbs. / 907 kg
4000 lbs. / 1814 kg 2000 lbs. / 907 kg
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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GENERAL INFORMATION
MODEL: 2013 BRUTUS HD
STD MODELS: D131L9JDJ ENGINE NUMBER: 3TNM72-APB
Engine Platform Engine Number Engine Displacement Number of Cylinders Bore & Stroke Compression Ratio Compression Pressure High Idle Low Idle Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Starting Aid Fuel Injection Unit (non-serviceable) Fuel Transfer System Fuel Pump Pressure Fuel Tank Capacity Fuel Requirement Transmission Type Shift Type Travel Control Fuel System Yanmar MC Fuel Injection Pump Indirect Injection Electronic Fuel Pump (in-line) 1-5 psi (7-34 kPa) 10 gal. (37.8 L) Yanmar 3-Cylinder, Liquid Cooled, Diesel 3TNM72-APB 904 cc 3 72 x 74 mm 23.5:1 470 ± 15 PSI 3700 ± 100 RPM 1350 ± 100 RPM Pressurized Wet Sump Polaris DIESEL Oil 2.75 qts. (2.6 L) 6.6 qts. (6.2 L) Instrument Cluster Indicator Canister Style Glow Plugs / Opt. Block Heater Relays DC Outlets Alternator Rated Output Headlights Tail Lights Brake Lights Starting System Battery Electrical 90A / 1215 Watts @ 3000 RPM Halogen: Low 55W / High 60W x 2 L.E.D. (10): 0.2 Watts x 2 L.E.D. (10): 2.9 Watts x 2 Electric Start Flooded-Filled / 32 Amp Hr. 575 CCA / 12 Volt (2) - Standard 12 Volt Located in Fuse/Relay Boxes: Chassis - ECM - Fuel Hold - Fuel Pull - Glow Plug - Starter - Tilt Lock Externally Mounted Relays: - Rear Differential - Cooling Fan Cargo Box Lift 20 Amp: - Cargo Box Lift 40 Amp: - Cooling Fan Motor
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Circuit Breakers Fuses Steering Type Toe Out Front Travel Rear Travel Front Suspension Rear Suspension Shock Preload Adjustment Front Wheel Size / Type Rear Wheel Size / Type Front Tire Make / Model / Size Rear Tire Make / Model / Size Tire Air Pressure Brake System Brake Fluid
Low Sulfur or Ultra Low Sulfer
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Hydrostatic Drive / Hydraulics / Drivetrain
Hydrostatic Driven
In Line Shift - H / L / N / P
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Pedal Drive Hydrostatic Drive Forward / Reverse Engine Driven Gear Type
Hydraulic Pump Steering Flow
Hydraulic Pump Capacity Steering Relief Valve Charge Relief Valve Hydraulic Filtration
7.6 gpm (28.8 L) @ 3600 RPM 2.2 gpm (8.3 L) @ 3600 RPM 850 psi (58.6 bar) 87 psi (6 bar) Full flow with 50 psi (3.4 bar) cold weather bypass valve 2.75 qts. (2.6 L) 8.4 qts. (7.9 L) Demand Drive 6.75 oz. (200 ml) AGL 41 oz. (1200 ml)
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Hydraulic Fluid Capacity (Reservoir Only) Hydraulic Fluid Capacity (Full System) Front Gearcase Lubricant Requirements Transmission Lubricant Requirements
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Steering / Suspension Wheels / Brakes DOT 4
20 Amp: - Accessory - Drive - ECU - Fuel Hold Solenoid - Hydro - Lights 30 Amp: - Chassis - Fuel Pull Solenoid Glow Plug Hydraulic Power Steering 1/8 - 1/4 in. (3.2 - 6.35 mm) Dual A-arm 6 in. (15.2 cm) Multi-Link Coil Over De-Dion 6 in. (15.2 cm) Cam Adjustment 12 x 6 / Steel 12 x 8 / Steel Carlisle / All Trail II / 25 x 9 R12 Carlisle / All Trail II / 25 x 11 R12 Front: 20 psi (138 kPa) Rear: 20 psi (138 kPa) 4 Wheel Hydraulic Disc
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HDPTO
MODEL NUMBER: D132M9JDJ ENGINE NUMBER: 3TNM72-APB
Category Length (with bucket) Width (tires) Height Wheel Base Ground Clearance Min. Turning Radius (Unlocked "Turf Mode") Cargo Box Dimensions (inside dimensions) Dry Weight Curb Weight Operator / Passenger Capacity Cargo Box Capacity Attachment Arm Rated Operating Capacity Hitch Tongue Capacity Rated Vehicle Payload (includes weight of operator, passenger, cargo and attachment) Rated Vehicle Capacity (GVWR) Hitch Towing Capacity Dimension / Capacity 157.9 in. / 401 cm 63.2 in. / 160.5 cm 74 in. / 188 cm 84 in. / 213.4 cm 7 in. / 17.8 cm 90 in. / 229 cm 43.5 x 54 x 11.5 in. (108 x 137 x 29 cm) 2148 lbs. / 974.3 kg 2232 lbs. / 1012 kg 500 lbs. / 227 kg 1250 lbs. / 567 kg 500 lbs. / 227 kg 150 lbs. / 68 kg 1750 lbs. / 794 kg
4000 lbs. / 1814 kg 2000 lbs. / 907 kg
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GENERAL INFORMATION
MODEL: 2013 BRUTUS HDPTO
STD MODELS: D132M9JDJ ENGINE NUMBER: 3TNM72-APB
Engine Platform Engine Number Engine Displacement Number of Cylinders Bore & Stroke Compression Ratio Compression Pressure High Idle Low Idle Lubrication Oil Requirements Oil Capacity Coolant Capacity Overheat Warning Exhaust System Starting Aid Fuel Injection Unit (non-serviceable) Fuel Transfer System Fuel Pump Pressure Fuel Tank Capacity Fuel Requirement Transmission Type Shift Type Travel Control Fuel System Yanmar MC Fuel Injection Pump Indirect Injection Electronic Fuel Pump (in-line) 1-5 psi (7-34 kPa) 10 gal. (37.8 L) Yanmar 3-Cylinder, Liquid Cooled, Diesel 3TNM72-APB 904 cc 3 72 x 74 mm 23.5:1 470 ± 15 PSI 3700 ± 100 RPM 1350 ± 100 RPM Pressurized Wet Sump Polaris DIESEL Oil 2.75 qts. (2.6 L) 6.9 qts. (6.5 L) Instrument Cluster Indicator Canister Style Glow Plugs / Opt. Block Heater Relays DC Outlets Alternator Rated Output Headlights Tail Lights Brake Lights Starting System Battery Electrical 90A / 1215 Watts @ 3000 RPM Halogen: Low 55W / High 60W x 2 L.E.D. (10): 0.2 Watts x 2 L.E.D. (10): 2.9 Watts x 2 Electric Start Flooded-Filled / 32 Amp Hr. 575 CCA / 12 Volt (2) - Standard 12 Volt Located in Fuse/Relay Boxes: Chassis - Condenser Fan - ECM Fuel Hold - Fuel Pull - Glow Plug - PTO - Starter - Tilt Lock Externally Mounted Relays: - Rear Differential - Cooling Fan HVAC - Cargo Box Lift 20 Amp: - Cargo Box Lift - Condenser Fan Motor 40 Amp: - Cooling Fan Motor 20 Amp: - Accessory - Drive - ECU - Fuel Hold Solenoid - Hydro - Lights PTO 30 Amp: - Chassis - Fuel Pull Solenoid Glow Plug - HVAC*
* Located external from Fuse/Relay Box
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Circuit Breakers Fuses A/C Refrigerant Steering Type Toe Out Front Suspension Front Travel Rear Suspension Rear Travel Shock Preload Adjustment Front Wheel Size / Type Rear Wheel Size / Type Front Tire Make / Model / Size Rear Tire Make / Model / Size Tire Air Pressure Brake System Brake Fluid
Low Sulfur or Ultra Low Sulfer
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Hydrostatic Drive / Hydraulics / Drivetrain
Hydrostatic Driven
In Line Shift - H / L / N / P
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Pedal Drive Hydrostatic Drive Forward / Reverse Engine Driven Gear Type
Hydraulic Pump Steering Flow
Hydraulic Pump Capacity Steering Relief Valve Charge Relief Valve Hydraulic Filtration
7.6 gpm (28.8 L) @ 3600 RPM 2.2 gpm (8.3 L) @ 3600 RPM 850 psi (58.6 bar) 87 psi (6 bar) Full flow with 50 psi (3.4 bar) cold weather bypass valve 2.75 qts. (2.6 L) 8.4 qts. (7.9 L) Demand Drive 6.75 oz. (200 ml) AGL 41 oz. (1200 ml) PTO Gearbox Oil 6 oz. (177 ml)
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Hydraulic Fluid Capacity (Reservoir Only) Hydraulic Fluid Capacity (Full System) Front Gearcase Lubricant Requirements Transmission Lubricant Requirements PTO Lubricant Requirements
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Air Conditioning R134A Steering / Suspension Wheels / Brakes DOT 4
Hydraulic Power Steering 1/8 - 1/4 in. (3.2 - 6.35 mm) Dual A-arm 6 in. (15.2 cm) Multi-Link Coil Over De-Dion 6 in. (15.2 cm) Cam Adjustment 12 x 6 / Steel 12 x 8 / Steel Carlisle / All Trail II / 25 x 9 R12 Carlisle / All Trail II / 25 x 11 R12 Front: 20 psi (138 kPa) Rear: 20 psi (138 kPa) 4 Wheel Hydraulic Disc
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GENERAL INFORMATION
FUEL INFORMATION, USAGE AND RECOMMENDATIONS
Fuel Information / Recommendations CAUTION
NEVER use an engine starting aid such as ether. Engine damage will result. NOTE: For the best engine performance, to prevent engine damage and to comply with EPA/ARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN Low Sulfur, Ultra Low Sulfur #2 or #1 Diesel Fuel containing no more than 5% bio-diesel. Diesel fuel should comply with the following world-wide specifications: Diesel Fuel Specification ASTM D975 No. 1D S15, S500 No. 2D S15, S500 EN590:96 ISO 8217 DMX BS 2869-A1 or A2 JIS K2204 Grade No. 2 KSM-2610 GB252 Location USA European Union International · Fuel additives are not recommended. Some fuel additives may cause poor engine performance. · Ash content must not exceed 0.01% by volume. · Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred.
· Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test analysis method JPI-5S-44-95).
Bio-Diesel Fuels
NOTE: Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle. In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. YANMAR approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with 95% (by volume) of approved mineral oil derived diesel fuel. Such bio-diesel fuels are known in the marketplace as B5 diesel fuels.
United Kingdom Japan Korea China
· The fuel cetane number should be equal to 45 or higher. · The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Especially in the U.S.A. and Canada, Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low Sulfur fuel should be used.
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Additional Technical Fuel Requirements
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· NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel. · Water and sediment in the fuel should not exceed 0.05% by volume. · Keep the fuel tank and fuel-handling equipment clean at all times. · Poor quality fuel can reduce engine performance and/or cause engine damage.
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B5 Diesel Fuel Requirements
1. The bio-fuels must meet the minimum specifications for the country in which they are used. · In Europe, bio-diesel fuels must comply with the European Standard EN14214 · In the United States, bio-diesel fuels must comply with the American Standard ASTMD-6751.2 2. Bio-fuels should be purchased only from recognized and authorized diesel fuel suppliers.
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· Lubricity: Wear mark of WS1.4 should be Max. 0.018 in. (.460 µm) at HFRR test.
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· PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.
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· Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.
GENERAL INFORMATION
Bio-Fuel Precautions
1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components. 2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth. 3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization. 4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil. 5. Even bio-diesel fuels that comply with a suitable standard as delivered, will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and/or fuel storage containers, may be necessary. 6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.
Engine Warranty
Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty. The same applies to damages or other concerns induced by not complying with the recommended operating conditions of YANMAR engines with bio-diesel fuel.
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Cold Weather Operation
Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the fuel blending guideline table below to prevent this from occurring.
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Temperature Above 15° F (9° C) Below -20° F (-29° C)
Cold Weather Fuel Blending Guideline: NO. 2 Diesel NO. 1 Diesel 0% 50% 100%
Down to -20° F (-29° C) 50% 0%
B6 to B20 Bio-Diesel Fuel Blend
Approved Engines
Only the YANMAR TNM engine series (3TNM72) may operate with bio-diesel fuel concentrations up to B5 for Polaris vehicle applications. Approved Fuel
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IMPORTANT: Raw pressed vegetable oils are not considered bio-diesel, and are unacceptable for use as fuel in any concentration in YANMAR engines. Bio-diesel fuel blends up to B5 must comply with the following standards: · EN14214 (European standard) and/or ASTM D6751 (American standard) · All applicable engines may operate with bio-diesel fuel up to a maximum B5 (5% bio-diesel blend) concentration
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B6 to B20 bio-diesel is NOT approved for this Polaris vehicle application.
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Block Heater Usage
If this vehicle will be operated when temperatures are in the +5° to -25° F (-15° to -32° C) range, a block heater must be installed. Please see your dealer to purchase a block heater kit.
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100%
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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1.13
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
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°C to °F: °C x 9/5 + 32 = °F
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1.14
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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°F to °C: °F - 32 x 5/9 = °C
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GENERAL INFORMATION
Standard Bolt Torque Specification
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Grade 5 Grade 8
Grade 2
Bolt Size 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20
6 (8) 11 (15) 12 (16) 20 (27) 23 (32) 30 (40) 35 (48) 50 (69) 55 (76)
10 (14) 17 (23) 19 (26) 30 (40) 35 (48) 50 (69) 55 (76)
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75 (104) 90 (124) Grade 8.8 / 8.9 ft-lbs (Nm) Dry Threads .5 (.7) 1 (1.5) 2 (3) 4 (5.5) 10 (13) 18 (25) 33 (45) 55 (75) 85 (115) 118 (160) 1 (1.3) 2 (3) 4.5 (6) 7.5 (10) 18 (25) 37 (50) 63 (85) 103 (140) 159 (215) 225 (305) 1.5 (2) 3 (4.5) 6.5 (9) 11 (15) 26 (35) 55 (75) 97 (130) 151 (205) 232 (315) 321 (435) 10.9 4.8
Metric Bolt Torque Specification
Bolt Size
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4.6
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M4
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M3
.3 (.5)
.8 (1.1)
M5 M6
1.5 (2.5) 3 (4)
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M8
7 (9.5) 14 (19) 26 (35) 37 (50) 59 (80) 81 (110)
M10
M12
M14 M16 M18
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14 (19) 25 (35) 29 (40) 45 (62) 50 (69) 70 (97) 80 (110) 110 (152) 120 (166) 12.9 1.5 (2) 4 (5) 7.5 (10) 13 (18) 33 (45) 63 (85) 11 (150) 177 (240) 273 (370) 376 (510)
5 (7)
8 (11)
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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12 (16)
Grade 2 ft-lbs (Nm)
Grade 5 ft-lbs (Nm)
Grade 8 ft-lbs (Nm)
1.15
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
Metric Tap / Drill Sizes
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1.16
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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