Operator's Manual

ManualsBrandsToro ManualsAttachmentsMauser KS-525 Full Safety Cab Kit, LT3240/R3240T/T4240 Mowers

Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 1 of 64 Part No. 111-4431 (A)

Spellbrook, Bishop’s Stortford, Herts. CM23 4BU, England.

Telephone: 01279 723444 Fax: 01279 723821 E-mail: sales@hayter.co.uk

Service@hayter.co.uk Web: www.toro.com / www.hayter.co.uk

SAFETY CAB WITH AIR CONDITIONING & HEATER BLOWER INSTRUCTION MANUAL & PARTS LIST

Model 02880

For LT3240 / T4240 / R3240T

Models 02740 / 02750 / 02770

ORIGINAL VERSION (EN)

SERIAL NO. 311000001

CONTENTS Page No.

INTRODUCTION 3

SAFETY PRECAUTIONS 4 - 7

Training 5

Preparation 5

Operation 5 - 6

Safety Symbols 7

EC CONFORMITY INFORMATION 8

Noise / Vibration levels 8

EC Declaration of Conformity 8

SPECIFICATIONS 9

CONTROLS 9

AIR CONDITIONING FITTING KIT (02740) 10 - 11

AIR CONDITIONING FITTING KIT (02770) 12 - 13

AIR CONDITIONING FITTING KIT (02750) 14 - 15

HEATER BLOWER KIT MODEL 02881 16 - 17

AIR CONDITIONING & HEATER BLOWER KIT MODEL 02882 18 - 21

SAFETY CAB MODEL 02880 22 - 35

Cab Frame 22 - 23

Rear Window 24

Front Window 25

Main Frame / Doors 26 - 27

Side Windows 28

Roof 29

Roof Insert 30 - 31

Front Mounting 32

Rear Mounting 33 - 34

Windscreen Washer 35

SAFETY CAB GENERAL ASSEMBLY 36 - 43

Introduction 36

Assembly 36 - 42

2 Post ROPS Removal 37

Water Bottle Assembly 37

Platform Tasks 38

Wiring 41

Template 1 - Washer Bottle Mounting Bracket 43

Summary of content (64 pages)

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Spellbrook, Bishop’s Stortford, Herts. CM23 4BU, England. Telephone: 01279 723444 Fax: 01279 723821 E-mail: sales@hayter.co.uk Service@hayter.co.uk Web: www.toro.com / www.hayter.co.uk SAFETY CAB WITH AIR CONDITIONING & HEATER BLOWER INSTRUCTION MANUAL & PARTS LIST Model 02880 For LT3240 / T4240 / R3240T Models 02740 / 02750 / 02770 ORIGINAL VERSION (EN) SERIAL NO. 311000001 CONTENTS Page No.
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CONTENTS Page No.
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INTRODUCTION This manual provides instructions on the use of the safety cab and it’s accessories. The Cab KS-524 (Model 02880) is designed to be fitted to the machines listed above. This provides additional operator protection, particularly when the mower is to be used on slopes and provides limited safety protection in the event of a rollover. For maximum safety, the seat belt must be correctly fitted and worn by the operator.
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SAFETY PRECAUTIONS ATTENTION THIS SYMBOL MEANS BE ALERT! YOUR SAFETY IS INVOLVED THIS SAFETY CAB AND ACCESSORIES ARE FOR USE ON THE LT3240, T4240 & R3240T. READ THIS MANUAL BEFORE FITTING OR CARRYING OUT ANY WORK. IT IS ESSENTIAL THAT SERVICE PERSONNEL AND OPERATORS STUDY IT FOR THEIR OWN SAFETY Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 4 of 64 Part No.
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SAFETY PRECAUTIONS THESE INSTRUCTIONS ARE IN ADDITION TO THOSE CONTAINED IN THE MACHINE OPERATORS MANUAL UNLESS OTHERWISE STATED. READ AND UNDERSTAND THE SEPARATE MACHINE OPERATORS MANUAL BEFORE ATTEMPTING TO FIT THIS KIT. THE FOLLOWING PRECAUTIONS MUST BE TAKEN TO HELP PREVENT ACCIDENTS. SAFETY PRECAUTIONS - TRAINING Read the instructions carefully. Be familiar with the use of the equipment. Ensure that the specified torque settings are adhered to.
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SAFETY PRECAUTIONS - OPERATION Continued Remember there is no such thing as a ‘safe’ slope. Travel on grass slopes requires particular care. To guard against overturning or loss of traction when travelling or mowing on a slope: - Exercise extreme care when changing direction on a slope. - Do not stop or start suddenly. - Engage drive slowly. - Keep machine speed low. - Avoid tight turns. - Stay alert for humps, hollows and other hidden hazards.
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SAFETY SYMBOLS Decal - Warning Crush Hazard Part No: 111-0773 (A) Location: Centre platform Fig 4 A) Safety Alert - Be aware to the possibility of injury B) Crushing fingers.
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NOISE LEVEL Operator’s Daily Personal Noise Exposure: TORO have no control over site conditions, duration of use, degree of cab doors/ windows, state of maintenance or adjustment of the mower.
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SPECIFICATIONS Dimensions of machines with cab and Air conditioning Weight: 84kg Machine Model Overall Height Total weight with 8" cutterheads LT3240 1785 mm 1317 kg CAB T4240 R3240T Beacon N/A 1775 mm 1775 mm Add 150 mm 202 kg 1870 kg 1869 kg N/A Windscreen washer bottle capacity: 0.
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AIR CONDITIONING FITTING KIT (MODEL 02885) - 02740 PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Issued: 01.04.11 DESCRIPTION PART NO. SCREW M8*25 SCREW M8*30 SETSCREW M10*40*1.25 FINE PITCH NUT M8 WASHER - M10 SPRING CLIP - 11-17mm PULLEY V1505 CRANKSHAFT HOSE CLAMP HI-TORQUE 30-50mm SETSCREW M10*35*1.
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AIR CONDITIONING FITTING KIT (MODEL 02885) - 02740 PARTS LIST Continued Fig 11 15 1 To Compressor 4 19 19 13 1 19 To Alternator 2 19 19 17 14 1 Engine Mount Nut 18 4 19 19 To Exhaust Manifold 16 4 To Chassis 3 Outlet hose To Engine Block 20 To Engine 6 8 Hose Inlet hose 8 10 Hose 11 6 12 To Radiator Cut 15mm of the hose and connect Tee piece to the hoses. Tighten the hoses with clamps. Issued: 01.04.11 Approved: Engine Remove Plug from the engine block.
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AIR CONDITIONING FITTING KIT (MODEL 02844) - 02770 PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Issued: 01.04.11 DESCRIPTION PART NO. SETSCREW M10*25*1.25 FINE PITCH SETSCREW M12*40*1.25 FINE PITCH BRACKET - AIR CON ALTERNATOR ADJUSTER BRACKET AIR CON SUPPORT AIR CON ADJUSTER FAN BELT - XPA 1060 BELT - XPA 1382 SETSCREW M8*25 WASHER M8 SPRING SETSCREW M10*30 NUT M8 NYLOC INSERT T TYPE WASHER M10*21*1.
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Issued: 01.04.11 Part of Alternator 4 Approved: Hose 8 Mod. No. 5060358 23 Hose Outlet hose 22 Cut 15mm of the hose and connect Tee piece to the hoses. Tighten the hoses with clamps. 20 To A/C Compressor Detail A Part of Engine Remove Plug from engine. Connect the Union Pipe.
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AIR CONDITIONING FITTING KIT (MODEL 02844) - 02750 PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Issued: 01.04.11 DESCRIPTION PART NO. SCREW M8*25 SCREW M8*30 NUT M8 WASHER PLAIN M12 ADAPTOR 3/8" BSP - ½" HOSE CLAMP HI-TORQUE 30-50mm FITTING - TEE 35mm FITTING - TEE 27mm PIPE UNION COMPRESSOR BRACKET BRACKET - SIDE SUPPORT BRACKET - SUPPORT EXHAUST CLAMP - COMPRESSOR CLAMP - ALTERNATOR BELT - DRIVE HOSE CLAMP SETSCREW M12*40*1.
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AIR CONDITIONING FITTING KIT (MODEL 02844) - 02750 PARTS LIST Continued Fig 13 1 18 12 To Compressor 1 18 13 To Exhaust Manifold 3 18 2 11 18 1 Engine Mount Nut 15 10 To Alternator 3 18 To Chassis 3 14 18 3 17 To Engine Block 4 Outlet hose To Engine 16 6 Hose Inlet hose 6 7 Hose 8 16 9 5 Cut 15mm of the hose and connect Tee piece to the hoses. Tighten the hoses with clamps. Issued: 01.04.11 Approved: To Radiator Engine Remove Plug from engine block. Connect the Union Pipe. Mod.
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HEATER BLOWER KIT (MODEL 02881) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Issued: 01.04.11 DESCRIPTION PART NO. HEATER MATRIX WASHER PLAIN M8 AIR DUCT - HEATER WASHER PLAIN M6*12*1.6 NUT M6 NYLOC T TYPE SWITCH - HEATER LENS - HEATER SWITCH FUSE - 5 AMP HANDLE - TEMP CONTROL MOUNT - TEMP CONTROL HANDLE TAP - HEATER HOSE NUT M8 CLIP JUBILEE O/D ¾" TUBE CLIP - HOSE CONNECTOR - HOSE HOSE - HOT WATER I/D 14mm*0.85m CABLE - WIRING HOSE - HOT WATER I/D 10.
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Issued: 01.04.11 Approved: 21 FORWARD TRAVEL Remove Plug from engine block. Connect the Pipe Union. To Engine 25 Mod. No. 5060358 Sheet 17 of 64 9 10 B Rear Pillar RH 1 11 13 2 12 13 5 4 14 3 8 4 5 B 16 15 18 6 19 7 A A Rear Pillar RH 20 23 T424 Only To Engine/ Radiator Cut 15mm off of the hose and connect tee piece to the hoses. Tighten the hoses with clamps. 20 22 HEATER BLOWER KIT (MODEL 02881) - PARTS LIST Continued Fig 14 Part No.
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AIR CONDITIONING & HEATER BLOWER KIT (MODEL 02882) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Issued: 01.04.11 DESCRIPTION PART NO. QTY SCREW M8*25 WASHER ¼"*7/8"*0.8" THK SCREW M6*20 SETSCREW M10*25*1.25 FINE PITCH NUT M6 NYLOC INSERT TYPE NUT M8 NYLOC INSERT TYPE WASHER PLAIN M6*12*1.
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AIR CONDITIONING & HEATER BLOWER KIT (MODEL 02882) - PARTS LIST Continued Fig 15 5 9 7 42 41 47 Engine 48 8 20 To Front Pillar RH A 50 D 54 C 13 53 To Rear Pillar RH 55 To A/C Compressor Rear Pillar LH 23 30 3 22 32 37 43 27 57 36 25 32 56 35 29 39 33 55 40 24 32 54 2 53 To Front Pillar LH 62 17 28 58 50 57 B 6 Engine / Radiator 63 13 To A/C Compressor Rear Pillar LH 62 8 28 8 8 7 12 49 5 21 1 44 18 38 5 D 5 C B A 58 7 26 1 7 16 45 FORWA
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AIR CONDITIONING & HEATER BLOWER KIT (MODEL 02882) - PARTS LIST Continued ITEM NO. 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Issued: 01.04.11 DESCRIPTION PART NO. HOSE - HOT WATER I/D 10.5mm*0.2m WATER DRAIN HOSE - 1.70m HOSE DIA. 17mm HOSE GUARD - 1.80m T-FITTING - A/C HOSE WATER DRAIN HOSE - 0.40m WATER DRAIN HOSE - 0.
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AIR CONDITIONING & HEATER BLOWER KIT (MODEL 02882) - PARTS LIST Continued Fig 15 5 9 7 42 41 47 Engine 48 8 20 To Front Pillar RH A 50 D 54 C 13 53 To Rear Pillar RH 55 To A/C Compressor Rear Pillar LH 23 30 3 22 32 37 43 27 57 36 25 32 56 35 29 39 33 55 40 24 32 54 2 53 To Front Pillar LH 62 17 28 58 50 57 B 6 Engine / Radiator 63 13 To A/C Compressor Rear Pillar LH 62 8 28 8 8 7 12 49 5 21 1 44 18 38 5 D 5 C B A 58 7 26 1 7 16 45 FORWA
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SAFETY CAB - CAB FRAME (MODEL 02880) - PARTS LIST ITEM NO. DESCRIPTION PART NO.
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SAFETY CAB - CAB FRAME (MODEL 02880) - PARTS LIST Continued Fig 16 8 4 15 5 30 14 26 27 13 10 11 32 12 35 23 18 7 17 16 1 34 28 29 22 25 31 3 33 9 40 32 36 34 38 37 2 31 39 21 24 20 19 FORWARD TRAVEL 6 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 23 of 64 Part No.
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SAFETY CAB - REAR WINDOW (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION PART NO. QTY GLASS ASSEMBLY GLASS GASKET HINGE SCREW M8*25 NUT M8 WASHER M8 GAS STRUT MOUNTING CLAMPING SLEEVE GAS STRUT BRACKET BUCKLE HOLDER INSERT PIECE 111-1759 964220 111-1738 964150 03162 09441 ZWP1H000U 111-1756 964227 964228 964208 964230 964111 111-1747 ITEM NOTE 1 1 1 2 2 2 2 2 2 2 2 2 1 2 Fig 17 SET INCLUDE 2 & 3 2.
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SAFETY CAB - FRONT WINDOW (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION PART NO. QTY UPPER GLASS ASSEMBLY UPPER GLASS UPPER GASKET LABEL HINGE GAS STRUT MOUNTING GAS STRUT BRACKET BUCKLE LOWER GLASS ASSEMBLY LOWER GLASS LOWER GASKET GLASS FIXING SCREW M5*16 111-1757 964147 964215 111-1744 964150 111-1756 964152 964229 964154 111-1758 964180 964215 964182 964183 1 1 1 1 2 2 2 2 1 1 1 1 3 3 ITEM NOTE SET INCLUDE 2 & 3 3.84m SET SET SET SET INCLUDE 11 & 12 3.
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SAFETY CAB - MAIN FRAME/DOORS (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Issued: 01.04.11 DESCRIPTION PART NO.
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SAFETY CAB - MAIN FRAME/DOORS (MODEL 02880) - PARTS LIST Continued Fig 19 17 16 25 15 13 12 24 7 8 16 15 14 20 18 14 21 19 16 15 11 9 FORWARD TRAVEL 14 23 5 6 22 3 Issued: 01.04.11 Approved: 10 Mod. No. 5060358 4 Sheet 27 of 64 Part No.
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SAFETY CAB - SIDE WINDOWS (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 DESCRIPTION PART NO. QTY Seal Bezel Screw Washer M6 Bracket Glass 964215 964182 964218 ZWP1F000U 964217 111-1674 1 2 2 2 2 1 ITEM NOTE 2.19m Fig 20 2 4 3 5 6 1 5 FORWARD TRAVEL 2 4 3 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 28 of 64 Part No.
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SAFETY CAB - ROOF (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION PART NO. COVER WASHER M6 SCREW M6*25 ROOF NUT M6 WASHER M6 WASHER M8 SCREW M8*40 SCREW M8*30 WASHER M8 WASHER M4 SCREW 3.
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SAFETY CAB - ROOF INSERT (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Issued: 01.04.11 DESCRIPTION PART NO. SUN VISOR EARTHING STRIP RIVET 4*10 FRAME BLANKING PLATE - SWITCH INTERIOR LIGHT 5W BULB BLANKING PLATE - RADIO AIR NOZZLE RELAY WASHER M4 RIVET 4*8 FUSE BOX FUSE BRIDGE 5 AMP FUSE 7.5 AMP FUSE SWITCH EMBLEM COVER SCREW 3.
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SAFETY CAB - ROOF INSERT (MODEL 02880) - PARTS LIST Continued Fig 22 28 11 19 8 20 24 23 12 11 27 29 26 5 17 18 10 25 22 29 4 3 11 2 11 28 9 7 6 1 13 16 15 14 FORWARD TRAVEL Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 31 of 64 Part No.
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SAFETY CAB - FRONT MOUNTING (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 DESCRIPTION PART NO. QTY SUPPORT LH NUT M10 FLEXIBLE BUSH MOUNTING WASHER M10 LOCKING PIN SUPPORT RH SCREW M10*30 964133 ZNN1J000U 964135 ZWP1H000U 964142 964132 964134 ITEM NOTE 1 6 2 12 2 1 6 Fig 23 5 7 4 7 3 4 1 6 FORWARD TRAVEL 3 4 2 4 2 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 32 of 64 Part No.
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SAFETY CAB - REAR MOUNTING (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Issued: 01.04.11 DESCRIPTION PART NO. SUPPORT POST RH FLEXIBLE MOUNTING PIN HOLDER LOCKING PIN WASHER M16 SCREW M16*100 PLATE NUT M16 SCREW M10*30 WASHER M10 NUT M10 SCREW M12*35 WASHER M12 NUT M12 SUPPORT POST LH 964137 111-1686 964141 964142 111-1690 ZBH1P100U 111-1745 09456 964134 ZWP1H000U ZNN1J000U ZDH1L035U HY09485 09650 964138 Approved: Mod. No.
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SAFETY CAB - REAR MOUNTING (MODEL 02880) - PARTS LIST Continued Fig 24 6 5 3 4 9 9 10 10 6 2 5 3 10 4 11 10 9 15 11 10 10 12 2 7 8 13 10 11 10 1 11 12 7 13 10 10 8 14 10 14 10 FORWARD TRAVEL 14 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 34 of 64 Part No.
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SAFETY CAB - WINDSCREEN WASHER (MODEL 02880) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 DESCRIPTION PART NO. QTY BRACKET RESERVOIR WITH PUMP HOSE NOZZLE CABLE TIE GROMMET CHECK VALVE 111-1731 964234 111-1741 111-1735 HY3966 111-1742 964239 1 1 1 1 7 2 1 ITEM NOTE 4.65m NOT SHOWN Fig 25 2 1 3 6 7 4 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 35 of 64 Part No.
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SAFETY CAB GENERAL ASSEMBLY - INTRODUCTION Check that all parts have been correctly supplied.
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SAFETY CAB GENERAL ASSEMBLY - 2 POST ROPS REMOVAL (If applicable) This cab is a fully tested ROPS cab and is approved to Directive 79/622/EEC as amended. Remove existing ROPS: Fig 28 1. Support the ROPS by a safe manner. Remove securing bolts and ensure that is safely supported using the harness to hold the weight. 2. Remove the bolts securing the front hoop to the chassis. 3. Remove the front ROPS hoop. 4. Remove the two bolts each side that fix the ROPS to the fuel tank supports. 5.
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SAFETY CAB GENERAL ASSEMBLY - PLATFORM TASKS 10. Seek assistance to steady the operator platform and remove the gas strut. Refer to Fig 31. Fig 31 11. Seek assistance and carefully lower the operator platform. Fold the seat and arms forwards to provide adequate clearance for the cab assembly. Refer to Fig 32. 12. Remove both of the front pivot support plates at the front of the platform. Refer to Fig 33. 13. Assemble the pivot support plates to the front of the cab assembly using the pivot retaining pins.
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SAFETY CAB GENERAL ASSEMBLY - ASSEMBLY Continued 17. Ensure straps are positioned to the back of the cab. Allowing the front of the cab to tilt in a forward direction. Refer to Fig 35. Fig 35 18. Carefully guide the cab assembly over the vehicle using the lifting equipment and lower with the front of the cab tilting forward. Refer to Fig 35 and Fig 36. 19. Loosely bolt the front pivot plates in position. Refer to Fig 37. 20.
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SAFETY CAB GENERAL ASSEMBLY - ASSEMBLY Continued 21. Push the pivot retaining pins towards the centre to fully engage with the original platform pivot pin at the front of the cab assembly and retain with the M6 screws, nuts and washers provided. Fig 39 22. Finally tighten the pivot plate fasteners to the recommended torque. Refer to page 42. 23. Drill ten holes 8.5 mm diameter through the operator platform, using the cab frame holes as a template.
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SAFETY CAB GENERAL ASSEMBLY - WIRING 29. Connect the red positive washer bottle wire to the red fuse box positive battery feed. Refer to Fig 43. Fig 43 Connect the red/black wire from the cab to the other side of the fuse box. Connect the brown negative wire tot he frame. Connect the short red/black ignition wire assembly connected to the other side of the fuse in the fuse box to terminal 58 on the ignition switch. Cable tie the cab wiring connections and the fuse box to secure them safely in place. 30.
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SAFETY CAB GENERAL ASSEMBLY - ASSEMBLY Continued Fig 45 40. For 200 mm MK3 cutterheads proceed as follows: Remove the nut caps, M24 nuts and washers which retain each of the front cutterheads and slide both assemblies forward to dismount them from the suspension pins. Refer to Figs 45, 46 and 47. - Remove both suspension pin assemblies. - Remove the nut caps, M24 nuts and pin retainers from the suspension pins and refit them to longer suspension pins supplied. Refer to Fig 47.
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SAFETY CAB GENERAL ASSEMBLY - TEMPLATE 1 - WASHER BOTTLE MOUNTING BRACKET 5.5 Issued: 01.04.11 Approved: DRILL 2 HOLES Mod. No. 5060358 Sheet 43 of 64 Part No.
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BEACON INSTALLATION - INTRODUCTION The wiring loom and mounting bracket are supplied with the cab. The mounting bracket can be attached to the right or left side of the cab as required. BEACON INSTALLATION - ASSEMBLY 1. Disconnect the negative (-ve) battery lead first and then disconnect the positive (+ve) battery lead. 2. Remove the cab roof to gain access to the beacon wiring loom connector. 3.
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BEACON INSTALLATION - (MODELS 02843 & 02848) - PARTS LIST ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 DESCRIPTION PART NO.
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BEACON INSTALLATION - (MODELS 02843 & 02848) - PARTS LIST Continued Fig 51 7 12 13 1 13 11 4 B 8 10 8 9 13 A 9 11 6 2 5 3 REAR DEFLECTOR - ASSEMBLY 1. Align item 1, the rear deflector with the brackets shown on the cutterhead. Refer to Fig 52. Fig 52 4 2. Use the fasteners (items 2, 3, 4) to secure the deflector into position. Refer to Fig 52. 3 1 4 3 3 2 3 2 Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 46 of 64 Part No.
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REAR DEFLECTOR - PARTS LIST ITEM NO. 1 2 3 4 DESCRIPTION PART NO. QTY DEFLECTOR ASSEMBLY - CAB KIT NUT M5 NYLOC WASHER PLAIN M5 SETSCREW M5*16 111-0177 09430 09470 ZDH1E016U ITEM NOTE 2 8 16 8 NOISE REDUCTION KIT - ASSEMBLY Note: Before fitting any of the noise reduction components, ensure that the sticking surfaces are free from dirt and grease by using a suitable cleaner. 1. Inside the cab, fold the seat-back down to gain access to the rear of the cab.
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AIR-CONDITIONING & HEATING INSTALLATION - INTRODUCTION The Heater Blower must be fitted by an authorised dealer who is conversant with the installation of air conditioning systems. It is advisable to install the air conditioning before fitting of the cab. Read and understand the assembly instructions before proceeding.
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AIR-CONDITIONING & HEATING INSTALLATION - ASSEMBLY Continued 7. Cut a hole in the roof lining from inside the cab roof to mount the hot water valve. Refer to Fig 58 (L). Fig 57 8. Insert the plastic housing for temp switch (H) and snap in position. Refer to Fig 57. (H) 9. Cut two holes in the roof lining for the air con control panel (I) and fit the control panel. Refer to Fig 57. 10. Screw on the valve and operating handle. (I) 11.
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AIR-CONDITIONING & HEATING INSTALLATION - ASSEMBLY Continued 22. Lead the thick hoses with the connections already fitted down inside the rear left hand post. Then tape it carefully with the special tar rich tape. Refer to Fig 60 (O). Fig 60 (O) 23. Lay the thick and the medium hose down inside the cab rear cross member. Refer to Fig 60 (P).
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AIR-CONDITIONING & HEATING INSTALLATION - ASSEMBLY Continued 24. Pick up the wiring harness and connect the 2 pole plug with green cable to the pressure plug. Fig 63 25. Connect the 2 pole plugs (red/brown) (Q) to the fans on the roof (when installed later). Refer to Fig 63 (Q). 26. Put canvas covering (R) onto tarred hoses to prevent them from sticking to the roof. Refer to Fig 64 (R). 27. Run the rest of the wiring harness inside the left hand top cab rail to the front of the roof space.
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COMPRESSOR INSTALLATION - ASSEMBLY NOTE: The connections on the compressor must be kept blanked off during installation. The refrigerator oil in the compressor is highly hygroscopic. Fig 68 Mount the bracket for the compressor - Although the parts are different for the basic models, they are sufficiently similar to require only one set of instructions. 1. Remove the alternator and its adjuster. Refer to Fig 68. 2. Remove the screws of the rear engine mount on the right side of the machine.
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COMPRESSOR INSTALLATION - ASSEMBLY Continued 11. Fit additional stay straps to ensure that the mounting is rigid. Refer to Fig 72 (F). Fig 72 12. Tighten all bolts and set belt tension. Refer to Fig 72. 13. If belts are not running true and there is misalignment of compressor and or alternator with the engine pulleys, slacken the mounting bracket fixing screws, adjust and retighten. Refer to Fig 72. 14. Run the air conditioning hoses over the engine. Refer to Fig 75 (G). (F) 15.
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COMPRESSOR INSTALLATION - ASSEMBLY Continued Full electrical circuit diagram Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 54 of 64 Part No.
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HEATER BLOWER INSTALLATION - ASSEMBLY The heater blower must be fitted by an authorised dealer. Fig 77 Read and understand the assembly instructions before proceeding. FUSE BOARD Refer to the Spare Parts and the cab installation section of this manual before proceeding. The installation of the heater blower unit can be carried out with the cab in its lowered position. 1. Disconnect the battery terminals, first the negative (-ve) and then the positive (+ve). Refer to Fig 77. 2. Remove the cab roof.
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HEATER BLOWER INSTALLATION - ASSEMBLY Continued 12. Route both heater hoses down and inside the rear cab post. Refer to Fig 80. Fig 80 13. Slide the hose protection sleeves over both hoses. 14. Connect the wiring harness as shown in the electrical wiring section. 15. Tie the hoses together using the cable ties supplied. 16. Route the hoses through the engine compartment down the right side of the engine. Ensure that they are routed away from the engine exhaust silencer and manifold. Refer to Fig 81. 17.
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HEATER BLOWER INSTALLATION - ASSEMBLY Continued 24. Connect the heater hoses from the cab, one to the connector on the thermostat housing and the other to the T connector in the bottom hose. Use the hose clips supplied. Refer to Fig 85 and Fig 86. 25. Tie hoses back to prevent them from chafing and ensure that they are routed away from rotating parts and exhaust components. Refer to Fig 86. 26. Refit the roof. Fig 85 Fig 86 27.
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ROPS CAB, AIR CONDITIONING AND HEATING INSTALLATION - OPERATION Fig 88 HEATER BLOWER ONLY: 1. Rotate the hot water valve mounted in the right hand side of the roof console to achieve the desired air temperature. Anti clockwise to increase temperature, clockwise in reduce temperature. 2. The fan speed is controlled by the rocker switch on the left hand side of the roof console. 3. The five air vents in the roof console can be rotated and angled to achieve the desired air direction. 4.
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ROPS CAB, AIR CONDITIONING AND HEATING INSTALLATION - OPERATION Continued AIR CONDITIONING ONLY Continued: (Normal operation) 1. Switch the blower switch to achieve the desired airflow. 2. Turn the temperature regulator clockwise to set the desired cooling temperature. When the set temperature in the cab is reached the thermostat will switch off the compressor and the blower will continue to run. When the temperature rises above the set temperature, the compressor will automatically restart. 3.
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ROPS CAB, AIR CONDITIONING AND HEATING INSTALLATION - MAINTENANCE Continued Component Maintenance Work Hose lines Carry out leak test with leak detector Refrigerant circuit: Connections Refrigerant filling Condenser Dryer - filter Water drain Examine for abrasion and condition Examine refrigerant quantity in the sight glass Examine cleanliness of fins Change every 2 years Monthly 6 Monthly Annually • • • Ensure that they are clear Examine all parts for tightness • Magnetic clutch Examine start
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ROPS CAB, AIR CONDITIONING AND HEATING INSTALLATION - MAINTENANCE Continued General notes for refrigerant filling: Low levels of refrigerant can reduce the efficiency of the air conditioning unit. Extremely low levels can cause the low pressure switch to shut down the system. As a check on refrigerant level, there is an integrated sight glass in the collecting tank. After filling, run the system for 5 minutes to allow all air bubbles to be purged from the system.
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CUSTOMER INFORMATION Serial No: ......................................... Please note that the serial number if required, can be found at the rear right hand side of the radiator bulk head. See Operator's Manual for visual description. Date of sale:: ......................................... Your local Dealer: Notes: Issued: 01.04.11 Approved: Mod. No. 5060358 Sheet 62 of 64 Part No.
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WARRANTY The Toro Total Coverage Guarantee A Limited Warranty • Conditions and Products Covered Toro® The Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
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