TABLE OF CONTENTS PAGE Introduction
4
Safety Precautions
5
Packing List
6
Parts Photos
7
Machine Prep Instructions
8
Optional Heater Installation
9
Cab Installation
16
Decals Page
23
Fan Wiring Schematic (Optional Heater Install, Step 10)
24
Bulb Seal Schematic (Cab Install, Step 6)
25
Bolt Alignment Procedure/Schematic (Cab Install, Step 9)
26
Floor Mat Blueprint – with optional heater (Cab Install, Step 17)
27
INTRODUCTION TO THE PURCHASER All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before installation or operation. This manual has been prepared to assist the owner and operators in the safe installation, and suitable maintenance of this cab. The information is applicable to products at the time of manufacture and does not include modifications made afterwards. Read and understand mounting instructions before attempting to mount cab. Familiarize yourself with the operating instructions and all safety recommendations contained in this manual, and on the tractor. Follow the safety recommendations and make sure that those with whom you work follow them.
DIRECTION REFERENCE All references to right and left, forward or rearward, are from the operators’ seat, facing the steering wheel.
To assist you dealer in handling your needs, please record hereafter the model number and serial number of your cab and tractor. It is also advisable to supply them to your insurance company. It will be helpful in the event that the cab or tractor is lost or stolen.
TRACTOR
CAB
MODEL: SERIAL NUMBER: DATE OF PURCHASE: DEALER NAME:
Page 4
SAFETY PRECAUTIONS
SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this cab. DANGER:
Indicates an immediate hazardous situation which, if not avoided, could result in death or serious injury.
WARNING:
Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury.
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
IMPORTANT: Indicates that the cab or property damage could result if instructions are not followed. NOTE:
Gives helpful information.
All products are designed to give safe, dependable service if they are operated and maintained according to instructions. Read and understand this manual before installation or operation. It is the owner’s responsibility to be certain anyone operating this product reads this manual, and all other applicable manuals, to become familiar with this cab and all safety precautions. Failure to do so could result in serious personal injury or cab damage. If you have any questions, consult your dealer.
Page 5
PACKING LIST
Heater Installation Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
JDP Part # 101318 101211 101319 101320 101066 101321 101322 101323 101249 100401 100059 100223 101324 101325 101200 100914 101199 100211
Description Rad Hose Splicer, 1 1/8� Fitting, Elbow, 3/8NPTx3/8"Barb Louvers, Round, 2" Heater Hose Cover Plate 3/8" Heater Hose Heater Assembly Switchplate Assembly 36" Length, 2" Heater Hose Ducting Screw, Philips, #8 x 3/4", Plated Bolt, Flange, 1/4" x 3/4", YD Bolt, Hex, 1/4" x 1", YD Nut, Flange, 1/4", MB HS-32 Gear Clamps Bushing, Snap-In, 11/16", Black, 315-733 HS-6 Hose Clamps HS-10 Hose Clamp HS-20 Hose Clamps Cable Zip Ties, Black
QTY 1 1 4 1 18 LF 1 1 4 8 4 2 4 4 2 4 1 2 5
Cab Installation Item # 1A 1B 2 3A 3B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
JDP Part # 101326 101327 101328 101329 101330 101334 100478 101069 101331 101332 100114 101333 100115 100449 100046 101169 100018 100441 100223 100059
Description Left Rear Bracket Right Rear Bracket Front Bracket Left Front Composite Boots Right Front Composite Boots Cab Lift Brackets (2" Tube) Snap Caps, 3/8" O-rubber, 180D Floor mat Retainer Plates Main Cab Floor mat Bolt, Hex, 5/8" x 3", Gr. 8, YD Nut, Hex, 5/8", Gr. 8, YD, Nylon Locking Washer, Flat, Steel, 5/8" x 2", YD (Trimmed One Side) Washer, Flat, Black, 9/16" x 2 1/2", (Trimmed One Side) Isolator, 5/8" x 2", Black Bolt, Hex, 3/8" x 1 1/2", Gr. 8, YD Nut, Flange, 3/8", Gr. 8, YD Screw, Button Head, 1/4" x 1", MB Nut, Flange, 1/4", MB Bolt, Hex, 1/4" x 1", YD
Page 6
QTY 1 1 1 1 1 2 2 19 LF 2 1 4 4 4 4 4 6 6 4 6 6
PARTS PHOTOS
Ruler for measuring nuts, bolts, and screws. NOTE – Parts photos are not to scale.
Page 7
MACHINE PREP Note: All references to left and right are taken from the operator’s point of view when s/he is sitting in the driver’s seat. Step 1.
Remove roll bar. NOTE – Set aside fasteners and deck safety prop, for reinstallation. —————————————————————————————————————
Step 2.
Remove seats from interior. Remove the guard rail from seat. Remove retractor portion of seatbelt from seat. NOTE – Set aside seatbelt and fasteners, for reinstallation. —————————————————————————————————————
Step 3.
Re-install seat on vehicle chassis (without the seatbelt and guard rail) —————————————————————————————————————
Step 4.
Remove front bumper. —————————————————————————————————————
Step 5.
If machine is equipped with optional box heater, go to step one of Heater Installation. If machine is not equipped with box heater, go on to Cab Installation.
Page 8
OPTIONAL HEATER INSTALLATION Step 1.
A. Drill two 2 ½” holes in dashboard of vehicle for louvers according to drawings.
B. Drill two 5/16” holes in floor for heater core assembly.
C. Drill two 7/8” holes in under seat platform as shown in photo, for heater hoses.
Page 9
Step 2.
Remove cup holder. Set aside cup holder and fasteners for re-installation. —————————————————————————————————————
Step 3.
Remove skid plate from under the machine. Set aside skid plate and fasteners for re-installation. —————————————————————————————————————
Step 4.
Install two louvers on top of dashboard.
————————————————————————————————————— Step 5.
Install four duct hoses to heater hose assembly with eight Phillips #8 x ¾” screws provided.
Page 10
Step 6.
Install heater core assembly to vehicle (using holes drilled in Step 2B ) with ¼” x ¾” flange bolts and nuts provided.
————————————————————————————————————— Step 7.
The two outer hoses will be attached to the top louvers. Thread the hoses through, and attach using gear clamps provided.
————————————————————————————————————— Step 8.
Thread the remaining two hoses (middle ones) through dashboard to the interior. Attach remaining two hoses to louvers on switch plate assembly using gear clamps provided.
Page 11
Step 9.
Install two louvers onto switch plate assembly.
————————————————————————————————————— Step 10.
Connect fan harness as shown in schematic. (Fan Wiring Schematic, page 24)
————————————————————————————————————— Step 11.
Attach ground wire to fuse block ground connection.
Page 12
Step 12.
Attach switch plate assembly to heater box assembly with two ¼” x ¾” flange bolts provided.
————————————————————————————————————— Step 13.
Take heater harness wire and connect to fan switch as shown in schematic. (Fan Wiring Schematic, page 24) Take the pigtail wires from the switch and connect to the pigtail wires on machine fuse block.
————————————————————————————————————— Step 14.
Connect hose attached to water valve (on switch plate assembly) onto heater core assembly using hose clamp provided.
Page 13
Step 15.
Insert snap in bushing to front under-seat panel holes (drilled in Step 2C). Run the heater hoses (suction and pressure hoses) through holes, and under vehicle into engine bay. Tie hoses back using cables provided. NOTE - suction hose side has water valve. CAUTION - Ensure hoses do not interfere with any moving parts.
————————————————————————————————————— Step 16.
Position hose protector cover butted against heater assembly. Mark and drill holes in floor for hose protector cap.
————————————————————————————————————— Step 17.
Drain engine antifreeze before proceeding. —————————————————————————————————————
Step 18.
Locate plug on fitting at the thermostat housing. Remove rubber cap. Connect the pressure hose to the fitting with provi ded hose clamp.
Page 14
Step 19.
Take the radiator hose splicer and locate the radiator return line. Cut hose and insert splicer. Attach with hose clamps provided.
————————————————————————————————————— Step 20.
Insert 90D fitting into splicer and connect with hose clamp. —————————————————————————————————————
Step 21.
Re-fill antifreeze. —————————————————————————————————————
Step 22.
Open water valve fully, turn engine on and run at high RPM. Continue to run engine adding antifreeze until the engine produces HOT air at the heater vents. TIP - Run engine with rad cap off, and funnel in radiator full of antifreeze, to re-fill engine easily and to purge air from the lines. CAUTION: Ensure that vehicle is in a well ventilated area before starting engine to avoid carbon monoxide fumes. —————————————————————————————————————
Step 23.
Reinstall cup holder, using original fasteners saved from step 2. —————————————————————————————————————
Step 24.
Remainder of Heater installation will be continued in Step 16 of Cab Installation instructions. For now, go to Step 1 of cab installation (Page 16).
Page 15
CAB INSTALLATION Step 1.
Install rear brackets using original fasteners from 2-post ROPS. Finger tighten bolts. NOTE – Rear bracket pads face outwards and forwards.
————————————————————————————————————— Step 2.
Install front brackets. Insert six 3/8” x 1 ½ “ bolts, using original holes. NOTE – Bolt head should be in the rear. Hang front bracket, then bumper to bolts. Fasten using 3/8” flange nuts. Ensure that the bumper is centered over slots. Tighten front bolts to torque specs (42 ft-lbs).
————————————————————————————————————— Step 3.
Remove doors from cab, by pulling out spring retainer clip from one end of gas shock, then lifting off doors. Set doors and fasteners for later reinstallation. NOTE - Do not lose hinge washer, it may come loose from rest of door hardware.
Page 16
————————————————————————————————————— Step 4.
Take cab lift bracket and slide bolt through holes in top of cab (upper A-C cross member) —————————————————————————————————————
Step 5.
Carefully lift cab off the shipping pallet using a hoist. WARNING: Cab is heavy, do not drop on machine or person(s) ! This may result in cab damage, personal injury or death.
————————————————————————————————————— Step 6.
Install bulb seal on cab as shown in blueprint/schematic (Bulb Seal Schematic, page 25), ensuring that there is no gap, and trimming seal to length as needed.
Page 17
TIP – Use remainder of bulb seal in doorway of cab as paint protectors during the lowering process
————————————————————————————————————— Step 7.
Position isolator pads on cab brackets. —————————————————————————————————————
Step 8.
Carefully lower cab on to machine, aligning front and rear of cab with mounting brackets. —————————————————————————————————————
Step 9.
Using the bolt alignment procedure schematic, (Bolt Alignment Procedure/Schematic, page 26) finger tighten all bolts in order shown to ensure alignment. —————————————————————————————————————
Step 10.
Remove cab lift bracket. —————————————————————————————————————
Step 11.
Tighten front and rear isolator bolts (four in total) until 7/8” spacing between steel plates (rubber isolators should be about 7/8”).
————————————————————————————————————— Step 12.
Tighten ROPS socket bolt (rear brackets bolts, that were only finger tightened in step 1 of Cab Installation) to factory torque specs (see your OEM manual).
Page 18
Step 13.
Remove deck safety bracket from original 2-Post ROPS, and install on to rear outer panel of cab. NOTE – bracket should just slide in.
————————————————————————————————————— Step 14.
Remove bottom side bolts from front cab fascia, saving fasteners.
————————————————————————————————————— Step 15.
Install left and right front fascia boots, using original fasteners for the top screw, and four ¼” x 1” button head screws for the rest. NOTE – Slide top portion of boots under bottom portion of fascia.
Page 19
Step 16.
Connect the main cab wiring. Connect the black ground wire to chassis ground wire. Connect red power wire to the starter wire for 12 volt power. Connect orange wire to the switched terminal on the alternator.
————————————————————————————————————— Step 17.
Place floor mat in cab on vehicle floorboard. Ensure mat is centered. Punch holes in floor mat using pre-drilled holes in cab floor as guide.
————————————————————————————————————— Step 18.
If you have the optional Heater Kit installed go to step 19 if not, go to step 24. —————————————————————————————————————
Step 19.
HEATER KIT ONLY!! Cut floor mat in half according to blue print. (Optional Heat er Floor Mat Blueprint, page 27) —————————————————————————————————————
Step 20.
HEATER KIT ONLY!! Place floor mat in cab. Ensure correct placement. Punch holes in floor mat for hose protector cap (holes made in step 18 of Heater Installation). —————————————————————————————————————
Step 21.
HEATER KIT ONLY!! Install floor mat, ensuring correct placement.
Page 20
Step 22.
HEATER KIT ONLY!! Install hose protector cap. Bolt down using two ¼” x 1” hex bolts and flange nuts. NOTE - You must go under vehicle to tighten nuts.
————————————————————————————————— ———— Step 23.
HEATER KIT ONLY!! Reinstall skid plate under vehicle using original fasteners. Carry on to step 25.
————————————————————————————————————— Step 24.
NO HEATER KIT!! Install floor mat. Ensure correct placement.
Page 21
Step 25.
Install left and right floor mat retainers using six ¼” x 1” hex bolts and flange nuts.
————————————————————————————————————— Step 26.
Install two 3/8” black snap caps (plug butts) in upper A-C cross member holes (holes used by lifting bracket in step 4 of cab installation) —————————————————————————————————————
Step 27.
Rehang doors using original fasteners and configuration. Ensure that the washer is between the hinges. NOTE - Pull out spring retainer clip to reattach gas shock easily, replace clip to hold gas shock to door.
————————————————————————————————————— Step 28.
Re-install seat belt retractors, using original configuration and fasteners.
Page 22
DECALS PAGE Replace immediately if damaged or missing. Contact Jodale Perry for replacement decals.
Page 23
FAN WIRING SCHEMATICS Schematic A
Schematic B
Page 24
BULB SEAL SCHEMATIC
—————————————————————————————————————
Page 25
BOLT ALIGNMENT PROCEDURE/SCHEMATIC
Page 26
OPTIONAL HEATER FLOOR MAT BLUEPRINT
Page 27
Fixed Glass Item # 1 2 3 4 5 6 n/a n/a
Description Rear Window Glass Bushing, Neoprene, 5MM, Black Bushing, Neoprene, 8MM, Black Bolt, Step, 1/4" x 1 1/4", Macro-black Nut, Flange, 1/4", Macro-black Right Side Glass Weatherstripping (14.48LF) Windshield Glass Left Side Glass Weatherstripping (11.37LF)
Qty. JDP P/N 1 10 10 10 10 1 1 1
101341 100382 100381 100003 100223 100358 101338 100358
Side Opening Window Assembly Item # 1 n/a 2 3 4 5 6 7 8 9 n/a 10
Description Left Side Window Glass Weatherstripping (9.44LF) Nut, Flange, 1/4", Macro-black Bolt, Step, 1/4" x 1", Macro-black Bushing, Neoprene, 5MM, Black Bolt, Carriage, 5/16" x 1", YD Side Window Latch Nut, Flange, 5/16", YD Side Window Latch Bracket Side Window Hinge Weldment Hinge Brass Flat Washer Washer, Flat, 1/4", YD
Qty. JDP P/N 1 1 4 4 8 1 1 1 1 2 4 2
101340 100358 100223 100003 100382 100374 100027 100005 100375 100379 100026 100380
Item # n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a
Description Right Side Window Glass Weatherstripping (9.44LF) Nut, Flange, 1/4", Macro-black Bolt, Step, 1/4" x 1", Macro-black Bushing, Neoprene, 5MM, Black Bolt, Carriage, 5/16" x 1", YD Side Window Latch Nut, Flange, 5/16", YD Side Window Latch Bracket Side Window Hinge Weldment Hinge Brass Flat Washer Washer, Flat, 1/4", YD
Qty. JDP P/N 1 1 4 4 8 1 1 1 1 2 4 2
101340 100358 100223 100003 100382 100374 100028 100005 100375 100379 100026 100380
Door Assembly Item # 1 n/a 2 3 4 5 6 7 8 9
Description Door Glass Rubber, Clip-on, Double Bulb, ??? Door Push Button Handle Bolt, Hex, 1/4" x 2 1/2" UNC, Plated Rubber, Injection Molded Bolt, Step, 1/4" x 1 1/2", Macro-black Bushing, Rubber, 5MM, Inj-Molded, 3" HC Left Door Hinge Weldment Door Hinge Support Weldment Stud, 10mm
Qty. JDP P/N 1 1 1 1 1 4 4 2 1 2
101339 100358 100009 100369 100011 100635 100362 100377 101565 100366
Item # 10 11 n/a 12 13 14 15 16 17 18
Description Nut, Serrated, Flange, 5/16", YD Nut, Flange, 1/4", Macro-black Washer, Brass Bolt, Flange, M6 x 1.0 x 25MM, YD Latch, Door, Interior, Left Bushing, Rubber, 5MM Bolt, Step, 1/4" x 1", Macro-black Left Door Latch Weldment Left Gas Shock Mount Plate Nut, Flange, M6, Yellow Dichrome
Qty. JDP P/N 1 6 2 5 1 5 2 1 1 2
100005 100223 100026 100007 100006 100382 100003 101566 100368 100008
Toro Workman
Composites/Hardware Item #
Description Left Composite Side Panel Right Composite Side Panel Front Red Composite Panel Left Front Black Composite Side Panel Right Front Black Composite Side Panel Roof Screw, Button Head, 1/4" x 1" Nut, Extruded Panel, 1/4"
Operator Manual
Qty. JDP P/N 1 1 1 1 1 1 14 14
101336 101337 101607 101329 101330 101335 100441 100042