Toro 580-D BOXER Parts List & Mounting Instructions

Transcription

1 Toro 580-D BOXER Parts List & Mounting Instructions Jodale Perry Printed: 2004/01

2 Standard Parts List Qty Description Photo 1 Front Bracket L&R Rear Brackets 1 Underplatform HST Pedal Shield (mylar) 1 Front Plastic Fascia 2 Cab Lift Brackets (2 Tube) 2 3/8 Black Snap Caps 16 LF 180 O-rubber 2 LF 90 O-rubber 7 LF NDA-X, ½ x ¾ 1 Mylar, (Steering Tower Plate) 1 Floormat, 5 ¼ x 16 7/16 (RH Rear Platform) 1 Floormat, 10 3/8 x 28 1/8 (Toolbox Lid) 1 Floormat, 23 1/8 x 28 ¼ (LH Platform) 1 Floormat, 21 7/8 x 22 ¾ (RH Front Platform) 1 Step Weldment

3 Standard Bolts List Qty Description 4 Bolt, Hex, 5/8 x 3, Gr. 8, Yellow Dichrome 4 Nut, Hex, 5/8, Gr. 8, Yellow Dichrome 4 Washer, Lock, 5/8 4 Washer, Flat, Steel, 5/8, Gr. 8 4 Washer, Flat, Rubber, 5/8 x 2 1/2 4 Isolator, Rubber, 5/8 x 2 4 Bolt, Hex, ¾ x 2 ½, Gr. 8, Yellow Dichrome 4 Washer, Flat, Steel, ¾, Gr. 8 4 Washer, Lock, 3/4 6 Bolt, Hex, 7/16 x 1 ½, Gr. 8, Yellow Dichrome 6 Nut, Hex, 7/16, Gr. 8, Yellow Dichrome 6 Washer, Flat, Steel, 7/16, Yellow Dichrome 6 Washer, Lock, 7/16 2 Bolt, Flange, 3/8 x ¾, Gr. 8, Yellow Dichrome

4 Optional Parts Lists Heater Option (if equipped) Qty Description Photo 1 16MM x 16MM x 3/8NPT Sensor Adaptor 2 3/8NPT x 5/8 Barb Straight Fitting 2 HS-10 Hose Clamps 30 LF 5/8 Heater Hose

5 NOTE: Use the following torque specifications for all hardware: 5/8 hardware 177 ft-lbs, ¾ hardware 319 ft-lbs, 7/16 hardware 60 ft-lbs. 1. Remove the air intake cowling units located behind the operator seat. Remove the two plates and angle used to seal around the air intakes as well. Un-bolt the hydrostatic pedal from the operator platform. diameter of ½. Place the bracket against the platform and attach with the 7/16 x 1 ½ hex bolts, 7/16 flat washers, 7/16 lock washers, and 7/16 hex nuts provided. Torque front mount hardware to specifications provided. See Figure 3. Figure 2 2. Tilt the steering tower back towards the seat. Take a 12 piece of ¾ x ¾ NDA-X and install along the front edge of the control tower to seal the air space. See Figure 1. Figure 1 Figure 3 3. Remove the plate directly underneath the steering tower (below operator platform). Take the 6 x 11 ½ piece of mylar and position it on the plate. Peal off the backing and glue into place with the mylar on the inside of the panel when it is installed. Re-install the panel, see Figure Take the front bracket. Note all the holes in the front platform angle and the front bracket. Drill out all holes to a 5. Take the left rear bracket and slide it into the 2-post socket so that the bolt holes on the bracket line up with the bolt holes in the platform and the mount plate is on the inside. Take the ¾ x 2 ¼ hex bolts, ¾ flat washers, and ¾

6 lock washers and loosely bolt the bracket into place. Do not tighten until cab is installed. See Figure 4. Figure 4 lid. Trim the edges so that it does not fit too snugly and allows for the toolbox to open properly. Glue the floormat onto the toolbox lid. See Figure 5. Take the 23 1/8 x 28 ¼ piece of floormat and place it onto the left side of the platform. Ensure that it fits snugly against the tool box lid mat at the rear and the platform lips, and glue into place. Figure 5 6. Go to the cab and prepare to install the O-rubber. Remove the left door, right escape window, and lower right window before lifting cab. Take the cab lift brackets provided and bolt through the holes in the upper A-C crossmember in front of the B-post. Attach a chain or lift strap to the lifting brackets and hoist the cab off of the shipping pallet a couple of feet to make O-rubber installation easier. 9. Take the underplatform shield and line it up with the holes in the platform. Bolt into place with the 5/16 x 1 flange bolts and nuts provided. Ensure that the Figure 6 7. Take the 5 ¼ x 16 7/16 piece of floormat and position it on the platform around the right and rear side of the HST pedal. Glue the floormat into place onto the platform. See Figure 5. Take the 22 ¾ x 21 7/8 floormat piece and place in on the platform so that it fits snugly around the steering tower and brake pedal. Glue the floormat into place. 8. Take the 10 3/8 x 28 1/8 piece of floormat and position it on the tool box

7 HST pedal and all linkages in the area nearby operate properly and are not restricted in anyway. If the linkages are binding, or hitting a part of the shield, reposition the shielding until normal operation of all parts has been attained, see Fiugre Re-install the HST pedal with the longer fasteners provided, 5/16 x 1 ¼. Figure 8 Figure 7 Figure 9 See Figures 7-11 for weatherstripping installation. 11. Take the 180d O-rubber and move to the sheetmetal edge at the left front of the cab, near the lower windshield crossmember. Slide the rubber onto the edge and work your away around to the back of the cab. Take the 90d O-rubber and put a short piece onto the rear shield as shown, with the blub facing outward. Take the 180d O-rubber and continue along the rear shield until you reach the same spot on the right side for the 90d O-rubber. Continue with the 180d O-rubber until you reach the end of the sheetmetal on the right shield. Take the ½ x ¾ NDA-X and attach to the horizontal bottom right fixed window tube along the inside edge as shown in the Figure. Take a short piece of 90d O-rubber and install on the short edge as Figure 10 shown, then continue with 180d O-rubber until you reach the lower windshield crossmember. 12. Take the ½ x ¾ NDA-X and move to the front bracket that is installed on the tractor. Peel back the adhesive back and attach to the top edge of the bracket as shown in Figure 12.

8 Figure Remove cab lift brackets and install 3/8 snap caps into holes. Re-install cab door, right escape window, and lower right window. 15. Connect main cab electrical now. Connect the heavy red wire to 12V on the tractor. Connect the heavy black wire to main tractor ground. Connect the orange wire to a switched source on the tractor. Proceed with the steps 16 to 21 if cab is equipped with the heater option. Figure Drain the anti-freeze from the engine. 17. Suction: Locate the 3/8NPT plug on top of the water pump housing. Remove the plug and save for use with the pressure fitting. REMEMBER to use a water sealant material around the threads of the fitting. Take one of 3/8NPT x 5/8 barb straight fittings and screw into the housing. See Figure 13. Figure Lift the cab over the tractor. Place one rubber isolator onto each mount bracket plate. Slowly lower the cab until the mount plate contacts the rubber isolators. Using 5/8 x 3 hex bolts, 5/8 steel flat washers, 5/8 rubber flat washers, 5/8 lock washers, and 5/8 hex nuts, start each mounting bolt. As soon as all bolts are started begin torquing all mounting hardware to the specifications provided. For the rubber isolated mounts, torque bolts until there is a 7/8 space between mounting plates. Torque bracket hardware as well. 18. Pressure: Locate the thermostat sensor on the right side of the engine bay and remove. REMEMBER to use a

9 water sealant material around the threads of the fitting. You will notice that there are two 3/8NPT ports on the adaptor. One will be for the sensor, the other will require the plug from the suction port, this allows adjustability in how far the adpator gets screwed into the housing. Take the 16MM x 16MM x 3/8NPT sensor adaptor and screw into port where the thermostat sensor was. When you are near the end of the thread, decide which port is more convenient for the pressure fitting, and screw the plug from the suction fitting into the other adaptor port. Then screw the thermostat sensor into the end of the adaptor fitting. Take the remaining 3/8NPT x 5/8 barb straight fitting and screw it into the thermostat adaptor. See Figure 14 Figure 14 hose to the pressure fitting with the HS-10 hose clamp provided. 20. Take the remaining heater hose and route it to the suction fitting. Tie down the hose as required to ensure that it does not interfere with any controls, levers, or accessories of the unit. Measure off the distance to the fitting and cut the hose. Connect the hose to the fitting with the HS-10 hose clamp provided. 21. Ensure that all connections are tight and fill in anti-freeze. Open the water valve using the rotary control on the switchplate of the cab, approximately half-way and turn on the fan. Start the tractor, and run at PTO RPM for 5 minutes. Once the heater begins to heat, open the valve all the way. It is necessary to completely purge all of the air bubbles in the coolant system, so it may be necessary to leave the radiator cap off while the engine is running. Continue adding engine coolant and checking for any leaks while running the engine. The heater core should produce HOT AIR when the system has been purged properly. It may be necessary to start and stop the engine while adding coolant for a while. 19. Locate the 5/8 heater hose at the base of the C-post of the cab frame labelled pressure. Route the hose to the pressure fitting. Tie down the hose as required to ensure that it does not interfere with any controls, levers, or accessories of the unit. Measure off the distance to the fitting (allow for some excess) and cut the hose. Connect the 22. To ensure cab is sealed properly, use a black silicone sealant, and seal off any cracks and small openings that may be present.

10 ADDENDUM ALL Mounting Instructions Electrical Connectors List Qty Description 2 Connectors, Loop, 10GA, ¼ 1 Connectors, Loop, 10GA, ½ 1 Connectors, Loop, 10GA, 3/8 1 Splicer, Wire, Blue

11

12

13

14

15