Winter Enclosure

• The ROPS is an integral part of the cab, which is an effective safety device.

• The ROPS consists of the roll bar, the seat, the seat belt, the seat latch, and cab.

• Always wear the seat belt when you operate the machine with a cab.

• Ensure that the seat belt can be released quickly in the event of an emergency.

• Drive slowly and carefully.

• Check carefully for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Keep the cab in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight.

• Replace a damaged cab. Do not repair or revise.

• Do not remove or modify the ROPS.

Parts needed for this procedure:

Note: Save the shipping pallet for long term storage after the cab is removed. Save all hardware for the machine when installing or removing the cab.

1. Park the machine on a level surface, engage the parking brake, lower the attachment, shut off the engine, and remove the key.

2. Disconnect the negative (-) battery cable from the battery.

3. Remove the nut, bolt, and spacer securing the cable to the traction pedal and rotate the pedal towards the seat (Figure 1).

   

   Figure 1

   1. Foot pedal
   2. Locknut
   3. Bolt
   4. Spacer

4. Remove the ROPS pins and place them into down position hole (Figure 2).

   

   Figure 2

   1. Cotter pin
   2. Pin

5. Install the bolt (3/4 x 4 inches) into the top hole of the roll bar and secure it finger tight with a nut (3/4 inch). Refer to (Figure 3).

   Note: Ensure that the bolt is installed on the inside of the roll bar.

   

   Figure 3

   1. Install the bolt (3/4 x 4 inches) on the inside.
   2. Nut (3/4 inch)

6. Remove the front mower-deck latch from the front of the machine (Figure 4). Save the latch and hardware.

   

   Figure 4

   1. Nut
   2. Mower-deck latch
   3. Bolt

7. Remove the nuts and bolts from the right armrest and fold it to the center (Figure 5).

   

   Figure 5

   1. Bolt
   2. Locknut

8. Tilt the steering column to its lowest position; refer to the Operators Manual.

9. Remove the R-clamps from the roll bar securing the vent tubes (Figure 6).

10. Lay the vent tubes out of the way for mounting the cab.

11. Install the R-clamps back into the roll bar without the vent tubes (Figure 6).

    

    Figure 6

    1. Bolt
    2. Fuel-vent tube
    3. R-clamp

Parts needed for this procedure:

1. Caulk the existing firewall openings on both sides at the locations shown in Figure 7 with black RTV sealant.

   

   Figure 7

   1. Caulk these areas on both sides.

2. Caulk the cab firewall at the locations shown in Figure 8 with black RTV sealant.

   

   Figure 8

   1. Caulk these areas only

3. Remove the existing hardware that connects the existing firewall to the roll bar tube.

4. Place the cab firewall around the seat and onto the existing firewall (Figure 9).

   

   Figure 9

   1. Cab firewall
   2. Existing hardware—reuse
   3. Existing firewall

5. Use the existing hardware to install the cab firewall.

Parts needed for this procedure:

Important: Loosely install the fasteners for the cab until all hardware is installed. After all the hardware is installed, tighten the fasteners.

1. Remove the left and right panels from inside the cab as shown in Figure 10.

   

   Figure 10

   1. Left panel
   2. Screws

2. Remove the cab roof as shown in Figure 11.

   

   Figure 11

   1. Bolt
   2. Washer
   3. Cab roof

3. Use a hoist to support the cab and connect the cab hoist to the 4 lift points on the cab (Figure 12).

   Note: A cab hoist is available through your authorized Toro distributor.

   

   Figure 12

   1. Front lift point
   2. Rear lift point

4. Raise the cab with a hoist (Figure 12).

5. Install the foam seal on the bottom of the cab as shown in Figure 13.

   

   Figure 13

   1. Foam seal
   2. Foam seal installed

6. Align the cab over the roll bar.

7. While lowering the cab, position the vent tubes through the rear posts (Figure 16).

   Note: Ensure that the traction pedal is rotated rearward towards the seat.

8. Lower the cab until it is approximately 51 mm (2 inches) above the firewall and machine.

9. Install the roll bar seals around each side of the roll bar (Figure 14).

10. Install the left cover and 1 retainer cover into the left seal and secure the covers with 4 screws (1/4 x 3/4 inches); refer to Figure 14.

11. Install the right cover and 1 retainer cover into the right seal and secure the covers with 4 screws (1/4 x 3/4 inches); refer to Figure 14.

    

    Figure 14

    1. Retainer cover
    2. Roll bar seal
    3. Screws (1/4 x 3/4 inches)
    4. Right cover
    5. Left cover
    6. Covers installed

12. Lower the cab onto the firewall and machine.

13. Loosely install the mower deck latch to the front of the cab (Figure 4).

14. Loosely install the ROPS mounts to secure the cab to the roll bar on the machine (Figure 15).

15. Loosely install the left ROPS stop on the corner of the roll bar with 2 bolts (3/8 x 1 inch), a ROPS brace, and 2 nuts (3/8 inch).

16. Loosely install the right ROPS stop on the corner of the roll bar with 2 bolts(3/8 x 1 inch), a ROPS brace, and 2 nuts (3/8 inch).

    

    Figure 15

    1. Bolt (3/8 x 1 inch)
    2. ROPS stop
    3. ROPS mount
    4. ROPS brace
    5. Nuts (3/8 inch)
    6. Hardware installed

    Note: Ensure that the ROPS bolts are tightened last (Figure 3).

17. After all the parts and hardware is installed, tighten the hardware.

18. Torque all nuts and bolts attaching the cab to the roll bar to 127 to 157 N∙m (94 to 116 ft-lb). Refer to Figure 15

19. Torque the nuts and bolts for the mower deck latch in the front of the cab to 127 to 157 N∙m (94 to 116 ft-lb). Refer to Figure 4.

20. Torque the roll bar bolt and nut to 329 to 403 N∙m (243 to 297 ft-lb). Refer to Figure 3.

21. Install the cab roof (Figure 11).

22. Install the nut, bolt, and spacer to secure the cable to the traction pedal (Figure 1).

Parts needed for this procedure:

1. Install the vent tubes to each side of the cab. Refer to Figure 16.

2. Secure each vent tube with a bolt (5/16 x 1-1/2 inch), a plate clamp, a tube clamp, and a nut (5/16 inch) (Figure 16).

   

   Figure 16

   1. Nut (5/16 inch)
   2. Left side of the machine (from operator’s position)
   3. Bolt (5/16 x 1-1/2 inch),
   4. Plate clamp
   5. Tube clamp
   6. Vent tube
   7. Vent tube installed in the lower left of the cab

3. Install the side panels previously removed (Figure 11).

Parts needed for this procedure:

1. Remove the existing step on the side of the machine (Figure 17).

   Note: The existing step does not need to be installed when the cab is removed. Use the step that comes with the cab.

   

   Figure 17

   1. Bolt
   2. Step mount
   3. Nut

2. Install the deck step to the step mount with a carriage bolt (5/16 x 1-1/4 inch) and a nut (5/16 inch). Refer to Figure 18.

3. Install the step to the side of the machine with 2 carriage bolts (3/8 x 7/8 inches), 2 nuts (3/8 inch), a carriage bolt (3/8 x 7/8 inch),and nut (3/8 inch). Refer to Figure 18.

   

   Figure 18

   1. Carriage bolt (5/16 x 3/4 inch)
   2. Step mount
   3. Nut (5/16 inch)
   4. Deck step
   5. Carriage bolt (5/16 x 1-1/4 inch)
   6. Nut (3/8 inch)
   7. Carriage bolt (3/8 x 7/8 inches)

4. Install the floor mat into the cab (Figure 19).

   

   Figure 19

   1. Floor mat

Parts needed for this procedure:

1. Apply sealant to the straight fittings (3/8 NPT x 5/8 barb), skipping the first thread.

2. Slip hose clamps over the hoses.

3. Slip the dust plug and dust cap over the barbed end of the assemblies (Figure 20).

4. Thread the straight fittings (3/8 NPT x 5/8 barb) into the male and female couplers (Figure 20).

5. Tighten the straight fittings (3/8 NPT x 5/8 barb) in the male and female couplers 2 to 3 turns from finger-tight.

6. Insert the barbed end of the assemblies into the hoses and secure them with the hose clamps (Figure 20).

7. Install the straight adapter (3/8 inch) onto the engine fitting for the hose with the male coupler (Figure 20).

8. Install the straight adapter (M16) onto the engine fitting for the hose with the female coupler (Figure 20).

   

   Figure 20

   1. Male coupler
   2. Straight fitting (3/8 NPT x 5/8 barb)
   3. Hose clamp
   4. Dust cap
   5. R-clamp
   6. Nut (1/4 inch)
   7. Hose
   8. Engine fitting
   9. Straight adaptor (3/8 inch)
   10. Direction of fluid flow
   11. Carriage bolt (1/4 x 3/4 inch)
   12. Female coupler
   13. Female dust plug
   14. Adaptor (M16)
   15. Engine plug

9. Remove the existing bracket from the machine frame and radiator (Figure 21). Save the hardware.

   

   Figure 21

   1. Nut
   2. Bolt
   3. Right side
   4. Existing bracket
   5. Radiator valve

10. Drain half of the engine coolant from the radiator by using the valve on the right side of the radiator as shown in Figure 21.

11. Locate and remove the engine plugs shown in Figure 20.

12. Apply pipe sealant to the threads on the engine fittings.

13. Manually secure the engine fittings into the ports until they are finger-tight.

14. Secure the engine fittings 2 to 3 additional turns from finger-tight.

15. Slip the hose clamps over the hoses.

16. Insert the hoses over the barb ends of the engine fittings and secure them with the hose clamps (Figure 20).

17. Install the R-clamps around the hoses (Figure 20).

18. Secure the hoses to the back of the cab with 2 carriage bolts and 2 nuts (Figure 20 and Figure 22).

    

    Figure 22

    1. Direction of fluid flow
    2. Couplers installed
    3. R-clamp
    4. Cable tie
    5. Nut (1/4 inch)
    6. Carriage bolt (1/4 x 3/4 inch)
    7. Tag—noting hot line

19. Secure the hoses away from moving parts and hot surfaces with cable ties.

20. Fill the radiator with engine coolant.

21. Start the engine and purge the air out of the cooling system.

22. Shut off the engine and check the engine-coolant level.

23. If needed, add more engine coolant.

    Note: When the engine is cold, the coolant level should be no higher than the FULL (COLD) mark (bottom mark).

    Note: Refer the traction unit Operator’s Manual for the correct fluid.

Parts needed for this procedure:

1. Apply sealant to the straight fittings (3/8 NPT x 5/8 barb), skipping the first thread.

2. Slip hose clamps over the hoses.

3. Slip the dust plug and dust cap over the barbed end of the assemblies (Figure 24).

4. Thread the straight fittings (3/8 NPT x 5/8 barb) into the male and female couplers (Figure 24).

5. Tighten the straight fittings (3/8 NPT x 5/8 barb) in the male and female couplers 2 to 3 turns from finger-tight.

6. Insert the barbed end of the assemblies into the hoses and secure them with the hose clamps (Figure 24).

7. Remove the existing bracket from the machine frame and radiator (Figure 23). Save the hardware.

   

   Figure 23

   1. Nut
   2. Bolt
   3. Right side
   4. Existing bracket
   5. Radiator valve

8. Drain half of the engine coolant from the radiator by using the valve on the right side of the radiator as shown in Figure 23.

9. Locate and remove the engine plugs shown in Figure 24.

   

   Figure 24

   1. Male coupler
   2. Straight fitting (3/8 NPT x 5/8 barb)
   3. Hose clamp
   4. Dust cap
   5. R-clamp
   6. Nut (1/4 inch)
   7. Hose
   8. Engine fitting
   9. Direction of fluid flow
   10. Carriage bolt (1/4 x 3/4 inch)
   11. Female coupler
   12. Female dust plug
   13. Hose
   14. Cable tie
   15. Engine plug

10. Apply pipe sealant to the threads on the engine fittings.

11. Manually secure the engine fittings into the ports until they are finger-tight.

12. Secure the engine fittings 2 to 3 additional turns from finger-tight.

13. Slip the hose clamps over the hoses.

14. Insert the hoses over the barb ends of the engine fittings and secure them with the hose clamps (Figure 24).

15. Install the R-clamps around the hoses (Figure 24).

16. Secure the hoses to the back of the cab with 2 carriage bolts and 2 nuts (Figure 24 and Figure 25).

    

    Figure 25

    1. Direction of fluid flow
    2. Couplers installed
    3. R-clamp
    4. Cable tie
    5. Nut (1/4 inch)
    6. Carriage bolt (1/4 x 3/4 inch)
    7. Tag—noting hot line

17. Secure the hoses away from moving parts and hot surfaces with cable ties (Figure 25).

18. Fill the radiator with engine coolant.

19. Start the engine and purge the air out of the cooling system.

20. Shut off the engine and check the engine-coolant level.

21. If needed, add more engine coolant.

    Note: When the engine is cold, the coolant level should be no higher than the FULL (COLD) mark (bottom mark).

    Note: Refer the traction unit Operator’s Manual for the correct fluid.

Parts needed for this procedure:

1. Install the tank to the bracket with 4 carriage bolts (5/16 x 3/4 inch) and 4 nuts (5/16 inch); refer to Figure 26.

   

   Figure 26

   1. Washer-fluid tank
   2. Locknut (5/16 inch)
   3. Existing hardware
   4. Carriage bolt (5/16 x 3/4 inch)
   5. Washer-fluid bracket

2. Install the tank and bracket to the frame and radiator with the previously removed hardware (Figure 21 or Figure 23).

Parts needed for this procedure:

Note: The hoses are extra long and need to be cut to install the connections.

1. Route the hoses along the frame and back to the washer-fluid tank (Figure 28).

2. Install the hose to the washer-fluid tank as shown in Figure 27.

   

   Figure 27

   1. Washer-fluid tank
   2. Washer-fluid hose

3. Install the hose to the tank.

4. Cut the hose at the location shown in Figure 28.

5. Install the fitings as shown in Figure 28.

   

   Figure 28

   1. Cut the hose here.
   2. Hose end
   3. Female fitting
   4. Male fitting
   5. Plastic ties

6. Secure the hose with plastic ties (Figure 28).

Parts needed for this procedure:

1. Route the wire harness along the machine frame (Figure 29).

   

   Figure 29

   1. Cable tie
   2. Relay (70 A)
   3. Connect to the main machine harness
   4. Fluid tank connector
   5. Battery terminals
   6. Unused connector

2. Remove the nut that secures the positive-battery clamp to the positive-battery terminal.

3. Attach the positive-battery terminal from the wire harness to the bolt used to secure the battery clamp.

4. Secure the clamp with the nut you removed previously.

5. Repeat the previous steps for the negative battery terminal on the wire harness.

6. Install the connector to the fluid tank (Figure 29).

7. Plug the connector shown in Figure 29 to the main harness of the machine.

8. Install a fuse (10 A) to the traction-unit fuse block; refer to the electrical-system maintenance section of your traction unit Operator’s Manual for the appropriate location.

Parts needed for this procedure:

1. Install 2 weights (6 kg or 15 lb) between the frame and the rear bumper with 2 bolts (3/8 x 3-1/2 inches), 2 washers (3/8 inch), and 2 locknuts (3/8 inch). Refer to Figure 30.

2. If you also install an attachment (e.g., a snow blade, snow broom, or cutting unit), refer to the traction unit Operator's Manual for the appropriate amount of rear weight.

Figure 30

1. Bolt (3/8 x 3-1/2 inches)
2. Rear bumper
3. 6 kg (15 lb) weights
4. Washer (3/8 inch)
5. Locknut (3/8 inch)
6. Frame
7. 19 kg (42 lb) weights

1. Check for leaks.

2. Check for parts that interfere with moving parts and make corrections before operating the machine.

3. Connect the negative (-) battery cable to the battery.

4. Check the operation of all controls before operating the machine.

5. Have an assistant help to adjust the rearview and side mirrors before operating the machine.

Use this switch to turn the windshield wipers on or off (Figure 31).

Rotate the temperature control knob to regulate the air temperature in the cab (Figure 31).

Rotate the fan control knob to regulate the speed of the fan (Figure 31).