Toro Mauser KS-534 Full Safety Cab User manual

FormNo.3395-604RevA
AirConditioningKit
MauserKS-534FullSafetyCab
ModelNo.02891
Registeratwww.Toro.com.
OriginalInstructions(EN)*3395-604*A

ThisproductcomplieswithallrelevantEuropeandirectives.
Fordetails,pleaseseetheDeclarationofIncorporation(DOI)
atthebackofthispublication.
Introduction
Thismanualprovidesinstructionsontheoperationoftheair
conditioningsystemwhenttedtothecabKS-534,Model
02890.
TheheaterblowerisstandardintheCabKS-534(Model
02890).
InstalltheSuppressedBeaconKit(Part111-7134)whenusing
thiskitifanamberbeaconisrequired.
Fittingoftheair-conditioningsystemmustbecarriedoutby
aqualiedtechnician.
Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.RefertothetractionunitandcabOperator’s
Manualsforadditionalinformation.
YoumaycontactTorodirectlyatwww.Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Writethenumbersinthespaceprovided.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure1),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure1
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
Contents
Safety...........................................................................3
GeneralSafety.........................................................3
SafetyandInstructionalDecals.................................3
ProductOverview..........................................................4
Controls................................................................5
Specications.........................................................6
Attachments/Accessories.........................................6
Operation.....................................................................6
UsingtheAirConditionerfortheFirst
Time..................................................................6
OperatingtheAir-ConditioningSystem......................6
OperatingtheHeatingSystem...................................6
Maintenance..................................................................7
RecommendedMaintenanceSchedule(s).......................7
CheckingtheRefrigerantPressure.............................8
TroubleshootingthePressureReadings......................8
CheckingtheRefrigerantLevel..................................8
CheckingtheCompressorMagneticClutch.................9
CheckingtheDrainTube..........................................9
CheckingtheCompressor-FanBelt............................9
LocatingtheFuses..................................................10
Storage........................................................................10
Schematics...................................................................11
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUK
AllRightsReserved

Safety
WARNING
Ifyoudonotfollowcertainsafetyprocedures,
someonecouldbeseriouslyinjured.
Beforeworkingonthemachine,ensurethe
following:
•Theengineisswitchedoff.
•Theparkingbrakeisapplied.
•Thereisnopressureinthehydraulicsystem.
•Thecuttingunitsarefullydownontheground.
WARNING
Performingmaintenancewithouteyeprotection
couldresultinseriousinjury.
Whencarryingoutmaintenanceoperationsalways
weareyeprotection.
WARNING
Workingontheelectricalsysteminanunsafe
mannercouldresultinseriousinjury.
Beforeworkingontheelectricalsystemofthe
machine,alwaysdisconnectthebatteryterminals
(negativeterminalrst)andensurethatnocontact
ismadebetweentheterminalsandthemetal
componentsofthemachine.
GeneralSafety
•Ifafaultarisesintheair-conditioningsystemthenitmust
beinspectedandrepairedbyqualiedpersonnel.
•Neverallowrefrigeranttobedischargedintothe
atmosphere.
•Neverattempttowarmanypartoftheair-conditioning
systemwithanopename.
•Neverallowrefrigeranttocomeintocontactwiththe
skin.Refertotherefrigerantdatasheetforguidance.
•Wearsuitablepersonalprotectiveequipmentwhen
handlingrefrigerant.
•Nevercarryoutsolderingorweldingonornearany
partsoftheair-conditioningsystemasheatcancause
expansionandruptureofthecomponents.
•Alwaysallowtheair-conditioningsystemtocooldown
beforeworkingonanypartofit.
Toensureoptimumperformanceandcontinuedsafety
certicationofthemachine,useonlygenuineToro
replacementpartsandaccessories.Replacementpartsand
accessoriesmadebyothermanufacturerscouldbedangerous,
andsuchusecouldvoidtheproductwarranty.
SafetyandInstructional
Decals
Safetydecalsandinstructionsareeasily
visibletotheoperatorandarelocatednear
anyareaofpotentialdanger.Replaceany
decalthatisdamagedorlost.
978004
1.Cooling/air-conditioning
system
3.High-pressure
uid—hazardofinjection
intothebody
2.ReadtheOperator’s
Manual.
4.Poisonousfumesortoxic
gases—asphyxiation
hazard
3

ProductOverview
g0 1841 4
1
2
3
Figure2
Evaporator,heater,andfans—mountedinfrontofthecabroof
1.Airconditioner:evaporator,heater,anddoubleradialblower3.Expansionvalve
2.Heatervalve
g018399
Figure3
Compressor—mountedontheengine
4

1
2
3
g018436
Figure4
Condenseranddryer/lter—mountedinrearofthecabroof
1.Condenser3.Pressureswitch
2.Dryer/lter
Controls
Thecontrolsaremountedontherightsideintherooflining.
G025784
1 2
0
3
Figure5
1.3-positionswitchfor
radial-blowerspeed
3.Air-conditionerswitch
2.Temperaturecontroller
5

Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
AIRCONDITIONER
Coolingperformance4.2kW
RefrigerantR134A
Recommendedquantityofrefrigerant850g(1.87
lb)
Evaporator—volumetricairowoftheblower660m3/h
(23,307
ft3/h)
ELECTRICAL
Operatingvoltage12V
Fuseforradialblower/compressor15A
Fuseforaxialblower25A
COMPRESSOR
DesignationTM-08HS
Directionofrotation(viewingthepulley)clockwise
Operatingspeed700to6000
rpm
Pistondisplacement82
cm3/rev(5
inch3/rev)
Pressure-sideconnection3/4inch
O-ring
Suction-sideconnection7/8inch
O-ring
Magneticclutchoperatingvoltage12V
Magneticclutchpowerconsumption0.45W
RefrigerantoilZXL100
PAG
Refrigerantoilvolumeincompressor150cm3
(9.15inch3)
Refrigerantoil—additionalrequiredtoll
air-conditionersystem
25cm3
(1.53inch3)
Powerconsumptionofair-conditionersystem2.5kW
Attachments/Accessories
AselectionofToroapprovedattachmentsandaccessoriesare
availableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealeror
Distributororgotowww .Toro.comforalistofallapproved
attachmentsandaccessories.
Tobestprotectyourinvestmentandmaintainoptimal
performanceofyourToroequipment,countonTorogenuine
parts.Whenitcomestoreliability,Torodeliversreplacement
partsdesignedtotheexactengineeringspecicationofour
equipment.Forpeaceofmind,insistonTorogenuineparts.
Operation
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
UsingtheAirConditionerfor
theFirstTime
1.Starttheengine.
2.Switchontheblowerswitch(Figure5).
3.Switchontheair-conditioningswitch(Figure5).
4.Setthetemperaturecontroller(Figure5)tothe
maximumColdsetting(fullcounterclockwise
direction).
Note:After3minutes,theair-outletlouversshould
emitcoldair.
5.Adjustthefanspeedandtemperaturecontrolto
achievetherequiredamountofcooling.
OperatingtheAir-Conditioning
System
Donotruntheair-conditioningsystemwithoutrunning
theengineasitwillnotfunctionandthebatterywillbe
discharged.
Topreventprematurefailureofthecompressor-shaftseals,
runtheair-conditioningsystemfor15minutesevery14days.
1.SettheswitchtotheONposition.
2.Setthefan-speedswitchtothedesiredspeed.
3.Setthetemperatureregulatortotherequiredsetting.
Note:Thethermostatinthesystemswitchesthe
compressoronandofftomaintainthesettemperature.
OperatingtheHeatingSystem
1.SettheswitchtotheOFFposition.
2.Setthefan-speedswitchtothedesiredspeed.
3.Setthetemperatureregulatortotherequiredsetting.
6

Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
IntervalMaintenanceProcedure
Aftertherst100hours•Checkallconnectionsfortightness.
Every50hours•Checktherefrigerantlevel.
Every250hours
•Checkthecompressormagneticclutchforcorrectoperation.
•Checkthewaterdrainforblockage,andcleanitasnecessary.
•Examineandcleanthecondensernsasnecessary.
•Examinetheconditionoftheelectricalcables.
•Examinetheconditionandtightnessoftheelectricalconnectors.
Every500hours
•Checkthecompressor-fanbeltconditionandtension,andadjustitasnecessary.
•Examinethehoselinesforabrasionandgeneralcondition.
•Checkallconnectionsforleaks.
•Examinetheconditionoftheclimaticunitinthecabroof,andcheckthepartsfor
tightness.
•Checkthecompressorbracketstightnessofttings.
Every2years•Changethedryer/lter.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure
youorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
Important:Allworkontherefrigerantpartoftheair-conditioningsystemshouldbecarriedoutbyfullyqualied
personnel.
•Youcanusetheair-conditioningsystemformanymonthsofthecuttingseason.Followtheregularprescribedmaintenance
toprolongthelifeofthesystemandensureefcientoperation.Failuretocarryouttheprescribedanddocumented
maintenancecouldinvalidatethewarrantyonthesystemanditscomponents.
•Eveniftheair-conditioningsystemisusedinfrequently,followthemaintenanceschedule,asagingandrefrigerantloss
canoccurwithtime.
•Cleanthecondenserandevaporatornswithcompressedairintheoppositedirectionofthenormalairow.Ifthere
isanybuildupofgreasydeposits,cleanitwithanon-abrasivesoapsolution.
•Lowlevelsofrefrigerantcanreducetheefciencyoftheair-conditioningunit.
•Extremelylowlevelscancausethelow-pressureswitchtoshutdownthesystem.
•Tochecktherefrigerantlevel,thereisanintegratedsightglassinthecollectingtank.Afterlling,runthesystemfor5
minutestoallowallairbubblestobepurgedfromthesystem.Checkthelevelafterthisperiodandtopupisnecessary.
Theoccasionalairbubblecanbeaccepted.
Important:Donotspillcompressoroilonthevehiclesurface.Itcancausediscolorationofvehiclepaintand
deteriorationofacrylicorABSplasticcomponents.
•Whenattachingtheclimatichoses,oilthesealingringswithrefrigeratoroil.
•Afterremovalofclimatichosesfromtheair-conditionersystem,alwaysreplacetheO-ringswithnewonesspecied
forrefrigerant134A.
•Whentighteningorlooseningttings,alwaysuse2wrenchestopreventthetubesfromtwisting.
7

CheckingtheRefrigerant
Pressure
Whenusingtheair-conditioningsystemtheoperating
pressureisdifferentonthesuctionsideandthepressureside
ofthecompressor.
Thispressuredifferenceisinuencedbythespeedofthe
compressor,theinsidetemperatureofthevehicle,theoutside
airtemperatureandtherelativeairhumidity.
Pressuresthatdifferfromthoseinthetablebelowindicatea
possiblefaultinthesystem.
Tocheckthepressures,setthecompressorspeedto2000
rpmwithanairtemperaturebetween20and40degreesC(68
and104degreesF).Operatethebloweratposition3(fastest
speedsetting).
SystemRefrigerantPressures
OutsideTemperatureLow-PressureSideHigh-PressureSide
20°C(68°F)1.7to2.1bar(24.7to30.5psi)10to14bar(145to203psi)
25°C(77°F)1.8to2.2bar(26.1to31.9psi)12to16bar(174to232psi)
30°C(86°F)1.9to2.3bar(27.6to33.4psi)14to18bar(203to261psi)
TroubleshootingthePressure
Readings
Duringthecompressiontest,deviationsfromthevaluesin
thetablemaybemeasured.Locatingthecausecandetermine
whetherapartrequiresrepairorreplacement.
Thefollowingisashortlistofsomepressuredeviationthat
maybemeasuredandsomepossiblecauses.
•Pressureonhigh-pressuremanometertoohigh
–Theairvolumeinthecondenseristoosmall.
–Refrigerantquantityistoohigh
–Thedryer/lterisblocked.
•Pressureonhigh-pressuremanometeristoolow
–Therefrigerantquantityistoolow(checkthesight
glass).
–Thecompressorspeedistoolow(checkthedrive
beltforslip/tension).
–Thereisafaultwiththecompressor.
•Pressureonlow-pressuremanometertoohigh
–Theexpansionvalveisincorrect.
–Thecompressorspeedistoolow(checkthedrive
beltforslip/tension).
–Thereisafaultwiththecompressor.
•Pressureonlow-pressuremanometertoolow
–Thereisrestrictioninthesuctionorpressurehoses.
–Theexpansionvalveisincorrect.
–Therefrigerantquantityistoolow(examinethe
sedimentbowl).
–Theairvolumeintheevaporatoristoosmall.
Haveaqualiedpersonexamineandrepairalldeviations
inpressurefromthevaluesinthetable.
Important:Donotallowrefrigeranttodischargeinto
theatmosphere.Beforeopeningordisconnectingparts
fromtherefrigerantcircuit,emptytherefrigerantintoa
speciedrecyclingbottle,anddisposeofitcorrectly.
AlwaysusegenuineTorosparepartswhenrepairingor
servicingtheair-conditioningsystem.
CheckingtheRefrigerantLevel
ServiceInterval:Every50hours
Checktherefrigeranttoassureitisatthecorrectlevelfor
operation.Astheleveloftherefrigerantlowers,more
airbubblescanbeseenpassingthroughthesightglass.
Lowlevelsofrefrigerantcanreducetheefciencyofthe
air-conditioningunit.Extremelylowlevelscancausethe
low-pressureswitchtoshutdownthesystem.
1.Usingthesightgaugeinthecollectingtank,checkon
refrigerantlevel(Figure6).
g019080
1
Figure6
1.Refrigerant-levelsightgauge
2.Afterlling,runthesystemfor5minutestoallowall
airbubblestobepurgedfromthesystem.
8

3.Checkthelevelafterthisperiodandtopupisnecessary.
Note:Theoccasionalairbubbleisacceptable.
CheckingtheCompressor
MagneticClutch
ServiceInterval:Every250hours
Thecompressormagneticclutchisoperatingcorrectlyifit
clickswhenitisturnedon(Figure7).
g019082
1
Figure7
1.Compressormagneticclutch
CheckingtheDrainTube
ServiceInterval:Every250hours
Thewaterdrainistheclearplastictubeconnectedtothe
condenser.Itrunsfromthecondenserthroughthecab
structuretobelowthefrontofthecab(Figure8).Checkthe
waterdrainforblockagesandcleanasnecessary.
Ifthetubeisblocked,useaexibleunblockingtool
(pipecleaner)ordisconnectthetubeandblowitoutwith
compressedair.
g019083
1
Figure8
1.Draintube
Note:Iftheblockageisnotreachablewithaexible
unblockingtool,theotherendofthetubecanbedisconnected
andblownoutwithcompressedair(Figure9).
g019079
1
Figure9
1.Disconnectthetubehere.
CheckingtheCompressor-Fan
Belt
ServiceInterval:Every500hours
1.Propertensionallows10mm(3/8inch)deection
whenapplyingaforceof40N(9lb)onthebelt,
midwaybetweenthepulleys.
2.Ifthedeectionisnot10mm(3/8inch),loosenthe
upperandlowercompressor-mountingbolts.
9

g019081
1
2
Figure10
1.Compressor2.Checkthebeltdeection
here.
3.Increaseordecreasethecompressor-belttensionand
tightenthebolts.
4.Checkthedeectionofthebeltagaintoensurethat
thetensioniscorrect.
LocatingtheFuses
Thefuseboxislocatedinthecabrooflinerinfrontofthe
driver.
g018402
1 2 34
Figure11
1.25amp3.5amp
2.15amp4.5amp
Storage
RefertothetractionunitOperator’sManualfordetailson
storingthemachine.
10