Toro Polar Trac Cab 30474 User manual

FormNo.3427-218RevA
PolarTrac®Cab
Groundsmaster®7200SeriesMower
ModelNo.30474—SerialNo.403380001andUp
ModelNo.30675—SerialNo.403380001andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3427-218*A

WARNING
CALIFORNIA
Proposition65Warning
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Introduction
Thiskittransformsasummerride-on,rotary-blade
lawnmowerintoasnow-removalmachinethatis
intendedforusebyprofessional,hiredoperatorsin
commercialapplications.
ThiskitwasdesignedtobeusedwithcabModel
30474.However,youcanusethekitwithcabModel
30371withminormodications.Pleaseseeyour
authorizedTorodistributorfordetails.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.Toro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineT oroparts,or
additionalinformation,contactanAuthorizedService
DealerorT oroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Important:Withyourmobiledevice,youcan
scantheQRcode(ifequipped)ontheserial
numberplatetoaccesswarranty,parts,andother
productinformation.
g271386
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety.......................................................................4
SafetyandInstructionalDecals..........................4
Setup........................................................................7
1PreparingtheMachine.....................................9
2InstallingtheHeatShields................................9
3AssemblingtheHeaterHoses........................10
4InstallingtheBulkheadBracket......................12
5RoutingtheHeaterHoses..............................14
6InstallingtheT emperatureSensor..................18
7InstallingtheWasherBottle............................18
8InstallingtheWireHarness............................21
9InstallingtheSkidPlate.................................26
10RemovingtheRollBar.................................26
11RemovingtheSummerFrame......................26
12InstallingtheCab.........................................30
13InstallingtheWinterFrame..........................33
14CompletingtheInstallation...........................40
ProductOverview...................................................41
Controls...........................................................41
Climate-ControlsPanel.................................41
Light-ControlsPanel.....................................42
Rear-WindowLatch......................................42
FootPedalOperation....................................43
Operation................................................................43
PuttingSafetyFirst...........................................43
UsingtheAttachments......................................44
RoutingtheSnowthrowerWires........................44
RemovingtheWinterFrame.............................44
InstallingtheSummerFrame............................49
Maintenance...........................................................53
RecommendedMaintenanceSchedule(s)...........53
Lubrication..........................................................53
GreasingandLubricatingtheMachine..............53
ElectricalSystemMaintenance...........................53
CheckingtheFuses..........................................53
DriveSystemMaintenance..................................54
CheckingtheTirePressure...............................54
CabMaintenance.................................................54
CleaningtheCab..............................................54
CleaningtheAirFilters......................................55
Storage...................................................................56
StoringtheMachine..........................................56
3

Safety
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal120-0250
120–0250
1.Slow-movingvehicle
decal125-9688
125-9688
1.Windshieldwipers—off3.Windshieldwipers—on
2.Windshieldwipers4.Spraywindshieldwasher
uid
decal130-0457
130-0457
1.Left2.Right
decal132-3600
132-3600
1.ReadtheOperator's
Manualformore
informationonfuses.
5.Workinglight—20A
2.Headlight—25A6.Auxiliarypower—15A
3.CondenserfanandA/C
clutch—30A
7.Cablight—15A
4.Fan—25A8.Windshieldwipers—15A
decal130-0611
130-0611
1.Warning—1)Removethepin;2)Raisethedoors;3)Exit
thecab
decal133-8061
133-8061
4

decal130-5361
130-5361
1.Warning—readtheOperator'sManual;onlyoperatefrom
thedriver'sseat;wearaseatbelt;wearhearingprotection.
5

decal121-8378
121-8378
1.Fan—off5.Externalair
2.Fan—onfull6.Internalair
3.Coldair7.Airconditioner—off
4.Hotair8.Airconditioner—on
decal125-9659
125-9659
1.Headlight–on5.Hazardlight–on
2.Headlight–off6.Hazardlight–off
3.Cablight–on7.Left-turnsignal
4.Cablight–off8.Right-turnsignal
6

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachineforinstallingthe
kit.
Rear-panelshield1
2Under-seatshield1Installtheheatshields.
Straighttting(3/8NPTx0.625barb)1
Hoseclamp(1/2to1-1/4inches)4
Hoseclamp(3/4to1-1/2inches)1
Teetting1
Female-dusttting1
3
Male-dusttting1
Assembletheheaterhoses.
Grommet1
Bulkheadbracket1
Bolts(5/16x5/8inch)2
R-clamp2
Carriagebolt(1/4x3/4inch)2
4
Flangenut(1/4inch)2
Installthebulkheadbracket.
Hoseclamp(1/2to1-1/4inches)1
Straighttting(3/8nptx0.625barb)1
Temperaturesensor(Yanmarengine
only)1
5
Adapter(Yanmarengineonly)1
Routetheheaterhose.
6Nopartsrequired–Installthetemperaturesensor.
Washerbottle1
Bracket1
R-clamp1
Carriagebolt(5/16x1inch)3
Bolt(5/16x3/4inch)2
Flangenut(5/16inch)5
Carriagebolt(1/4x3/4inch)1
7
Nut(1/4inch)1
Installthewasherbottle.
Wireharness1
Relay1
Fuse(60A)1
Fuse(10A)2
Cabletie3
Wireharnessfuseblock—ToroPartNo.
92-2641(purchasedseparately)1
8
Keystartharness—T oroPartNo.
107-0672(purchasedseparately)1
Installthewireharness.
Skidplate1
Bolt(3/8x1-1/4inches)2
Bolt(3/8x1inch)2
9Flangenut(3/8inch)4
Installtheskidplate.
7

ProcedureDescriptionQty.Use
10Nopartsrequired–Removetherollbar.
Rollerassembly2
Leftbracket1
Rightbracket1
Bolt(3/8x2-1/4inches)2
Bolt(3/8x5/8inch)2
Flangenut(3/8inch)4
Clevispin2
Self-tappingscrew(1/4inch)2
11
Hoseplugs2
Removethesummerframe.
Cab1
Bulbseal2
Rearfoamseal1
Right,rear-foamseal1
Left,rearfoamseal1
Right,middlefoamseal1
Left,middlefoamseal1
Right,tankfoamseal1
Side,frontfoamseal2
Frontfoamseal1
Left,sidefoamseal1
Right,sidefoamseal1
Rubberisolator4
Bolt(1/2x3-1/4inches)4
Washer(1/2inch)4
Largewasher4
Nut(1/2inch)4
Bolt(3/4x3-1/2inches)2
12
Locknut(3/4inch)2
Installthecab.
Winterframe1
Couplerlink2
Bolt(3/4x4inches)2
Washer(3/4inch)2
Supply-hosecover1
13
Return-hosecover1
Installthewinterframe.
14Nopartsrequired–Completetheinstallation.
8

1
PreparingtheMachine
NoPartsRequired
Procedure
1.Parkthemachineonalevelsurface,lowerthe
cuttingunittothelowestheight-of-cutsetting,
shutofftheengine,andremovethekey.
2.Disconnectthebatterycableconnectedtothe
negative(-)batteryterminal.
3.Allowtheenginecoolanttocoolandthendrain
thecoolantfromthemachine;refertothe
machineServiceManual.
4.Removethehoodfromthemachineandsetit
aside;refertothemachineServiceManual.
2
InstallingtheHeatShields
Partsneededforthisprocedure:
1Rear-panelshield
1Under-seatshield
InstallingtheRear-PanelShield
1.Movetheseatforwardtoallowyoutohave
accesstotherearpanel.
2.Togglethe3swelllatchesandremovetherear
panel(Figure3).
g032347
Figure3
1.Swelllatch2.Backpanel
3.Cleanbackoftheplatetoensureproper
adhesionwhenyouapplytheheatshield.
4.Removethebackingandapplytherear-panel
shieldtotheenginesideoftherearpanel
(Figure4).
g032348
Figure4
1.Rearpanel3.29mm(1-1/8inches)
2.Rear-panelshield
Note:Centertherear-panelshieldalongthe
widthoftheplateleaving29mm(1-1/8inches)
fromeachedge(Figure4).
5.Setthepanelaside.
InstallingtheOperator-Deck
Shield
1.Releasetheseatlatchandtilttheseatforward.
2.Disconnecttheseat-switchonthebottomofthe
seatdeckfromthewireharness(Figure5).
9

g032391
Figure5
1.Seatconnector3.Wireclip
2.Wireharness
3.Removethewireclipfromthebottomoftheseat
deckFigure5.
4.Cleanthebottomoftheseatdecktoensure
properadhesionoftheunder-seatshield.
5.Removethebackingandapplytheunder-seat
shieldtothebottomoftheseatdeck(Figure6).
g032392
Figure6
1.Heatshield2.Cutout
Note:Usethecutoutsfortheboltstoalignthe
under-seatshieldtotheplate.
6.Installthewirecliptothebottomoftheseat
plate(Figure7).
g032393
Figure7
1.Holeforwireclip2.Wireclip
7.Connecttheseat-switchtothewireharness
(Figure7).
3
AssemblingtheHeater
Hoses
Partsneededforthisprocedure:
1Straighttting(3/8NPTx0.625barb)
4Hoseclamp(1/2to1-1/4inches)
1Hoseclamp(3/4to1-1/2inches)
1Teetting
1Female-dusttting
1Male-dusttting
AssemblingtheSupplyHose
Note:Usethe86.3cm(34inches)hosefora
machineequippedwiththeYanmarengineand
usethe57.1cm(22.5inches)hoseforamachine
equippedwiththeKubotaengine.
1.Applysealanttothestraighttting(3/8NPTx
0.625barb);skippingtherstthread.
10

g032343
Figure8
1.Malecoupler4.Hoseclamp(1/2to1-1/4
inches)
2.Maledustplug5.Supplyhose
3.Straighttting(3/8NPTx
0.625barb)
2.Slidethedustplugoverthethreadedendofthe
straighttting(Figure8).
3.Threadthestraighttting(3/8NPTx0.625barb)
tothemalecoupler(Figure8).
4.Tightenthestraighttting(3/8NPTx0.625
barb)intothemalecouple2to3turnsfrom
nger-tight.
5.Slideahoseclamp(1/2to1-1/4inches)over
thehose.
6.Insertthebarbedendoftheassemblyintothe
hoseandsecureitwiththehoseclamp(1/2to
1-1/4inches).
AssemblingtheReturnHose
Note:Usethe86.3cm(34inches)hosefora
machineequippedwiththeYanmarengineanduse
the132cm(54inches)hoseforamachineequipped
withtheKubotaengine.
1.Applysealanttothestraighttting(3/8NPTx
0.625barb);skippingtherstthread.
g030360
Figure9
1.Femalecoupler5.Returnhose
2.Femaledustplug6.Teetting
3.Straighttting(3/8NPTx
0.625barb)
7.Hoseclamp(1/2to1-1/4
inches)
4.Hoseclamp(1/2to1-1/4
inches)
2.Slidethedustplugoverthethreadedendofthe
straighttting(Figure9).
3.Threadthestraighttting(3/8NPTx0.625barb)
tothefemalecoupler(Figure9).
4.Tightenthestraighttting(3/8NPTx0.625
barb)intothefemalecouple2to3turnsfrom
nger-tight.
5.Slide2ofthehoseclampsoverthehose.
6.Insertthebarbedendoftheassemblyintothe
hoseandsecureitwiththehoseclamp(1/2to
1-1/4inches)asshowninFigure9.
7.Insertthebarbedendoftheteettingintothe
hoseandsecureitwiththehoseclamp(1/2to
1-1/4inches)asshowninFigure9.
11

ConnectingtotheRadiatorHose
YanmarEngineOnly
1.Locatetheradiatorhose(Figure10).
g032396
Figure10
1.Cutlines
2.Useacuttingtooltocuttheradiatorhoseatthe
cutlines(Figure10).
3.Slidethecutendsovertheteettingandsecure
itusingthehoseclamp(3/4to1-1/2inches)as
showninFigure11.
g032398
Figure11
1.Hoseclamp(3/4to1-1/2
inches)
2.Teetting
ConnectingtotheRadiatorHose
KubotaEngineOnly
1.Locateandremovetheradiatorhose(Figure
12).
g032421
Figure12
1.Cutlines
2.Useacuttingtooltocuttheradiatorhoseatthe
cutlines(Figure12).
3.Slidethecutendsovertheteettingandsecure
itusingthehoseclamp(3/4to1-1/2inches)as
showninFigure13.
g032420
Figure13
1.Teetting2.Hoseclamp(3/4to1-1/2
inches)
12

4
InstallingtheBulkhead
Bracket
Partsneededforthisprocedure:
1Grommet
1Bulkheadbracket
2Bolts(5/16x5/8inch)
2R-clamp
2Carriagebolt(1/4x3/4inch)
2Flangenut(1/4inch)
InstallingtheGrommet
Note:Ifthegrommetsarenotinstalled,performthis
procedure.
1.Removethecapscoveringtheholesinthe
supporttube(Figure9).
g234097
g032344
Figure14
1.Cap
2.Ifitispresent,removethepunch-outlocated
betweenthe2holes(Figure15).
g032345
Figure15
1.Punch-out
Note:Ifnecessary,useametal-cuttingtoolto
removethematerialbetweenthe2holesinthe
supporttube.
3.Installthegrommetintotheopening(Figure16).
g032346
Figure16
1.Grommet
InstallingtheHoseBracket
1.Usethe2bolts(5/16x5/8inch)toinstallthe
brackettotheframe(Figure17).
13

g032394
Figure17
1.Frame3.Hosebracket
2.Bolts(5/16x5/8inch)
2.Torquetheboltsto1978to2542N∙cm(175to
225in-lb).
3.PositionanR-clampovereachhose(Figure18).
g032395
Figure18
1.Supplyhose4.Returnhose
2.R-clamp5.Flangenut(1/4inch)
3.Carriagebolt(1/4x3/4
inch)
4.Usethe2carriagebolts(1/4x3/4inch)and
angenutstoinstalltheR-clampandhose
assemblytothebracketmount(Figure18).
5.Torquetheboltto1017to1243N∙cm(90to110
in-lb).
5
RoutingtheHeaterHoses
Partsneededforthisprocedure:
1Hoseclamp(1/2to1-1/4inches)
1Straighttting(3/8nptx0.625barb)
1Temperaturesensor(Yanmarengineonly)
1Adapter(Yanmarengineonly)
RoutingtheSupplyHose
KubotaEngineOnly
1.RoutethesupplyhoseasshowninFigure19.
g032423
Figure19
1.Supplyhose2.Returnhose
2.Locate,disconnect,andremovethetemperature
sensor(Figure20).
14

g032422
Figure20
1.Supplyhose3.Straighttting(3/8NPTx
0.625barb)
2.Hoseclamp(1/2to1-1/4
inches)
4.Temperaturesensor
3.Applysealanttothestraighttting(3/8NPTx
0.625barb);skippingtherstthread.
4.Finger-tightenthestraightttingintotheport.
5.Tightenthestraighttting2to3additionalturns.
6.Slidethehoseclampoverthehoseend(Figure
20).
7.Insertthehoseoverstraightttingandsecure
itwiththehoseclamp(1/2to1-1/4inches)as
showninFigure20.
RoutingtheReturnHose
KubotaEngineOnly
RoutethereturnhoseasshowninFigure21.
g032423
Figure21
1.Supplyhose2.Returnhose
MovingtheTemperatureSensor
YanmarEngineOnly
1.Removethesocketterminalfromthecoolant
temperaturesensor(Figure22).
g233716
Figure22
1.Socketterminal
(coolant-temperature
sensor)
3.Water-pumphousing
2.Temperaturesensor
15

2.Removethetemperaturesensorandgasket
fromtherearportofthewaterpump(Figure23).
Note:Retainthetemperaturesensorfor
installationinstep5.
g233715
Figure23
1.Temperaturesensor(old)4.Forwardport(water-pump
housing)
2.Gasket(temperature
sensor)
5.Gasket(plug)
3.Rearport(water-pump
housing)
6.Plug
3.Removetheplugandgasketfromtheforward
portofthewaterpump(Figure23).
Note:Younolongerneedtheplugandgasket.
4.Installthereducerandthegasket(plug)intothe
forwardportofthewaterpump(Figure24).
g233712
Figure24
1.Reducer3.Forwardport(water-pump
housing)
2.O-ring4.Temperaturesensor
5.ApplyPTFEthreadsealanttothethreadsofthe
temperaturesensorthatyouremovedinstep2
andtothethreadsofthestraightbarbedtting.
6.Installthenewtemperaturesensorintothe
reducer(Figure24).
7.Installthebarbedttingintotherearportofthe
water-pumphousing(Figure25)andtightenthe
tting2to3turnsbeyondngertight.
16

g233713
Figure25
1.Straighttting(3/8nptx
0.625barb)
3.Socketterminal
(coolant-temperature
sensor)
2.Rearport(water-pump
housing)
4.Bladeterminal
(temperaturesensor)
RoutingtheSupplyHose
YanmarEngineOnly
1.RoutethesupplyhoseasshowninFigure26.
g032427
Figure26
1.Returnhose2.Supplyhose
2.Slidethehoseclampoverthehoseend(Figure
27).
g233714
Figure27
1.Supplyhose3.Barbedtting
2.Hoseclamp
3.Insertthehoseoverstraightttingandsecure
itwiththehoseclamp(1/2to1-1/4inches)as
showninFigure27.
17

RoutingtheReturnHose
YanmarEngineOnly
RoutethesupplyhoseasshowninFigure28.
g032427
Figure28
1.Returnhose2.Supplyhose
6
InstallingtheTemperature
Sensor
KubotaEngineOnly
NoPartsRequired
Procedure
1.Locatethethermostathosingontheengine
blockandremovetheengine-portplug(Figure
29).
g032524
Figure29
1.Thermostathousing5.Yellowwire
2.Engine-portplug6.Engine-warmconnector
3.Dual-temperaturesensor7.Orangewire
4.Engine-hotconnector
2.Applysealanttothetemperaturesensor;
skippingtherstthread.
3.Finger-tightenthetemperaturesensorintothe
port.
4.Tightenthetemperaturesensor2to3additional
turns.
5.Locatetheyellowwirethatyoudisconnected
instep2inRoutingtheSupplyHose(page14)
andconnectittotheengine-hotconnectorofthe
temperaturesensor(Figure29).
6.Locatetheorangewirethatiscabletiedtothe
yellowwire,removethecabletie,andconnect
thewiretotheengine-warmconnectorofthe
temperaturesensor(Figure29).
7.Usecabletiestosecurethewires.
Note:Donotsecurethewireharnesstohotor
movingparts.
18

7
InstallingtheWasherBottle
Partsneededforthisprocedure:
1Washerbottle
1Bracket
1R-clamp
3Carriagebolt(5/16x1inch)
2Bolt(5/16x3/4inch)
5Flangenut(5/16inch)
1Carriagebolt(1/4x3/4inch)
1Nut(1/4inch)
InstallingtheWasherBottle
KubotaEngineOnly
1.Usethe3carriagebolts(5/16x1inch),(5/16x
1inch),and3angenutstosecurethebracket
totheframe(Figure30).
g032446
Figure30
1.Flangenut(5/16inch)3.Bolt(5/16x3/4inch)
2.Carriagebolt(5/16x1
inch)
4.Flangenut(5/16inch)
2.Torquetheboltsto1978to2542N∙cm(175to
225in-lb).
3.Usethe2carriagebolts(5/16x3/4inch)and
angenutstosecurethewasherbottletothe
bracket(Figure31).
g032447
Figure31
1.Bracket3.Flangenut(5/16inch)
2.Carriagebolt(5/16x3/4
inch)
4.Washerbottle
4.Torquetheboltsto1978to2542N∙cm(175to
225in-lb).
5.Connectthewashertubetothewasherbottle
andsecureittotheframewithcableties(Figure
32).
g032449
Figure32
1.Washertube
19

Note:Donotsecurethehosestohotormoving
parts.
InstallingtheWasherBottle
YanmarEngineOnly
1.Usethe3carriagebolts(5/16x2inch),(5/16x
1inch),and3angenutstosecurethebracket
totheframe(Figure33).
g032448
Figure33
1.Bolt(5/16x2inch)3.Bolts(5/16x1inch)
2.Flangenut(5/16inch)4.Flangenut(5/16inch)
2.Torquetheboltsto1978to2542N∙cm(175to
225in-lb).
3.Usethe2carriagebolts(5/16x3/4inch)and
angenutstosecurethewasherbottletothe
bracket(Figure34).
g032450
Figure34
1.Carriagebolt(5/16x3/4
inch)
2.Flangenut(5/16inch)
4.Torquetheboltsto1978to2542N∙cm(175to
225in-lb).
5.Connectthewashertubetothewasherbottle
andsecureittotheframewithcableties(Figure
35).
g032515
Figure35
1.Washertube
Note:Donotsecurethehosestohotormoving
parts.
20