Toro Groundsmaster 7200 Series User manual

FormNo.3395-735RevA
PolarTracCab
Groundsmaster®7200Series
ModelNo.30474—SerialNo.315000001andUp
ModelNo.30675—SerialNo.315000001andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3395-735*A

WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
ThisproductcomplieswithallrelevantEuropeandirectives.
Fordetails,pleaseseetheDeclarationofIncorporation(DOI)
atthebackofthispublication.
Introduction
Thiskittransformsasummerride-on,rotary-blade
lawnmowerintoawintersnowremovalmachinethatis
intendedtobeusedbyprofessional,hiredoperatorsin
commercialapplications.
ThiskitwasdesignedtobeusedwithCabmodel30474.
Howeveritcanbeusedwith30371withminormodications.
Pleaseseeyourdistributorfordetails.
Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comforproduct
safetyandoperationtrainingmaterials,accessoryinformation,
helpndingadealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,oradditional
information,contactanAuthorizedServiceDealerorToro
CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.
©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety...........................................................................3
SafeOperatingPractices...........................................3
SafetyandInstructionalDecals.................................6
Setup............................................................................9
1InstallingtheHeatShields.....................................11
2PreparingtheEngineCoolingSystem.....................12
3ConnectingthePressureLine(forMachineswith
KubotaEngines)................................................14
4ConnectingthePressureLineforMachineswith
YanmarEngines................................................15
5PreparingtheElectricalSystem..............................16
6InstallingtheWasherBottle...................................18
7InstallingtheSkidPlate(RequiredforMachines
withaKubotaEngine).........................................19
8RemovingtheMowerDeck...................................19
9InstallingtheWinter-FrameAssembly.....................22
10RemovingtheSummerROPS..............................26
11InstallingthePanels............................................26
12InstallingtheFoamSealstotheCab......................27
13MountingtheCab..............................................28
14MakingtheFinalConnectionsandChecking
theOperation.....................................................30
15ReadingtheManuals..........................................31
ProductOverview.........................................................32
Controls...............................................................32
Operation....................................................................32
PuttingSafetyFirst.................................................32
UsingtheAttachments............................................33
RoutingtheSnowthrowerWireEyelet.......................33
ConvertingtheMachinefromWintertoSummer
Operation..........................................................33
ConvertingtheMachinefromSummertoWinter
Operation..........................................................38
Maintenance.................................................................47
RecommendedMaintenanceSchedule(s)......................47
Lubrication...............................................................47
GreasingandLubricatingtheMachine.......................47
ElectricalSystemMaintenance....................................48
CheckingtheFuses.................................................48
DriveSystemMaintenance.........................................49
CheckingtheTirePressure......................................49
RemovingtheRearWheel........................................49
Storage........................................................................50
StoringtheMachine................................................50
Safety
Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructionsand
alwayspayattentiontothesafetyalertsymbol,which
meansCaution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.
SafeOperatingPractices
Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.
Training
•ReadtheOperator'sManualandothertrainingmaterial
carefully.Befamiliarwiththecontrols,safetysigns,and
theproperuseoftheequipment.
•Neverallowchildrenorpeopleunfamiliarwiththese
instructionstousethemachine.Localregulationscan
restricttheageoftheoperator.
•Neveroperatewhilepeople,especiallychildren,orpets
arenearby.
•Keepinmindthattheoperatororuserisresponsiblefor
accidentsorhazardsoccurringtootherpeopleortheir
property.
•Donotcarrypassengers.
•Alldriversshouldseekandobtainprofessionaland
practicalinstruction.Suchinstructionshouldemphasize:
–theneedforcareandconcentrationwhenworking
withride-onmachines;
–controlofaride-onmachineslidingonaslopewill
notberegainedbytheapplicationofthecontrol
levers.Themainreasonsforlossofcontrolare:
◊insufcienttrackgrip,especiallyonwetgrass,ice
orsnow;
◊beingdriventoofast;
◊thetypeofmachineisunsuitableforitstask;
◊lackofawarenessoftheeffectofground
conditions,especiallyslopes;
◊incorrecthitchingandloaddistribution.
Preparation
•Whileoperating,alwayswearsubstantialfootwearand
longtrousers.Donotoperatetheequipmentwhen
barefootorwearingopensandals.
•Thoroughlyinspecttheareawheretheequipmentisto
beusedandremoveallobjectswhichmaybethrownby
themachine.
3

•Replacefaultysilencers/mufers.
•Beforeusing,alwaysvisuallyinspecttoseethatthe
attachmentsarenotwornordamaged.Replacewornor
damagedcomponents.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,useextreme
careinhandlingfuel.Fuelisextremelyammableandthe
vaporsareexplosive.
•Extinguishallcigarettes,cigars,pipes,andothersources
ofignition.
•Useonlyanapprovedfuelcontainer.
•Neverremovefuelcaporaddfuelwiththeengine
running.
•Allowenginetocoolbeforerefueling.
•Neverrefuelthemachineindoors.
•Neverstorethemachineorfuelcontainerwherethereis
anopename,spark,orpilotlightsuchasonawater
heateroronotherappliances.
•Neverllcontainersinsideavehicleoronatruckor
trailerbedwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.
•Removeequipmentfromthetruckortrailerandrefuelit
ontheground.Ifthisisnotpossible,thenrefuelsuch
equipmentwithaportablecontainer,ratherthanfroma
fueldispensernozzle.
•Keepthenozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingiscomplete.
Donotuseanozzlelockopendevice.
•Iffuelisspilledonclothing,changeclothingimmediately.
•Neveroverllfueltank.Replacefuelcapandtighten
securely.
Operation
•Holdingtheattachmentcontrolpedalsupordownduring
operationisdetrimentaltothehydraulicsystem.
•Bealert,slowdownandusecautionwhenmakingturns.
Lookbehindandtothesidebeforechangingdirections.
•Engineexhaustcontainscarbonmonoxide,whichisan
odorless,deadlypoisonthatcankillyou.Donotrun
engineindoorsorinanenclosedareawherefumescan
collect.
•Operateonlyindaylightoringoodarticiallight.
•Beforeattemptingtostarttheengine,disengageall
attachmentclutchesandplaceinneutral.
•Whenoperatingneardropoffsorbodiesofwater,donot
useonslopesgreaterthan15degrees.
•Usecarewhenpullingloadsorusingheavyequipment.
–Useonlyapproveddrawbarhitchpoints.
–Limitloadstothoseyoucansafelycontrol.
–Donotturnsharply.Usecarewhenreversing.
•Thismachineisnotdesignedorequippedforon-road
useandisa“slow-movingvehicle."Ifyoumustcross
ortravelonapublicroad,youshouldbeawareofand
complywithlocalregulations,suchasrequiredlights,
slowmovingvehiclesigns,andreectors.
•Whenusinganyattachments,neverdirectdischargeof
materialtowardbystandersnorallowanyonenearthe
machinewhileinoperation.Someattachments,suchasa
snowthrower,arecapableofamputatinghandsandfeet
andthrowingobjects
•Neveroperatethemachinewithdamagedguards,shields,
orwithoutsafetyprotectivedevicesinplace.
•Donotoperatethemachineundertheinuenceof
alcoholordrugs.
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.
•Donotchangetheenginegovernorsettingsoroverspeed
theengine.Operatingtheengineatexcessivespeedmay
increasethehazardofpersonalinjury.
•Beforeleavingtheoperatorsposition:
–disengagethepowertakeoffandlowerthe
attachments;
–placeinneutralandsettheparkingbrake;
–stoptheengineandremovethekey.
•Ifanattachmentshouldstarttovibrateabnormally,stop
themachineandcheckimmediatelyforthecause.
•Disengagedrivetoattachments,stoptheengine,setthe
parkingbrakeandremovetheignitionkey:
–beforeclearingblockagesoruncloggingchute;
–beforechecking,cleaningorworkingonthe
attachment
–afterstrikingaforeignobject.Inspecttheattachment
fordamageandmakerepairsbeforerestartingand
operatingtheequipment;
–ifthemachinestartstovibrateabnormally(check
immediately).
•Disengagedrivetoattachmentswhentransporting,notin
useoranytimetheattachmentisintheraisedposition.
•Stoptheengineanddisengagedrivetoattachment:
–beforerefuelling;
–beforemakingheightadjustmentunlessadjustment
canbemadefromtheoperatorsposition.
•UseonlyToroapprovedattachments.
SlopeOperation
•Rememberthereisnosuchthingasasafeslope.Travel
onslopesrequiresparticularcare.Toguardagainst
overturning:
–donotstoporstartsuddenlywhenonaslope;
4

–useslowspeedsonslopesandduringtightturns;
–stayalertforhumpsandhollowsandotherhidden
hazards;
•Donotoperateneardrop-offs,ditches,steepbanksor
water.Tracksdroppingoveredgescancauserollovers,
whichmayresultinseriousinjury,deathordrowning.
•Donotoperateonslopeswhereslipperyconditions
couldreducetractionandcouldcauseslidingandloss
ofcontrol.
•Donotmakesuddenturnsorrapidspeedchanges.
•Reducespeedanduseextremecautiononslopes.
•Removeormarkobstaclessuchasrocks,treelimbs,etc.
fromtheoperatingarea.Tallgrasscanhideobstacles.
•Watchforditches,holes,rocks,dips,andrisesthatchange
theoperatingangle,asroughterraincouldoverturnthe
machine.
•Avoidsuddenstartswhenoperatinguphillbecausethe
machinemaytipbackwards.
•Donotoperateoniceincapableofsupportingtheweight
ofthismachine.
MaintenanceandStorage
•Keepallnuts,boltsandscrewstighttobesurethe
equipmentisinsafeworkingcondition.
•Neverstoretheequipmentwithfuelinthetankinsidea
buildingwherefumesmayreachanopenameorspark.
•Allowtheenginetocoolbeforestoringinanyenclosure.
•Toreducetherehazard,keeptheengine,
silencer/mufer,batterycompartmentandfuelstorage
areafreeofgrass,leaves,orexcessivegrease.
•Replacewornordamagedpartsforsafety.
•Ifthefueltankhastobedrained,dothisoutdoors.
•Whenmachineistobeparked,storedorleftunattended,
lowertheattachmentunlessapositivemechanicallock
isused.
•UseonlygenuineTororeplacementpartstoensurethat
originalstandardsaremaintained.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
trailerortruck.
•Usefullwidthrampsforloadingmachineintotraileror
truck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine
5

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.
Thefollowinginstructionaldecalisappliedtocomponentssuppliedwiththiskitandisusedinthe
conversionprocess.
112-6312
1.ReadtheOperator'sManual.
125-9688
1.Windshieldwipers—off3.Windshieldwipers—on
2.Windshieldwipers4.Spraywindshieldwasher
uid
130-0457
1.Left2.Right
130-0458
1.ReadtheOperator's
Manualformore
informationonfuses
5.Headlights—25A
2.Electricalpower
accessory—15A
6.CondenserfanandA/C
clutch—30A
3.Domelight—15A7.Fan—15A
4.Windshieldwiper
uid—15A
8.Worklight—15A
130-0611
1.Warning—1)Removethepin;2)Raisethedoors;3)Exit
thecab
6

130-5361
1.Warning—readtheOperator'sManual;onlyoperatefrom
thedriver'sseat;wearaseatbelt;wearhearingprotection.
7

121-8378
1.Fan—off5.Externalair
2.Fan—onfull6.Internalair
3.Coldair7.Airconditioner—off
4.Hotair8.Airconditioner—on
125-9659
1.Headlight—on5.Hazardlight—on
2.Headlight—off6.Hazardlight-off
3.Cablight—on7.Left-handturnsignal
4.Cablight—off8.Right-handturnsignal
8

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Heatshield—rearpanel1
Heatshield—seat1
1Rubbergrommet3
Installtheheatshields.
Cabassembly(suppliedwithcabmodel
30474)1
Nipplecoupler2
Quickdisconnectcoupler2
Hoseclamp4
Teetting1
Hoseclamp—large2
Hoseclamp—small2
Hose-adaptertting1
Bulkheadbracket1
Self-tappingscrew(5/16inch)2
Dustplug1
Dustcap1
2
Dualcontactswitch1
Preparetheenginecoolingsystem.
3Nopartsrequired–Connectthepressureline.
Hoseadaptertting1
4Hoseclamp1Connectthepressureline.
Cabharness1
Powerharness1
Cabletie2
5Cabletie4
Preparetheelectricalsystem.
Washerbottle1
Nut5
Bolt2
Carriagebolt3
6
Bracket1
Installthewasherbottle.
Skidplate1
Flange-headbolt(3/8x1-3/4inches)2
Flangenut(3/8inch)4
7Bolt(3/8x1inch)2
Installtheskidplate.
Verticaltubesupportassembly2
Conversionbracket,Left1
Conversionbracket,Right1
Clevispin2
Self-tappingscrew(1/4inch)2
Screw(3/8x2–1/4inch)6
Flangenut(3/8inch)6
Hoseplug2
Selftappingscrews(3/8inch)4
8
Hairpin2
Removethemowerdeck.
9

ProcedureDescriptionQty.Use
Hosecover2
Cabletie4
Winterframeassembly1
Wheelandtireassembly6
Lugnut20
Couplerpin2
9
Tracks2
Installthewinterframeassembly.
10Nopartsrequired–Installthecabmountsupports.
11Bulbseal2Installthepanels.
Rearfoampiece(suppliedwithcab
model30474)1
Right,rearfoampiece(suppliedwith
cabmodel30474)1
Left,rearfoampiece(suppliedwithcab
model30474)1
Right,middlefoampiece(suppliedwith
cabmodel30474)1
Leftmiddlefoampiece(suppliedwith
cabmodel30474)1
Righttankfoampiece(suppliedwith
cabmodel30474)1
Side,frontfoampiece(suppliedwith
cabmodel30474)2
Frontfoampiece(suppliedwithcab
model30474)1
Left,sidefoampiece(suppliedwithcab
model30474)1
12
Right,sidefoampiece(suppliedwith
cabmodel30474)1
Installthefoamsealstothecab.
Rubbercabmount(suppliedwithcab
model30474)4
Bolt(1/2x3inches)(suppliedwithcab
model30474)4
Steelwasher(suppliedwithcabmodel
30474)4
Rubberwasher(suppliedwithcab
model30474)4
Nut(1/2inch)(suppliedwithcabmodel
30474)4
Cornermat(suppliedwithcabmodel
30474)2
13
PowerPointShield1
Mountthecab.
Operator'sManual1
PartsCatalog1
Pre-deliveryInspectionSheet1
CerticateofQuality1
Jackingtube1
Jackingtubebolts2
Eyelet1
Spacer1
15
Flangenut(1/4inch)1
Readthemanualsbeforeoperatingthe
machineandusethejackingtubefor
seasonalconversion.
10

Note:Allreferencestotheinstallationoroperationofthe
cabrefertoCabModel30474only.
Important:Thefastenersonthecoversofthismachine
aredesignedtoremainonthecoverafterremoval.
Loosenallofthefastenersoneachcoverafewturnsso
thatthecoverisloosebutstillattached,thengoback
andloosenthemuntilthecovercomesfree.Thiswill
preventyoufromaccidentallystrippingtheboltsfree
oftheretainers.
1
InstallingtheHeatShields
Partsneededforthisprocedure:
1Heatshield—rearpanel
1Heatshield—seat
3Rubbergrommet
Procedure
Note:Togainadditionalaccesstotheenginearea,thehood
mayberemovedbyremovingthehairpincottersecuringthe
hoodtothepivotbrackets.
1.Startthemachineandlowerthemowerdecktothe
lowestheightofcut.
2.Positionthemachineonalevelsurfacesothatthe
mowerdeckframecanberolledawayandreplaced
withthewinterframe.
3.Movetheseattothefullyforwardposition.Releasethe
seatlatchandtiptheseatforward.
4.Removethe3quickreleaselatchessecuringtherear
paneltotheframeandremovetherearpanel(Figure3).
g028080
Figure3
1.Rearpanel
5.Cleantheenginesideoftherearpanel.
Note:Makesurethatallgreaseand/oroilisremoved
fromthepaneltoassureproperadhesion.
6.Removethebackingandafxtheself-adhesive
heat-shieldmaterialtotheenginesideoftherearpanel,
positioningasshowninFigure4.
Note:Donotinstallthepanelatthistime.
Note:Theheat-shieldmaterialmustbeafxedsothat
therearpanelmustbeinstalledtotheframewithout
pinchingtheheatshieldmaterial.
1
2g028353
Figure4
1.Rearpanel2.Heat-shieldmaterial
7.Unplugtheseat-switchwiringharnessfromthebottom
oftheseat(Figure5).
Note:Useacabletieand2smallcutstotheheatshield
tofurthersecuretheseatswitch-harnessconnectorto
thebottomoftheseat.
g028354
1
Figure5
1.Seat-switch-harnessconnector
8.Cleanthebottomoftheseatmountplate.
11

Note:Makesurethatallgreaseand/oroilisremoved
fromtheseatplatetoassureproperadhesion.
9.Removethebackingandafxtheself-adhesiveheat
shieldtothebottomoftheseat-mountplate(Figure6).
g028355
1
2
Figure6
1.Heatshield2.Seat
10.Inserttheseatwiringharnessthroughtheslitinthe
heatshield.
11.Installrubbergrommetsintothe3holesintherear
framemountasshowninFigure7.
Figure7
1.Rubbergrommets
2
PreparingtheEngineCooling
System
Partsneededforthisprocedure:
1Cabassembly(suppliedwithcabmodel30474)
2Nipplecoupler
2Quickdisconnectcoupler
4Hoseclamp
1Teetting
2Hoseclamp—large
2Hoseclamp—small
1Hose-adaptertting
1Bulkheadbracket
2Self-tappingscrew(5/16inch)
1Dustplug
1Dustcap
1Dualcontactswitch
Procedure
1.Locatethe2mountingholesintheleftsideoftherear
framemount(Figure8).
Figure8
1.Rearframemount
2.Installthebulkheadbrackettotheleftrearframe
mountwith2self-tappingscrews(5/16inch)(Figure
9).
12

1
2
3
g028356
Figure9
1.Bulkheadbracket3.Selftappingscrew
2.Left,rearframemount
3.Locatethe4heaterhoses,themaleandfemalequick
disconnectttings,the2straightnipplecouplers,the
2Rclamps,2hoseclamps,thedustcap,andthedust
plugs.
4.Assemblethemalequickdisconnecttting,thedust
cap,andastraightnipplecouplertothecorrectheater
hoseusingahoseclamp.
Note:FormachineswithYanmarengineusethe86.3
cm(34inch)hose.FormachineswithKubotaengines
usethe57.1cm(22.5inch)heaterhose.Thisisthe
pressurehose.
5.Assemblethepressurehoseontothebulkheadbracket
intheleftpositionusinganR-clamp,acarriagebolt
(1/4inch),andanut(1/4inch)(Figure10)
6.Assemblethefemalequickdisconnecttting,thedust
plug,andastraightnipplecouplertothecorrectheater
hoseusingahoseclamp.
Note:FormachineswithaYanmarengineusethe
86.3cm(34inch)heaterhose.Formachineswith
Kubotaenginesusthe132cm(52inch)heaterhose.
Thisisthereturnhose.
7.Assemblethereturnhoseontothebulkheadbracket
intherightpositionusinganR-clamp,acarriagebolt
(1/4inch),andanut(1/4inch)(Figure10).
1
2
3
4g028357
Figure10
1.Quick-disconnectcoupler3.Nipplecoupler
2.Dustplug4.Dustcap
8.Placeasuitabledrainpanundertheradiatoranddrain
theradiator.
9.Cutthelowerradiatorhoseinhalfonthewhitelineas
showninFigure11.
Note:ForKubotamachinesthehoseislocatedonthe
rightsideofthemachine.ForYanmarmachines,itis
locatedontheleft.
Figure11
1.Lowerradiatorhose2.Whiteline
10.Installtheteettingintothehosesandsecurewith
hoseclampsasshowninFigure12andFigure13.
Note:FormachineswithKubotaengines,thehose
barbistopointrearwardtowardtheradiatorfan
shroud.
13

Figure12
Kubotaengine
1.Radiatorhose3.Returnhose
2.Teetting
1
1
3
2
g028095
Figure13
Yanmarengine
1.Radiatorhose3.Returnhose
2.Teetting
11.Connectthelooseendofthereturnhosetothenew
teettingintheradiatorhose(Figure12).
12.Securethehosetotheteettingwithahoseclamp
(Figure14).
3
ConnectingthePressureLine
(forMachineswithKubota
Engines)
NoPartsRequired
Procedure
1.Routethehosebehindtheradiatoroverowtank,
uptherightsideoftheradiator,acrossthetopofthe
radiatortotheleftsideandundertheaircleaneras
showninFigure14.
Figure14
1.Pressurehose3.Cabletie
2.Returnhose
2.Disconnectthewireandremovethethermo-switch
fromtheleftsideoftheenginethermostathousing
(Figure15).Discardtheswitch.
14

Figure15
1.Thermo-switch
3.Installthehoseadapterttingintotheengine
thermostathousing(Figure16).
Note:Applypipesealanttothemale-pipethreadof
allswitchesandadapterspriortoinstallation.
Figure16
1.Engine-thermostat
housing
3.Pressurehose
2.Hose-adaptertting4.Hoseclamp
4.Connectthelooseendofthepressurehosetothe
enginethermostat-housing-adaptertting(Figure16).
Note:Securethehosetotheadapterttingwitha
hoseclamp.Routethehoseundertheaircleaneras
showninFigure16.
Note:Routethehosesawayfromanyhot,rotatingor
sharpobjects.Securethe2couplerhosestogetherwith
acabletieasshowninFigure16.
5.Disconnectthewireandremovetheswitchfromthe
rightsideoftheengine-thermostathousing(Figure17).
Figure17
1.Engine-thermostat
housing
2.Switch
6.Installthenewdualcontactswitchtotherightsideof
theengine-thermostathousing(Figure18).
Figure18
1.Dual-contactswitch2.Wirefromoldleftswitch
7.Securethewire,previouslyconnectedtotherightside
switch,tothemalespadeterminal.
8.Connectthewire,previouslyconnectedtotheleftside
switch,totheleadonthenewswitch.
15

4
ConnectingthePressureLine
forMachineswithYanmar
Engines
Partsneededforthisprocedure:
1Hoseadaptertting
1Hoseclamp
Procedure
1.Routethehoseacrosstheengine(Figure19).
1
2g028372
Figure19
1.Pessurehose2.Returnhose
2.Disconnectthewiresandremovethethermo-switch
fromtheleftsideoftheengine-thermostathousing
(Figure20).
Note:Keeptheswitchforsummeruse.
Note:Cabletiethe2loosewirestotheengineharness
andensurethattheyarefreefromtheenginefan.
1
g028374
Figure20
1.Thermo-switch
3.Installthehoseadapterttingintothe
engine-thermostathousing(Figure21).
Note:Applypipesealanttothemale-pipethreadof
allswitchesandadapterspriortoinstallation.
1
2
3
g028373
Figure21
1.Pressurehose3.Hose-adaptertting
2.Hoseclamp
4.Connectthelooseendofthepressurehosetothe
engine-thermostat-housing-adaptertting(Figure21).
5.Securethehosetotheadapterttingwithahoseclamp.
6.RoutethehoseundertheaircleanerasshowninFigure
21.
Note:Routethehosesawayfromanyhot,rotating
orsharpobjects.
16

5
PreparingtheElectrical
System
Partsneededforthisprocedure:
1Cabharness
1Powerharness
2Cabletie
4Cabletie
Procedure
Routeandsecurethecabharnessandpowerharnessas
follows:
1.Insertthewiresfromthelarge-harnessconnectordown
throughtherightgrommetintherearframemount.
2.Unlatchthecontrol-panelcoverandlayittotheside
(Figure22).
Figure22
1.Control-panelcover2.Latches
3.Fromthesameendoftheharnessasthelarge
connector,routethelongcabwire(with3connectors),
downtheROPSpost,undertherearpanelframe
memberandupthroughtheholeinthebottomofthe
controlpanel(Figure23).
2
1
34
5
6
7
g028429
Figure23
1.Harness-wireclips5.Harness
2.Connector6.Longcabwire(orange)
3.Connector7.Cabletie
4.Connector
4.SecurethelongwiretothelowerROPSpostwitha
cabletie.
5.Insidethecontrolpanel,locatethepinkwirewiththe
connectorenclosedinaplasticbubble(Figure24).
Figure24
1.Pinkwirewithplasticbubble(cutofftheendoftheplastic
bubble)
6.Carefullycutofftheendoftheplasticbubbleandplug
theappropriatewireconnectorintoit.
7.Closeandlatchthecontrol-panelcover.
Note:IfanAuxiliaryPowerKitisinstalledonthe
machine,proceedasfollows:
A.Unplugthepinkwirefromtheauxiliarypower
kitconnector.
B.Plugthepinkwireconnectorintotheappropriate
connectoronthenewharness.
C.Plugtheotherharnessconnectorintotheauxiliary
powerkitconnector.
17

8.Routetheotherendoftheharnessundertherear
framemounttowardtheleftsideofthemachinewhile
insertingtheharnesswireclipsintotheholesinthe
undersideoftherearframemount(Figure24).
Note:Makesuretoroutethewiresawayfromany
hot,rotatingorsharpobjects.Securethewireswith
cableties.
1
g028435
Figure25
1.Wiringharness
9.Connecttheredharnesswiretothepowerharness.
10.Insertthepowerharnessconnectorthroughtherubber
bootonthepositivebatterycable.
11.Connectthepowerharnesstothepositivebatterypost
(Figure26).
12.Connecttheblackwiretothenegativebatterypost
(Figure26).
Figure26
1.Negativebatterycable(-)3.Powerharness
2.Positivebatterycable(+)4.Blackwire
13.Securethewirestothecableswithcableties.
6
InstallingtheWasherBottle
Partsneededforthisprocedure:
1Washerbottle
5Nut
2Bolt
3Carriagebolt
1Bracket
Procedure
ForamachinewithaKubotaengine:Installthebracket
andmountthewasherbottleintotheframebymountingthe
washerbottletothebracketandthebrackettotheframeof
machineusingthenutsandboltsprovided(Figure27).
Note:Thebracketandwasherbottlegoontheleftsideof
theframe.
2
3
4
1
1
5
1
6
g028229
7
Figure27
Kubotamodels
1.Nut5.Carriagebolt
2.Bolt6.Bolt
3.Carriagebolt7.Washerbottle
4.Bracket
ForamachinewithaYanmarengine:Installthebracket
andmountthewasherbottleontotheframebymountingthe
brackettotherightsideofthemachineaboveanexisting
tank,andthenmountthewasherbottleontothebracket
(Figure28).
18

Note:Removetheexistinghardwareontheexistingtankto
securethewasherbottletothebracket.
g028230
1
2
4
5
3
Figure28
YanmarModels
1.Washerbottle4.Bracket
2.Nut5.Carriagebolt
3.Bolt
7
InstallingtheSkidPlate
(RequiredforMachineswitha
KubotaEngine)
Partsneededforthisprocedure:
1Skidplate
2Flange-headbolt(3/8x1-3/4inches)
4Flangenut(3/8inch)
2Bolt(3/8x1inch)
Procedure
1.Positionasuitableoorjackundertherearbumper
tube,raisetherearofthemachine,andsupportitwith
ajackstands(Figure29).
Figure29
1.Rear-bumpertube2.Floorjack
2.Installtheskidplate(Figure30)totheframebelow
theengineasfollows:
A.Mountthefrontoftheskidplatetotheskid
mountingplatewith2ange-headbolts(3/8x
1-3/4inches)andangenuts(3/8inch)(Figure
30).
B.Mounttherearoftheskidplatetotheframecross
memberwith2bolts(3/8x1inch)andange
nuts(3/8inch)(Figure30).Installtherearbolts
fromthetop.
Figure30
1.Skidplate3.Skid-mountingplate
2.Frame-crossmember
19

8
RemovingtheMowerDeck
Partsneededforthisprocedure:
2Verticaltubesupportassembly
1Conversionbracket,Left
1Conversionbracket,Right
2Clevispin
2Self-tappingscrew(1/4inch)
6Screw(3/8x2–1/4inch)
6Flangenut(3/8inch)
2Hoseplug
4Selftappingscrews(3/8inch)
2Hairpin
Procedure
1.Positionasuitableoorjackundertherearbumper
tubeandraisethereartiresofftheground(Figure31).
Figure31
1.Rearbumpertube2.Floorjack
2.Ontractionunitsthathaveaserialnumberpriorto
312999999,installtheverticaltubesupportassembly
toeachrearcornerofthedeckframewithaclevispin
anda1/4inchself-tappingscrew(Figure32)
g028084
1
2
3
4
5
Figure32
1.Deckframe4.Vertical-tube-support
assembly
2.Self-tappingscrew5.Hairpin
3.Clevispin
3.Ontractionunitsthathaveaserialnumbergreaterthan
313000001,installaconversionbracket(rightorleft
hand)totheundersideoftheappropriaterearcorner
ofthedeckframewitha3/8x5/8inchself-tapping
screw(Figure33).
Note:Pointthebrackettowardtheendoftherear
frame.
g028085
1
4
5
3
2
6
5
Figure33
1.Deckframe4.Bolt
2.Flangenut5.Self-tappingscrew
3.Conversionbracket(left
sideshown)
6.Verticaltubesupport
assembly
4.Installthevertical-tube-supportassemblytothe
conversionbracket(rightorlefthand)oneachcorner
20