Form No. 3395-735 Rev A Polar Trac Cab Groundsmaster® 7200 Series Model No. 30474—Serial No. 315000001 and Up Model No. 30675—Serial No. 315000001 and Up Register at www.Toro.com.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. This product complies with all relevant European directives. For details, please see the Declaration of Incorporation (DOI) at the back of this publication. Figure 1 1.
Contents Safety Safety ........................................................................... 3 Safe Operating Practices........................................... 3 Safety and Instructional Decals ................................. 6 Setup ............................................................................ 9 1 Installing the Heat Shields .....................................11 2 Preparing the Engine Cooling System .....................
• This machine is not designed or equipped for on-road • Replace faulty silencers/mufflers. • Before using, always visually inspect to see that the use and is a “slow-moving vehicle." If you must cross or travel on a public road, you should be aware of and comply with local regulations, such as required lights, slow moving vehicle signs, and reflectors. attachments are not worn or damaged. Replace worn or damaged components.
– use slow speeds on slopes and during tight turns; – stay alert for humps and hollows and other hidden hazards; • Do not operate near drop-offs, ditches, steep banks or water. Tracks dropping over edges can cause roll overs, which may result in serious injury, death or drowning. • Do not operate on slopes where slippery conditions could reduce traction and could cause sliding and loss of control. • Do not make sudden turns or rapid speed changes. • Reduce speed and use extreme caution on slopes.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. The following instructional decal is applied to components supplied with this kit and is used in the conversion process. 112-6312 130-0458 1. Read the Operator's Manual. 1. Read the Operator's Manual for more information on fuses 2. Electrical power accessory—15A 5. Head lights—25A 3. Dome light—15A 7.
130-5361 1. Warning—read the Operator's Manual; only operate from the driver's seat; wear a seatbelt; wear hearing protection.
121-8378 1. 2. 3. 4. 5. 6. 7. 8. Fan—off Fan—on full Cold air Hot air External air Internal air Air conditioner—off Air conditioner—on 125-9659 1. Head light—on 5. Hazard light—on 2. Head light—off 6. Hazard light-off 3. Cab light—on 7. Left-hand turn signal 4. Cab light—off 8.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 6 7 8 Description Qty. Heat shield—rear panel Heat shield—seat Rubber grommet Cab assembly (supplied with cab model 30474) Nipple coupler Quick disconnect coupler Hose clamp Tee fitting Hose clamp—large Hose clamp—small Hose-adapter fitting Bulkhead bracket Self-tapping screw (5/16 inch) Dust plug Dust cap Dual contact switch 1 1 3 Install the heat shields.
Procedure 9 10 11 12 13 15 Description Use Qty. Hose cover Cable tie Winter frame assembly Wheel and tire assembly Lug nut Coupler pin Tracks 2 4 1 6 20 2 2 Install the winter frame assembly. No parts required – Install the cab mount supports. Bulb seal 2 Install the panels.
Note: All references to the installation or operation of the cab refer to Cab Model 30474 only. 6. Remove the backing and affix the self-adhesive heat-shield material to the engine side of the rear panel, positioning as shown in Figure 4. Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free.
Note: Make sure that all grease and/or oil is removed from the seat plate to assure proper adhesion. 2 9. Remove the backing and affix the self-adhesive heat shield to the bottom of the seat-mount plate (Figure 6).
3 3 2 1 1 g028356 Figure 9 1. Bulkhead bracket 3. Self tapping screw 2. Left, rear frame mount 4 2 g028357 Figure 10 3. Locate the 4 heater hoses, the male and female quick disconnect fittings, the 2 straight nipple couplers, the 2 R clamps, 2 hose clamps, the dust cap, and the dust plugs. 4. Assemble the male quick disconnect fitting, the dust cap, and a straight nipple coupler to the correct heater hose using a hose clamp. 1. Quick-disconnect coupler 3. Nipple coupler 2. Dust plug 4.
3 Connecting the Pressure Line (for Machines with Kubota Engines) No Parts Required Procedure Figure 12 Kubota engine 1. Radiator hose 2. Tee fitting 1. Route the hose behind the radiator over flow tank, up the right side of the radiator, across the top of the radiator to the left side and under the air cleaner as shown in Figure 14. 3. Return hose 3 1 2 1 Figure 14 1. Pressure hose 2. Return hose 3. Cable tie g028095 Figure 13 Yanmar engine 1. Radiator hose 2. Tee fitting 2.
5. Disconnect the wire and remove the switch from the right side of the engine-thermostat housing (Figure 17). Figure 15 Figure 17 1. Thermo-switch 1. Engine-thermostat housing 3. Install the hose adapter fitting into the engine thermostat housing (Figure 16). 2. Switch 6. Install the new dual contact switch to the right side of the engine-thermostat housing (Figure 18). Note: Apply pipe sealant to the male-pipe thread of all switches and adapters prior to installation. Figure 18 Figure 16 1.
1 4 Connecting the Pressure Line for Machines with Yanmar Engines Parts needed for this procedure: 1 Hose adapter fitting 1 Hose clamp g028374 Figure 20 Procedure 1. Thermo-switch 1. Route the hose across the engine (Figure 19). 1 3. Install the hose adapter fitting into the engine-thermostat housing (Figure 21). Note: Apply pipe sealant to the male-pipe thread of all switches and adapters prior to installation. 3 2 2 g028372 Figure 19 1. Pessure hose 1 2. Return hose g028373 Figure 21 2.
3 5 4 2 1 Preparing the Electrical System 5 Parts needed for this procedure: 1 Cab harness 1 Power harness 2 Cable tie 4 Cable tie 6 7 g028429 Figure 23 Procedure Route and secure the cab harness and power harness as follows: 1. Insert the wires from the large-harness connector down through the right grommet in the rear frame mount. 2. Unlatch the control-panel cover and lay it to the side (Figure 22). 1. Harness-wire clips 5. Harness 2. Connector 6. Long cab wire (orange) 3.
8. Route the other end of the harness under the rear frame mount toward the left side of the machine while inserting the harness wire clips into the holes in the underside of the rear frame mount (Figure 24). 13. Secure the wires to the cables with cable ties. 6 Note: Make sure to route the wires away from any hot, rotating or sharp objects. Secure the wires with cable ties.
Note: Remove the existing hardware on the existing tank to secure the washer bottle to the bracket. 1 5 4 Figure 29 1. Rear-bumper tube 2. Install the skid plate (Figure 30) to the frame below the engine as follows: g028230 2 3 A. Mount the front of the skid plate to the skid mounting plate with 2 flange-head bolts (3/8 x 1-3/4 inches) and flange nuts (3/8 inch) (Figure 30). Figure 28 Yanmar Models 1. Washer bottle 2. Nut 2. Floor jack 4. Bracket 5. Carriage bolt B. 3.
2.
of the deck frame with a screw (3/8 x 2–1/4 inch )and flange nut (3/8 inch) (Figure 33). 5. Disconnect the floor plate from the seat plate by removing the 2 pivot pins connecting them. 6. Connect the seat plate to the frame by installing the pivot pins (Figure 34). 2 Figure 36 1. Deck-lift cylinder 3. Screw 2. Retaining ring 4. Cylinder pin 10. Remove the screw securing the front-cylinder pivot pin to the mower frame (Figure 36). 1 Note: Remove the cable tie securing the pressure and tank hoses.
Note: Retain 4 of the bolts for installation and store the remaining bolts, washers, and nuts for the summer changeover. 9 Note: The floor jack can be raised or lowered to ease removal of the bolts. Lower the floor jack completely once you remove the bolts. Installing the Winter-Frame Assembly Parts needed for this procedure: 1 2 Hose cover 4 Cable tie 1 Winter frame assembly 6 Wheel and tire assembly 20 Lug nut 2 Coupler pin 2 Tracks Procedure 1.
Figure 43 Figure 41 1. Pump 1. Washer and nut on the bogie pivot stud (2) 2. Pressure hosed fitting (rotated 45 degrees) 6. Remove the 2 screws securing the floor plate cover to the floor and remove the plate (Figure 44). 3. Insert a block of wood between the front bogie stop and the frame to tilt the winter frame toward the rear (Figure 42). Figure 44 1. Floor plate cover Figure 42 2. Mounting screws 1. Block of wood 7.
4 2, 3 Figure 45 2. Frame tube 1. Drive shaft 6 G016205 5 1 8. Route the hoses as follows: Figure 47 • Route the pressure hose under the lift cylinder and between the cylinder mounting brackets to the valve (Figure 46). 1. Pressure hose 2. Tank hose 3. Hose cover • Route the tank hose along side the PTO shaft to 4. Cable tie 5. Bolts 6. Roll pin the valve (Figure 46). 11. With the winter frame against the rear frame, raise the floor jack enough to remove the summer drive tires (Figure 48).
1 2 G009488 Figure 51 1. Pressure hose Figure 49 2. Tank hose 1. Coupler pin 16. Raise the rear of the machine until 2 jack stands can be positioned under the rear tube at a height that supports the rear tires 2.5 to 7.5 cm (1 to 3 inches) off the ground. 14. Adjust the floor jack as required to install the bolts (3/4 inch) on each side (Figure 50). Note: Torque the bolts to 359 N-m (265 ft-lb). 17. Lower the floor jack so the rear frame rests on the jack stands. 18.
27. Install the side access covers with the screws previously removed (Figure 55). CAUTION The track guides have many pinch points. Coming into contact with one of these pinch points could cause severe personal injury. Carefully grasp the rubber track on the outer edges outboard of the steel guides when moving the track. 23. Adjust the floor jack to a suitable height to install the front tire. 24. With a helper, lift the front of the track enough to carefully install the front tires (Figure 53).
11 Installing the Panels Parts needed for this procedure: 2 Bulb seal Procedure 1. Install the large bulb seal on each side of the real panel. 2. Place the rear panel into position and align the top mounting holes with the holes in the frame cross member (Figure 57). Figure 58 1. Floor-plate cover 2. Mounting screws 5. Install the hood.
Note: The inner edge of the forward legs of the foam pieces should be approximately 0.32 cm (1/8 inch) away from the inner edge of the side-sealing panels of the cab frame. 3. Align the innermost edges of the left, middle and right, middle foam pieces with the left, rear and right, rear foam pieces and interlock the tabs (Figure 59). Note: The inner edge of the forward legs of the foam pieces should be approximately 0.32 cm (1/8 inch) away from the inner edge of the side-sealing panels of the cab frame.
1 13 Mounting the Cab Parts needed for this procedure: 4 Rubber cab mount (supplied with cab model 30474) 4 Bolt (1/2 x 3 inches) (supplied with cab model 30474) 4 Steel washer (supplied with cab model 30474) 4 Rubber washer (supplied with cab model 30474) 4 Nut (1/2 inch) (supplied with cab model 30474) 2 Corner mat (supplied with cab model 30474) 1 g027683 Figure 63 Outside view Power Point Shield 1. Front mounting points Procedure 1.
6. Loosely install the rear rubber mounts and the cab mount supports to each side of the rear mounts of the cab. (Figure 65). 1 2 1 2 3 4 5 3 4 g028096 Figure 65 1. Cab 2. Cab mount 3. Machine frame 4. Rubber mount 7. At each mounting point, secure the cab to the machine with a bolt (1/2 x 3 inch), steel washer, rubber washer, and nut (1/2 inch) (Figure 66). g027682 Figure 66 1. Bolt 2. Rubber washer 3. Center-bonded mount 4. Steel washer 5. Nut 8.
8. Start the machine. Run the lift arm up and down and check for hydraulic leaks. 14 9. Check the hydraulic fluid and radiator levels and replenish as required. Making the Final Connections and Checking the Operation 15 No Parts Required Reading the Manuals Procedure 1. Tighten the bolts and nuts securing the cab mount supports to the ROPS posts. Parts needed for this procedure: 2. Connect the cab pressure and return heater hoses to the quick couplers on the rear frame mount (Figure 68).
Operation Product Overview Note: Determine the left and right sides of the machine from the normal operating position. Putting Safety First Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Operating on wet grass, ice or slippery steep slopes can cause sliding and loss of control. Tracks dropping over edges can cause roll overs, which may result in serious injury, death or drowning. Figure 69 1. Track 2.
Using the Attachments 2. Make sure that the lift arm A-frame is lowered all the way. Read the Operator's Manual supplied with the attachment before operating. 3. Remove the 2 bolts securing the floor-plate cover and remove the cover (Figure 72). Make sure that the hydraulic quick couplers are free of any contaminates before connecting. Keep output shaft oiled to prevent rust. Never operate the PTO with attachment in the raised position. Noise from the PTO drive line will be evident.
12. Raise the floor jack high enough so that the track can be slid off the front tire. CAUTION The track guides have many pinch points. Coming into contact with one of these pinch points could cause severe personal injury. Carefully grasp the rubber track on the outer edges outboard of the steel guides when moving the track. 13. Repeat the procedure on the other side of the machine. 14. Move the tracks away from the machine. 15. Place an additional jack stand under front of machine. 16.
Figure 79 1. Summer drive tire 28. Install the center tires on the winter frame. Figure 77 1. Pressure hose 29. Install the cab jack tube into the cutouts in the cab floor (Figure 80). 2. Return hose Note: Tighten the jacking bolts until the tapered ends go through the hole in the floor plate and just contact the frame. 24. Plug the couplers into each other to keep clean. 25. Install the cap and dust covers onto the quick couplers on the machine.
Figure 83 Figure 81 1. Cab mount 2. ROPS post 1. Coupler pin 3. Bolts and nuts 4. ROPS post 36. Carefully roll the front frame away from the rear frame making sure that the hydraulic hoses and drive shaft are not hanging up. 33. Loosen the 2 front cab mounting bolts so the cab can pivot freely. Note: Make sure that the rear of the cab clears the seat and control handles. Adjust the position of the floor jack if necessary to gain clearance between the seat and the rear of the cab. 34.
1 Figure 87 g028364 1. Drive shaft 2. Gear box Figure 85 3. Bolt 4. Roll pin 1. 3 mounting bolts (3/4 inch), washers, and nuts (left side) 44. Route and connect the hydraulic pressure and tank hoses to the valve (Figure 88). 39. Remove the lift cylinder pins and rear drive tires (if required) to gain access to the bolts on the right hand side. 1 Note: Torque the bolts to 360 N-m (265 ft-lbs). 40.
1 4 2 3 5 Figure 89 1. Deck-lift cylinder 3. Screw 2. Retaining ring 4. Cylinder pin and screw G004634 Figure 91 4. Bolt and nut 5. ROPS post 1. ROPS 2. Pin 3. Cotter pin 47. Remove the bolts and nuts securing the cab-mount supports to the ROPS posts (Figure 90). 50. Start the machine, raise and lower the deck. Note: Check for leaks and make sure that the hoses do not rub against the frame. Converting the Machine from Summer to Winter Operation 1.
1 4. Loosely install a cab mount support to each ROPS post with 2 bolts (1/2 x 3 inches), 2 nuts (1/2 inch), 2 bolts (3/4 x 3–1/2 inch) and 2 nuts (3/4 inch) (Figure 93). Note: Make sure that the top plate hole is positioned forward. Do not tighten bolts at this time. 2 3 4 G024844 Figure 95 3. Clevis pin 4. Vertical-tube-support assembly 7.
Figure 97 1. Deck-lift cylinder 3. Screw 2. Retaining ring 4. Cylinder pin Figure 99 10. Remove the screw securing the front cylinder pivot pin to the mower frame (Figure 97). 11. Remove the cable tie securing the pressure and tank hoses. 1. Drive shaft 3. Roll pin 2. Gear box 4. Yoke 15. Slide the drive shaft off the gearbox shaft. 16. Disconnect the tank hose from the control valve (Figure 100). 12. Remove the front pivot pin and slide the cylinder off the rear pin (Figure 97).
Note: Retain 4 of the bolts for installation and store the remaining for summer change over. Note: Raise or lower the floor jack to ease removal of the bolts. Lower the floor jack completely once the bolts are removed. 1 Figure 103 1. Pump 2. Pressure-hose fitting (rotated 45 degrees) 26. Remove the 2 screws securing the winter frame floor plate cover to the floor and remove the plate (Figure 104). g028364 Figure 101 1. 3 mounting bolts (3/4 inch), washers, and nuts (left side) Figure 104 g028365 1.
Figure 105 1. Drive shaft 2. Frame tube G016166 Note: If the rear of the cab is not high enough to clear the control handles, evenly tighten the jacking bolts on each side of the cab jack tube to raise the rear of the cab (Figure 106). Figure 107 1. Tank hose 2. Pressure hose 29. Connect the drive shaft to the gear box shaft in the winter frame and torque the bolts (5/16 inch) to 20 to 25 N-m (175-225 in-lb). 30. Install the roll pin (Figure 108). 4 2, 3 Figure 106 1. Jacking bolts 28.
Figure 111 Figure 109 1. 3/4 inch bolts 1. Summer drive tire 32. 2. Coupler pin Note: The rear tires will need to be removed to torque the rear bolts (3/4 inch). After torquing the frame bolts, install the rear tires and torque lug nuts to 88 to 115 N-m (65 to 85 ft-lb). Install the winter tires with 2 lug nuts per side. 33. Adjust the floor jack to line up the 2.5 cm (1 inch) holes in the frame and install a coupler pin on each side (Figure 110). 35.
Figure 115 Figure 113 1. Jacking bolts 1. Cab mount 2. ROPS post 2. Cab-jack tube 3. Bolts and nuts 4. ROPS post 39. Loosen the jacking bolts and remove the cab-jack tube from the cutouts in the cab floor (Figure 116). 37. At the rear mounting points, secure the cab to the machine with a bolt (1/2 x 3 inches), steel washer (1/2 x 2–1/2 inches), rubber washer (1/2 x 2–1/2 inches) and nut (1/2 inch) (Figure 114).
1 2 Figure 119 G009488 1. Front tire Figure 117 1. Pressure hose 2. Tank hose 46. Carefully lift the tracks over the rear wheel and front hubs. The direction of the track rotation is printed on the track. The V design in the rubber track must point forward. 41. Raise the rear of the machine until 2 jack stands can be positioned under the rear tube at a height that supports the rear tires 2.5 to 7.5 cm (1 to 3 inches) off the ground. CAUTION 42.
Figure 121 50. Lower the floor jack until the front wheels support the frame. Figure 123 51. Install the flat washers (1/2 inch) and locknuts on the bogie pivot stud (Figure 121) and torque to 102 N-m (75 ft-lb). 1. Floor-plate cover Note: You may need to move the floor jack to the rear bumper to raise the rear of the machine high enough to install the flat washer and locknut. 2. Mounting screws 54. Connect the cab pressure and return hoses to the quick couplers on the rear-frame mount (Figure 124).
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 10 hours • Torque the frame mounting bolts. • Torque wheel lug nuts. Every 50 hours • Lubricate grease fittings. • Check the tire pressure. Every 200 hours • Torque wheel lug nuts. CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or bystanders. Remove the key from the ignition before you do any maintenance.
Electrical System Maintenance Important: Whenever working with the electrical system, always disconnect the battery cables, negative (-) cable first, to prevent possible wiring damage from short-outs. Checking the Fuses Refer to the Operator's Manual supplied with the cab for instructions on fuses. If the machine has any electrical system issues, check the fuses. Grasp each fuse and remove them one at a time, checking to see if any are blown.
Drive System Maintenance 3. Loosen and remove the locknut and flat washer from the bogie-pivot weldment (Figure 129). Checking the Tire Pressure Service Interval: Every 50 hours Check the tire pressure every 50 hours (Figure 127). Maintain the air pressure in the tires at 240 kPa (35 psi). Uneven tire pressure can cause loss of traction. If a loss of traction occurs, tire pressure may be increased to 344 kPa (50 psi) to increase track tension.
Storage Storing the Machine 1. Thoroughly clean the machine and cab, paying special attention to these areas: • PTO shaft assembly • All grease fittings and pivot points • Oil the spline on the PTO output shaft to prevent rusting 2. Check and adjust tire pressure; refer to Checking the Tire Pressure (page 49). 3. Check all fasteners for looseness and tighten them as necessary. Especially torque the 5 bolts securing the winter frame to the traction unit to 359 N-m (265 ft-lb). 4.
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Declaration of Incorporation The Toro Company, 8111 Lyndale Ave. South, Bloomington, MN, USA declares that the following unit(s) conform(s) to the directives listed, when installed in accordance with the accompanying instructions onto certain Toro models as indicated on the relevant Declarations of Conformity. Model No. Serial No.
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Toro General Commercial Product Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
