Toro Polar Trac Cab 30474, Operator'S Manual

Page 1: ...o 3427 218 Rev A Polar Trac Cab Groundsmaster 7200 Series Mower Model No 30474 Serial No 403380001 and Up Model No 30675 Serial No 403380001 and Up Register at www Toro com Original Instructions EN 3427 218 A ...

Page 2: ...you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided Important With your mobile device you can scan the QR code if equipped on the serial number plat...

Page 3: ...e Winter Frame 33 14 Completing the Installation 40 Product Overview 41 Controls 41 Climate Controls Panel 41 Light Controls Panel 42 Rear Window Latch 42 Foot Pedal Operation 43 Operation 43 Putting Safety First 43 Using the Attachments 44 Routing the Snowthrower Wires 44 Removing the Winter Frame 44 Installing the Summer Frame 49 Maintenance 53 Recommended Maintenance Schedule s 53 Lubrication 5...

Page 4: ...indshield wipers off 3 Windshield wipers on 2 Windshield wipers 4 Spray windshield washer fluid decal130 0457 130 0457 1 Left 2 Right decal132 3600 132 3600 1 Read the Operator s Manual for more information on fuses 5 Working light 20 A 2 Headlight 25 A 6 Auxiliary power 15 A 3 Condenser fan and A C clutch 30 A 7 Cab light 15 A 4 Fan 25 A 8 Windshield wipers 15 A decal130 0611 130 0611 1 Warning 1...

Page 5: ...decal130 5361 130 5361 1 Warning read the Operator s Manual only operate from the driver s seat wear a seatbelt wear hearing protection 5 ...

Page 6: ...n on full 6 Internal air 3 Cold air 7 Air conditioner off 4 Hot air 8 Air conditioner on decal125 9659 125 9659 1 Head light on 5 Hazard light on 2 Head light off 6 Hazard light off 3 Cab light on 7 Left turn signal 4 Cab light off 8 Right turn signal 6 ...

Page 7: ...tall the bulkhead bracket Hose clamp 1 2 to 1 1 4 inches 1 Straight fitting 3 8 npt x 0 625 barb 1 Temperature sensor Yanmar engine only 1 5 Adapter Yanmar engine only 1 Route the heater hose 6 No parts required Install the temperature sensor Washer bottle 1 Bracket 1 R clamp 1 Carriage bolt 5 16 x 1 inch 3 Bolt 5 16 x 3 4 inch 2 Flange nut 5 16 inch 5 Carriage bolt 1 4 x 3 4 inch 1 7 Nut 1 4 inch...

Page 8: ...al 1 Left rear foam seal 1 Right middle foam seal 1 Left middle foam seal 1 Right tank foam seal 1 Side front foam seal 2 Front foam seal 1 Left side foam seal 1 Right side foam seal 1 Rubber isolator 4 Bolt 1 2 x 3 1 4 inches 4 Washer 1 2 inch 4 Large washer 4 Nut 1 2 inch 4 Bolt 3 4 x 3 1 2 inches 2 12 Locknut 3 4 inch 2 Install the cab Winter frame 1 Coupler link 2 Bolt 3 4 x 4 inches 2 Washer ...

Page 9: ...lling the Rear Panel Shield 1 Move the seat forward to allow you to have access to the rear panel 2 Toggle the 3 swell latches and remove the rear panel Figure 3 g032347 Figure 3 1 Swell latch 2 Back panel 3 Clean back of the plate to ensure proper adhesion when you apply the heat shield 4 Remove the backing and apply the rear panel shield to the engine side of the rear panel Figure 4 g032348 Figu...

Page 10: ...to the bottom of the seat plate Figure 7 g032393 Figure 7 1 Hole for wire clip 2 Wire clip 7 Connect the seat switch to the wire harness Figure 7 3 Assembling the Heater Hoses Parts needed for this procedure 1 Straight fitting 3 8 NPT x 0 625 barb 4 Hose clamp 1 2 to 1 1 4 inches 1 Hose clamp 3 4 to 1 1 2 inches 1 Tee fitting 1 Female dust fitting 1 Male dust fitting Assembling the Supply Hose Not...

Page 11: ...s hose for a machine equipped with the Kubota engine 1 Apply sealant to the straight fitting 3 8 NPT x 0 625 barb skipping the first thread g030360 Figure 9 1 Female coupler 5 Return hose 2 Female dust plug 6 Tee fitting 3 Straight fitting 3 8 NPT x 0 625 barb 7 Hose clamp 1 2 to 1 1 4 inches 4 Hose clamp 1 2 to 1 1 4 inches 2 Slide the dust plug over the threaded end of the straight fitting Figur...

Page 12: ...inches as shown in Figure 11 g032398 Figure 11 1 Hose clamp 3 4 to 1 1 2 inches 2 Tee fitting Connecting to the Radiator Hose Kubota Engine Only 1 Locate and remove the radiator hose Figure 12 g032421 Figure 12 1 Cut lines 2 Use a cutting tool to cut the radiator hose at the cut lines Figure 12 3 Slide the cut ends over the tee fitting and secure it using the hose clamp 3 4 to 1 1 2 inches as show...

Page 13: ...ps covering the holes in the support tube Figure 9 g234097 g032344 Figure 14 1 Cap 2 If it is present remove the punch out located between the 2 holes Figure 15 g032345 Figure 15 1 Punch out Note If necessary use a metal cutting tool to remove the material between the 2 holes in the support tube 3 Install the grommet into the opening Figure 16 g032346 Figure 16 1 Grommet Installing the Hose Bracke...

Page 14: ...uts to install the R clamp and hose assembly to the bracket mount Figure 18 5 Torque the bolt to 1017 to 1243 N cm 90 to 110 in lb 5 Routing the Heater Hoses Parts needed for this procedure 1 Hose clamp 1 2 to 1 1 4 inches 1 Straight fitting 3 8 npt x 0 625 barb 1 Temperature sensor Yanmar engine only 1 Adapter Yanmar engine only Routing the Supply Hose Kubota Engine Only 1 Route the supply hose a...

Page 15: ...de the hose clamp over the hose end Figure 20 7 Insert the hose over straight fitting and secure it with the hose clamp 1 2 to 1 1 4 inches as shown in Figure 20 Routing the Return Hose Kubota Engine Only Route the return hose as shown in Figure 21 g032423 Figure 21 1 Supply hose 2 Return hose Moving the Temperature Sensor Yanmar Engine Only 1 Remove the socket terminal from the coolant temperatur...

Page 16: ... 23 Note You no longer need the plug and gasket 4 Install the reducer and the gasket plug into the forward port of the water pump Figure 24 g233712 Figure 24 1 Reducer 3 Forward port water pump housing 2 O ring 4 Temperature sensor 5 Apply PTFE thread sealant to the threads of the temperature sensor that you removed in step 2 and to the threads of the straight barbed fitting 6 Install the new temp...

Page 17: ...or Routing the Supply Hose Yanmar Engine Only 1 Route the supply hose as shown in Figure 26 g032427 Figure 26 1 Return hose 2 Supply hose 2 Slide the hose clamp over the hose end Figure 27 g233714 Figure 27 1 Supply hose 3 Barbed fitting 2 Hose clamp 3 Insert the hose over straight fitting and secure it with the hose clamp 1 2 to 1 1 4 inches as shown in Figure 27 17 ...

Page 18: ...re 4 Engine hot connector 2 Apply sealant to the temperature sensor skipping the first thread 3 Finger tighten the temperature sensor into the port 4 Tighten the temperature sensor 2 to 3 additional turns 5 Locate the yellow wire that you disconnected in step 2 in Routing the Supply Hose page 14 and connect it to the engine hot connector of the temperature sensor Figure 29 6 Locate the orange wire...

Page 19: ...re 30 g032446 Figure 30 1 Flange nut 5 16 inch 3 Bolt 5 16 x 3 4 inch 2 Carriage bolt 5 16 x 1 inch 4 Flange nut 5 16 inch 2 Torque the bolts to 1978 to 2542 N cm 175 to 225 in lb 3 Use the 2 carriage bolts 5 16 x 3 4 inch and flange nuts to secure the washer bottle to the bracket Figure 31 g032447 Figure 31 1 Bracket 3 Flange nut 5 16 inch 2 Carriage bolt 5 16 x 3 4 inch 4 Washer bottle 4 Torque ...

Page 20: ...Flange nut 5 16 inch 2 Torque the bolts to 1978 to 2542 N cm 175 to 225 in lb 3 Use the 2 carriage bolts 5 16 x 3 4 inch and flange nuts to secure the washer bottle to the bracket Figure 34 g032450 Figure 34 1 Carriage bolt 5 16 x 3 4 inch 2 Flange nut 5 16 inch 4 Torque the bolts to 1978 to 2542 N cm 175 to 225 in lb 5 Connect the washer tube to the washer bottle and secure it to the frame with c...

Page 21: ... to the hose bracket Figure 36 3 Torque the bolt to 1017 to 1243 N cm 90 to 110 in lb 8 Installing the Wire Harness Parts needed for this procedure 1 Wire harness 1 Relay 1 Fuse 60 A 2 Fuse 10 A 3 Cable tie 1 Wire harness fuse block Toro Part No 92 2641 purchased separately 1 Key start harness Toro Part No 107 0672 purchased separately Assembling the Wire Harness 1 Assemble the following component...

Page 22: ...uting the Wire Harness Kubota Engine Only 1 Route the 3 cab connectors through the grommet Figure 38 g032517 Figure 38 1 Cab connectors 5 Positive connector red 2 Relay assembly 6 Negative connector black 3 Fuse assembly 60 A 7 Auxiliary power wire 4 Washer bottle connector 2 Route the auxiliary power wire across the frame support down along the ROPS tube and toward the operator controls Figure 38...

Page 23: ... ties to secure the wire harness to the frame Note Do not secure the wire harness to hot or moving parts Connecting the Auxiliary Power Wire Fuse Block of the Machine Note If you do not have an open slot in the fuse block for the machine skip to Connecting the Auxiliary Power Wire Additional Wire Harness Fuse Block page 24 1 Toggle the swell latches and open the operator controls compartment Figur...

Page 24: ...ss fuse block Part No 92 2641 5 Blue wire 18 gauge key start harness Part No 107 0672 2 Fuse 10 A 6 Red wire 12 gauge wire harness fuse block Part No 92 2641 3 Fuse block of the machine 7 Red wire 10 gauge wire harness fuse block Part No 92 2641 4 Green wire 18 gauge Polar Trac kit harness 8 Pink wire fuse block of the machine 2 Connect the wire harness fuse block Part No 92 2641 to the fuse block...

Page 25: ...he 10 gauge red and black wires along the ROPS tube on the left side of the frame and toward the battery Figure 38 2 Loosen and remove the negative post clamp and then the positive post clamp from the battery Figure 44 g032519 Figure 44 1 Positive post clamp 4 Ring connector 2 Negative post clamp 5 Bolt 3 Nut 3 Remove the nuts from the post bolts Figure 44 4 Install the negative terminal connector...

Page 26: ...oll Bar No Parts Required Procedure Note Have another person help you remove the roll bar from the machine 1 Have another person support the roll bar 2 Remove the hairpins and the pivot lock pins from the roll bar and set the hairpins aside Figure 46 g032775 Figure 46 1 Pivot bolt 4 Pivot lock pin 2 Lanyard washer 5 Lower ROPS pin 3 Roll bar 6 Hairpin 3 Remove the pivot bolt and lanyard washer 4 R...

Page 27: ... g024844 Figure 47 1 Deck frame 3 Clevis pin 2 Self tapping screw 1 4 inch 4 Roller assembly 3 On traction units that have a serial number greater than 313000001 install a conversion bracket right or left hand to the under side of the appropriate rear corner of the deck frame with a self tapping screw 3 8 x 5 8 inch Figure 48 Note Point the bracket toward the end of the rear frame g024845 Figure 4...

Page 28: ...atform Figure 51 Note Set the deck aside for seasonal conversion 5 Install each of the pivot pins you removed earlier through the seat platform and pivot bracket and secure it with the hairpins Disconnecting the PTO 1 Loosen the PTO drive shaft bolts and nuts 2 Remove the roll pin and pull the drive shaft off the gearbox shaft Figure 52 g004928 Figure 52 1 Drive shaft 3 Bolts 2 Gearbox 4 End yolk ...

Page 29: ...il them up and store them inside the control box until the next changeover 5 Install the caps from the winter valve kit into the control valve fitting and plug the hoses with the plugs supplied Note Clean up any hydraulic fluid that spilled 6 Remove the retaining ring remove the bolt securing the pivot pin and remove the pivot pin to allow you move the cylinder out of the way g032735 Figure 56 1 R...

Page 30: ...Cab 2 Bulb seal 1 Rear foam seal 1 Right rear foam seal 1 Left rear foam seal 1 Right middle foam seal 1 Left middle foam seal 1 Right tank foam seal 2 Side front foam seal 1 Front foam seal 1 Left side foam seal 1 Right side foam seal 4 Rubber isolator 4 Bolt 1 2 x 3 1 4 inches 4 Washer 1 2 inch 4 Large washer 4 Nut 1 2 inch 2 Bolt 3 4 x 3 1 2 inches 2 Locknut 3 4 inch Applying the Safety Decal F...

Page 31: ...dge of the forward legs of the foam seals should be approximately 3 mm 1 8 inch away from the inner edge of the side seal panels of the cab frame 4 Align the innermost edges of the left tank and right tank foam seals with the left and right middle foam seal and interlock the tabs Figure 62 Note The inner edge of the forward legs of the foam seals should be approximately 3 mm 1 8 inch away from the...

Page 32: ... point Note Ensure that the lifting tool does not contact the cab roof or headliner when supporting the cab 2 Lower the cab to the machine aligning the 2 bolt holes on the front mounts Figure 65 g032780 Figure 65 1 Lower mount 5 Flange nut 1 2 inch 2 Bolt 1 2 x 3 1 4 inches 6 Large washer 3 Washer 1 2 inch 7 Rubber isolator 4 Upper mount 3 Insert a rubber isolator at each of the mounting locations...

Page 33: ...e 67 g032782 Figure 67 1 Lift screw 2 Lift bar assembly 3 Alternate between turning the lift screws a few turns at a time until the cab pivots forward Figure 67 4 Rotate the lift screws a few turns then alternate to the other to pivot the cab forward Connecting the Winter Frame to the Machine 1 Align the winter frame into the machine frame and roll it back Figure 68 g032779 Figure 68 1 Winter fram...

Page 34: ...gure 71 g032662 Figure 71 1 Flange nut 1 2 inch 4 Locknut 3 4 inch 2 Cab bracket mount 5 ROPS tube 3 Bolt 1 2 x 3 1 4 inches 6 Bolt 3 4 x 3 1 2 inches Note Point the cab bracket mount toward the front of the machine 3 Insert a rubber isolator at each of the mounting locations on the cab frame Figure 72 g032784 Figure 72 1 Bolt 1 2 x 3 1 4 inches 4 Cab frame 2 Large washer 5 Cab mount bracket 3 Rub...

Page 35: ...r supply hose 4 Drain tube 2 Connect the washer tube heater supply hose and heater return hose to its counterpart 3 Route the drain hose through the grommet and down the lower ROPS tube Figure 73 4 Use cable ties to secure the drain hose to the ROPS tube Connecting the Wire Harness 1 Route the wire harness from the cab toward the wire harness from the machine Figure 74 g032664 Figure 74 1 Machine ...

Page 36: ... bolts to 37 to 45 N m 27 to 33 ft lb Removing the Rear Wheels 1 Loosen the lug nuts on the rear wheels 2 Use a floor jack to raise the rear wheels off the ground and then support the frame with jack stands Figure 76 g032569 Figure 76 1 Jack stand 2 Machine frame 3 Remove the rear wheels from the machine 4 Install the bolt 3 4 x 4 inches as shown in Figure 77 g032575 Figure 77 1 Washer 2 Bolt 3 4 ...

Page 37: ...rlier to secure the operator deck to the winter frame Figure 78 Connecting the Hydraulic Hoses 1 At the gear pump loosen the supply hose fitting and rotate it toward the front of the machine Figure 80 g032631 Figure 80 1 Gear pump 2 Supply hose 2 Locate the 2 hoses that you removed from the deck lift cylinder and install the appropriate hose cover to each hose 3 Use a cable tie to secure each end ...

Page 38: ...8 to 115 N m 65 to 85 ft lb in the following order Figure 84 g032629 Figure 84 Installing the Tracks 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 1 Place 2 jack stands underneath the rear of frame to support ...

Page 39: ...g032732 Figure 87 1 Attachment lift arm 2 Pivot point 4 Use a floor jack to lift the winter frame Figure 88 g032738 Figure 88 1 Jack stand 2 3 Floor jack 2 Pivot point 5 Use jack stands to support the winter frame Figure 89 g032740 Figure 89 1 Jack stand 6 Remove the front wheels Figure 89 7 Arrange the tracks around center and rear wheels Figure 90 39 ...

Page 40: ...Installation No Parts Required Procedure 1 Install the hood on to the machine 2 Fill the washer fluid tank 3 Fill the radiator refer to the machine Operator s Manual for fluid specifications 4 Check the hydraulic fluid level and replenish as needed refer to the machine Operator s Manual for the hydraulic fluid specification 5 Connect the negative battery cable to the battery 6 Start the machine ra...

Page 41: ...l panel to adjust the cab temperature Figure 94 g032787 Figure 94 1 Fan control position 2 Temperature control position 3 Recirculation control position 4 Air condition switch position Temperature Control Rotate the temperature control knob to regulate the air temperature in the cab Figure 94 Fan Control Rotate the fan control knob to regulate the speed of the fan Figure 94 Air Recirculation Contr...

Page 42: ... or off Figure 95 Turn Signal Switch Use this switch to activate the left or right turn signal Figure 95 Windshield Wiper Switch Use this switch to turn the windshield wipers on or off Figure 93 Power Point Selector Use this selector to determine which power point is activate Figure 93 Rear Window Latch Rear Window Latch g032824 Figure 96 1 Window latch Lift up the window latches to open the windo...

Page 43: ...tanders avoid injury DANGER Operating on wet grass ice or slippery slopes can cause sliding and loss of control The tracks dropping over edges can cause a rollover which may result in serious injury or death Read and follow the rollover protection instructions and warnings To avoid loss of control and possibility of rollover Do not operate near drop offs or near water Reduce speed and use extreme ...

Page 44: ...n in Figure 99 g004972 Figure 99 1 Attachment pin 3 Machine mount adapter 2 Hairpin 4 Attachment mount adapter Routing the Snowthrower Wires Route the snow thrower wires from the cab through the eyelet and to the snowthrower g032850 Figure 100 1 Wire eyelet Removing the Winter Frame Note Retain or loosely install the hardware that you removed during this procedure so that it is available for seaso...

Page 45: ...3 Set aside the roll pin Removing the Tracks 1 Place 2 jack stands underneath the back of machine frame Figure 103 g032669 Figure 103 1 Machine frame 2 Jack stand 2 Remove the locknut and washer from the threaded stud on the bogie stop assembly Figure 104 g032573 Figure 104 1 Locknut 3 Threaded stud 2 Washer 4 Bogie stop assembly 3 Position a floor jack under the pivot point for the attachment ass...

Page 46: ...table drain pan underneath the control valve Figure 106 2 Disconnect the supply hose from the tube connector and pull it out of the through hole Figure 106 g032630 Figure 106 1 Through hole 4 Return hose 2 Supply hose 5 Control valve 3 Tube 3 Disconnect the return hose from the control valve Figure 106 4 Place caps on the fittings for seasonal storage Note Wipe up any fluid that spilled Disconnect...

Page 47: ...easonal storage 4 Use the hose plugs to cap the hoses for seasonal storage 5 Replace the winter grommet with the summer grommet Figure 110 g032851 Figure 110 1 Winter grommet 2 Summer grommet 6 Install the rear cover refer to Installing the Rear Cover page 36 Note Wipe up any spilled fluid Disconnecting the Cab 1 Remove the bolts securing the cab mount bracket to the ROPS tube at the rear of the c...

Page 48: ...e 113 Disconnecting the Winter Frame from the Machine 1 Remove the cover plates and set them aside Figure 114 g032736 Figure 114 1 Bolts 2 Cover plates 2 Use a floor jack to raise the back of the machine high enough to install the summer wheels and support the frame with jack stands Figure 115 g032669 Figure 115 1 Machine frame 2 Jack stand 3 Remove the rear wheels 4 Remove the bolts and washers t...

Page 49: ...her 8 Roll the winter frame away from the machine frame Figure 118 g032768 Figure 118 1 Winter frame 3 Jack stands 2 Machine 9 Install the rear cover to the cab refer to Installing the Rear Cover page 36 Installing the Summer Frame Connecting the Summer Frame to the Machine 1 Align the summer frame to the machine frame and roll it back Figure 119 g032769 Figure 119 1 Summer frame 2 Machine frame 2...

Page 50: ...table drain pan underneath the valve and disconnect the hydraulic hoses from the control valve 2 Loosen the supply hose fitting that is connected to the gear pump and rotate the supply hose toward the right side of the machine Figure 122 g032777 Figure 122 1 Gear pump 2 Supply hose fitting 3 Use the retaining ring pivot pin and bolt to secure the deck lift cylinder to the pivot post Figure 123 g03...

Page 51: ... Gearbox shaft 4 Locknut 2 Bolt 5 Roll pin 3 PTO yolk 2 Torque the bolts on the PTO yolk to 20 to 25 N m 15 to 18 ft lb Installing the Deck and Cover Plates 1 Use the pivot pin and hairpin to secure the operator deck as shown in Figure 126 g032773 Figure 126 1 Hairpin 3 Pivot pin 2 Operator deck 2 Use the washer and hairpin to secure the lift arm to the operator plate Figure 127 g032774 Figure 127...

Page 52: ...the holes in the lower ROPS tube Figure 130 g032775 Figure 130 1 Pivot bolt 4 Pivot lock pin 2 Lanyard washer 5 Lower ROPS tube 3 Roll bar 6 Hairpin 2 Assemble the pivot bolt and lanyard washer to the upper holes in the roll bar and lower ROPS tube and tighten the bolt by hand Figure 130 3 Repeat step 2 at the other side of the machine 4 Install the pivot lock pins through the lower holes in the r...

Page 53: ...evel surface disengage the PTO and engage the parking brake 2 Shut off the engine remove the key and wait for all moving parts to stop before you leave the operating position 3 Clean the grease fittings with a rag Note Remove any paint off the front of the fitting 4 Connect a grease gun to the fitting and pump grease into the fittings until grease begins to ooze out of the bearings 5 Wipe clean ex...

Page 54: ... losses traction increase air pressure in the tire to 344 kPa 50 psi to increase track tension g001055 Figure 131 Cab Maintenance Cleaning the Cab Important Use care around the cab seals and lights Figure 132 If you are using a pressure washer keep the washer wand at least 0 6 m 2 ft away from the machine Do not use the pressure washer directly on the cab seals and lights or under the rear overhan...

Page 55: ...e in cab and rear cab air filters Figure 133 and Figure 134 g028378 Figure 133 1 Filter 3 Thumb screw 2 Grate g028379 Figure 134 1 Filter 3 Thumb screw 2 Grate 2 Clean the filters by blowing clean oil free compressed air through them Important If either filter has a hole tear or other damage replace it 3 Install the filters and grate securing them with the thumb screws 55 ...

Page 56: ...tput shaft to prevent rusting 3 Check and adjust the tire pressure refer to Checking the Tire Pressure page 54 4 Check all fasteners for looseness and tighten them as necessary Ensure that the 5 bolts that secure the winter frame to the traction unit are torqued to 359 N m 265 ft lb 5 Grease or oil all grease fittings and pivot points and wipe off any excess lubricant 6 Lightly sand and use touch ...

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Page 60: ...to restaurants grocery stores hotels schools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs How do the California warnings compare to federal limits Prop 65 standards are often more stringent than federal and international standards There are various substances that require a Prop 65 warnin...