Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table Of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Kubota Diesel Engine
- 4 - Hydraulic System
- Specifications
- General Information
- Hydraulic Schematics
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction System Operation Testing
- Charge Relief Valve Pressure Test (Using Pressure Gauge)
- Transmission Piston Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)
- Traction Relief Valve Pressure Test (Using Tester with Pressure Gauges and Flow Meter)
- Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter)
- PTO Pressure Valve Test (Using Pressure Gauge)
- Implement Relief Pressure Test (Using Pressure Gauge)
- Gear Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)
- Lift Cylinder Internal Leakage Test
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Flush Hydraulic System
- Charge Hydraulic System
- Hydraulic Tank
- Wheel Motors
- Wheel Motor Service
- Transmission
- Transmission Service
- Gear Pump
- Gear Pump Service
- Manual Lift Control Valve (SN Below 313000000)
- Manual Lift Control Valve Service (SN Below 313000000)
- Lift Control Manifold (SN Above 313000000)
- Lift Control Manifold Service (SN Above 313000000)
- Polar TracTM Hydraulic Control Valve
- Polar TracTM Hydraulic Control Valve Service
- Lift Cylinder
- Lift Cylinder Service
- Polar TracTM Lift Cylinder
- Polar TracTM Lift Cylinder Service
- Oil Cooler
- 5 - Electrical System
- Electrical Schematics and Diagrams
- Special Tools
- Troubleshooting
- Electrical System Quick Checks
- Component Testing
- Ignition Switch
- Indicator Lights
- Hour Meter
- PTO Switch
- Neutral Switches
- Seat Switch
- Parking Brake Switch (SN Below 310000000)
- Parking Brake Switch (SN Above 310000000)
- Standard Control Module
- Standard Control Module Logic Chart
- PTO Solenoid Valve Coil
- Lift Control Manifold Solenoid Valve Coils (SN Above 313000000)
- Fusible Link Harness
- Diode Assembly
- Glow Relay
- High Temperature Warning Switch
- High Temperature Shutdown Switch
- Dual Temperature Switch (Polar TracTM Machines)
- Deck Lift/Lower Switch (SN Above 313000000)
- Fuel Pump
- Fuel Stop Solenoid
- Glow Controller
- Service and Repairs
- 6 - Chassis
- 7 - Cutting Deck
- 8 - Foldout Diagrams
- Electrical Drawing Designations
- Hydraulic Schematics
- Hydraulic Schematic (SN Below 313000000)
- Hydraulic Schematic (SN Below 313000000) with Rear Attach Lift Kit
- Hydraulic Schematic (SN Below 313000000) with Polar Trac Installed)
- Hydraulic Schematic (SN Below 313000000) with Polar Trac and Rear Attach Lift Kit
- Hydraulic Schematic (SN From 313000001 to 314999999)
- Hydraulic Schematic (SN Above 315000000)
- Electrical Schematics
- Circuit Diagrams
- Wire Harness
Groundsmaster 7200/7210 Hydraulic SystemPage 4 - 95
Disassembly (Fig. 107)
1. Plug all ports and c lean the outside of the valve thor-
oughly.
IMPORTANT: Match- mark spools to their associat-
ed bores before disassembly. Spools must be rein-
stalled to the bore from which they were removed.
2. Remove both spool caps (item 10) and slide the
spool assemblies from their bores.
3. Remove O- ring (item 12) and bushing (item 8) from
each spool assembly.
4. Remove wiper seals (item 20) and O- rings (item 12)
from the spool bore ends that are opposite the spool
caps.
NOTE: Disassemble spool assemblies only if the re-
taining r ing (item 13), spacer (item 3), spool spring (item
16) or washer (item 14) need replacing.
5. Remove seat retaining plugs (items 7 and 15), back-
up washers, O- rings and check spring (item 9) from the
valve body.
6. Remove check poppet (item 1), seats (item 5), O-
rings (item 27) and plungers (items 2 and 21) from the
valve body.
7. Remove solid plug (item 6), back- up washer and O-
ring from the opposite end of the plunger.
8. Remove detent plug (item 19) and O- ring from the
valve body. Remove disc, spring and detent plunger
from the body.
Inspection
1. Inspect spools and spool bores for wear. If wear is
excessive, replace control valve with new one.
2. Inspect springs and replace as necessary.
3. Inspect plunger and detent plunger for wear. Re-
place as necessary.
4. Inspect caps and plugs for damaged threads and in-
spect O- ring sealing surfaces. Replace as necessary.
Assembly (Fig. 107)
IMPORTANT: Do not wipe control valve parts with
dry paper towels or rags. Lint may cause damage to
the hydraulic system.
CAUTION
Use eye protection such as goggles when using
compressed air.
1. Clean all metal parts with solvent and blow dry with
compressed air.
2. Replace check poppet (item 1), O- rings and back-
up washers with new ones.
3. Install new O- rings (item 12) into the valve body.
4. If a spool was disassembled, install washer ( item
14), spool spring (item 16), spacer (item 3) and retaining
ring (item 13) to the spool.
5. Slide bushings (item 8) and new O- rings (item 12)
over the spools.
6. Lubricate spools liberally with clean hydraulic fluid
and carefully install into their proper bore.
7. Install spool caps (item 10) into valve body. Torque
caps from 20 to 25 ft- lb (27 to 33 N- m).
8. Lubricate both plungers (items 2 and 21) liberally
with clean hydraulic fluid and install into their proper
bore.
9. Install new O- rings, seats (item 5), check poppet
(item 1) and check spring (item 9) into the plunger bores.
10.Install O- rings, back- up washers and seat retaining
plugs (items 7 and 15) into their plunger bores. Torque
plugs from 30 to 35 ft- lb (41 to 47 N- m).
11. Install new O- ring, back- up washer and solid plug
(item 6) into the bore with the detent plunger. Torque
plug from 30 to 35 ft- lb (41 to 47 N- m).
12.Lubricate detent plunger (item 22), spring a nd disc
liberally with clean hydraulic fluid and install into valve
body bore.
13.Install O- ring and detent plug (item 19) into valve
body. Torque plug from 4to5ft-lb(5.4to6.8N-m).
Hydraulic
System