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 7200/7210Page 3 – 16Kubota Diesel Engine
IMPORTANT: Make sure to not damage the engine,
flywheel housing, fuel hoses, hydraulic lines, elec-
trical harness or other parts while removing engine.
Also, make sure that transmission does not shift
during engine removal.
CAUTION
One person should operate lift or hoist while a
second person guides the engine assembly out
of the machine.
18.Move engine toward the rear of the machine to sepa-
rate it from the transmission input shaft and flywheel
housing. Carefully raise engine from the machine.
19.Locate and retrieve two (2) dowel pins that locate fly-
wheel housing to engine.
20.If necessary, remove six (6) cap screws that secure
flywheel coupling to engine flywheel and remove cou-
pling from engine.
21.If necessary, remove engine mount and muffler
bracket from engine.
Engine Installation (Fig. 9)
1. Make sure that all engine components removed dur-
ing maintenance or rebuilding are installed to the en-
gine.
2. If removed, install engine mount and muffler bracket
to engine with cap screws and lock washers. Torque cap
screws from 50 to 60 ft–lb (68 to 81 N–m).
3. If flywheel coupling was removed from engine, apply
Loctite #271 (or equivalent) to threads of six (6) cap
screws and secure coupling to engine flywheel. Torque
cap screws 19 ft–lb (25.7 N–m).
4. Position two (2) dowel pins to engine endplate.
5. Support transmission to prevent it from moving dur-
ing engine installation.
CAUTION
When installing engine assembly, make sure lift
or hoist can safely support 250 pounds (114 kg).
6. Connect lift or hoist to the front and rear engine lift
tabs.
Figure 13
1. Temp shutdown switch 2. Temp warning switch
1
2
CAUTION
One person should operate lift or hoist while a
second person guides the engine assembly into
the machine.
IMPORTANT: Make sure to not damage the engine,
flywheel housing, fuel or hydraulic lines, electrical
harness or other parts while installing the engine.
Also, make sure that transmission does not shift
during engine installation.
7. Carefully lower engine assembly into the machine.
Move engine toward the front of the machine while align-
ing flywheel coupling to transmission input shaft and en-
gine endplate to flywheel housing.
8. Secure flywheel housing and fuel/water separator
bracket to engine endplate with eight (8) flange head
screws and two (2) socket head screws.
9. Secure engine to the engine mounts attached to the
frame with two (2) cap screws, snubbing washers and
lock nuts.
10.Connect fuel hoses to the fuel/water separator (Fig.
11). Connect return fuel hose to front injector nozzle
(Fig. 12).
11. Connect electrical wires to engine using labels
placed during engine removal:
A. Negative battery cable, wire harness ground and
fuel stop solenoid (Fig. 11).
B. Glow plug bus (Fig. 12).
C. High temperature warning switch and high tem-
perature shutdown switch (Fig. 13).
D. Starter motor, fusible link harness, alternator and
oil pressure switch.