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 – 5
Hydraulic Fitting Installation (SAE Straight Thread O–Ring Fitting into Component Port)
Non–Adjustable Fitting (Fig. 4)
1. Make sure all threads and sealing surfaces of fitting
and component port are free of burrs, nicks, scratches
or any foreign material.
2. As a preventative measure against leakage, it is rec-
ommended that the O–ring be replaced any time the
connection is opened.
3. Lightly lubricate the O–ring with clean hydraulic oil.
Fitting threads should be clean with no lubricant applied.
IMPORTANT: Before installing fitting into port, de-
termine port material. If fitting is to be installed into
an aluminum port, installation torque is reduced.
4. Install the fitting into the port. Then, use a torque
wrench and socket to tighten the fitting to the recom-
mended installation torque shown in Figure 5.
NOTE: Use of an offset wrench (e.g. crowfoot wrench)
will affect torque wrench calibration due to the effective
length change of the torque wrench. Tightening torque
when using a torque wrench with an offset wrench will
be less than the recommended installation torque. See
Using a Torque Wrench with an Offset Wrench in the
Torque Specifications section of Chapter 2 – Product
Records and Maintenance to determine necessary con-
version information.
5. If a torque wrench is not available, or if space at the
port prevents use of a torque wrench, an alternate meth-
od of assembly is the Flats From Finger Tight (F.F.F.T.)
method.
A. Install the fitting into the port and tighten it down
full length until finger tight.
B. If port material is steel, tighten the fitting to the
listed F.F.F.T. If port material is aluminum, tighten fit-
ting to 60% of listed F.F.F.T.
Size F.F.F.T.
4 (1/4 in. nominal hose or tubing) 1.00 +
0.25
6 (3/8 in.) 1.50 +
0.25
8 (1/2 in.) 1.50 +
0.25
10 (5/8 in.) 1.50 +
0.25
12 (3/4 in.) 1.50 +
0.25
16 (1 in.) 1.50 +
0.25
Figure 4
O–ring
Fitting
Fitting
Dash Size
Fitting Port Side
Thread Size
Installation Torque Into
Steel Port
Installation Torque Into
Aluminum Port
4 7/16 – 20 15 to 19 ft–lb (21 to 25 N–m) 9 to 11 ft–lb (13 to 15 N–m)
5 1/2 – 20 18 to 22 ft–lb (25 to 29 N–m) 11 to 15 ft–lb (15 to 20 N–m)
6 9/16 – 18 34 to 42 ft–lb (47 to 56 N–m) 20 to 26 ft–lb (28 to 35 N–m)
8 3/4 – 16 58 to 72 ft–lb (79 to 97 N–m) 35 to 43 ft–lb (48 to 58 N–m)
10 7/8 – 14 99 to 121 ft–lb (135 to 164 N–m) 60 to 74 ft–lb (82 to 100 N–m)
12 1 1/16 – 12 134 to 164 ft–lb (182 to 222 N–m) 81 to 99 ft–lb (110 to 134 N–m)
14 1 3/16 – 12 160 to 196 ft–lb (217 to 265 N–m) 96 to 118 ft–lb (131 to 160 N–m)
16 1 5/16 – 12 202 to 248 ft–lb (274 to 336 N–m) 121 to 149 ft–lb (165 to 202 N–m)
20 1 5/8 – 12 247 to 303 ft–lb (335 to 410 N–m) 149 to 183 ft–lb (202 to 248 N–m)
Figure 5
Hydraulic
System