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 7200/7210Hydraulic System Page 4 – 24
Testing
The most effective method for isolating problems in the
hydraulic system is by using hydraulic test equipment
such as pressure gauges and flow meters in the circuits
during various operational checks (see the Special
Tools section in this Chapter).
Before Performing Hydraulic Tests
IMPORTANT: All obvious areas such as oil supply,
oil filter, binding linkages, loose fasteners or im-
proper adjustments must be checked before as-
suming that a hydraulic component is the source of
the problem.
Precautions for Hydraulic Testing
CAUTION
Failure to use gauges with expected pressure
(psi) rating as listed in test procedures could re-
sult in damage to the gauge and possible person-
al injury from leaking hot oil.
CAUTION
All testing should be performed by two (2)
people. One person should be in the seat to oper-
ate the machine. The second person should
monitor test equipment and record test results.
WARNING
Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pres-
sure. Do not use hands to search for leaks; use
paper or cardboard. Hydraulic fluid escaping un-
der pressure can have sufficient force to pene-
trate the skin and cause serious injury. If fluid is
injected into the skin, it must be surgically re-
moved within a few hours by a doctor familiar with
this type of injury. Gangrene may result from such
an injury.
1. Clean machine thoroughly before disconnecting or
disassembling any hydraulic components. Always keep
in mind the need for cleanliness when working on hy-
draulic equipment. Contamination can cause excessive
wear or binding of hydraulic components.
2. When conducting tests on the hydraulic system,
wear eye protection.
3. Before testing, check traction control lever linkages
for improper adjustment, binding or broken parts.
4. All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System
Pressure in the General Information section.
5. Put clean metal caps or plugs on any hydraulic lines
left open or exposed during testing or component re-
moval.
6. When using hydraulic tester (pressure and flow), the
inlet and the outlet hoses must be properly connected
and not reversed to prevent damage to the hydraulic
tester or components.
7. Install hydraulic fittings finger tight and far enough to
make sure that they are not cross–threaded before tight-
ening them with a wrench.
8. Position tester hoses to prevent rotating machine
parts from contacting and damaging the hoses or tester.
9. After connecting test equipment, check oil level in
the hydraulic tank to make sure that oil level is correct.
10.When using hydraulic tester (pressure and flow),
open tester load valve completely before starting engine
to minimize the possibility of damaging components.
11. The engine must be in good operating condition. En-
gine speed can affect the accuracy of the hydraulic test-
er readings. When performing hydraulic tests, check
engine speed with a phototac.
12.If a traction circuit problem exists, consider perform-
ing one or more of the following tests: Charge Relief
Valve Pressure, Transmission Piston Pump Flow, Trac-
tion Relief Valve Pressure and/or Wheel Motor Efficien-
cy.
13.If a lift circuit problem exists, consider performing
one or more of the following tests: Implement Relief
Pressure, Gear Pump Flow and/or Lift Cylinder Internal
Leakage.
14.If a PTO circuit problem exists, consider performing
the PTO Pressure Valve Test.