Form No.
Revision History Revision Date -- 2007 Initial Issue. A 2016 Updated Hydraulic and Electrical chapters. B 03/2018 Added revision history. C 03/2019 Updated Engine and Chassis chapters. D 06/2020 Updated Foldout Diagrams. © THE TORO COMPANY 2020 Description This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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PART NO. 07150SL (Rev. D) Service Manual (Models with Kubota Engine) Groundsmaster 7200/7210 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on Groundsmaster 7200 and 7210 machines that are powered by a Kubota diesel engine. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3 -- Kubota Diesel Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 General Information . . . . . . . . . . . . . . . . .
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Safety Table of Contents GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .
Before Operating 1. Review and understand the contents of the Operator’s Manual and Operator Training DVD before starting and operating the machine. Become familiar with the controls and know how to stop the machine and engine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com. 5. Since fuel is highly flammable, handle it carefully: A. Store fuel in containers specifically designed for this purpose. B. Do not remove machine fuel tank cap while engine is hot or running.
1. Before servicing or making adjustments, lower cutting deck (or implement), stop engine, set parking brake and remove key from the switch. 12.Do not overspeed the engine by changing engine governor setting. To assure safety and accuracy, check maximum engine speed with a tachometer. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 13.Shut engine off before checking or adding oil to the engine crankcase. 3.
Jacking Instructions CAUTION When changing attachments, tires or performing other service, use correct blocks, hoists and jacks. Make sure machine is parked on a solid level floor such as a concrete floor. Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block wheels. Use appropriate jack stands to support the raised machine.
Chapter 2 Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 – 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in–lb in–lb N–cm 10 + 2 13 + 2 147 + 23 # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 282 + 56 # 8 – 36 UNF # 10 – 24 UNC 18 + 2 30 + 5 339 + 56 # 10 – 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in–lb 644 + 68 N–cm 78 + 8 in–lb 881 + 90 N–cm M6 X 1.0 96 + 10 in–lb 1085 + 113 N–cm 133 + 14 in–lb 1503 + 158 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 28 + 3 ft–lb 38 + 4 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb Recommended Torque** 7/16 – 20 UNF Grade 5 65 + 10 ft–lb 88 + 14 N–m 1/2 – 20 UNF Grade 5 80 + 10 ft–lb 108 + 14 N–m M12 X 1.25 Class 8.
Chapter 3 Kubota Diesel Engine Table of Contents Groundsmaster 7200/7210 Page 3 – 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Groundsmaster 7200 . . . . . . . . . . . . . . . . . . . . . . . . 2 Groundsmaster 7210 . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Stopping the Engine (Groundsmaster 7210) . . . .
Specifications: Groundsmaster 7200 Item Description Make / Designation Kubota D1105–E2B, 4–stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in3 (1123 cc) Compression Ratio 22.0:1 Firing Order 1 (fan end) – 2 – 3 (flywheel end) Dry Weight (approximate) 205 lb. (93 kg) Fuel No. 2–D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 11.5 U.
Specifications: Groundsmaster 7210 Item Description Make / Designation Kubota D1105T–E2B, 4–stroke, Turbocharged Liquid Cooled, OHV Diesel Number of Cylinders 3 3.07” x 3.09” (78 mm x 78.4 mm) Total Displacement 68.53 in3 (1123 cc) Compression Ratio 22.0:1 Firing Order 1 (fan end) – 2 – 3 (flywheel end) Dry Weight (approximate) 215 lb. (98 kg) Fuel No. 2–D Diesel Fuel (ASTM D975) Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle (DNOPD) Fuel Tank Capacity 11.5 U.S.
General Information This Chapter gives information about specifications, troubleshooting, testing and repair of the Kubota D1105 diesel engine used in the Groundsmaster 7200 and 7210. Refer to the Operator’s Manual for engine maintenance information. Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor.
Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. 2 1. Move remote throttle control lever to FAST position. 3 2. Check position of speed control lever on engine fuel injection pump. Speed control lever should be contacting high speed screw when throttle control lever is in FAST (detent) position (Fig. 1). Kubota Diesel Engine 1 3.
Service and Repairs Air Cleaner Assembly 6 RIGHT FRONT 5 3 7 4 8 9 10 4 1 2 Figure 3 1. 2. 3. 4. Hose clamp Inlet hose (GM 7200 shown) Hose clamp Flange nut (4 used) Kubota Diesel Engine 5. Cap screw (2 used) 6. Air inlet hose 7. Air cleaner support Page 3 – 6 8. Frame 9. Cap screw (2 used) 10.
Removal (Fig. 3) 3 NOTE: See Operator’s Manual for air cleaner maintenance procedures and intervals. 1. Park machine on a level surface, lower cutting unit (or implement), stop engine, engage parking brake and remove key from the ignition switch. 2 1 2. Unlatch and raise hood. 4. Check air cleaner housing and cover for damage that could cause possible air leaks. 5. Check air inlet hoses for damage or wear. Installation (Fig. 3) 5 8 7 4 6 Figure 4 1. 2. 3. 4.
Exhaust System 17 to 21 ft–lb (23 to 28 N–m) 1 7 38 to 48 in–lb (4.3 to 5.4 N–m) 4 5 6 2 3 RIGHT FRONT Figure 5 1. Muffler (GM 7200 shown) 2. Exhaust gasket 3. Engine (GM 7200 shown) Kubota Diesel Engine 4. Carriage screw (2 used) 5. Muffler bracket Page 3 – 8 6. Flange lock nut (2 used) 7.
Removal (Fig. 5) 2 CAUTION The engine and exhaust system may be hot. To avoid possible burns, allow the engine and exhaust system to cool before working on the exhaust system. 1 1 1. Park machine on a level surface, lower cutting unit (or implement), stop engine, engage parking brake and remove key from the ignition switch. 2. Unlatch and raise hood. Figure 6 3. Remove two (2) carriage screws and flange lock nuts that secure the muffler to the muffler bracket (Fig. 6). 1. Flange lock nut 2.
Fuel System 21 RIGHT 16 FRONT 35 15 5 15 6 3 30 17 39 6 29 40 20 34 41 4 30 15 33 23 42 22 8 6 43 38 44 24 15 16 15 3 41 42 11 15 13 36 26 37 19 43 44 32 27 26 37 25 36 7 11 18 15 28 18 1 10 15 9 15 2 31 15 12 14 15 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
D. Loosen hose clamp and disconnect fuel supply hose from strainer (outlet) fitting on fuel tank. DANGER E. Lift left side fuel tank from machine. 4. To remove right side (RH) fuel tank: A. Loosen hose clamp and disconnect vent hose from fitting on RH fuel tank. IMPORTANT: When removing right side fuel tank, take care to not damage wire harness, electrical components or throttle cable. Check Fuel Lines and Connections B. Loosen two (2) latches and remove control panel access cover.
Radiator 11 RIGHT 3 FRONT 26 8 36 10 7 37 13 35 25 22 9 6 5 2 24 33 16 23 4 32 15 22 28 17 30 29 18 17 18 38 18 34 18 31 21 27 14 26 12 1 20 19 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Radiator Oil cooler Flange nut (4 used) Clamp Cap screw Washer (2 used) Flange nut (2 used) Flange nut (2 used) Cap screw (2 used) Rubber grommet (2 used) Radiator frame Pipe plug Air inlet hose Kubota Diesel Engine 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
Removal (Fig. 8) Installation (Fig. 8) 1. Park machine on a level surface, lower cutting unit (or implement), stop engine, engage parking brake and remove key from the ignition switch. 1. Remove all plugs placed in radiator and coolant hose openings during the removal procedure. 2. Open hood and secure it in the raised position. 2. Carefully position radiator to the radiator frame. 3. Secure radiator to the radiator frame with four (4) cap screws and flange nuts.
Engine 9 RIGHT 8 FRONT 5 4 11 6 33 36 35 50 to 60 ft–lb (68 to 81 N–m) 7 10 19 ft–lb (25.7 N–m) Loctite #271 40 15 12 25 26 27 37 29 17 1 43 2 19 14 38 23 41 22 39 19 16 39 32 14 28 3 26 23 34 42 18 13 30 42 31 21 39 18 20 24 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
6. Disconnect both battery cables at the battery. Disconnect negative cable first and then positive cable (see Battery Service in the Service and Repairs section of Chapter 5 – Electrical System). 3 7. Remove muffler from the engine (see Muffler Removal in this section). 8. Remove radiator from machine (see Radiator Removal in this section). Remove fan shroud. 2 4 9. Label all electrical wires for assembly purposes. Disconnect electrical wires from engine: A.
IMPORTANT: Make sure to not damage the engine, flywheel housing, fuel hoses, hydraulic lines, electrical harness or other parts while removing engine. Also, make sure that transmission does not shift during engine removal. 2 1 CAUTION One person should operate lift or hoist while a second person guides the engine assembly out of the machine. Figure 13 1. Temp shutdown switch 18.Move engine toward the rear of the machine to separate it from the transmission input shaft and flywheel housing.
12.Secure wire harness to engine with cable ties at locations noted during engine removal. 19.Connect and secure positive battery cable to the battery. Then connect negative battery cable. 13.Carefully position fan shroud around the engine fan. 20.Install air cleaner to the engine (see Air Cleaner Assembly Installation in this section). 15.Make sure that drain plug is installed in radiator. Fill radiator with coolant. 16.Install muffler to the engine (see Exhaust System Installation in this section).
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Chapter 4 Hydraulic System SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Hose and Tube Installation . . . . . . . . . . 4 Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . 5 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pushing Traction Unit . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Transmission Kanzaki dual, variable displacement traction piston pumps with integral charge pump and multi–disc PTO clutch 1.1 Cubic Inches (18 cc) 4000 PSI (276 bar) 0.37 Cubic Inches (6 cc) 70 to 100 PSI (4.8 to 6.
General Information Hydraulic Hoses Hard, cracked, cut, abraded, charred, leaking or otherwise damaged hose. Kinked, crushed, flattened or twisted hose. Blistered, soft, degraded or loose hose cover. Cracked, damaged or badly corroded hose fittings. When replacing a hydraulic hose, be sure that the hose is straight (not twisted) before tightening the fittings. This can be done by observing the imprint (layline) on the hose.
Hydraulic Hose and Tube Installation (O–Ring Face Seal Fitting) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2.
Hydraulic Fitting Installation (SAE Straight Thread O–Ring Fitting into Component Port) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
Adjustable Fitting (Fig. 6) 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 recommended that the O–ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O–ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back–up Washer 4. Turn back the lock nut as far as possible.
Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance procedures and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine. Pushing Traction Unit In case of emergency, your Groundsmaster can be pushed for a very short distance. However, Toro does not recommend this as a standard procedure.
Traction Circuit (Closed Loop) Component Failure The traction system on Groundsmaster 7200 and 7210 machines consists of two identical and independent closed loop traction circuits. If a component in one of these traction circuits (e.g. wheel motor or transmission piston pump) should fail, debris and contamination from the failed component will circulate throughout the traction circuit.
Hydraulic Schematics Hydraulic System The hydraulic schematics for the Groundsmaster 7200 and 7210 are located in Chapter 8 – Foldout Diagrams.
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR REAR PORT FRONT PORT FRONT PORT REAR PORT BYPASS VALVE FORWARD BYPASS VALVE FORWARD Working Pressure Low Pressure (Charge) Return or Suction Flow PORT D PORT C PORT B PORT A FLUSHING VALVE (SHIFTED) FLUSHING VALVE (SHIFTED) 4000 PSI (276 bar) 4000 PSI (276 bar) Groundsmaster 7200/7210 Traction Circuits (Forward Shown) LIFT CYLINDER Hydraulic Flow Diagrams Page 4 – 10 Groundsmaster 7200/7210
Traction Circuits The angle of the swash plate determines pump flow and ultimately traction speed. When a traction lever is moved a small amount, a small swash plate rotation results in low pump output and lower traction speed. When the traction lever is moved fully, the pump swash plate rotates fully to provide maximum pump output flow and traction speed.
Hydraulic System Page 4 - 12 Rev.
Lift Circuit (Raise) During conditions of not raising or lowering the cutting deck (or implement), flow from the gear pump by- passes the lift circuit and is routed directly to the oil cooler and then to the transmission. Flow then returns to the hydraulic tank. NOTE: The engine must be running to allow the cutting deck (or implement) to be raised.
Hydraulic System Page 4 - 14 Rev.
Lift Circuit (Lower) Circuit operation for lowering the cutting deck (or implement) is similar to raising it. However, hydraulic flow is used to contract the lift cylinder and this action allows the cutting deck (or implement) to lower. During conditions of not raising or lowering the cutting deck (or implement), flow from the gear pump by- passes the lift circuit and is routed directly to the oil cooler and transmission. Flow then returns to the hydraulic tank.
Hydraulic System Page 4 – 16 Groundsmaster 7200/7210 MOTOR LH WHEEL RH WHEEL MOTOR REAR PORT FRONT PORT FRONT PORT REAR PORT BYPASS VALVE FORWARD BYPASS VALVE FORWARD Working Pressure Low Pressure (Charge) Return or Suction Flow Groundsmaster 7200/7210 PTO Circuit PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) (ENGAGED) (ENERGIZED) LIFT CYLINDER
PTO Circuit The transmission used on Groundsmaster 7200 and 7210 machines includes a hydraulic, multi–plate clutch that is used to engage the PTO. Hydraulic flow for PTO clutch engagement is provided by the transmission charge pump. When the PTO switch is turned off, the transmission solenoid valve is de–energized and the PTO clutch is disengaged. The integral PTO brake is applied to control the stopping rate of the drive shaft and cutting deck (or implement).
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 bar), 5000 PSI (350 bar) and 10000 PSI (700 bar) gauges.
Hydraulic Test Fitting Kit Toro Part Number: TOR4079 This kit includes a variety of O- ring Face Seal fittings to enable the connection of test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Figure 11 O- ring Kit Toro Part Number: 117- 2727 Hydraulic System The O- ring kit includes O- rings in a variety of sizes for face seal and port seal hydraulic connections.
Troubleshooting The chart that follows contains information to assist in troubleshooting. There may possibly be more than one cause for a machine malfunction. Refer to the Testing section of this Chapter for precautions and specific hydraulic test procedures.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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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). 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.
Traction System Operation Testing 1. If machine does not track in a straight line, look for a problem with components that affect the weaker traction side of the machine. During operation, the machine will steer toward the weaker side of the traction system. Because piston pump swash plate is controlled by traction control lever movement, if one lever rotates its swash plate more than the other lever, the machine will not track in a straight line. 2.
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR BYPASS VALVE FORWARD BYPASS VALVE FORWARD PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Charge Relief Valve Pressure Test (Using Pressure Gauge) PRESSURE GAUGE Figure 14 Page 4 – 26 Groundsmaster 7200/7210
Procedure for Charge Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature. 2. Make sure that traction drive is correctly adjusted for the neutral position. 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. 3. Park machine on a level surface with the cutting deck (or implement) lowered and off. Apply parking brake.
FLUSHING VALVE PORT D Port C Port D BYPASS VALVE PORT C Port B Port A LH WHEEL MOTOR RH WHEEL MOTOR HYDRAULIC TESTER FORWARD PORT B BYPASS VALVE RIGHT SIDE TRACTION (PISTON) PUMP TESTING SHOWN PORT A FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Transmission Piston Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) Figure 16 Hydraulic System Page 4 – 28 Groundsmaster 7200/7210
The Transmission Piston Pump Flow Test should be performed if a traction circuit problem is identified. This test will determine if hydraulic flow from a transmission piston pump is correct. 8. Sit in the operator seat, start engine and run at low idle speed (1500 to 1650 RPM). Check for any hydraulic leakage from test connections and correct before proceeding with test.
FLUSHING VALVE PORT D Port B Port A Port C Port D MOTOR LH WHEEL BYPASS VALVE PORT C PORT B RH WHEEL MOTOR HYDRAULIC TESTER FORWARD RIGHT SIDE FORWARD TRACTION RELIEF VALVE TESTING SHOWN BYPASS VALVE PORT A FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Traction Relief Valve Pressure Test (Using Tester with Pressure Gauges and Flow Meter) Figure 17 Hydraulic System Page 4 – 30 Groundsmaster 7200/7210
The Traction Relief Valve Pressure Test should be performed if a traction circuit problem is identified. This test will determine if a transmission relief valve is operating correctly. Procedure for Traction Relief Valve Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature. Also, make sure that traction drive is correctly adjusted for the neutral position. WARNING 3. Read Precautions for Hydraulic Testing listed at the beginning of this section. 4.
Port A Port C PORT D FLUSHING VALVE Port B Port D BYPASS VALVE FORWARD PORT C PORT B BYPASS VALVE RIGHT SIDE WHEEL MOTOR EFFICIENCY TESTING SHOWN FORWARD PORT A FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) MOTOR LH WHEEL RH WHEEL MOTOR HYDRAULIC TESTER Figure 18 Hydraulic System Page 4 – 32 Groundsmaster 7200/7210
NOTE: Over a period of time, a wheel motor can wear internally. A worn motor may by–pass oil to its case drain causing the motor to be less efficient. Eventually, enough oil loss will cause the wheel motor to stall under heavy load conditions. Continued operation with a worn, inefficient motor can generate excessive heat, cause damage to seals and other components in the hydraulic system and affect overall machine performance. Procedure for Wheel Motor Efficiency Test: 1.
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR BYPASS VALVE FORWARD BYPASS VALVE FORWARD PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) PRESSURE GAUGE LIFT CYLINDER PTO Pressure Valve Test (Using Pressure Gauge) Figure 19 Page 4 – 34 Groundsmaster 7200/7210
The PTO Pressure Valve Test should be performed if a PTO engagement problem is identified. This test will determine if the PTO pressure valve in the transmission is operating correctly. Procedure for PTO Pressure Valve Test: 1. Make sure hydraulic oil is at normal operating temperature. WARNING 11. If specification is not met, repair or replace pressure valve in transmission (see Transmission Service in the Service and Repairs section of this chapter).
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR BYPASS VALVE FORWARD BYPASS VALVE FORWARD PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Implement Relief Pressure Test (Using Pressure Gauge) PRESSURE GAUGE Figure 21 Page 4 – 36 Groundsmaster 7200/7210
The Implement Relief Pressure Test should be performed if a cutting deck (or implement) raise and lower problem is identified. This test will determine if the implement relief valve is operating correctly. Procedure for Implement Relief Pressure Test: 1. Make sure hydraulic oil is at normal operating temperature. 2. Make sure that traction drive is correctly adjusted for the neutral position.
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR BYPASS VALVE FORWARD BYPASS VALVE FORWARD PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) LIFT CYLINDER Gear Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) HYDRAULIC TESTER Figure 24 Page 4 – 38 Groundsmaster 7200/7210
Procedure for Gear Pump Flow Test: NOTE: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump will by–pass oil and make the pump less efficient. Eventually, enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions. Continued operation with a worn, inefficient pump can generate excessive heat and cause damage to seals and other components in the hydraulic system. 1. Make sure hydraulic oil is at normal operating temperature. 2.
Hydraulic System MOTOR LH WHEEL RH WHEEL MOTOR BYPASS VALVE FORWARD BYPASS VALVE FORWARD PORT D PORT C PORT B PORT A FLUSHING VALVE FLUSHING VALVE 4000 PSI (276 bar) 4000 PSI (276 bar) CHECK FOR CYLINDER RETRACTING CAP LIFT CYLINDER PLUG (PARTIALLY RAISED) Lift Cylinder Internal Leakage Test Figure 26 Page 4 – 40 Groundsmaster 7200/7210
NOTE: Raise/lower circuit operation will be affected by lift cylinder binding, extra weight on the cutting deck (or implement) and/or binding of lift components. Make sure that these items are checked before proceeding with the lift cylinder internal leakage test. Procedure for Lift Cylinder Internal Leakage Test: 1. Park machine on a level surface with the PTO switch OFF. Position the cutting deck (or implement) in a partially raised position and turn the engine off. Apply the parking brake. 2.
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Service and Repairs General Precautions for Removing and Installing Hydraulic System Components 1. Before removing any parts from the hydraulic system, park machine on a level surface, engage parking brake, lower cutting deck (or implement) and stop engine. Remove key from the ignition switch. 6. Put clean caps or plugs on any hydraulic lines, hydraulic fittings and components left open or exposed to prevent contamination. Cap the opening as soon as line or port is exposed.
Flush Hydraulic System IMPORTANT: Flush the hydraulic system any time there is a severe component failure or if the system is contaminated (oil appears milky, black or contains metal particles). IMPORTANT: If a component failure occurred in the traction circuit, refer to Traction Circuit (Closed Loop) Component Failure in the General Information section for information regarding the importance of removing contamination from the traction circuit. 1.
Charge Hydraulic System NOTE: When initially starting the hydraulic system with new or rebuilt components such as wheel motors, gear pump or lift cylinder, it is important that the hydraulic system be charged properly. Air must be purged from the system and its components to reduce the chance of damage. 10.Make sure traction control levers and lift control lever are in the neutral position. Start engine and run at low idle speed (1500 to 1650 RPM).
Hydraulic Tank 66 to 70 ft–lb (90 to 94 N–m) 15 11 16 17 10 60 to 66 ft–lb (82 to 90 N–m) 12 9 28 18 14 27 13 8 5 29 13 22 19 3 66 to 70 ft–lb (90 to 94 N–m) 7 6 20 24 19 26 4 22 23 25 21 7 2 RIGHT FRONT 1 32 33 31 30 16 to 18 ft–lb (22 to 24 N–m) Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hydraulic tank O–ring Strainer Hose clamp Hydraulic hose Hydraulic hose Grommet Hose clamp Dipstick O–ring Tank cap 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
8. Put clean plugs in disconnected hydraulic hoses and fittings to prevent system contamination. 9. Remove two (2) washer head screws and tank support that retain hydraulic tank to frame. 10.Remove hydraulic tank toward front of machine. 11. Inspect foam strips under hydraulic tank. Replace strips if damaged. 8. Fill hydraulic tank with new hydraulic fluid. 9. Install operator seat and seat base (see Operator Seat Installation in the Service and Repair section of Chapter 6 – Chassis). 10.Operate machine.
Wheel Motors 18 99 to 121 ft–lb (135 to 164 N–m) 17 14 99 to 121 ft–lb (135 to 164 N–m) 13 11 11 10 12 9 8 300 to 400 ft–lb (407 to 502 N–m) 9 6 Loctite #271 19 3 16 Loctite #271 15 1 7 5 RIGHT 4 FRONT 75 to 85 ft–lb (102 to 115 N–m) 2 Figure 32 1. 2. 3. 4. 5. 6. 7. Lock nut Lug nut (5 used per wheel) Wheel assembly Wheel hub Wheel stud (5 used per wheel) Socket head screw (4 used per motor) Wheel motor (LH shown) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
IMPORTANT: DO NOT hit wheel hub, wheel hub puller or wheel motor with a hammer during removal or installation. Hammering may cause damage to the wheel motor. 5. Use appropriate puller to loosen wheel hub from wheel motor. 6. Remove lock nut and loosened wheel hub from motor shaft. Locate and retrieve woodruff key from wheel motor shaft. 7. Thoroughly clean hydraulic hose ends and fittings on wheel motor to prevent hydraulic system contamination. 8.
Wheel Motor Service 45 to 55 ft–lb (61 to 75 N–m) 10 7 7 8 9 7 6 11 5 3 4 12 13 7 2 15 1 14 16 17 7 18 19 Figure 34 1. 2. 3. 4. 5. 6. 7. Lock nut Dirt/water seal Housing Back–up washer Shaft seal Coupling shaft Body seal (5 used) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Manifold Commutator ring Cap screw (7 used) End cover Commutator Commutator ring NOTE: The two wheel motors used on the Groundsmaster 7200/7210 have the same basic construction.
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Transmission RIGHT 16 33 38 37 FRONT 35 36 Antiseize Lubricant 30 41 40 39 25 400 in–lb (45 N–m) 42 34 33 32 26 43 17 31 19 10 30 8 29 28 27 7 5 6 22 21 16 23 20 9 17 38 18 24 10 15 14 24 3 2 4 13 12 44 1 43 11 37 39 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Transmission Removal (Fig. 35) 1 WARNING FRONT 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. 3 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 5 4 6 2.
10.Remove oil filter from transmission. Discard filter. If necessary, remove gear pump from transmission (see Gear Pump Removal in this section). 14.On both sides of transmission, remove retaining ring that secures pump control rod end onto transmission control arm (Fig. 36). Slide control rod from control arm. NOTE: Two (2) 8 mm eyebolts can be installed into threaded bosses in top of transmission to allow use of a lift or hoist to remove transmission (Fig. 37). 15.
6. Place two (2) dowel pins in flywheel housing. IMPORTANT: Make sure to not damage the transmission, flywheel housing, hydraulic lines, electrical harness or other parts while installing transmission. CAUTION Support transmission assembly when installing it to the flywheel housing to prevent it from falling and causing personal injury. 7. Lower transmission into machine. Align transmission input shaft with flywheel coupler and slide transmission to flywheel housing.
Transmission Service 3 2 1 4 10 11 8 9 7 5 6 12 1314 23 19 21 56 52 29 30 57 58 59 31 32 33 55 54 51 28 24 25 40 26 27 18 17 16 22 41 15 37 53 50 26 44 49 48 47 46 45 66 63 61 39 20 42 77 38 43 64 65 35 36 67 57 30 34 68 69 40 41 26 57 62 63 43 60 40 38 44 39 41 78 37 75 37 74 73 72 71 31 70 76 Figure 39 Hydraulic System Page 4 – 56 Groundsmaster 7200/7210
Figure 39 (continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
5. Remove filter bypass plug, spring and valve from transmission pump body. Remove and discard O–ring from plug. 2 1 Figure 41 1. Filter bypass plug 2. Bypass valve 6. Remove pressure valve plug, spring and valve from transmission pump body. Remove and discard O–ring from plug. 7. Remove charge relief plug, spring and valve from transmission pump body. Remove and discard O–ring from plug. 1 2 Figure 42 1. Pressure valve plug 2. Charge relief plug 8.
12.Remove three (3) shorter (45 mm) and two (2) longer (95 mm) flange head screws that secure pump body to center case. Remove pump body from center case. 1 2 Figure 45 1. Pump body 2. Center case 2 1 1 Figure 46 1. Pin 14.Slide outer and inner charge pump rotors from RH pump shaft. Remove key from keyslot in pump shaft. 2 2. Pump body 3 1 Figure 47 1. RH pump shaft 2. Outer pump rotor Groundsmaster 7200/7210 Page 4 – 59 3. Inner pump rotor Hydraulic System Hydraulic System 13.
15.Remove eight (8) socket head screws that secure center case to transmission pump housing. 16.Carefully remove center case assembly from transmission pump housing. 1 17.Remove two (2) pins from transmission pump housing bores. Remove and discard gasket. 3 2 Figure 48 1. Center case 2. Pump housing 18.Remove bypass valves from center case. Remove and discard O–rings and backup rings from bypass valves. 3. Pin (2 used) 1 5 IMPORTANT: The forward and reverse relief cartridges are different.
21.Remove six (6) hex plugs from center case. Remove and discard O–rings from plugs. 2 3 22.Remove RH and LH flushing valve plugs, springs and valves from center case. Note differences in flushing valves and their locations for assembly purposes. Remove and discard O–rings from plugs. 4 1 Figure 51 1. Hex plug (6 used) 2. RH flushing valve 3. LH flushing valve 4. Center case 23.Taking care to not drop pistons from cylinder block, slide both cylinder block assemblies from pump shafts.
28.Remove two (2) hex plugs and one (1) socket head plug from gear case housing. Remove and discard O– rings from plugs. 1 2 1 Figure 54 1. Hex plug 2. Socket head plug 29.Remove fifteen (15) flange head screws that secure gear case housing to transmission pump housing. 30.Carefully remove gear case housing from pump housing. 1 31.Locate and retrieve two (2) pins from gear case housing holes. Remove and discard gasket. 3 32.
33.Remove input shaft, RH pump shaft and LH pump shaft assemblies from transmission pump housing. 1 34.Slide pipe assembly from bore of pump housing. Remove and discard two (2) O–rings from grooves in pipe. 3 2 4 Figure 56 1. Input shaft 2. RH pump shaft 3. LH pump shaft 4. Pipe Hydraulic System 35.If pump shaft bearing replacement is necessary, remove and discard seal ring from RH and LH pump shafts. Remove bearings from pump shaft using a bearing puller. Discard removed bearings.
37.Remove PTO shaft assembly from transmission pump housing. 2 1 Figure 58 1. PTO shaft assembly 38.Remove final friction plate from transmission pump housing. 2. Pump housing 2 1 NOTE: This friction plate may have been removed with PTO shaft assembly. Figure 59 1. Friction plate Hydraulic System Page 4 – 64 2.
39.Disassemble PTO shaft assembly: 5 6 2 A. Using a bearing puller, remove bearing from PTO shaft. Discard bearing. 1 4 B. Remove spacer from PTO shaft. C. Slide gear and clutch assembly from PTO shaft. D. Remove key from PTO shaft slot. 3 E. Remove two (2) seal rings from PTO shaft grooves. Discard seal rings. F. Remove B–plate, C–plate, three (3) A–plates and three (3) friction plates from PTO shaft. Figure 60 4. Gear 5. Clutch assembly 6. Key 1. Bearing 2. PTO shaft 3. Spacer G.
42.If necessary, remove two (2) bearings from PTO gear. Discard removed bearings. Remove retaining ring from groove in PTO gear bore. 1 3 2 1 Figure 63 1. Bearing 2. PTO gear 3. Retaining ring 43.Remove two (2) plugs from transmission pump housing. Remove and discard O–rings from plugs. 2 3 1 Figure 64 1. Socket head plug 2. Hex plug 3. Pump housing 44.Remove three (3) socket head screws that secure both side covers to transmission pump housing. 45.
47.Carefully remove swash plates from transmission pump housing. Remove washer from each swash plate. 1 2 48.Thoroughly clean and inspect all transmission components. 3 Figure 66 3. Pump housing Hydraulic System 1. Swash plate (2 used) 2.
Transmission Assembly (Fig. 39) 1 IMPORTANT: When assembling the transmission, lubricate all transmission components with clean hydraulic oil. 2 3 1. Make sure that all transmission components are thoroughly clean before assembling the transmission. 2. Apply clean hydraulic oil to washers and swash plate surfaces. Install washer onto each swash plate and carefully install swash plates into transmission pump housing. Figure 67 1. Swash plate (2 used) 2. Washer 3. Pump housing 3.
6. Install retaining ring into groove in bore of PTO gear. Press two (2) bearings into PTO gear until each bearing contacts the installed retaining ring. 1 3 2 1 Figure 70 1. Bearing 2. PTO gear 3. Retaining ring 7. Slide three (3) rods into holes in clutch assembly. 8. Slide PTO gear assembly into clutch assembly. Hydraulic System 3 2 1 Figure 71 1. Rod (3 used) 2. Clutch assembly 3. PTO gear 9. Assemble PTO shaft: 7 A. Press new bearing onto PTO shaft so that bearing is flush with shaft shoulder.
10.Install clutch assembly and gear onto PTO shaft: 5 6 2 A. Install key into PTO shaft slot making sure that rounded ends of key align with rounded ends of shaft slot. 1 4 B. Slide clutch assembly and gear onto PTO shaft making sure to align slot in clutch with key in shaft. Also, align rods in clutch with holes in B–plate. 3 C. Place spacer onto PTO shaft. D. Press bearing onto PTO shaft so bearing is flush with shaft shoulder. Figure 73 4. Gear 5. Clutch assembly 6. Key 1. Bearing 2.
13.If shafts were disassembled, install gear and two (2) bearings onto input shaft, RH pump shaft and/or LH pump shaft. Make sure that bearings are pressed fully to the shaft shoulder. 14.Lubricate seal rings and install seal ring onto RH and LH pump shafts. 1 4 3 4 2 1. RH pump shaft 2. LH pump shaft 15.Install RH and LH pump shaft assemblies into transmission pump housing. Then, install input shaft into pump housing making sure to align input shaft gear teeth with gears on PTO and pump shafts. 3.
17.Place two (2) pins into transmission pump housing holes. Position new gasket to housing. 18.Carefully place gear case housing onto pump housing making sure to align pins, pipe and shaft bearings. 1 19.Secure gear case housing to pump housing with fifteen (15) flange head screws. Tighten screws evenly in a crossing pattern and then torque screws from 17 to 19 ft–lb (22 to 27 N–m). 3 2 20.Taking care to not damage input shaft oil seal, install oil seal into gear case housing bore.
22.Taking care to not damage PTO oil seal, install oil seal into pump housing bore at PTO shaft. Place spacer on oil seal and secure with retaining ring. 2 23.Lubricate both sides of thrust plates with clean hydraulic oil. Place thrust plate onto each swash plate making sure to position the beveled side of the thrust plates against the swash plate surface. 3 1 24.Slide control arm onto each trunnion shaft and secure with socket head screw and nut. Torque nut from 20 to 23 ft–lb (27 to 32 N–m).
30.Lubricate O–rings and backup rings for bypass valves. Position rings on bypass valves and install valves into center case. Torque valves from 62 to 79 in– lb (7 to 9 N–m). 1 5 31.Lubricate sealing washers and install onto forward and reverse relief valve cartridges. 2 IMPORTANT: The forward and reverse relief cartridges are different. Use labels made during disassembly to make sure the relief cartridges are properly installed. 32.
37.Install key into keyslot in RH pump shaft. Lubricate inner and outer charge pump rotors with clean hydraulic oil. Slide inner rotor onto pump shaft and align with key. Place outer rotor onto inner rotor. 2 3 1 Figure 86 1. RH pump shaft 2. Outer pump rotor 3. Inner pump rotor 38.Install two (2) pins into pump body bores. 39.Apply clean grease to pump body O–rings to hold them in position during assembly. Place O–rings in pump body locations. Hydraulic System 2 1 1 Figure 87 1. Pin 2.
41.Lubricate new O–rings and install O–rings onto two (2) hex plugs. Install plugs into pump body. Torque plugs from 14 to 15 ft–lb (18 to 21 N–m). 42.Apply sealant to threads of four (4) socket head plugs and install into pump body. Torque plugs from 78 to 95 in–lb (8.8 to 10.8 N–m). 1 2 Figure 89 1. Hex plug (2 used) 2. Socket plug (4 used) 43.Lubricate accumulator components with clean hydraulic oil. Install piston, spring and collar into pump body.
50.Lubricate solenoid valve spring, sleeve and spool with clean hydraulic oil and install into pump body. Make sure that sleeve is installed so that holes are closest to the spring location and that step in spool is toward spring location as well. Place pin in spool. 7 6 51.Install solenoid valve stem into pump body and torque from 186 to 195 in–lb (21 to 22 N–m). 5 2 52.Place O–ring, solenoid coil, O–ring, washer, lock washer and nut onto solenoid valve stem.
Gear Pump 14 RIGHT FRONT 35 to 43 ft–lb (48 to 58 N–m) 15 16 17 13 12 18 11 20 to 26 ft–lb (28 to 35 N–m) 10 9 8 2 4 5 3 1 6 20 to 26 ft–lb (28 to 35 N–m) 7 Figure 94 1. 2. 3. 4. 5. 6. Transmission assembly Coupler O–ring O–ring Hydraulic fitting O–ring 7. 8. 9. 10. 11. 12. Hydraulic hose (output) Cap screw (2 used) Lock washer (2 used) O–ring Hydraulic fitting Hose clamp Hydraulic hose Hydraulic hose (suction) O–ring Hydraulic fitting O–ring Gear pump 5.
11. Remove gear pump from transmission. Remove and discard O–ring (item 3). Locate and remove coupler from transmission or gear pump shaft. 2 12.If necessary, remove hydraulic fittings from pump. Remove and discard O–rings from fittings. Installation (Fig. 94) 4 1. If hydraulic fittings were removed from pump, lubricate and install new O–rings to fitting. Tighten fittings to torque values identified in Figure 94 (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
Gear Pump Service 220 in–lb (25 N–m) 7 6 5 4 2 8 3 1 10 9 11 7 12 15 18 14 13 220 in–lb (25 N–m) 16 17 Figure 96 1. 2. 3. 4. 5. 6. Shaft seal Front pressure seal Front back–up ring Drive gear Rear back–up ring Rear pressure seal 7. 8. 9. 10. 11. 12. O–ring Implement relief valve Socket head screw (4 used) Lock washer (4 used) Back plate Body Disassembly (Fig. 96) 13. 14. 15. 16. 17. 18.
6. Remove front plate from the body, then remove back plate. Locate and remove dowel pins from body. D. Bearing areas of bearing blocks should not have excessive wear or scoring. IMPORTANT: Mark the relative positions of the gear teeth and bearing blocks so they can be assembled in the same position. Do not touch the gear surfaces as residue on hands may be corrosive to gear finish. E. Face of bearing blocks that are in contact with gears should be free of wear, roughness or scoring. 7.
9. Install dowel pins in body. IMPORTANT: Do not dislodge O–rings, pressure seals or back–up rings during final assembly. 10.Gently slide the back plate onto the assembly using marker lines for proper location. Firm hand pressure should be sufficient to engage the dowel pins. 11. Place thin sleeve or tape on pump shaft splines to prevent seal damage. 12.Position the pump with back plate downwards. Carefully slide the front plate onto the assembly using marker lines for proper location.
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Manual Lift Control Valve (Serial Number Below 313000000) 8 34 to 42 ft- lb (47 to 56 N- m) 10 7 5 6 5 4 3 23 9 5 2 21 11 20 12 13 14 2 22 1 19 16 15 18 17 RIGHT FRONT Figure 99 1. 2. 3. 4. 5. 6. 7. 8. Lift cylinder O- ring Hydraulic hose Hydraulic hose O- ring Hydraulic tee fitting O- ring Hydraulic hose (to oil cooler) 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 99) Installation (Fig. 99) 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. 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on lift control valve to prevent hydraulic system contamination. 3.
Manual Lift Control Valve Service (Serial Number Below 313000000) 18 to 20 ft- lb (24 to 27 N- m) Loctite #242 10 to 15 ft- lb (14 to 20 N- m) 35 to 40 ft- lb (47 to 54 N- m) 18 to 20 ft- lb (24 to 27 N- m) Loctite #242 35 to 40 ft- lb (47 to 54 N- m) 16 1 21 23 22 2 17 19 18 24 to 36 in- lb (2.7 to 4.1 N- m) Loctite #242 22 23 15 11 10 14 9 7 5 12 8 4 4 6 20 3 13 Figure 101 1. 2. 3. 4. 5. 6. 7. 8.
10.If necessary, remove plug from control valve (Fig. 102). Note: If machine is equipped with optional rear lift kit, a fitting and sleeve will be installed in place of plug. Inspection 1. Inspect spool and spool bore for wear. If wear is excessive, replace lift control valve assembly. 2. Inspect all springs and replace if damaged or broken. 3. Inspect detent plunger, detent ball and poppet for wear. Replace as necessary. 4. Inspect lockout seats for wear or damage. Replace as necessary. 5.
Lift Control Manifold (Serial Number Above 313000000) 11 2 10 13 7 12 17 18 8 9 1 16 4 3 15 14 6 5 19 RIGHT FRONT Figure 103 1. 2. 3. 4. 5. 6. 7. Lift cylinder Lift control manifold Hydraulic hose O- ring Hydraulic fitting O- ring Hydraulic hose 8. 9. 10. 11. 12. 13. O- ring 90o hydraulic fitting O- ring Hydraulic hose O- ring Hydraulic hose 14. 15. 16. 17. 18. 19.
Lift Control Manifold Removal (Fig. 103) Lift Control Manifold Installation (Fig. 103) 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. 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. WARNING 2.
Lift Control Manifold Service (Serial Number Above 313000000) SERIAL NUMBER FROM 313000000 TO 314999999 7 7 6 SERIAL NUMBER ABOVE 315000000 60 in- lb (6.7 N- m) 8 60 in- lb (6.7 N- m) 8 10 5 5 20 ft- lb (27 N- m) 20 ft- lb (27 N- m) 4 5 4 3 3 20 ft- lb (27 N- m) 1 2 25 ft- lb (34 N- m) 1 20 ft- lb (27 N- m) 25 ft- lb (34 N- m) 2 9 Figure 104 1. 2. 3. 4. Lift control manifold Zero leak plug with O- ring Solenoid valve (raise) Solenoid valve (lower) 5. Solenoid coil 6. Coil spacer 7.
B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. Deck Lift Manifold Service (Figure 104) CAUTION Before opening hydraulic system, operate all hydraulic controls to relieve system pressure and avoid injury from pressurized hydraulic oil. See Relieving Hydraulic System Pressure in the General Information section of this chapter. CAUTION Use eye protection such as goggles when using compressed air.
Polar TracTM Hydraulic Control Valve 22 RIGHT FRONT 3 4 2 1 2 5 6 6 7 21 20 2 6 9 19 6 8 8 13 10 12 15 13 14 17 18 13 16 11 Figure 105 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic hose O- ring 45o hydraulic fitting O- ring 90o hydraulic fitting O- ring Hair pin (2 used) 45o hydraulic fitting Hydraulic System 9. 10. 11. 12. 13. 14. 15. Hydraulic hose O- ring Hydraulic hose 90o hydraulic fitting O- ring Flange nut (2 used) Hydraulic fitting Page 4 - 92 16. 17. 18. 19. 20. 21. 22.
4. Remove plugs that were installed in hydraulic hoses during the removal procedure. Attach hydraulic hoses to fittings on control valve using labels placed during removal (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). Removal (Fig. 105) 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.
Polar TracTM Hydraulic Control Valve Service 26 4 to 5 ft- lb (5.4 to 6.8 N- m) 30 to 35 ft- lb (41 to 47 N- m) 25 19 15 17 30 to 35 ft- lb (41 to 47 N- m) 21 to 24 ft- lb (29 to 32 N- m) 5 27 23 12 22 20 24 30 29 7 18 28 26 25 33 4 30 to 35 ft- lb (41 to 47 N- m) 11 21 20 to 25 ft- lb (27 to 33 N- m) 27 32 31 5 6 2 27 1 5 12 10 9 8 14 29 16 30 3 7 13 30 to 35 ft- lb (41 to 47 N- m) Figure 107 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Disassembly (Fig. 107) Assembly (Fig. 107) 1. Plug all ports and clean the outside of the valve thoroughly. IMPORTANT: Do not wipe control valve parts with dry paper towels or rags. Lint may cause damage to the hydraulic system. 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.
Lift Cylinder 15 to 19 ft- lb (20 to 25 N- m) 7 8 4 5 2 9 6 15 to 19 ft- lb (20 to 25 N- m) 4 3 13 1 10 11 12 RIGHT FRONT Figure 108 1. 2. 3. 4. 5. Lift cylinder O- ring Hydraulic fitting O- ring Hydraulic fitting (0.052 orifice) Hydraulic System 6. 7. 8. 9. Hydraulic hose Hydraulic hose Retaining ring Lift control valve Page 4 - 96 10. 11. 12. 13.
Removal (Fig. 108) 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. Remove plugs that were installed in hydraulic hoses during the removal procedure. Correctly connect hydraulic hoses to lift cylinder fittings using labels placed during lift cylinder removal (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 6.
Lift Cylinder Service 1 3 13 4 12 7 2 5 11 10 9 8 6 13 12 11 9 1 10 8 2 3 7 4 5 6 Figure 110 1. 2. 3. 4. 5. Grease fitting Barrel Nut O- ring Head Hydraulic System 6. 7. 8. 9. Collar Shaft Dust seal Rod seal Page 4 - 98 10. 11. 12. 13.
Disassembly (Fig. 110) Assembly (Fig. 110) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft. Plug both ports and clean the outside of the cylinder. 1. Make sure all parts are clean before reassembly. 2. Mount lift cylinder in a vise. Use of a vise with soft jaws is recommended. A. Install piston seal and O- ring to the piston. B. Install dust seal, O- ring, back- up ring and dust seal to the head. 3. Carefully remove collar with a pipe wrench.
Polar TracTM Lift Cylinder RIGHT FRONT 3 11 9 2 1 12 4 8 11 9 2 11 6 10 1 5 7 11 9 12 Figure 111 1. 2. 3. 4. Pivot pin Screw Hydraulic control valve Lift arm Hydraulic System 5. 6. 7. 8. Hydraulic hose Hydraulic cylinder Hydraulic hose O- ring Page 4 - 100 9. 10. 11. 12.
Removal (Fig. 111) Installation (Fig. 111) 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. 1. Park machine on a level surface, lower implement, stop engine, engage parking brake and remove key from the ignition switch. 2. Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination. 3.
Polar TracTM Lift Cylinder Service 3 13 1 7 12 2 5 4 6 11 10 8 9 13 4 6 11 9 2 8 3 7 12 1 250 to 300 ft- lb (339 to 406 N- m) 10 5 Figure 112 1. 2. 3. 4. 5. Cap seal Barrel Lock nut O- ring Head Hydraulic System 6. 7. 8. 9. O- ring Rod Wiper Seal 10. 11. 12. 13.
Disassembly (Fig. 112) Assembly (Fig. 112) 1. Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder rod. Plug both ports and clean the outside of the cylinder. 1. Make sure all lift cylinder parts are clean before assembly. 2. Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel. Use of a vise with soft jaws is recommended. 3. Using a spanner wrench, rotate head clockwise until the edge of the retaining ring appears in the barrel opening.
Oil Cooler Removal (Figs. 113 and 114) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 2. Raise hood and secure it in the raised position. CAUTION 2. Lubricate and place new O- rings in oil cooler ports. Remove plugs from hydraulic hoses. Connect hydraulic hoses to oil cooler using labels placed during removal (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 3.
Chapter 5 Electrical System Table of Contents Standard Control Module . . . . . . . . . . . . . . . . . . . . Standard Control Module Logic Chart . . . . . . . . . PTO Solenoid Valve Coil . . . . . . . . . . . . . . . . . . . . Lift Control Manifold Solenoid Valve Coils (Serial Number Above 313000000) . . . . . . . . . . . . . . . . Fusible Link Harness . . . . . . . . . . . . . . . . . . . . . . . Diode Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Relay . . . . . . . . . . . . . . .
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL VoltOhm- Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Electrical System Figure 4 Groundsmaster 7200/7210 Page 5 - 3 Rev.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Chapter 8 Foldout Diagrams). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. Make sure that all machine interlock switches are functioning correctly for proper troubleshooting and safety.
Starting Problems (continued) Problem Possible Causes Engine cranks, but does not start. The fuel tank is empty. Wiring in the engine crank circuit is loose, corroded or damaged (see Chapter 8 - Foldout Diagrams). Fuel filter is plugged. Engine and/or fuel may be too cold. Engine run solenoid or circuit wiring is faulty. Engine fuel pump or circuit wiring is faulty. The engine glow circuit does not operate properly. Engine or fuel system is malfunctioning (see Chapter 3 - Kubota Diesel Engine).
General Run and Transport Problems Problem Possible Causes Engine stops during operation (operator sitting on seat). Operator not in center of seat (seat switch is not depressed). The engine temperature is excessive (above 240oF / 115oC). The engine high temperature shutdown switch is faulty. Machine is being operated on a slope with a low fuel level. The parking brake was engaged or the parking brake switch is faulty. The seat switch is faulty. Fuse F1, F3 and/or F4 are/is faulty.
Cutting Deck Operating Problems Problem Possible Causes The cutting deck will not run with the PTO switch in the ON (up) position. The operator seat is unoccupied. Oil level in hydraulic tank is low. The seat switch or circuit wiring is faulty. Wiring to the transmission PTO solenoid valve coil is loose, corroded or damaged (see Chapter 8 - Foldout Diagrams). The transmission PTO solenoid valve coil is faulty. The PTO switch is faulty. Engine temperature is excessive (above 220oF / 105oC).
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100oF (16o to 38oC). The ignition key should be off and all accessories turned off.
Check Operation of Interlock Switches 1. Make sure all bystanders are away from the area of operation. Keep hands and feet away from cutting deck (or implement). CAUTION Check the operation of the interlock switches daily for proper operation. Replace any malfunctioning switches before operating the machine. Groundsmaster 7200 and 7210 machines are equipped with a Standard Control Module (SCM) which monitors interlock switch operation.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). NOTE: For engine component testing information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Indicator Lights Charge Indicator Light The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. 3 2 Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
Hour Meter 1. Make sure ignition switch is in the OFF position. Locate the hour meter and disconnect the wire harness electrical connector from the meter. 2. Connect the positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 3. Connect the negative (- ) terminal of the voltage source to the other terminal of the hour meter. 4. The hour meter should move 1/10 of an hour in six minutes. 5. Disconnect the voltage source from the hour meter. 6. Replace the hour meter if necessary.
PTO Switch The PTO switch is located on the control panel (Fig. 10). The PTO switch is pulled up to engage the PTO (cutting deck or implement). The Standard Control Module (SCM) monitors the position of the PTO switch (up or down). Using inputs from the PTO switch and other switches in the interlock system, the SCM controls the energizing of the transmission solenoid valve and thus, the PTO.
Neutral Switches The Groundsmaster 7200 and 7210 use two (2), identical neutral switches. These neutral switches are normally open and close when the traction levers are in the neutral locked position. The neutral switches are located under the front panel beneath the operator seat (Figs. 12 and 13). The Standard Control Module (SCM) monitors the status of the neutral switches.
Seat Switch The Standard Control Module (SCM) monitors the status of the seat switch. If the ignition switch is in the ON position and the seat is occupied, the SCM in seat input LED should be illuminated. Testing 1. Before disconnecting the seat switch for testing, the switch and its circuit wiring should be tested as a SCM input (see Standard Control Module in this section). 2. If the SCM verifies that the seat switch and circuit wiring are functioning correctly, no further switch testing is necessary.
Parking Brake Switch (Serial Number Below 310000000) The parking brake switch on machines with serial number below 310000000 is a normally closed switch that opens when the parking brake is applied. The switch is located under the front panel (Fig. 16 and 17). The Standard Control Module (SCM) monitors the status of the parking brake switch. If the ignition switch is in the ON position and the parking brake is disengaged, the SCM Parking Brake Off input LED should be illuminated.
Parking Brake Switch (Serial Number Above 310000000) When the parking brake is released, a tab on the parking brake shaft is positioned near the target end of the parking brake switch so the switch is closed. The tab on the parking brake shaft is moved away from the switch when the parking brake is applied causing the switch to open. The Standard Control Module (SCM) monitors the status of the parking brake switch.
Standard Control Module Groundsmaster 7200/7210 machines are equipped with a Standard Control Module (SCM) to monitor and control electrical components required for safe operation. The SCM is attached to the control panel cover (Fig. 20). Inputs from the ignition, neutral, parking brake, PTO, seat, high temperature warning switch and high temperature shutdown switch are monitored by the SCM.
Standard Control Module Logic Chart Each line of the following chart identifies the necessary component position (INPUTS) in order for the SCM to energize the appropriate OUTPUTS for machine operation.
PTO Solenoid Valve Coil The hydraulic system on the Groundsmaster 7200 and 7210 uses a solenoid valve coil on the front of the transmission (Fig. 22). When the solenoid valve coil is energized, hydraulic flow is directed to operate the PTO system. The Standard Control Module (SCM) provides current to the solenoid valve coil based on the position of several inputs. The PTO LED on the SCM will be illuminated when the solenoid valve coil is energized.
Lift Control Manifold Solenoid Valve Coils (Serial Number Above 313000000) The hydraulic lift control manifold used on machines with serial number above 313000000 includes two (2) solenoid valves for system control (Fig. 24). When the solenoid coils are energized, valve shift occurs to control hydraulic flow. Electrical testing of the coils can be done with the coil installed on the hydraulic valve.
Fusible Link Harness The Groundsmaster 7200 and 7210 uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the main wire harness. If any of these links should fail, current to the protected circuit will cease. Refer to Electrical Schematics in Chapter 8 - Foldout Diagrams for additional circuit information.
Glow Relay The glow relay used on the Groundsmaster 7200 and 7210 allows electrical current to the engine glow plugs when energized. The glow relay is attached to the frame in the engine compartment. 2 The glow relay is energized by the glow controller when the ignition switch is initially turned to ON/PREHEAT and also when the ignition switch is turned to START. 1 Testing 1. Raise and support hood. 2. Make sure ignition switch is in the OFF position.
High Temperature Warning Switch The high temperature warning switch is attached to the water pump housing on the engine and has a yellow wire attached to it (Fig. 30). This switch is normally open and closes when engine coolant temperature reaches approximately 220oF (105oC). When engine coolant temperature rises to approximately 220oF (105oC), the high temperature warning switch closes.
High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing (Fig. 32). The high temperature shutdown switch is normally open and closes when engine coolant temperature reaches approximately 240oF (115oC). When excessive engine coolant temperature causes the shutdown switch to close, the engine shuts down. There is a blue/white wire attached to the shutdown switch. 5. Replace shutdown switch if specifications are not met.
Dual Temperature Switch (Polar TracTM Machines) On machines equipped with Polar TracTM, the dual temperature switch includes two normally open circuits used to monitor engine coolant temperature. These switch circuits are the high temperature warning circuit and the high temperature shutdown circuit. The dual temperature switch is attached to the engine water pump housing (Fig. 34). When engine coolant temperature rises to approximately 220oF (105oC), the high temperature warning circuit closes.
Deck Lift/Lower Switch (Serial Number Above 313000000) The deck lift/lower switch is used to raise and lower the cutting deck on machines with a serial number above 313000000. The switch is attached to the right side traction lever (Fig. 36). The lift/lower switch is connected to the switch wire harness that runs through the right side lever and connects to the main wire harness below the control panel.
Fuel Pump The fuel pump is attached to the main frame rail behind the front panel under the operator seat (Fig. 38). The Standard Control Module Run output LED will be illuminated when the fuel pump is energized. Operational Test 1 1. Park machine on a level surface, lower cutting deck (or implement), stop engine and engage parking brake. Make sure ignition switch is in the OFF position. Unlatch and raise operator seat to gain access to fuel pump. 2 2.
Fuel Stop Solenoid The fuel stop solenoid used on the Groundsmaster 7200/7210 must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 40). The fuel stop solenoid includes two coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel stop solenoid is initially energized and the pull coil retracts the solenoid plunger.
Glow Controller The glow controller is attached to the inside of the control panel cover (Fig. 42). NOTE: Refer to Chapter 8 - Foldout Diagrams when troubleshooting the glow controller. 5. If any of the conditions in Step 3 are not met or power to terminal 1 exists and any of the other conditions in Step 4 are not met: Controller Operation A. Verify continuity of the circuitry from the battery to the glow relay and glow plugs (see Chapter 8 - Foldout Diagrams). 1.
Service and Repairs NOTE: For engine electrical component repair information, see the Kubota Workshop Manual, Diesel Engine, 05 Series. PTO Solenoid Valve Coil The PTO solenoid valve coil on the transmission (Fig. 44) can be replaced without opening the hydraulic system. Removal 1. Park machine on a level surface, lower cutting deck (or implement), engage parking brake, stop engine and remove key from the ignition switch. 2.
Battery Storage If the machine will be stored for more than 30 days: 1. Make sure ignition switch is in the OFF position. Remove the battery and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 3. Leave cables disconnected if the battery is stored on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To help prevent the battery from freezing during storage, make sure it is fully charged (see Battery Service).
Battery Service IMPORTANT: Before cleaning the battery, tape or block vent holes to the filler caps and make sure the caps are on tightly. C. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or overfilling. Also, check battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse it with clean water.
B. Temperature correct each cell reading. For each 10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the specific gravity reading. For each 10oF (5.5oC) below 80oF (26.7oC) subtract 0.004 from the specific gravity reading. Example: Cell Temperature 100oF Cell Gravity 1.245 100oF minus 80oF equals 20oF (37.7oC minus 26.7oC equals 11.0oC) 20oF multiply by 0.004/10oF equals 0.008 (11oC multiply by 0.004/5.5oC equals 0.008) ADD (conversion above) 0.008 Correction to 80oF (26.7oC) 1.253 F.
7. Connect negative (- ) cable connector to the negative (- ) battery post. Secure cable cap screw and lock nut using two wrenches. 8. After connections are made, apply battery terminal protector (Toro Part No. 107- 0392) or a light coat of grease on all battery posts and cable connectors to reduce corrosion. Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.3 hrs @ 4 amps 10.5 hrs @ 4 amps 15.
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Chapter 6 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Polar TracTM Wheels . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parking Brakes . . . . . . . . . . . . . .
Specifications Item Description Rear tire pressure 15 PSI (103 kPa) Castor wheel (front) tire pressure 25 PSI (172 kPa) Tire pressure (machines with Polar TracTM) 30 PSI (103 kPa) Rear wheel lug nut torque 75 to 85 ft–lb (102 to 115 N–m) Wheel lug nut torque (machines with Polar TracTM) 65 to 85 ft–lb (88 to 115 N–m) Rear wheel hub lock nut torque Chassis 300 to 400 ft–lb (407 to 502 N–m) Page 6 – 2 Groundsmaster 7200/7210
General Information Operator’s Manual Chassis The Operator’s Manual provides information regarding the operation, general maintenance procedures and maintenance intervals for your Groundsmaster machine. Refer to that publication for additional information when servicing the machine.
Service and Repairs Rear Wheels 14 13 11 12 9 11 10 8 9 6 4 3 15 1 7 5 RIGHT 75 to 85 ft–lb (102 to 115 N–m) FRONT 2 Figure 1 1. 2. 3. 4. 5. Lock nut Lug nut (5 used per wheel) Wheel assembly Wheel hub Wheel stud (5 used per wheel) Chassis 6. 7. 8. 9. 10. Socket head screw (4 used) Wheel motor (LH shown) Woodruff key O–ring Hydraulic fitting Page 6 – 4 11. 12. 13. 14. 15.
Removal (Fig. 1) Installation (Fig. 1) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine and remove key from the ignition switch. 1. Secure wheel to machine with five (5) lug nuts. NOTE: If machine is equipped with Polar TracTM Kit, see Polar TracTM Wheels in this section for information regarding wheel removal. 2. Lower wheel to ground. Torque wheel lug nuts in a crossing pattern from 75 to 85 ft–lb (102 to 115 N–m). 2.
Polar TracTM Wheels 1 8 12 4 13 3 5 11 14 75 ft–lb (102 N–m) 10 15 2 9 16 17 7 6 5 6 65 to 85 ft–lb (88 to 115 N–m) RIGHT FRONT Figure 2 1. 2. 3. 4. 5. 6. Front frame Bogie assembly Lock nut Rear wheel hub (LH shown) Wheel assembly (6 used) Lug nut (5 used per wheel) Chassis 7. 8. 9. 10. 11. 12. Drive track Woodruff key Wheel stud (5 used per hub) Rear wheel motor (LH shown) Parking brake (LH shown) Screw (4 used per motor) Page 6 – 6 13. 14. 15. 16. 17.
Removal (Fig. 2) Installation (Fig. 2) NOTE: Refer to the Polar TracTM Operator’s Manual for additional information regarding drive track and wheel removal. 1. If the track was removed from the machine, position track to wheel location. Make sure that direction arrow on track is properly orientated. 1. Park machine on a level surface, lower implement, stop engine and remove key from the ignition switch.
Parking Brakes 18 14 17 13 11 12 9 11 10 8 19 300 to 400 ft–lb (407 to 502 N–m) 9 6 Loctite #271 16 3 20 15 21 1 7 22 5 RIGHT Loctite #271 35 to 40 ft–lb (48 to 54 N–m) 4 FRONT 75 to 85 ft–lb (102 to 115 N–m) 2 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Lock nut Lug nut (5 used per wheel) Wheel assembly Wheel hub Wheel stud (5 used per wheel) Socket head screw (4 used) Wheel motor (LH shown) Woodruff key 9. 10. 11. 12. 13. 14. 15.
IMPORTANT: If wheel hub removal is necessary, do not hit wheel hub or hub puller with a hammer during removal. Hammering may cause damage to the hydraulic wheel motor or wheel hub. 3 35 to 40 ft–lb (48 to 54 N–m) 1 8. If necessary, use wheel hub puller to loosen wheel hub from the wheel motor shaft. Remove loosened lock nut and wheel hub from wheel motor. Remove woodruff key from the shaft. 2 Installation (Fig. 4) 1. If wheel hub was removed: 4 A.
Parking Brake Service 18 to 23 ft–lb (24 to 31 N–m) 14 15 13 12 11 10 30 to 40 ft–lb (41 to 54 N–m) 14 9 8 2 13 7 16 11 3 12 4 18 17 19 1 2 5 6 3 30 to 40 ft–lb (41 to 54 N–m) 5 4 Figure 8 1. 2. 3. 4. 5. 6. 7. Lever Assembly sleeve (2 used) Hardened washer (2 used) Hex bolt (2 used) Mounting lock nut (2 used) Hex nut (2 used) Stationary actuator 8. 9. 10. 11. 12. 13. Sleeve (2 used) Steel ball (3 used) Spring pin Compression spring (2 used) Mount sleeve (2 used) Hex nut (2 used) 14.
Disassembly (Fig. 8) Assembly (Fig. 8) 1. Loosen and remove hex bolts (item 4), socket head screws (item 15) and hex nuts (items 5 and 6). 1. Position stationary stator on level work surface. 2. Slide inner and outer stators from sleeves and stationary actuator. 3. Secure brake assembly with hex bolts (item 4), socket head screws (item 15) and hex nuts (items 5 and 6). Torque fasteners to values identified in Figure 8. Chassis 3. Inspect parking brake components.
Parking Brake Assembly 2 RIGHT 3 7 FRONT 6 4 5 9 19 8 20 9 22 1 17 2 23 10 24 17 11 12 13 14 15 18 16 21 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Front brake rod (2 used) Hex nut (6 used) Flat washer (6 used) Compression spring (2 used) Swivel (2 used) Rear brake rod (2 used) Retaining ring (2 used) Retaining ring (2 used) Chassis 9. 10. 11. 12. 13. 14. 15. 16.
Disassembly (Fig. 9) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine and remove key from the ignition switch. 2. Remove front panel under the operator seat (Fig. 10). 3. If removal of brake handle (item 12) is necessary: A. On both sides of machine, unlatch spring pin from brake linkage yoke. Remove spring pin from yoke and brake handle brackets. B. Support brake handle to prevent it from shifting or falling. Figure 10 1. Front panel C.
Front Castor Wheels 1 RIGHT See text for tightening procedure 2 6 FRONT 3 5 4 12 4 5 10 7 8 9 11 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. Grease cap Lock nut Belleville washer Bearing cone Disassembly (Fig. 13) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. WARNING Lock nut Cap screw Castor wheel assembly Plug 3. Remove cap screw and lock nut that secure castor wheel to castor fork.
7. Pry seal from carrier frame. Discard seal. Remove lower bearing cone from frame. 8. Inspect bearing cups in carrier frame for wear or damage. If bearing cups are damaged, remove bearing cups from frame and replace. 9. If necessary, remove spacers, seals and bearings from castor wheel using Figure 15 as a guide. Inspect and replace all wheel components that show signs of wear or damage. NOTE: Periodic greasing of castor fork bearing area is not necessary.
Polar TracTM Wheel Hub Service 11 10 1 9 7 8 65 to 85 ft–lb (88 to 115 N–m) 2 6 RIGHT 4 3 FRONT 5 Figure 16 1. 2. 3. 4. Frame Bogie assembly Flange nut Shoulder screw Chassis 5. 6. 7. 8. Wheel assembly Lug nut (5 used per wheel) Drive track Pivot pin Page 6 – 16 9. Pivot (LH shown) 10. Pivot pin 11.
Disassembly (Figs. 16 and 17) NOTE: Refer to the Polar TracTM Operator’s Manual for additional information regarding drive track and wheel removal. 1. Park machine on a level surface, lower implement, stop engine, engage parking brake and remove key from the ignition switch. 2. Remove wheels as needed to gain access to wheel hub(s) (see Polar TracTM Wheels Removal in this section). 3. Make sure that machine is supported with jack stands. 4. Remove the dust cap from the wheel hub. 5.
PTO Drive Shaft 175 to 225 in–lb (20 to 25 N–m) RIGHT FRONT 4 5 175 to 225 in–lb (20 to 25 N–m) 1 3 4 2 2 3 6 Figure 18 1. 2. Transmission assembly Cap screw (4 used) 3. 4. Roll pin (2 used) Lock nut (4 used) 5. 6. PTO drive shaft Cutting deck gearbox WARNING Do not start the engine and engage the PTO switch when the PTO drive shaft is disconnected from the cutting deck (or implement).
Removal (Fig. 18) 1 NOTE: PTO drive shaft removal is easier if machine is positioned on a hoist. 2 3 4 5 1. Park machine on a level surface, lower cutting deck (or implement) to lowest setting, stop engine, engage parking brake and remove key from the ignition switch. 6 2 2. To prevent unintentional engagement of the PTO clutch, remove fuse F1 (15 amp) from fuse block. 7 3. Disconnect end yoke of PTO drive shaft from PTO shaft on transmission: A. Remove roll pin from end yoke and PTO shaft. B.
PTO Drive Shaft Cross and Bearing Service 1. Remove PTO drive shaft from vehicle (see PTO Drive Shaft Removal in this section). D. Hold cross in alignment and press bearing in until it hits the yoke. IMPORTANT: When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is recommended. E. Carefully place second bearing into yoke bore and onto cross shaft. Press bearing into yoke. 2. Lightly clamp yoke in vise.
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Cutting Deck Lift Arms 2 18 5 3 6 19 7 11 50 ft–lb (67 N–m) 8 1 9 17 23 22 21 14 26 16 24 13 23 10 25 20 23 15 20 RIGHT 12 50 ft–lb (67 N–m) 31 22 FRONT 4 27 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. Roll pin Flange head screw RH rear lift arm Lock nut (2 used) Cap screw Spacer Flange nut (2 used) Height of cut pin LH rear lift arm 10. 11. 12. 13. 14. 15. 16. 17. 18.
4. Remove lift arm components as necessary using Figures 21 and 23 as guides. 4 1 2 NOTE: If pull link assembly (item 27) removal is necessary, refer to Cutting Deck Pull Links in the Service and Repairs section of Chapter 7 – Cutting Deck. 3 5 Assembly (Fig. 21) 1. Check flange bushing(s) in carrier frame for wear or damage (Fig. 24). Replace flange bushing(s) if necessary. 2. Install lift arm components as necessary using Figures 21 and 23 as guides. A.
Operator Seat 12 11 16 9 16 11 2 20 4 24 12 3 14 8 19 7 5 17 7 5 13 19 20 20 10 RIGHT 18 23 1 19 20 20 FRONT 10 22 6 21 15 Figure 27 1. 2. 3. 4. 5. 6. 7. 8. E–ring (2 used) Manual housing Housing cap R–clamp (2 used) Latch angle (2 used) Seat stop lever Latch lever (2 used) Seat plate Chassis 9. 10. 11. 12. 13. 14. 15. 16. Operator seat Flat washer (2 used) Lock washer (2 used) Cap screw (2 used) Latch Grommet Cap screw Seat belt Page 6 – 24 17. 18. 19. 20. 21. 22. 23. 24.
Removal (Fig. 27) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 2. Unlatch and raise operator seat. 3 WARNING 1 If seat switch service is necessary, remove seat from seat plate to access switch. To prevent injury, DO NOT attempt to reach switch through openings in seat plate. 3. Disconnect machine wire harness electrical connector from the seat switch harness connector (Fig. 28). 2 Figure 28 1.
Operator Seat Service 4 3 5 6 3 7 2 23 22 8 1 9 24 10 11 12 27 21 20 26 19 14 13 18 15 25 17 16 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. Bottom cushion Back cushion Armrest RH armrest mount assembly Back panel LH armrest mount assembly Seat frame assembly Lumbar support knob Label Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18. Shock absorber assembly Suspension spring (2 used) Suspension base Spring saddle Bearing shaft Hex nut Cable (2 used) Weight adjust bar Label Page 6 – 26 19. 20. 21.
Removal (Fig. 29) 5. Position seat frame to suspension base. 1. Remove operator seat from machine (see Operator Seat Removal in this section). 6. Align bearing blocks on frame with receivers on suspension base and guide frame into place. Insert two (2) bearing shafts and split nylon bushings to suspension base and frame. Secure bearing shafts with two (2) roll pins. 2. Remove armrest assemblies and then back panel from back of seat. 3. Carefully peel label from back rest knob (Fig. 30).
Hood 10 18 7 RIGHT 18 FRONT 4 8 2 9 19 6 2 1 16 19 15 19 11 13 21 11 19 20 14 3 5 2 35 to 45 in–lb (4.0 to 5.1 N–m) 10 17 20 12 Figure 31 1. 2. 3. 4. 5. 6. 7. Hood Flat washer (4 used) Rubber latch (2 used) Grommet Washer head screw (2 used) Hair pin cotter Intake screen Chassis 8. 9. 10. 11. 12. 13. 14. Hood prop rod Cotter pin Screw (21 used) Lock nut (21 used) Cap screw (3 used) Latch catch (2 used) Seal angle Page 6 – 28 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 31) Installation (Fig. 31) 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. 1. Install all removed hood components using Figure 31 as a guide. If intake screen was removed from hood, make sure that hood support, seal angle and prop rod support are attached to hood before installing screen. Secure screen to hood with screws and lock nuts.
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Chapter 7 Cutting Deck Table of Contents Cutting Deck GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Blade Stopping Time . . . . . . . . . . . . . . . . . . . . . . . .
General Information Specifications Several cutting decks are available for the Groundsmaster 7200 and Groundsmaster 7210. Refer to the Operator’s Manual for specifications and optional accessories for the cutting deck used on your Groundsmaster. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine.
Factors That Can Affect Cutting Performance There are a number of factors that can contribute to unsatisfactory quality of cut, some of which may be turf conditions. Turf conditions such as excessive thatch, “sponginess” or attempting to cut off too much grass height may not always be overcome by adjusting the machine. It is important to remember that the lower the height–of–cut, the more critical these factors are.
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Service and Repairs CAUTION WARNING Never work on the cutting deck with the engine running. Always stop engine and remove key from ignition switch first. Do not start the engine and engage the PTO switch when the PTO drive shaft is disconnected from the cutting deck (or implement). If the engine is started and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result.
Cutting Deck Removal and Installation Removal 1. Park machine on a level surface with the cutting deck in the fully raised position. Stop engine, engage parking brake and remove key from the ignition switch. 4 2 NOTE: When the cutting deck is in the raised position, pull link torsion spring tension is reduced making it much easier to disconnect pull links from machine. 2. Disconnect pull link from each side of machine (Fig. 1): 1 3 CAUTION Figure 1 Be careful when disconnecting the pull links.
6. Disconnect end yoke of PTO drive shaft from cutting deck gearbox shaft (see PTO Drive Shaft Removal in the Service and Repairs section of Chapter 6 – Chassis). Position and support drive shaft end away from deck gearbox. 7. Remove four (4) ring pins and clevis pins that secure deck lift chains to adjustment clevises on cutting deck (Fig. 3). 8. Slide cutting deck away from machine. 4. Start engine and fully raise cutting deck. Stop engine and remove key from the ignition switch.
Idler Assembly 9 5 16 6 17 7 8 19 14 10 22 21 12 13 18 15 2 9 11 4 3 15 5 6 7 8 16 19 20 1 RIGHT FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. 8. Cutting deck Flat washer LH spindle assembly Drive belt Snap ring Flange bushing Torsion spring Washer Cutting Deck 9. 10. 11. 12. 13. 14. 15. Grease fitting Drive belt Idler pulley Idler pulley Center spindle assembly RH spindle assembly Socket head screw Page 7 – 8 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 4) 4. Install drive belt to pulleys. 1. Park machine on a level surface with cutting deck (or implement) lowered. Stop engine, engage parking brake and remove key from the ignition switch. 5. If idler arm on right side of cutting deck was removed, check that clearance between idler arm and stop bolt is from 0.100” to 0.160” (2.5 to 4.0 mm) (Fig. 5). If necessary, adjust jam nut location on stop bolt to allow proper clearance. 2. Lift the footrest, exposing the top of the cutting deck.
Blade Spindle 1 2 3 5 4 9 6 7 8 RIGHT FRONT Figure 6 1. 2. 3. RH spindle assembly Drive belt Idler pulley 4. 5. 6. 7. 8. 9. Center spindle assembly Idler pulley Drive belt LH spindle assembly Cutting deck Drive pulley Removal (Fig. 6) 1. Park machine on a level surface with cutting deck raised. Stop engine, engage parking brake and remove key from the ignition switch. Support the cutting deck so it cannot fall accidentally. 1 2. Lift the footrest, exposing the top of the cutting deck.
5. Remove cutting blade, anti–scalp cup and blade bolt from spindle to be serviced (Fig. 8). 1 6. Remove eight (8) flange head screws and flange nuts that secure spindle assembly to deck. Remove spindle assembly from deck. 2 3 Installation (Fig. 6) 1. Position spindle on cutting deck noting orientation of grease fitting (Fig. 9). Secure spindle assembly to deck with eight (8) flange head screws and flange nuts. 4 88 to 108 ft–lb (119 to 146 N–m) 2.
Blade Spindle Service Disassembly (Fig. 10) 1 2 1. Remove lock nut from top of spindle shaft. NOTE: Early production spindle assemblies included a v–ring seal (item 4) which has been found to be unnecessary. Discard v–ring seal if found in spindle assembly. 3 130 to 150 ft–lb (176 to 203 N–m) 4 2. Remove special hardened washer and pulley from shaft. If spindle is equipped with a v–ring seal, remove and discard v–ring seal. 5 6 3.
3. Using an arbor press, push the bearing cups into the top and bottom of the spindle housing. The top bearing cup must contact the outer spacer previously installed, and the bottom bearing cup must contact the snap ring. Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it (Fig 12). PRESS 4 4. Pack the bearing cones with grease. Apply a film of grease on lips of oil seals and O–ring. 5.
Gearbox 1 2 6 9 4 3 11 12 14 10 7 13 8 17 16 15 7 5 RIGHT FRONT 18 Figure 15 1. 2. 3. 4. 5. 6. Flange nut (3 used) Washer (3 used) LH gearbox bracket Mount (3 used) Carriage screw (3 used) Gearbox 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Grommet (5 used) Taperlock bushing RH gearbox bracket Cap screw (4 used) Lock washer (4 used) Woodruff key Deck drive pulley RH deck cover LH deck cover Knob (2 used) Set screw (2 used) Retainer nut (2 used) Removal (Fig. 15) 1.
5. Disconnect PTO drive shaft from gearbox (see PTO Drive Shaft Removal). 8. Connect PTO drive shaft to gearbox (see PTO Drive Shaft Installation). 6. Remove four (4) cap screws (item 10) and lock washers (item 11) that secure gearbox assembly to gearbox brackets. 9. Install drive belt and deck covers to cutting deck. 7. Remove fasteners that secure left side gearbox bracket (item 3) to deck mounting plate. Remove bracket from deck. 10.Torque plug in gearbox to 175 in–lb (19.8 N–m).
Cutting Deck Pull Links 1 2 4 5 6 7 8 9 18 10 16 12 15 6 14 17 13 3 21 11 18 20 8 RIGHT FRONT 19 Figure 18 1. 2. 3. 4. 5. 6. 7. LH lift arm Retainer pin Clevis pin Shoulder screw LH lift arm Flange bushing Grease fitting Cutting Deck 8. 9. 10. 11. 12. 13. 14. Lock nut Cap screw Pivot pin Ring pin Grease fitting Spacer Torsion spring Page 7 – 16 15. 16. 17. 18. 19. 20. 21.
Disassembly (Figs. 18 and 19) 2. Position pull link to cutting deck. 1. Remove cutting deck from machine (see Cutting Deck Removal and Installation in this section). 3. Slide pivot pin (item 10) through cutting deck, pull link and spacer. 4. Insert cap screw (item 17) through pivot pin and holes in deck. Make sure that torsion spring end is below screw. Secure cap screw with lock nut. CAUTION Be careful when removing the pull links from the cutting deck.
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Chapter 8 Foldout Diagrams Table of Contents Foldout Diagrams ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 HYDRAULIC SCHEMATICS Serial Number Below 313000000 . . . . . . . . . . . . . 3 Serial Number Below 313000000 (With Rear Attach Lift Kit Installed) . . . . . . . . . . . . . . . . . . . . . 4 Serial Number Below 313000000 (With Polar TracTM Installed) . . . . . . . . . . . . . . . . . . . . . 5 Serial Number Below 313000000 (With Polar TracTM and Rear Attach Lift Kit Installed) . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on some of the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Reelmaster machines include a line with an alternate color.
LIFT CYLINDER PORT 4000 PSI (276 bar) A FORWARD RH WHEEL MOTOR 300 to 310 cc LSHT REAR PORT BYPASS VALVE FRONT PORT PORT B FLUSHING VALVE PORT C FORWARD LH WHEEL MOTOR 300 to 310 cc LSHT FRONT PORT BYPASS VALVE REAR PORT PORT D FLUSHING VALVE 4000 PSI (276 bar) Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 All solenoids are shown as de-- energized.
LIFT CYLINDER PORT A 4000 PSI (276 bar) FORWARD RH WHEEL MOTOR 300 to 310 cc LSHT REAR PORT BYPASS VALVE FRONT PORT PORT B FLUSHING VALVE PORT C SV6 FORWARD LH WHEEL MOTOR 300 to 310 cc LSHT FRONT PORT BYPASS SV6 VALVE REAR PORT PORT D FLUSHING VALVE Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Rear Attach Lift Kit Installed) All solenoids are shown as de-- energized.
PORT 4000 PSI (276 bar) A RH WHEEL MOTOR 300 to 310 cc LSHT REAR PORT FORWARD BYPASS VALVE FRONT PORT PORT B FLUSHING VALVE PORT C FORWARD LH WHEEL MOTOR 300 to 310 cc LSHT FRONT PORT BYPASS VALVE REAR PORT PORT D FLUSHING VALVE 4000 PSI (276 bar) Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Polar Trac TM Installed) All solenoids are shown as de-- energized.
PORT 4000 PSI (276 bar) A FORWARD RH WHEEL MOTOR 300 to 310 cc LSHT REAR PORT BYPASS VALVE FRONT PORT PORT B FLUSHING VALVE PORT SV6 C FORWARD LH WHEEL MOTOR 300 to 310 cc LSHT FRONT PORT SV6 BYPASS VALVE REAR PORT PORT D FLUSHING VALVE 4000 PSI (276 bar) Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Polar Trac TM and Rear Attach Lift Kit Installed) All solenoids are shown as de-- energized.
CUSTOMER SUPPLIED ATTACHMENT POLAR TRAC KIT (OPTIONAL) REPLACES STANDARD DECK LIFT VALVE IN WINTER CONFIGURATION WINTER KIT LIFT CYLINDER (OPT) 2.250” BORE 2.160” STROKE 1.250” ROD P A REAR ATTACHMENT LIFT CYLINDER (OPT) DECK CYLINDER B REAR HYDRAULIC POWERED ATTACHMENT (OPT) 2.00” BORE 1.75” STROKE 0.75” ROD 1.50” BORE 3.68” STROKE 0.75” ROD .052 D BR C M1 DECK LIFT MANIFOLD 0.028 in 2 PB A B M2 0.028 in 3 CD T 1 4 SV2 SV3 CHARGE PRESSURE TEST PORT SV6 PORT 2 15.
CUSTOMER SUPPLIED ATTACHMENT OPTIONAL 100” DECK A WING CYLINDER BORE: 1.75” STROKE: 2.25” ROD: 0.75” EXTEND TO LOWER OPTIONAL WINTER KIT LIFT CYLINDER BORE: 2.25” STROKE: 2.16” ROD: 1.25” EXTEND TO LIFT P WING CYLINDER BORE: 1.75” STROKE: 2.25” ROD: 0.75” EXTEND TO LOWER A B DECK CYLINDER BORE: 1.50” STROKE: 3.68” ROD: 0.75” EXTEND TO LIFT REAR ATTACHMENT LIFT CYLINDER (OPT) BORE: 2.00” STROKE: 1.75” ROD: 0.
FOR OPTIONAL PTO FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Electrical Schematic Serial Number Below 313000000 FOR ACCESSORY POWER KIT All relays and solenoids are shown as de-- energized. All ground wires are black.
Groundsmaster 7200/7210 Electrical Schematic Serial Number Below 313000000 (With Optional Electrical Kits Shown) All relays and solenoids are shown as de-- energized. All ground wires are black.
Groundsmaster 7200/7210 Electrical Schematic Serial Numbers 313000000 to 403440000 (With Optional Electrical Kits Shown) All solenoids are shown as de-- energized.
All solenoids are shown as de--energized.
(ENERGIZED) PARKING BRAKE SWITCH (BRAKE OFF) SEAT SWITCH (OCCUPIED) LH NEUTRAL SWITCH (IN NEUTRAL LOCK) RH NEUTRAL SWITCH (IN NEUTRAL LOCK) FOR OPTIONAL PTO FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Glow Circuits Serial Number Below 313000000 Shown Power Current Control Current FOR ACCESSORY POWER KIT Indication Current Page 8 -- 13
(ENERGIZED) PARKING BRAKE SWITCH (BRAKE OFF) SEAT SWITCH (OCCUPIED) LH NEUTRAL SWITCH (IN NEUTRAL LOCK) RH NEUTRAL SWITCH (IN NEUTRAL LOCK) (PTO OFF) FOR OPTIONAL PTO FOR ACCESSORY POWER KIT FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Crank Circuits Serial Number Below 313000000 Shown Power Current Control Current Indication Current Page 8 -- 14
(NOT ENERGIZED) PARKING BRAKE SWITCH (BRAKE OFF) SEAT SWITCH (OCCUPIED) LH NEUTRAL SWITCH (NOT IN NEUTRAL) RH NEUTRAL SWITCH (NOT IN NEUTRAL) (PTO OFF) FOR OPTIONAL PTO FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Run Circuits Serial Number Below 313000000 Shown Power Current FOR ACCESSORY POWER KIT Control Current Indication Current Page 8 -- 15
(NOT ENERGIZED) PARKING BRAKE SWITCH (BRAKE OFF) SEAT SWITCH (OCCUPIED) LH NEUTRAL SWITCH (NOT IN NEUTRAL) RH NEUTRAL SWITCH (NOT IN NEUTRAL) (PTO ON) FOR OPTIONAL PTO FOR ACCESSORY POWER KIT FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Run Circuits (PTO Engaged) Serial Number Below 313000000 Shown Power Current Control Current Indication Current Page 8 -- 16
(SERIAL NUMBERS ABOVE 28000000) (SERIAL NUMBERS BELOW 28000000) Groundsmaster 7200/7210 Wire Harness Drawing (Serial Number Below 310000000) Page 8 -- 17
BROWN YELLOW BLACK BLACK BLACK VIOLET GRAY GREEN ORANGE WHITE/BLACK BLUE BLUE/WHITE BLACK TAN YELLOW RED/BLACK PINK BLACK BROWN BLACK TAN BROWN VIOLET BLACK TAN BROWN VIOLET GREEN BLACK BLACK BLACK FUSIBLE LINK WHITE RED/BLACK PINK BLACK RED/BLACK BLACK PINK PINK PINK WHITE PINK ORANGE TAN YELLOW YELLOW PINK RED RED BLACK PINK ORANGE VIOLET PINK ORANGE BLACK/WHITE PINK PINK PINK PINK RED RED RED Groundsmaster 7200/7210 Wire Harness Diagram (Serial Number Below
Groundsmaster 7200/7210 Wire Harness Drawing (Serial Number From 310000001 to 312999999) Page 8 -- 19
FUSIBLE LINK Groundsmaster 7200/7210 Wire Harness Diagram (Serial Number From 310000001 to 312999999) Page 8 -- 20
Groundsmaster 7200/7210 Wire Harness Drawing (Serial Numbers 313000000 to 403440000) Page 8 -- 21
FUSIBLE LINK Groundsmaster 7200/7210 Wire Harness Diagram (Serial Numbers 313000000 to 403440000) Page 8 -- 22
122--1414 Rev A Groundsmaster 7200/7210 Wire Harness Drawing (Serial numbers above 403440001) CV Page 8 -- 23
122--1414 Rev A Groundsmaster 7200/7210 Wire Harness Drawing (Serial numbers above 403440001) Page 8 -- 24
