Form No. 16222SL Rev F Groundsmaster 7210 (Models with Yanmar Engine) © 2021—The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420 Original Instructions (EN) Contact us at www.Toro.com.
Revision History Revision Date A 2016 Initial issue. B 2017 Added Foldout Drawings. C 03/2018 Updated Engine chapter. Added Revision History and published in new format. D 03/2019 Updated Chassis chapter. E 06/2020 Updated Foldout Drawings. F 06/2021 Updated Engine chapter.
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.
NOTES: NOTES: Page 4 Groundsmaster 7210 16222SL Rev F
Preface The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of Groundsmaster 7210 machines that are powered by a Yanmar diesel engine. Refer to the Operator’s Manuals for operating, maintenance, and adjustment instructions. Space is provided in Chapter 2 (page 2–1) of this book to insert the Operator’s Manuals and Parts Catalog for your machine.
g034400 Figure 1 Service Procedure Icons The following icons appear throughout this Service Manual to bring attention to specific important details of a service procedure. Critical Process This icon is used to highlight: • installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
Table of Contents Preface ................................................................................................................ 5 Chapter 1: Safety ............................................................................................ 1–1 Safety Instructions ....................................................................................... 1–2 Jacking Instructions ..................................................................................... 1–6 Safety and Instructional Decals .
Wire Harness Drawing - Platform (2 of 2) (For machine serial number above 403430001)......................................................................................A–13 Wire Harness Drawing - Engine (1 of 2).......................................................A–14 Wire Harness Drawing - Engine (2 of 2).......................................................A–15 Wire Harness Drawing - Cab Power............................................................A–16 Wire Harness Drawing - Cab Headliner........
Chapter 1 Safety Table of Contents Safety Instructions ................................................................................................................................ 1–2 Supervisor’s Responsibilities ............................................................................................................. 1–2 Before Operating the Machine ........................................................................................................... 1–2 While Operating the Machine ..........
Safety Instructions The Groundsmaster 7210 machine meets or exceeds safety standard specifications as identified in the Operator’s Manuals. Although the hazard control and accident prevention are dependent partially upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Before Operating the Machine (continued) – If you spill fuel, do not attempt to start the engine but move the machine away from the spill. Avoid creating any source of ignition until fuel vapors have dissipated. Wipe up any spilled fuel. While Operating the Machine • Sit on the seat when starting and operating the machine. • Anytime you park the machine (short or long term), lower the cutting deck (or implement) to the ground.
Before stopping the machine 1. Ensure that the 2 drive handles are in the NEUTRAL LOCK position. 2. Lower and disengage the cutting deck (or implement) and wait for all moving parts to stop. 3. Set the parking brake. 4. Shut off the engine and remove the key from the key switch.
Maintenance and Service (continued) • If welding on the machine is necessary, disconnect all the battery cables to prevent damage to the electrical system. Disconnect the negative battery cable and then the positive cable. • Disconnect and remove the engine ECU from the machine. • At the time of manufacture, the machine conformed to the safety standards for riding mowers. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories.
Jacking Instructions CAUTION Failing to properly support the machine with appropriate jack stands can cause the machine to move or fall and can result in personal injury. When changing the attachments, tires, or performing other services, do the following steps: • Use correct blocks, hoists, and jacks to raise and support the machine. • Park the machine on a solid level surface, such as a concrete floor.
Raising the Rear of the Machine IMPORTANT Do not support the machine on the wheel hubs (brake rotors). g033385 Figure 3 1. Protection plate 2. Rear jacking point 3. Rear wheel 1. Block the 2 front castor wheels with chocks to prevent the machine from moving. 2. Position the jack securely under the flat surface of the protection plate (Figure 3). 3. Lift the rear wheels off the ground. 4. Use appropriate jack stands under the frame to support the rear of the machine.
Safety and Instructional Decals Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor.
Chapter 2 Specifications and Maintenance Table of Contents Specifications ....................................................................................................................................... 2–2 Decimal and Millimeter Equivalents ................................................................................................... 2–2 U.S. to Metric Conversions ................................................................................................................
Specifications Insert a copy of the Operator’s Manuals and Parts Catalogs for your machine at the end of this chapter. Additionally, if any optional equipment or accessories are installed to your machine, insert the Installation Instructions, Operator’s Manuals, and Parts Catalogs for those options at the end of this chapter. The maintenance procedures and recommended service intervals for your machine are covered in the Operator’s Manual.
U.S. to Metric Conversions To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.914 Feet Meters 0.305 Feet Centimeters 30.48 Inches Meters 0.025 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.093 Square Inches Square Centimeters 6.452 Acre Hectare 0.405 Cubic Yards Cubic Meters 0.765 Cubic Feet Cubic Meters 0.028 Cubic Inches Cubic Centimeters 16.39 Tons (Short) Metric Tons 0.
Torque Specifications The 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 the fasteners will apply to all the fasteners which do not have a specific requirement identified in this Service Manual.
Calculating the Torque Values When Using a Drive-Adapter Wrench g034401 Figure 6 Using a drive-adapter wrench (e.g., crowfoot wrench) in any position other than 90º and 270º to the frame of the torque wrench will affect the torque value measured by the torque wrench because of the effective length (lever) of the torque wrench changes.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC # 10 - 32 UNF Grade 1, 5 and 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in-lb in-lb N∙cm 10 ± 2 13 ± 2 147 ± 23 13 ± 2 25 ± 5 282 ± 56 18 ± 2 30 ± 5 339 ± 56 SAE Grade 5 Bolts, Screws, Studs, and Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Thread Size 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 Recommended Torque 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 Thread Cutting Screws (Zinc Plated Steel) Type 1, Type 23 or Type F Thread Size Baseline Torque** No. 6 - 32 UNC 20 ± 5 in-lb No. 8 - 32 UNC 30 ± 5 in-lb No.
Shop Supplies The procedures found in this Service Manual may recommend the use of commonly used shop supplies (lubricants, sealants, and adhesives). A symbol denoting the use of a shop supply may appear in figures that support a procedure. Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies.
Anti-seize lubricant Used to prevent corrosion, galling, and seizure between metal parts. Most often applied to shafts and bores during assembly. Unless otherwise specified, high viscosity regular grade lithium-graphite based anti-seize lubricant should be used. Grease Can be used to pre-fill (pack) bearings, boots, and seals before assembly, ease installation of components during assembly, or fill cavities between moving parts through grease fittings after assembly.
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
150 LPM (40 GPM) Hydraulic Tester Toro Part No. AT40002 Use this tester to test the hydraulic circuits and components for flow and pressure capacities. The tester flow measurement maximum is 151 LPM (40 GPM). This tester includes the following: Load Valve – Turn the valve to restrict the flow to create a simulated working load in the circuit. Pressure Gauge – A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure.
Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system.
High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Multimeter Obtain this tool locally The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter. This excess current can damage the circuits that are not designed to carry it. Battery Terminal Protector Toro Part No.
Specifications and Maintenance: Special Tools Page 2–16 Groundsmaster 7210 16222SL Rev F
Chapter 3 Diesel Engine Table of Contents Specifications ....................................................................................................................................... 3–2 ........................................................................................................................................................... 3–2 General Information ..............................................................................................................................
Specifications Item Description Make/Designation Yanmar Model 3TNV88C-DTR2: 4-cycle, 3 cylinder common-rail water cooled diesel with EGR and diesel-particulate filter (DPF). EPA Tier 4 Final compliant. Bore 88 mm (3.46 inches) Stroke 90 mm (3.54 inches) Total displacement 1642 cm3 (100.
General Information This chapter gives information about specifications and repair of the Yanmar diesel engine used in the Groundsmaster 7210 machine. The general maintenance procedures are described in the Operator’s Manual. Detailed information on engine troubleshooting, testing, disassembly, and assembly is identified in the Yanmar Service Manual and Yanmar Troubleshooting Manual. Additionally, some engine repair procedures are described in this manual.
Engine Electronic Control Unit (ECU) (continued) If the engine ECU identifies that an engine problem exists, the engine speed may be reduced or the engine may shut off. The Yanmar troubleshooting manual and electronic diagnosis tool and should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting.
Diesel Particulate Filter (DPF) can be found in the Yanmar Operation Manual Industrial Engines TNV supplied with your machine. Regeneration The engine ECU monitors the exhaust pressure before and after the soot filter in the DPF to determine if soot is accumulating. If soot is accumulating during normal engine operation, the pressure differential will increase. The increase in pressure will signal the engine to begin a process called Regeneration.
Regeneration (continued) Types of regeneration that are performed manually (while the machine is stationary) Type Conditions Description Parked Occurs when exhaust back pressure in the DPF increases due to continued soot buildup. May be caused by prolonged operation at low engine speed, low engine load, or the use of incorrect fuel or engine oil. Manually initiate a parked regeneration as soon as possible.
Soot Accumulation If the types of regeneration that are performed automatically (while the machine is operating) are bypassed or not allowed to complete before shutting off the engine, soot will continue to accumulate in the soot filter. When enough soot accumulates, the engine ECU will generate an engine fault to prompt a parked or recovery regeneration. In addition to an engine fault appearing on the InfoCenter, the engine output power will be reduced.
Service and Repairs Air Cleaner System g034293 Figure 8 1. Air inlet hose 4. Carriage screw (2 each) 7. Inlet hose 2. Flange nut (4 each) 5. Screw (2 each) 8. Hose clamp 3. Bracket 6. Hose clamp 9. Air cleaner Assembly Removing the Air Cleaner System Note: Refer to the Traction Unit Operator's Manual for the maintenance procedures and intervals of the air cleaner.
Removing the Air Cleaner System (continued) g034294 Figure 9 1. 2. Service indicator Housing 5. 6. Air filter Gasket 3. Cover assembly 7. Air cleaner bracket 4. Vacuator valve 8. Nipple 1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. 3. Remove the air cleaner components as shown in Figure 8 and Figure 9. 4.
Exhaust System g035049 Figure 10 1. Gasket 13. DPF gasket (2 each) 25. Sensor pipe assembly 37. Connector clip (2 each) 2. DPF stay 14. Bolt (16 each) 26. Sensor pipe assembly 38. Bolt (2 each) 3. DPF stay 15. DPF lifter 27. Exhaust hose assembly 39. Bolt (3 each) 4. DPF stay 16. DPF stiffener (5 each) 28. Hose clip (2 each) 40. Bolt (4 each) 5. DPF stay 17. DPF stiffener 29. Exhaust hose assembly 41. Bolt (2 each) 6. DPF unit 18. DPF stiffener 30.
The engine that powers your Groundsmaster 7210 machine is a Yanmar model 3TNV88C with EPA Tier 4F emission regulations. The engine is equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel-particulate filter (DPF). These exhaust components require service or component replacement at regular intervals, refer to the Operator’s Manual.
Removing the Exhaust System (continued) 2. Unlatch the hood and raise it. 3. Remove the exhaust tube as shown in Figure 11. Note: The exhaust system DPF and DOC can be removed from the exhaust system without removing the entire exhaust from the engine. Refer to the Yanmar Service Manual for complete disassembly and assembly procedures. 4. Disconnect all the electrical connectors from the DPF. 5. Remove the 2 nuts (item 44 in Figure 10) that attach the DPF to the DPF stay. 6.
Radiator g034297 Figure 12 1. Cooling bracket 12. Cap 23. Coolant hose 34. Bulb seal (2 each) 2. Bolt (2 each) 13. O-ring 24. Hose clamp 35. Upper radiator hose 3. Radiator 14. Washer (2 each) 25. Overflow tank cap 36. Bulb seal (2 each) 26. 4. Isolator mount (3 each) 15. Bulkhead nut (2 each) Overflow tank 37. Radiator cap 5. Clip (4 each) 16. Hydraulic hose (2 each) 27. Worm clamp 38. O-ring 6. Hose clamp (3 each) 17. Screw (2 each) 28. Coolant hose 39.
Removing the Radiator (continued) DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot. WARNING Ethylene-glycol antifreeze is poisonous. Keep coolant away from children and pets. Keep the coolant in a labeled container. Discard the coolant in accordance with local hazardous waste ordinances. 3. Remove the radiator cap (item 5 in Figure 13) from the radiator. g035023 Figure 13 1. 5.
Removing the Radiator (continued) • The lower radiator hose (item 7 in Figure 12) that is connected to the engine block. • The coolant hose (item 28 in Figure 12) that is connected to the overflow tank. 6. Align a drain pan under the 90° hydraulic fitting of the oil cooler. 7. Disconnect the upper and lower hydraulic tubes (items 33 and 11 in Figure 12) from the 90° hydraulic fittings in the oil cooler. 8. Remove the (2 each) 90° hydraulic fittings from the oil cooler. 9.
Installing the Radiator (continued) 11. Connect the upper and lower hydraulic tubes to the 90° hydraulic fittings in the oil cooler. 12. Apply thread sealant to the threads of the pipe plug (item 6 in Figure 13). Install the plug into the radiator opening. 13. Install the radiator cap (item 5 in Figure 13) to the radiator. 14. Check that no gaps exist between the radiator, radiator frame, and machine frame. 15. Fill the radiator with coolant; refer to the Traction Unit Operator’s Manual.
Fuel System g034299 Figure 14 1. Right-vent tube 2. Left-vent tube 13. Hinge 24. Foam pad (4 each) 35. Fuel return hose 3. Vent hose (2 each) 14. Spacer 25. Clamp (4 each) 36. Fuel/water separator 4. Screw (6 each) 15. Rubber washer (2 each) 26. Flange nut (4 each) 37. Fuel return hose 5. Tool box cover 16. Plain washer (2 each) 27. Fuel supply hose 38. Cable clamp 6. Instruction decal 17. Flat washer (2 each) 28. Right fuel tank 39. Screw (2 each) 7.
DANGER Diesel fuel is highly flammable and explosive. A fire or an explosion from the fuel can burn you, burn other people, and damage property. • Use caution whenever you store or handle diesel fuel. • Do not smoke while filling the fuel tank. • Do not fill the fuel tank while the engine is running, while the engine is hot, or when the machine is in an enclosed area. • Always fill the fuel tank outside and wipe up any spilled diesel fuel before starting the engine.
Removing the Fuel Tanks (continued) G036995 g036995 Figure 15 1. Flange-head screw (5 each) 4. Control panel cover 2. Control panel 5. Swell latch (2 each) 3. Locknut (2 each) 11. At the right fuel tank, remove the 5 flange-head screws (item 1 in Figure 15) that secure the control panel to the right fuel tank. Carefully position the control panel away from the fuel tank. 12.
Installing the Fuel Tanks (continued) 3. Assemble the fuel tanks to the frame of the machine with the screws (items 18 and 30 in Figure 14), flat washers, plain washers, rubber washers, spacer, and the flange nuts. 4. Align the fuel tank to the machine and secure the tank to the frame with a screw, clamp, and flange nut (items 32, 25, and 26 in Figure 14). 5.
Engine g186589 Figure 16 1. Dual temperature switch 8. Screw 15. Flywheel housing 22. Exhaust support 2. Locknut (2 each) 9. Snubbing washer (2 each) 16. Lock washer (16 each) 23. Flange nut (2 each) 3. Motor mount (2 each) 10. Screw (2 each) 17. Screw (3 each) 24. Guide bracket 4. Lock washer (8 each) 11. Flange nut (4 each) 18. Screw (13 each) 25. Bolt (8 each) 5. Screw (8 each) 12. Engine mount (2 each) 19. Lock washer 26. Yanmar engine 6. Harness tab 13.
Removing the Engine 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the hood; refer to Removing the Hood (page 6–40). g035026 Figure 17 1. Negative battery cable 2. Positive battery cable 3. Engine block g035041 Figure 18 1. Negative eye cable 4. Ground eye cable 2. 3. Yanmar ECU Positive eye cable 5. 6. Socket connector Connector 3.
Removing the Engine (continued) 5. Remove the air cleaner from the engine; refer to Removing the Air Cleaner System (page 3–8). 6. Remove the exhaust tube from the engine (Figure 11). 7. Remove the radiator and oil cooler from the frame; refer to Removing the Radiator (page 3–13). 8. Label all the electrical connectors to assure correct assembly. Note the location of cable ties, anchors, and wire routing to assure correct assembly.
Removing the Engine (continued) 13. Remove the 7 screws (item 17 in Figure 16) and 7 lock washers that secure the flywheel housing to the engine. 14. Remove the locknut (item 2 in Figure 16), snubbing washer, and screw that secures each side of the engine to the engine mounts that are attached to the frame. IMPORTANT When removing the engine ensure that you do not damage the engine, flywheel housing, fuel hoses, hydraulic lines, electrical harness or other parts.
Installing the Engine (continued) 5. Support the transmission to prevent it from moving during the engine installation. 6. Carefully lower the engine into the machine, align the engine with the transmission input shaft, and move the engine toward the flywheel housing. IMPORTANT When installing the engine ensure that you do not damage the engine, flywheel housing, fuel hoses, hydraulic lines, electrical harness or other parts. Also, ensure that transmission does not shift during engine installation.
Installing the Engine (continued) g035042 Figure 20 1. Glow relay 2. Start relay 3. EGR relay 7. Align the engine with the engine mounts that are attached to the frame with the locknut (item 2 in Figure 16), snubbing washer, and screw. 8. Install the engine to the flywheel housing with the 7 screws (item 17 in Figure 16), 7 lock washers; torque the screws to 45.19 N·m (33.33 ft-lb). Follow same procedure for verifying hose fitting torque. Paint mark screws prior to final torque. 9.
Installing the Engine (continued) Note: Make sure that the engine and frame ground surfaces are free from corrosion, oil and paint. 13. Install the radiator to the machine; refer to Installing the Radiator (page 3–15). 14. Install the exhaust tube to the engine (Figure 11). 15. Install the air cleaner to the frame of the machine; refer to Installing the Air Cleaner System (page 3–9). 16. Install the ROPS assembly; refer to Installing the Rollover Protection System (page 6–34). 17. Lower the operator seat.
Diesel Engine: Service and Repairs Page 3–28 Groundsmaster 7210 16222SL Rev F
Chapter 4 Hydraulic System Table of Contents Specifications ....................................................................................................................................... 4–3 ........................................................................................................................................................... 4–3 General Information ..............................................................................................................................
Charging the Hydraulic System........................................................................................................ 4–61 Hydraulic Tank ................................................................................................................................. 4–63 Wheel Motors................................................................................................................................... 4–65 Servicing the Wheel Motor ................................................
Specifications Item Description Transmission Maximum traction pump displacement (per revolution) Traction circuit relief pressure (forward and reverse) Charge pump displacement (per revolution) Charge pressure Gear pump Displacement (per revolution) Implement relief pressure Casappa single section, positive displacement gear type pump 6.7 cm³ (0.
General Information Hydraulic Hoses The hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage conditions, in addition to mishandling during operation and maintenance. These conditions can cause damage to the hose or deterioration to the hose material. Some hoses are more susceptible to these conditions than others.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) 1. Ensure that all the threads, the sealing surfaces of the hose/tube, and the fitting are free of burrs, nicks, scratches, or unwanted material. g212099 Figure 21 1. Tube or hose 3. O-ring 2. Swivel nut 4. Fitting body g212098 Figure 22 2. To help prevent a hydraulic leak, replace the face seal O-ring when you open the connection. Ensure that the O-ring is installed and correctly seated in the groove of the fitting.
Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (continued) C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (FFWR); refer to the Flats From Wrench Resistance Table (page 4–6). Note: The markings on the nut and body of the fitting show that the connection is correctly tightened.
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) Installing the Non-Adjustable Fittings g212226 Figure 23 1. Fitting 2. O-ring 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid.
Installing the Non-Adjustable Fittings (continued) Fitting Installation Torque Table (continued) 10 7/8—14 135 to 164 N∙m (99 to 121 ft-lb) 82 to 100 N∙m (60 to 74 ft-lb) 12 1–1/16—12 182 to 222 N∙m (134 to 164 ft-lb) 110 to 134 N∙m (81 to 99 ft-lb) 14 1–3/16—12 217 to 265 N∙m (160 to 196 ft-lb) 131 to 160 N∙m (96 to 118 ft-lb) 16 1–5/16—12 274 to 336 N∙m (202 to 248 ft-lb) 165 to 202 N∙m (121 to 149 ft-lb) 20 1–5/8—12 335 to 410 N∙m (247 to 303 ft-lb) 202 to 248 N∙m (149 to 183 ft-lb) F
Installing an Adjustable Fitting (continued) 2. To help prevent a hydraulic leak, replace the O-ring when you open the connection. 3. Lightly lubricate the O-ring with clean hydraulic fluid. Ensure that the threads of the fitting are clean with no lubricant applied. 4. Turn back the locknut as far as possible. Ensure that the back-up washer is not loose and it is pushed up as far as possible (Step 1 in Figure 25).
Pushing the Traction Unit In case of emergency, push the machine for a very short distance. However, Toro does not recommend this as a standard procedure. g033387 Figure 26 1. Transmission 2. Bypass valve 1. Find the 2 bypass valves on the transmission (Figure 26). Loosen the 2 valves and rotate them counterclockwise 1 to 2 turns. IMPORTANT Pushing the machine faster than 2 mph can damage the drive system.
Releasing Pressure from the Hydraulic System Release all the pressure in the hydraulic system before you work on the hydraulic system. • Release the hydraulic pressure from the traction circuit as follows: Note: If you park the machine on an incline or slope, the pressure in the traction circuit does not release. 1. Move the machine to a level surface. 2. Lower the cutting deck (or implement). 3. Shut off the engine. 4. Turn the key switch to the OFF position and allow the engine to stop.
Traction Circuit (Closed Loop) Component Failure The traction system of the Groundsmaster 7210 machine consists of 2 identical and independent closed loop traction circuits. If a component failure occurs in 1 of these traction circuits (e.g., wheel motor or transmission piston pump), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Hydraulic Schematics Refer to the Hydraulic Schematic in Appendix A (page A–1)—Foldout Drawings.
g186588 Figure 27 Hydraulic System: Hydraulic Schematics Page 4–14 Groundsmaster 7210 16222SL Rev F
Traction Circuits The traction system of the Groundsmaster consists of a transmission that is directly connected to, and driven by, the engine flywheel. The transmission provides 2 identical and independent closed loop traction circuits: one for the right wheel motor and the other for the left wheel motor. Each of these transmission circuits includes a variable displacement, slipper foot design piston pump which provides hydraulic flow for a wheel motor.
Reverse Direction The traction circuit operates essentially the same in reverse as it does in the forward direction. When a traction lever is pulled rearward, the rod connected to the lever positions the swash plate in the transmission-piston pump to provide hydraulic fluid flow from the transmission (port B for the right side or D for the left side). This fluid flows to the wheel motor and turns the motor in the reverse direction.
Reverse Direction (continued) g186586 Figure 28 Groundsmaster 7210 16222SL Rev F Page 4–17 Hydraulic System: Hydraulic Schematics
Lift Circuit (Raise) A single-section gear pump is directly coupled to the transmission which is driven by the engine. This gear pump supplies hydraulic flow for raising and lowering the cutting deck (or implement). The pump takes its suction from the hydraulic tank. During the conditions of not raising or lowering the cutting deck (or implement), flow from the gear pump is bypassed by the lift-control manifold directly to the oil cooler and then to the transmission.
Electrical Lift Control (continued) g186585 Figure 29 Groundsmaster 7210 16222SL Rev F Page 4–19 Hydraulic System: Hydraulic Schematics
Lift Circuit (Lower) A single-section gear pump is directly coupled to the transmission which is driven by the engine. This gear pump supplies hydraulic flow for raising and lowering the cutting deck (or implement). The pump takes its suction from the hydraulic tank. The circuit operation for lowering the cutting deck (or implement) is similar to raising it. However, the hydraulic flow is used to retract the lift cylinder and this action allows the cutting deck (or implement) to lower.
Cutting Deck Float (continued) g186587 Groundsmaster 7210 16222SL Rev F Page 4–21 Figure 30 Hydraulic System: Hydraulic Schematics
PTO Circuit The transmission of the Groundsmaster 7210 machine consists of a hydraulic, multi-plate clutch that is used to engage the PTO. The hydraulic flow for the PTO clutch engagement is provided by the transmission-charge pump. When the PTO switch is turned on, the transmission solenoid valve is energized to allow the hydraulic flow to engage the PTO clutch.
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit g031764 Figure 31 Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools. A high-pressure hose is given for remote readings.
15 GPM Hydraulic Tester Kit (Pressure and Flow) (continued) 3. Pressure Gauge: A glycerine filled pressure gauge 0 to 34,500 kPa (0 to 5,000 psi) to provide operating circuit pressure. 4. Flow Meter: This meter measures the actual fluid flow in the operating circuit with a gauge rated at 5 to 55 L/minute (1 to 15 gallons/minute). 5. Outlet Hose: A hose from the outlet side of the hydraulic tester that connects to the hydraulic system circuit. 6.
High Flow Hydraulic Filter Kit g035050 Figure 35 Toro Part Number: TOR6011 The high flow hydraulic filter kit is designed with large flow (150 L/minute or 40 gallons/minute) and high pressure (34,500 kPa or 5,000 psi) capabilities. This kit provides for bi-directional filtration which prevents filtered unwanted material from entering into the circuit regardless of the flow direction.
Hydraulic Hose Kit (continued) Toro Part No. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components.
Remote Starter Switch (continued) g035022 Figure 39 1. 2. 3. Starter motor Starter solenoid B+ terminal After flushing the hydraulic system or replacing a hydraulic component (e.g., gear pump, piston pump, or wheel motor), it is necessary to prime the hydraulic pumps. A remote starter switch (Figure 37) can be used for priming the hydraulic pumps. You can get this switch locally.
Troubleshooting The following chart contains information to troubleshoot hydraulic circuit problems. There can be more than 1 cause for a machine malfunction. Refer to Testing the Hydraulic System (page 4–31) for precautions and specific hydraulic test procedures. General Hydraulic System Problems Problem Possible Causes The hydraulic fluid is leaking from the system. • The fitting(s), hose(s), or tube(s) are loose or damaged. • The O-ring(s) or seal(s) are missing or damaged.
Traction Circuit Problems (continued) No traction exists in either direction. • • • • • The hydraulic-fluid level in the hydraulic tank is low. The transmission bypass valves are open. The charge pressure is low. The engine flywheel coupling is damaged. The transmission or wheel motor(s) is worn or damaged. Note: If 1 traction circuit component has internal wear or damage, it is possible that the other traction components are also damaged. The wheel motor does not turn.
Lift/Lower Circuit Problems Problem Possible Causes The gear pump is noisy (cavitation). • • • • The cutting deck (or implement) does not lift or lifts slowly. • The engine speed is too low. • The lift cylinder linkage is binding or broken. • The lift arm bushings are binding. • The hydraulic-fluid level in the hydraulic tank is low. • The gear pump pressure or flow is insufficient. • The gear pump is damaged. • The implement-relief valve (in the gear pump) is stuck open.
Testing the Hydraulic System The most effective procedure to isolate the problems in the hydraulic system is to use hydraulic test equipment, such as pressure gauges and flow meters in the circuits during different operational checks; refer to Special Tools (page 4–23). WARNING Opening the hydraulic system without releasing pressure from the system will cause the hydraulic fluid to escape, causing possible injury.
IMPORTANT Use 2 people to perform all the tests, with 1 person in the seat and the other to read and record the test results. 1. Clean the machine fully before you disconnect or disassemble the hydraulic components. Note: Cleanliness is required whenever you work on the hydraulic equipment. Contamination causes too much wear on hydraulic components. 2. When you perform tests on the hydraulic system, wear the eye protection. 3.
Testing the Traction System Operation Because the traction system of the Groundsmaster 7210 machine uses 2 different circuits, it is difficult to identify which circuit is causing a problem and what hydraulic tests should be performed. Use the following operation tests and suggestions before you perform the hydraulic tests described in this section. 1. If the machine does not track in a straight line, look for a problem with the components that affect the weaker traction side of the machine.
Testing the Charge Relief Valve Pressure (Using Pressure Gauge) g187016 Figure 40 Hydraulic System: Testing the Hydraulic System Page 4–34 Groundsmaster 7210 16222SL Rev F
Perform the charge relief valve pressure test if you identify a traction circuit problem. This test determines if the transmission charge relief valve operates correctly. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature. 2. Ensure that the traction drive is correctly adjusted for the NEUTRAL position.
Test Procedure (continued) D. A pressure drop of more than 15% indicates a traction circuit leak (e.g., a leaking transmission check valve, a worn/damaged transmission piston pump). If charge pressure is good under no load, but the pressure drops below specification when under a traction load, the transmission piston pump(s) are probably worn or damaged. Note: When a pump is worn or damaged, the charge pump cannot keep up with internal leakage in the traction circuit. 13.
Testing the Transmission Piston Pump Flow (Using Tester with Pressure Gauges and Flow Meter) g187022 Figure 41 Groundsmaster 7210 16222SL Rev F Page 4–37 Hydraulic System: Testing the Hydraulic System
Perform the transmission piston pump flow test if you identify a traction circuit problem. This test determines if hydraulic flow from a transmission piston pump is correct. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature. 2. Ensure that the traction drive is correctly adjusted for the NEUTRAL position.
Test Procedure (continued) 10. Use a phototac to measure the engine speed, move the throttle so that the engine speed is 2,800 rpm (not full speed). 11. Have an operator slowly push the traction lever for the pump that is being tested to fully forward position. Keep the other traction lever in the NEUTRAL position. 12. Slowly close the tester flow control valve until the pressure gauge reading is 6,900 kPa (1,000 psi). 13.
Testing the Traction Relief Valve Pressure (Using Tester with Pressure Gauges and Flow Meter) g187021 Figure 42 Hydraulic System: Testing the Hydraulic System Page 4–40 Groundsmaster 7210 16222SL Rev F
Perform the traction relief valve pressure test if you identify a traction circuit problem. This test determines if a transmission relief valve operates correctly. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature. 2. Ensure that the traction drive is correctly adjusted for the NEUTRAL position. WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11).
Test Procedure (continued) Note: The pressure gauge reading should be approximately 27,600 kPa (4,000 psi) as the relief valve lifts. 13. Release the traction lever to the NEUTRAL position, open the tester flow-control valve, and shut off the engine. Record the test results. Note: The forward relief valves for the 2 transmission pump circuits are identical and thus you can interchange them. The reverse relief valves are also identical.
Testing the Wheel Motor Efficiency (Using Tester with Pressure Gauges and Flow Meter) g187023 Figure 43 Groundsmaster 7210 16222SL Rev F Page 4–43 Hydraulic System: Testing the Hydraulic System
Perform the wheel motor efficiency test if you identify a traction circuit problem. This test determines if a wheel motor has excessive internal leakage and wear. Note: Over a period of time, a wheel motor can wear internally. A worn motor may bypass the hydraulic fluid to its case drain that reduces the motor efficiency. After sometime, sufficient fluid loss causes the wheel motor to stall under heavy load conditions.
Test Procedure (continued) IMPORTANT Do not run the engine at full speed when performing this test using Toro hydraulic tester (pressure and flow) (TOR214678). The traction pump output at full engine speed can damage the hydraulic tester. 11. Use a phototac to measure the engine speed, move the throttle so that the engine speed is 2,800 rpm (not full speed). Set the parking brake to keep the wheel from rotating during test. CAUTION The rear wheel that you are testing will try to move the machine forward.
FO RW ARD FO RW ARD Testing the PTO Pressure Valve (Using Pressure Gauge) g187020 Figure 44 Hydraulic System: Testing the Hydraulic System Page 4–46 Groundsmaster 7210 16222SL Rev F
Perform the PTO pressure valve test if you identify a PTO engagement problem. This test determines if the PTO pressure valve in the transmission is operating correctly. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature. WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11). 2.
Testing the Implement Relief Pressure (Using Pressure Gauge) g187018 Figure 45 Hydraulic System: Testing the Hydraulic System Page 4–48 Groundsmaster 7210 16222SL Rev F
Perform the implement relief pressure test if you identify a cutting deck (or implement) raise and lower problem. This test determines if the implement relief valve is operating correctly. Test Procedure 1. Ensure that the hydraulic fluid is at normal operating temperature. 2. Ensure that the traction drive is correctly adjusted for the NEUTRAL position.
Test Procedure (continued) 4. Read all Warning, Cautions, and precautions listed at the beginning of this section. 5. Clean the junction of the hydraulic hose and upper fitting on the front side of the lift control manifold (Figure 46). 6. Disconnect the hydraulic hose from the upper fitting on the front side of the lift control manifold (Figure 46). This hose is from the gear pump outlet and provides fluid flow to the lift control manifold (Figure 47). 7.
Testing the Gear Pump Flow (Using Tester with Pressure Gauges and Flow Meter) g187017 Figure 48 Groundsmaster 7210 16222SL Rev F Page 4–51 Hydraulic System: Testing the Hydraulic System
Perform the gear pump flow test if you identify a cutting deck (or implement) raise and lower problem. This test determines if the hydraulic flow from the gear pump is correct. Test Procedure Note: Over a period of time, the gears and wear plates in the gear pump can wear. A worn pump may bypass the hydraulic fluid and make the pump less efficient. After some time, sufficient fluid loss might occur and cause the cutting deck lift cylinder to operate slowly.
Test Procedure (continued) 8. Start the engine and run it at low-idle speed (1,400 rpm). Check for hydraulic-fluid leaks from the test connections and correct before continuing the test. 9. With the engine running, move the throttle to full speed (3,000 rpm). 10. Monitor the tester pressure gauge carefully while you slowly close the flow control valve until you get 6,900 kPa (1,000 psi). Do not close the tester load valve fully. 11.
FO RW ARD FO RW ARD Testing the Lift Cylinder for Internal Leakage g187019 Figure 50 Hydraulic System: Testing the Hydraulic System Page 4–54 Groundsmaster 7210 16222SL Rev F
Perform the lift cylinder internal leakage test if you identify a cutting deck (or implement) raise and lower problem. This test determines if the lift cylinder is damaged. Note: The raise/lower circuit operation can be affected by the lift cylinder binding, extra weight on the cutting deck (or implement), and/or binding of the lift components. Ensure that these items are checked before continuing with the lift cylinder internal leakage test. Test Procedure 1.
Test Procedure (continued) g033411 Figure 52 1. 2. Lift cylinder collar Tape 6. Remove the jack stands from under the cutting deck (or implement). Note: The cutting deck (or implement) should settle slightly and then be supported by the capped lift cylinder. 7. Place a piece of tape on the lift cylinder rod near the rod end (Figure 52). Measure and record the distance from the lift cylinder collar to the tape location. 8. Keep the machine parked for 4 hours and monitor the lift cylinder.
Service and Repairs General Precautions for Removing and Installing the Hydraulic System Components Before Repairing or Replacing the Components 1. Before removing any parts from the hydraulic system, park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the machine before you disconnect, remove, or disassemble the hydraulic components.
After Repairing or Replacing the Components (continued) Fitting) (page 4–5) and Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–7). 5. After you complete the repairs, check the control linkages or cables for proper adjustment, binding, or broken parts. 6. After you disconnect or replace any hydraulic components, operate the machine functions slowly until the air is out of the system; refer to Charging the Hydraulic System (page 4–61). 7.
Priming the Hydraulic Pumps (continued) g035022 Figure 53 1. 2. 3. Starter motor Starter solenoid B+ terminal Note: A blue wire connects to the starter motor solenoid B+ terminal (Figure 53). It is not necessary to remove this blue wire from the solenoid terminal for hydraulic pump priming. 3. Connect the remote starter switch electrical leads to the starter motor solenoid B+ terminal and positive post of the battery. 4.
Flushing the Hydraulic System (continued) WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11). 2. Park machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. Note: Ensure that you clean all the hydraulic connections that are disconnected for draining. 3.
Charging the 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 is charged properly. Remove the air from the system and its components to reduce the chance of damage. IMPORTANT Change the hydraulic-fluid filter when you repair or replace the hydraulic components. 1. Park the machine on a level surface and shut off the engine. 2.
Charging the Hydraulic System (continued) E. The gear pump that is damaged. 10. After the lift cylinder moves normally, proceed to step 11. 11. Operate the traction control levers in the forward and reverse directions. The drive wheels should rotate in the proper direction. If the wheels rotate in the wrong direction, shut off the engine, inspect the wheel motor location and hydraulic lines to the wheel motors; refer to Installing the Transmission (page 4–73). 12.
Hydraulic Tank g033412 Figure 54 1. Hydraulic tank 12. Elbow fitting 23. R-clamp 2. O-ring 13. Hose clamp 24. Bolt 3. Strainer 14. Hydraulic hose 25. Flange nut 4. Hose clamp 15. Hydraulic hose 26. Hydraulic hose 5. Hydraulic hose 16. Hose clamp 27. Straight fitting 6. Hydraulic hose 17. Hydraulic T-fitting 28. Cable tie 7. Grommet 18. Hydraulic hose 29. Breather 8. Hose clamp 19. O-ring 30. Washer-head screw (2 each) 9. Dipstick 20. Straight fitting 31.
Removing the Hydraulic Tank (continued) 3. Remove the brake handle from the machine to allow removal of the hydraulic tank; refer to Parking Brake Assembly (page 6–15). 4. Drain the hydraulic fluid from the hydraulic tank. 5. Clean the hydraulic hose ends and fittings on the hydraulic tank to prevent contaminants from entering into the hydraulic system. 6. For assembly purposes, label all the hydraulic hoses and fittings.
Wheel Motors g033415 Figure 55 1. Locknut 8. Woodruff key 15. Brake caliper (left) 2. Lug nut (5 each per wheel) 9. O-ring 16. Flange nut (4 each per side) 3. Wheel assembly 10. Hydraulic fitting 17. Bolt (2 each per side) 4. Wheel hub 11. O-ring 18. Bolt (2 each per side) 19. Brake support 5. Wheel stud (5 each per wheel) 12. Hydraulic fitting 6. Socket-head screw (4 each per motor) 13. Hydraulic hose 7. Wheel motor (left) 14.
Removing the Wheel Motor (continued) IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). 2. Lift the machine with a jack and remove the drive wheel, support the machine with jack stands; refer to Removing the Rear Wheel (page 6–4). 3. Remove the brake assembly from the machine; refer to Removing the Parking Brakes (page 6–9). IMPORTANT Do not hit the wheel hub, wheel-hub puller, or wheel motor with a hammer while removing or installing.
Removing the Wheel Motor (continued) 14. Remove the 4 socket-head screws that secure the wheel motor to the machine. 15. Remove the wheel motor from the frame. Installing the Wheel Motor IMPORTANT Because of the internal differences in the wheel motors, do not interchange the wheel motors on the machine (e.g., do not put the right motor on the left side of the machine).
Servicing the Wheel Motor g033417 Figure 57 1. 2. Locknut Dirt/water seal 3. Housing 8. 9. 10. Manifold Commutator ring 15. 16. Drive link Wear plate Bolt (7 each) 17. Thrust bearing 4. Back-up washer 11. End cover 18. Woodruff key 5. Shaft seal 12. Commutator 19. Back-up ring 6. Coupling shaft 13. Commutator ring 7. Body seal (5 each) 14. Stator assembly Note: The 2 wheel motors of the Groundsmaster 7210 machine have the same basic construction.
Servicing the Wheel Motor (continued) IMPORTANT If a wheel motor fails; refer to the Traction Circuit (Closed Loop) Component Failure (page 4–12) for information regarding the importance of removing contamination from the traction circuit.
Transmission g034385 Figure 58 1. Transmission 16. Hydraulic tube 31. O-ring 2. Coupler 17. O-ring 32. Hydraulic hose 3. O-ring 18. Hydraulic fitting 33. Hose clamp 4. Gear pump 19. 90° hydraulic fitting 34. 90° hydraulic fitting 5. Bolt (40 mm long) 20. Hydraulic fitting 35. 90° hydraulic fitting 6. Lock washer (7 each) 21. Hose clamp 36. Hydraulic hose 7. Bolt (50 mm long) (6 each) 22. Hydraulic hose 37. Hydraulic hose (2 each) 8. Tube 23. O-ring 38.
Removing the Transmission WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11). 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the operator seat and seat base; refer to Removing the Operator Seat (page 6–35). g033419 Figure 59 1. 2.
Removing the Transmission (continued) 10. Remove the oil filter from the transmission and discard the filter. If necessary, remove the gear pump from the transmission; refer to Removing the Gear Pump (page 4–106). g033420 Figure 60 Left wheel motor 4. Right wheel motor 2. Hydraulic tank 5. 8mm threaded boss 3. Gear pump 6. Transmission 1. 7.
Removing the Transmission (continued) 13. Locate and note the location of the 2 dowel pins from the transmission and flywheel housing. 14. On both sides of the transmission, remove the retaining ring that secures the pump control rod end onto the transmission control arm (Figure 59). Slide the control rod from the control arm. 15. If the hydraulic fittings are to be removed from the transmission, put a mark on the fitting orientation for correct assembly.
Installing the Transmission (continued) 5. Apply a generous amount of anti-seize lubricant to the splines of the transmission input shaft and flywheel coupler. 6. Place the 2 dowel pins in the flywheel housing. IMPORTANT Ensure that you do not damage the transmission, flywheel housing, hydraulic lines, electrical harness, or other parts while installing the transmission.
Servicing the Transmission g033422 Figure 62 Groundsmaster 7210 16222SL Rev F Page 4–75 Hydraulic System: Service and Repairs
Figure 62 (continued) 1. Solenoid assembly 27. Seal (4 each) 53. Valve plate (2 each) 2. Solenoid valve assembly 28. O-ring (2 each) 54. Cylinder block assembly (2 each) 3. Bolt (3 each) 29. Washer (2 each) 55. Thrust plate (2 each) 4. Bolt (2 each) 30. Bearing (5 each) 56. Swash plate (2 each) 5. Hex plug (2 each) 31. Bearing (2 each) 57. Pin (4 each) 6. O-ring 32. Side cover (2 each) 58. Gasket 7. Pump body 33. Socket-head screw (3 each per cover) 59.
Disassembling the Transmission g033423 Figure 63 1. Solenoid coil 4. Spool 2. 3. Solenoid valve stem Pin 5. Sleeve 1. Clean the exterior of the transmission. 2. Remove the nut, lock washer, washer, O-ring, solenoid coil, and O-ring from the solenoid valve stem. 3. For assembly purposes, note that the "KANZAKI" molded into the coil has the "I" nearest the location of the nut as coil direction is important for proper solenoid operation. 4.
Disassembling the Transmission (continued) g033425 Figure 65 1. Pressure valve plug 2. Charge relief plug 9. Remove the pressure valve plug, spring, and valve from the transmission pump body. 10. Remove and discard the O-ring from the pressure valve plug. 11. Remove the charge relief plug, spring, and valve from the transmission pump body. 12. Remove and discard the O-ring from the charge relief plug. g033426 Figure 66 1. 2. Accumulator cover Collar 3. Piston 13.
Disassembling the Transmission (continued) g033427 Figure 67 1. Hex plug (2 each) 2. Socket head plug (4 each) 15. Remove the 2 hex plugs from the pump body. 16. Remove and discard the O-rings from the plugs. 17. Remove the 4 socket head plugs from the pump body. g033428 Figure 68 1. Pump body 2. Center case 18. Remove the 3 shorter (45 mm) and 2 longer (95 mm) flange-head screws that attach the pump body to the center case, and remove the pump body from the center case.
Disassembling the Transmission (continued) g033429 Figure 69 1. Pin 2. Pump body 19. Remove the 2 pins that locate the pump body. 20. Remove and discard the O-rings. g033430 Figure 70 1. Right pump shaft 2. Outer pump rotor 3. Inner pump rotor 21. Slide the outer and inner charge pump rotors from the right pump shaft, and remove the key from the key slot in the pump shaft.
Disassembling the Transmission (continued) g033431 Figure 71 1. Center case 2. Pump housing 3. Pin (2 each) g033432 Figure 72 Groundsmaster 7210 16222SL Rev F 1. Bypass valve 4. Forward relief cartridge 2. Center case 5. Valve plate 3.
Disassembling the Transmission (continued) g033433 Figure 73 1. Forward relief cartridge 2. Reverse relief cartridge 3. Hex head groove 22. Remove the 8 socket-head screws that attach the center case to the transmission pump housing. 23. Carefully remove the center case assembly from the transmission pump housing. 24. Remove the 2 pins from the transmission pump housing bores. 25. Remove and discard the gasket. 26. Remove the bypass valves from the center case. 27.
Disassembling the Transmission (continued) 31. Remove and discard the O-rings from the plugs. 32. Remove the right and left flushing valve plugs, springs, and valves from the center case. Note the differences in the flushing valves and their locations for assembly purposes. 33. Remove and discard the O-rings from the plugs. g033435 Figure 75 1. Cylinder block assembly 2. Pipe 34. Slide the 2 cylinder block assemblies from the pump shafts.
Disassembling the Transmission (continued) 38. Remove the thrust plate from each swash plate. For assembly purposes, note that the beveled sides of the thrust plates are against the swash plate surfaces. 39. Remove the socket-head screw and nut that secures the control arm onto each trunnion shaft. Slide the control arm from each trunnion shaft. g033437 Figure 77 1. Hex plug 2. Socket head plug 40. Remove the 2 hex plugs and 1 socket head plug from the gear case housing. 41.
Disassembling the Transmission (continued) 46. Remove the retaining ring that secures the input shaft oil seal into the gear case housing bore, and remove the spacer and oil seal from the housing. Discard the seal. Note: Ensure that you do not damage the seal bore in the housing. g033439 Figure 79 1. Input shaft 3. Left pump shaft 2. Right pump shaft 4. Pipe 47. Remove the input shaft, right pump shaft, and left pump shaft assemblies from transmission pump housing. 48.
Disassembling the Transmission (continued) g033440 Figure 80 1. Right pump shaft 3. Input shaft 2. Left pump shaft 4. Seal ring 50. If the pump shaft bearing replacement is necessary, remove and discard the seal ring from the right and left pump shafts. 51. Use a bearing puller to remove the bearings from the pump shaft. 52. Discard the bearings that were removed, and remove the gear from the pump shaft. 53.
Disassembling the Transmission (continued) 55. Remove the PTO shaft assembly from the transmission pump housing. g033442 Figure 82 1. Friction plate 2. Pump housing 56. Remove the final friction plate from the transmission pump housing. Note: This friction plate may have been removed with the PTO shaft assembly. g033443 Figure 83 1. Groundsmaster 7210 16222SL Rev F Bearing 4. Gear 2. PTO shaft 5. Clutch assembly 3. Spacer 6.
Disassembling the Transmission (continued) g033444 Figure 84 1. Seal ring (2 each) 5. A-plate (3 each) 2. PTO shaft 6. Friction plate (3 each) 3. B-plate 7. Bearing 4. C-plate 57. Disassemble the PTO shaft assembly as follows: A. Use a bearing puller to remove the bearing from the PTO shaft. Discard the bearing. B. Remove the spacer from the PTO shaft. C. Slide the gear and clutch assembly from the PTO shaft. D. Remove the key from the PTO shaft slot. E.
Disassembling the Transmission (continued) g033446 Figure 86 1. Bearing 2. PTO gear 3. Retaining ring 60. If necessary, remove the 2 bearings from the PTO gear and discard the bearings that were removed. 61. Remove the retaining ring from the groove in the PTO gear bore. g033447 Figure 87 1. Socket head plug 2. Hex plug 3. Pump housing 62. Remove the socket head plug and hex plug from the transmission pump housing. 63. Remove and discard the O-rings from the plugs.
Disassembling the Transmission (continued) g033448 Figure 88 1. Side cover 4. Retaining ring 2. O-ring 5. Oil seal 3. Pump housing 64. Remove the 3 socket-head screws that attach the 2 side covers to the transmission pump housing. 65. Carefully slide the side covers from the trunnion shafts and housing. 66. Remove and discard the O-rings from the side covers. 67. Remove the retaining rings that attach the oil seals into the 2 side covers. 68.
Assembling the Transmission g033450 Figure 90 1. Swash plate (2 each) 2. Washer 3. Pump housing Note: When assembling the transmission, lubricate all the transmission components with clean hydraulic fluid. 1. Ensure that all the transmission components are clean before you assemble the transmission. 2. Apply clean hydraulic fluid to the washers and surfaces of the swash plate. Install the washer onto each swash plate and carefully install the swash plates into the transmission pump housing.
Assembling the Transmission (continued) g033452 Figure 92 1. Socket head plug 2. Hex plug 3. Pump housing 6. Lubricate new O-rings and install the O-rings onto the socket head plug and hex plug. Install both the plugs into the transmission pump housing; torque the plugs to 23 to 26 N∙m (17 to 19 ft-lb). g033453 Figure 93 1. Bearing 2. PTO gear 3. Retaining ring 7. Install the retaining ring into the groove in the PTO gear bore.
Assembling the Transmission (continued) g033454 Figure 94 1. Rod (3 each) 2. Clutch assembly 3. PTO gear assembly 8. Slide the 3 rods into the holes in the clutch assembly. 9. Slide the PTO gear assembly into the clutch assembly. g033455 Figure 95 1. Seal ring (2 each) 5. A-plate (3 each) 2. PTO shaft 6. Friction plate (3 each) 3. B-plate 7. Bearing 4. C-plate 10. Assemble the PTO shaft assembly as follows: A.
Assembling the Transmission (continued) g033456 Figure 96 1. Bearing 4. Gear 2. PTO shaft 5. Clutch assembly 3. Spacer 6. Key 11. Install the clutch assembly and gear onto the PTO shaft: A. Install the key into the PTO shaft slot. Note: Ensure that the rounded ends of the key are aligned with the rounded ends of the shaft slot. B. Slide the clutch assembly and gear onto the PTO shaft. Also, align the rods in the clutch with the holes in the B-plate.
Assembling the Transmission (continued) g033458 Figure 98 1. PTO shaft assembly 3. Friction plate tabs 2. Pump housing 4. Housing groove 13. Install the PTO shaft assembly into the transmission pump housing. Note: Ensure that the tabs on the friction plates are placed in the housing grooves. g033459 Figure 99 1. Right pump shaft 3. Input shaft 2. Left pump shaft 4. Seal ring 14.
Assembling the Transmission (continued) g033460 Figure 100 1. Input shaft 3. Left pump shaft 2. Right pump shaft 4. Pipe assembly 16. Install the right and left pump shaft assemblies into the transmission pump housing, and install the input shaft into the pump housing. Note: Ensure that the gear teeth of the input shaft is aligned with the gears on the PTO and pump shafts. 17. Lubricate the 2 new O-rings and install the O-rings into the grooves in the pipe.
Assembling the Transmission (continued) 19. Carefully place the gear case housing onto the pump housing and align the pins, pipe, and shaft bearings. 20. Assemble the gear case housing to the pump housing with the 15 flange-head screws. Tighten the screws evenly in a crossing pattern and then torque the screws to 23 to 26 N∙m (17 to 19 ft-lb). 21. Install the oil seal into the gear case housing bore. Note: Ensure that you do not damage the input shaft oil seal. 22.
Assembling the Transmission (continued) Note: Ensure that you do not damage the PTO oil seal. 25. Place the spacer on the oil seal and secure the seal with the retaining ring. 26. Lubricate the both sides of the thrust plates with clean hydraulic fluid. Place the thrust plate onto each swash plate. Note: Ensure that you position the beveled side of the thrust plates against the swash plate surface. 27.
Assembling the Transmission (continued) 31. Lubricate new O-rings and install the O-rings onto the 6 hex plugs. Install the plugs into the center case; torque the plugs to 19 to 20 N∙m (14 to 15 ft-lb). 32. Lubricate the flushing valves with clean hydraulic fluid and place them in the center case bores. Note: Ensure that you place the right and left flushing valves in the correct location. 33. Lubricate new O-rings and install the O-rings onto the 2 flushing valve plugs.
Assembling the Transmission (continued) IMPORTANT The forward and reverse relief cartridges are different. Use the labels that you attached during disassembly to correctly install the relief cartridges. 36. Thread the relief cartridges into the correct center case ports and torque the cartridges to 32 to 37 N∙m (24 to 27 ft-lb). Note: You can identify the reverse relief valve cartridges by the groove in the hex head (Figure 107). 37.
Assembling the Transmission (continued) g033469 Figure 109 1. Right pump shaft 2. Outer pump rotor 3. Inner pump rotor 41. Install the key into the key slot in the right pump shaft. Lubricate the inner and outer charge pump rotors with clean hydraulic fluid. Slide the inner pump rotor onto the pump shaft and align the pump rotor with the key. Place the outer pump rotor onto the inner pump rotor. 42. Install the 2 pins into the bores of the pump body. 43.
Assembling the Transmission (continued) g033471 Figure 111 1. Pump body 2. Center case 44. Place the pump body onto the center case and ensure that the O-rings remain in position. Install the 3 shorter and 2 longer flange-head screws to attach the pump body to the center case; torque the screws to 23 to 26 N∙m (17 to 19 ft-lb) in a crossing pattern. g033472 Figure 112 1. Hex plug (2 each) 2. Socket plug (4 each) 45. Lubricate new O-rings and install the O-rings onto the 2 hex plugs.
Assembling the Transmission (continued) g033473 Figure 113 1. Accumulator piston 3. Collar hole 2. Accumulator collar 4. Accumulator cover 47. Lubricate the accumulator components with clean hydraulic fluid. Install the piston, spring, and collar into the pump body. Note: Ensure that the hole in the collar is toward the outside of the pump body. 48. Align new gasket to the accumulator cover and secure the cover to the pump body with the 2 bolts; torque the bolts to 23 to 26 N∙m (17 to 19 ft-lb).
Assembling the Transmission (continued) g033475 Figure 115 1. Filter bypass valve 2. Filter bypass plug 52. Lubricate the filter bypass valve and spring with clean hydraulic fluid and install them into the pump body. 53. Lubricate new O-ring and install the O-ring onto the plug. Install the plug into the pump body; torque the plug to 23 to 26 N∙m (17 to 19 ft-lb). g033476 Figure 116 1. Sleeve 5. Spool step 2. Spool 6. Solenoid valve stem 3. 4. Pin Sleeve holes 7. Solenoid coil 54.
Assembling the Transmission (continued) 55. Place the pin in the spool. 56. Install the solenoid valve stem into the pump body and torque the solenoid valve stem to 21 to 22 N∙m (186 to 195 in-lb). 57. Install the O-ring, solenoid coil, O-ring, washer, lock washer, and nut onto the solenoid valve stem; torque the nut to 5.9 to 7.8 N∙m (52 to 69 in-lb). Note: The coil should be installed so that the "KANZAKI" molded into the coil has the "I" nearest the nut location.
Gear Pump g034386 Figure 117 1. Transmission assembly 7. Hydraulic hose (output) 13. Hydraulic hose 2. Coupler 8. Bolt (2 each) 14. Hydraulic hose (suction) 3. O-ring 9. Lock washer (2 each) 15. O-ring 4. O-ring 10. O-ring 16. Hydraulic fitting 5. Hydraulic fitting 11. Hydraulic fitting 17. O-ring 6. O-ring 12. Hose clamp 18.
Removing the Gear Pump (continued) g033478 Figure 118 1. Hydraulic tank 4. Right wheel motor 2. 3. Transmission Gear pump 5. Left wheel motor 6. Disconnect the hydraulic hoses from the fittings on the hydraulic tank and gear pump (Figure 118). Allow the hoses to drain into a suitable container. 7. Install clean caps or plugs in the hose and fitting openings to prevent system contamination. 8.
Installing the Gear Pump (continued) 3. Position the gear pump to the transmission and secure the pump with the 2 bolts and 2 lock washers. 4. Move the hydraulic tank toward the rear of the machine to its proper position and assemble the tank to the reservoir support; refer to Installing the Hydraulic Tank (page 4–64). 5. Install the parking brake handle to the machine; refer to Assembling the Parking Brake Assembly (page 6–16).
Servicing the Gear Pump g033479 Figure 119 1. Shaft seal 7. O-ring 13. Dowel pin (2 each) 2. Front pressure seal 8. Implement relief valve 14. Rear bearing block 3. Front back-up ring 9. Socket-head screw (4 each) 15. Idler gear 4. Drive gear 10. Lock washer (4 each) 16. Front bearing block 5. Rear back-up ring 11. Back plate 17. Front plate 6. Rear pressure seal 12. Body 18. Retaining ring Disassembling the Gear Pump 1.
Disassembling the Gear Pump (continued) 2. Use a marker to make a "V" across the front plate, body, and back plate for assembly purposes (Figure 120). IMPORTANT Clamping the pump body in a vise could damage the pump. When you clamp the pump in a vise, clamp the mounting flange only. 3. Clamp the mounting flange of the pump in a vise with the shaft end down. 4. Loosen the 4 socket-head screws that attach the back plate and front plate together. 5.
Inspecting the Gear Pump CAUTION Use eye protection such as goggles when using compressed air. 1. Clean all the pump parts with solvent and dry them with compressed air. 2. Inspect the drive gear, idler gear, and bearing blocks for the following. If damage is found, the pump replacement is necessary. g033481 Figure 121 1. Gear shaft spline 3. Gear teeth 2. Gear shaft 4. Gear face edge A. Gear shafts must be free from rough surfaces and excessive wear at the bushing points and sealing areas.
Assembling the Gear Pump (continued) 4. Lubricate and install the O-rings into the body. 5. Lubricate and install the pressure seals into the machined grooves of the bearing blocks and carefully place the back-up rings into the grooves. 6. Lubricate the gear faces and bearing surfaces of the drive gear, idler gear, and bearing blocks with clean hydraulic fluid. 7. Use the identification marks that you made during disassembly and carefully assemble the bearing blocks and gears. 8.
Lift Control Manifold g035138 Figure 122 1. Lift cylinder 6. O-ring 11. Hydraulic hose 16. O-ring 2. Lift control manifold 7. Hydraulic hose 12. O-ring 17. Bolt (2 each) 3. Hydraulic hose 8. O-ring 13. Hydraulic hose 18. Lock washer (2 each) 9. 90° hydraulic fitting 14. O-ring 19. Clip (2 each) O-ring 15. Hydraulic tee fitting 4. O-ring 5. Hydraulic fitting 10.
Removing the Lift Control Manifold (continued) 2. Clean the hydraulic hose ends and fittings on the lift control manifold to prevent contaminants from entering into the hydraulic system. 3. For assembly purposes, label all the hydraulic hoses and electrical connections. 4. Disconnect the hydraulic hoses from the fittings on the lift control manifold and drain the hoses into a suitable container. 5. Install clean caps or plugs on the hydraulic hoses and fittings to prevent system contamination. 6.
Servicing the Lift Control Manifold g035139 Figure 123 1. Lift control manifold 5. Solenoid coil 2. Zero-leak plug with O-ring 6. Coil spacer 3. Solenoid valve (raise) 7. Nut 4. Solenoid valve (lower) 8. Nut 9. 10. Expander plug (non-serviceable) Solenoid coil The lift control manifold on the machines with a serial number from 313000001 to 314999999 is different than the manifold used on the machines with a serial number above 315000000. Both the manifolds are shown in Figure 123.
Servicing the Lift Control Manifold CAUTION Before opening the hydraulic system, operate all the hydraulic controls to release system pressure and avoid injury from the pressurized hydraulic fluid; refer to Releasing Pressure from the Hydraulic System (page 4–11). WARNING If the lift control manifold is attached to the machine, ensure that the cutting deck is fully lowered and supported before loosening the hydraulic lines, and cartridge valves, or plugs from the lift manifold.
Servicing the Lift Control Manifold (continued) CAUTION Use eye protection such as goggles when using compressed air. CAUTION Sudden movement of the internal spools can release the stored fluid suddenly. 7. Use clean-mineral spirits to clean the cartridge valve. Put the valve in clean-mineral spirits to flush out contamination. IMPORTANT Particles as fine as talcum powder can affect the operation of high-pressure hydraulic valves.
Polar Trac Hydraulic Control Valve g033626 Figure 124 1. Grease fitting (2 each) 16. 45° hydraulic fitting (2 each) 31. O-ring 2. Pin assembly 17. O-ring 32. O-ring 3. Flange bearing 18. 45° hydraulic fitting 33. Hydraulic tube 4. Right pedal assembly 19. O-ring 34. Flange nut (2 each) 5. Flange bearing 20. Cable tie 35. Hairpin (2 each) 6. Left pedal assembly 21. O-ring 36. Lever valve link (2 each) 7. Regulatory decal 22. Hydraulic fitting 37. O-ring 8.
Removing the Polar Trac Hydraulic Control Valve WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11). 1. Park the machine on a level surface, lower the implement, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the hydraulic hose ends and fittings on the control valve to prevent contaminants from entering into the hydraulic system. 3.
Installing the Polar Trac Hydraulic Control Valve (continued) 2. Position the control valve to the frame of the machine and attach the control valve to the frame with the 2 carriage screws and 2 flange nuts. 3. Attach the lift lever valve links to the control valve spools with the 2 hairpins (Figure 125). 4. Remove the caps or plugs that were installed to the hydraulic hoses during the removal process. 5.
Servicing the Polar Trac Hydraulic Control Valve g034395 Figure 126 1. Check poppet 12. O-ring 23. Detent spring 2. Detent plunger 13. Retaining ring 24. O-ring 3. Spacer 14. Washer 25. O-ring 4. Spool 15. Seat retaining plug 26. Back-up washer 5. Seat (3 each) 16. Spool spring 27. O-ring 6. Solid plug 17. Disc 28. O-ring 7. Seat retaining plug (2 each) 18. Plug 29. O-ring 8. Bushing 19. Detent plug 30. Back-up washer 9. Check spring 20. Wiper seal 31.
Disassembling the Polar Trac Hydraulic Control Valve (continued) IMPORTANT Match-mark spools to their associated bores before disassembly. The spools must be installed again to the bore from which they were removed. 2. Remove the 2 spool caps (item 10 in Figure 126) and slide the spool assemblies from their bores. 3. Remove the O-ring (item 12 in Figure 126) and bushing from each spool assembly. 4.
Assembling the Polar Trac Hydraulic Control Valve (continued) 4. If a spool was disassembled, install the washer (item 14 in Figure 126), spool spring, spacer, and retaining ring to the spool. 5. Slide the bushings (item 8 in Figure 126) and new O-rings over the spools. 6. Lubricate the spools with a thick layer of clean hydraulic fluid and carefully install the spools into their proper bores. 7.
Lift Cylinder g033629 Figure 127 1. Grease fitting 10. O-ring 19. Flange-head screw 2. Retaining ring 11. Tee fitting 20. Bolt (2 each) 3. O-ring 12. O-ring 21. Lock washer (2 each) 4. Straight fitting (2 each) 13. O-ring 22. Lift control manifold 5. O-ring 14. Straight fitting 23. O-ring 6. Hydraulic hose assembly 15. O-ring 24. 90° hydraulic fitting 7. O-ring 16. Lift cylinder 25. O-ring 8. O-ring 17. Locknut 9. Hydraulic hose 18.
Removing the Lift Cylinder (continued) 3. For assembly purposes, label the hydraulic hoses. Also, label the orientation of the hydraulic hose at the cylinder head for correct assembly. g033630 Figure 128 1. Lift cylinder 2. Pivot pin 3. Flange-head screw 4. Disconnect the hydraulic hoses that are connected to the hydraulic fittings on the lift cylinder. 5. Install clean caps or plugs in the hose openings to prevent system contamination. 6.
Installing the Lift Cylinder (continued) 8. Ensure that the hydraulic tank is full. Add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. Servicing the Lift Cylinder g033631 Figure 129 1. Grease fitting 6. Collar 11. O-ring 2. Cylinder head 7. Shaft 12. Piston 3. 4. Nut O-ring 8. 9. Dust seal Rod seal 13. Piston seal 5. Head 10. Back-up ring Disassembling the Lift Cylinder 1.
Disassembling the Lift Cylinder (continued) IMPORTANT When you clamp the hydraulic cylinder in a vise, clamp the clevis only to prevent damage. 2. Mount the lift cylinder in a vise. Use a vise equipped with soft jaws. 3. Carefully remove the collar with a pipe wrench. 4. Remove the plugs from the ports. Carefully twist and pull the shaft and remove the shaft with head and piston. IMPORTANT Clamping the vise jaws against the shaft surface could damage the shaft.
Assembling the Lift Cylinder (continued) 5. Put a light coating of clean hydraulic fluid on all internal parts. Carefully slide the piston, shaft, and head assembly into the cylinder head. Note: Do not damage the seals. 6. Use a pipe wrench to install the collar and secure the head in the cylinder head.
Polar Trac Lift Cylinder g033632 Figure 130 1. Pin assembly 14. Bulkhead fitting (2 each) 27. Flange bushing 2. Flange bearing (2 each) 15. O-ring 28. Retaining ring (2 each) 3. Grease fitting (4 each) 16. Quick disconnect nipple 29. Shaft 4. Locknut (2 each) 17. Dust cap 30. Rubber grommet (4 each) 5. Locknut 18. Dust plug 31. Screw 6. Lift cylinder 19. Quick disconnect coupler 32. Locknut (2 each) 7. O-ring (2 each) 20. O-ring 33. Flange-head screw (2 each) 8.
Removing the Polar Trac Lift Cylinder WARNING Before disconnecting or doing any work on the hydraulic system, release all the pressure in the system; refer to Releasing Pressure from the Hydraulic System (page 4–11). 1. Park the machine on a level surface, lower the implement, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Clean the hydraulic hose ends and fittings on the lift cylinder to prevent contaminants from entering into the hydraulic system. 3.
Servicing the Polar Trac Lift Cylinder g033633 Figure 131 1. Cap seal 6. O-ring 11. Back-up ring 2. Cylinder head 7. Rod 12. Piston 3. Locknut 8. Wiper 13. Wear ring 4. O-ring 9. Seal 5. Head 10. Retaining ring Disassembling the Polar Trac Lift Cylinder 1. Slowly pump the cylinder rod and remove the hydraulic fluid from the lift cylinder into a drain pan. Plug the 2 ports and clean the outer surface of the cylinder.
Disassembling the Polar Trac Lift Cylinder (continued) IMPORTANT When you clamp the lift cylinder in a vise, clamp the clevis end of the cylinder head only to prevent damage. 2. Mount the lift cylinder correctly in a vise by clamping the clevis end of the cylinder head. Use a vise equipped with soft jaws. 3. Use a spanner wrench, rotate the head clockwise until the edge of the retaining ring appears in the cylinder head opening.
Assembling the Polar Trac Lift Cylinder (continued) B. Carefully install the back-up ring, O-ring, seal, and wiper to the head. IMPORTANT Clamping the vise jaws against the rod surface could damage the rod. When securing the rod in a vise, clamp the rod clevis only. 3. Mount the rod correctly in a vise by clamping on the clevis of the rod, and do the following steps: A. Put a coating of clean hydraulic fluid on the rod. B. Slide the head onto the rod. C.
Oil Cooler Removing the Oil Cooler 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. CAUTION A hot radiator and oil cooler can cause burns. Allow the engine and cooling systems to cool before working on or near them. 3. Remove the radiator and oil cooler from the machine; refer to Removing the Radiator (page 3–13). 4.
Inspecting the Oil Cooler (continued) g035023 Figure 132 1. 5. Screw (3 each) Radiator cap 2. Flat washer (6 each) 6. Pipe plug 3. Lock washer (3 each) 7. Radiator 4. Nut (3 each) 8. Oil cooler 2. Use compressed air in the opposite direction of the fluid flow and dry the interiors of the oil cooler. 3. Install clean plugs on the oil cooler ports. Clean the outer surface of the cooler. Note: The oil cooler must be free from corrosion, cracked tubes, or excessive pitting of tubes.
Hydraulic System: Service and Repairs Page 4–136 Groundsmaster 7210 16222SL Rev F
Chapter 5 Electrical System Table of Contents General Information .............................................................................................................................. 5–3 Standard Control Module ................................................................................................................... 5–3 Standard Control Module Logic Chart ................................................................................................
Adjustments ........................................................................................................................................ 5–54 Parking Brake Sensor ...................................................................................................................... 5–54 Service and Repairs ........................................................................................................................... 5–56 PTO Solenoid Valve Coil ........................................
General Information The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine. Standard Control Module g034387 Figure 133 1. Flange nut 4. Control panel cover 2. Standard Control Module (SCM) 5. Latch 3.
SCM Inputs (continued) The PTO switch input LED should be illuminated when the PTO switch is ON (pulled out). The In seat input LED should be illuminated when the operator is sitting in the seat. The high-temperature shutdown input LED should be illuminated when the engine dual temperature switch closes due to engine coolant temperature of approximately 115°C (240°F).
Standard Control Module Logic Chart Each line of the following chart (Figure 135) identifies the necessary component position (inputs) in order for the SCM to energize the appropriate outputs for operating the machine. Example: To start the engine with an operator in the seat, when the key is in the START position, the 2 traction control levers in the NEUTRAL LOCK position, and the parking brake is not set, the engine components and engine starter is energized.
Standard Control Module Logic Chart (continued) g034737 Figure 135 Electrical System: General Information Page 5–6 Groundsmaster 7210 16222SL Rev F
Yanmar Engine Electronic Control Unit (ECU) g034741 Figure 136 1. Air cleaner 2. Electronic Control Unit (ECU) 3. Battery The Yanmar engine that powers the Groundsmaster 7210 machine uses an electronic control unit (ECU) for engine management and to communicate with the InfoCenter display on the machine. If you must disconnect the engine ECU for any reason, ensure that the key switch is in the OFF position with the key removed for a minimum of 30 seconds before disconnecting the engine ECU.
CAN-bus Communications (continued) The CAN bus link controls each of the components that requires only 4 wires to operate and communicate to the system: CAN High, CAN Low, B+ (power), and ground. Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A (page A–1)—Foldout Drawings.
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter g033636 Figure 137 The meter can test the electrical components and circuits for current, resistance, or voltage. Note: Use a digital multimeter when testing the electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter.
Battery Hydrometer g033640 Figure 139 Use the battery hydrometer when measuring the specific gravity of the battery electrolyte. You can get this tool locally. Dielectric Gel g033639 Figure 140 Use the dielectric gel to prevent corrosion of unsealed connection terminals.
InfoCenter Display The InfoCenter Display used on your Groundsmaster is a LCD device that is located on the console. The InfoCenter provides information to the operator during the operation of the machine, provides the electrical system diagnostic assistance for the technicians, and allows inputs for the adjustable machine settings. The power for the InfoCenter is available when the main power relay is energized (key switch in the RUN or START position).
Main Information Screen g035029 Figure 142 1. Engine coolant temperature 4. Right button 2. Battery voltage 5. Down button 3. Hour meter 6. Menu/back button g035030 Figure 143 1. Engine coolant temperature 4. Right button 2. Battery voltage 5. Down button 3. Engine RPM 6. Menu/back button The 2 InfoCenter main information screens (Figure 142 and Figure 143) are displayed after the initial splash screen has been displayed for several seconds.
Main Information Screen (continued) provide machine information to the operator. Toggling between the main information screens is done by pressing the right button on the InfoCenter. The main information screens can be used to monitor the engine coolant temperature, battery voltage, and engine RPM. If an electrical engine fault occurs during the operation of the machine, the fault will be displayed on the InfoCenter to notify the operator.
Service Screen The service screen contains operational information of the machine including hours and counts. The values listed for these service menu items cannot be changed. If the machine PIN has been entered to get access to the protected menu items in the settings screen, the protected service menu items will be listed and available in the service screen. Note: If the protected menu items are available, the PIN is shown in the upper right corner of the InfoCenter display.
Settings Screen (continued) To get access to the protected menu items, enter the 4 digit pin PIN using the center and right InfoCenter buttons. After the PIN has been entered, a check mark should be visible above the center InfoCenter button. Press the center button and the InfoCenter display screen should indicate “PIN” in the upper right hand corner if the correct PIN number was entered. Use the back button to return to the settings menu.
Troubleshooting CAUTION Remove all the jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For the effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components that are used on this machine; refer to the Electrical Schematics in Appendix A (page A–1)—Foldout Drawings.
Starting Problems (continued) Groundsmaster 7210 16222SL Rev F Nothing happens when you attempt to start the engine. The InfoCenter display operates with the key switch in the RUN position. • The traction levers are not in the NEUTRAL LOCK position. • The operator seat is unoccupied or the parking brake is not applied. • The traction neutral switch(es) is(are) damaged or out of adjustment. • The PTO switch is in the ON (up) position or it is damaged.
General Run and Transport Problems Problem Possible Causes The engine continues to run, but should not, when the key switch is turned to the OFF position. • The batteries are discharged. • The battery cables are loose or corroded. • The fuse F1 (15 A) to the key switch is damaged. • The key switch or circuit wiring is damaged. The engine shuts off during the operation, but it is able to start again. • The parking brake is engaged.
Cutting Deck Operating Problems (continued) The cutting deck run, but should not, with the PTO switch in the OFF (disengage) position. • The PTO switch or circuit wiring is damaged. • A hydraulic problem in the mow circuit exists; refer to Chapter 4: Hydraulic System (page 4–1). The cutting deck does not operate with the PTO switch in the ON (up) position. • The operator seat is unoccupied. • The hydraulic-fluid level in the hydraulic tank is low. • The seat switch or circuit wiring is damaged.
Electrical System Quick Checks Testing the Battery (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals; refer to Battery Test Table (page 5–20). Set the multimeter to the DC volts settings. The battery must be at a temperature of 16°C to 38°C (60°F to 100°F). Ensure that the key is in the OFF position and all the accessories are turned off. Connect the positive (+) meter lead to the positive battery post and negative (-) meter lead to the negative battery post.
Testing the Charging System (continued) Battery Voltage Table At least 0.50 V over the initial battery voltage. Initial battery voltage = 12.30 V Battery voltage after 3 minutes charge = 12.85 V Difference = +0.55 V Testing the Glow Plug System This is a fast, simple test that helps to determine the integrity and operation of the Groundsmaster glow plug system. Perform this test when you find hard starting (cold engine) on a diesel engine equipped with a glow plug system.
Checking the Operation of the Interlock Switches (continued) 3. With the operator in the seat, the traction control levers in the NEUTRAL LOCK position, the parking brake off and the PTO switch in the OFF position, the engine must start. Lift off the seat and slowly move the traction control levers from the NEUTRAL LOCK position, the engine must stop in 1 to 3 seconds. Correct the problem if the machine is not operating properly.
Testing the Electrical Components For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g., unplug the key switch connector before doing a continuity check of the switch). Note: For the engine component testing information; refer to the Yanmar Engine Service Manual. IMPORTANT When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit.
g033642 Figure 149 The key switch (item 1 in Figure 147) has 3 positions (OFF, ON/PREHEAT , and START ) (Figure 148). The key switch terminals are identified as shown in Figure 149. The Standard Control Module (SCM) monitors the operation of the key switch. When the key switch is in the ON position, the SCM power input LED must be illuminated. Testing the Key Switch 1.
PTO Switch g034742 Figure 150 1. PTO switch 2. Control panel g033647 Figure 151 1. 2. 3. COM B terminal NO B terminal NC B terminal 4. 5. 6. COM C terminal NO C terminal NC C terminal The PTO switch is located on the control panel (Figure 150). Pull up the PTO switch to engage the PTO (cutting deck or implement). The Standard Control Module (SCM) monitors the position of the PTO switch (up or down).
IMPORTANT During the operation of the machine, if the PTO shuts down and the console temperature warning light is illuminated because of excessive engine coolant temperature, avoid shutting off the engine. Under this condition, push the PTO knob down, slowly drive to a safe flat area, move the throttle lever to the SLOW position, move the traction control levers into the NEUTRAL LOCK position, and set the parking brake.
Neutral Switches g035048 Figure 152 1. Left cover 2. Bolts 3. Right cover g033649 Figure 153 1. 2. Traction lever (left) Neutral switch The Groundsmaster 7210 machine uses 2 identical neutral switches. These neutral switches are normally open and close when the traction levers are in the NEUTRAL LOCK position. The neutral switches are located under the left cover and right cover below the operator seat (Figure 152 and Figure 153).
Testing the Neutral Switches (continued) 2. If the SCM verifies that the neutral switches and circuit wiring are functioning correctly, then no more switch testing is necessary. 3. If the SCM determines that the neutral switch and circuit wiring are not functioning correctly, then test each neutral switch as follows: A. Ensure that the key switch is in the OFF position and locate the neutral switches for testing. B. Disconnect the machine wire harness electrical connector from the neutral switch. C.
Seat Switch The seat switch is normally open and closes when the operator is on the seat. If the traction system or PTO switch is engaged when the operator raises out of the seat, the engine shuts off. The seat switch and its electrical connector are located directly under the seat (Figure 155). The Standard Control Module (SCM) monitors the status of the seat switch. If the key switch is in the ON position and the seat is occupied, the SCM In seat input LED should be illuminated.
Testing the Seat Switch (continued) WARNING To prevent injury, do not attempt to reach the switch through openings in the seat plate. If seat switch service is necessary, remove the seat from the seat plate to access the switch. F. If the continuity test is incorrect, remove the seat; refer to the Operator Seat (page 6–35). Check the seat switch and/or seat switch harness for continuity. Repair or replace the components as necessary. G.
Engine Oil Pressure Switch g035302 Figure 156 1. Engine oil pressure switch 2. Engine oil filter The engine oil pressure switch is located on the engine near the oil filter (Figure 156). The oil pressure switch is a normally closed switch that opens with oil pressure. The oil pressure switch opens from 40 to 60 kPa (5.8 to 8.8 psi). The oil pressure switch is connected to the engine controller.
Testing the Engine Oil Pressure Switch (continued) 7. After you complete the oil pressure switch testing, connect the ECU wire harness connector to the oil pressure switch.
Parking Brake Sensor g034729 Figure 157 1. Parking brake lever 5. Lock washer (2 each) 2. Parking brake shaft 6. Bracket 3. Flange bearing 7. Parking brake sensor 4. Jam nut (2 each) 8. Tab The parking brake sensor is a normally open proximity sensor that is mounted below the parking brake shaft (Figure 157). The sensing plate for the brake sensor is the tab that is on the brake shaft.
Testing the Parking Brake Sensor (continued) 7. Turn the key switch to the RUN position (do not start the engine) and check the LED on the cable end of the parking brake sensor. The LED should be illuminated when the parking brake is not set (the brake latch is not engaged). 8. With the key switch is still in the RUN position (do not start the engine), set the parking brake (the brake latch engaged) and check the LED on the cable end of the parking brake sensor.
PTO Solenoid Valve Coil g033657 Figure 158 1. 2. Transmission Solenoid valve and coil 3. Coil connector The hydraulic system of the Groundsmaster 7210 machine uses a solenoid valve coil on the front of the transmission (Figure 158). 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.
Fusible Link Harness g034743 Figure 159 1. Fusible link harness g033658 Figure 160 The Groundsmaster 7210 machine uses 3 fusible links for the 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 fail, current to the protected circuit stops; refer to the Electrical Schematics in Appendix A (page A–1)—Foldout Drawings.
Diode Assemblies Several identical diodes are used on the Groundsmaster 7210 machines. The maximum current allowed through any of the diodes is 6 A. The diode assemblies can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 161). A diode assembly is used for circuit protection from the voltage spikes that occur when the engine starter solenoid is de-energized.
Testing the Diode Assembly (continued) Diode Test Table Multimeter Red Lead (+) on Terminal Multimeter Black Lead (-) on Terminal Continuity Female Male Yes Male Female No Resistor Assembly The resistor assembly is used in all the engine wire harnesses for GM7210 machines that is necessary for operating the key switch.
Glow Relay g035044 Figure 163 1. Glow relay g034744 Figure 164 The glow relay of the Groundsmaster 7210 machine has 4 terminals and allows electrical current to the engine glow plugs when energized. The glow relay is attached to the ECU bracket that is located above the battery. The ECU energizes the glow relay when you initially turn the key switch to the ON/PREHEAT position and also to the START position. Testing the Glow Relay 1. Unlatch the hood and raise it. 2.
Testing the Glow Relay (continued) 3. Check the coil resistance between the terminals 85 and 86 with a multimeter (ohms setting). Note: The resistance must be approximately 72 ohms. 4. Connect the multimeter (ohms setting) leads to the relay terminals 30 and 87. Then ground terminal 85 and apply +12 VDC to terminal 86. The relay must break the continuity between the terminals 30 and 87 as +12 VDC is set and removed from terminal 86. 5. Disconnect the voltage and leads from the relay terminals. 6.
Start and EGR Relays g034747 Figure 165 1. Start relay 3. ECU bracket 2. EGR relay 4. ECU g034753 Figure 166 1. Coil terminal 3. Normally open term 2. Normally closed term 4. Common terminal The Groundsmaster 7210 machine uses 2 identical relays that have 5 terminals to control power to the starter motor solenoid and EGR valve of the engine. The relays are attached to the ECU bracket above the battery (Figure 165).
Testing the Start or EGR Relays (continued) 6. Use a multimeter (ohms setting), measure the coil resistance between the terminals 85 and 86. Note: The resistance should be 71 to 88 ohms. 7. Connect the multimeter (ohms setting) leads to the relay terminals 30 and 87. Then ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between the terminals 30 and 87 as +12 VDC is set and removed from terminal 85. 8.
Fuel Pump g034746 Figure 167 1. Fuel supply hose 3. ROPS tube 2. Left fuel tank 4. Fuel pump The fuel pump is attached to the ROPS tube near the left fuel tank (Figure 167). The Standard Control Module Run output LED illuminates when the fuel pump is energized. Testing the Fuel Pump 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, and set the parking brake. Ensure that the key switch is in the OFF position. 2.
Testing the Fuel Pump (continued) Note: The amount of fuel pumped in 30 seconds must be approximately 350 ml (11.8 fl oz). 9. Replace the fuel pump as necessary. Connect the fuel hose to the fuel filter. 10. Prime the fuel system; refer to Priming the Fuel System (page 3–18). Fuel Pump Specifications Pump Capacity 700 ml/minute (23.5 fl oz/minute) Pressure 21.5 to 37.3 kPa (3.1 to 5.4 psi) Maximum Current Draw 0.9 A 11. Lower the operator seat. 12. Lower the hood and secure it with the latches.
Dual Temperature Switch g034740 Figure 168 1. Dual temperature switch g035304 Figure 169 1. Dual temperature switch 2. Shutdown circuit 3. Warning circuit The dual temperature switch includes 2 normally open circuits that are used to monitor the engine coolant temperature. These switch circuits are the high-temperature warning circuit and high-temperature shutdown circuit. The dual temperature switch is attached to the engine water pump housing (Figure 168).
and its circuit wiring using the SCM before you perform the following testing procedure. Testing the Dual Temperature Switch 1. Park the machine on a level surface, lower the implement, shut off the engine, set the parking brake, and remove the key from the key switch. Open the hood to get access to the engine. DANGER If the radiator or engine is hot, pressurized hot coolant can escape and cause burns. Do not open the radiator cap or drain the radiator when the coolant is hot.
Testing the Dual Temperature Switch (continued) B. Thread the switch into the housing; torque the switch to 29.4 to 39.2 N∙m (22 to 28 ft-lb). C. Connect the harness wires to the temperature switch. 7. Fill the engine cooling system. 8. Lower the hood and secure it with the latches. Fuses g034750 Figure 171 1. Fuse F4 (2 A) 3. Fuse F2 (10 A) 2. Fuse F3 (10 A) 4. Fuse F1 (15 A) g034749 Figure 172 1. ECU 2.
In addition to the fuses in the fuse block, a 25 A fuse is included in the engine wire harness to protect the power circuit to the ECU. This fuse is located near the ECU (Figure 172). Identification and Function Refer to Figure 171 to identify each individual fuse and its correct amperage in the fuse block. The fuses have the following functions. The fuse F1 (15 A) protects power supply for the key switch circuits and optional light kit. The fuse F2 (10 A) protects the SCM start circuit.
CAN-bus Terminator Resistor g035036 Figure 173 1. CAN-bus terminator resistor 2. Keyway The system communication between the electrical components on the Groundsmaster 7210 machine is accomplished on a CAN-bus communication system. The 2 specially designed, twisted wires form the bus for the network are used on your machine. These wires provide the data pathways between the machine components.
Deck Lift/Lower Switch g035037 Figure 174 1. Right traction lever 2. Deck lift/lower switch The deck lift/lower switch is used to raise and lower the cutting deck of your machine. The switch is attached to the right traction lever (Figure 174). The lift/lower switch is connected to the switch wire harness that runs through the right traction lever and connects to the main wire harness below the control panel.
Testing the Deck Lift/Lower Switch g035038 Figure 175 1. Switch cap 4. Screw (2 used) 2. Switch wire harness 5. Right traction lever 3. Deck lift/lower switch 1. Ensure that the key switch is in the OFF position and the key is removed from the key switch. 2. Move the right traction lever out of the NEUTRAL position and remove the 2 screws that secure the switch cap to the right motion control handle (Figure 175).
Lift Control Manifold Solenoid Valve Coil g034755 Figure 176 1. Solenoid coil 2. Deck lift manifold g034754 Figure 177 The hydraulic lift control manifold valve is located on the right side of the machine, near the rear left wheel. When the solenoid coils are energized, the valve shift occurs to control the hydraulic fluid flow. The electrical testing of the coils can be done with the coil installed on the hydraulic valve.
Testing the Lift Control Manifold Solenoid Valve Coil 1. Ensure that the key switch is in the OFF position. 2. Disconnect the wire harness electrical connector from the solenoid valve coil that is to be tested (Figure 176). 3. Identify the coil resistance specification by measuring the coil diameter and coil height (Figure 177). Note: Before taking the small resistance readings with a digital multimeter, short the multimeter test leads together. The multimeter displays a small resistance value (usually 0.
Adjustments Parking Brake Sensor g034729 Figure 178 1. Parking brake lever 5. Lock washer (2 each) 2. Parking brake shaft 6. Bracket 3. Flange bearing 7. Parking brake sensor 4. Jam nut (2 each) 8. Tab g035039 Figure 179 1. Parking brake shaft 3. Parking brake sensor 2. Tab 4. Gap The parking brake sensor acts as an input for the SCM controller to determine when the parking brake is set (the brake latch engaged).
When the parking brake is not set (the brake latch not engaged), the parking brake tab is positioned near the target end of the parking brake sensor so that the sensor is closed. The parking brake tab is moved away from the sensor when the parking brake is set (the brake latch engaged) causing the sensor to open. Adjusting the Parking Brake Sensor 1. When the parking brake is not set (the brake latch is not engaged), the gap between the parking brake sensor and the tab on the parking brake should be 2.
Service and Repairs Note: For the engine electrical component repair information; refer to Chapter 3: Diesel Engine (page 3–1). PTO Solenoid Valve Coil g036991 Figure 180 1. 2. Transmission Solenoid valve and coil 3. Coil connector g036300 Figure 181 1. 2. 3. Hex nut Lock washer Washer 4. 5. Seal Solenoid valve coil You can replace the PTO solenoid valve coil on the transmission without opening the hydraulic system (Figure 180).
Removing the PTO Solenoid Valve Coil 1. Park the machine on a level surface, lower the cutting deck (or implement), set the parking brake, shut off the engine, and remove the key from the key switch. 2. Raise the operator seat to get access to the PTO solenoid valve coil. 3. Disconnect the wire harness electrical connector from the PTO solenoid valve coil connector. 4. Remove the nut from the spool assembly. 5. Slide the coil assembly from the solenoid valve stem (Figure 181). 6.
Lift Control Manifold Solenoid Valve Coils g035040 Figure 182 1. Solenoid nut 5. Zero-leak plug 2. 3. 4. Coil Solenoid Valve Deck lift manifold 6. 7. 8. Solenoid valve Coil Coil nut You can replace a hydraulic solenoid valve coil on the deck lift manifold (Figure 182) without opening the hydraulic system. Removing the Lift Control Manifold Solenoid Valve Coils 1.
Battery Storage If you store the machine for more than 30 days: 1. Ensure that the key switch is in the OFF position. Remove the battery and charge it fully; refer to Servicing the Battery (page 5–61). 2. Either store the battery on a shelf or on the machine. 3. Disconnect the cables if the battery is kept on the machine. 4. Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
Battery Care 1. The battery-electrolyte level must be properly maintained. The top of the battery must be kept clean. If the machine is stored in a location where the temperatures are extremely high, the battery will discharge more rapidly than if the machine is stored in a location where the temperatures are cool. WARNING The gases are explosive; also, they can cause nausea. • Wear safety goggles and rubber gloves when working with electrolyte.
Servicing the Battery The battery is the heart of the electrical system. With the regular and correct service, the battery life can be extended. Additionally, the battery and electrical component failure can be prevented. CAUTION Battery-electrolyte is corrosive and can burn skin and eyes and damage clothing. While working with the batteries, use extreme caution to avoid splashing or spilling of the electrolyte. Always wear the safety goggles and a face shield while working with batteries.
Removing the Battery (continued) IMPORTANT Be careful when removing the battery cables and ensure that you do not damage the terminal posts or cable connectors. 1. Unlatch, raise the hood and support it. Loosen the battery retainer that secures the side of the battery to the frame. 2. Loosen the nut on the ground cable (-) first and remove the ground cable from the battery. This must prevent the short circuiting the battery, other components, or the operator’s hands. 3.
Inspecting, Maintaining, and Testing the Battery (continued) B. Temperature correct each cell reading. For each 5.5°C (10°F) above 26.7°C (80°F) add 0.004 to the specific gravity reading. For each 5.5°C (10°F) below 26.7°C (80°F) subtract 0.004 from the specific gravity reading; refer to the Cell Specific Gravity Example (page 5–63). Cell Specific Gravity Example Cell Temperature 100°F Cell Specific Gravity 1.245 37.7°C minus 26.7°C equals 11.0°C (100°F minus 80°F equals 20°F) 11°C multiply by 0.004/5.
Inspecting, Maintaining, and Testing the Battery (continued) H. Use the Minimum Voltage Table (page 5–64), determine the minimum voltage for the center cell electrolyte temperature reading. Minimum Voltage Table Minimum Voltage I. Battery-Electrolyte Temperature 9.6 70°F (and up) 21.1°C (and up) 9.5 60°F 15.6°C 9.4 50°F 10.0°C 9.3 40°F 4.4°C 9.1 30°F -1.1°C 8.9 20°F -6.7°C 8.7 10°F -12.2°C 8.5 0°F -17.8°C If the test voltage is below the minimum, replace the battery.
Charging the Battery To minimize damage to the battery and allow the battery to charge fully, do the following slow charging procedure. You can do this charging procedure with a constant current battery charger that is locally available. IMPORTANT Follow the manufacturer's instructions when using a battery charger. Note: Using specific gravity of the battery cells is the most accurate procedure of determining the battery condition. 1.
Charging the Battery (continued) CAUTION Charging a frozen battery can cause explosion and can cause personal injury. Let the battery warm to 15.5°C (60°F) before connecting to a charger. • Charge the battery in a well-ventilated place to dissipate the gases produced from the charging. • These gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke. • Inhaling the battery gases can cause nausea.
Chapter 6 Chassis Table of Contents Specifications ....................................................................................................................................... 6–2 ........................................................................................................................................................... 6–2 General Information ..............................................................................................................................
Specifications Item Description Rear tire pressure 124 kPa (18 psi) Castor wheel (front) tire pressure 172 kPa (25 psi) Tire pressure (machines with Polar Trac) 241 kPa (35 psi) Rear wheel lug nut torque 102 to 115 N∙m (75 to 85 ft-lb) Wheel lug nut torque (machines with Polar Trac) 88 to 115 N∙m (65 to 85 ft-lb) Rear wheel hub locknut torque Chassis: Specifications 407 to 542 N∙m (300 to 400 ft-lb) Page 6–2 Groundsmaster 7210 16222SL Rev F
General Information The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine.
Service and Repairs Rear Wheels g033677 Figure 184 1. Locknut 2. Wheel lug nut (5 each per wheel) 3. Wheel assembly 4. Wheel hub 9. 5. Wheel stud (5 each per wheel) 6. Socket-head screw (4 each) 11. O-ring 7. Wheel motor (left) 12. Hydraulic fitting 8. Woodruff key 13. Hydraulic hose O-ring 14. Hydraulic hose Hydraulic fitting 15. Parking brake (left) 10. Removing the Rear Wheel 1.
Removing the Rear Wheel (continued) IMPORTANT Before lifting the machine with a jack, review and follow Jacking Instructions (page 1–6). Do not support the machine on the rear wheel hubs (brake rotors). 3. Lift the rear wheel with a jack and use appropriate jack stands to support the machine. 4. Remove the 5 wheel-lug nuts and 5 wheel studs that attach the rear wheel to the wheel hub, and remove the rear wheel. Installing the Rear Wheel 1.
Polar Trac Wheels g033678 Figure 185 7. 8. Drive track Woodruff key 13. 14. Locknut Flat washer 9. Wheel stud (5 each per hub) 15. Hex nut Rear wheel motor (left) 16. Bogie pivot assembly (left) 11. Parking brake (left) 17. Wheel stud (5 each per hub) 12. Screw (4 each per motor) 1. 2. Front frame Bogie assembly 3. Locknut 4. Rear wheel hub (left) 10. 5. Wheel assembly (6 each) 6.
Removing the Polar Trac Wheels (continued) g033679 Figure 186 1. Side access cover 2. Locknut and flat washer 2. Loosen, but do not remove the wheel-lug nuts that attach the wheels to the machine. 3. Position the 2 jack stands under the rear bumper tube at a height so that they contact or nearly contact the bumper. 4. On the side of the machine that is to have the wheel(s) removed (Figure 186): A. Remove the 2 screws that attach the side access cover to the machine, and remove the access cover. B.
Installing the Polar Trac Wheels 1. If the track was removed from the machine, position the track to the wheel location. Note: Ensure that the direction arrow on the track is correctly orientated. Note: When installing the wheels to a Polar Trac equipped machine, install the center wheel last to allow track clearance for the front and rear wheels. 2. Have a second person to lift the track to install the front and/or rear wheel to the machine. 3. Install the wheel(s) to the machine with the 5 wheel-lug nuts.
Parking Brakes g033680 Figure 187 1. Locknut 2. Wheel lug nut (5 each per wheel) 3. Wheel assembly 11. O-ring 19. Brake support 4. Wheel hub 12. Hydraulic fitting 20. Brake rod assembly 5. Wheel stud (5 each per wheel) 13. Hydraulic hose 21. Flat washer 6. Socket-head screw (4 each) 14. Hydraulic hose 22. Retaining ring 7. Wheel motor (left) 15. Parking brake (left) 8. Woodruff key 16. Flange nut (4 each per side) 9. 10. O-ring 17.
Removing the Parking Brakes (continued) g033681 Figure 188 1. Parking brake assembly 3. Brake support 2. Locknut 4. Hardened washer g033682 Figure 189 1. Wheel hub 4. Brake support 2. Parking brake assembly 5. Hardened washer 3. Locknut 4. Remove the retaining ring and flat washer that retains the brake rod assembly to the parking brake lever. Separate the brake rod from the brake lever. 5. Remove the 4 bolts and 4 flange nuts that attach the brake support to the frame. 6.
Removing the Parking Brakes (continued) IMPORTANT If you must remove the wheel hub, do not hit the wheel hub or hub puller with a hammer while removing. Hammering can damage the hydraulic wheel motor or wheel hub. 9. If necessary, use a wheel-hub puller to loosen the wheel hub from the wheel motor shaft. 10. Remove the locknut that is loosened, remove the wheel hub from the wheel motor, and remove the woodruff key from the shaft. Installing the Parking Brakes 1.
Installing the Parking Brakes (continued) g033683 Figure 190 1. 2. Brake swivel Caliper brake lever 3. Wheel hub disc 4. 5. Hardened washer Clearance 7. Adjust the position of the brake support so that the clearance between the wheel hub disc and the 2 springs in the parking brake is 0.8 to 1.7 mm (0.030 to 0.070 inch). When the clearance is correct, fully tighten the 4 bolts and 4 flange nuts (Figure 190). 8.
Servicing the Parking Brake g033684 Figure 191 1. Lever 8. Sleeve (2 each) 15. Socket-head screw (2 each) 2. Assembly sleeve (2 each) 9. Steel ball (3 each) 16. Outer stator (brake pad) 3. Hardened washer (2 each) 10. Spring pin 17. Inner stator (brake pad) 4. Hex bolt (2 each) 11. Compression spring (2 each) 18. Shim 19. Washer 5. Mounting locknut (2 each) 12. Mount sleeve (2 each) 6. Hex nut (2 each) 13. Hex nut (2 each) 7. Stationary actuator 14.
Assembling the Parking Brake (continued) 3. Secure the brake assembly with the 2 hex bolts (item 4 in Figure 191), 2 socket-head screws, and 4 hex nuts; torque the hex bolts to 41 to 54 N∙m (30 to 40 ft-lb) and socket-head screws to 24 to 31 N∙m (18 to 23 ft-lb).
Parking Brake Assembly g033685 Figure 192 1. Brake handle 9. Retaining ring (2 each) 17. Control bearing (4 each) 2. Nut (4 each) 10. Screw (4 each) 18. Hairpin cotter (6 each) 3. Flange bearing (2 each) 11. Proximity switch assembly 19. Clevis pin (2 each) 4. Rear brake rod (2 each) 12. Hex nut (2 each) 20. Brake linkage yoke (2 each) 5. Hex nut (10 each) 13. Lock washer (2 each) 21. Front brake rod (2 each) 6. Swivel assembly (2 each) 14. Switch bracket 22.
Disassembling the Parking Brake Assembly (continued) g033686 Figure 193 1. Left cover 2. Bolt (2 each) 2. Remove the 2 bolts (item 2 in Figure 193) that attach the left cover to the machine, and remove the left cover. 3. If necessary, remove the brake handle (item 1 in Figure 192) as follows: A. On both sides of the machine, remove the hairpin cotter and clevis pin from the brake linkage yoke. B. Support the brake handle to prevent it from shifting or falling. C.
Assembling the Parking Brake Assembly (continued) g033688 Figure 195 1. Rear brake rod 4. Rear hex nut (2 each) 2. Compression spring 5. Swivel 3. Flat washer (2 each) 6. Front hex nut (2 each) 2. After you assemble the brake system, set the parking brake and check the length of the compression spring on the rear brake rod. Note: Ensure that the length of the spring with the brake applied is 7.4 to 7.6 cm (2.880 to 3.000 inch).
Front Castor Wheels g033689 Figure 196 1. Floorplate assembly 8. Plug 15. Seal (2 each) 2. Carrier frame assembly 9. Bearing cup 16. Bearing cone (4 each) 3. Retainer pin (2 each) 10. Locknut (3 each) 17. Belleville washer (6 each) 4. Taptite screw (2 each) 11. Bolt (2 each) 18. Locknut (2 each) 19. Grease cap (2 each) 5. Grease fitting (2 each) 12. Castor wheel assembly (2 each) 6. Castor arm assembly 13. Locknut (2 each) 7. Screw (3 each) 14.
Disassembling the Front Castor Wheels (continued) g033690 Figure 197 1. Locknut 2. Belleville washer 3. Upper bearing cone g033691 Figure 198 1. Bearing spacer 4. Bearing cup 2. 3. Seal Bearing cone 5. 6. Castor wheel Castor spacer 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch.
Disassembling the Front Castor Wheels (continued) 6. Support the castor fork to prevent it from falling. Remove the locknut (item 18 in Figure 196) from the castor fork and slide the castor fork from the machine. 7. Remove the 3 belleville washers and upper bearing cone from the carrier frame. Note the orientation of the washers while removing them (Figure 197). Note: The belleville washer orientation is critical for proper movement of the castor wheel. 8.
Assembling the Front Castor Wheels (continued) Note: Periodic greasing of the castor fork bearing area is not necessary. Do not replace the plug (item 8 in Figure 196) with a grease fitting. The grease cap (item 19 in Figure 196) will loosen if the castor fork has excessive grease installed. 8. Install new grease cap (item 19 in Figure 196) so that the cap shoulder is flush with the top of the carrier frame. Note: There should be no evidence that the cap is indented by the top of the castor fork. 9.
Servicing the Polar Trac Wheel Hub g033692 Figure 199 1. Frame 5. Wheel assembly 2. Bogie assembly 6. Wheel lug nut (5 each per wheel) 10. Pivot pin 3. Flange nut 7. Drive track 11. Shoulder bolt 4. Shoulder screw 8. Pivot pin 9. Pivot (left) Disassembling the Polar Trac Wheel Hub Note: Refer to the Polar Trac Operator's Manual for additional information regarding the drive track and wheel removal.
Disassembling the Polar Trac Wheel Hub (continued) g033693 Figure 200 1. Dust cap 5. Bearing cup 2. Cotter pin 6. Wheel hub 3. Slotted hex nut 7. Wheel stud (5 each) 4. Bearing cone 8. Seal 1. Park the machine on a level surface, lower the implement, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the wheels as necessary to get access to the wheel hub(s); refer to Removing the Polar Trac Wheels (page 6–6). 3.
Assembling the Polar Trac Wheel Hub (continued) 3. Lubricate the inside of a new seal and press the seal into the wheel hub with the seal lip toward the bearing. 4. Fill the wheel hub cavity between the bearings with approximately 50% full of grease. Position the remaining bearing into the outer bearing cup. 5. Slide the wheel hub assembly onto the spindle shaft and thread the slotted hex nut onto the shaft. Do not fully tighten the nut or install the cotter pin. 6.
PTO Driveshaft g033694 Figure 201 1. Transmission assembly 3. Roll pin (2 each) 5. PTO driveshaft 2. Bolt (4 each) 4. Locknut (4 each) 6. Cutting deck gearbox Removing the PTO Driveshaft Note: The PTO driveshaft removal is easier if the machine is positioned on a hoist. 1. Park the machine on a level surface, lower the cutting deck (or implement) to the lowest setting, shut off the engine, set the parking brake, and remove the key from the key switch. 2.
Removing the PTO Driveshaft (continued) B. Loosen the 2 bolts and 2 locknuts. C. Slide the driveshaft end yoke from the gearbox shaft. D. Remove the PTO driveshaft from the machine. Installing the PTO Driveshaft 1. Position the PTO driveshaft to the machine. g033695 Figure 202 1. End yoke 5. Grease fitting 2. Cross and bearing set 6. Yoke and slip tube 3. Grease fitting 7. End yoke 4.
Servicing the PTO Driveshaft Cross and Bearing 1. Remove the PTO driveshaft from the machine; refer to Removing the PTO Driveshaft (page 6–25). IMPORTANT When you place the yoke in a vise, clamp lightly on the solid part of the yoke to prevent damage. Use a vise equipped with soft jaws. 2. Lightly clamp the yoke in a vise. Use the 2 screwdrivers to remove the 4 snap rings that attach the bearings at the inside of each yoke. Remove the yoke from the vise.
Servicing the PTO Driveshaft Cross and Bearing (continued) Note: Ensure that all the bearing rollers are correctly seated in the bearing cage. B. Press 1 bearing partially into the yoke. IMPORTANT When installing the cross into the bearing, ensure that you do not damage the bearing seal. C. Carefully insert the cross into the bearing and yoke. D. Hold the cross to align and press the bearing in until it hits the yoke. E. Carefully position the second bearing into the yoke bore and onto the cross shaft.
Cutting Deck Lift Arms g033697 Figure 204 1. Screw 7. Nut (4 each) 13. Screw (4 each) 2. Locknut (4 each) 8. Bearing cup (4 each) 14. Screw (3 each) 3. Lift shaft 9. Flange nut (8 each) 15. Grease fitting (2 each) 4. Link assembly (2 each) 10. Bolt (4 each) 16. Lift arm 5. Spherical ball joint (4 each) 11. Deck lift chain (4 each) 17. Washer (2 each) 6. Jam nut (4 each) 12. Bearing plate (2 each) 18. Retaining ring (2 each) Disassembling the Cutting Deck Lift Arms 1.
Disassembling the Cutting Deck Lift Arms (continued) g033698 Figure 205 1. HOC pin 2. HOC bracket g033699 Figure 206 1. T-bar (4 each) 4. Clevis pin (4 each) 2. Clevis yoke (4 each) 5. Flange nut (8 each) 3. Cotter pin (4 each) 6. Cutting deck 2. Note the location of the HOC pin in the HOC bracket for assembly purposes, and remove the HOC pin from the HOC bracket (Figure 205). 3. Start the engine and fully lower the cutting deck.
Assembling the Cutting Deck Lift Arms g033700 Figure 207 1. Carrier frame 2. Flange bushing (2 each) g033702 Figure 208 1. Check the flange bushings in the carrier frame for wear or damage (Figure 207). Note: Replace the flange bushings if necessary. 2. Install the lift arm components as shown in Figure 204 and Figure 206. A. If the ball joints were removed from the link (item 4 in Figure 204), install the ball joints equally on both ends of the link.
Assembling the Cutting Deck Lift Arms (continued) 5. Install the HOC pin into the HOC bracket to allow desired height-of-cut (Figure 205).
Rollover Protection System g035305 Figure 209 1. Rear panel 6. Fold pin (2 each) 11. Locknut (3 each) 2. Swell latch (3 each) 7. Screw (2 each) 12. Flange nut (4 each) 3. Screw (4 each) 8. Warning decal 13. Upper ROPS assembly 4. Rivet (4 each) 9. Nut (2 each) 14. Cross-member assembly 5. Leaf spring (2 each) 10. Double loop hairpin cotter (2 each) Removing the Rollover Protection System 1.
Removing the Rollover Protection System (continued) g036980 Figure 210 1. Vent hose (2 each) 2. Oil breather 3. Remove the 2 double loop hairpin cotters (item 10 in Figure 209) from the 2 fold pins and pull the fold pins from the ROPS support plate. 4. Remove the 2 screws (item 7 in Figure 209) and 2 nuts from the ROPS support plate, and remove the ROPS tube. 5. Remove the 3 swell latches (item 2 in Figure 209) that secure the rear panel to the cross-member assembly, and remove the rear panel. 6.
Operator Seat g035046 Figure 211 1. Seat 12. Cotter pin 23. Right cover 2. Flat washer (2 each) 13. Brake lever grip 24. Bolt (2 each) 3. Retractable seat belt 14. Clevis pin 25. Top console decal 4. Flat washer (2 each) 15. Seat lever 26. Carriage screw 5. Screw (2 each) 16. Torsion spring 27. Housing cap 6. Carriage bolt (4 each) 17. Flange nut (8 each) 28. R-clamp (2 each) 7. Seat support 18. Seat prop 29. Manual tube 8. Nut (2 each) 19. Left cover 30.
Removing the Operator Seat (continued) 2. Unlatch the operator seat and raise it. WARNING To prevent injury, do not attempt to reach the seat switch through the openings in the seat plate. If seat switch service is necessary, remove the seat from the seat plate to access the switch. g033704 Figure 212 1. Harness connector 2. Latch angle 3. Flange nut 3. Disconnect the machine wire harness electrical connector from the seat switch harness connector (Figure 212). 4.
Servicing the Operator Seat g033705 Figure 213 1. Bottom cushion 10. Shock absorber assembly 19. Weight adjustment knob 2. 3. Back cushion 11. Suspension spring (2 each) 20. Weight indicator Armrest 12. Suspension base 21. Washer 4. Right armrest mount assembly 13. Spring saddle 22. Back rest knob 5. Back panel 14. Bearing shaft 23. Label 6. Left armrest mount assembly 15. Hex nut 24. Seat switch 7. Seat frame assembly 16. Cable (2 each) 25. Seat adjuster 8.
Disassembling the Operator Seat (continued) g033706 Figure 214 1. Back rest knob 3. Lumbar support knob 2. Seat suspension knob 4. Seat position lever 3. Carefully peel the label from the back rest knob, and remove the nut and knob from the seat frame (Figure 214). 4. Remove the 6 push clips that attach the back cushion to the seat frame, and remove the back cushion. 5. Remove the 2 bolts that attach the bottom cushion to the seat frame, and remove the bottom cushion. 6.
Assembling the Operator Seat (continued) 3. Position the spring saddle on the spring arm and slide the saddle down. Hook the spring ends on the top of the suspension base. 4. Use the suspension base as a pry point, place a prybar on the top of the spring saddle and push the saddle down to elongate the springs to install the bolt to the top of the shock absorber and suspension base. Align the bolt in position with the nut. 5. Position the seat frame to the suspension base. 6.
Hood g033707 Figure 215 1. Hood 2. Screw (2 each) 3. 4. 9. Seal plate 17. Hairpin cotter (2 each) 10. Bulb seal 18. Carriage screw (7 each) Nut (11 each) 11. Hood support 19. Foam seal (2 each) Intake screen 12. Locknut (4 each) 20. Bulb seal 5. Plastic plug (26 each) 13. Flat washer (3 each) 21. Air shield 6. Hood decal (2 each) 14. Hood prop 22. Clip (3 each) 7. Screw (4 each) 15. Screw (5 each) 8. Catch latch (2 each) 16.
Installing the Hood 1. Install all the hood components that were removed (Figure 215). Note: If the intake screen was removed from the hood, ensure that the hood support, seal plate are attached to the hood before you install the screen. 2. Attach the screen to the hood with the 26 plastic plugs. 3. Check the condition of all the seals on the frame and hood. Replace the damaged or missing seals. 4. Check that no gaps exist between the hood components and the machine frame.
Chassis: Service and Repairs Page 6–42 Groundsmaster 7210 16222SL Rev F
Chapter 7 Cutting Deck Table of Contents General Information .............................................................................................................................. 7–2 Specifications..................................................................................................................................... 7–2 Cutting Deck Operator's Manual ........................................................................................................
General Information Specifications Several cutting decks are available for Groundsmaster 7210 machine. Refer to the Cutting Deck Operator's Manual for specifications and optional accessories for the cutting deck used on your machine. Note: This chapter gives information about troubleshooting and repair of 60, 62, and 72 inch cutting decks. The 100 inch cutting deck information is not covered in this chapter.
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. The turf conditions such as the 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.
Service and Repairs WARNING Do not start the engine and engage the PTO switch when the PTO driveshaft is disconnected from the cutting deck (or implement). If you start the engine and the PTO shaft is allowed to rotate, serious personal injury and machine damage could result. Before disconnecting the PTO driveshaft from the cutting deck (or implement), remove the fuse F1 (15 A) from the fuse block to prevent the PTO clutch from engaging accidentally.
Blade Stopping Time (continued) When the machine operator disengages the cutting deck, record the time that it takes for the blades to come to a complete stop. If this time is more than 7 seconds, inspect the PTO brake assembly in the transmission; refer to PTO Circuit Problems (page 4–29). Cutting Deck Refer to specific Cutting Deck Operator’s Manual for cutting deck removal and installation procedure.
Idler Assembly g033711 Figure 217 1. Cutting deck 10. Drive belt 19. Idler spacer (2 each) 2. Flat washer 11. Idler pulley 20. Left idler arm 3. Left spindle assembly 12. Idler pulley 21. Stop bolt 4. Drive belt 13. Center spindle assembly 22. Jam nut (2 each) 5. Snap ring (2 each) 14. Right spindle assembly 23. Doubler ring (3 each) 6. Flange bushing 15. Socket-head screw (2 each) 24. Flange nut (24 each) 25. Ribbed neck bolt (24 each) 7.
Removing the Idler Assembly (continued) 4. Loosen the 2 jam nuts (item 22 in Figure 217) that attach the idler stop bolt to the cutting deck to allow clearance between the idler arm and stop bolt. 5. Remove the drive belt from the deck pulleys. 6. Insert a nut driver or small piece of pipe onto the torsion spring end of the idler arm. CAUTION The spring is under heavy load and can cause personal injury. Be careful when removing the tension from the torsion spring of the idler arm. 7.
Installing the Idler Assembly (continued) 3. Carefully push down on the torsion spring end to get the spring under the idler arm mounting plate. Then release the spring slowly to lock it in place. 4. Install the drive belt onto the pulleys. 5. If the idler arm on the right side of cutting deck was removed, check that the clearance between the idler arm and stop bolt is 2.5 to 4.0 mm (0.100 to 0.160 inch) (Figure 218).
Blade Spindle g033713 Figure 219 1. Right spindle assembly 6. Drive belt 11. Blade bolt (3 each) 2. Drive belt 7. Left spindle assembly 12. Flange nut (24 each) 3. Idler pulley 8. Cutting deck 13. Doubler ring (3 each) 4. Ribbed neck bolt (24 each) 9. Blade (3 each) 14. Center spindle assembly 5. Idler pulley Anti-scalp cup (3 each) 15. Drive pulley Groundsmaster 7210 16222SL Rev F 10.
g033716 Figure 220 1. Right spindle grease fitting 2. Center spindle grease fitting 3. Left spindle grease fitting Removing the Blade Spindle g033714 Figure 221 1. Idler arm (right) 2. 1/2 inch square drive 3. 3/8 inch square drive 1. Park the machine on a level surface, raise the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. Support the cutting deck so that it cannot fall accidentally. 2.
Removing the Blade Spindle (continued) 4. Remove the drive belt from the deck pulleys; refer to the Cutting Deck Operator's Manual. 5. Remove the cutting blade, anti-scalp cup, and blade bolt from the spindle (Figure 219). 6. Remove the 8 ribbed neck bolts and 8 flange nuts that attach the spindle assembly to the deck, and remove the spindle assembly from the deck. Installing the Blade Spindle 1. Position the spindle on the cutting deck and note the orientation of the grease fitting (Figure 220).
Servicing the Blade Spindle Disassembling the Blade Spindle G036992 g036992 Figure 222 1. Locknut 7. Bearing spacer 2. Special hardened washer 8. Ribbed neck bolt (8 each) 3. Pulley 9. 4. O-ring 10. Grease fitting 5. Oil seal (2 each) 11. Shaft spacer 6. Bearing set 12. Spindle shaft Spindle housing 1. Remove the locknut from the top of the spindle shaft. 2. Remove the special hardened washer and pulley from the shaft. 3.
Assembling the Blade Spindle (continued) Note: A replacement bearing spacer set includes the inner spacer and outer spacer (items 4 and 5 in Figure 223). Do not mix the bearing spacers from one deck spindle to the another. IMPORTANT If new bearings are installed into a used spindle housing, it is not necessary to replace the original large snap ring. If the original snap ring is in good condition with no sign of damage (e.g.
Assembling the Blade Spindle (continued) 1. If the large snap ring was removed from the spindle housing, install the snap ring into the housing groove. Note: Ensure that the snap ring is fully seated in the housing groove. 2. Install the outer spacer into the top of the spindle housing. Note: Ensure that the outer spacer fits against the snap ring. 3. Use an arbor press to push the bearing cups into the top and bottom of the spindle housing.
Assembling the Blade Spindle (continued) 7. Examine the spindle shaft and shaft spacer to ensure that there are no burrs or nicks that could damage the oil seals. Lubricate the shaft and spacer with grease. 8. Install the spindle shaft spacer onto the shaft. Place a thin sleeve or tape on the spindle shaft splines to prevent damage of the seal during the installation of the shaft. 9. Carefully slide the spindle shaft with the spacer up through the spindle housing.
Gearbox g033722 Figure 227 1. Flange nut (3 each) 7. Grommet (5 each) 13. Deck drive pulley 2. Washer (3 each) 8. Taper lock bushing 14. Right deck cover 3. Left gearbox bracket 9. Right gearbox bracket 15. Left deck cover 4. Mount (3 each) 10. Bolt (4 each) 16. Knob (2 each) 5. Carriage screw (3 each) 11. Lock washer (4 each) 17. Set screw (2 each) 6. Gearbox 12. Woodruff key 18.
Removing the Gearbox g033723 Figure 228 1. Set screw installation position 2. Set screw removal position g033724 Figure 229 1. Breather plug 5. Plug 2. Oil cap 6. Oil cap 3. 4. Gearbox Oil seal 7. Washer 1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Lift the footrest to get access to the top of the cutting deck. 3. Support the raised footrest with the prop rod. 4.
Removing the Gearbox (continued) 7. Remove the 4 bolts (item 10 in Figure 227) and 4 lock washers that attach the gearbox assembly to the gearbox brackets. 8. Remove the 3 carriage screws, 3 flange nuts, 3 washers, and 3 mounts that attach the left and right gearbox brackets (items 3 and 9 in Figure 227) to the deck mounting plate, and remove the brackets from the deck. 9. Remove the gearbox assembly (with the drive pulley attached) from the deck. Drain the lubricant from the gearbox. 10.
Cutting Deck Pull Links g033725 Figure 230 1. Bolt (2 each) 7. Flange nut (2 each) 13. Bolt 2. Pull link assembly (2 each) 8. T-bar (4 each) 14. Bolt 3. Locknut (4 each) 9. Clevis yoke (4 each) 15. Retainer pin (2 each) 4. Flange bushing (4 each) 10. Cotter pin (4 each) 16. 45° lube fitting (2 each) 5. Plain spacer (2 each) 11. Clevis pin (4 each) 17. Torsion spring (2 each) 6. Bumper (2 each) 12. Flange nut (8 each) 18.
Disassembling the Cutting Deck Pull Links (continued) g033726 Figure 231 1. Pull link (raised) 4. Clevis yoke 2. Bolt 5. Retainer pin 3. Torsion spring end 2. Remove the clevis yoke from the deck so that the retainer pin (item 5 in Figure 231) can be accessed. A. Remove the flange nut (item 12 in Figure 230) that secures the clevis yoke to the deck. B. Remove the clevis yoke from the deck. 3. Remove the bolt and locknut that secure the retainer pin (item 15 in Figure 230) to the deck. 4.
Appendix A Foldout Drawings Table of Contents Electrical Drawing Designations.........................................................................................................A–2 Hydraulic Schematic ..........................................................................................................................A–3 Electrical Schematic - Platform (For machine serial number below 403430000).................................
Electrical Drawing Designations Note: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g., SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
Hydraulic Schematic g186843 , Drawing 105-7260 Rev E, Sheet 1 16222SL Rev F Page A–3
Electrical Schematic - Platform (For machine serial number below 403430000) g186842 Page A–4 16222SL Rev F Groundsmaster 7210 (For machines serial number below 403430000), Drawing 119-4372 Rev C, Sheet 1
Electrical Schematic - Platform (For machine serial number above 403430001) g328506 Groundsmaster 7210 (For machines serial number above 403430001), Drawing 122-1411 Rev B, Sheet 1 16222SL Rev F Page A–5
g326106 Page A–6 16222SL Rev F , Drawing Rev , Sheet
Electrical Schematic - Engine g186841 , Drawing 119-4377 Rev C, Sheet 1 16222SL Rev F Page A–7
Electrical Schematic - Cab (1 of 2) g186839 Page A–8 16222SL Rev F , Drawing 122-0350 Rev C, Sheet 1 of 2
Electrical Schematic - Cab (2 of 2) g186840 , Drawing 122-0350 Rev C, Sheet 2 of 2 16222SL Rev F Page A–9
Wire Harness Drawing - Platform (1 of 2) (For machine serial number below 403430000) g186849 Page A–10 16222SL Rev F Groundsmaster 7210-D (For machine serial number below 403430000), Drawing 119-4370 Rev E, Sheet 1 of 2
Wire Harness Drawing - Platform (2 of 2) (For machine serial number below 403430000) g186846 Groundsmaster 7210-D (For machine serial number below 403430000), Drawing 119-4370 Rev E, Sheet 2 of 2 16222SL Rev F Page A–11
Wire Harness Drawing - Platform (1 of 2) (For machine serial number above 403430001) CV g328507 Page A–12 16222SL Rev F Groundsmaster 7210-D (For machine serial number above 403430001), Drawing 122-1412 Rev B, Sheet 1 of 2
Wire Harness Drawing - Platform (2 of 2) (For machine serial number above 403430001) g328508 Groundsmaster 7210-D (For machine serial number above 403430001), Drawing 122-1412 Rev B, Sheet 2 of 2 16222SL Rev F Page A–13
Wire Harness Drawing - Engine (1 of 2) g186848 Page A–14 16222SL Rev F , Drawing 119-4371 Rev G, Sheet 1 of 2
Wire Harness Drawing - Engine (2 of 2) g186845 , Drawing 119-4371 Rev G, Sheet 2 of 2 16222SL Rev F Page A–15
Wire Harness Drawing - Cab Power g186851 Page A–16 16222SL Rev F , Drawing 119-4386 Rev A, Sheet 1
Wire Harness Drawing - Cab Headliner g186847 , Drawing 122-0723 Rev A, Sheet 1 of 2 16222SL Rev F Page A–17
Wire Harness Diagram - Cab Headliner g186844 Page A–18 16222SL Rev F , Drawing 122-0723 Rev A, Sheet 2 of 2
Wire Harness Drawing - Cab Power Point Kit g186852 , Drawing 122-0158 Rev A, Sheet 1 16222SL Rev F Page A–19
Wire Harness Drawing - Auxiliary Power Model 30382 g186850 Page A–20 16222SL Rev F , Drawing 108-2099 Rev C, Sheet 1
Wire Harness Drawing - Light Kit Model 30374 g186853 , Drawing 110-1659 Rev A, Sheet 1 16222SL Rev F Page A–21
