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Groundsmaster 7200/7210

1. a HOLD r R BK R a W REAR LIFT OPTION L PULL y 3 w 1 LOWER svi R ea 5 PK 44 og cac g Ng 3 Raise a E 105C TEMP SWITCH py 3 PK pk 5 OR 5 s2 ENGINE OIL PRESSURE eN N8 BARE Bn BN C SWICH DPDT ON OFF ON v 8 ws 3 GN eps 13 w svs ovane w Y ew BU W a lt 1150 TEMP SWITCH amp 8 1 e amp i Da GY 3 z l 3 z E w w g l o a SA 8 s BK R BK S E EOS g ORS A sA p FUEL PUMP 8 21 3 elt va A 3 RAISE RELEASE PES TAN 2 2 4 30 i s B7 A SLOW PLUGS 3 OR 5 O O O O o PIS 1 0 8 FLOAT 38 sa 3 PK 5 5 t o 4h Ig 2 gc 8 Pe oy a dl 3 3 e Han DPDT ON NONE ON ree rer s TEMP Eo q g i la vio START 1 BK W BK ak dio 1X LAMP s GLOW 3 Al oR A ROUNI Ns 6 GROUND HOUR METER BK KUBOTA GLOW PLUG CONTROLLER R PK 4 B G e DN La y NS SP R BK FUSIBLE LINK L d EN BK BK L KUBOTA STARTER U BK coe TES BU 80 X p K au w 228 ER reue soo pro cor e BN R F4 2A 2 C IGN SW i RUN 1 C PTO ENGAGE PK W BK lt BY R BK MOM s s ENGI
2. Figure 31 1 Hydraulic tank 3 Gear pump 2 Transmission Groundsmaster 7200 7210 Page 4 47 Hydraulic System Wheel Motors 99 to 121 ft lb 135 to 164 N m 14 99 to 121 ft lb 135 to 164 N m 300 to 400 ft lb 407 to 502 N m Loctite 271 Loctite 271 N e Figure 32 1 Lock nut 8 Woodruff key 14 Hydraulic hose 2 Lug nut 5 used per wheel 9 O ring 15 Brake caliper LH shown 3 Wheel assembly 10 Hydraulic fitting 16 Flange nut 4 used per side 4 Wheel hub 11 O ring 17 Cap screw 2 used per side 5 Wheel stud 5 used per wheel 12 Hydraulic fitting 18 Cap screw 2 used per side 6 Socket head screw 4 used per motor 13 Hydraulic hose 19 Brake support 7 Wheel motor LH shown Removal Fig 32 2 Loosen but do not remove lock nut that secures wheel hub to wheel motor Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 3 Jack up machine enough to allow the removal of the 1 Park machine on a level surface lower cutting deck drive wheel Support machine with jack stands or implement stop engine engage parking brake and rem
3. lt RIGHT FRONT Figure 37 1 LH wheel motor 2 Hydraulic tank 3 Gear pump Groundsmaster 7200 7210 4 RH wheel motor 5 8mm threaded boss Page 4 53 6 Transmission 7 Flywheel housing Hydraulic System 2 L3 cs gt T 10 Remove oil filter from transmission Discard filter If necessary remove gear pump from transmission see Gear Pump Removal in this section NOTE Two 2 8 mm eyebolts can be installed into threaded bosses in top of transmission to allow use of a lift or hoist to remove transmission Fig 37 Support transmission assembly when removing it from the flywheel housing to prevent it from fal ling and causing personal injury 11 Remove seven 7 cap screws and lock washers that secure the transmission to the flywheel housing Note location of the shorter cap screw for assembly pur poses IMPORTANT Make sure to not damage the trans mission flywheel housing hydraulic lines electri cal harness or other parts while removing transmission 12 Move transmission assembly toward the front of the machine and away from the flywheel housing and cou pler on engine flywheel Lift transmission from machine 13 Locate and note location of two 2 dowel pins from
4. Inip Charge Pressure Test Port Figure 15 Hydraulic System 9 s O a Y oP Transmission Piston Pump Flow Test Using Tester with Pressure Gauges and Flow Me ter LIFT CYLINDER GEAR PUMP Gr EE y E al rev ol Fal 4000 PSI 276 bar RIGHT SIDE TRACTION FLUSHING VALVE PORT 4000 PSI 276 bar FLUSHING VALVE PORT D PISTON PUMP TESTING SHOWN BYPASS VALVE OO HYDRAULIC E TESTER N e o E o z dz d z I de Hydraulic System NE FORWARD BYPASS U il LH WHEEL Figure 16 Page 4 28 Groundsmaster 7200 7210 The Transmission Piston Pump Flow Test should be performed if a traction circuit problem is identified This test will determine if hydraulic flow from a transmission piston pump is correct Procedure for Transmission Piston Pump Flow Test 1 Make sure hydraulic oil is at normal operating tem perature Also make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on th
5. c oz c o B 6 5 O cg E 5 p 2 S s S 8 a 5 5 2 m 5 E Eg E CE O Z 5 p 2 gj ec sg ele CE H sse 223 P BE MACHINE FUNCTION a AH Z ni nb S E E m u u a Engine Start Operator in Seat O O O na o Engine Start No Operator in Seat OOP O O O ONA eo Engine Run Operator in Seat O O O O O O O NA O O Engine Run No Operator in Seat e O e O O O O O NA e O O mow 6 000 O O na 6060 High Temperature Warning O O O NA O O High Temperature Shutdown O O NA O O O KEY TO CHART LED ON Circuit closed to ground LED ON Circuit is energized Q LED OFF Circuit is open to ground or circuit is de energized Circuit is not involved with this machine function LED OFF NA Backlap Input is not used on the Groundsmaster 7200 7210 IMPORTANT During machine operation if the PTO shuts down and the console temperature warning light is illuminated avoid shutting off the engine Under this condition the operator should 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 locked position and engage the parking brake The engine should be allowed to idle for several minutes while it cools to a safe level Then the cooling system should be checked before returning the machine to service Electrical System Page 5 18 Groundsmaster 7200 7210
6. EI NA UN WA VEM Figure 14 1 Upper seal 3 Flat washer 2 O ring 4 Lock nut Groundsmaster 7200 7210 Page 7 13 Cutting Deck Gearbox Figure 15 1 Flange nut 3 used 7 Grommet 5 used 2 Washer 3 used 8 Taperlock bushing 3 LH gearbox bracket 9 RH gearbox bracket 4 Mount 3 used 10 Cap screw 4 used 5 Carriage screw 3 used 11 Lock washer 4 used 6 Gearbox 12 Woodruff key Removal Fig 15 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Lift the footrest exposing the top of the cutting deck Support the footrest with prop rod 3 Remove belt covers from top of cutting deck 4 Remove drive belt from deck pulleys Cutting Deck Page 7 1 13 Deck drive pulley 14 RH deck cover 15 LH deck cover 16 Knob 2 used 17 Set screw 2 used 18 Retainer nut 2 used Do not start the engine and engage the PTO switch when the PTO drive shaft is discon nected from the cutting deck or implement If the engine is started and the PTO shaft is al lowed to rotate serious personal injury and machine damage could result If the PTO drive shaft is disconnected from the cutting deck or implement remove fuse F1 15 amp from fuse block to prevent unintentional engagement of the PTO clutch 4 Groundsmaster 7200 7210 5 D
7. LIFT CYLINDER 4 Hydraulic Schematic All solenoids are _ shown as de energized a ERR La A A RELIEF VALVES E n 3 4 16 UNF Por 4000 PSI 276 bar PB T Standard Deck Lift SIRI i Summer mode PORT E Q BYPASS d VALVE H J cS FRONT N PORT L E LON j CHARGE PRESSURE IN MM TEST PORT OIL HH COOLER 3 4 16 UNF s ME I8cc rev KONR EM A a a 3 4 16 UNE p Li u Tag PRESSURE VALVE FORWARD uo a LU Kana PORT ai PRESSURE VALVE BYPASS T AU BAS wh CHARGE RELIEF 313430 psi N 86415 1 PORT B O i A Line Filter il E idu gt Beta I 200 43 psi NA HI FLUSHING RELIEF VALVES 18 C AE A 3 4 16 UNF Su VALVE 4000 PSI tre lisi SES X NG GEAR PUMP G CE rey ES 3200 engine rpm MPLEMENT RELIEF CHARGE PUMP 3000PSI 6cc rev Al Port EN Suction Screen m SZ 100
8. n Q i O bw d X O 9e RELIEF VALVES 4000 PSI 276 bar IBec rev 3200 engine rpm C PB T CHARGE PRESSURE TEST PORT OIL COOLER Port 2 BI PRESSURE VALVE TEST PORT PRESSURE VALVE CHARGE RELIEF 313430 psi A Laon Final seer 43 psi Ge Beta IIl 200 X i ISO 16889 GEAR PUMP o ec Tey e IMPLEMENT CHARGE PUMP 3000PS 6cc rev I Port Suction Screen lt gt 100 mesh ry LI ACCUMULATOR 2250 rpm PTO pressure test port Groundsmaster 7200 7210 Hydraulic Schematic With Polar Trac All solenoids are shown as de energized Page 8 5 RH WHEEL MOTOR 300 to 310 cc LSHT LH WHEEL MOTOR 300 to 310 cc LSHT WINTER Gro
9. General Information Service and Repairs Chapter 7 Cutting Deck General Information Factors That Can Affect Cutting Performance Service and Repairs Chapter 8 Foldout Diagrams Hydraulic Schematics Electrical Schematics Electrical Circuit Diagrams Wire Harness Drawings Product Records and Maintenance Kubota System Diesel Engine Hydraulic Electrical System o 2 s gt E a This page is intentionally blank Groundsmaster 7200 7210 TORO Table of Contents GENERAL SAFETY INSTRUCTIONS 1 Supervisor s Responsibilities 1 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING INSTRUCTIONS 4 General Safety Instructions Groundsmaster 7200 and 7210 machines meet or ex ceed safety standard specifications as identified in the Operator s Manual Although hazard control and acci dent 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 trans port maintenance and storage of the machine Improp
10. RUN SOLENOID HOLD R BK w PULL ENGNE Y 105C TEMP SWITCH PK e GN ENGINE OIL PRESSURE SWITCH oN uJ w E Y OR E BU W HA 115C TEMP SWITCH a ra 5 l e a s A ee ee e A DS a lt lt eeeeeeeeeereeeeeeereeeeeee ES zi T Z 5 n aa S BK R BK x 5 5 b o x FUEL PUMP sa 3 o e GLOW PLUGS 3 z gt gt D 3 z OR O PK 2 g a s 8 D 3 3 col col H zN NAL 58 ZE eu START TEMP O e lt 2 1 LA BK W si VIO 4 dB LAMP GLOW 3 312 mY B Pi 12M 5 LO GROUND GA g HOUR METER KUBOTA NG GLOW PLUG CONTROLLER LI Start SP FUSIBLE LINK IN BK q De BK KUBOTA STARTER 2 A START 12 V 1 A s su 2 OVER TEMP SHUTDOWN PTO COIL 1 B PTO Ka N GAG E BU W lt BN F4 2A 2 0 IGN sw RUN i e lt P A A A A A A A r a lt ee R BK TEM AICA ENGINE GROUND 2 D PARKING BRAKE pro sw 1 0 1 COM c NO 4 BK e e ce a ee ee vc ee ee ew U co o T C BK ENGINE PARKING BRAKE NCI7 SWITCH Z E BACKLAP OVER TEMP
11. req 942 ISd 000P S3ATVA 431738 a 1HOd INA 91 P E paga 1HOd LHS wes OIE OF 00 INVA Fa HOLOW 1HOd SSvdA8 Jo BamM CE VMyOY h INN 91 7 J 133HM HH GHVAHO3 NN 91 yit NO d lt uonong JO uJnjeH ie eBriey amsselig MO ainssalg uom UMOYUS PABM10 4 S HINDIID UOIDEAL 0124 0034 Ja sewspun019 Page 4 10 Groundsmaster 7200 7210 Hydraulic System Traction Circuits The Groundsmaster traction system consists of a trans mission that is directly coupled to and driven by the en gine flywheel The transmission provides two identical and independent closed loop traction circuits one for the right wheel motor and one for the left wheel motor Each of these transmission circuits include a variable displacement slipper foot design piston pump which provides hydraulic flow for one wheel motor The swash plate in each of the piston pumps is controlled by one of the operator traction levers The angle of the swash plate determines pump flow and ultimately traction speed When a traction lever is moved a small amount a small swash plate rotation re sults in low pump output and lower traction speed When the traction lever is moved fully the pump swash plate rotates fully to provide maximum pump output flow and traction speed Because hydraulic flow to each rear wheel is deter mined by traction lever movement and subsequent swash plate posit
12. 11 Lower the machine to the ground 12 Torque lock nut item 1 from 300 to 400 ft Ib 407 to 502 N m 13 Make sure hydraulic tank is full Add correct oil if nec essary Figure 33 3 RH wheel motor 4 LH wheel motor 1 Hydraulic tank 2 Transmission Hydraulic System 2 s a Ln ER ZO Wheel Motor Service 45 to 55 ft lb __ gt 10 61 to 75 N m Figure 34 1 Lock nut 8 Manifold 14 Stator assembly 2 Dirt water seal 9 Commutator ring 15 Drive link 3 Housing 10 Cap screw 7 used 16 Wear plate 4 Back up washer 11 End cover 17 Thrust bearing 5 Shaft seal 12 Commutator 18 Woodruff key 6 Coupling shaft 13 Commutator ring 19 Back up ring 7 Body seal 5 used NOTE The two wheel motors used on the Grounds master 7200 7210 have the same basic construction The left wheel motor has a yellow sticker on the port side of the stator The right wheel motor has a reverse timed manifold IMPORTANT DO NOT interchange wheel motors on machine i e do not put RH motor on left side of ma chine If necessary use parts catalog and part num ber on wheel motor to identify RH and LH motors NOTE For wheel motor repair procedures see the Parker Torqmotor Service Procedure TC TB TE TJ TF TG TH and TL Series at the end of this chapter Hydraulic System Page 4 50 IMPORTANT If a wheel motor failure occurred refer to Traction Circuit Closed Loop Component Fail ure
13. 4 Lower and latch hood Figure 111 2 Clamp 1 Oil cooler f NG f Figure 112 tubes or excessive pitting of tubes i Gllteooler 6 Roll pin I 2 Flange nut 7 O ring 2 used Installation Figs 111 and 112 3 Washer 8 Hydraulic hose 4 Cap screw 9 Hydraulic hose 1 Install right side mount of oil cooler through hole in 5 Clamp 10 Radiator trame radiator frame Then slide left side cooler mount into ra diator frame by aligning roll pin and slotted hole in radia tor frame Tilt cooler to radiator frame and secure with clamp Hydraulic System Page 4 100 Groundsmaster 7200 7210 TORO Table of Contents Chapter 5 Electrical System ELECTRICAL SCHEMATICS AND DIAGRAMS 1 Standard Control Module 17 SPEGIAL TOOLS aa ida studs 2 Standard Control Module Logic Chart 18 TROUBLESHOOTING 4 PTO Solenoid Valve Coil 19 Starting Problems 4 Fusible Link Harness 20 General Run amp Transport Problems 6 Diode Assembly 20 Cutting Deck Operating Problems 7 Glow Relay oer eR RM 21 ELECTRICAL SYSTEM QUICK CHECKS 8 High Temperature Warning Switch 22 Battery Test Open Circuit Test 8 High Temperature Shutdown Switch 23 Charging System Test 8 Dual Temperature Swit
14. Electrical System Page 5 10 When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Figure 7 SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS o BA KY Groundsmaster 7200 7210 Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni tion switch is in the ON position with the engine not run ning Also it should illuminate with an improperly operating charging circuit while the engine is running Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running Also it should illuminate with the engine run ning if the engine oil pressure drops to an unsafe level IMPORTANT If the oil pressure indicator light is il luminated with the engine running shut off the en gine immediately To test the oil pressure light and circuit wiring ground the green wire attached to oil pressure switch located on the engine near the oil filter Turn ignition switch to the ON position the engine oil pressure light should come on in dicating correct operation of the indicator light and cir cuit wiring High Temperature Warning Light If the engine coolant temperature reaches 220 F 105 C approximate the high temperature warning light will come on NOTE The PTO will disengage if the engine co
15. This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test Ad caution Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 4 VDC charge the battery before proceeding with test B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D Measure the electrolyte temperature of the cen ter cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals Groundsmaster 7200 7210 Page 5 31 F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take the test voltage reading at 15 seconds then remove the load H Using the table below determine the minimum voltage for the center cell electrolyte temperature reading Voltage Temperature oe oren 15 6 C 10 0 C 4 4 C 1 19C 209F 6 79C 109F 12 29C Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum retu
16. 1 Control panel Figure 12 4 COM Cterminal 5 NOCterminal 6 NC C terminal 1 COMB terminal 2 NO Bterminal 3 NC B terminal SWITCH CLOSED OPEN POSITION CIRCUITS CIRCUITS OFF DOWN COM B NC B COM B NO B COM C NC C COM C NO C ON UP COM B NOB COMB NC B COM C NO C COM C NC C Electrical System o o o 2 wi g 2 D E c Neutral Switches The Groundsmaster 7200 and 7210 use two 2 identi cal neutral switches These neutral switches are nor mally open and close when the traction levers are in the neutral locked position The neutral switches are lo cated under the front panel beneath the operator seat Figs 13 and 14 The Standard Control Module SCM monitors the sta tus of the neutral switches If the ignition switch is in the ON position and the traction levers are both in the neu tral locked position the SCM Neutral input LED should be illuminated The switches are connected in series so both of the switches must be closed for the neutral input to be completed for the SCM Testing 1 Before disconnecting a neutral switch for testing the switch and its circuit wiring should be tested as a SCM input see Standard Control Module in this section 2 If the SCM verifies that the neutral switches and cir cuit wiring are functioning correctly no further switch testing is necessary 3 If the SCM determ
17. 3 Carefully install new O rings into control valve spool bore taking care to not damage O rings during installa tion 4 Lubricate spool liberally with clean hydraulic fluid and carefully install into control valve bore 5 Coat spacer item 13 spring item 20 and washer item 6 liberally with MPG 2 or equivalent grease Ap ply Loctite 242 or equivalent to threads of screw item 5 Install washer spring and spacer into valve and se cure with screw Retain spool to prevent it from turning and torque screw from 24 to 36 in Ib 2 7 to 4 1 N m Groundsmaster 7200 7210 Page4 87 6 Apply Loctite 242 or equivalent to threads of Screws item 7 7 Position gasket item 3 and end cap item 12 to con trol valve Secure end cap to valve with two 2 screws with lock washers item 7 Torque screws from 24 to 36 in Ib 2 7 to 4 1 N m 8 Lubricate detent plunger item 19 with clean hydrau lic oil and slide into control valve bore 9 Install new O rings items 23 to lockout seats items 22 Apply Loctite 242 or equivalent to threads of lockout seats Install seats into control valve Torque seats from 18 to 20 ft lb 24 to 27 N m 10 Lubricate poppet item 11 spring item 2 and pop pet stop item 10 liberally with clean hydraulic fluid and install into control valve bore Make sure that stop ex tends into spring coils after installation 11 Install adapter plug item 14 with new O ring it
18. 3 Slide PTO drive shaft end yokes onto transmission PTO shaft and gearbox shaft 4 Secure end yokes of PTO drive shaft A Install roll pins in end yokes and shafts B Tighten lock nuts to secure end yokes to gearbox shaft and PTO shaft Torque lock nuts from 175 to 225 in lb 20 to 25 N m 5 Lubricate PTO drive shaft grease fittings 6 Install fuse F1 15 amp into fuse block Groundsmaster 7200 7210 Page 6 19 PINS Figure 19 End yoke Cross and bearing set Grease fitting Slip yoke shaft 5 Grease fitting 6 Slip yoke tube 7 End yoke Chassis PTO Drive Shaft Cross and Bearing Service 1 Remove PTO drive shaft from vehicle see PTO Drive Shaft Removal in this section IMPORTANT When placing yoke in vise clamp lightly on the solid part of the yoke to prevent yoke damage Also the use of a vise with soft jaws is rec ommended 2 Lightly clamp yoke in vise Use two screwdrivers to remove snap rings that secure bearings at the inside of each yoke Remove yoke from vise IMPORTANT Yokes must be supported when re moving and installing bearings to prevent damage 3 Use a press to remove cross and bearings from yokes A Place a small socket against one bearing and a large socket against the yoke on the opposite side B While supporting the large socket apply pres sure on small socket to partially push the opposite bearing into the large socket C Remove yoke from press grasp part
19. 45 Lubricate charge relief valve and spring with clean hydraulic oil and install into pump body 46 Lubricate pressure valve and spring with clean hy draulic oil and install into pump body 47 Lubricate new O rings and install O ings onto valve plugs Install plugs into pump body Torque plugs from 17 to 19 ft lb 22 to 27 N m Figure 91 1 Charge relief valve 3 Charge relief plug 2 Pressure valve 4 Pressure valve plug 48 Lubricate filter bypass valve and spring with clean hydraulic oil and install into pump body 49 Lubricate new O ring and install O ring onto plug Install plug into pump body Torque plug from 17 to 19 ft Ib 22 to 27 N m Figure 92 1 Filter bypass valve 2 Filter bypass plug Hydraulic System Page 4 76 Groundsmaster 7200 7210 50 Lubricate solenoid valve spring sleeve and spool with clean hydraulic oil and install into pump body Make sure that sleeve is installed so that holes are closest to the spring location and that step in spool is toward spring location as well Place pin in spool 51 Install solenoid valve stem into pump body and torque from 186 to 195 in Ib 21 to 22 N m 52 Place O ring solenoid coil O ring washer lock washer and nut onto solenoid valve stem Coil should be installed so the KANZAKI molded into the coil has the P nearest the nut location Torque nut from 52 to 69 in Ib 5 9 to 7 8 N m Figure 93 1 Sleeve 5 Spoolstep 2 Spool 6 So
20. MAJ 1HOd uva 1eq 922 ISd 0007 S3ATVA 331134 MO 4 uonong Jo uJnjeH eBreyo eunssejd MO eunsseJg BUIMJOM HOLOW 133HM HI 55 OIE Of 00 HOLOW 33HM HH HNO Old 0124 0034 Ja sewspun019 Groundsmaster 7200 7210 16 Page 4 ic System Hydraul PTO Circuit The transmission used on Groundsmaster 7200 and 7210 machines includes a hydraulic multi plate clutch that is used to engage the PTO Hydraulic flow for PTO clutch engagement is provided by the transmission charge pump When the PTO switch is turned on the transmission so lenoid valve is energized to allow hydraulic flow to en gage the PTO clutch As the PTO clutch engages an integral PTO brake is simultaneously released to allow rotation of the drive shaft and cutting deck or imple ment An orifice and accumulator in the transmission prevent abrupt engagement of the PTO Groundsmaster 7200 7210 Page 4 17 Pressure to the PTO clutch is limited by the pressure valve in the transmission Pressure valve setting is from 280 to 340 PSI 19 3 to 23 4 bar When the PTO switch is turned off the transmission so lenoid valve is de energized and the PTO clutch is dis engaged The integral PTO brake is applied to control the stopping rate of the drive shaft and cutting deck or implement Hydraulic System e as O a Y SO Io Special Tools Order special tools from your Toro Distributor Some tools
21. gt gt R Bk a See ENGINE GROUND gt 2 0 PARKING BRAKE PTO SW 1 D 1 COM nola ENGINE u Soe OR lt gt T C aa PARKING BRAKE 0 SWITCH 2 E BACKLAP OVER TEMP WARNING 1 E NO 1 BRAE OFP lt q gt Y 2 F SEAT SW GROUND 1 F 79 5 DX i O cY lt gt BK 21504 8 oP vio Bk 4 x SL OCCUPIED 2 G NEUTRAL sw So ee SOLENOID o o BN o Do Soe RH NEUTRAL SWITCH en SCM pd kd IN NEUTRAL E FRAME GROUND NONU xd Aa vig PELS PTO SWITCH YELLOW DIODE T BN VO 4 FOR OPTIONAL PTO STOP NONE 8 AJ RUN Be X Y START B I S Xj PK D BI IGNITION SWITCH t ore UM star Fl 45A F5 104 gt R vm d FOR ACCESSORY POWER KIT F2 104A VIO Glow Circuits FOR ACCESSORY Power Current POWER KIT Control Current Indication Current Page 8 9 ALTERNATOR RUN SOLENOID B HOLD R BK R w mr PULL w R ENGINE Ns Y 105C TEMP SWITCH PK o GN ENGINE OIL PRESSURE E SWITCH GN w Y OR po nat o BU W A 115C TEMP SWITCH DE ty t o n ES E E E x e 1 a e S 3 a ATM 0 B s gl 3 UEL PUMP o x 9 6 j j GLOW PLUGS 3 Tr rr rr o 9 2 2
22. A On machines with cutting deck position jack se curely under the square carrier frame tube near the front castor wheel Fig 1 Do not use the cutting deck as a jacking point B On machines with Polar Trac M Kit position jack securely under the lift arm pivot tube on the front of machine Do not use the implement as a jacking point 3 Use jack to raise front of machine 4 After raising the front of the machine use appropri ate jack stands under the frame to support the front of the machine Jacking the Rear Fig 2 IMPORTANT Do not support machine on wheel hubs brake rotors 1 Chock both front castor wheels to prevent the ma chine from moving 2 Place jack securely under the rear frame 3 Jack rear wheels off the ground 4 Use appropriate jack stands under the frame to sup port the rear of the machine Safety Page 1 4 Figure 1 1 Front castor wheel 2 Front jacking point FRONT OF MACHINE Figure 2 Groundsmaster 7200 7210 Chapter 2 TORO Product Records and Maintenance Table of Contents S8 o PRODUCT RECORDS 1 Using a Torque Wrench with an Offset Wrench 3 MAINTENANCE 1 Standard Torque for Dry Zinc Plated and Steel MEE EQUIVALENTS AND CONVERSIONS 2 Fasteners Inch Series 4 E E Decimal and Millimeter Equivalents 2 Standard Torque for Dry Zinc Plated and Steel U
23. B Install dust seal O ring back up ring and dust seal to the head IMPORTANT Do not clamp vise jaws against the shaft surface Clamp on the clevis ONLY 3 Mount shaft securely in a vise by clamping on the cle vis of the shaft A Coat shaft with clean hydraulic oil B Slide head onto the shaft taking care to not dam age the seals Install rod seal onto shaft and into head C Install piston onto the shaft and secure with nut D Remove shaft from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis ONLY 4 Mount barrel in a vise 5 Coat all internal parts with a light coat of clean hy draulic oil Carefully slide piston shaft and head assem bly into the barrel being careful not to damage the seals 6 Install collar using a pipe wrench to secure head in barrel Hydraulic System 2 L3 cs gt lt Polar Trac Lift Cylinder Figure 109 1 Pivot pin 5 Hydraulic hose 9 90 hydraulic fitting 2 Screw 6 Hydraulic cylinder 10 Hydraulic fitting 3 Hydraulic control valve 7 Hydraulic hose 11 O ring 4 Liftarm 8 O ring 12 Lock nut Hydraulic System Page 4 96 Groundsmaster 7200 7210 Removal Fig 109 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 1 Park machine on a level sur
24. Charge Hydraulic System NOTE When initially starting the hydraulic system with new or rebuilt components such as wheel motors gear pump or lift cylinder it is important that the hydraulic sys tem be charged properly Air must be purged from the system and its components to reduce the chance of damage IMPORTANT Change hydraulic oil filter whenever hydraulic components are repaired or replaced 1 Park machine on a level surface with engine off 2 Make sure all hydraulic connections lines and com ponents are secured tightly 3 If component failure was severe or the system is con taminated flush and refill hydraulic system and tank see Flush Hydraulic System in this section 4 Make sure hydraulic tank is full Add correct oil if nec essary 5 Check traction control components for proper adjust ment binding or damaged parts 6 Disconnect wire harness connector from engine fuel stop solenoid to prevent the engine from starting 7 Make sure traction control levers and the lift control lever are in the neutral position Turn ignition key switch and engage starter for ten 10 seconds to prime the transmission and gear pump Repeat this step again 8 Connect wire harness connector to fuel stop sole noid Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 9 Raise both drive wheels off the ground and place jackstands under the frame to support the machine
25. Cutting deck blades will not turn An electrical problem exists see Chapter 5 Electrical System The engine coolant temperature is excessive Transmission solenoid valve is stuck Transmission charge pump is damaged traction charge circuit also affected Transmission pressure valve is faulty Cutting deck problem exists see Chapter 7 Cutting Deck Cutting deck blade s turn too slowly Engine speed is too low Cutting deck problem exists see Chapter 7 Cutting Deck PTO does not stop when disen An electrical problem exists see Chapter 5 Electrical System gaged A Transmission solenoid valve is stuck or damaged PTO brake friction plates are worn or damaged Cutting deck or implement will not Engine speed is too low lift or lifts slowly Lift cylinder linkage is binding or broken Lift arm bushings are binding Hydraulic tank oil level is low Gear pump pressure or flow is insufficient Gear pump is damaged Implement relief valve in gear pump is stuck open Lift cylinder leaks internally Lift control valve is defective Cutting deck or implement raises Lift cylinder leaks internally but will not stay up NOTE Lift cylinder and check valve Check valve within the lift control valve leaks in lift control valve cannot provide an absolutely perfect seal The cutting deck or implement may eventually lower if left in the raised position Lift control valve is worn or defectiv
26. Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque 140 20 in lb 73 12 inb Thread Size 1 4 20 UNC 5 116 18UNC 215 35 in Ib 145 20 inb 3 8 16 UNC 1 2 13 UNC 75 15 ft lb 50 10 ft lb 35 10 ft lb 18 3 ft Ib 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 Ib 1 4 20 UNC 85 15 inb 5 16 18 UNC 110 20 in Ib 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in Ib Conversion Factors in lb X 11 2985 N cm ft lb X 1 3558 N m Product Records and Maintenance Page 2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 N m 7 16 20 UNF 65 10 ftHb Grade 5 1 2 20 UNF 80 10 ft 1b Grade 5 108 14 N m M12X 1 25 Class 8 8 M12X1 5 80 10 ftHb Class 8 8 For steel wheels and non lubricated fasteners 80 10 ft lb 108 14 N m 108 14 N m Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Type A Type B 1 1 1 Baseline Torque No No noe f is mos is 8 5 Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners N cm X 0 08851 in lb N
27. 1 PK E z a 0 as START TEMP M L i go s5 BK W PNG i LAMP CLOW OR 2 mooo 12 GROUND 2 8 PK CM METER KUBOTA IS GLOW PLUG CONTROLLER R SA B PAR Stort SP FUSIBLE LINK A BK q L BK KUBOTA STARTER START 12V 1 A BU j PK s L T L 4 H 2 8 OVER TEMP SHUTDOWN PTO COIL 1 B PTO ENGAGE BU W lt BN R FA DA 2 0 IGN Sw RUN 1 C e o W DK lt R BK a ENGINE GROUND 2 PARKING BRAKE PTO SW 1 D 1 COM C e NO 4 ENGINE Bk t E R x ra n T cC BK al SWITCH 2 E BACKLAP OVER TEMP WARNING 1 E nc _ gt BRAKE OFF gl Y 2 F SEAT SW GROUND 1 F 2 COM B NO 5 x E h amp GK ia ia VIO BK SEAT SWITCH KANZAKI CLUTCH OCCUPIED 2 6 NEUTRAL SW SOLENOID LS mn n T ro LH NEUTRAL SWITCH RH NEUTRAL SWITCH SCM NOE IN NEUTRAL LOCK IN NEUTRAL LOCK 2 H IGN Sw sr PTO SWITCH YELLOW FRAME GROUND BATTERY O ee ae PTO OFF r BN T FOR OPTIONAL PTO S PK Fl 15A F3 10 A Xx R FOR ACCESSORY POWER KIT A Groundsmaster 7200 7210 Crank Circuits Power Current Control Current Indication Current Page 8 10 x FOR ACCESSORY POWER KIT ALTERNATOR
28. Clamp on the clevis ONLY 3 Mount rod securely in a vise by clamping on the cle vis of the rod A Coat rod with clean hydraulic oil B Slide head onto the rod C Install piston onto the rod and secure with lock nut Torque lock nut from 250 to 300 ft Ib 339 to 406 N m D Remove shaft assembly from the vise IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis end of the barrel ONLY 4 Mount barrel securely in a vise by clamping on the clevis end of the barrel IMPORTANT When installing the head into the bar rel pay careful attention to the retaining ring slot in the barrel to insure that the piston and head seals do not lodge in the slot 5 Coat all internal parts with a light coat of clean hy draulic oil Slide piston shaft and head assembly into the barrel being careful not to damage the seals 6 Secure head in barrel by installing retaining ring Align retaining ring hole in the head with the access slot in the barrel Insert the retaining ring hook into the hole and rotate head clockwise until the retaining ring is com pletely pulled into the barrel and the ring ends are cov ered Hydraulic System 9 s O a Y oP Oil Cooler Removal Figs 111 and 112 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Raise hood and secure it in the raised p
29. Fig 2 Remove HOC pin from HOC bracket 4 Start engine and fully lower cutting deck Stop en gine and remove key from the ignition switch Figure 2 1 HOC pin 2 HOC bracket Do not start the engine and engage the PTO switch when the PTO drive shaft is discon nected from the cutting deck If the engine is started and the PTO shaft is allowed to rotate serious personal injury and machine damage could result If the PTO drive shaft is discon nected from the cutting deck remove fuse F1 15 amp from fuse block to prevent uninten tional engagement of the PTO clutch 5 To prevent unintentional engagement of the PTO clutch remove fuse F1 15 amp from fuse block 3 Figure 3 Clevis pin 3 Adjustment clevis 2 Deck lift chain _ Cutting Deck Page 7 6 Groundsmaster 7200 7210 6 Disconnect end yoke of PTO drive shaft from cutting deck gearbox shaft see PTO Drive Shaft Removal in the Service and Repairs section of Chapter 6 Chas sis Position and support drive shaft end away from deck gearbox 7 Remove four 4 ring pins and clevis pins that secure deck lift chains to adjustment clevises on cutting deck Fig 3 8 Slide cutting deck away from machine Installation 1 Slide cutting deck under carrier frame of machine 2 Install four 4 clevis pins and ring pins to secure deck lift chains to adjustment clevises on cutting deck Fig 3 3 Connect end yoke of PTO drive shaft to cutting deck gear
30. NOTE If one traction circuit component has internal wear or dam age it is possible that other traction components are also dam aged Transmission by pass valve s is open or defective Brake is dragging or binding Transmission check valve relief valve and or flushing valve is leak ing Charge pressure is low Hydraulic oil is very cold Transmission or wheel motor s is worn or damaged NOTE If one traction circuit component has internal wear or dam age it is possible that other traction components are also dam aged Page 4 20 Groundsmaster 7200 7210 Problem Neutral is difficult to find No traction exists in either direction Wheel motor will not turn Wheel motor will not hold load in neutral NOTE Machine may not be com pletely stationary if parked on an in cline without the parking brake en gaged Single wheel motor turns while un loaded but slows down or stops when load is applied Machine does not track straight NOTE If machine does not track straight look for problem with com ponents that effect the weaker trac tion side of the machine Groundsmaster 7200 7210 Possible Cause External control linkage is misadjusted disconnected binding or damaged Orifice in transmission check valve s is plugged Transmission is worn or damaged Oil level in hydraulic tank is low Transmission by pass valves are open Charge pressure is low Engine flywheel coupling is d
31. Park machine on a level surface lower cutting unit or implement stop engine engage parking brake and remove key from the ignition switch 2 Open hood and secure it in the raised position Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene gly col antifreeze is poisonous Dispose of coolant properly or store it in a properly labeled contain er away from children and pets 3 Place a suitable container under the left corner of the radiator to collect the coolant Remove plug item 12 hex socket head from bottom of the radiator and com pletely drain the radiator 4 Disconnect following hoses from the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air inlet hose to the air cleaner assembly 5 Remove four 4 screws and flat washers that secure fan shroud to radiator Carefully position fan shroud away from radiator taking care to not damage fan 6 Remove four 4 cap screws and flange nuts secur ing the radiator to the radiator frame 7 Carefully pull radiator from the radiator frame and machine 8 Plug radiator and hose openings to prevent contami nation Groundsmaster 7200 7210 Page 3 13 Installation Fig 8 1 Remove all plugs placed in radiator and coolant hose openings during the removal procedure 2 Carefull
32. Pressure in the General Information section 3 Park machine on a level surface with the cutting deck or implement lowered and off Apply parking brake Make sure engine is off 4 Read Precautions for Hydraulic Testing listed at the beginning of this section 5 Thoroughly clean transmission area surrounding charge pressure test port on right side of transmission Fig 15 6 Remove plug from charge pressure test port Fig 15 Connect hydraulic pressure gauge 1000 PSI 70 bar with an attached hydraulic hose to the transmission charge pressure port 7 Make sure that traction levers are in the neutral locked position and that the parking brake is applied 8 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test 9 With engine running move throttle to full speed 3200 RPM 10 Pressure gauge should read from 70 to 100 PSI 4 8 to 6 9 bar Record test result 11 If charge relief pressure specification is not met consider the following A The transmission charge relief valve is faulty Re pair or replace the charge relief valve see Transmis sion Service in the Service and Repairs section B A transmission traction relief valve or flushing valve is leaking or damaged see Transmission Ser vice in the Service and Repairs section Groundsmaster 7200 7210 Page 4 27 C The charge pump in the trans
33. Pump housing 2 Hex plug Hydraulic System Page 4 68 Groundsmaster 7200 7210 6 Install retaining ring into groove in bore of PTO gear Press two 2 bearings into PTO gear until each bearing contacts the installed retaining ring Figure 70 1 Bearing 3 Retaining ring 2 PTO gear 7 Slide three 3 rods into holes in clutch assembly 8 Slide PTO gear assembly into clutch assembly 2 L3 cs gt Figure 71 1 Rod 3 used 3 PTO gear 2 Clutch assembly 9 Assemble PTO shaft A Press new bearing onto PTO shaft so that bear ing is flush with shaft shoulder B Alternately place three 3 A plates and three 3 friction plates onto PTO shaft C Place C plate and then B plate onto shaft D Carefully install two 2 seal rings into grooves of PTO shaft Figure 72 1 Sealring 2 used 5 A plate 3 used 2 PTO shaft 6 Friction plate 3 used 3 B plate 7 Bearing 4 C plate Groundsmaster 7200 7210 Page 4 69 Hydraulic System 10 Install clutch assembly and gear onto PTO shaft A Install key into PTO shaft slot making sure that rounded ends of key align with rounded ends of shaft slot B Slide clutch assembly and gear onto PTO shaft making sure to align slot in clutch with key in shaft Also align rods in clutch with holes in B plate C Place spacer onto PTO shaft D Press bearing onto PTO shaft so bearing is flush Figure 73 with shaft shoulder 1 Beating
34. Rear Wheels 4 Polar Trac Wheels 6 Parking Brakes 8 Parking Brake Service 10 Parking Brake Assembly 12 Front Castor Wheels 14 Polar TracTM Wheel Hub Service 16 PTO Drive Shaft 0 cece eee ees 18 PTO Drive Shaft Cross and Bearing Service 20 Cutting Deck Lift Arms 22 Operator Seat 24 Operator Seat Service 26 OOO 2 2 Dat ER kum Qua dae as 28 Groundsmaster 7200 7210 Page 6 1 Chassis Specifications Item Description Rear tire pressure 15 PSI 103 kPa Castor wheel front tire pressure 25 PSI 172 kPa Tire pressure machines with Polar TracTM 30 PSI 103 kPa Rear wheel lug nut torque 75 to 85 ft lb 102 to 115 N m Wheel lug nut torque machines with Polar Trac 65 to 85 ft lb 88 to 115 N m Rear wheel hub lock nut torque 300 to 400 ft lb 407 to 502 N m Chassis Page 6 2 Groundsmaster 7200 7210 General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance procedures and maintenance intervals for your Groundsmaster ma chine Refer to that publication for additional information when servicing the machine Groundsmaster 7200 7210 Page 6 3 Chassis Service and Re
35. nals Groundsmaster 7200 7210 Page 5 15 E Press directly onto the seat switch through the seat cushion There should be continuity between the seat switch harness terminals as the seat cush ion approaches the bottom of its travel indicating that the seat switch is functioning If seat switch service is necessary remove seat from seat plate to access switch To prevent injury DO NOT attempt to reach switch through openings in seat plate F If the continuity test is incorrect remove seat see Operator Seat in Chapter 6 Chassis Check seat switch and or seat switch harness for continuity Re pair or replace components as needed G If the seat switch tests correctly and a circuit prob lem still exists check machine wire harness see Electrical Schematics and Circuit Drawings in Chap ter 8 Foldout Diagrams H After seat switch testing is complete connect ma chine wire harness connector to seat switch electri cal lead Lower seat assembly Check seat switch operation Figure 16 1 Seat harness connector 2 Machine wire harness Electrical System o o o E wi g 2 D E c Parking Brake Switch The parking brake switch is a normally closed switch that opens when the parking brake is applied The switch is located under the front panel Fig 17 and 18 The Standard Control Module SCM monitors the sta tus of the parking brake switch If the ignition switch is in the ON posi
36. rioration damage leakage or loose connections Replace fuel lines clamps and connections as needed Drain and Clean Fuel Tank Drain and clean the fuel tank periodically as recom mended in the Operator s Manual Also drain and clean the fuel tank if the fuel system becomes contaminated or if the machine is to be stored for an extended period To clean fuel tank flush tank out with clean diesel fuel Make sure tank is free of all contaminates and debris Fuel Tank Removal Fig 7 1 Park machine on a level surface lower cutting unit or implement stop engine engage parking brake and remove key from the ignition switch Unlatch and raise hood and operator seat NOTE The fuel tanks on Groundsmaster 7200 and 7210 machines are connected to a common tee fitting item 7 under the seat If either of the fuel tanks are to be removed from the machine make sure that fuel is re moved from both tanks before disconnecting any fuel hoses 2 Use a fuel transfer pump to remove fuel from both fuel tanks 3 To remove left side fuel tank A Loosen hose clamps and disconnect fuel return and vent hoses from fittings on left side fuel tank B Loosen and remove two 2 clamps item 22 that secure fuel tank to frame C Loosen and remove cap screw item 27 three 8 washers items 36 26 and 37 and flange nut item 28 that secure fuel tank to frame Locate and retrieve spacer item 25 Groundsmaster 7200 7210 Page
37. sary adjust jam nut location on stop bolt to allow proper clearance 6 Install deck covers to cutting deck Lower the foot rest 0 100 to 0 160 2 5 to 4 0 mm Figure 5 1 Idler arm 3 Jamnut 2 Stop bolt Cutting Deck Blade Spindle Figure 6 1 RH spindle assembly 4 Center spindle assembly 7 LH spindle assembly 2 Drive belt 5 Idler pulley 8 Cutting deck 3 Idler pulley 6 Drive belt 9 Drive pulley Removal Fig 6 1 Park machine on a level surface with cutting deck raised Stop engine engage parking brake and remove key from the ignition switch Support the cutting deck so it cannot fall accidentally 2 Lift the footrest exposing the top of the cutting deck Support the footrest with prop rod 3 Remove belt covers from top of cutting deck NOTE When removing deck drive belt use breaker bar in idler arm square drive holes to rotate idler pulley away from belt Fig 7 4 Remove drive belt from deck pulleys see Operator s Manual 1 Figure 7 Idler arm RH shown 3 3 8 square drive 2 1 2 square drive Cutting Deck Page 7 10 Groundsmaster 7200 7210 5 Remove cutting blade anti scalp cup and blade bolt from spindle to be serviced Fig 8 6 Remove eight 8 flange head screws and flange nuts that secure spindle assembly to deck Remove spindle assembly from deck Installation Fig 6 1 Position spindle on cutting deck noting orientation of grease fit
38. stop engine engage parking brake and remove key from the ignition switch 2 Remove wheels as needed to gain access to wheel hub s see Polar Trac Wheels Removal in this sec tion 3 Make sure that machine is supported with jack stands 4 Remove the dust cap from the wheel hub 5 Remove the cotter pin and slotted hex nut Slide the wheel hub with bearings from the spindle shaft 6 Remove the seal from the wheel hub Discard seal 7 Remove the bearing cones from both sides of the wheel hub 8 Clean the bearings in solvent Make sure the bear ings are in good operating condition Clean the inside of the wheel hub Check the bearing cups for wear pitting or other damage Replace all worn or damaged parts Assembly Figs 16 and 17 1 If bearing cups were removed from the wheel hub press new cups into the hub until they seat against the shoulder of the hub IMPORTANT The lip of the seal must be toward the bearing The seal should be pressed in so it is flush with the end of the wheel hub 2 Pack both bearings with grease Install one bearing into the bearing cup on inboard side of the wheel hub Lubricate the inside of a new seal and press it into the wheel hub with the seal lip toward the bearing 3 Fill wheel hub cavity between bearings approximate ly 50 full of grease Position remaining bearing into the outer bearing cup 4 Slide the wheel hub assembly onto the spindle shaft and secure it in pla
39. 147 23 282 56 339 56 599 79 100 10 1130 113 140 15 1582 169 734 113 115 12 1299 136 160 17 1808 192 1186 169 200 25 2260 282 300 30 3390 339 1446 192 225 25 2542 282 325 33 3672 373 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115115 105 15 5 16 24 UNF 138 17 128 17 o oe 99 Po Nm al c l N I I o de wo cory ie eal pb cm en cae 39 uc 16x2 o coe f wee ee cem gt memme e gt sce f x e cae gt 3 8 16 UNC 16 2 3 8 24 UNF 17 2 7 16 14 UNC 27 3 7 16 20 UNF 29 3 NOTE Torque values may have to be reduced when NOTE The nominal torque values listed above for installing fasteners into threaded aluminum or brass Grade 5 and 8 fasteners are based on 75 of the mini The specific torque value should be determined based mum proof load specified in SAE J429 The tolerance is on the fastener size the aluminum or base material approximately 10 of the nominal torque value Thin strength length of thread engagement etc height nuts include jam nuts NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite Product Records and Ma
40. 184 N m 1 11 16 12 140 to 172 ft lb 190 to 233 N m Figure 3 Hydraulic System Page 4 4 Groundsmaster 7200 7210 Hydraulic Fitting Installation SAE Straight Thread O Ring Fitting into Component Port Non Adjustable Fitting Fig 4 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As apreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 4 Install the fitting into the port Then use a torque wrench and socket to tighten the fitting to the recom mended installation torque shown in Figure 5 NOTE Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be less than the recommended installation torque See Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance to determine necessary con version information Fitting Dash Size Fitting Port Side Thread Size
41. 2 Check condition of all seals on frame and hood Re place damaged or missing seals Check that no gaps ex ist between hood components and machine frame If necessary seal gaps with silicone caulk 3 Position hood to machine and slide hood support onto frame rods 4 Secure hood to frame rods with hair pin cotter item 6 5 Close and latch hood Chassis This page is intentionally blank Chassis Page 6 30 Groundsmaster 7200 7210 Chapter 7 Cutting Deck TORO Table of Contents GENERAL INFORMATION 2 Specifications 2 Operator s Manual 2 FACTORS THAT CAN AFFECT CUTTING PERFORMANCE 3 SERVICE AND REPAIRS 5 Blade Stopping Time 5 Cutting Deck Removal and Installation 6 Idler Assembly 8 Blade Spindle 10 Blade Spindle Service 12 O ries kk tt Ritter iet cones noah 14 Cutting Deck Pull Links 16 Groundsmaster 7200 7210 Page 7 1 Cutting Deck General Information Specifications Several cutting decks are available for the Grounds master 7200 and Groundsmaster 7210 Refer to the Op erators Manual for specifications and optional accessories for the cutting deck used on your Groundsmaster Operator s Manual The Operator s Manual prov
42. 2 lag la T D 3 QoS L B XS x SA E START TEMP by jo ls vio 1 H BK W a oues LAMP 2 s GLOW a 3 Bl 2 OR 2 12 GROUND 3 6 PK Cm METER D KUBOTA 1 GLOW PLUG CONTROLLER am ji ras N NR R BK Stort SP FUSIBLE LINK IN BK q P BK KUBOTA STARTER PA START 12 V 1 A BUGA gt k BU 2 B OVER TEMP SHUTDOWN PTO COIL 1 B E BU W lt sn 2A 2 C IGN SW RUN 1 C n kK AKA R Bk ENGINE GROUND 2 0 PARKING BRAKE pro sw 1 0 ENGINE BK Im a p ORE OSS _ NE 1 o PARKING BRAKE SWITCH 2 E BACKLAP OVER TEMP WARNING 1 E t BRAKE OFF lt q gt Y w a M GROUND he S s A SEAT SWITCH NEUTRAL W a BH 2 OCCUPIED e 2 G NEUTRAL SI LH NEUTRAL SWITCH RH NEUTRAL SWITCH S gt C M NOT IN NEUTRAL NOT IN NEUTRAL 2H IGN SW S FRAME GROUND BATTERY 1 VIO lt 7 BN VIO FOR OPTIONAL PTO NONE 8 X BH KEY START B I S 3 Y PK D BI IGNITION SWITCH OFF RUN START F1 154A SETA L gt R e FOR ACCESSORY POWER KIT F2 18A vio o x12 Run Circuits PTO Engaged a FOR ACCESSORY POWER KIT Page 8 12 Power Current Control Current Indication Current PTO SWITCH YELLOW PTO ON PTO ENGAGE 4 BK 3K SOLENOID DIODE KANZAKI CLUTCH P11 SEAT SWITCH J02 ALTERN
43. 3IC x ox E Groundsmaster 7200 7210 NUS Electrical Schematic rE a With Optional Kits Included PER px px n 6 w All relays and solenoids 2 8 are shown as de energized FUSE BLOCK 4 WAY All ground wires are black Page 8 8 ALTERNATOR RUN SOLENOID m HOLD R BK R mE A w PULL w 1 5C TEMP SWITCH SS GN ENGINE OIL PRESSURE VIC PPP m GN w Y OR BONE e BU W t 2 i 1150 TEMP SWITCH w a S a mu mimm L t 3 2 t a AK sese mm 5 a im ax YM S ngo FUEL PUMP R BK 1 1 EZ 3 gt d g l TEONE 2 GLOW PLUGS 3 ok Q CQ HC Es 2 g _ Pk i D m a 0 FE l go START TEMP lsh a VIO i op BK W 1 a y LAMF GLOW 0 D a Lg sep o A 12 GROUND GA PK p HOUR METER BK KUBOTA O GLOW PLUG CONTROLLER maa a APK a a o R BK I FUSIBLE LINK d 29 we Boves BK BK 1 KUBOTA STARTER 2 A START 12 v 1 A BU i 80 X p22 PK i Bu w 2 0ER TEMP SHUTOOWN Pro cow ue Ha PTO ENGAGE 1 F 2A 2 C IGN SW I RUN 1 C 4 PK W BK lt
44. 4 a uonong Jo umy ebreyo ainssald MO eissejg Buloy 190 1112412 YI 0L24 0024 Ja sewspun019 Groundsmaster 7200 7210 14 Page 4 ic System Hydraul 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 suc tion from the hydraulic tank Circuit operation for lowering the cutting deck or imple ment is similar to raising it However hydraulic flow is used to contract the lift cylinder and this action allows the cutting deck or implement to lower During conditions of not raising or lowering the cutting deck or implement flow from the gear pump is by passed by the lift control valve directly to the oil cooler and transmission Flow then returns to the hydraulic tank When the cutting deck or implement is to be lowered the lift control valve spool is shifted by moving the lift control lever to LOWER This shifted spool allows gear pump flow to unseat the pilot check valve in the lift con trol valve and then to the barrel end of the lift cylinder The lift cylinder contracts causing the cutting deck or implement to lower The fluid displaced from the barrel end of the lift cylinder is routed to the oil cooler transmis sion and hydraulic tank An orifice fitting at the barrel end of the lif
45. 7210 47 Carefully remove swash plates from transmission pump housing Remove washer from each swash plate 48 Thoroughly clean and inspect all transmission com ponents Figure 66 1 Swash plate 2 used 3 Pump housing 2 Washer 2 1 cs gt lt Groundsmaster 7200 7210 Page 4 67 Hydraulic System Transmission Assembly Fig 39 IMPORTANT When assembling the transmission lubricate all transmission components with clean hydraulic oil 1 Make sure that all transmission components are thoroughly clean before assembling the transmission 2 Apply clean hydraulic oil to washers and swash plate surfaces Install washer onto each swash plate and carefully install swash plates into transmission pump housing 3 Press oil seal into both side covers and secure with retaining ring Lubricate new O rings and install onto side covers 4 Carefully slide side covers over trunnion shafts tak ing care to not damage seals Secure both side covers to transmission pump housing with three 3 socket head screws Torque screws from 78 to 95 in Ib 8 8 to 10 8 N m 5 Lubricate new O rings and install onto two 2 plugs Install plugs into transmission pump housing Torque plugs from 17 to 19 ft lb 22 to 27 N m Figure 67 1 Swash plate 2 used 3 Pump housing 2 Washer Figure 68 1 Side cover 4 Retaining ring 2 O ring 5 Oil seal 3 Pump housing Figure 69 1 Socket head plug 3
46. Figure 12 4 Hex nut 2 used 5 Swivel Chassis Front Castor Wheels C 2 See text T 2 for tightening S 7 procedure X Figure 13 1 Grease cap 5 Bearing cup 9 Lock nut 2 Locknut 6 Carrier frame 10 Cap screw 3 Belleville washer 7 Seal 11 Castor wheel assembly 4 Bearing cone 8 Castor fork 12 Plug Disassembly Fig 13 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels Jack front of machine enough to al low the removal of the castor wheel Support machine with appropriate jack stands Chassis Page 6 14 3 Remove cap screw and lock nut that secure castor wheel to castor fork Remove castor wheel assembly from machine 4 Remove grease cap item 1 from carrier frame Dis card cap 5 Support castor fork to prevent it from falling Remove lock nut from castor fork Slide castor fork from machine 6 Remove three 3 belleville washers and upper bear ing cone from carrier frame Note orientation of washers as they are removed Fig 14 Belleville washer orienta tion is critical for proper castor wheel movement Groundsmaster 7200 7210 7 Pry seal from carrier frame Discard seal Remove lower bearing cone from frame 8 Inspect bearing cups in carrier frame for we
47. Firing Order 1 fan end 2 3 flywheel end Dry Weight approximate 205 Ib 93 kg Fuel No 2 D Diesel Fuel ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mini Nozzle DNOPD Fuel Tank Capacity 11 5 U S Gallons 43 5 Liters Governor Centrifugal Mechanical Low Idle Speed no load 1500 to 1650 RPM High Idle Speed no load 3200 to 3250 RPM Engine Oil API Classification CH 4 Cl 4 or Higher see Operator s Manual for viscosity recommendations Oil Pump Gear Driven Trochoid Type Crankcase Oil Capacity 4 0 U S Quarts 3 8 Liters with Filter Cooling System Capacity including reserve tank 6 U S Quarts 7 5 Liters Starter 12 VDC 1 4 KW Alternator 12 VDC 40 Amp with Internal Regulator Kubota Diesel Engine Page 3 2 Groundsmaster 7200 7210 Specifications Groundsmaster 7210 Item Description Make Designation Kubota D1105T E2B 4 stroke Turbocharged Liquid Cooled OHV Diesel Number of Cylinders Bore x Stroke 3 07 x 3 09 78 mm x 78 4 mm Total Displacement 68 53 in3 1123 cc Compression Ratio 22 0 1 Firing Order 1 fan end 2 3 flywheel end Dry Weight approximate 215 Ib 98 kg Fuel No 2 D Diesel Fuel ASTM D975 Fuel Injection Pump Bosch MD Type Mini Fuel Injector Nozzle Mi
48. Make sure that all pistons are placed in cylinder blocks Taking care to not drop pistons from cylinder block slide both cylinder block assemblies onto pump shafts 26 Lubricate two 2 new O rings and install O rings into grooves in pipe Slide pipe assembly into bore of transmission pump housing 27 Lubricate new O rings and install O rings onto six 6 hex plugs Install plugs into center case Torque plugs from 14 to 15 ft lb 18 to 21 N m 28 Lubricate flushing valves with clean hydraulic oil and place them in center case bores making sure to place RH and LH flushing valves in correct location 29 Lubricate new O rings and install O rings on two 2 flushing valve plugs Install springs and plugs to secure flushing valves Torque plugs from 17 to 19 ft lb 22 to 27 N m Figure 80 1 Oil seal 3 Thrust plate bevel 2 Thrust plate 4 Control arm 2 1 cs gt lt Figure 81 1 Cylinder block assembly 2 Pipe Figure 82 1 Hex plug 6 used 3 LH flushing valve 2 RH flushing valve 4 Center case Groundsmaster 7200 7210 Page 4 73 Hydraulic System 30 Lubricate O rings and backup rings for bypass valves Position rings on bypass valves and install valves into center case Torque valves from 62 to 79 in Ib 7 to 9 N m 31 Lubricate sealing washers and install onto forward and reverse relief valve cartridges IMPORTANT The forward and reverse relief car tridges are different Use labels m
49. Pivot pin Hydraulic System 2 cs gt Lift Cylinder Service Figure 108 1 Grease fitting 6 Collar 10 Back up ring 2 Barrel 7 Shaft 11 O ring 3 Nut 8 Dust seal 12 Piston 4 O ring 9 Rod seal 13 Piston seal 5 Head Hydraulic System Page 4 94 Groundsmaster 7200 7210 Disassembly Fig 108 1 Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder shaft Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the hydraulic cylinder into a vise clamp on the clevis ONLY 2 Mount lift cylinder in a vise Use of a vise with soft jaws is recommended 3 Carefully remove collar with a pipe wrench 4 Remove plugs from ports Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the shaft surface Clamp on the clevis ONLY 5 Mount shaft securely in a vise by clamping on the cle vis of the shaft Remove nut and piston from the shaft Slide head off the shaft 6 Remove piston seal and O ring from the piston Re move O ring back up ring rod seal and dust seal from the head Groundsmaster 7200 7210 Page 4 95 Assembly Fig 108 1 Make sure all parts are clean before reassembly 2 Coat new O rings piston seal rod seal back up ring and dust seal with clean hydraulic oil A Install piston seal and O ring to the piston
50. Shaft seal 7 O ring 13 Dowel pin 2 Front pressure seal 8 Implement relief valve 14 Rear bearing block 3 Front back up ring 9 Socket head screw 4 used 15 Idler gear 4 Drive gear 10 Lock washer 4 used 16 Front bearing block 5 Rear back up ring 11 Back plate 17 Front plate 6 Rear pressure seal 12 Body 18 Retaining ring Disassembly Fig 96 1 Install clean plugs in pump ports and clean the out side of the pump thoroughly After cleaning remove plugs and drain any oil out of the pump 2 Use a marker to make a V across the front plate body and back plate for assembly purposes Fig 97 IMPORTANT When clamping the pump in a vise clamp only on mounting flange DO NOT clamp pump body in a vise 3 Clamp mounting flange of pump in a vise with the shaft end down Figure 97 4 Loosen four 4 socket head screws that secure the back plate 5 Remove pump from the vise Remove socket head screws and lock washers Hydraulic System Page 4 80 Groundsmaster 7200 7210 6 Remove front plate from the body then remove back plate Locate and remove dowel pins from body IMPORTANT Mark the relative positions of the gear teeth and bearing blocks so they can be assembled in the same position Do not touch the gear surfaces as residue on hands may be corrosive to gear finish 7 Place pump on its side and push on the rear bearing block to remove bearing blocks and gear set from the pump body NOTE Press
51. Special hardened washer 8 Spacer set Pulley 9 Spindle housing V ring seal if equipped 10 Grease fitting O ring 11 Shaft spacer Oil seal 12 Spindle shaft Figure 11 Bearing 4 Inner spacer Spacer ring 5 Outer spacer Large snap ring Groundsmaster 7200 7210 3 Using an arbor press push the bearing cups into the top and bottom of the spindle housing The top bearing cup must contact the outer spacer previously installed and the bottom bearing cup must contact the snap ring Make sure that the assembly is correct by supporting the first bearing cup and pressing the second cup against it Fig 12 4 Pack the bearing cones with grease Apply a film of grease on lips of oil seals and O ring 5 Install lower bearing cone and oil seal into bottom of spindle housing Note The bottom seal must have the lip facing out down Fig 13 This seal installation al lows grease to purge from the spindle during the lubrica tion process IMPORTANT If bearings are being replaced make sure to use the spacer ring that is included with new bearing set Fig 11 6 Slide spacer ring and inner bearing spacer into spindle housing then install upper bearing cone and oil seal into top of housing Note The upper seal must have the lip facing in down Fig 13 Make sure upper seal is flush to 0 080 2 0 mm recessed to housing surface 7 Inspect the spindle shaft and shaft spacer to make sure there are no burrs or nicks that c
52. WARNING 1 E pa BRAKE OFF lt q Y 2 F SEAT SW GROUND F 2 COM Bg na NO 5 CC U J U J U J M we CY U U la gt VIO BK SEAT SWITCH Ncl8 KANZAKI CL OCCUPIED 25 NEUTRAL SW SOLENOID To BN o o GN lt gt a LH NEUTRAL SWITCH RH NEUTRAL SWITCH SCM A al ae B NOT IN NEUTRAL NOT IN NEUTRAL 2 H IGN SW S PTO SWITCH YELLOW FRAME GROUND BATERY VIO lt PTO OFF DIODE 7 BN vio FOR OPTIONAL PTO STOP NONE 8 A RUN B i amp X Y START B I S s WW PK D BI IGNITION SWITCH OFF RUN START F1 454A FS 104 gt n FOR ACCESSORY POWER KIT F2 10A VIO o xl o o a Run Circuits FOR ACCESSORY POWER KIT Power Current Control Current Indication Current Page 8 11 ALTERNATOR RUN SOLENOID HOLD a de PULL pc Y 105C TEMP SWITCH PK GN ENGINE on PRESSURE SWITCH oN ld w E Y OR PO S BU W HA 115C TEMP SWITCH a o a E o ATAY AA laudis uui ai bred oie HA AH HAT ls 2 lt 3 a El 5 K R BK 5 B 3 B FUEL PUMP B z Ej 3 me 9000 PK 2
53. all ports and clean the outside of the valve thor oughly IMPORTANT Match mark spools to their associat ed bores before disassembly Spools must be rein stalled to the bore from which they were removed 2 Remove both spool caps item 10 and slide the spool assemblies from their bores 3 Remove O ring item 12 and bushing item 8 from each spool assembly 4 Remove wiper seals item 20 and O rings item 12 from the spool bore ends that are opposite the spool caps NOTE Disassemble spool assemblies only if the re taining ring item 13 spacer item 3 spool spring item 16 or washer item 14 need replacing 5 Remove seat retaining plugs items 7 and 15 back up washers O rings and check spring item 9 from the valve body 6 Remove check poppet item 1 seats item 5 O rings item 27 and plungers items 2 and 21 from the valve body 7 Remove solid plug item 6 back up washer and O ring from the opposite end of the plunger 8 Remove detent plug item 19 and O ring from the valve body Remove disc spring and detent plunger from the body Inspection 1 Inspect spools and spool bores for wear If wear is excessive replace control valve with new one 2 Inspect springs and replace as necessary 3 Inspect plunger and detent plunger for wear Re place as necessary 4 Inspect caps and plugs for damaged threads and in spect O ring sealing surfaces Replace as necessary Gro
54. and head 4 Remove plugs from ports Extract shaft head and piston by carefully twisting and pulling on the shaft IMPORTANT Do not clamp vise jaws against the rod surface Clamp on the clevis ONLY 5 Mount rod securely in a vise by clamping on the cle vis of the rod Remove lock nut and piston from the rod Carefully slide head off the shaft 6 Taking care to not scratch or damage the piston re move cap seal and O ring from the piston If necessary remove wear ring from piston 7 Taking care to not scratch or damage the head re move O ring back up ring wiper and seal from the head Inspection 4h caution Use eye protection such as goggles when using compressed air 1 Wash all lift cylinder components in solvent Dry parts with compressed air 2 Inspect internal surface of barrel for deep scratches out of roundness and bending Replace if worn or damaged 3 Inspect head shaft and piston for excessive pitting scoring and wear Replace any worn or damaged parts Groundsmaster 7200 7210 Page 4 99 Assembly Fig 110 1 Make sure all lift cylinder parts are clean before as sembly 2 Coat new O rings back up ring and other seals with clean hydraulic oil A Carefully install cap seal and O ring to the piston Install wear ring on piston if removed B Carefully install back up ring O ring seal and wiper to the head IMPORTANT Do not clamp vise jaws against the rod surface
55. at the beginning of this section 5 Thoroughly clean junction of hydraulic hose and low er fitting on rear of lift control valve 6 Disconnect hydraulic hose from lower fitting on rear of lift control valve Fig 25 This hose is from the gear pump outlet and provides oil flow to the lift control valve 7 Install hydraulic tester pressure and flow in series with the gear pump fitting and the disconnected hose Make sure that tester flow arrow points from the pump outlet port and toward the disconnected hose Make sure the flow control valve on the tester is fully open 8 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test Groundsmaster 7200 7210 Page 4 39 9 With engine running move throttle to full speed 3200 RPM 10 Watch tester pressure gauge carefully while slowly closing the flow control valve until 1000 PSI 69 bar is obtained Do not close tester load valve fully Verify with a phototac that the engine speed remains 3200 RPM while maintaining 1000 PSI 69 bar on the tester pres sure gauge 11 Observe flow gauge Flow indication for a pump in good condition is 5 4 GPM 20 4 LPM 12 Open tester load valve and then stop engine Record test results 13 Normal pump flow is 5 4 GPM 20 4 LPM Lower pump flow would result in reduced circuit performance If flow was less than 4 8 GPM 18 2 LPM or a pr
56. center of the lift arm pivot tube 6 Raise the front of the machine with the jack until the rear of the machine is supported on the jack stands and the center tire swings back and nearly contacts the rear tire Support front of machine with jack stands The track guides have many pinch points Care fully grasp the rubber track on the outer edges outboard of the steel guides when moving the tracks 7 Have a second person lift the center of the track to allow removal of the center wheel Remove lug nuts that secure center wheel to machine Carefully remove cen ter wheel from track and machine 8 Once center wheel has been removed have a sec ond person lift the track from other wheel s as neces sary to allow removal of additional wheel s from machine Groundsmaster 7200 7210 Page 6 7 Installation Fig 2 1 If the track was removed from the machine position track to wheel location Make sure that direction arrow on track is properly orientated NOTE When installing wheels to a Polar Trac equipped machine the center wheel must be installed last to allow track clearance for front and rear wheels 2 Have a second person lift the track to allow installa tion of the front and or rear wheel to machine Secure wheel s to machine with five 5 lug nuts 3 After front and rear wheels are installed on machine have a second person lift the center of the track to allow installation of the center wheel Secure ce
57. excessive wear or scoring E Face of bearing blocks that are in contact with gears should be free of wear roughness or scoring 3 Inspect front plate and back plate for damage or wear Replace pump if plates are damaged or worn Figure 98 3 Gear teeth 4 Gear face edge 1 Gear shaft spline 2 Gear shaft Assembly Fig 96 NOTE When assembling the pump check the V shaped marker line made during disassembly to make sure components are properly aligned 1 Lubricate new O rings pressure seals and back up gaskets with a thin coat of petroleum jelly Lubricate all internal pump parts freely with clean hydraulic oil 2 Install new shaft seal in front plate Seal should be pressed into place until it reaches the bottom of the bore 3 Install retaining ring into the groove of the front plate 4 Install lubricated O rings to the body 5 Install lubricated pressure seals into the machined grooves of the bearing blocks and follow by carefully placing the back up rings into the grooves 6 Lubricate gear faces and bearing surfaces of drive gear idler gear and bearing blocks with clean hydraulic oil Carefully assemble bearing blocks and gears noting identification marks made during disassembly 7 Position the pump body on its side Carefully slide bearing block and gear assembly into the body cavity using identification marks made during disassembly 8 Remove any excess lubrication from mating sur faces of bo
58. flywheel coupling to transmission input shaft and en gine endplate to flywheel housing 8 Secure flywheel housing and fuel water separator bracket to engine endplate with eight 8 flange head screws and two 2 socket head screws 9 Secure engine to the engine mounts attached to the frame with two 2 cap screws snubbing washers and lock nuts 10 Connect fuel hoses to the fuel water separator Fig 11 Connect return fuel hose to front injector nozzle Fig 12 11 Connect electrical wires to engine using labels placed during engine removal A Negative battery cable wire harness ground and fuel stop solenoid Fig 11 B Glow plug bus Fig 12 C High temperature warning switch and high tem perature shutdown switch Fig 13 D Starter motor fusible link harness alternator and oil pressure switch Groundsmaster 7200 7210 12 Secure wire harness to engine with cable ties at loca tions noted during engine removal 13 Carefully position fan shroud around the engine fan 14 Install radiator to machine see Radiator Installation in this section Make sure that radiator hoses are se cured with hose clamps 15 Make sure that drain plug is installed in radiator Fill radiator with coolant 16 Install muffler to the engine see Exhaust System Installation in this section 17 Connect throttle cable to the support bracket and swivel on the speed control lever 18 Adjust throttle cable see Adjust Throttl
59. grease gun through plug hole in frame fill area sur rounding the castor fork shaft with grease Allow grease to fill cavities below lower bearing between bearings and above upper bearing Reinstall plug into frame Groundsmaster 7200 7210 Page 6 15 NOTE Periodic greasing of castor fork bearing area is not necessary Do not replace plug item 12 with grease fitting Grease cap item 1 will loosen if castor fork has excessive grease installed 7 Install new grease cap item 1 so cap shoulder is flush with top of carrier frame There should be no evi dence that the cap is indented by top of castor fork 8 Position castor wheel to castor fork and secure with cap screw and lock nut 9 Lower machine to ground Figure 14 1 Locknut 2 Belleville washer 3 Upper bearing cone Figure 15 4 Bearing cup 5 Castor wheel 6 Castor spacer 1 Bearing spacer 2 Seal 3 Bearing cone Chassis Polar Trac Wheel Hub Service 65 to 85 ft Ib 88 to 115 N m Figure 16 1 Frame 5 Wheel assembly 9 Pivot LH shown 2 Bogie assembly 6 Lug nut 5 used per wheel 10 Pivot pin 3 Flange nut 7 Drive track 11 Shoulder bolt 4 Shoulder screw 8 Pivot pin Chassis Page 6 16 Groundsmaster 7200 7210 Disassembly Figs 16 and 17 NOTE Refer to the Polar TracTM Operator s Manual for additional information regarding drive track and wheel removal 1 Park machine on a level surface lower implement
60. in the General Information section for informa tion regarding the importance of removing contamination from the traction circuit Groundsmaster 7200 7210 2 55 CO 0 UO gt gt N lt This page is intentionally blank Groundsmaster 7200 7210 Page 4 51 Hydraulic System Transmission Antiseize m 30 Lubricant 400 in Ib 45 N m NB K 139 X CCE Figure 35 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 Cap screw 40 mm long 20 Hydraulic fitting 35 90 hydraulic fitting 6 Lock washer 7 used 21 Hose clamp 36 Hydraulic hose i det a 50 mm long 6 used SS gt hose 37 Hydraulic hose 2 used 9 Flywheel housing 24 O ring 38 Hydraulic hose 2 used 10 Dowel pin 2 used 25 Hex nut 39 O ring ESO 11 Hydraulic fitting 26 Clip 40 Hydraulic fitting 12 O ring 27 Cap screw 41 O ring 13 Hydraulic hose 28 O ring 42 Hydraulic hose 14 Cap screw 2 used 29 Hydraulic fitting 43 Hydraulic fitting 4 used 15 Lock washer 2 used 30 O ring 44 O ring Hydraulic System Page 4 52 Groundsmaster 7200 7210 Transmission Removal Fig 35 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Informat
61. key from the switch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the machine or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and all hydraulic hoses and lines are in good condition be fore applying pressure to the hydraulic system 5 Keep body and hands away from pin hole leaks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be re lieved by parking the machine on a level surface lower ing the cutting deck or implement completely to the ground and then stopping the engine 7 When working on the hydraulic system and its com ponents wear eye protection 8 If major repairs are ever needed or assistance is de sired contact your Authorized Toro Distributor 9 Use care when checking or servicing the cutting deck Wear gloves and use caution when servicing it 10 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and d
62. may also be available from a local tool supplier Hydraulic Pressure Test Kit Toro Part Number TOR47009 Use to take various pressure readings for diagnostic tests Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools A high pressure hose is provided for remote readings Test Kit contains one each 1000 PSI 70 bar 5000 PSI 350 bar and 10000 PSI 700 bar gauges Use gauges as recommended in the Testing Section of this chapter Hydraulic Tester Pressure and Flow Toro Part Number TOR214678 This tester requires O ring face seal ORFS adapter fit tings for use on this machine Use this tester as recom mended in the Testing Section of this chapter 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 LOW PRESSURE GAUGE Low range gauge to pro vide accurate reading at low pressure 0 to 1000 PSI 0 to 70 bar A protector valve cuts out when pressure is about to exceed the normal range for the gauge The cutout pressure is adjustable 4 HIGH PRESSURE GAUGE High range gauge which accommodates pressures beyond the capacity of the low pressure gauge 0 to 5000 PSI 0 to 350 bar 5 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated at 15 GPM 6 OUTLET HOSE A hose from
63. or damage Fig 24 Replace flange bushing s if neces sary 2 Install lift arm components as necessary using Fig ures 21 and 23 as guides A If rear lift arm was removed from deck lift shaft make sure to thoroughly clean tapers of shaft and lift arm bore before installing lift arm to shaft Also when installing washer item 26 position washer cavity to ward lift arm Fig 25 B If ball joints were removed from link item 13 install ball joints equally on both ends of link Adjust center to center length of link assembly from 18 070 to 18 180 45 9 to 46 1 cm Fig 26 Tighten jam nuts to secure ball joints to link Make sure that ball joints stay inline when tightening jam nuts NOTE Do not change the link assembly length to adjust the height of cut or for any other reason NOTE When properly installed flange nuts item 23 should have flange surface against lift arm and not against chain C If cap screw item 20 was removed from chain item 22 insert screw into upper link of chain and thread flange nut item 23 onto screw with flange away from link Torque flange nut to 50 ft lb 67 N m When fastening chain to front lift arm torque second flange nut to 50 ft Ib 67 N m When instal ling chain to rear lift arm torque cap screw to 50 ft Ib 67 N m 3 Lubricate all lift arm grease fittings after assembly 4 Start engine and fully raise cutting deck Stop engine and remove key from the i
64. or D for the LH side This oil flows to the wheel motor and turns the motor in the reverse direction Oil flow from the wheel motor re turns to the transmission port A or C and is continuous ly pumped as long as the traction lever is pushed rearward As the traction load increases reverse traction circuit pressure can increase to the relief valve setting of 4000 PSI 276 bar If pressure exceeds the relief setting oil flows through the reverse relief valve in the transmission to the low pressure side of the closed loop traction cir cuit The charge circuit functions the same in reverse as it does in the forward direction The check valve placed in the reverse side of the traction circuit includes an orifice which allows the traction neutral position to be easier to adjust The flushing valve remains seated during re verse operation Hydraulic System 9 s O a Y Io 21012 Old MG a req 922 ISd 0007 INVA SINIYA 331138 ONIHSM4 1HOd uvau SUM elc W Yoon NA THA HI 1HOd ANOS INVA ONIHSM14 1S31 34hnSS3Hd 39HVHO iL 1HOd jus ANOHS gt gt 01 ok 00 INYA V Hoon SSvdAg VA IMH 1HOd uv3u nal NOILISOd 3SIYH QHYMHOS a
65. positive terminal of the hour meter 3 Connect the negative terminal of the voltage source to the other terminal of the hour meter 4 The hour meter should move 1 10 of an hour in six minutes 5 Disconnect the voltage source from the hour meter 6 Replace the hour meter if necessary Figure 10 7 Connect harness electrical connector to the hour meter Electrical System Page 5 12 Groundsmaster 7200 7210 PTO Switch The PTO switch is located on the control panel Fig 11 The PTO switch is pulled up to engage the PTO cutting deck or implement The Standard Control Module SCM monitors the posi tion of the PTO switch up or down Using inputs from the PTO switch and other switches in the interlock sys tem the SCM controls the energizing of the transmis sion solenoid valve and thus the PTO If the ignition switch is in the ON position and the PTO switch is en gaged the SCM PTO switch input LED should be illumi nated IMPORTANT During machine operation if the PTO shuts down and the console temperature warning light is illuminated due to excessive engine coolant temperature avoid shutting off the engine Under this condition the operator should push the PTO knob down slowly drive to a safe flat area move the throttle lever to the SLOW position move the trac tion control levers into the neutral locked position and engage the parking brake The engine should be allowed to idle for several minute
66. so do not interchange forward and reverse relief valves 13 If traction relief valve pressure is not met remove and inspect relief valve from transmission see Trans mission Service in the Service and Repairs section of this chapter Clean or replace relief valve Relief valves are not adjustable 14 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect tester from pump outlet fitting and hydraulic hose Connect hose to pump fitting 15 If necessary repeat pressure test for other traction relief valves Hydraulic System o o O o kt ES Io Wheel Motor Efficiency Test Using Tester with Pressure Gauges and Flow Meter LIFT CYLINDER RIGHT SIDE WHEEL MOTOR EFFICIENCY TESTING SHOWN ola AN 4000 PSI 276 bar FLUSHING PORT B VALVE RE 4000 PSI 276 bar FLUSHING O FO FORWARD BYPASS VALVE 1 HYDRAULIC Hydraulic System TESTER MOTOR RH WHEEL 310 to 300 JNF 3 4 16 FORWARD BYPASS 314 16 UNF porr Figure 18 Page 4 32 Groundsmaster 7200 7210
67. the ignition switch NOTE The installation torque of the lock nut used to secure wheel hub to wheel motor is from 300 to 400 ft Ib 407 to 542 N m If hub removal is necessary use impact wrench to loosen lock nut 2 If wheel hub is to be removed loosen but do not re move lock nut that secures wheel hub to wheel motor 3 Remove rear wheel see Rear Wheel Removal in this section Make sure that machine is properly sup ported with jack stands Chassis Page 6 8 4 Remove retaining ring and flat washer that retains brake rod assembly to parking brake lever Separate brake rod from brake lever 5 Remove four 4 cap screws and flange nuts that se cure brake support to frame 6 Slide brake support with parking brake assembly at tached from wheel hub disc and frame 7 Remove two 2 lock nuts that secure parking brake assembly to brake support Remove brake from sup port Locate and retrieve two 2 hardened washers from between parking brake and brake support Figs 5 and 6 Groundsmaster 7200 7210 IMPORTANT If wheel hub removal is necessary do not hit wheel hub or hub puller with a hammer dur ing removal Hammering may cause damage to the hydraulic wheel motor or wheel hub 8 If necessary use wheel hub puller to loosen wheel hub from the wheel motor shaft Remove loosened lock nut and wheel hub from wheel motor Remove woodruff key from the shaft Installation Fig 4 1 If wheel hub was remove
68. the beveled sides of the thrust plates are against the swash plate surfaces 27 Remove socket head screw and nut that secures control arm onto each trunnion shaft Slide control arm from each trunnion shaft Figure 51 1 Hex plug 6 used 3 LH flushing valve 2 RH flushing valve 4 Center case 2 1 cs gt lt Figure 52 1 Cylinder block assembly 2 Pipe Figure 53 1 Oil seal 3 Thrust plate bevel 2 Thrust plate 4 Control arm Groundsmaster 7200 7210 Page 4 61 Hydraulic System 28 Remove two 2 hex plugs and one 1 socket head plug from gear case housing Remove and discard O rings from plugs Figure 54 1 Hex plug 2 Socket head plug 29 Remove fifteen 15 flange head screws that secure gear case housing to transmission pump housing 30 Carefully remove gear case housing from pump housing 31 Locate and retrieve two 2 pins from gear case housing holes Remove and discard gasket 32 Remove retaining ring that secures input shaft oil seal into gear case housing bore Remove spacer and oil seal from housing taking care to not damage seal bore in housing Discard seal Figure 55 1 Gear case housing 3 Pin 2 used 2 Pump housing Hydraulic System Page 4 62 Groundsmaster 7200 7210 33 Remove input shaft RH pump shaft and LH pump shaft assemblies from transmission pump housing 34 Slide pipe assembly from bore of pump housing Re move and discard two 2 O r
69. the machine on jack stands and operate the trac tion circuit to allow oil flow through the circuit With the machine raised off the ground the traction circuit will have maximum oil flow at minimum pressure to mini mize damage from any remaining contamination The filter will remove contamination from the closed loop traction circuit during operation Remove the filter from the machine after contamination has been removed from the traction circuit IMPORTANT When operating the traction system with the high pressure filter installed make sure that flow is always directed through the filter e g do not move the traction levers in the reverse direction if the filter is placed for forward direction flow If flow is reversed debris from the filter will re enter the traction circuit Groundsmaster 7200 7210 Hydraulic Schematics The hydraulic schematics for the Groundsmaster 7200 and 7210 are located in Chapter 8 Foldout Diagrams 2 s a LY ER EX Groundsmaster 7200 7210 Page 4 9 Hydraulic System Flow Diagrams IC Hydraul E r gt N19 Old hos D z z lt _ 7a ls IGNITAO L417 1eq 922 isa ooo GaldHS 31134 INIYA TAS a ONIHS Y14 aa1aiHs ANIYA SNIHSMS
70. the outlet side of the hydraulic tester connects to the hydraulic system circuit Hydraulic System Page 4 18 Figure 9 Figure 10 Groundsmaster 7200 7210 Hydraulic Test Fitting Kit Toro Part Number TOR4079 This kit includes a variety of O ring Face Seal fittings to enable the connection of test gauges into the system The kit includes tee s unions reducers plugs caps and male test fittings O ring Kit Toro Part Number 16 3799 This kit includes O rings in a variety of sizes for face seal and port seal hydraulic connections As a preventa tive measure against leakage it is recommended that an O ring be replaced any time a hydraulic connection is opened High Pressure Hydraulic Oil Filter If a component failure occurs in the closed loop traction circuit contamination from the failed part will remain in the circuit until removed When connecting hydraulic test gauges in order to test traction circuit components or after replacing a failed traction circuit component e g hydrostat or wheel motor a high pressure hydraulic fil ter can be installed in the traction circuit The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component dam age A high pressure hydraulic oil filter can be obtained local ly Toro Test Fitting Kit TOR4079 Fitting Tool Number Figure 11 Hydraulic Figure 12 Figure 13 Groundsmaster 7200 7
71. to make sure that oil level is correct Hydraulic System 9 s O a Y oP Charge Relief Valve Pressure Test Using Pressure Gauge H21012 O udi 0822 Im il ATT eq 922 ISd 0007 INVA SIATVA 3317394 9NIHSMA fH LHST in 22 01 94 00 INVA fW OLOW SSVdA8 Va TH3HM HI ih QHVMHO4 INIYA SNIHSM14 AN yl LHST DET 2 gt CIE o4 OC INVA ZY Hoon SSVdA8 Cay HSHMHH GQHVAAHOd S INN 91 eq 972 ISd 000P S3ATVA 331134 PRESSURE GAUGE HIONNAO LIN Figure 14 Groundsmaster 7200 7210 Page 4 26 Hydraulic System The Charge Relief Valve Pressure Test should be per formed if a traction circuit problem is identified This test will determine if the transmission charge relief valve is operating correctly Procedure for Charge Relief Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature 2 Make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System
72. transmission and flywheel housing 14 On both sides of transmission remove retaining ring that secures pump control rod end onto transmission control arm Fig 36 Slide control rod from control arm 15 1f hydraulic fittings are to be removed from transmis sion mark fitting orientation to allow correct assembly Remove hydraulic fittings from transmission as needed Discard fitting O rings 16 Inspect flywheel housing and coupler on engine fly wheel for evidence of wear or damage Transmission Installation Fig 35 1 Make sure that flywheel coupler and flywheel hous ing are secure on engine see Engine Installation in the Service and Repairs section of Chapter 3 Kubota Die sel Engine 2 If hydraulic fittings were removed from transmission lubricate and install new O rings to fittings Install fit tings into transmission ports see Hydraulic Fitting Installation in the General Information section of this chapter Tighten fittings to torque values identified in Figure 38 3 If gear pump was removed from transmission install gear pump see Gear Pump Installation in this section 4 Slide both pump control rods onto transmission con trol arms and secure with retaining rings Fig 36 58 to 72 ft Ib 79 to 97 N m O 60 to 74 ft Ib 5 t gt 82 to 100 N m 9 to 11 ft lb 35 to 43 ft Ib 48 to 58 N m o 20 to 26 ft lb SEN T 28 to 35 N m 13 to 15 m DNA 60 to 74 ft Ib A p 82 to 1
73. using a torque wrench with an offset wrench will be lower than the listed installation torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifications section of Chapter 2 Product Records and Maintenance 8 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method Hold the fitting in the desired position with a wrench and if port material is steel tighten the lock nut with a second wrench to the listed F F F T Step 4 If port material is aluminum tighten fitting to 60 of listed F F F T Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Hydraulic System Page 4 6 Lock Nut e T NS Back up Washer O ring Figure 6 Figure 7 Groundsmaster 7200 7210 Operator s Manual The Operator s Manual provides information regarding the operation general maintenance procedures and maintenance intervals for your Groundsmaster ma chine Refer to that publication for additional information when servicing the machine Pushing Traction Unit In case of emergency your Groundsmaster can be pushed for a very short distance However Toro does not recommend this as a standard procedure 1 Locate two 2 by pass valves on transmission Fig 8 Loos
74. 00 N m 35 to 43 ft lb _ 81 to 99 ft lb 110 to 134 N m 58 to 72 ft Ib 79 to 97 N m Figure 38 Hydraulic System Page 4 54 Groundsmaster 7200 7210 5 Apply a generous amount of antiseize lubricant to splines of transmission input shaft and flywheel coupler 6 Place two 2 dowel pins in flywheel housing IMPORTANT Make sure to not damage the trans mission flywheel housing hydraulic lines electri cal harness or other parts while installing transmission Support transmission assembly when installing it to the flywheel housing to prevent it from fal ling and causing personal injury 7 Lower transmission into machine Align transmis sion input shaft with flywheel coupler and slide transmis sion to flywheel housing Support transmission to prevent it from shifting 8 Secure transmission to the flywheel housing with seven 7 cap screws and lock washers Make sure that shorter cap screw is properly positioned Torque cap screws 400 in Ib 45 N m 9 Install hydraulic tank to machine see Hydraulic Tank Installation in this section Groundsmaster 7200 7210 Page 4 55 10 On both sides of machine secure the pump control rod to the traction control hub with cap screw and lock nut Fig 36 Note that cap screw is installed from the outside toward the center of the machine 11 Remove plugs that were installed to hydraulic hoses and fittings during the removal procedure 12 Us
75. 2 and or F3 are is faulty The PTO switch or circuit wiring is faulty The Standard Control Module is faulty Engine fuel stop solenoid or circuit wiring is faulty pull coil operates but hold coil or circuit wiring is faulty The ignition switch is faulty 5 5 Electrical System Electrical General Run and Transport Problems Engine stops during operation operator sitting on seat Battery does not charge Electrical System Page Possible Causes Operator not in center of seat seat switch is not depressed The engine temperature is excessive above 240 F 115 C The engine high temperature shutdown switch is faulty Machine is being operated on a slope with a low fuel level The parking brake was engaged or the parking brake switch is faulty The seat switch is faulty Fuse F1 F3 and or F4 are is faulty The engine run solenoid or fuel pump failed Wiring in the run circuit is faulty or disconnected see Chapter 8 Foldout Diagrams Loose or broken wire s see Chapter 8 Foldout Diagrams Engine alternator belt is loose or damaged The alternator is faulty The battery is faulty The alternator warning lamp is faulty The alternator warning lamp wiring is loose corroded or damaged The fusible link harness at the engine starter motor is faulty 5 6 Groundsmaster 7200 7210 Cutting Deck Operating Problems The cutting deck will not run with the PTO switch in the ON up
76. 2 to 15 in Ib 1 4 to 1 6 N m to secure fitting in tank 2 Position fuel tank to the machine 3 Secure tank to frame with two 2 clamps item 22 spacer cap screw three 3 washers items 36 26 and 37 and flange nut 4 Connect removed hoses to fuel tank fittings Secure hoses with hose clamps 5 If right side fuel tank was removed carefully position control panel to fuel tank and secure with five 5 flange head screws Install control panel access cover and se cure with two 2 latches 6 Lower and secure hood and operator seat Fill fuel tanks Kubota Diesel Engine o 2 a z3 2 Radiator oouogmgRON Radiator Oil cooler Flange nut 4 used Clamp Cap screw Washer 2 used Flange nut 2 used Flange nut 2 used Cap screw 2 used Rubber grommet 2 used Radiator frame Pipe plug Air inlet hose Kubota Diesel Engine Figure 8 Screw 4 used Overflow bottle bracket Overflow bottle Hydraulic hose Hose clamp 4 used Cap screw 4 used Foam strip Flange head screw 4 used Hydraulic hose Hose Roll pin R clamp Flat washer 6 used Page 3 12 Fan shroud Fan spacer Bulb seal 2 used Flange nut 4 used Cooling fan Flange head screw 4 used O ring Upper radiator hose Lower radiator hose Hose Radiator cap Washer head screw Groundsmaster 7200 7210 Removal Fig 8 1
77. 200 and 7210 machines consists of two identical and independent closed loop traction circuits If a component in one of these traction circuits e g wheel motor or transmission piston pump should fail debris and contamination from the failed component will circulate throughout the trac tion circuit This contamination can damage other com ponents in the circuit so it must be removed to prevent additional component failure If a component failure occurs in one of the traction cir cuits it is critical to disassemble drain and thoroughly clean the entire traction circuit transmission piston pump hydraulic hoses and wheel motor This proce dure will ensure that all contamination is removed from the circuit If any debris remains in the traction circuit and the machine is operated the debris can cause addition al component failure An additional step for removing all traction circuit con tamination would be to temporarily install a high pres sure hydraulic oil filter see Special Tools into the circuit The filter could be used when connecting hydraulic test gauges in order to test traction circuit components or af ter replacing a failed traction circuit component e g wheel motor or transmission piston pump The filter will ensure that contaminates are removed from the closed loop and thus do not cause additional component dam age Hydraulic System Page 4 8 Once the filter has been placed in the traction circuit place
78. 210 Page 4 19 Hydraulic System System Troubleshooting The chart that follows contains information to assist in Refer to the Testing section of this Chapter for precau troubleshooting There may possibly be more than one tions and specific hydraulic test procedures cause for a machine malfunction Problem Possible Cause Hydraulic oil leaks from system Hydraulic fluid foams excessively causing oil leakage from hydraulic tank breather NOTE Some aeration of hydraulic oil on this machine is normal Hydraulic system operates hot Traction response is sluggish Hydraulic System Fitting s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Oil level in hydraulic tank is low Hydraulic system has wrong type of oil One of the pump suction lines has an air leak Incompatible hydraulic oils mixed in system Water in hydraulic system Transmission pressure is high due to load or dragging brakes Oil level in hydraulic tank is low or inlet filter is loose or clogged Oil is contaminated or oil viscosity is too light Oil cooler is damaged or plugged Oil cooler air flow is obstructed Transmission by pass valve s is open or defective Gear pump relief valve is stuck open Lift control valve is being held in the lift or lower position Transmission check valve is not seating or is damaged Charge pressure is low Transmission or wheel motor s is worn or damaged
79. 3 11 D Loosen hose clamp and disconnect fuel supply hose from strainer outlet fitting on fuel tank E Lift left side fuel tank from machine 4 To remove right side RH fuel tank A Loosen hose clamp and disconnect vent hose from fitting on RH fuel tank IMPORTANT When removing right side fuel tank take care to not damage wire harness elec trical components or throttle cable B Loosen two 2 latches and remove control panel access cover Position cover away from RH fuel tank C Remove five 5 flange head screws that secure control panel to RH fuel tank Carefully position con trol panel away from RH fuel tank D Loosen and remove two 2 clamps item 22 that secure RH fuel tank to frame E Loosen and remove cap screw item 13 three 3 washers items 36 26 and 37 and flange nut item 28 that secure RH fuel tank to frame Locate and retrieve spacer item 19 F Loosen hose clamp and disconnect fuel supply hose from strainer outlet fitting on fuel tank G Lift RH fuel tank from machine 5 If necessary loosen hose clamp and remove strainer outlet fitting from fuel tank Clean strainer with low pressure compressed air 50 PSI maximum pressure Fuel Tank Installation Fig 7 1 If strainer outlet fitting was removed from fuel tank clean threads and apply Loctite 30558 thread sealant or equivalent to threads of fitting Install fitting into fuel tank Install and torque hose clamp from 1
80. 50 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 034375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 046875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilomet
81. 7 16 20 1 2 20 Installation Torque Into Steel Port 15 to 19 ftHb 21 to 25 N m 18 to 22 ft Ab 25 to 29 N m 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If port material is aluminum tighten fit ting to 60 of listed F F F T Size F F FT 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 Fitting Figure 4 Installation Torque Into Aluminum Port 9 to 11 ft lb 13 to 15 N m 11 to 15 ft lb 15 to 20 N m 9 16 18 3 4 16 7 8 14 1 1 16 12 13 16 12 15 16 12 1 5 8 12 34 to 42 ft lb 47 to 56 N m 58 to 72 ft lb 79 to 97 N m 99 to 121 ft lb 135 to 164 N m 134 to 164 ftHb 182 to 222 N m 160 to 196 ftHb 217 to 265 N m 202 to 248 ft lb 274 to 336 N m 247 to 303 ft lb 335 to 410 N m 20 to 26 ft lb 28 to 35 N m 35 to 43 ft lb 48 to 58 N m 60 to 74 ft lb 82 to 100 N m 81 to 99 ft lb 110 to 134 N m 96 to 118 ft lb 131 to 160 N m 121 to 149 ftHb 165 to 202 N m 149 to 183 ft lb 202 to 248 N m Figure 5 Groun
82. 7210 Page 4 37 11 System pressure should be approximately 3000 PSI 207 bar as the implement relief valve lifts Return lift lever to the neutral position 12 Stop engine Record test results 13 If specification is not met repair or replace imple ment relief valve in gear pump see Gear Pump Service in the Service and Repairs section of this chapter Also consider a leaking lift cylinder a damaged lift control valve or a worn gear pump 14 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect T connector with test gauge from lift control valve fitting and hydraulic hose Reconnect hydraulic hose to control valve fitting Figure 22 1 Lift control valve 2 Hose from gear pump Figure 23 2 Hoseto lift control valve 1 Gear pump Hydraulic System 2 r L3 cs gt lt Gear Pump Flow Test Using Tester with Pressure Gauges and Flow Meter 21012 Old NN l wds esui amp u ooze req 922 ISd 0007 ANIA SINTYA 431734 ONIHSNTA KAI ab yo LA 55 OIE 04 00 PG VS soon J SSvdAa AA T33HM HI quvMdod INN 9 vit INVA SNIHSN14 INN 9 AN ih VLA 29 OIE 94 00 E ANIYA ZY Holon S
83. 9 Electrical System oS 2 o 2 lu Fusible Link Harness The Groundsmaster 7200 and 7210 uses three 3 fus ible links for circuit protection These fusible links are lo p4 FUSIBLE LINK x d cated in a harness that connects the starter B terminal mmu BIT FUSIBIEUNK U LER B HARNESS FUSIBLE LINK B i to the main wire harness If any of these links should fail current to the protected circuit will cease Refer to Elec trical Schematics in Chapter 8 Foldout Diagrams for additional circuit information b1 lt O Na Make sure that ignition switch is OFF and disconnect negative battery cable from battery terminal Then dis connect positive cable from battery see Battery Service in the Service and Repairs section of this chapter Lo cate and unplug fusible link connector P1 from machine wire harness Use a multimeter to make sure that conti nuity exists between each terminal pin in connector P1 and connector J1 at the starter Fig 23 If any of the fus ible links are open replace the fusible link harness Figure 23 After testing is complete make sure that fusible link har ness connectors are securely attached to starter and machine wire harness Connect positive battery cable to battery terminal first and then connect negative cable to battery Diode Assembly The diode assembly is used for circuit pr
84. ATOR P05 ALTERNATOR J03 OIL PRESSURE JOL GLOW PLUGS P30 NEUTRAL SWITCH RIGHT p12 STARTER J06 ENGINE GROUND p03 STARTER 5 J09 ACCESSORY P08 GROUND FUEL SOLENOID P20 GLOW CONTROLLER 2 4 p25 OIL PRESS ALT 17 m P31 IGNITION SWITCH HE P27 PTO SWITCH P18 PARKING BRAKE SW P0k STARTER B P26 GNI TION SWITCH P29 NEUTRAL SWITCH LEFT P28 FUEL PUMP P32 P10 FUSE DEBRIS BLOCK BLOWER OPTIONAL FUSE BLOCK Groundsmaster 7200 7210 e 2 Wire Harness Drawing rm Page 8 13 PTO SWITCH OVER OVER NEUTRAL SWITCH dua s SCM SEAT TEMP EMP a ST oe a ee quum s ODE PTO CLUTCH LEFT RIGHT SWITCH HOT WARM PPM a pe ws 32 33 POT Pol P02 P29 30 I Jol J05 23 4 5 6 1 8 9 A B A B EERE tate Las AB A B I Y z E z
85. Groundsmaster 7200 7210 Page 4 89 4 Remove plugs that were installed in hydraulic hoses during the removal procedure Attach hydraulic hoses to fittings on control valve using labels placed during re moval see Hydraulic Hose and Tube Installation in the General Information section of this chapter 5 Make sure hydraulic tank is full Add correct oil if nec essary Figure 104 1 Control valve 3 Lever valve link 2 Hair pin Hydraulic System 2 1 cs gt lt Polar Trac Hydraulic Control Valve Service 4 to 5 ft lb 5 4 to 6 8 N m 19 30 to 35 ft lb 41 to 47 N m n EN p m 21 to 24 ft lb 29 to 32 N m dd QU 21 27 20 to 25 ft lb 27 to 33 N m Check poppet Detent plunger Spacer Spool Seat 3 used Solid plug Seat retaining plug 2 used Bushing Check spring 10 Spool cap 2 used 11 Valve body e eo N 9 m P N Hydraulic System Figure 105 O rin Retaining ring Washe Seat retaining plug Spool spring Disc Plug Detent plug Wiper seal Plunger Detent plunger Page 4 90 LONG O IST 5 30 to 35 ft lb ea acc 011947 Nem di n 30 to 35 ft lb 41 to 47 N m Png 29 30 30 to 35 ft lb 7 4 41 to 47 N m Detent spring O ring O rin Back up washer O ring O ring O rin Back up washer Plug O ring Spool Groundsmaster 7200 7210 Disassembly Fig 105 1 Plug
86. Io PTO Pressure Valve Test Using Pressure Gauge 39NV9 3y4NSSIYA YOd 1831 El req 922 ISd 000P 3 1 134 INIYA ONIHSN14 INVA SSYdAg QHVMHO4 HIONNAO LIN INVA ONIHSN13 M 3 SNWA SSvdAa8 QHVMHO4 req 972 ISd 000P NIYA 23 38 usi 5 01 OF 0 w HOLOM Nal TH3HM HI 133HM HH Figure 19 Page 4 34 Groundsmaster 7200 7210 Hydraulic System The PTO Pressure Valve Test should be performed if a PTO engagement problem is identified This test will de termine if the PTO pressure valve in the transmission is operating correctly Procedure for PTO Pressure Valve Test 1 Make sure hydraulic oil is at normal operating tem perature Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 2 Park machine on a level surface with the cutting deck or implement lowered and off Make sure engine is off and the parking brake is applied 3 Read Precautions for Hydraulic Testing listed at the b
87. L MOTOR Ya s NN PRESSURE VALVE 800 to 310 co eS a CHARGE RELIEF 313430 psi NI 86415 psi FORT LI r1 OX E XA Line Filter ili L Y lt gt Beta Il 200 43 psi 4 HI FLUSHING RELIEF VALVES ISO 16889 3 4 16 UNF arai VALVE 4000 PSI E76 ban GOAT X ls GEAR PUMP 6 cc rev A 3200 engine rpm a iMPLEMENT RELIEF CHARGE PUMP 3000PSI 6cc rev M Port LT Suction Screen E 100 mesh Were rs LI n ACCUMULATOR 2250 rpm PTO CLUTCH O X a lt X X X OHO Ot 7490 Sv v3 ims sv Sv4 SV5 RN O F Optional Aux Hydraulics kit Optional Rear Attach Lift kit RH WHEEL MOTOR 300 to 310 cc LSHT LH WHEEL MOTOR 300 to 310 cc LSHT RELIEF VALVES 4000 PSI 276 bar FORWARD Ka WINTER ATTACHMENT PO SWING O CYLINDER RE DE WI CO LAR TRAC KIT PT ACES STANDARD IFT VALVE IN naar L ER IGURATION TER KIT T CYL FORWARD Ix
88. Make sure machine is safely supported so it will not move and accidentally fall to prevent injuring anyone under machine Groundsmaster 7200 7210 Page 4 45 10 Make sure traction control levers and lift control lever are in the neutral position Start engine and run at low idle speed 1500 to 1650 RPM The charge and gear pumps should pick up oil and fill the hydraulic system If there is no indication of fill in 30 seconds stop the en gine and determine the cause 11 After the hydraulic system starts to show signs of fill actuate lift control lever until the lift cylinder moves in and out several times If the lift cylinder does not move after 3 to 5 seconds or if the pump emits abnormal sounds shut the engine off immediately and determine cause or problem Inspect for the following A Loose oil filter or suction lines B Incorrect hose routing C Blocked suction line D Faulty implement relief valve E Faulty gear pump 12 After lift cylinder moves normally proceed to step 13 13 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 direc tion stop engine inspect wheel motor location and hy draulic lines to wheel motors see Transmission Installation in the Service and Repairs section of this chapter 14 Adjust traction control levers to the neutral position see Operator s Manual 15 Lower ma
89. NE GROUND 2 0 PARKING BRAKE pro sw 1 0 ENGINE Pa ok T KING BRA OR 2 T T Toon eg Sm BK e PARKING BRAKI SN 2 Backup over TEMP WARNING 1 my se lt q gt Y 2 F SEAT SW GROUND F t um nn lunc pecus Te we 1 t SEAT SWITCH RAI Pere NCjS KANZAKI CLUTCH a e o BN o GN SOLENOID FUSIBLE LINK NEUTRAL SWITCH NEUTRAL SWITCH 30M aan AE ES FRAME GROUND EN LEFT RIGHT vio 221 e sss PTO SWITCH YELLOW DiopE GND Bk BE HEADLIGHT AND HAZARD LIGHTS LIGHT KIT DEBRIS BLOWER KIT WINTER BATTERY POWER R MO Pe2 1 A A Pa GY 1 m NOl4 CAB KIT 2 sk NUM gt sJ SWITCHED POWER No GY GY I ue s 7 L ng MESE Sd cy BK 6 mm PARKER HYD VALVE PK x DPDT ON OFF ON LZ suren Quo IGNITION SWITCH DIODE OFF RUN START F1 A ETT TURN SIGNALS T NN OR B 1 Y E eK E mw 21 poe pos l TR to ol F2 Ng WORKLIGHT IG A Da 08 HEADLIGHT T VIO 5 HEADLIGHT HEADLIGHT O eg TAO Bk o LA DADI ON DFFE N KA E R Y BRAKE TURN A OR r pi LEFT TURN OUTPUT 1 t BK GROUND JB gy TAL NG RIGHT TURN OUTPUT 2 T GY cY A GN HAZARD INPUT 22 is on em 0 ACCESSORY POWER KIT Rer eU da in tan uos S 3 I PK LEFT TURN INPUT EN BU S 3 GROUND amp x xX BK El FLASHER DUAL RATE 12 I R Eb 2d Bd n rer s j POWER POINT RIGHT HAZARD OUTPUT 9 vio E BRAKE TURN ma y DAT LEFT HAZARD OUTPUT 11 EN BK GROUND LEFT HAZARD OUTPUT 12 C cY TAL lt WARNING TURN NG BK YY vo
90. ORQMOTOR SERVICE PROCEDURE 30 TC TB TE TJ TF TG TH AND TL SERIES 32 34 36 38 40 Page 4 1 Hydraulic System 9 s O a Y Io Specifications Item Description Transmission Maximum Traction Pump Displacement per revolution Traction Circuit Relief Pressure Forward and Reverse Charge Pump Displacement per revolution Charge Pressure Kanzaki dual variable displacement traction piston pumps with integral charge pump and multi disc PTO clutch 1 1 Cubic Inches 18 cc 4000 PSI 276 bar 0 37 Cubic Inches 6 cc 70 to 100 PSI 4 8 to 6 9 bar Gear Pump Displacement per revolution Implement Relief Pressure Casappa single section positive displacement gear type pump 0 41 Cubic Inches 6 7 cc 3000 PSI 207 bar Wheel Motors Displacement per revolution Parker orbital rotor motor TG Series 19 0 Cubic Inches 310 cc Hydraulic Filter Spin on cartridge type Hydraulic Oil Capacities Approximate Hydraulic Oil Change Hydraulic Tank and Transmission Hydraulic System All Components and Lines 10 9 Qt U S 10 3 L 16 Qt U S 15 1 L Hydraulic Oil See Operator s Manual Hydraulic System Page 4 2 Groundsmaster 7200 7210 General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure to weather sun chemicals very warm storage condi tions or mi
91. OX Eos Line Filter PA sys L 3 os 1 Beta z200 sy _ pont FLUSHNG RELIEF VALVES I8cc rev X 159165888 3 4 16 UNF D VALVE 4000 PSI 276 bar EE GEAR PUMP 6 cc rev c Optional Aux Hydraulics kit 3200 engine rpm i MPLEMENT R IEF P T CHARGE PUMP 306051 6cc rev I Optional Rear attach lift kit Port lt Suction Screen 100 mesh A T4LM LI Hau n ACCUMULATOR 2250 rpm PTO CLUTCH ALTERNATOR RUN SOLENOID 8 HOLD R BK w i PULL w 105C TEMP SWITCH oo EN ENGINE OIL PRESSURE SWITCH GN w w 5 NG OR MON BU W n 115 TEMP SWITCH x tu T S x a E a E zi amp o 3 i z x 9 r BK FUEL PUMP RABK 5 2 3 3 o 5 3 3 GLOW PLUGS 3 2 O O O O 2 OR o o s gl PK an EF START TEMP ed LLLA yg VIO 1 EM BK W o QUE LAMP GLOW EREI o lay a L i mu 12 3 6 GROUND GA HOUR METER O BK KUBOTA GLOW PLUG BK CONTROLLER R wh Ek Liz G e R BK ies r start Ng SP FUSIBLE LINK i BK BK q B BK KUBOTA STARTER 2 A S
92. PTO Solenoid Valve Coil The hydraulic system on the Groundsmaster 7200 and 7210 uses a solenoid valve coil on the front of the trans mission Fig 22 When the solenoid valve coil is ener gized hydraulic flow is directed to operate the PTO system The Standard Control Module SCM provides current to the solenoid valve coil based on the position of several inputs The PTO LED on the SCM will be illuminated when the solenoid valve coil is energized Testing NOTE The solenoid does not have to be removed from the cartridge valve for testing 1 Make sure ignition switch is in the OFF position Un plug wire harness electrical connector from solenoid valve coil NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing 2 Measure resistance between the two solenoid coil connector terminals Resistance of the solenoid coil should be approximately 7 5 ohms 3 Connect wire harness connector to the solenoid coil 4 If solenoid coil needs replacement see PTO Sole noid Valve Coil in the Service and Repairs section of this chapter Figure 22 3 Coil connector 1 Transmission 2 Solenoid valve and coil Groundsmaster 7200 7210 Page 5 1
93. S to Metric Conversions 2 Fasteners Metric Fasteners 5 TORQUE SPECIFICATIONS 3 Other Torque Specifications 6 Fastener Identification 3 Conversion Factors 6 Product Records Insert a copy of the Operator s Manual and Parts Cata log for your Groundsmaster 7200 or 7210 at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Operator s Manuals and Parts Catalogs for those options at the end of this chap ter Maintenance Maintenance procedures and recommended service in tervals for the Groundsmaster 7200 and 7210 are cov ered in the Operators Manuals Refer to those publications when performing regular equipment main tenance Groundsmaster 7200 7210 Page 2 1 Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1116 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 62
94. SE O a Y o Flush Hydraulic System IMPORTANT Flush the hydraulic system any time there is a severe component failure or ifthe system is contaminated oil appears milky black or con tains metal particles IMPORTANT If a component failure occurred in the traction circuit refer to Traction Circuit Closed Loop Component Failure in the General Informa tion section for information regarding the impor tance of removing contamination from the traction circuit 1 Make sure hydraulic oil is at normal operating tem perature by operating the machine for at least four 4 hours Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 2 Park machine on a level surface Lower cutting deck or implement stop engine and engage parking brake Remove key from the ignition switch IMPORTANT Make sure to thoroughly clean around all hydraulic connections that will be disassembled 3 Drain hydraulic tank and transmission 4 Drain hydraulic system Drain all hoses tubes and components while the system is warm 5 Remove and replace hydraulic oil filter 6 Inspect and clean hydraulic oil tank see Hydraulic Tank Inspection in this section 7 Reconnect all hydraulic hoses lines and compo nents that were disconnected to drain hydraulic system see Hydraulic Hose and Tube Installa
95. Standard Control Module Run output LED will be il luminated when the fuel pump is energized Operational Test 1 Park machine on a level surface lower cutting deck or implement stop engine and engage parking brake Make sure ignition switch is in the OFF position Unlatch and raise operator seat to gain access to fuel pump 2 Disconnect electrical connector from the engine fuel stop solenoid to prevent the engine from starting 3 Disconnect fuel hose pump discharge from the inlet fitting on the fuel water separator Fig 34 4 Make sure fuel hoses attached to the fuel pump are free of obstructions 5 Place disconnected fuel hose pump discharge into a large graduated cylinder sufficient enough to collect 32 fluid ounces 0 9 liter IMPORTANT When testing the fuel pump DO NOT turn ignition switch to START 6 Collect fuel in the graduated cylinder by turning igni tion switch to the ON position Allow pump to run for 30 seconds then return switch to OFF 7 Amount of fuel pumped in 30 seconds should be approximately 11 8 fluid ounces 350 ml 8 Replace fuel pump as necessary Connect fuel hose to the fuel filter 9 Connect wire harness electrical connector to the fuel stop solenoid 10 Bleed fuel system Groundsmaster 7200 7210 Page 5 25 Figure 33 4 Screw 2 used 5 Fuel hose 6 Fuel filter 1 Fuel hose discharge 2 Hose clamp 3 Fuel pump Figure 34 3 Hose clamp 4 Fuel
96. SvdAg VA Bamm HU QHYMHO4 eq 922 ISd 000 SIATVA 331138 INN 91 v 2 HYDRAULIC TESTER H3IONNAO LIN Figure 24 Groundsmaster 7200 7210 Page 4 38 Hydraulic System The Gear Pump Flow Test should be performed if a cut ting deck or implement raise and lower problem is identified This test will determine if hydraulic flow from the gear pump is correct Procedure for Gear Pump Flow Test NOTE Over a period of time the gears and wear plates in the gear pump can wear A worn pump will by pass oil and make the pump less efficient Eventually enough oil loss will occur to cause the cutting unit motors to stall under heavy cutting conditions Continued operation with a worn inefficient pump can generate excessive heat and cause damage to seals and other components in the hydraulic system 1 Make sure hydraulic oil is at normal operating tem perature 2 Make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 3 Park machine on a level surface with the cutting deck lowered and off Make sure engine is off and the parking brake is engaged 4 Read Precautions for Hydraulic Testing listed
97. TART 12 v i A BU BU lt PK 2 8 OVER TEMP SHUTDOWN pro COIL 1 8 PTO ENGAGE F4 BU W lt gt BN R 2A 2 0 IGN SW RUN 1 C PK W BK lt gt R BK HS ENGINE GROUND 2 D PARKING BRAKE PTO SW 1 0 1 COM C NO A ENGINE BK 1 9 OR lt gt T t EPI PARKING BRAKE oy NGI 7 QNG BIR 2E Jackia CERTENA ces 2 F SEAT SW GROUND i F 1 el 10 5 maf GY lt gt BK A i vio frm BK IT i SEAT SWIGH 2 6 NEUTRAL sw zi MESE o 15 D BN o GN zi NEUTRAL SWITCH NEUTRAL SWITCH SCM ERE CERTES lt LEFT RIGHT 27H IGN SW S PTO SWITCH YELLOW FRAME GROUND o vio lt DIODE T BN VIO FOR OPTIONAL PTO STOP NONE B A RUN B l A X Y START BHI S Y PK D X IGNITION SWITCH OFF _RUN START F1 45A F3 10A R OR B Y pi 1 ol FOR ACCESSORY POWER KIT of F2 10A 9 3 T VIO x E o Y PK m BK Electrical Schematic AX All relays and solenoids FOR ACCESSORY are shown as de energized POWER KIT All ground wires are black Page 8 7 ALTERNATOR RUN SOLENOID
98. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Groundsmaster 7200 and 7210 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manual and Parts Catalog for your machine Replacement Operator s Manuals and Parts Catalogs are available on the internet at www Toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice PART NO 07150SL Service Manual Groundsmaster 7200 7210 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE ANOTE will give general information about the correct operation maintenance service testing or repair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2007 This page is intentionally blank Groundsmaster 7200 7210 Table Of Conten
99. The Wheel Motor Efficiency Test should be performed if a traction circuit problem is identified This test will de termine 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 by pass oil to its case drain causing the motor to be less efficient Eventually enough oil loss will cause the wheel motor to stall under heavy load conditions Continued operation with a worn inefficient motor can generate excessive heat cause damage to seals and other components in the hydraulic system and affect overall machine performance Procedure for Wheel Motor Efficiency Test 1 Make sure hydraulic oil is at normal operating tem perature Also make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 2 Park machine on a level surface with the cutting deck or implement lowered and off Apply parking brake and make sure engine is off 3 Read Precautions for Hydraulic Testing listed at the beginning of this section 4 Attach a heavy chain to the rear of the machine frame and an immovable object to prevent the machine from moving during testing As an alternative machine can be raised and supported with jack stands so that both rear wheels are of
100. achine see Operator Seat Removal in this section 2 Remove armrest assemblies and then back panel from back of seat 3 Carefully peel label from back rest knob Fig 30 Remove nut and knob from seat frame 4 Remove six 6 x mas tree clips that secure back cushion to seat frame Remove back cushion 5 Remove two 2 cap screws that secure bottom cushion to seat frame Remove bottom cushion 6 Remove hex nut that secures weight adjustment knob to weight adjust bar Remove adjustment knob from weight adjust bar to remove cable tension Re move cables from spring saddle 7 Remove eighteen 18 x mas tree clips from seat frame to separate seat boot from frame 8 Remove two 2 roll pins that secure bearing shafts to seat frame Remove bearing shafts and split nylon bushings from frame 9 Lift seat frame from suspension base 10 Remove nut and bolt that secure top of shock ab sorber to suspension base 11 Slide spring saddle from spring arm while disengag ing springs at top of suspension base 12 Remove springs from spring saddle Pay close attention to orientation of springs and spring saddle for assembly purposes 13 Remove nut and bolt that secure bottom of shock ab sorber to spring saddle Remove shock absorber Installation Fig 29 1 Secure bottom of shock absorber to spring saddle with nut and bolt 2 Attach springs to spring saddle in the same orienta tion noted during removal 3 Positi
101. ade during disas sembly to make sure the relief cartridges are properly installed 32 Thread relief cartridges into correct center case ports and torque from 24 to 27 ft lb 32 to 37 N m The reverse relief valve cartridges can be identified by the groove in the hex head Fig 84 33 Apply clean grease to mating surfaces of center case and valve plates to hold valve plates in position during assembly Install valve plates to dowel pins in center plate 34 Install two 2 pins into transmission pump housing bores Position new gasket on pump housing 35 Position center case assembly to transmission pump housing making sure that valve plates remain in posi tion 36 Secure center case to transmission pump housing with eight 8 socket head screws Tighten screws even ly in a crossing pattern and then torque screws from 17 to 19 ft lb 22 27 N m Figure 83 1 Bypass valve 4 Forward relief cartridge 2 Center case 5 Valve plate 3 Reverse relief cartridge p o A Figure 84 Forward relief cartridge 3 Hexhead groove 2 Reverse relief cartridge Figure 85 Center case 3 Pin 2 used 2 Pump housing Hydraulic System Page 4 74 Groundsmaster 7200 7210 37 Install key into keyslot in RH pump shaft Lubricate inner and outer charge pump rotors with clean hydraulic oil Slide inner rotor onto pump shaft and align with key Place outer rotor onto inner rotor Figure 86 1 RH pump shaf
102. al Gear 2 PTO shaft 5 Clutch assembly 3 Spacer 6 Key 11 Apply clean hydraulic oil to friction plate and place in transmission pump housing Make sure that tabs on fric tion plate are placed in housing grooves Figure 74 1 Friction plate 2 Pump housing 12 Install PTO shaft assembly into transmission pump housing Make sure that tabs on friction plates are placed in housing grooves Figure 75 1 PTO shaft assembly 3 Friction plate tabs 2 Pump housing 4 Housing groove Hydraulic System Page 4 70 Groundsmaster 7200 7210 13 If shafts were disassembled install gear and two 2 bearings onto input shaft RH pump shaft and or LH pump shaft Make sure that bearings are pressed fully to the shaft shoulder 14 Lubricate seal rings and install seal ring onto RH and LH pump shafts 15 Install RH and LH pump shaft assemblies into trans mission pump housing Then install input shaft into pump housing making sure to align input shaft gear teeth with gears on PTO and pump shafts 16 Lubricate two 2 new O rings and install O rings into grooves in pipe Slide pipe assembly into bore of transmission pump housing Figure 76 1 RH pump shaft 3 Input shaft 2 LH pump shaft 4 Seal ring 2 cs gt Figure 77 1 Input shaft 3 LH pump shaft 2 RH pump shaft 4 Pipe assembly Groundsmaster 7200 7210 Page 4 71 Hydraulic System 17 Place two 2 pins into transmission pump housing holes Pos
103. amaged Transmission or wheel motor s is worn or damaged NOTE If one traction circuit component has internal wear or dam age it is possible that other traction components are also dam aged Transmission by pass valve s is open Transmission or wheel motor is worn or damaged NOTE If one traction circuit component has internal wear or dam age it is possible that other traction components are also dam aged Make up fluid from charge pump is not available Check valves in transmission are damaged Valve plate s in transmission is worn or damaged Wheel motor is worn or damaged Cylinder block assembly in transmission is worn or damaged Wheel motor is worn or damaged Transmission components e g piston pump relief valve check valve for the problem wheel motor are worn or damaged NOTE If one traction circuit component has internal wear or dam age it is possible that other traction components are also dam aged External traction control linkage is misadjusted disconnected bind ing or damaged Transmission by pass valve s is open Brake is dragging or binding Transmission check valve is not seating or is damaged Transmission or wheel motor s is worn or damaged Page 4 21 Hydraulic System Hydraulic Problem Possible Cause Gear pump is noisy cavitation Hydraulic tank oil level is low Hydraulic oil is very cold Suction line is restricted Suction line has an air leak
104. ance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number 505 165 Battery Terminal Protector Battery Terminal Protector is an aerosol spray that should be used on battery terminals to reduce corrosion problems Apply terminal protector after battery cable has been secured to battery terminal Toro Part Number 107 0392 Electrical System Page 5 2 Figure 1 Figure 2 Figure 3 Groundsmaster 7200 7210 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure complete coating of ter minals liberally apply gel to both component and wire harness connector plug connector to component un plug connector reapply gel to both surfaces and recon nect harness connector to component Connectors should be thoroughly packed with gel for effective re sults Toro Part Number 107 0342 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Groundsmaster 7200 7210 Page 5 3 DOW CORNING 111 SILICONE COMPOUND oF CON wit NS WATER E Figure 4 Figure 5 Electrica
105. and outer stators from sleeves and sta tionary actuator 3 Inspect parking brake components Replace com plete brake assembly if excessive wear or damage to any component is detected Assembly Fig 8 1 Position stationary stator on level work surface 2 Assemble brake components in order using Figure 8 as a guide 3 Secure brake assembly with hex bolts item 4 sock et head screws item 15 and hex nuts items 5 and 6 Torque fasteners to values identified in Figure 8 Groundsmaster 7200 7210 Page 6 11 Chassis Parking Brake Assembly ISA O N Front brake rod 2 used Hex nut 6 used Flat washer 6 used Compression spring 2 used Swivel 2 used Rear brake rod 2 used Retaining ring 2 used Retaining ring 2 used Chassis Figure 9 Hair pin 4 used Cap screw 4 used Brake lever grip Brake handle Phillips head screw 2 used Flat washer 2 used Brake switch Switch nut Page 6 12 Flange bearing 2 used Cable tie Brake pivot 2 used Control bearing 4 used Lock nut 4 used Brake linkage yoke 2 used Clevis spring pin 2 used Frame bracket Groundsmaster 7200 7210 Disassembly Fig 9 1 Park machine on a level surface lower cutting deck or implement stop engine and remove key from the ignition switch 2 Remove front panel under the operator seat Fig 10 3 Ifremoval of brake handle item 12 is necessary A On
106. ar or damage If bearing cups are damaged remove bearing cups from frame and replace 9 If necessary remove spacers seals and bearings from castor wheel using Figure 15 as a guide Inspect and replace all wheel components that show signs of wear or damage Assembly Fig 13 1 If components were removed from castor wheel as semble castor wheel Fig 15 A Press bearing cups into castor wheel until they are flush with shoulder in wheel B Install grease packed bearing cone into wheel C Install seals into wheel D Carefully fit bearing spacers and then castor spacer into wheel 2 If bearing cups were removed from carrier frame press new cups into carrier frame until they are flush with shoulder in frame 3 Pack both bearing cones with new grease Place grease packed bearing cone into lower bearing cup of carrier frame Install new seal 4 Slide castor fork up through carrier frame taking care to not damage seal Position grease packed bearing cone onto castor fork Place three 3 belleville washers onto castor fork noting orientation shown in Figure 14 IMPORTANT After correctly tightening the lock nut that secures castor fork to carrier frame it should take from 70 to 80 in Ib 7 9 to 9 0 N m to rotate the castor fork 5 Install lock nut onto castor fork Tighten lock nut until castor fork requires from 70 to 80 in Ib 7 9 to 9 0 N m to rotate 6 Remove plug item 12 from carrier frame Using
107. at base see Operator Seat Removal in the Service and Repair section of Chapter 6 Chassis 3 Remove front cover from machine Fig 30 Hydraulic System Page 4 46 4 Remove brake handle from machine to allow remov al of hydraulic tank see Parking Brake Assembly in the Service and Repairs section of Chapter 6 Chassis 5 Drain hydraulic oil from hydraulic tank 6 Thoroughly clean hydraulic hose ends and fittings on hydraulic tank to prevent hydraulic system contamina tion 7 Label all hydraulic hoses and fittings for assembly purposes Remove hydraulic hoses from fittings on hy draulic tank Drain hoses into a suitable container Groundsmaster 7200 7210 8 Put clean plugs in disconnected hydraulic hoses and fittings to prevent system contamination 9 Remove two 2 washer head screws and tank sup port that retain hydraulic tank to frame 10 Remove hydraulic tank toward front of machine 11 Inspect foam strips under hydraulic tank Replace strips if damaged 12 As needed remove fittings from hydraulic tank using Figure 29 as a guide Discard and replace any removed O rings Hydraulic Tank Inspection Fig 29 1 Clean hydraulic tank and suction strainer with sol vent 2 Inspect hydraulic tank for leaks cracks or other dam age Hydraulic Tank Installation Fig 29 1 If suction strainer was removed from hydraulic tank place new lubricated O ring on strainer Thread strain er i
108. both sides of machine unlatch spring pin from brake linkage yoke Remove spring pin from yoke and brake handle brackets B Support brake handle to prevent it from shifting or falling C Remove cap screws and lock nuts that secure flange bearings to frame D Remove brake handle and flange bearings from machine 4 Remove additional parking brake components as necessary using Figure 9 as a guide Assembly Fig 9 1 Assemble parking brake components as necessary using Figure 9 as a guide A If brake linkage yoke was removed from front brake rod install yoke onto rod so that center to cen ter length is from 8 290 to 8 350 21 1 to 21 2 cm Fig 11 B Make sure that cap screws item 10 used to se cure flange bearings item 17 are installed from the outside of the frame to the inside 2 After assembly of brake system apply parking brake and check length of compression spring on rear brake rod Spring length with brake applied should be from 2 880 to 3 000 7 4 to 7 6 cm Fig 12 If necessary adjust spring length with hex nuts on rear of brake rod 3 Check operation of parking brake and parking brake switch 4 Install front panel to the machine Fig 10 Groundsmaster 7200 7210 Page 6 13 Figure 10 2 Washer head screw 8 290 to 8 350 21 1 to 21 2 cm _ Compression spring Figure 11 3 Brake linkage yoke 2 880 to 3 000 7 4 to 7 6 cm
109. box shaft see PTO Drive Shaft Installation in the Service and Repairs section of Chapter 6 Chassis Groundsmaster 7200 7210 Page 7 7 4 Start engine and fully raise cutting deck Stop engine and remove key from the ignition switch Be careful when connecting the pull links to the machine The pull link torsion springs may cause some rotation of pull links during installation 5 Align pull link to carrier frame and attach link with re tainer pin Secure retainer pin to frame with shoulder screw Fig 1 6 Install HOC pin into HOC bracket to allow desired height of cut Fig 2 7 Install fuse F1 15 amp into fuse block Cutting Deck Idler Assembly Figure 4 1 Cutting deck 9 Grease fitting 2 Flat washer 10 Drive belt 3 LH spindle assembly 11 Idler pulley 4 Drive belt 12 Idler pulley 5 Snap ring 13 Center spindle assembly 6 Flange bushing 14 RH spindle assembly 7 Torsion spring 15 Socket head screw 8 Washer Cutting Deck Page 7 8 16 17 18 19 20 21 22 Lock nut RH idler arm Drive pulley Idler spacer LH idler arm Stop bolt Jam nut Groundsmaster 7200 7210 Removal Fig 4 1 Park machine on a level surface with cutting deck or implement lowered Stop engine engage parking brake and remove key from the ignition switch 2 Lift the footrest exposing the top of the cutting deck Support the footrest with prop rod 3 Remove deck covers from
110. c fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Hydraulic System 9 s O a Y gt Io Hydraulic Hose and Tube Installation O Ring Face Seal Fitting 1 Make sure threads and sealing surfaces of the hose tube and the fitting are free of burrs nicks scratches or any foreign material 2 As apreventative measure against leakage it is rec ommended that the face seal O ring be replaced any time the connection is opened Make sure the O ring is installed and properly seated in the fitting groove Lightly lubricate the O ring with clean hydraulic oil 3 Place the hose tube against the fitting body so that the flat face of the hose tube sleeve fully contacts the O ring in the fitting 4 Thread the swivel nut onto the fitting by hand While holding the hose tube with a wrench use a torque wrench to tighten the swivel nut to the recommended installation torque shown in Figure 3 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lower than the listed installa
111. cap and plug to ensure that fluid leakage will not occur Plastic plugs will not hold hydraulic pressure that will be developed during this test procedure 4 Place a steel cap on the open lift cylinder fitting to seal the lift cylinder Also install a steel plug in the open end of the disconnected hose to prevent leakage or con tamination 5 Remove the jack stands from under the cutting deck or implement The cutting deck or implement should settle slightly and then be supported by the capped lift cylinder 6 Place a piece of tape on the lift cylinder rod near the rod end Fig 28 Measure and record the distance from the lift cylinder collar to the tape location 7 Leave the machine parked for 4 hours and monitor the lift cylinder The weight of the cutting deck or imple ment will cause the lift cylinder to gradually retract Use the change in distance from the lift cylinder collar to the tape location to determine lift cylinder rod movement A If the cutting deck or implement is still sus pended after 4 hours and lift cylinder rod movement is less than 1 4 6 4 mm consider that the lift cylin der is in good condition A lift cylinder in good usable condition will show minimal rod movement Groundsmaster 7200 7210 Page 4 41 B Rod movement in excess of 1 4 6 4 mm after 4 hours indicates a lift cylinder with internal seal dam age or excessive internal wear Replace or repair the lift cylinder s
112. ce with the slotted hex nut DO NOT fully tighten the nut or install the cotter pin Groundsmaster 7200 7210 Page 6 17 5 While rotating the wheel hub by hand torque the slotted hex nut from 75 to 100 in lb 8 5 to 11 3 N m to set the bearings Then loosen the nut until the hub has endplay 6 While rotating the wheel hub by hand torque the slotted hex nut from 15 to 20 in Ib 1 7 to 2 3 N m while aligning hex nut slot with shaft hole After tighten ing make sure that the wheel hub does not have any free play 7 Install cotter pin 8 Install dust cap 9 Install drive track and wheels to machine see Polar Trac Wheels Installation in this section Make sure that drive track is installed in the correct direction of rota tion 10 Lower machine to ground 11 Torque all removed lug nuts evenly in a crossing pat tern from 65 to 85 ft Ib 88 to 115 N m See text for tightening procedure Figure 17 1 Dust cap 5 Bearing cup 2 Cotter pin 6 Wheel hub 3 Slotted hex nut 7 Wheel stud 5 used 4 Bearing cone 8 Seal Chassis PTO Drive Shaft NS 175 to 225 in Ib 20 to 25 N m A 4 175 to 225 in Ib 20 to 25 N m Figure 18 1 Transmission assembly 3 Roll pin 2 used 5 PTO drive shaft 2 Cap screw 4 used 4 Lock nut 4 used 6 Cutting deck gearbox Do not start the engine and engage the PTO switch when the PTO drive shaft is discon nected from the cutting deck or impleme
113. ch Polar Trac M Glow Plug System Test 8 Machines as Peary sumy E rn 24 Check Operation of Interlock Switches 9 Fuel PUMP uote bm eR ERE Er EE S 25 COMPONENT TESTING 10 Fuel Stop Solenoid 26 Ignition Switch Lu uu yaoa uyan eee 10 Glow Controller 27 Indicator Lights 11 SERVICE AND REPAIRS 28 Hour Meter hocico u a ee pk 12 PTO Solenoid Valve Coil 28 PTO SWitch iieri eid Paces 13 Battery Storage 29 Neutral Switches 14 Battery Care 29 Seat Switch 15 Battery Service 30 Parking Brake Switch 16 Electrical Schematics and Diagrams The electrical schematics and other electrical drawings for the Groundsmaster 7200 and 7210 are located in Chapter 8 Foldout Diagrams Groundsmaster 7200 7210 Page5 1 Electrical System o o o 2 wi Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local tool supplier Multimeter The multimeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high imped
114. chine to ground 16 1f the transmission or a wheel motor was replaced or rebuilt operate the traction circuit on level ground so both drive wheels turn slowly for 10 minutes 17 Operate machine by gradually increasing its work load to full over a 10 minute period 18 Stop the machine Check hydraulic oil level and ad just if necessary do not overfill Check hydraulic com ponents for leaks Tighten any loose connections Hydraulic System 2 L3 cs gt T o N gt 77 Hydraulic Tank 60 to 66 ft Ib 82 to 90 N m 16 to 18 ft Ib 22 to 24 N m Ping C 66 to 70 ft lb 90 to 94 N m Xo D 66 to 70 ft lb 90 to 94 N m 4 19 Y J p d Figure 29 1 Hydraulic tank 12 Elbow fitting 23 R clamp 2 O ring 13 Hose clamp 24 Cap screw 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 used 9 Dipstick 20 Straight fitting 31 Tank support 10 O ring 21 Elbow fitting 32 O ring 11 Tank cap 22 Hose clamp 33 Plug Hydraulic Tank Removal Fig 29 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Remove operator seat and se
115. cluded in the Component Testing section of this Chap ter NOTE The machine is equipped with an interlock switch on the parking brake The engine will stop if the traction control levers are moved from the neutral locked position with the parking brake engaged Groundsmaster 7200 7210 Page 5 9 1 Make sure all bystanders are away from the area of operation Keep hands and feet away from cutting deck or implement 2 With operator in the seat the engine must not start with either the PTO switch in the ON position or the trac tion control levers moved from the neutral locked posi tion Correct problem if machine is not operating properly 3 With operator in the seat the traction control levers in the neutral locked position the parking brake off and the PTO switch in the OFF position the engine should start Lift off the seat and slowly move traction control levers from the neutral locked position the engine should stop in one to three seconds Correct problem if machine is not operating properly Electrical System SE m 9 Sh lu Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check on the switch NOTE For engine component testing information see the Kubota Workshop Manual Diesel Engine 05 Se ries Ignition Switch The ignition key
116. ct negative cable first and then positive cable see Battery Service in the Service and Repairs section of Chapter 5 Electrical System 7 Remove muffler from the engine see Muffler Re moval in this section 8 Remove radiator from machine see Radiator Re moval in this section Remove fan shroud 9 Label all electrical wires for assembly purposes Dis connect electrical wires from engine A Negative battery cable wire harness ground and fuel stop solenoid Fig 11 B Glow plug bus Fig 12 C High temperature warning switch and high tem perature shutdown switch Fig 13 D Starter motor fusible link harness alternator and oil pressure switch 10 Disconnect throttle cable from the throttle support bracket and swivel on the speed control lever Position cable away from engine 11 Disconnect fuel supply hose at injector pump Fig 11 Disconnect return fuel hose from front injector nozzle Fig 12 Plug and position disconnected hoses to prevent fuel leakage 12 Note location of cable ties securing the wire harness to engine Remove cable ties 13 Support transmission to prevent it from moving dur ing engine removal 4h CAUTION When removing engine assembly make sure lift or hoist can safely support 250 pounds 114 kg 14 Attach a suitable lift or hoist to lift tabs on front and rear of engine Support engine with lift or hoist to prevent engine from shifting or moving 15 Remove tw
117. d A Make sure that wheel hub and wheel motor shaft are cleaned thoroughly B Install key to the slot on the wheel motor shaft Slide wheel hub onto the shaft C Secure wheel hub to the motor shaft with lock nut 2 Place two 2 hardened washers on brake mounting screws Figs 5 and 6 IMPORTANT When installing brake to brake sup port take care to not get Loctite on brake pad sur face 3 Apply Loctite 271 or equivalent to threads of brake mounting screws Secure parking brake to brake sup port with two 2 lock nuts Torque lock nuts from 35 to 40 ft lb 48 to 54 N m 4 Place brake support with parking brake assembly attached to wheel hub disc and frame making sure that disc is between the two 2 stators brake pads in the brake assembly 5 Place four 4 cap screws and flange nuts in mount ing holes of brake support and frame but do not fully tighten 6 Adjust position of brake support so that the clear ance between the wheel hub disc and both springs in the parking brake Fig 7 is from 0 030 to 0 070 0 8 to 1 7 mm When clearance is correct fully tighten fasten ers 7 Attach brake rod assembly to parking brake lever with flat washer and retaining ring 8 Secure wheel to machine with five 5 lug nuts 9 Lower wheel to ground Torque wheel lug nuts in a crossing pattern from 75 to 85 ft lb 102 to 115 N m 10 If wheel hub was removed apply parking brake and torque lock nut
118. dsmaster 7200 7210 Page 4 5 Hydraulic System 2 L3 cs gt lt System Adjustable Fitting Fig 6 1 Make sure all threads and sealing surfaces of fitting and component port are free of burrs nicks scratches or any foreign material 2 As apreventative measure against leakage it is rec ommended that the O ring be replaced any time the connection is opened 3 Lightly lubricate the O ring with clean hydraulic oil Fitting threads should be clean with no lubricant applied 4 Turn back the lock nut as far as possible Make sure the back up washer is not loose and is pushed up as far as possible Step 1 in Figure 7 IMPORTANT Before installing fitting into port de termine port material If fitting is to be installed into an aluminum port installation torque is reduced 5 Install the fitting into the port and tighten finger tight until the washer contacts the face of the port Step 2 6 To put the fitting in the desired position unscrew it by the required amount but no more than one full turn Step 3 7 Hold the fitting in the desired position with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 5 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when
119. dy back plate and front plate Make sure that these surfaces are clean and dry Hydraulic System 2 L3 cs gt T 9 Install dowel pins in body IMPORTANT Do not dislodge O rings pressure seals or back up rings during final assembly 10 Gently slide the back plate onto the assembly using marker lines for proper location Firm hand pressure should be sufficient to engage the dowel pins 11 Place thin sleeve or tape on pump shaft splines to prevent seal damage 12 Position the pump with back plate downwards Care fully slide the front plate onto the assembly using marker lines for proper location Take care to not damage the seal during front plate installation Remove sleeve or tape from shaft splines 13 Install the four 4 socket head screws with lock washers and hand tighten Hydraulic System Page 4 82 IMPORTANT When clamping the pump in a vise clamp only on mounting flange DO NOT clamp pump body in a vise 14 Clamp mounting flange of pump in a vise with the shaft end down 15 Alternately torque the socket head screws 220 in Ib 25 N m 16 If implement relief valve was removed from back plate install relief valve Torque relief valve 220 in Ib 25 N m 17 Put a small amount of hydraulic oil in inlet port of pump and rotate input shaft one revolution Place cou pler on input shaft and use pliers on coupler to rotate pump shaft If input shaft binds disassemble pump and repeat assemb
120. e Hydraulic System Page 4 22 Groundsmaster 7200 7210 2 55 CO 0 UO gt gt N lt This page is intentionally blank Groundsmaster 7200 7210 Page 4 23 Hydraulic System Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks see the Special Tools section in this Chapter Before Performing Hydraulic Tests IMPORTANT All obvious areas such as oil supply oil filter binding linkages loose fasteners or im proper adjustments must be checked before as suming that a hydraulic component is the source of the problem Precautions for Hydraulic Testing Failure to use gauges with expected pressure psi rating as listed in test procedures could re sult in damage to the gauge and possible person al injury from leaking hot oil All testing should be performed by two 2 people One person should be in the seat to oper ate the machine The second person should monitor test equipment and record test results Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pres sure Do not use hands to search for leaks use paper or cardboard Hydraulic fluid escaping un der pressure can have sufficient force to pene trate the skin and cause serious injury If fluid is injected into the skin it must be surgically re moved w
121. e Cable in the Adjustments section of this chapter Groundsmaster 7200 7210 Page 3 17 19 Connect and secure positive battery cable to the bat tery Then connect negative battery cable 20 Install air cleaner to the engine see Air Cleaner As sembly Installation in this section 21 Check engine oil level and adjust as needed 22 Secure rear panel to frame with six 6 flange head screws Fig 10 23 Install hood to the machine see Hood Installation in the Service and Repairs section of Chapter 6 Chas sis 24 Bleed fuel system 25 Close and latch hood Lower operator seat Kubota Diesel Engine E s3 Su s o lt Y 2 a This page is intentionally blank Kubota Diesel Engine Page 3 18 Groundsmaster 7200 7210 TORO Table of Contents SPECIFICATIONS GENERAL INFORMATION Hydraulic Hoses Hydraulic Hose and Tube Installation Hydraulic Fitting Installation Operator s Manual Pushing Traction Unit Relieving Hydraulic System Pressure Traction Circuit Closed Loop Component Failure HYDRAULIC SCHEMATICS HYDRAULIC FLOW DIAGRAMS Traction Circuits Lift Circuit Raise Lift Circuit Lower PTO Circuit SPECIAL TOOLS Hydraulic Pressure Test Kit Hydraulic Tester Pressure and Flow Hydraulic Test Fitting Kit O Ring Kit High Pressure Hydraulic Oil Filter TROUBLESHOOTING TESTING Traction System Operation Testing Charge Relief Valve Pressure Test Transmission Piston Pump Flow Test Trac
122. e cou pling from engine 21 If necessary remove engine mount and muffler bracket from engine Engine Installation Fig 9 1 Make sure that all engine components removed dur ing maintenance or rebuilding are installed to the en gine 2 If removed install engine mount and muffler bracket to engine with cap screws and lock washers Torque cap screws from 50 to 60 ft Ib 68 to 81 N m 3 If flywheel coupling was removed from engine apply Loctite 271 or equivalent to threads of six 6 cap screws and secure coupling to engine flywheel Torque cap screws 19 ft lb 25 7 N m 4 Position two 2 dowel pins to engine endplate 5 Support transmission to prevent it from moving dur ing engine installation When installing engine assembly make sure lift or hoist can safely support 250 pounds 114 kg 6 Connect lift or hoist to the front and rear engine lift tabs Kubota Diesel Engine Page 3 16 Figure 13 1 Temp shutdown switch 2 Temp warning switch One person should operate lift or hoist while a second person guides the engine assembly into the machine IMPORTANT Make sure to not damage the engine flywheel housing fuel or hydraulic lines electrical harness or other parts while installing the engine Also make sure that transmission does not shift during engine installation 7 Carefully lower engine assembly into the machine Move engine toward the front ofthe machine while align ing
123. e hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 2 Park machine on a level surface with the cutting deck or implement lowered and off Make sure engine is off 3 Read Precautions for Hydraulic Testing listed at the beginning of this section Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 4 Raise and support machine with jack stands so that both rear wheels are off the ground In this test the rear wheels need to spin freely to allow hydraulic flow through the traction circuit Make sure that the parking brake is not applied 5 Thoroughly clean transmission area surrounding traction circuit hoses on top of transmission Fig 16 Determine which piston pump is to be tested 6 Disconnect hydraulic hose from transmission pump outlet fitting for piston pump to be tested Fig 16 Piston Pump to be Tested Pump Outlet PortA Right Side Pump Left Side Pump 7 Install hydraulic tester pressure and flow in series between the pump outlet fitting and the disconnected hose Make sure that the tester flow arrow points from the pump outlet and toward the hose Make sure the flow control valve on the tester is fully open Groundsmaster 7200 7210 Page 4 29 8 Sit in the operator seat start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage
124. ect hy draulic hoses to lift cylinder fittings using labels placed during lift cylinder removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Lubricate grease fittings on cylinder pivot pins 7 Make sure hydraulic tank is full Add correct oil if nec essary Hydraulic System 9 s O a Y oP Polar Trac Lift Cylinder Service 3 N p Y na NG 250 to 300 ft Ib 339 to 406 N m Figure 110 1 Cap seal 6 O ring 10 Retaining ring 2 Barrel 7 Rod 11 Back up ring 3 Lock nut 8 Wiper 12 Piston 4 O ring 9 Seal 13 Wear ring 5 Head Hydraulic System Page 4 98 Groundsmaster 7200 7210 Disassembly Fig 110 1 Remove oil from lift cylinder into a drain pan by slowly pumping the cylinder rod Plug both ports and clean the outside of the cylinder IMPORTANT Prevent damage when clamping the lift cylinder into a vise clamp on the clevis end of the barrel ONLY 2 Mount lift cylinder securely in a vise by clamping on the clevis end of the barrel Use of a vise with soft jaws is recommended 3 Using a spanner wrench rotate head clockwise until the edge of the retaining ring appears in the barrel open ing Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the open ing Rotate the head counter clockwise to remove re taining ring from barrel
125. ectrical connec 1 Harness connector 3 Flange nut tor from the seat switch harness connector Fig 28 2 Eatenengl 4 Support seat and latch angles to prevent them from shifting during seat removal 5 Remove four 4 flange nuts that secure seat and latch angles to seat plate Remove seat from machine 6 Remove seat parts as necessary using Figure 27 as a guide Installation Fig 27 1 Install all removed seat parts using Figure 27 as a guide 2 Position seat and latch angles to seat plate Secure assembly with four 4 flange nuts 3 Connect wire harness electrical connector to the seat switch harness Fig 28 4 Lower and latch seat 5 Check operation of operator seat switch Groundsmaster 7200 7210 Page 6 25 Chassis Operator Seat Service fo m NO e0 Bottom cushion Back cushion Armrest RH armrest mount assembly Back panel LH armrest mount assembly Seat frame assembly Lumbar support knob Label Chassis Figure 29 Shock absorber assembly Suspension spring 2 used Suspension base Spring saddle Bearing shaft Hex nut Cable 2 used Weight adjust bar Label Page 6 26 2 ge Pa 3 erp 4 P E V 6 Weight adjustment knob Weight indicator Washer Back rest knob Label Seat switch Seat adjuster Seat adjuster slave Seat boot Groundsmaster 7200 7210 Removal Fig 29 1 Remove operator seat from m
126. ee Lift Cylinder and Lift Cylinder Ser vice in the Service and Repairs section of this chap ter 8 Once lift cylinder condition has been determined use a jack to raise both sides of the cutting deck or im plement slightly which will remove the load from the lift cylinder Support both sides of the cutting deck or im plement with jack stands Remove the cap from the cyl inder fitting and the plug from the hydraulic hose Connect the hydraulic hose to the lift cylinder fitting 9 Remove tape from lift cylinder rod 10 Remove the jack stands from under the cutting deck or implement Start engine and operate lift cylinder through several raise and lower cycles Stop the engine and check for any leakage 11 Check oil level in hydraulic reservoir Figure 27 1 Lift cylinder 2 Barrel end hose MEASURED DISTANCE Figure 28 1 Lift cylinder collar 2 Tape Hydraulic System 2 E S 3 LE r o D gt n This page is intentionally blank Hydraulic System Page 4 42 Groundsmaster 7200 7210 Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park machine on a level surface engage parking brake lower cutting deck or implement and stop en gine Remove key from the ignition switch 2 Thoroughly clean machine before disconnecting re mo
127. eginning of this section 4 Thoroughly clean transmission area surrounding pressure valve test port Fig 20 5 Remove plug from pressure valve test port Fig 20 Connect hydraulic pressure gauge 1000 PSI 70 bar with an attached hydraulic hose to the test port 6 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test 7 With engine running move throttle to full speed 3200 RPM 4h caution Keep away from deck or implement during test to prevent personal injury 8 Have operator engage PTO and monitor the pres sure gauge 9 With the engine running at full speed and PTO en gaged pressure should be from 280 to 340 PSI 19 3 to 23 4 bar 10 Disengage PTO and then stop engine Record test results Groundsmaster 7200 7210 Page 4 35 11 If specification is not met repair or replace pressure valve in transmission see Transmission Service in the Service and Repairs section of this chapter Also con sider a worn or damaged charge pump in the transmis sion traction charge circuit would be affected as well 12 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect test gauge from pressure valve test port Install plug into port and torque plug from 14 to 15 ft lb 18 to 21 N m Pressure Valve Test Port Figure 20 Hydra
128. el from rotating during test Use extreme caution when performing test The rear wheel that is being tested will be trying to move the machine forward 11 While sitting in operator seat slowly push traction control lever for wheel motor being tested in the forward direction until 1000 PSI 69 bar is displayed on the test er pressure gauge 12 Wheel motor internal leakage will be shown on the tester flow meter in GPM LPM 13 Return traction control lever to the neutral position Shut off engine and record test results Rotate wheel and retest Testing of wheel motor leakage in three 3 different wheel positions will provide the most accurate test results 14 Flow should be less than 1 5 GPM 5 7 LPM for the tested wheel motor If specification is not met the tested wheel motor needs to be repaired or replaced 15 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect tester from pump outlet fitting and hydraulic hose Connect hose to pump fitting 16 If other wheel motor requires testing complete steps 6 to 15 for the remaining motor 17 After testing is completed remove jumper wire from parking brake harness connector Connect wire harness to parking brake switch see Parking Brake Switch in the Components section of Chapter 5 Electrical System Make sure that brake switch operation is correct Hydraulic System o 35 o CO o o gt
129. elay and glow plugs see Chapter 8 Fold out Diagrams B Verify continuity of the circuitry from the battery to ignition switch glow controller glow plug indicator light glow relay and ground see Chapter 8 Foldout Diagrams C Replace parts as necessary 6 Connect wire harness electrical connector to the fuel stop solenoid Ne Figure 37 1 Control panel cover 2 Glow plug controller WADE IN JAPAN NGK LE S CONTROLLER 8127 TOU 10 17045 65661 DEL TGC7OI6A NEL SPARK PLUG C8 LTO i CONTROLLER CONNECTIONS START 1 4 TEMP not used VIOLET ORANGE BLK WHITE 12V 3 6 GROUND I LAMP 2 5 GLOW BLACK PINK Figure 38 1 Controller top view 2 Controller end view Electrical System es SE o2 259 Llu Service and Repairs NOTE For engine electrical component repair informa tion see the Kubota Workshop Manual Diesel Engine 05 Series PTO Solenoid Valve Coil The PTO solenoid valve coil on the transmission Fig 39 can be replaced without opening the hydraulic sys tem Removal 1 Park machine on a level surface lower cutting deck or implement engage parking brake stop engine and remove key from the ignition switch 2 Disconnect the wire harness electrical connector from the PTO solenoid valve coil connector 3 Remove the nut from the spool assembly 4 Slide the coil assembly f
130. em 15 and plug item 9 with new O ring item 21 into con trol valve Torque plugs from 35 to 40 ft lb 47 to 54 N m 12 Install new O ring to detent plug item 16 Lubricate detent ball item 1 and spring item 17 with clean hy draulic fluid and install into detent plug 13 Install detent plug assembly to control valve Torque plug from 10 to 15 ft Ib 14 to 20 N m 14 1f plug was removed carefully thread plug into con trol valve housing Fig 102 Torque plug from 60 to 70 ft Ib 81 to 94 N m 60 to 70 ft Ib 81 to 94 N m Figure 102 1 Lift control valve 3 O ring 2 Plug Hydraulic System o 35 o CO a 0 gt oP Polar Trac Hydraulic Control Valve Figure 103 1 Hydraulic hose 9 Hydraulic hose 16 Hydraulic hose 2 O ring 10 O ring 17 Hydraulic hose 3 45 hydraulic fitting 11 Hydraulic hose 18 Hydraulic cylinder 4 O ring 12 90 hydraulic fitting 19 Hydraulic hose 5 90 hydraulic fitting 13 O ring 20 90 hydraulic fitting 6 O ring 14 Flange nut 2 used 21 Hydraulic control valve 7 Hair pin 2 used 15 Hydraulic fitting 22 Carriage screw 2 used 8 45 hydraulic fitting Hydraulic System Page 4 88 Groundsmaster 7200 7210 Removal Fig 103 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 1 Park machine on a level sur
131. en rotate counterclockwise both of the valves from one 1 to two 2 turns IMPORTANT Do not push the machine faster than 2 mph because the drive system may be damaged If machine must be moved a considerable distance more than a few feet transport it on a truck or trail er 2 Slowly push machine 3 Before starting engine tighten both by pass valves to close them Torque valves from 62 to 79 in Ib 7 to 9 N m Do not start engine when by pass valves are open Relieving Hydraulic System Pressure Before disconnecting or performing any work on the Groundsmaster 7200 and 7210 hydraulic system all pressure in the hydraulic system must be relieved To relieve hydraulic pressure in the traction circuit park machine on a level surface with the cutting deck or im plement lowered and off Turn key switch to OFF and allow engine to stop If machine is parked on an incline or slope pressure in the traction circuit WILL NOT be re lieved Groundsmaster 7200 7210 Page 4 7 Figure 8 2 By pass valve 1 Transmission To relieve hydraulic pressure in lift circuit fully lower the cutting deck or implement onto solid blocks Turn key switch to OFF and allow engine to stop Make sure that after lowering the cutting deck or implement is not be ing supported by the lift cylinder Hydraulic System 9 s O a Y Io Traction Circuit Closed Loop Component Failure The traction system on Groundsmaster 7
132. enished Groundsmaster 7200 7210 Page 4 11 A charge pump in the transmission supplies hydraulic flow for maintaining 70 to 100 PSI 4 8 to 6 9 bar to the low pressure side of both of the traction circuits The charge pump also provides pressure for the transmis sion PTO drive system The charge pump replenishes the closed loop traction circuits with fluid from the hy draulic tank The charge relief valve in the transmission maintains sufficient pressure so that charge pump flow is guided past check valves to the low pressure side of each traction circuit Charge pump flow in excess of sys tem requirements is relieved through the charge relief valve back to the hydraulic tank Both of the transmission traction circuits include a flush ing valve that bleeds off a small amount of hydraulic fluid for cooling of the closed loop traction circuits The flush ing valves are opened only during forward direction op eration When the flushing valves are unseated some oil from the low pressure side of the traction loop is re turned to the hydraulic tank Oil loss from the closed loop due to the flushing valve is replenished by the charge pump Reverse The traction circuit operates essentially the same in re verse as it does in forward When a traction lever is pulled rearward the rod con nected to the lever positions the swash plate in the trans mission piston pump to provide oil flow from the transmission port B for the RH side
133. ent Groundsmaster 7200 7210 Page 4 13 Load on the lift cylinder causes lift circuit pressure to in crease If lift circuit pressure reaches implement relief valve pressure 3000 PSI 207 bar the relief valve in the gear pump shifts to allow pump flow to return to the hy draulic tank This condition occurs in both the raise and lower modes When the lift control lever is released from RAISE spring action returns the control valve spool to its origi nal centered position stopping lift cylinder movement Gear pump flow is again bypassed through the oil cool er transmission and to the hydraulic tank The pilot check valve in the control valve will be reseated to lock the lift cylinder in place Hydraulic System 9 s O a Y oP P A req 922 ISd 000P INVA SINIYA 431738 ONIHSM4 IANYA SSvdAg Qquvwuod 1HOd ps WV3H gt gt 01 OF 00 VW HOLOM Va 133HMHI 1HOd 1NOYyW3 INVA ONIHSMS INVA SSvdAa8 QHVMHO4 1HOd ISI INOHA gt gt QI OF 00 YN HOLOW Ca TMH 1HOd uvad ueq 922 ISd 0007 SIATIVA 471134 rra X ONILOVH L38 IONNAO LIN MO
134. er ring from the spindle housing 6 Using an arbor press remove both of the bearing cups and the outer bearing spacer from the housing 7 The large snap ring can remain inside the spindle housing Removal of this snap ring is very difficult Assembly Fig 10 NOTE A replacement spindle bearing set contains two 2 bearings a spacer ring and a large snap ring items 1 2 and 3 in Fig 11 These parts cannot be purchased separately Also do not mix bearing set components from one deck spindle to another NOTE A replacement bearing spacer set includes the inner spacer and outer spacer items 4 and 5 in Fig 11 Do not mix bearing spacers from one deck spindle to another IMPORTANT If new bearings are installed into a used spindle housing it may not be necessary to re place the original large snap ring If the original snap ring is in good condition with no evidence of damage e g spun bearing leave the snap ring in the housing and discard the snap ring that comes with the new bearings If the large snap ring is found to be damaged replace the snap ring 1 If large snap ring was removed from spindle housing install snap ring into housing groove Make sure snap ring is fully seated in housing groove 2 Install outer spacer into top of spindle housing The spacer should fit against the snap ring DARON n Cutting Deck Page 7 12 130 to 150 ft Ib 176 to 203 N m Figure 10 Lock nut 7 Bearing set
135. er use or maintenance by the operator or owner of the machine can result in injury To reduce the potential for any injury comply with the following safety instructions as well as information found in the Operator s Manual Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator s Manual Operator Training DVD and all of the operating and safety decals on the machine 2 Be sure to establish your own special procedures and work rules for unusual operating conditions e g Groundsmaster 7200 7210 Page 1 1 Chapter 1 Safety To reduce the potential for injury or death comply with the following safety instructions slopes too steep for machine operation Survey mow ing site completely to determine which hills can be Operated on safely When performing this site survey always use common sense and take into consideration the turf condition and the rollover risk To perform a site survey follow the procedure outlined in the Operator s Manual Safety Before Operating 1 Review and understand the contents of the Opera tor s Manual and Operator Training DVD before starting and operating the machine Become familiar with the controls and know how to stop the machine and engine quickly A replacement Operator s Manual is available on the Internet at www Toro com or by sending the com plete model and serial number to The Toro Company Attn Technical Publicat
136. ers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Groundsmaster 7200 7210 Torque Specifications 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 spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors should be considered when applying torque cleanliness o
137. essure of 1000 PSI 69 bar cannot be obtained check for re striction in the pump inlet line If inlet line is not restricted remove gear pump and repair or replace as necessary NOTE Implement relief valve pressure can also be tested with hydraulic tester pressure and flow in series with the gear pump fitting and the disconnected hose Use pressure gauges on hydraulic tester and follow pro cedure for Implement Relief Pressure Test in this sec tion 14 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect tester from lift control valve fitting and hydraulic hose Reconnect hose to the control valve fitting Figure 25 2 Hose from gear pump 1 Lift control valve Hydraulic System e 5 35 o Lift Cylinder Internal Leakage Test HOLS Old uds 0522 ME LJ eq 972 ISd 000 331738 INVA ONIHSM14 H aasiva ATIVILHYA HIONNAO 13N ONILIVH1L3H tI3GNI TAS 404 M93H9 v Y INIYA 9NIHSN13 INVA SSWdAd INN YI vit vv QHVMHO0O3 gt gig oF HOLOW 133HM HI INVA SSVvdAa Qquv
138. ew 3 used 33 Exhaust gasket 5 Carriage screw 2 used 20 Fuel water separator 34 Wire harness ground bo een 21 Fuel hose 35 Fan pulley 22 Lock washer 36 V belt S Fan Spacer 23 Negative battery cabl 37 C 4 used 9 Flange head screw 4 used Neg artery cabro y Zab screw 4 used 10 Cooling fan 24 Flange nut 4 used 38 E ring 11 Engine GM 7200 shown 25 Rear mount 39 Hose clamp 3 used 12 Lock nut 2 used 26 Lock washer 9 used 40 Hose clamp 13 Separator bracket 27 Cap screw 8 used 41 Throttle cable 14 Flange head screw 8 used 28 Socket head screw 2 used 42 Flange nut 3 used 15 Fuel hose return 29 Engine mount 2 used 43 Flywheel housing Engine Removal Fig 9 NOTE When removing the engine using the following procedure the flywheel housing and transmission will remain in the machine 1 Park machine on a level surface lower cutting unit or implement stop engine engage parking brake and remove key from the ignition switch Kubota Diesel Engine Page 3 14 2 Remove hood from machine see Hood Removal in the Service and Repairs section of Chapter 6 Chas sis 3 Raise and support operator seat 4 Remove six 6 flange head screws that retain rear panel to frame Fig 10 Remove rear panel 5 Remove air cleaner from the engine see Air Cleaner Assembly Removal in this section Groundsmaster 7200 7210 6 Disconnect both battery cables at the battery Dis conne
139. f Valve Pressure Test should be per formed if a traction circuit problem is identified This test will determine if a transmission relief valve is operating correctly Procedure for Traction Relief Valve Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature Also make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 2 Park machine on a level surface with the cutting deck or implement lowered and off Make sure engine is off and that the parking brake is not applied 3 Read Precautions for Hydraulic Testing listed at the beginning of this section 4 Thoroughly clean transmission area surrounding traction circuit hoses on top of transmission Fig 17 Determine which traction relief valve is to be tested 5 Disconnect hydraulic hose from transmission pump outlet fitting for relief valve to be tested Fig 17 Relief Valve to be Tested Pump Outlet Right Side Forward Port A Port B Port C Right Side Reverse Left Side Forward Left Side Reverse 6 Install hydraulic tester pressure and flow in series with the pump outlet and the disconnected hose Make sure that the tester flow arrow points from the pump out let port and toward the hose for the relief valve direction that i
140. f the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature e g Nylock nut hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 1 Grade 5 Inch Series Bolts and Screws Figure 1 Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibration due to the effective change of torque wrench length When using a torque wrench with an offset wrench multiply the listed torque recommen dation by the calculated torque conversion factor Fig 3 to determine proper tightening torque Tightening torque when using a torque wrench with an offset wrench will be lower than the listed torque recommen dation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 18 The measured effective length of the torque wrench with the offset wrench installed distance from the center of the handle to the center of the offset wrench is 19 The calculated torque conversion factor for this torque wrench with this offset wrench would be 18 19 0 947 Groundsmaster 7200 7210 Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque va
141. f the ground 5 Disconnect wire harness connector from parking brake switch see Parking Brake Switch in the Compo nents section of Chapter 5 Electrical System Install jumper wire across harness connector terminals to al low traction circuit operation with the parking brake ap plied 6 Thoroughly clean transmission area surrounding traction circuit hoses on top of transmission Fig 18 Determine which wheel motor is to be tested 7 Disconnect hydraulic hose from transmission pump outlet fitting for wheel motor to be tested Fig 18 Wheel Motor to be Tested Pump Outlet Right Side Motor Port A eft Side Motor Groundsmaster 7200 7210 Page 4 33 8 Install hydraulic tester pressure and flow in series between the pump outlet fitting and the disconnected hose Make sure that the tester flow arrow points from the pump outlet and toward the hose Make sure the flow control valve on the tester is fully open 9 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test IMPORTANT Do not run engine at full speed when performing this test using Toro Hydraulic Tester Pressure and Flow TOR214678 Traction pump output at full engine speed can damage hydraulic tester 10 Using a phototac to measure engine speed move throttle so engine speed is 2800 RPM not full speed Make sure parking brake is applied to keep whe
142. face lower implement stop engine engage parking brake and remove key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on control valve to prevent hydraulic system contamina tion 3 Label all hydraulic hoses and fittings for assembly purposes 4 Disconnect hydraulic hoses connected to the hy draulic fittings on the control valve Allow hoses to drain into a suitable container Install clean plugs in hose openings to prevent system contamination 5 Remove hair pins that secure lever valve links to con trol valve spools Fig 104 Slide links from spools 6 Support the control valve to prevent it from falling during removal 7 Remove two 2 carriage screws and flange nuts that secure control valve to machine Remove control valve from machine 8 If necessary remove hydraulic fittings from control valve Note orientation of fittings for assembly purposes Remove and discard O rings from fittings Installation Fig 103 1 If hydraulic fittings were removed from control valve lubricate and install new O rings to fittings Install fit tings into valve ports see Hydraulic Fitting Installation in the General Information section of this chapter Orientate fittings as noted during removal 2 Position control valve to machine frame and secure with two 2 carriage screws and flange nuts 3 Attach lift lever valve links to control valve spools and secure with hair pins Fig 104
143. face lower implement stop engine engage parking brake and remove key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination 3 Label hydraulic hoses for assembly purposes 4 Disconnect hydraulic hoses connected to the hy draulic fittings on the lift cylinder Install clean plugs in hose openings to prevent system contamination 5 Remove lock nut screw and pivot pin that secure lift cylinder barrel end to carrier frame 6 Remove lock nut screw and pivot pin that secure lift cylinder rod end to lift arm 7 Remove lift cylinder from machine 8 If necessary remove hydraulic fittings from lift cylin der Note orientation of fittings for assembly purposes Remove and discard O rings from fittings Groundsmaster 7200 7210 Page 4 97 Installation Fig 109 1 If hydraulic fittings were removed from lift cylinder lu bricate and install new O rings to fittings Install fittings into lift cylinder ports see Hydraulic Fitting Installation in the General Information section of this chapter Orientate fittings as noted during removal 2 Position lift cylinder to the machine 3 Secure cylinder barrel end to carrier frame with pivot pin screw and lock nut 4 Secure cylinder rod end to lift arm with pivot pin screw and lock nut 5 Remove plugs that were installed in hydraulic hoses during the removal procedure Correctly conn
144. for as sembly purposes The reverse relief valve cartridges can be identified by the groove in the hex head Fig 50 20 Remove valve plates from center case Mark the positions of the valve plates so they can be assembled in the same position Figure 48 1 Center case 2 Pump housing 3 Pin 2 used Figure 49 1 Bypass valve 2 Center case 3 Reverse relief cartridge kd 4 Forward relief cartridge 5 Valve plate p o v Figure 50 1 Forward relief cartridge 2 Reverse relief cartridge Hydraulic System Page 4 60 3 Hex head groove Groundsmaster 7200 7210 21 Remove six 6 hex plugs from center case Remove and discard O rings from plugs 22 Remove RH and LH flushing valve plugs springs and valves from center case Note differences in flush ing valves and their locations for assembly purposes Remove and discard O rings from plugs 23 Taking care to not drop pistons from cylinder block slide both cylinder block assemblies from pump shafts Mark the positions of the cylinder blocks so they can be assembled in the same position 24 Slide pipe assembly from bore of transmission pump housing Remove and discard O rings from grooves in pipe 25 Remove retaining ring that secures PTO shaft oil seal into housing bore Remove spacer and oil seal from housing taking care to not damage housing bore 26 Remove thrust plate from each swash plate For as sembly purposes note that
145. from test connections and correct before pro ceeding with test IMPORTANT Do not run engine at full speed when performing this flow test using Toro Hydraulic Tes ter Pressure and Flow TOR214678 Traction pump output at full engine speed can damage hy draulic tester 9 Using a phototac to measure engine speed move throttle so engine speed is 2800 RPM not full speed 10 Have operator slowly push traction lever for pump being tested to fully forward position Leave other trac tion lever in neutral position 11 Slowly close tester flow control valve until pressure gauge reads 1000 PSI 69 bar Verify with a phototac that the engine speed is still 2800 RPM 12 Observe flow gauge TESTER READING should be approximately 13 3 GPM 50 3 LPM for a traction pump in good condition 13 Open tester flow control valve release traction lever to the neutral position and stop engine Record test re sults 14 Normal traction pump flow is 13 3 GPM 50 3 LPM Lower pump flow would result in reduced traction circuit performance If flow is less than 11 GPM 41 6 LPM or a pressure of 1000 PSI 69 bar cannot be obtained A The traction control lever may need adjustment B Ifthe engine speed drops excessively as the test er flow control valve is closed engine performance should be evaluated see Chapter 3 Kubota Diesel Engine C If engine speed does not drop and pressure and flow specifications are not met the tested t
146. fy coil resistance between terminals 85 and 86 with a multimeter ohms setting Resistance should be approximately 72 ohms 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 412 VDC is applied and removed from terminal 85 SE 2 9 o D lu 5 Disconnect voltage and leads from the relay termi nals 6 Connect wire harness electrical connector to glow relay after testing is completed Figure 26 7 Close and secure hood Groundsmaster 7200 7210 Page 5 21 Electrical System High Temperature Warning Switch The high temperature warning switch is attached to the water pump housing on the engine and has a yellow wire attached to it Fig 27 This switch is normally open and closes when engine coolant temperature reaches approximately 220 F 105 C When engine coolant temperature rises to approximate ly 220 F 105 C the high temperature warning switch closes The closed switch causes the High Temperature Warning Light on the console to illuminate and also pro vides an input to the Standard Control Module SCM This input causes the SCM high temperature warning LED to illuminate and the cutting deck or implement to shut down The temperature warning switch and circuit wiring should be tested as a SCM input before perform ing the following testin
147. g procedure Testing 1 Park machine on a level surface lower cutting deck or implement stop engine apply parking brake and re move key from ignition switch Open hood to gain ac cess to engine Make sure engine is cool before removing the temperature warning switch from engine Do not Open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot coolant can es cape and cause burns 2 Lower the coolant level in the engine remove wire harness connector from high temperature warning switch and remove the switch from the engine 3 Put the end of the switch in a container of oil with a thermometer and slowly heat the oil Fig 28 CAUTION Handle the hot oil with extreme care to prevent NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from from the measured value of the component you are testing Electrical System Page 5 22 4 Check resistance of the warning switch with a multi meter ohms setting as the temperature increases The high temperature warning switch is normally open and should close from 216 to 226 F 102 to 108 C 5 After testing install warning switch to the engine housing A Clean threads of housing and switch thor
148. gher 12 45 V 12 24V 50 charged 12 06 V 25 charged 11 89 V 0 charged Start the engine and run at high idle 3200 to 3250 RPM Allow the battery to charge for at least 3 minutes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage Example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 v Battery Voltage after 3 Minute Charge 12 85 v Set the multimeter to the correct scale With the ignition switch in the OFF position place the ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow plug system Adjust the meter to read zero if applicable Activate the glow plug system and record the multimeter results The glow plug system on Groundsmaster 7200 and 7210 machines should have a reading of approximately 27 Amps Groundsmaster 7200 7210 Check Operation of Interlock Switches Check the operation of the interlock switches daily for proper operation Replace any malfunc tioning switches before operating the machine Groundsmaster 7200 and 7210 machines are equipped with a Standard Control Module SCM which monitors interlock switch operation Information on the SCM is described in the Component Testing section of this Chapter Testing of individual interlock switches is in
149. gnition switch Install HOC pin into HOC bracket to allow desired height of cut Fig 22 Figure 23 1 Adjustment clevis 4 Ring pin 2 Jamnut 5 Flange nut 3 Clevis pin 6 Cutting deck Figure 24 1 Carrier frame 3 Flange bushing 2 used 2 Flange bushing 2 used Figure 25 1 Rear lift arm 3 Washer cavity 2 Washer 4 Deck lift shaft L EI H 18 070 to 18 180 in 45 9 to 46 1 cm Figure 26 Groundsmaster 7200 7210 Page 6 23 Chassis Operator Seat E ring 2 used Manual housing Housing cap R clamp 2 used Latch angle 2 used Seat stop lever Latch lever 2 used Seat plate AAA Nz Chassis Figure 27 Operator seat Flat washer 2 used Lock washer 2 used Cap screw 2 used Latch Grommet Cap screw Seat belt Page 6 24 Torsion spring Seat link Carriage bolt 4 used Flange nut 9 used Spacer Washer head screw 2 used Clevis pin Seat switch harness Groundsmaster 7200 7210 Removal Fig 27 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Unlatch and raise operator seat lf seat switch service is necessary remove seat from seat plate to access switch To prevent injury DO NOT attempt to reach switch through openings in seat plate Figure 28 3 Disconnect machine wire harness el
150. ground connection Fuse F1 F2 F3 and or F4 are is faulty Fusible link harness at the engine starter motor is faulty Wiring in the crank circuit is loose corroded or damaged see Chapter 8 Foldout Diagrams The ignition switch is faulty Starter solenoid wiring is loose corroded or damaged Starter solenoid is faulty The Standard Control Module is faulty Electrical System Page 5 4 Groundsmaster 7200 7210 Starting Problems continued Engine cranks but does not start The glow plug circuit does not operate properly Engine cranks but should not with the PTO switch in the ON up position Engine starts but stops when the ignition switch is released from the START position Groundsmaster 7200 7210 Page Possible Causes The fuel tank is empty Wiring in the engine crank circuit is loose corroded or damaged see Chapter 8 Foldout Diagrams Fuel filter is plugged Engine and or fuel may be too cold Engine run solenoid or circuit wiring is faulty Engine fuel pump or circuit wiring is faulty The engine glow circuit does not operate properly Engine or fuel system is malfunctioning see Chapter 3 Kubota Diesel Engine Wiring in the engine glow circuit see Chapter 8 Foldout Diagrams is loose corroded or damaged Engine glow plug s is are faulty The glow relay or glow plug controller is faulty Fusible link harness at the engine starter motor is faulty Fuse F1 F
151. he bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Tool required Digital multimeter set to DC volts Test instructions Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative battery post Keep the test leads connected to the battery posts and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Glow Plug System Test This is a fast simple test that can help to determine the integrity and operation of the Groundsmaster glow plug system The test should be run anytime hard starting cold engine is encountered on a diesel engine equipped with a glow plug system Tool s required Digital multimeter and or inductive Ammeter AC DC Current Transducer Test instructions Properly connect the ammeter to the digital multimeter refer to manufacturers instructions Electrical System Page 5 8 Voltage Measured Battery Charge Level Fully charged 100 75 charged 12 68 V or hi
152. he pull link torsion springs may cause some rotation of pull links during the re moval process 2 To allow removal of pivot pin item 10 from cutting deck and pull link remove adjustment clevis from deck A Remove flange nut item 19 that secures adjust ment clevis to deck B Remove adjustment clevis from deck 3 Remove lock nut item 8 and cap screw item 17 from deck and pivot pin item 10 4 Slide pivot pin item 10 from deck and pull link 5 Remove pull link with torsion spring and spacer from deck 6 Inspect bushings items 6 and 16 in pull link Re place bushings if worn or damaged Assembly Figs 18 and 19 NOTE For 62 cutting decks the torsion spring item 14 is painted red The torsion spring on 72 decks is painted black 1 Place spacer inside torsion spring and then fit spring and spacer into pull link Make sure that torsion spring end is below cap screw item 9 in pull link Groundsmaster 7200 7210 Page 7 17 2 Position pull link to cutting deck 3 Slide pivot pin item 10 through cutting deck pull link and spacer 4 Insert cap screw item 17 through pivot pin and holes in deck Make sure that torsion spring end is below Screw Secure cap screw with lock nut 5 Install adjustment clevis to deck and secure with flange nut 6 Install cutting deck to machine see Cutting Deck Re moval and Installation in this section 7 Lubricate pull link grease fit
153. hose from pump 1 Fuel water separator 2 Inlet fitting Fuel Pump Specifications Pump Capacity 23 5 fl oz min 695 ml min 3 3 psi 22 8 kPa Electrical System Electrical System Fuel Stop Solenoid The fuel stop solenoid used on the Groundsmaster 7200 7210 must be energized for the diesel engine to run The solenoid is mounted to the injection pump on the engine Fig 35 The fuel stop solenoid includes two coils for operation the pull coil and the hold coil When the ignition switch is turned to START the fuel stop solenoid is initially ener gized and the pull coil retracts the solenoid plunger Once the plunger is retracted the hold coil will keep it re tracted for continued engine operation When the sole noid is de energized the plunger extends to shut off fuel supply to the engine causing the engine to stop running The fuel stop solenoid is grounded through the solenoid housing The Standard Control Module Run output LED will be il luminated when the fuel stop solenoid hold coil is ener gized NOTE Refer to Chapter 8 Foldout Diagrams when troubleshooting the fuel stop solenoid In Place Testing NOTE Prior to taking small resistance readings with a digital multimeter short the test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal re sistance of the meter and test leads Subtract this value from the mea
154. ially re moved bearing and tap on yoke to completely re move the bearing D Repeat process for remaining bearings E Thoroughly clean and inspect all components 4 To install new cross and bearings A Apply a coating of grease to bearing bores of end yoke and shaft yoke Also apply grease to bearings and seal of bearing assembly Make sure that all bearing rollers are properly seated in bearing cage B Press one bearing partially into yoke IMPORTANT Take care when installing cross into bearing to avoid damaging bearing seal C Carefully insert cross into bearing and yoke Chassis Page 6 20 D Hold cross in alignment and press bearing in until it hits the yoke E Carefully place second bearing into yoke bore and onto cross shaft Press bearing into yoke F Install snap rings to bearings to secure bearings in place G Repeat procedure for other yoke H Grease cross until grease comes out of all four 4 bearing cups 5 Make sure that assembled joint moves without bind ing Slight binding can usually be eliminated by lightly rapping the yoke lugs with a soft faced hammer If bind ing continues disassemble joint to identify source of binding 6 Install drive shaft to vehicle see PTO Drive Shaft Installation in this section Figure 20 1 End yoke 2 Cross and bearing kit 3 Snapring 4 used 4 Shaft yoke Groundsmaster 7200 7210 This page is intentionally blank Groundsma
155. id dust and debris Groundsmaster 7200 7210 Page 7 5 Never work on the cutting deck with the engine running Always stop engine and remove key from ignition switch first To verify blade stopping time have a second person stand back a safe distance from the machine and watch the blades on the cutting deck When the machine oper ator disengages the cutting deck record the time it takes for the blades to come to a complete stop If this time is greater than seven 7 seconds the PTO brake assem bly in the transmission should be inspected Cutting Deck Cutting Deck Removal and Installation Removal 1 Park machine on a level surface with the cutting deck in the fully raised position Stop engine engage park ing brake and remove key from the ignition switch NOTE When the cutting deck is in the raised position pull link torsion spring tension is reduced making it much easier to disconnect pull links from machine 2 Disconnect pull link from each side of machine Fig 1 Figure 1 Be careful when disconnecting the pull links 1 Pull link deck raised 3 Retainer pin 2 Shoulder screw 4 Torsion spring The pull link torsion springs may cause some rotation of pull links during the removal process A Remove shoulder screw that secures retainer pin to carrier frame B Carefully slide retainer pin from carrier frame and pull link 3 Note location of HOC pin in HOC bracket for assem bly purposes
156. ides information regarding the operation general maintenance and maintenance intervals for the cutting deck on your Groundsmaster machine Refer to that publication for additional informa tion when servicing the cutting deck Cutting Deck Page 7 2 Groundsmaster 7200 7210 Factors That Can Affect Cutting Performance There are a number of factors that can contribute to un Remember that the effective or actual height of cut satisfactory quality of cut some of which may be turf depends on cutting deck weight and turf conditions conditions Turf conditions such as excessive thatch sponginess or attempting to cut off too much grass height may not always be overcome by adjusting the machine It is important to remember that the lower the height of cut the more critical these factors are 1 Maximum governed engine speed Check maximum governed engine speed Adjust engine speed to specifications if necessary see Chapter 3 Kubota Diesel Engine 2 Blade speed All cutting deck blades should rotate at the same speed 3 Tire pressure Check air pressure of all tires including castor tires Adjust to pressures specified in Operator s Manual 4 Blade condition Sharpen blades if their cutting edges are dull or nicked Inspect blade sail for wear or damage Replace blade if needed 5 Mower housing condition Make sure that cutting chamber is in good condition Keep underside of deck clean Debris buildup will reduce cu
157. ig 6 Si Mumer E s gt Su e Co X o0 2 a 4 Remove four 4 flange nuts from the exhaust man ifold studs Separate muffler flange from the engine ex haust manifold Remove muffler from the machine 5 Remove exhaust gasket Replace gasket if dam aged or torn Installation Fig 5 NOTE Make sure muffler flange and engine exhaust manifold sealing surfaces are free of debris or damage that may prevent a tight seal 1 Place exhaust gasket on the engine exhaust man ifold IMPORTANT Finger tighten all fasteners before se curing the muffler to the muffler bracket so there is no preload on the exhaust system 2 Position muffler flange to the engine exhaust man ifold and loosely install four 4 flange nuts 3 With the muffler flange tight to the engine exhaust manifold no gaps visible position muffler so that muf fler is tight against muffler bracket no gaps visible 4 Tighten four 4 flange nuts to secure muffler flange to exhaust manifold Torque flange nuts 17 to 21 ft lb 23 to 28 N m 5 Check that clearance between muffler and muffler bracket is less than 0 015 0 4 mm If necessary re peat steps 3 and 4 above Once clearance is less than 0 015 0 4 mm secure muffler to the muffler bracket by tightening two 2 carriage screws and flange lock nuts Fig 6 Torque lock nuts from 38 to 48 in Ib 4 3 to 5 4 N m 6 Close and latch hood Groundsmaster 7200 7210 Page 3 9 Kubo
158. ines that the neutral switch and cir cuit wiring are not functioning correctly test each neu tral switch as follows A Make sure ignition switch is in the OFF position Locate neutral switches for testing B Disconnect machine wire harness electrical con nector from the neutral switch C Check the continuity of the switch by connecting a multimeter ohms setting across the connector ter minals D When the switch plunger is extended there should be no continuity open between the switch terminals E When the switch plunger is depressed there should be continuity closed between the switch ter minals F Replace switch if necessary G If the neutral switch tests correctly and a circuit problem still exists check wire harness see Electri cal Schematics and Circuit Drawings in Chapter 8 Foldout Diagrams H Connect machine wire harness connector to neu tral switch Check neutral switch operation Electrical System Page 5 14 Figure 13 1 Front panel 2 Washer head screw Figure 14 1 Traction lever LH 2 Neutral switch DISTANCE BETWEEN LEVER AND SWITCH S BODY WITH 0 015 TO 0 045 LEVER IN 0 4 to 1 0 mm NEUTRAL LOCK Figure 15 1 Traction lever 3 Screw 2 Neutral switch Groundsmaster 7200 7210 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 ou
159. ing labels placed during the removal process properly connect hydraulic hoses to transmission gear pump and hydraulic tank fittings see Hydraulic Hose and Tube Installation in the General Information section of this chapter 13 Lubricate gasket of new oil filter and install filter on transmission 14 Make sure that drain plugs are properly installed in hydraulic tank and transmission Fill hydraulic tank with new hydraulic fluid 15 Install operator seat and seat base see Operator Seat Installation in the Service and Repair section of Chapter 6 Chassis 16 Plug wire harness electrical connectors to solenoid valve coil and seat switch Secure harness to frame 17 Check parking brake and brake switch operation 18 Adjust traction drive for neutral Hydraulic System 9 s O a Y oP Transmission Service Figure 39 Hydraulic System Page 4 56 Groundsmaster 7200 7210 Figure 39 continued 1 Solenoid assembly 27 Seal 4 used 53 Valve plate 2 used 2 Solenoid valve assembly 28 O ring 2 used 54 Cylinder block assembly 2 used 3 Bolt 3 used 29 Washer 2 used 55 Thrust plate 2 used 4 Bolt 2 used 30 Bearing 5 used 56 Swash plate 2 used 5 Hex plug 2 used 31 Bearing 2 used 57 Pin 4 used 6 O ring 32 Side cover 2 used 58 Gasket 7 Pump body 33 Socket head screw 3 used per cover 59 Pump housing 8 Pin 2 used 34 Nut 2 used 60 PTO brake assembly 9 O ring 35 Co
160. ings from grooves in pipe 35 If pump shaft bearing replacement is necessary re move and discard seal ring from RH and LH pump shafts Remove bearings from pump shaft using a bear ing puller Discard removed bearings Remove gear from pump shaft 36 If input shaft bearing replacement is necessary re move bearings from input shaft using a bearing puller Discard removed bearings Remove gear from input shaft 1 Input shaft 2 RH pump shaft 1 RH pump shaft 2 LH pump shaft Groundsmaster 7200 7210 Page 4 63 Figure 56 3 LH pump shaft 4 Pipe Figure 57 3 Input shaft 4 Sealring Hydraulic System Hydraulic 37 Remove PTO shaft assembly from transmission pump housing Figure 58 1 PTO shaft assembly 2 Pump housing 38 Remove final friction plate from transmission pump housing NOTE This friction plate may have been removed with PTO shaft assembly Figure 59 1 Friction plate 2 Pump housing Hydraulic System Page 4 64 Groundsmaster 7200 7210 39 Disassemble PTO shaft assembly A Using a bearing puller remove bearing from PTO shaft Discard bearing B Remove spacer from PTO shaft C Slide gear and clutch assembly from PTO shaft D Remove key from PTO shaft slot E Remove two 2 seal rings from PTO shaft grooves Discard seal rings F Remove B plate C plate three 3 A plates and three 3 friction plates from PTO shaft G Using a bearing puller remove bea
161. intenance Page 2 4 Groundsmaster 7200 7210 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 57 6in lb 96 10 in Ib Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 644 68 N cm 78 8 in lb 881 90 N cm 1085 113 N cm 133 14 in lb 1503 158 N cm M6X 1 0 M8 X 1 25 M10 X 1 5 19 2 ft Ib 38 4 ft lb M12 X 1 75 M16 X 2 0 M20 X 2 5 NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc 66 7 ft lb 166 17 ft lb 325 33 ft lb NOTE The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 1096 of the nominal torque value Groundsmaster 7200 7210 26 3 N m 90 10 N m 93 10 ft lb 126 14 N m 225 23 N m 229 23 ft lb 310431 N m 450 46 ft lb 610 62 N m Page 2 5 28 3 ftHb 38 4 Nm NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as engine oil or thread sealant such as Loctite Product Records and Maintenance
162. ion steering is accomplished by mov ing the two traction levers a different amount or direc tion With the engine running and the traction levers in the neutral position the piston pump swash plates are held in the vertical position providing no flow to either wheel motor and the machine remains stationary The trans mission reverse check valves include an orifice which makes it easier to locate the transmission neutral posi tion Forward When a traction lever is pushed forward the rod con nected to the traction lever positions the swash plate in the piston pump to provide oil flow from the transmission port A for the RH side or C for the LH side This oil flows to the wheel motor and turns the motor in the forward direction Oil flow from the wheel motor returns to the transmission port B or D and is continuously pumped as long as the traction lever is pushed forward As the traction load increases forward traction circuit pressure can increase to the relief valve setting of 4000 PSI 276 bar If pressure exceeds the relief setting oil flows through the forward relief valve in the transmission to the low pressure side of the closed loop traction cir cuit The piston pumps use a small amount of hydraulic fluid for internal lubrication Fluid is designed to leak across pump parts into the transmission case drain This leak age results in the loss of hydraulic fluid from the closed loop traction circuits that must be repl
163. ion section 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Remove operator seat and seat base see Operator Seat Removal in the Service and Repair section of Chapter 6 Chassis 3 On both sides of machine remove cap screw and lock nut that secures the pump control rod to the traction control hub Fig 36 Note that cap screw is installed from the outside toward the center of the machine 4 Unplug wire harness electrical connector from trans mission solenoid valve coil Position wire harness away from transmission 5 Drain oil from hydraulic tank and transmission 6 Thoroughly clean hydraulic hose ends and fittings on transmission gear pump and hydraulic tank to prevent hydraulic system contamination Figure 36 4 Lock nut 5 Cap screw 6 Retaining ring 1 Transmission 2 Pump control rod 3 Traction control hub 7 Label all hydraulic hoses and fittings for assembly purposes Remove hydraulic hoses from fittings on transmission gear pump and hydraulic tank Allow hoses to drain into a suitable container 8 Install clean plugs in hose and fitting openings to pre vent system contamination 9 Remove hydraulic tank see Hydraulic Tank Remov al in this section
164. ions 8111 Lyndale Avenue South Bloomington Minnesota 55420 1196 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the ma chine 3 Tighten any loose nuts bolts or screws to ensure machine is in safe operating condition 4 Assure interlock switches are adjusted correctly so engine cannot be started unless both drive handles are in the neutral lock position the PTO switch is OFF dis engaged and either the seat is occupied or the parking brake is applied While Operating 1 Sit on the seat when starting and operating the ma chine 2 Before starting the engine A Engage the parking brake B Make sure both drive handles are in the neutral lock position and the PTO switch is OFF disen gaged C After engine is started release parking brake and keep both drive handles in the neutral lock position Machine must not move If movement is evident the traction linkage is adjusted incorrectly therefore shut engine off and adjust traction linkage until ma chine does not move when both drive handles are in the neutral lock position 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly Safety Page 1 2 5 Since fuel is highly flammable handle it carefully A Store fuel in containers specifically designed for this purp
165. irt Clean protective screen on machine frequently 11 If engine must be running to perform maintenance or to make an adjustment keep hands feet clothing and other parts of the body away from the cutting deck or im plement and other moving parts Keep bystanders away Groundsmaster 7200 7210 Page 1 3 12 Do not overspeed the engine by changing engine governor setting To assure safety and accuracy check maximum engine speed with a tachometer 13 Shut engine off before checking or adding oil to the engine crankcase 14 Disconnect battery before servicing the machine Disconnect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect the battery Reconnect positive battery cable first and negative cable last 15 Battery acid is poisonous and can cause burns Pre vent acid contact with skin eyes and clothing Protect your face eyes and clothing when working with a bat tery 16 Battery gases can explode Keep cigarettes sparks and flames away from the battery 17 If welding on the machine is necessary disconnect the battery cables to prevent electrical system damage Disconnect negative battery cable first and positive cable last 18 At the time of manufacture the machine conformed to the safety standards for riding mowers To assure op timum performance and continued safety certification of the machine use genuine Toro re
166. isconnect PTO drive shaft from gearbox see PTO Drive Shaft Removal 6 Remove four 4 cap screws item 10 and lock wash ers item 11 that secure gearbox assembly to gearbox brackets 7 Remove fasteners that secure left side gearbox bracket item 3 to deck mounting plate Remove brack et from deck 8 Remove gearbox assembly with drive pulley at tached from deck Drain lubricant from gearbox 9 Remove two 2 set screws that secure taper lock bushing to drive pulley on gearbox shaft 10 Thread one of the removed set screws into threaded hole of bushing Fig 16 Tighten set screw to loosen bushing from pulley hub 11 Slide bushing and pulley from gearbox shaft Locate and retrieve woodruff key 12 If necessary remove and replace oil seals and oil caps in gearbox Fig 17 NOTE If internal gearbox wear or damage occurs gearbox replacement is necessary Internal gearbox components are not available Installation Fig 15 1 Clean gearbox output shaft pulley ID and taper lock bushing thoroughly 2 Position woodruff key pulley and then taper lock bushing to gearbox output shaft Slide bushing to shoul der on shaft Align threaded holes of pulley with non threaded holes of bushing 3 Lightly oil threads of set screws and install screws into threads of pulley Fig 16 Alternately and evenly tighten set screws to a torque from 180 to 250 in Ib 20 to 28 N m 4 Fill allen recess in set screws a
167. item 6 from 300 to 400 ft lb 407 to 542 N m Release parking brake 11 Check parking brake and brake switch operation 35 to 40 ft lb x 48 to 54 N m Loctite 4271 Figure 5 1 Parking brake assembly 3 Brake support 2 Lock nut 4 Hardened washer Figure 6 1 Wheel hub 4 Brake support 2 Parking brake assembly 5 Hardened washer 3 Lock nut Figure 7 1 Brake swivel 4 Hardened washer 2 Caliper brake lever 5 Clearance 3 Wheel hub disc Groundsmaster 7200 7210 Page 6 9 Chassis Parking Brake Service NG aho NE 30 to 40 ft lb 41 to 54 N m Lever Assembly sleeve 2 used Hardened washer 2 used Hex bolt 2 used Mounting lock nut 2 used Hex nut 2 used Stationary actuator 18 to 23 ft Ib 24 to 31 N m 30 to 40 ft lb 41 to 54 N m 4 Figure 8 Sleeve 2 used Steel ball 3 used Spring pin Compression spring 2 used Mount sleeve 2 used Hex nut 2 used NOTE If parking brake wear or damage occurs brake replacement is necessary Individual brake components are not available Chassis Page 6 10 Mounting screw 2 used Socket head screw 2 used Outer stator brake pad Inner stator brake pad Shim Washer Groundsmaster 7200 7210 Disassembly Fig 8 1 Loosen and remove hex bolts item 4 socket head screws item 15 and hex nuts items 5 and 6 2 Slide inner
168. ithin a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury 1 Clean machine thoroughly before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination can cause excessive wear or binding of hydraulic components 2 When conducting tests on the hydraulic system wear eye protection Hydraulic System Page 4 24 3 Before testing check traction control lever linkages for improper adjustment binding or broken parts 4 All hydraulic tests should be made with the hydraulic oil at normal operating temperature Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 5 Put clean metal caps or plugs on any hydraulic lines left open or exposed during testing or component re moval 6 When using hydraulic tester pressure and flow the inlet and the outlet hoses must be properly connected and not reversed to prevent damage to the hydraulic tester or components 7 Install hydraulic fittings finger tight and far enough to make sure that they are not cross threaded before tight ening them with a wrench 8 Position tester hoses to prevent rotating machine parts from contacting and damaging the hoses or tester 9 After connecting test equipmen
169. ition new gasket to housing 18 Carefully place gear case housing onto pump hous ing making sure to align pins pipe and shaft bearings 19 Secure gear case housing to pump housing with fif teen 15 flange head screws Tighten screws evenly in a crossing pattern and then torque screws from 17 to 19 ft Ib 22 to 27 N m 20 Taking care to not damage input shaft oil seal install oil seal into gear case housing bore Place spacer on oil seal and secure with retaining ring 21 Lubricate new O rings and install O rings onto three 3 plugs Install plugs into transmission assembly Torque hex plugs from 14 to 15 ft Ib 18 to 21 N m and socket head plug from 17 to 19 ft lb 22 to 27 N m Figure 78 1 Gear case housing 3 Pin 2used 2 Pump housing Figure 79 1 Hex plug 2 Socket head plug Hydraulic System Page 4 72 Groundsmaster 7200 7210 22 Taking care to not damage PTO oil seal install oil seal into pump housing bore at PTO shaft Place spacer on oil seal and secure with retaining ring 23 Lubricate both sides of thrust plates with clean hy draulic oil Place thrust plate onto each swash plate making sure to position the beveled side of the thrust plates against the swash plate surface 24 Slide control arm onto each trunnion shaft and se cure with socket head screw and nut Torque nut from 20 to 23 ft lb 27 to 32 N m 25 Lubricate all components of cylinder blocks liberally with clean hydraulic oil
170. l System o o o 2 wi g o D E Jp Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components used on this machine see Chapter 8 Foldout Diagrams Remove all jewelry especially rings and watches before doing any electrical trouble Make sure that all machine interlock switches are func shooting or testing Disconnect the battery tioning correctly for proper troubleshooting and safety cables unless the test requires battery voltage NOTE Use the Standard Control Module input and out put LED s when troubleshooting a Groundsmaster 7200 or 7210 electrical problem Starting Problems Starter solenoid clicks but starter will not crank Low battery charge NOTE If the starter solenoid clicks the problem is not p dr Loose or corroded battery cables in the interlock circuit Loose or corroded ground connection Faulty wiring at the starter Faulty starter solenoid Nothing happens when start attempt is made The traction levers are not in neutral locked position The traction neutral switch es is are faulty or out of adjustment Parking brake is disengaged with seat unoccupied PTO switch is in the ON up position or is faulty The engine coolant temperature is excessive or the engine high temperature shutdown switch is faulty The battery is discharged Loose or corroded battery cables Loose or corroded
171. le has been disconnected from battery loosen nut on positive cable and remove positive cable from battery 4 Make sure battery vent caps are on tightly 5 Remove battery from the battery compartment to a service area to allow better access for service Inspection Maintenance and Testing IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water between the minimum and maxi mum fill lines Charge at 15 to 25 amps for 15 min utes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the te
172. lenoid valve stem 3 Pin 7 Solenoid coil 4 Sleeve holes 2 L3 cs gt lt Groundsmaster 7200 7210 Page 4 77 Hydraulic System Gear Pump N e 13 20 to 26 ft lb E N Ng 3 35 to 43 ft lb 48 to 58 N m 8t035Nm 10 5 lt a C AD y 20 to 26 ft Ib 28 to 35 N m Figure 94 1 Transmission assembly 7 Hydraulic hose output 13 Hydraulic hose 2 Coupler 8 Cap screw 2 used 14 Hydraulic hose suction 3 O ring 9 Lock washer 2 used 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 Gear pump Removal Fig 94 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Remove operator seat and seat base see Operator Seat Removal in the Service and Repair section of Chapter 6 Chassis 3 Drain hydraulic oil from hydraulic tank 4 Thoroughly clean hydraulic hose ends and fittings on gear pump and hydraulic tank to prevent hydraulic sys tem contamination Hydraulic System Page 4 78 5 Label all hydraulic hoses and fittings for assembly purposes 6 Disconnect hydraulic hoses from fit
173. lues may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 If the listed torque recommendation for a fastener is from 76 to 94 ft lb the proper torque when using this torque wrench with an offset wrench would be from 72 to 89 ft lb Offset wrench e Torque wrench effective length of torque wrench A effective length of torque wrench offset wrench TORQUE CONVERSION FACTOR A B Figure 3 Product Records and Maintenance 28 e S lt c EF 3 Sy aw Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 58 SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts
174. ly process 18 Remove pump from vise Groundsmaster 7200 7210 2 55 CO 0 UO gt gt N lt This page is intentionally blank Groundsmaster 7200 7210 Page 4 83 Hydraulic System Lift Control Valve 34 to 42 ft lb 47 to 56 N m 23 9 10 N Cr Figure 99 1 Lift cylinder 9 O ring 17 Flange nut 2 O ring 10 Hydraulic hose from gear pump 18 Washer 2 used 3 Hydraulic hose 11 Cap screw 2 used 19 Spacer 4 Hydraulic hose 12 Lock washer 2 used 20 Lift lever assembly 5 O ring 13 Flat washer 2 used 21 Valve link 6 Hydraulic tee fitting 14 Lift control valve 22 Cotter pin 2 used 7 O ring 15 Hydraulic fitting 23 Hydraulic fitting 8 Hydraulic hose to oil cooler 16 Cap screw Hydraulic System Page 4 84 Groundsmaster 7200 7210 Removal Fig 99 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on lift control valve to prevent hydraulic system contamina tion 3 Label all hydraulic hoses and fittings for assembly purposes 4 Disconnect hydraulic hoses connected to the hy draulic fittings on the lift control valve Allow h
175. m perature of the cell Figure 41 1 Perform the following inspections and maintenance 1 Negative cable 5 Flatwasher 2 Battery 6 Battery retainer A Check for cracks Replace battery if cracked or 3 Battery tray 7 Carriage screw 4 Flange nut 8 Positive cable leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts Electrical System Page 5 30 Groundsmaster 7200 7210 B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C be low 80 F 26 7 C subtract 0 004 from the specific gravity reading 100 F 1 245 Example Cell Temperature Cell Gravity 100 F minus 80 F equals 20 F 37 7 C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 119 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 26 7 C 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester
176. m X 0 7376 ft lb Groundsmaster 7200 7210 TORO Table of Contents SPECIFICATIONS 2 Groundsmaster 7200 2 Groundsmaster 7210 3 GENERAL INFORMATION 4 Operator s Manual 4 Stopping the Engine Groundsmaster 7210 4 ADJUSTMENTS 5 ERE Lp eda da ia 5 Adjust Throttle Control 5 SERVICE AND REPAIRS eee 6 Air Cleaner Assembly 6 Exhaust System 8 Fuel System 10 Check Fuel Lines and Connections 11 Drain and Clean Fuel Tank 11 Fuel Tank Removal 11 Fuel Tank Installation 11 Radiator ciar NAA NANANA ANA 12 ENGE uiv p eo eee 14 Engine Removal 14 Engine Installation 16 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 SERIES Groundsmaster 7200 7210 Page 3 1 Chapter 3 Kubota Diesel Engine Kubota Diesel Engine o 2 eu z3 2 Specifications Groundsmaster 7200 Item Description Make Designation Kubota D1105 E2B 4 stroke Liquid Cooled OHV Diesel Number of Cylinders Bore x Stroke 3 07 x 3 09 78 mm x 78 4 mm Total Displacement 68 53 in 1123 cc Compression Ratio 22 0 1
177. mesh Ul ACCUMULATOR 2250 rpm PTO CLUTCH PTO baat pang Groundsmaster 7200 7210 Page 8 3 3 4 16 UNF PORT ile RELIEF VALVES 4000 PSI 276 bar a Groundsmaster 7200 7210 Hydraulic Schematic With Rear Attach Lift Kit Installed All solenoids are _ shown as de energized Page 8 4 LIFT CYLINDER 17 LA PB T REAR ATTACHMENT LIFT CYLINDER OPT REAR HYDRAULIC POWERED ATTACHMENT OPT PTO pressure test port il Standard Deck Lift FORWARD r 2 Summer mode REAR laj RH WHEEL MOTOR ayo Q 300 to 310 cc BYPASS fal LSHT e VALVE HS ji Ni FRONT PORT E ia O X CHARGE PRESSURE Pale TEST PORT OIL I COOLER 3 4 16 UNF B7 TAE I8cc rev Port 2 3 4 16 UNF Port L m PRESSURE VALVE FORWARD FRONT L Q LU Sp TEST PORT LH WHEE
178. mission is faulty PTO operation would also be affected See Trans mission Service in the Service and Repairs section 12 A dynamic charge pressure test can be performed as follows A With hydraulic pressure gauge still connected sit in the operator seat and move the traction levers to forward B While machine is moving monitor the charge pressure reading on the pressure gauge C The charge pressure should drop no more than 1596 from initial test reading Step 10 above as the machine is moving e g if initial charge pressure was 100 PSI 6 9 bar charge pressure while machine is moving should be above 85 PSI 5 9 bar 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 drops below specification when under traction load the transmission piston pump s should be sus pected of wear or damage When a pump is worn or damaged the charge pump is not able to keep up with internal leakage in the traction circuit 13 Stop machine and shut off engine 14 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Remove pressure gauge from transmission charge pressure test port Install plug into port and torque plug from 13 to 15 ft lb 17 7 to 21 5 N m SAN il TA cs Saip
179. n the machine will steer toward the weaker side of the traction system Be cause piston pump swash plate is controlled by traction control lever movement if one lever rotates its swash plate more than the other lever the machine will not track in a straight line 2 Drive the machine up a moderate incline stop the engine place the traction control levers in the neutral locked position and allow the transmission to hold the machine in place parking brake not applied The ma chine should remain stationary on the incline or drift slowly backwards in a straight line If one of the trans mission traction circuits is faulty the machine will roll backwards toward the weaker traction circuit Groundsmaster 7200 7210 Page 4 25 3 Wheel speed should be the same on both rear wheels Make sure hydraulic oil is at normal operating temperature With machine jacked up off the ground and securely supported with jack stands have an operator in the seat move the traction control levers to the full for ward speed Using a phototac check the rotational speed of both rear wheels The wheel speed should be from 190 to 200 RPM for both rear wheels 4 If any of these operation tests suggest a traction sys tem problem check the following before performing hy draulic tests A Parking brake is dragging B Traction control lever is not adjusted correctly C Transmission bypass valve is not seated D Check oil level in the hydraulic tank
180. nd bushing threads with grease to prevent dirt from packing into crevices 5 Position gearbox assembly with drive pulley at tached to deck 6 Position and secure left side gearbox bracket item 12 to deck mounting plate 7 Secure gearbox assembly to gearbox brackets with four 4 cap screws item 10 and lock washers item 11 8 Connect PTO drive shaft to gearbox see PTO Drive Shaft Installation 9 Install drive belt and deck covers to cutting deck 10 Torque plug in gearbox to 175 in Ib 19 8 N m Fill gearbox with lubricant 11 Lower the footrest Figure 16 1 Set screw installation position 2 Set screw removal position 175 in Ib 175 in Ib 19 8 N m Figure 17 1 Oil cap 4 Gearbox 2 Dipstick 5 Oil seal 3 Oil cap 6 Plug Groundsmaster 7200 7210 Page 7 15 Cutting Deck Cutting Deck Pull Links Figure 18 1 LH lift arm 8 Lock nut 15 Pull link assembly 2 Retainer pin 9 Cap screw 16 Bushing 3 Clevis pin 10 Pivot pin 17 Cap screw 4 Shoulder screw 11 Ring pin 18 Cutting deck 5 LH lift arm 12 Grease fitting 19 Flange nut 6 Flange bushing 13 Spacer 20 Jam nut 7 Grease fitting 14 Torsion spring 21 Adjustment clevis Cutting Deck Page 7 16 Groundsmaster 7200 7210 Disassembly Figs 18 and 19 1 Remove cutting deck from machine see Cutting Deck Removal and Installation in this section Be careful when removing the pull links from the cutting deck T
181. nd components left open or exposed to prevent contamination Cap the opening as soon as line or port is exposed After Repair or Replacement of Components 1 Check oil level in the hydraulic tank and add correct oil if necessary Use only hydraulic fluids specified in Op erator s Manual Drain and refill hydraulic tank and change oil filter if component failure was severe or sys tem is contaminated see Flush Hydraulic System in this section 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see General Information sec tion 5 After repairs check control linkages or cables for proper adjustment binding or broken parts 6 After disconnecting or replacing any hydraulic com ponents operate machine functions slowly until air is out of system see Charge Hydraulic System in this sec tion 7 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in hydraulic tank and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mounting supports wear loose fittings weather deterioration and chemical deterioration Make any necessary repairs before operating equipment Hydraulic System 9
182. ne coolant temperature These switch circuits are the high temperature warning circuit and the high temperature shutdown circuit The dual temperature switch is attached to the engine water pump housing Fig 31 When engine coolant temperature rises to approximate ly 220 F 105 C the high temperature warning circuit closes This closed circuit causes the High Temperature Warning Light on the console to illuminate and also pro vides an input to the Standard Control Module SCM This input causes the SCM high temperature warning LED to illuminate and the PTO implement to shut down If engine coolant temperature rises to approximately 240 F 115 C the high temperature shutdown circuit closes and provides an input to the Standard Control Module SCM This input causes the SCM high temper ature shutdown LED to illuminate and the engine to shut down The Standard Control Module SCM monitors the op eration of the dual temperature switch If excessive cool ant temperature causes either switch circuit to close the appropriate LED on the SCM will be illuminated The switch and its circuit wiring should be tested using the SCM before performing the following testing procedure Testing 1 Park machine on a level surface lower implement stop engine apply parking brake and remove key from ignition switch Open hood to gain access to engine Make sure engine is cool before removing the dual temperature switch from engine Do
183. nergize as long as the switch is held in START The console glow plug indicator light will not light 3 When the ignition switch is released from the START to the ON position the glow plugs will de energize and the console glow plug indicator light will remain off Controller Checks 1 Make sure there is power from the battery 2 Disconnect the wire harness electrical connector from the engine fuel stop solenoid to prevent the engine from starting 3 Place ignition switch in the ON position Verify the fol lowing while in the ON position A Glow plug indicator light is on B Glow relay is energized C Glow plugs are energized D Glow plug indicator light goes out and glow plugs de energize after approximately 10 seconds 4 Place ignition switch in the START position Verify the following while in the START position A Glow plug indicator light is out B Glow relay is energized C Glow plugs are energized D Power exists at terminal 1 of the glow controller NOTE If there is no power to terminal 1 of the glow con troller verify continuity of the circuitry from the ignition switch to the controller and perform Step 4 again see Chapter 8 Foldout Diagrams Groundsmaster 7200 7210 Page 5 27 5 If any of the conditions in Step 3 are not met or power to terminal 1 exists and any of the other conditions in Step 4 are not met A Verify continuity of the circuitry from the battery to the glow r
184. ng the operation general maintenance procedures and maintenance intervals for your Groundsmaster ma chine Refer to that publication for additional information when servicing the machine Stopping the Engine Groundsmaster 7210 IMPORTANT The engine used on the Groundsmas ter 7210 is turbo charged Before stopping the en gine after mowing or full load operation on Groundsmaster 7210 machines cool the turbo charger by allowing the engine to idle at low speed for 5 minutes Failure to do so may lead to turbo charger trouble Kubota Diesel Engine Page 3 4 Service and repair parts for Kubota engines are sup plied through your Authorized Toro Distributor If no parts list is available be prepared to provide your distrib utor with the Toro equipment model and serial numbers as well as the Kubota engine model and serial numbers Groundsmaster 7200 7210 Adjustments Adjust Throttle Control Proper throttle operation is dependent upon proper ad justment of throttle control Make sure throttle control is operating properly 1 Move remote throttle control lever to FAST position 2 Check position of speed control lever on engine fuel injection pump Speed control lever should be contact ing high speed screw when throttle control lever is in FAST detent position Fig 1 3 lf necessary position of throttle control cable jam nuts can be adjusted until speed control lever contacts high speed screw when throttle contr
185. ni Nozzle DNOPD Fuel Tank Capacity 11 5 U S Gallons 43 5 Liters Governor Centrifugal Mechanical Low Idle Speed no load 1500 to 1650 RPM High Idle Speed no load 3200 to 3250 RPM Engine Oil API Classification CH 4 CI 4 or Higher see Operator s Manual for viscosity recommendations Oil Pump Gear Driven Trochoid Type Crankcase Oil Capacity 4 0 U S Quarts 3 8 Liters with Filter Cooling System Capacity including reserve tank 6 U S Quarts 7 5 Liters Starter 12 VDC 1 4 KW Alternator 12 VDC 40 Amp with Internal Regulator Groundsmaster 7200 7210 Page 3 3 Kubota Diesel Engine o 22 eu z3 E General Information This Chapter gives information about specifications troubleshooting testing and repair of the Kubota D1105 diesel engine used in the Groundsmaster 7200 and 7210 Refer to the Operator s Manual for engine mainte nance information Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kubota Workshop Manual Diesel Engine 05 Series included at the end of this chapter The use of some specialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Operator s Manual The Operator s Manual provides information regardi
186. not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot coolant can es cape and cause burns 2 Lower the coolant level in the engine and remove the dual temperature switch from the engine 3 Put the end of the switch in a container of oil with a thermometer and slowly heat the oil Fig 32 Handle the hot oil with extreme care to prevent personal injury or fire Electrical System Page 5 24 4 Check resistance of the switch with a multimeter ohms setting as the oil temperature increases A The high temperature warning circuit is normally open and should close from 214 to 226 F 101 to 108 C B The high temperature shutdown circuit is normal ly open and should close from 234 to 246 F 112 to 119 C 5 Replace the switch if either of the specifications are not met 6 After testing is complete install temperature switch to the engine housing A Clean threads of housing and switch thoroughly Apply thread sealant to the threads of the switch B Thread switch into the housing Torque switch from 22 to 28 ft Ib 29 4 to 39 2 N m C Reconnect harness wires to temperature switch 7 Fill engine cooling system Lower and secure hood Figure 31 1 Dual temp switch 3 Shutdown circuit 2 Warning circuit Figure 32 Groundsmaster 7200 7210 Fuel Pump The fuel pump is attached to the frame near the fuel filter Fig 33 The
187. nt If the engine is started and the PTO shaft is al lowed to rotate serious personal injury and machine damage could result If the PTO drive shaft is disconnected from the cutting deck or implement remove fuse F1 15 amp from fuse block to prevent unintentional engagement of the PTO clutch Chassis Page 6 18 Groundsmaster 7200 7210 Removal Fig 18 NOTE PTO drive shaft removal is easier if machine is positioned on a hoist 1 Park machine on a level surface lower cutting deck or implement to lowest setting stop engine engage parking brake and remove key from the ignition switch 2 To prevent unintentional engagement of the PTO clutch remove fuse F1 15 amp from fuse block 3 Disconnect end yoke of PTO drive shaft from PTO shaft on transmission A Remove roll pin from end yoke and PTO shaft B Loosen two 2 cap screws and lock nuts C Slide drive shaft end yoke from PTO shaft 4 Disconnect end yoke of PTO drive shaft from cutting deck gearbox shaft A Remove roll pin from end yoke and gearbox shaft B Loosen two 2 cap screws and lock nuts C Slide drive shaft end yoke from gearbox shaft 5 Remove PTO drive shaft from machine Installation Fig 18 1 Position PTO drive shaft to machine Make sure that drive shaft slip shaft yoke item 4 in Fig 19 is toward cutting deck gearbox shaft 2 Align splines and roll pin holes of drive shaft yokes with transmission and gearbox shafts
188. nter wheel to machine with five 5 lug nuts 4 Lower the front of the machine to the ground NOTE When securing bogey pivot to front frame it may be necessary to raise rear of machine to allow installation of flat washer and lock nut 5 Install flat washer item 14 and then lock nut item 13 to stud on bogey pivot Secure pivot to front frame by torquing lock nut to 75 ft lb 102 N m 6 Place side access cover to frame and secure with two 2 screws 7 Fully lower machine to the ground Torque all wheel lug nuts in a crossing pattern from 65 to 85 ft Ib 88 to 115 N m Figure 3 2 Lock nut flat washer 1 Side access cover Chassis Parking Brakes Loctite 4271 35 to 40 ft lb 48 to 54 N m 300 to 400 ft lb 407 to 502 N m Loctite 271 75 to 85 ft lb 102 to 115 xu M MR 2 Figure 4 1 Lock nut 9 O ring 16 Flange nut 4 used per side 2 Lug nut 5 used per wheel 10 Hydraulic fitting 17 Cap screw 2 used per side 3 Wheel assembly 11 O ring 18 Cap screw 2 used per side 4 Wheel hub 12 Hydraulic fitting 19 Brake support 5 Wheel stud 5 used per wheel 13 Hydraulic hose 20 Brake rod assembly 6 Socket head screw 4 used 14 Hydraulic hose 21 Flat washer 7 Wheel motor LH shown 15 Parking brake LH shown 22 Retaining ring 8 Woodruff key Removal Fig 4 1 Park machine on a level surface lower cutting deck or implement stop engine and remove key from
189. nto tank and torque from 60 to 66 ft lb 82 to 90 N m 2 Attach removed fittings with new lubricated O rings to hydraulic tank using Figure 29 as a guide see Hy draulic Fitting Installation in the General Information section of this chapter Tighten fittings to torque values identified in Figure 29 3 Position hydraulic tank to machine Secure tank to frame with tank support and two 2 washer head Screws 4 Remove plugs that were installed to hydraulic hoses and fittings during the removal procedure 5 Attach hydraulic hoses to fittings on hydraulic tank using labels placed during removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Install brake handle to machine see Parking Brake Assembly in the Service and Repairs section of Chapter 6 Chassis Make sure that parking brake switch op eration is correct after brake handle is installed 7 Secure front cover to machine Fig 30 8 Fill hydraulic tank with new hydraulic fluid 9 Install operator seat and seat base see Operator Seat Installation in the Service and Repair section of Chapter 6 Chassis 10 Operate machine Check hydraulic oil level and ad just if necessary Check hydraulic components for leaks Tighten any loose connections 2 E s L3 E 1 Screw 3 used 3 Frame 2 Front cover 4 Foam strip 3 used
190. ntrol arm 2 used 61 Push rod 3 used 10 Charge pump assembly 36 Socket head screw 2 used 62 PTO shaft 11 Key 37 Bearing 3 used 63 Seal ring 4 used 12 O ring 5 used 38 O ring 2 used 64 RH pump shaft 13 Piston 39 Socket head plug 2 used 65 LH pump shaft 14 Spring 40 O ring 8 used 66 Pump gear 2 used 15 Collar 41 Hex plug 8 used 67 Gasket 16 Bolt and washer 2 used 42 Pipe assembly 68 Gear case housing 17 Accumulator cover 43 Seal 2 used 69 Flange head screw 13 used 18 Gasket 44 Washer 2 used 70 Pipe assembly 19 Filter bypass valve assembly 45 LH flushing valve 71 Spacer 20 Hex drain plug 46 Reverse relief valve 2 used 72 Input gear 21 Charge relief valve assembly 47 Forward relief valve 2 used 73 PTO gear 22 Pressure valve assembly 48 Socket head screw 8 used 74 Input shaft 23 Socket head plug 4 used 49 RH flushing valve 75 Retaining ring 24 Filter adapter 50 Bypass valve 2 used 76 Clutch assembly 25 Oil filter 51 Center case 77 O ring 26 Retaining ring 4 used 52 Pin 4 used 78 Key IMPORTANT If a transmission failure occurred re fer to Traction Circuit Closed Loop Component Failure in the General Information section for infor mation regarding the importance of removing con tamination from the traction circuit 9 s O a Y oP Transmission Disassembly Fig 39 1 Thoroughly clean exterior of transmission 2 Remove nut lock
191. o Ww y x z z m zz zOx uxo gt Ze 5 O FS 09 z6 s SERE TEE 8 3 s 5 35 ES a VIOLET na Eg 232858 og am a y BLACK n uj HI BROWN mi GREEN 1 303 LOW OIL z PRESSURE Heese 1 P2 STARTER A Y Zei GROUND 309 M BLACK Tpos SP05 BLACK ENGINE os Ik BLACK ac SP10 GROUND SPO9 FUSIBLE LINK P03 STARTER voi PULL SP03 WHITE Ka P08 FUEL RED BLACK 4 e SOLENOID H PINK HOLD HOUR cal METER C 3 BLACK RED BLACK 3 FUEL BLACK 42 PUM PINK PINK Na cit Rese x fal 16 WARNING SP01 al P LIGHTS Y 26 PINK A2 pas A 3g WHITE tag ALT L B 4 ORANGE N IGNITION 9 TAN z or SWITCH YELLOW 15 WARNING P24 LIGHTS P31 ie YELLOW PINK 2A q GLOW SP08 SP07 RED STARTER Pod RED EN RED ul E 9 3 Ko t s 3 3 dis i n lt z gt o 3 z gt 5 a m a m oa ie 1 1 3 it TOECSONONOS A NT m J28 J02 POS 30 85 87A 87 86 J04 ag 2 BLOCK l OPTIONS Roi JD n B RELAY P20 a ALTERNATOR GLOW GLOW MM P Groundsmaster 7200 7210 RELAY LUGS CONTROLLER Wire Harness Diagram Page 8 14
192. o 2 flange head screws that secure fuel water separator bracket to engine Remove bracket and separator from engine 16 Remove six 6 flange head screws and two 2 sock et head screws securing the flywheel housing to engine 17 Remove lock nut snubbing washer and cap screw that secures each side of engine to the engine mounts attached to the frame Groundsmaster 7200 7210 Page 3 15 Figure 10 3 Flange screw 6 used 4 Clip 6 used 1 Machine frame 2 Rear panel Figure 11 4 Fuel hose from pump 5 Ground connections 1 Fuel water separator 2 Fuel supply hose 3 Fuel stop solenoid Figure 12 3 Return fuel hose 1 Glow plug wire 2 Front injector nozzle Kubota Diesel Engine s3 Su a Co o0 2 a IMPORTANT Make sure to not damage the engine flywheel housing fuel hoses hydraulic lines elec trical harness or other parts while removing engine Also make sure that transmission does not shift during engine removal One person should operate lift or hoist while a second person guides the engine assembly out of the machine 18 Move engine toward the rear ofthe machine to sepa rate it from the transmission input shaft and flywheel housing Carefully raise engine from the machine 19 Locate and retrieve two 2 dowel pins that locate fly wheel housing to engine 20 If necessary remove six 6 cap screws that secure flywheel coupling to engine flywheel and remov
193. ol lever is at FAST detent position Fig 2 4 Make sure that cable jam nuts are fully tightened af ter adjustment Mon IN J i KO s o ng y FA ZG a WWW 9 MAII 1420222022011 yyy 7 Figure 1 1 Throttle cable 3 Speed control lever 2 High speed screw Figure 2 1 Throttle cable 2 Cable jam nuts Groundsmaster 7200 7210 Page 3 5 Kubota Diesel Engine E s gt Su e o X Y 2 a Service and Repairs Air Cleaner Assembly Figure 3 1 Hose clamp 5 Cap screw 2 used 8 Frame 2 Inlet hose GM 7200 shown 6 Air inlet hose 9 Cap screw 2 used 3 Hose clamp 7 Air cleaner support 10 Air cleaner assembly 4 Flange nut 4 used Kubota Diesel Engine Page 3 6 Groundsmaster 7200 7210 Removal Fig 3 NOTE See Operator s Manual for air cleaner mainte nance procedures and intervals 1 Park machine on a level surface lower cutting unit or implement stop engine engage parking brake and remove key from the ignition switch 2 Unlatch and raise hood 3 Remove air cleaner components as needed using Figures 3 and 4 as guides 4 Check air cleaner housing and cover for damage that could cause possible air leaks 5 Check air inlet hoses for damage or wear Installation Fig 3 IMPORTANT Any leaks in the air filter system will allow dirt into engine and will cause serious engine damage Make sure that all air cleaner components are in good condition and are prope
194. olant temperature reaches 220 F 105 C approximate To test the high temperature warning light and circuit wir ing turn ignition switch to the ON position and ground the yellow wire attached to high temperature warning switch located on the engine water pump housing see High Temperature Warning Switch in this Chapter The high temperature warning light should illuminate Glow Plug Indicator Light The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START The light should stay lit for approximately 10 seconds while the ignition switch is left in the ON position Testing Indicator Lights 1 Apply 12 VDC to terminals 1A and 2A Fig 9 2 Ground terminals 1B and 2B Fig 9 3 Both indicator lights should illuminate Figure 8 1 Glow plug indicator light 3 2 High temp warning light 4 1 Glow plug indicator 2 High temperature 3 Engine oil pressure Groundsmaster 7200 7210 Page 5 11 Oil pressure light Charge indicator light Figure 9 4 5 6 Charge indicator Indicator light front Indicator light back Electrical System E e o D lu g 2 ra E c Hour Meter 1 Make sure ignition switch is in the OFF position Lo cate the hour meter and disconnect the wire harness electrical connector from the meter 2 Connect the positive terminal of a 12 VDC source to the
195. on a level surface with the cutting deck or implement lowered and off Make sure engine is off and the parking brake is engaged 4 Read Precautions for Hydraulic Testing listed at the beginning of this section 5 Thoroughly clean junction of hydraulic hose and low er fitting on rear of lift control valve Fig 22 6 Disconnect hydraulic hose from lower fitting on rear of lift control valve Fig 22 This hose is from the gear pump outlet and provides oil flow to the lift control valve Fig 23 NOTE Implement relief pressure can also be tested with hydraulic tester pressure and flow Connect tester in series with the lift control valve fitting and the discon nected hose Use pressure gauges on hydraulic tester and follow procedure below 7 Install T connector with hydraulic pressure gauge 5000 PSI 345 bar in series with the lift control valve fitting and the disconnected hose 8 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test 9 With engine running move throttle to full speed 3200 RPM IMPORTANT Hold lift lever in the raise position only long enough to get a system pressure reading Holding the lift lever in the raise position for an ex tended period may damage the lift control valve 10 Watch pressure gauge carefully while moving lift le ver to the raise position and holding Groundsmaster 7200
196. on machine i e do not put RH motor on left side of machine If necessary use parts catalog and part number on wheel motor to identify RH and LH mo tors 1 Position wheel motor to frame Make sure that ports in wheel motor are facing up 2 Clean threads in frame and on socket head screws 3 Apply Loctite 271 or equivalent to threads of sock et head screws Secure wheel motor to frame with four 4 socket head screws Groundsmaster 7200 7210 Page 4 49 4 Remove plugs from disconnected hydraulic hoses and wheel motor ports 5 Lubricate and install new O rings to hydraulic fit tings Install fittings into wheel motor ports see Hydrau lic Fitting Installation in the General Information section of this chapter Make sure that fittings are orientated correctly 6 Using labels placed during the removal process properly connect hydraulic hoses to wheel motor fittings see Hydraulic Hose and Tube Installation in the Gener al Information section of this chapter 7 Make sure that tapers of wheel motor shaft and wheel hub are thoroughly clean 8 Position woodruff key to keyslot in wheel motor shaft 9 Place wheel hub on motor shaft and secure with lock nut 10 Install brake assembly and wheel assembly to the machine Make sure that proper clearance exists be tween brake assembly and wheel hub rotor see Wheel Installation and Brake Installation in the Service and Re pairs section of Chapter 6 Chassis
197. on spring saddle on spring arm and slide down Hook spring ends on top of suspension base 4 Using the suspension base as a pry point place a prybar on the top of the spring saddle and push saddle down to elongate springs enough to allow installation of the bolt to the top of shock absorber and suspension base Secure bolt in position with nut Groundsmaster 7200 7210 Page 6 27 5 Position seat frame to suspension base 6 Align bearing blocks on frame with receivers on sus pension base and guide frame into place Insert two 2 bearing shafts and split nylon bushings to suspension base and frame Secure bearing shafts with two 2 roll pins 7 Position cables under the seat frame bars and on top of suspension base Insert cable ends in spring saddle slots 8 Pass weight adjustment knob shaft through weight indicator washer and seat frame hole Thread knob shaft into weight adjust bar Install hex nut on knob shaft 9 Position seat boot to seat frame and secure with eighteen 18 x mas tree clips 10 Position bottom cushion to seat frame and secure with two 2 cap screws 11 Position back cushion to seat frame and secure with six 6 x mas tree clips 12 Assemble back rest knob to seat and secure with nut Apply label to knob 13 Assemble back panel and then armrest assemblies to seat 14 Install operator seat on machine see Operator Seat Installation in this section Figure 30 3 Lumbar supp
198. ort knob 4 Seat position lever _ Back rest knob 2 Seat suspension knob Chassis Hood 35 to 45 in Ib 4 0 to 5 1 N m Figure 31 1 Hood 8 Hood prop rod 15 Hood support 2 Flat washer 4 used 9 Cotter pin 16 Prop rod support 3 Rubber latch 2 used 10 Screw 21 used 17 Bulb seal 4 Grommet 11 Lock nut 21 used 18 Flange head screw 8 used 5 Washer head screw 2 used 12 Cap screw 3 used 19 Flange nut 11 used 6 Hair pin cotter 13 Latch catch 2 used 20 Foam seal 2 used 7 Intake screen 14 Seal angle 21 Bulb seal Chassis Page 6 28 Groundsmaster 7200 7210 Removal Fig 31 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Unlatch and raise hood 3 Remove hair pin cotter item 6 from left side frame rod 4 Slide hood to left side of machine to free hood sup port from frame rods 5 Remove hood from machine 6 If necessary remove hood components using Figure 31 as a guide Groundsmaster 7200 7210 Page 6 29 Installation Fig 31 1 Install all removed hood components using Figure 31 as a guide If intake screen was removed from hood make sure that hood support seal angle and prop rod support are attached to hood before installing screen Secure screen to hood with screws and lock nuts Torque fasteners that secure screen from 35 to 45 in Ib 4 0 to 5 1 N m
199. ose B Do not remove machine fuel tank cap while en gine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill E Replace fuel tank and fuel container caps secure ly after refueling machine F If fuel is spilled do not attempt to start the engine but move the machine away from the area of the spill age Avoid creating any source of ignition until fuel vapors have dissipated Wipe up any spilled fuel 4 Do not touch engine radiator or exhaust system while engine is running or soon after it is stopped These areas could be hot enough to cause burns 5 Before getting off the seat A Ensure that both drive handles are in the neutral lock position B Lower and disengage cutting deck or imple ment and wait for all movement to stop C Set parking brake D Stop engine and remove key from ignition switch 6 Anytime the machine is parked short or long term the cutting deck or implement should be lowered to the ground This relieves pressure from the lift circuit and eliminates the risk of the cutting deck or implement ac cidentally lowering to the ground 7 Do not park on slopes unless wheels are chocked or blocked Groundsmaster 7200 7210 Maintenance and Service 1 Before servicing or making adjustments lower cut ting deck or implement stop engine set parking brake and remove
200. oses to drain into a suitable container Install clean plugs in hose openings to prevent system contamination 5 Remove cotter pin that secures lift lever valve link to control valve spool Fig 100 Slide link from spool 6 Support the control valve to prevent it from falling during removal 7 Remove two 2 cap screws lock washers and flat washers that secure lift control valve to machine Fig 100 Remove control valve 8 If necessary remove hydraulic fittings from lift con trol valve Note orientation of fittings for assembly pur poses Remove and discard O rings from fittings Groundsmaster 7200 7210 Page 4 85 Installation Fig 99 1 If hydraulic fittings were removed from lift control valve lubricate and install new O rings to fittings Install fittings into valve ports see Hydraulic Fitting Installation in the General Information section of this chapter Orientate fittings as noted during removal 2 Position lift control valve to machine frame and se cure with two 2 cap screws lock washers and flat washers Fig 100 3 Attach lift lever valve link to control valve spool and secure with cotter pin Fig 100 4 Remove plugs that were installed in hydraulic hoses during the removal procedure Attach hydraulic hoses to fittings on lift control valve using labels placed during re moval see Hydraulic Hose and Tube Installation in the General Information section of this chapter 5 Make sure h
201. osition The radiator and oil cooler may be hot To avoid possible burns allow the engine and cooling systems to cool before working on the oil cooler 3 Thoroughly clean hydraulic hose ends and oil cooler fittings to prevent hydraulic system contamination La bel hydraulic hoses for assembly purposes 4 Remove hydraulic hoses from oil cooler Install clean plugs in hose openings to prevent contamination Re move and discard O rings from oil cooler fittings 5 Rotate clamp and tilt oil cooler from radiator frame Slide left side of oil cooler from radiator frame by aligning roll pin in cooler mount with slot in radiator frame Then remove right side of cooler from radiator frame Inspection 1 Back flush oil cooler with cleaning solvent Make sure all solvent is drained from the cooler Use eye protection such as goggles when using compressed air to dry oil cooler 2 Dry inside of oil cooler using compressed air in the opposite direction of the oil flow 3 Install clean plugs on oil cooler ports Thoroughly clean exterior of cooler 4 The oil cooler should be free of corrosion cracked 2 Lubricate and place new O rings in oil cooler ports Remove plugs from hydraulic hoses Connect hydraulic hoses to oil cooler using labels placed during removal see Hydraulic Hose and Tube Installation in the Gener al Information section of this chapter 3 Make sure hydraulic tank is full Add correct oil if nec essary
202. otection from in ductive voltage spikes when the PTO clutch is de ener gized The diode plugs into the wiring harness under the operator seat Testing The diode Fig 24 can be tested using a digital multime ter diode test or ohms setting and the table below Multimeter Multimeter Red Lead Black Lead Continuity Figure 24 T inal T inal 1 Diode 3 Female terminal on lermina on lermina 2 Male terminal nme we x ru ceu cw Electrical System Page 5 20 Groundsmaster 7200 7210 Glow Relay The glow relay used on the Groundsmaster 7200 and 7210 allows electrical current to the engine glow plugs when energized The glow relay is attached to the frame in the engine compartment The glow relay is energized by the glow controller when the ignition switch is initially turned to ON PREHEAT and also when the ignition switch is turned to START Testing 1 Raise and support hood 2 Make sure ignition switch is in the OFF position Dis connect wire harness electrical connector from glow relay Figure 25 NOTE Prior to taking small resistance readings with a 1 Glow relay 2 Engine digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 3 Veri
203. oughly Apply thread sealant to the threads of the switch B Thread warning switch into the housing Torque switch from 16 to 20 ft lb 21 7 to 27 1 N m C Reconnect harness wire connector to warning switch 6 Fill engine cooling system 7 Lower and secure hood Figure 27 1 High temperature warning switch Figure 28 Groundsmaster 7200 7210 High Temperature Shutdown Switch The high temperature shutdown switch is located on the water pump housing Fig 29 The high temperature shutdown switch is normally open and closes when en gine coolant temperature reaches approximately 240 F 115 C When excessive engine coolant temperature causes the shutdown switch to close the engine shuts down There is a blue white wire attached to the shut down switch The Standard Control Module SCM monitors the op eration of the high temperature shutdown switch If ex cessive engine coolant temperature causes the high temperature shutdown switch to close the High Tem perature Shutdown LED on the SCM will be illuminated The switch and its circuit wiring should be tested using the SCM before performing the following testing proce dure Testing 1 Park machine on a level surface lower cutting deck or implement stop engine apply parking brake and re move key from ignition switch Open hood to gain ac cess to engine Make sure engine is cool before removing the high temperature shutdown s
204. ould be illuminated when the ignition key switch is in the ON position The Power input LED should also be illuminated when the ignition key switch is in the START position The Start input LED should be illuminated when the igni tion key switch is in the START position The Neutral input LED should be illuminated when both traction control levers are in the neutral locked position The Parking Brake Off input LED should be illuminated when the parking brake is not applied 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 high temperature shut down switch closes due to engine coolant temperature of 240 F 115 C approximate The High Temperature Warning input LED should be il luminated when the engine high temperature warning switch closes due to engine coolant temperature of 220 F 105 C approximate The Backlap input LED is not used on the Groundsmas ter 7200 7210 Groundsmaster 7200 7210 Page 5 17 SCM Outputs Fig 21 The Start output LED should be illuminated when the ignition key switch is in the START position with the trac tion control levers both in the neutral locked position the PTO switch OFF and either the seat occupied or parking brake engaged The Run output LED should be illuminated when
205. ould possibly dam age the oil seals Lubricate the shaft and spacer with grease 8 Install spindle shaft spacer onto shaft Place thin sleeve or tape on spindle shaft splines to prevent seal damage during shaft installation 9 Carefully slide spindle shaft with spacer up through spindle housing The bottom oil seal and spindle spacer fit together when the spindle is fully installed 10 Install O ring to top of spindle shaft Fig 14 NOTE Early production spindle assemblies included a V ring seal which has been found to be unnecessary Do not install a v ring seal when assembling the spindle 11 Install pulley hub down special hardened washer and lock nut to spindle shaft Fig 14 Tighten lock nut from 130 to 150 ft lb 176 to 203 N m IMPORTANT Pneumatic grease guns can produce high pressure inside spindle housing that can dam age spindle seals Pneumatic grease guns there fore are not recommended to be used for greasing of spindle housings 12 Attach a hand pump grease gun to grease fitting on housing and fill housing cavity with grease until grease starts to come out of lower seal 13 Rotate spindle shaft to make sure that it turns freely 1 Bearing cup 4 Arbor press 2 Large snap ring 5 Support 3 Outer spacer 6 Arbor press base Figure 13 1 Bottom seal installation 2 Upper seal installation
206. ove key from the ignition switch Hydraulic System Page 4 48 Groundsmaster 7200 7210 4 Remove wheel assembly and brake assembly from the machine see Wheel Removal and Brake Removal in the Service and Repairs section of Chapter 6 Chas sis IMPORTANT DO NOT hit wheel hub wheel hub puller or wheel motor with a hammer during removal or installation Hammering may cause damage to the wheel motor 5 Use appropriate puller to loosen wheel hub from wheel motor 6 Remove lock nut and loosened wheel hub from mo tor shaft Locate and retrieve woodruff key from wheel motor shaft 7 Thoroughly clean hydraulic hose ends and fittings on wheel motor to prevent hydraulic system contamination 8 Label all hydraulic hoses and fittings for assembly purposes Fig 33 Remove hydraulic hoses from fit tings on wheel motor Allow hoses to drain into a suitable container 9 Mark hydraulic fitting orientation to allow correct as sembly Remove hydraulic fittings from wheel motor Remove and discard O rings from fittings 10 Put clean plugs in disconnected hydraulic hoses and wheel motor ports to prevent system contamination 11 Support the wheel motor to prevent it from falling dur ing removal 12 Remove four 4 socket head screws that secure wheel motor to the machine 13 Remove wheel motor from frame Installation Fig 32 IMPORTANT Because of internal differences in wheel motors DO NOT interchange wheel motors
207. pairs Rear Wheels 75 to 85 ft lb 102 to 115 N m Figure 1 Socket head screw 4 used Wheel motor LH shown Woodruff key O ring 0 Hydraulic fitting Lock nut Lug nut 5 used per wheel Wheel assembly Wheel hub Wheel stud 5 used per wheel m p o ct SP PND Chassis Page 6 4 11 O ring 12 Hydraulic fitting 13 Hydraulic hose 14 Hydraulic hose 15 Parking brake LH shown Groundsmaster 7200 7210 Removal Fig 1 1 Park machine on a level surface lower cutting deck or implement stop engine and remove key from the ignition switch NOTE If machine is equipped with Polar TracTM Kit see Polar Trac Wheels in this section for information regarding wheel removal 2 Loosen but do not remove lug nuts that secure rear wheel that is to be removed Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety Do not support machine on rear wheel hubs brake ro tors 3 Jack up rear wheel and use appropriate jack stands to support the machine 4 Remove lug nuts from drive studs Remove rear wheel from machine Groundsmaster 7200 7210 Page 6 5 Installation Fig 1 1 Secure wheel to machine with five 5 lug nuts 2 Lower wheel to ground Torque wheel lug nuts in a crossing pattern from 75 to 85 ft Ib 102 to 115 N m Chassis Polar Trac Wheels Front frame Bogie assembly Lock nut Rear wheel hub LH shown Wheel as
208. placement parts and accessories Replacement parts and accessories made by other manufacturers may result in non conformance with the safety standards and the warranty may be voided 19 When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid level floor such as a concrete floor Prior to raising the machine remove any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use appropriate jack stands to support the raised machine If the machine is not properly supported by appropriate jack stands the machine may move or fall which may result in personal injury see Jacking In structions in this section Safety Jacking Instructions When changing attachments tires or performing other service use correct blocks hoists and jacks Make sure machine is parked on a solid lev el floor such as a concrete floor Prior to raising machine remove any attachments that may inter fere with the safe and proper raising of the ma chine Always chock or block wheels Use ap propriate jack stands to support the raised ma chine If the machine is not properly supported by appropriate jack stands the machine may move or fall which may result in personal injury Jacking the Front 1 Apply parking brake and chock both rear tires to pre vent the machine from moving 2 Position jack to machine
209. position Groundsmaster 7200 7210 Page 5 7 Possible Causes The operator seat is unoccupied Oil level in hydraulic tank is low The seat switch or circuit wiring is faulty Wiring to the transmission PTO solenoid valve coil is loose corroded or damaged see Chapter 8 Foldout Diagrams The transmission PTO solenoid valve coil is faulty The PTO switch is faulty Engine temperature is excessive above 220 F 105 C High temperature warning switch or circuit wiring is faulty The Standard Control Module is faulty Transmission hydraulic solenoid valve is faulty see Chapter 4 Hydraulic System PTO clutch in transmission is worn or damaged see Chapter 4 Hydraulic System Transmission pressure valve or charge pump is faulty see Chapter 4 Hydraulic System o o o E wi Electrical System Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals Set multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 38 C The ignition key should be off and all accessories turned off Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post Measure and record the bat tery voltage Use the chart at right to determine charge level of battery NOTE This test provides a relative condition of t
210. ransmis sion piston pump needs to be inspected repaired or replaced as necessary 15 If transmission piston pump flow specification is met and a traction circuit problem has been identified con sider that a wheel motor is worn or damaged see Wheel Motor Efficiency Test in this section 16 Relieve hydraulic system pressure see Relieving Hydraulic System Pressure in the General Information section Disconnect tester from transmission fitting and hose Reconnect hydraulic hose to transmission port fit ting 17 If necessary repeat flow test for other transmission piston pump Hydraulic System 2 s a z N ER ZO Traction Relief Valve Pressure Test Using Tester with Pressure Gauges and Flow Meter LIFT CYLINDER Hulu and VALVES 4000 PSI 276 bar 4000 PSI 276 bar RE SE FLUSHING VALVE FLUSHING VALVE PORT B PORT D RIGHT SIDE FORWARD TRACTION RELIEF VALVE TESTING SHOWN UNF BYPASS BYPASS Geo HYDRAULIC B TESTER FORWARD NN MOTOR g AA ce LSH LH WHEEL MOTOR A 00 to 310 RH WHEEL Figure 17 Hydraulic System Page 4 30 Groundsmaster 7200 7210 The Traction Relie
211. rating hours and every 30 days if machine is in storage 6 Maintain cell level with distilled or demineralized wa ter Do not fill cells above the fill line Electrical System E 2 o 2 Lu E 2 ra cp Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented When working with batteries use extreme cau tion to avoid splashing or spilling electrolyte Electrolyte can destroy clothing and burn skin or eyes Always wear safety goggles and a face shield when working with batteries Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size 26 540 CCA at 0 F 17 8 C Reserve Capacity of 80 minutes at 80 F 26 7 C Dimensions including terminal posts and caps Length 8 2 inches 20 8 cm Width 6 8 inches 17 3 cm Height 8 0 inches 20 3 cm Removal Fig 41 IMPORTANT Be careful to not damage terminal posts or cable connectors when removing the bat tery cables 1 Unlatch raise and support hood Loosen battery re tainer securing the side of the battery to the frame 2 Loosen nut on ground cable first and remove ground cable from battery This should prevent short cir cuiting the battery other components or the operators hands 3 Once negative cab
212. req 972 ISd 000P SINIYA 431738 r aC G MO 4 i uonong Jo unay eBieuo almsselg wo eunsseJg BUMIOM esieu uno WIT aa 0124 0024 Jasewspuno 9 VA 22 bo Page 4 12 Groundsmaster 7200 7210 Hydraulic System 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 suc tion from the hydraulic tank During conditions of not raising or lowering the cutting deck or implement flow from the gear pump is by passed by the lift control valve directly to the oil cooler and then to the transmission Flow then returns to the hydraulic tank When the lift control lever is moved to the RAISE posi tion the control valve spool is shifted This shifted spool allows hydraulic flow from the gear pump to the barrel end of the lift cylinder At the same time the pilot check valve in the lift control valve is unseated The lift cylinder extends causing the cutting deck or implement to raise The fluid displaced from the rod end of the lift cylin der is routed past the unseated pilot check valve to the oil cooler transmission and then to the hydraulic tank An orifice fitting at the barrel end of the lift cylinder con trols the extending speed of the lift cylinder while raising the cutting deck or implem
213. ring item 21 and lock out seat item 22 with O ring item 23 from valve body 8 Remove adapter plug item 14 with O ring item 15 poppet stop item 10 spring item 2 and poppet item 11 from control valve body Groundsmaster 7200 7210 9 Remove lockout seat item 22 with O ing item 23 from control valve body Remove detent plunger item 19 10 If necessary remove plug from control valve Fig 102 Note If machine is equipped with optional rear lift kit a fitting and sleeve will be installed in place of plug Inspection 1 Inspect spool and spool bore for wear If wear is ex cessive replace lift control valve assembly 2 Inspect all springs and replace if damaged or broken 3 Inspect detent plunger detent ball and poppet for wear Replace as necessary 4 Inspect lockout seats for wear or damage Replace as necessary 5 Inspect control valve housing threads and O ring sealing surfaces Replace as necessary 6 Inspect threads and O ring sealing surfaces on plugs Replace as necessary Assembly Fig 101 IMPORTANT Do not wipe parts with dry paper tow els or rags Lint may cause damage to the hydraulic system 4h caution Use eye protection such as goggles when using compressed air 1 Clean all control valve components with clean sol vent and blow dry with compressed air 2 Replace all removed O rings Lightly lubricate new O rings with clean hydraulic oil before assembly
214. ring from PTO shaft Discard bearing 40 Slide three 3 rods from holes in clutch assembly 41 Slide PTO gear assembly from clutch assembly NOTE Because individual clutch components are not available disassembly of the clutch assembly is not necessary Figure 60 1 Bearing 4 Gear 2 PTO shaft 5 Clutch assembly 3 Spacer 6 Key 2 r L3 cs gt lt Figure 61 1 Seal ring 2 used 5 A plate 3 used 2 PTO shaft 6 Friction plate 3 used 3 B plate 7 Bearing 4 C plate Figure 62 1 Rod 3 used 3 PTO gear 2 Clutch assembly Groundsmaster 7200 7210 Page 4 65 Hydraulic System 42 If necessary remove two 2 bearings from PTO gear Discard removed bearings Remove retaining ring from groove in PTO gear bore Figure 63 1 Bearing 3 Retaining ring 2 PTO gear 43 Remove two 2 plugs from transmission pump housing Remove and discard O rings from plugs Figure 64 1 Socket head plug 3 Pump housing 2 Hex plug 44 Remove three 3 socket head screws that secure both side covers to transmission pump housing 45 Carefully slide side covers from trunnion shafts and housing Remove and discard O rings from side cov ers 46 Remove retaining rings that secure oil seals into both side covers Remove oil seals from side covers Discard seals Figure 65 1 Side cover 4 Retaining ring 2 O ring 5 Oil seal 3 Pump housing Hydraulic System Page 4 66 Groundsmaster 7200
215. ring that secures lift cylinder barrel end to pin on carrier frame 6 Remove flange head screw and pivot pin that secure lift cylinder rod end to RH lift arm Fig 107 7 Remove lift cylinder from machine 8 If necessary remove hydraulic fittings from lift cylin der Remove and discard O rings from fittings Note that fitting on barrel end of cylinder is an orifice fitting that is different than fitting on rod end of cylinder Installation Fig 106 1 If hydraulic fittings were removed from lift cylinder lu bricate and install new O rings to fittings Install fittings into lift cylinder ports and torque fittings from 15 to 19 ft Ib 20 to 25 N m Make sure that fitting on barrel end of cylinder is the orifice fitting 2 Position lift cylinder to the machine 3 Secure cylinder barrel end to pin on carrier frame with retaining ring 4 Secure cylinder rod end to RH lift arm with pivot pin and flange head screw Fig 107 Groundsmaster 7200 7210 Page 4 93 5 Remove plugs that were installed in hydraulic hoses during the removal procedure Correctly connect hy draulic hoses to lift cylinder fittings using labels placed during lift cylinder removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 6 Lubricate grease fittings on lift cylinder and pivot pin 7 Make sure hydraulic tank is full Add correct oil if nec essary Figure 107 1 Lift cylinder 2
216. rly secured dur ing assembly 1 Assemble air cleaner system using Figures 3 and 4 as guides A Make sure that vacuator valve is pointed down af ter assembly Fig 4 B Make sure that inlet hose item 2 has clearance around it at all points after air cleaner installation is completed C Ifindicator and nipple were removed from hous ing apply sealant to threads of nipple before assem bly 2 Close and latch hood BON Groundsmaster 7200 7210 Page 3 7 Vacuator valve Air filter Gasket Bracket Nipple Kubota Diesel Engine E s3 Su a Co X o0 2 a Exhaust System 17 to 21 ft lb 23 to 28 N m 38 to 48 in Ib 4 3 to 5 4 N m Figure 5 1 Muffler GM 7200 shown 4 Carriage screw 2 used 6 Flange lock nut 2 used 2 Exhaust gasket 5 Muffler bracket 7 Flange nut 4 used 3 Engine GM 7200 shown Kubota Diesel Engine Page 3 8 Groundsmaster 7200 7210 Removal Fig 5 The engine and exhaust system may be hot To avoid possible burns allow the engine and ex haust system to cool before working on the ex haust system 1 Park machine on a level surface lower cutting unit or implement stop engine engage parking brake and remove key from the ignition switch 2 Unlatch and raise hood Figure 6 3 Remove two 2 carriage screws and flange lock nuts 1 Flange lock nut 3 Muffler bracket that secure the muffler to the muffler bracket F
217. rn the battery to service 60 F 50 F 9 3 40 F 30 F Installation Fig 41 IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure ignition and all accessories are OFF 2 Make sure battery compartment is clean and re painted if necessary Place battery tray in position 3 Make sure all battery cables battery retainer and electrical connections are in good condition 4 Place battery in its compartment Make sure battery is level and flat Connect positive cable connector onto positive battery post Secure cable cap screw and lock nut using two wrenches 5 Secure battery retainer with flat washer and flange nut Do not overtighten to prevent cracking or distorting the battery case 6 Connect a digital multimeter set to amps between the negative battery post and the negative cable connector The reading should be less than 0 1 amp A reading of more than 0 1 amp usually indicates a faulty switch a shorted circuit or grounded wire Identify and repair electrical faults before returning machine to ser vice Electrical System o o o E wi E 2 ra E 7 7 Connect negative cable connector to the nega tive battery post Secure cable cap screw and lock nut using two wrenches 8 After connections are made apply battery terminal protector Toro Part No 107 0392 or a light coat of grease on all battery post
218. rom the solenoid valve stem Fig 40 5 Clean any corrosion or dirt from the valve stem Installation 1 Slide new coil assembly seals and washers onto the solenoid valve stem Make sure to properly position seals and washers Fig 40 IMPORTANT When securing solenoid valve coil to solenoid do not over tighten hex nut 2 Install the hex nut onto the spool assembly and torque nut from 53 to 69 in Ib 5 9 to 7 8 N m 3 Connect the wire harness electrical connector to the solenoid valve coil connector Electrical System Page 5 28 Figure 39 1 Transmission 3 Coil connector 2 Solenoid valve and coil 53 to 69 in Ib 5 9 to 7 8 N m Figure 40 1 Hexnut 4 Seal 2 Lock washer 5 Solenoid valve coil 3 Washer Groundsmaster 7200 7210 Battery Storage If the machine will be stored for more than 30 days 1 Make sure ignition switch is in the OFF position Re move the battery and charge it fully see Battery Ser vice 2 Either store battery on a shelf or on the machine Battery Care 1 Battery electrolyte level must be properly main tained The top of the battery must be kept clean If the machine is stored in a location where temperatures are extremely high the battery will discharge more rapidly than if the machine is stored in a location where temper atures are cool Wear safety goggles and rubber gloves when working with electrolyte Charge battery in a well ventilated place
219. ry because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 3 Following the manufacturer s instructions con nect the charger cables to the battery posts Make sure a good connection is made 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Groundsmaster 7200 7210 Chapter 6 TORO Chassis Table of Contents SPECIFICATIONS 000 c eee cence 2 GENERAL INFORMATION 3 Operator s Manual 3 SERVICE AND REPAIRS eee 4
220. s and cable connectors to re duce corrosion Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which should be available locally Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its specific gravity or open circuit voltage Battery Charge Specific Open Circuit Level Gravity Voltage 100 1 265 12 68 50 1 190 12 24 25 1 155 12 06 0 1 120 11 89 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Electrical System Page 5 32 Battery Battery Charge Level Reserve Percent of Fully Charged Capacity ites 80 or 3 8 hrs 7 5 hrs 11 3 hrs 15 hrs less 3 amps 3amps 3 amps 3 amps 81 t0 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs o o o o 4amps 4amps 4amps 4amps 126 to 5 5 hrs 11 hrs 16 5 hrs 22 hrs 170 O 5 amps 5 amps 5 amps 5 amps 171 to 5 8 hrs 11 5 hrs 17 3hrs 23 hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 O O 10 amps 10 amps 10 amps 10 amps CAUTION Do not charge a frozen batte
221. s to be tested Make sure the flow control valve on the tester is fully open Groundsmaster 7200 7210 Page 4 31 7 Start engine and run at low idle speed 1500 to 1650 RPM Check for any hydraulic leakage from test con nections and correct before proceeding with test IMPORTANT Do not run engine at full speed when performing this test using Toro Hydraulic Tester Pressure and Flow TOR214678 Traction pump output at full engine speed can damage hydraulic tester 8 Using a phototac to measure engine speed move throttle so engine speed is 2800 RPM not full speed 9 Completely close flow control valve on tester 10 Leave traction control lever for transmission pump not being tested in the neutral position 11 While carefully monitoring tester pressure gauge have operator slowly push traction lever for pump being tested right side or left side in direction being tested forward or reverse until pressure gauge stabilizes indi cating that the relief valve has opened Pressure gauge should read approximately 4000 PSI 276 bar as relief valve lifts 12 Release traction lever to the neutral position open tester flow control valve and stop engine Record test re sults NOTE The forward relief valves for the two 2 trans mission pump circuits are identical and thus can be in terchanged The reverse relief valves are also identical The forward relief valves however are different than the reverse relief valves
222. s while it cools to a safe level Then the cooling system should be checked before returning the machine to service Testing 1 Before disconnecting the PTO switch for testing the switch and its circuit wiring should be tested as a SCM input see Standard Control Module in this section 2 If the SCM verifies that the PTO switch and circuit wiring are functioning correctly no further switch testing is necessary 3 If the SCM determines that the PTO switch and cir cuit wiring are not functioning correctly test PTO switch as follows A Make sure ignition switch is in the OFF position Locate PTO switch for testing B Disconnect machine wire harness electrical con nector from the PTO switch C The PTO switch terminals are identified as shown in Fig 12 The circuitry of the PTO switch is shown in ithe chart in the right column With the use of a multi meter ohms setting the switch functions may be tested to determine whether continuity exists be tween the various terminals for each switch position Verify continuity between switch terminals Groundsmaster 7200 7210 Page 5 13 D Replace PTO switch if necessary E If the PTO switch tests correctly and a circuit problem still exists check wire harness see Electri cal Schematics and Circuit Drawings in Chapter 8 Foldout Diagrams F Connect machine wire harness connector to PTO Switch Check PTO switch operation Ay Figure 11 2 PTO switch
223. sembly 6 used Lug nut 5 used per wheel PO PON Chassis fo 10 11 12 Figure 2 Drive track Woodruff key Wheel stud 5 used per hub Rear wheel motor LH shown Parking brake LH shown Screw 4 used per motor Page 6 6 g 13 14 15 16 17 1 o a e e i EN 65 to 85 ft lb 6 E 88 to 115 N m Lock nut Flat washer Hex nut Bogey pivot assembly LH shown Wheel stud 5 used per hub Groundsmaster 7200 7210 Removal Fig 2 NOTE Refer to the Polar TracTM Operator s Manual for additional information regarding drive track and wheel removal 1 Park machine on a level surface lower implement stop engine and remove key from the ignition switch NOTE When removing wheels from a Polar Trac equipped machine the center wheel must be removed first to allow track clearance for front or rear wheels 2 Loosen but do not remove lug nuts that secure wheels that are to be removed 3 Position two 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 Fig 3 A Remove two 2 screws securing the side access cover to the machine Remove the access cover B Remove the lock nut and flat washer that secures the bogie pivot to the front frame 5 Position a suitable floor jack under the
224. shandling during operation and maintenance These conditions can cause hose damage and deterio ration Some hoses are more susceptible to these conditions than others Inspect all machine hydraulic hoses frequently for signs of deterioration or damage Hard cracked cut abraded charred leaking or otherwise damaged hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose hose cover Cracked damaged or badly corroded hose fittings When replacing a hydraulic hose be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fit ting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an el bow at one end tighten the swivel nut on that end before tightening the nut on the straight end of the hose For additional hydraulic hose information refer to Toro Service Training Book Hydraulic Hose Servicing Part Number 94813SL Groundsmaster 7200 7210 Page 4 3 Before disconnecting or performing any work on hydraulic system relieve all pressure in system see Relieving Hydraulic System Pressure in this section Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydrauli
225. so gasses produced while charging can dissipate Since the gases are explosive keep open flames and electrical sparks away from the battery do not smoke Nausea may result if the gases are inhaled Un plug charger from electrical outlet before con necting or disconnecting charger leads to or from battery posts 2 Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution Flush top surface with water after cleaning Do not remove the fill caps while cleaning Groundsmaster 7200 7210 Page 5 29 3 Leave cables disconnected if the battery is stored on the machine 4 Store battery in a cool atmosphere to avoid quick de terioration of the battery charge 5 To help prevent the battery from freezing during stor age make sure it is fully charged see Battery Service 3 Battery cables must be tight on battery terminals to provide good electrical contact Connecting cables to the wrong post could re sult in personal injury and or damage to the electrical system 4 If corrosion occurs at battery terminals disconnect cables Always disconnect negative cable first Clean cable clamps and terminals separately Recon nect cables with positive 4 cable first Coat terminals with battery terminal protector Toro Part No 107 0392 or a light coat of grease to reduce corrosion after con nections are made 5 Check battery electrolyte level every 25 ope
226. ster 7200 7210 Page 6 21 Chassis Cutting Deck Lift Arms Figure 21 1 Roll pin 10 Retaining ring 2 used 19 Lift cylinder 2 Flange head screw 11 RH front lift arm 20 Cap screw 4 used 3 RH rear lift arm 12 Cap screw 4 used 21 Woodruff key 2 used 4 Lock nut 2 used 13 Link 2 used 22 Deck lift chain 4 used 5 Cap screw 14 Deck lift shaft 23 Flange nut 6 used 6 Spacer 15 Washer 2 used 24 Lock nut 3 used 7 Flange nut 2 used 16 Jam nut 1 used per ball joint 25 LH front lift arm 8 Height of cut pin 17 Ball joint 4 used 26 Washer 2 used 9 LH rear lift arm 18 Pivot pin 27 Pull link assembly 2 used Disassembly Fig 21 1 Park machine on a level surface with the cutting deck in the fully raised position Stop engine engage park ing brake and remove key from the ignition switch 2 Note location of HOC pin in HOC bracket for assem bly purposes Fig 22 Remove HOC pin from HOC bracket 3 Start engine and fully lower cutting deck Stop en gine and remove key from the ignition switch Figure 22 1 HOC pin 2 HOC bracket Chassis Page 6 22 Groundsmaster 7200 7210 4 Remove lift arm components as necessary using Figures 21 and 23 as guides NOTE If pull link assembly item 27 removal is neces sary refer to Cutting Deck Pull Links in the Service and Repairs section of Chapter 7 Cutting Deck Assembly Fig 21 1 Check flange bushing s in carrier frame for wear
227. sured value of the component you are test ing 1 Make sure ignition switch is in the OFF position Dis connect wire harness connector from fuel stop solenoid 2 Using a digital multimeter touch one test lead to the pull coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 36 The resistance of the pull coil should be less than 1 ohm but not zero 3 Using a digital multimeter touch one test lead to the hold coil terminal and the other test lead to the fuel stop solenoid frame ground Fig 36 The resistance of the hold coil should be approximately 15 ohms 4 If resistance of either coil is incorrect replace fuel stop solenoid 5 Connect wire harness connector to fuel stop sole noid Figure 35 1 Fuel stop solenoid 2 Harness connector Figure 36 1 Fuel stop solenoid 3 Hold coil terminal 2 Pull coil terminal Electrical System Page 5 26 Groundsmaster 7200 7210 Glow Controller The glow controller is attached to the inside of the con trol panel cover Fig 37 NOTE Refer to Chapter 8 Foldout Diagrams when troubleshooting the glow controller Controller Operation 1 When the ignition switch is initially placed in the ON position the glow controller energizes the glow plugs for 10 seconds The console glow plug indicator light will also be illuminated for 10 seconds 2 When the ignition switch is turned to the START posi tion the glow plugs will e
228. switch has three positions OFF ON PREHEAT and START Fig 6 The switch terminals are identified as shown in Figure 7 The Standard Control Module SCM monitors the op eration of the ignition switch When the ignition switch is in the ON position the SCM power input LED should be illuminated Testing 1 Before disconnecting the ignition switch for testing the switch and its circuit wiring should be tested as a SCM input see Standard Control Module in this sec tion 2 If the SCM verifies that the ignition switch and circuit wiring are functioning correctly no further switch testing is necessary 3 If the SCM determines that the ignition switch and cir cuit wiring are not functioning correctly test ignition switch as follows A Make sure ignition switch is in the OFF position Disconnect wire harness connector from ignition switch B The circuitry of the ignition switch is shown in the chart in the right column With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify continuity between switch terminals C Replace ignition switch if necessary D If the ignition switch tests correctly and a circuit problem still exists check wire harness see Electri cal Schematics and Circuit Drawings in Chapter 8 Foldout Diagrams E Connect machine wire harness connector to igni tion switch
229. t check oil level in the hydraulic tank to make sure that oil level is correct 10 When using hydraulic tester pressure and flow open tester load valve completely before starting engine to minimize the possibility of damaging components 11 The engine must be in good operating condition En gine speed can affect the accuracy of the hydraulic test er readings When performing hydraulic tests check engine speed with a phototac 12 If a traction circuit problem exists consider perform ing one or more of the following tests Charge Relief Valve Pressure Transmission Piston Pump Flow Trac tion Relief Valve Pressure and or Wheel Motor Efficien cy 13 If a lift circuit problem exists consider performing one or more of the following tests Implement Relief Pressure Gear Pump Flow and or Lift Cylinder Internal Leakage 14 If a PTO circuit problem exists consider performing the PTO Pressure Valve Test Groundsmaster 7200 7210 Traction System Operation Testing Because the Groundsmaster 7200 7210 traction sys tem uses two 2 separate circuits it can be difficult to identify which circuit is causing a problem and what hy draulic tests should be performed Use the following op eration tests and suggestions before performing the hydraulic tests described in this section 1 If machine does not track in a straight line look for a problem with components that affect the weaker traction side ofthe machine During operatio
230. t 3 Inner pump rotor 2 Outer pump rotor 38 Install two 2 pins into pump body bores 39 Apply clean grease to pump body O rings to hold them in position during assembly Place O rings in pump body locations 2 r LK cs gt lt Figure 87 1 Pin 2 Pump body 40 Place pump body onto center case making sure that O rings remain in position Install three 3 shorter and two 2 longer flange head screws to secure pump body to center case Torque screws in a crossing pattern from 17 to 19 ft Ib 22 to 27 N m Figure 88 1 Pump body 2 Center case Groundsmaster 7200 7210 Page 4 75 Hydraulic System 41 Lubricate new O rings and install O rings onto two 2 hex plugs Install plugs into pump body Torque plugs from 14 to 15 ft lb 18 to 21 N m 42 Apply sealant to threads of four 4 socket head plugs and install into pump body Torque plugs from 78 to 95 in Ib 8 8 to 10 8 N m Figure 89 1 Hex plug 2 used 2 Socket plug 4 used 43 Lubricate accumulator components with clean hy draulic oil Install piston spring and collar into pump body Make sure that hole in collar is toward the outside of the pump body lt a JS j 4 4 h 44 Position new gasket to accumulator cover Secure o cover to pump body with two 2 bolts Torque bolts from e 17 to 19 ft Ib 22 to 27 N m Figure 90 1 Accumulator piston 3 Collar hole 2 Accumulator collar 4 Accumulator cover
231. t cylinder controls the contracting speed of the lift cylinder while lowering the cutting deck or imple ment Groundsmaster 7200 7210 Page 4 15 Load on the lift cylinder causes lift circuit pressure to in crease If lift circuit pressure reaches implement relief valve pressure 3000 PSI 207 bar the relief valve in the gear pump shifts allowing pump flow to return to the hy draulic tank This condition occurs in both the raise and lower modes When the lift control lever is released from LOWER spring action returns the spool to its original centered position stopping lift cylinder movement Gear pump flow is again bypassed through the oil cooler transmis sion and to the hydraulic tank The pilot check valve in the control valve will be reseated to lock the lift cylinder in place Hydraulic System 9 s O a Y oP ysew 00 JooJ 5S Uuolfons aaziouaN3 331138 LNW 1dN ud euibue ooze eq 922 ISd 0007 INVA SIATVA 331738 ONIHSN14 KY SATA Ssvala Qquvwuod w Jeuung q puppurts Lo 7 HIONNAO 13N NIHSNT4 N 1HOd 1NOH4 INN
232. t of the seat the engine will stop The seat switch and its electri cal connector Fig 16 are located directly under the seat The Standard Control Module SCM monitors the sta tus of the seat switch If the ignition switch is in the ON position and the seat is occupied the SCM in seat input LED should be illuminated Testing 1 Before disconnecting the seat switch for testing the switch and its circuit wiring should be tested as a SCM input see Standard Control Module in this section 2 Ifthe SCM verifies that the seat switch and circuit wir ing are functioning correctly no further switch testing is necessary 3 If the SCM determines that the seat switch and circuit wiring are not functioning correctly test seat switch as follows A Make sure ignition switch is in the OFF position Tilt seat assembly up to gain access to seat switch electrical connections NOTE There is a short wire harness that is used to connect the sen at switch to the main wire harness of the machine This seat switch harness is between the seat and the seat plate B Disconnect machine wire harness electrical con nector from the seat switch harness electrical lead under the operator seat Fig 16 C Check the continuity of the seat switch by con necting a multimeter ohms setting across the seat switch harness connector terminals D With no pressure on the seat there should be no continuity between the seat switch harness termi
233. ta Diesel Engine Fuel System LH fuel tank RH fuel tank Fuel cap LH vent tube RH vent tube Vent hose Tee fitting Flange nut Fuel hose 10 Fuel pump 11 Fuel hose 12 R clamp 13 Cap screw 14 Fuel filter 15 Hose clamp O D DT RON Kubota Diesel Engine Figure 7 Cable tie Nut 3 used Washer head screw 3 used Spacer R clamp 2 used Fuel gauge Clamp 4 used Cap screw 4 used Flange nut 4 used Spacer Shield washer 2 used Cap screw Flange nut 2 used Toolbox cover Washer head screw 6 used Page 3 10 Fuel hose Hinge Flange head screw R clamp Rivet 2 used Flat washer 2 used Rubber washer 2 used Foam pad 4 used Grommet Elbow fitting Bushing 3 used Elbow fitting 2 used Hose clamp 2 used Strainer fitting 2 used Groundsmaster 7200 7210 Use caution when storing or handling diesel fuel Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running or hot or when machine is in an enclosed area Always fill fuel tank outside and clean up any spilled diesel fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use diesel fuel for the engine only not for any other purpose Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete
234. tem 22 spring and disc liberally with clean hydraulic fluid and install into valve body bore 13 Install O ring and detent plug item 19 into valve body Torque plug from 4 to 5 ft lb 5 4 to 6 8 N m Hydraulic System 9 s O a Y Io Lift Cylinder 15 to 19 ft lb 20 to 25 N m 15 to 19 ft lb 20 to 25 N m Figure 106 1 Lift cylinder 6 Hydraulic hose 10 Grease fitting 2 O ring 7 Hydraulic hose 11 Flange head screw 3 Hydraulic fitting 8 Retaining ring 12 Pivot pin 4 O ring 9 Lift control valve 13 Lift lever 5 Hydraulic fitting 0 052 orifice Hydraulic System Page 4 92 Groundsmaster 7200 7210 Removal Fig 106 Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 1 Park machine on a level surface lower cutting deck or implement stop engine engage parking brake and remove key from the ignition switch 2 Thoroughly clean hydraulic hose ends and fittings on lift cylinder to prevent hydraulic system contamination 3 Label hydraulic hoses for assembly purposes Also label orientation of hydraulic hose at barrel end of lift cyl inder to allow correct assembly 4 Disconnect hydraulic hoses connected to the hy draulic fittings on the lift cylinder Install clean plugs in hose openings to prevent system contamination 5 Remove retaining
235. the ignition key switch is in the ON position and inputs from the neutral parking brake PTO seat and engine cool ant temperature switches indicate safe engine opera tion e g seat occupied and parking brake disengaged when traction control levers are moved from the neutral locked position The PTO output LED should be illuminated when the ignition key switch is in the ON position and the PTO switch is ON pulled out Note If the SCM High Temper ature Warning input LED is illuminated PTO output LED will not be illuminated and PTO will be disengaged re gardless of PTO switch position Figure 20 1 Control panel cover 2 Latch Figure 21 1 Power input LED 7 Park brake off input LED 2 Start input LED 8 PTO switch input LED 3 Engine run output LED 9 Inseat input LED 4 Start output LED 10 Temp shutdn input LED 5 PTO output LED 11 Temp warning input LED 6 Neutral input LED 12 Backlap input LED Electrical System Electrical System Standard Control Module Logic Chart Each line of the following chart identifies the necessary component position INPUTS in order for the SCM to energize the appropriate OUTPUTS for machine opera tion Example To start the engine with an operator in the seat when the ignition key is in start the traction control levers both in neutral locked position and the parking brake is not applied engine components and the engine starter will be energized
236. ting Fig 9 Secure spindle assembly to deck 88 to 108 rb with eight 8 flange head screws and flange nuts 119 to 146 N m 2 Install cutting blade anti scalp cup and blade bolt Fig 8 Tighten blade bolt from 88 to 108 ft Ib 119 to 146 N m 3 Slowly rotate cutting blades to verify that blades do not contact any deck component s 4 Install drive belt to pulleys Figure 8 1 Flange screw 8 used 4 Blade 5 Lubricate spindle grease fittings 2 Spindle assembly 5 Anti scalp cup 3 Flange nut 8 used 6 Blade bolt 6 Install belt covers to cutting deck Lower the footrest Figure 9 1 RH spindle grease fitting 2 Center spindle grease fitting 3 LH spindle grease fitting Groundsmaster 7200 7210 Page 7 11 Cutting Deck Blade Spindle Service Disassembly Fig 10 1 Remove lock nut from top of spindle shaft NOTE Early production spindle assemblies included a V ring seal item 4 which has been found to be unnec essary Discard v ring seal if found in spindle assembly 2 Remove special hardened washer and pulley from shaft If spindle is equipped with a v ring seal remove and discard v ring seal 3 Remove the spindle shaft from the spindle housing which may require the use of an arbor press The spindle shaft spacer should remain on the spindle shaft as the shaft is being removed 4 Remove oil seals from spindle housing 5 Remove the bearing cones O ring inner bearing spacer and spac
237. tings 8 Check cutting deck mismatch and pitch Adjust if necessary 1 Pull link raised 2 Cap screw 3 Torsion spring end 4 Retainer pin 5 Pivot pin Cutting Deck This page is intentionally blank Cutting Deck Page 7 18 Groundsmaster 7200 7210 Chapter 8 TORO Foldout Diagrams Table of Contents HYDRAULIC SCHEMATICS 3 Hydraulic Schematic 3 Hydraulic Schematic With Rear Attach Lift Kit Installed a de on imei 4 Hydraulic Schematic With Polar Trac 5 Hydraulic Schematic With Polar Trac and Rear Attach Lift Kit Installed 6 ELECTRICAL SCHEMATICS 7 Electrical Schematic 7 Electrical Schematic With Optional Kits INCIUGEd ieee eae tal it E RE 8 ELECTRICAL CIRCUIT DIAGRAMS 9 Glow Circuits 0 cece eee eee 9 Crank Circuits 10 RUN GireuitS edi iaa 11 Run Circuits PTO Engaged 12 WIRE HARNESS DRAWINGS 13 Wire Harness Drawing 13 Wire Harness Diagram 14 a gt Ed a 1 Groundsmaster 7200 7210 Page 8 1 Foldout Diagrams This page is intentionally blank Foldout Diagrams Page 8 2 Groundsmaster 7200 7210 RH WHEEL MOTOR 300 to 310 cc LSHT LH WHEEL MOTOR 300 to 310 cc LSHT q
238. tings on the hy draulic tank and gear pump Fig 95 Allow hoses to drain into a suitable container Install clean plugs in hose and fitting openings to prevent system contamination 7 Remove parking brake handle from machine to allow hydraulic tank repositioning see Parking Brake Assem bly in the Service and Repairs section of Chapter 6 Chassis 8 Remove reservoir support that secures hydraulic tank to machine see Hydraulic Tank Removal in this section Move hydraulic tank toward front of machine to allow clearance for gear pump removal 9 Support the gear pump to prevent it from falling dur ing removal 10 Remove two 2 cap screws and lock washers that secure gear pump to the transmission Groundsmaster 7200 7210 11 Remove gear pump from transmission Remove and discard O ring item 3 Locate and remove coupler from transmission or gear pump shaft 12 If necessary remove hydraulic fittings from pump Remove and discard O rings from fittings Installation Fig 94 1 If hydraulic fittings were removed from pump lubri cate and install new O rings to fitting Tighten fittings to torque values identified in Figure 94 see Hydraulic Fit ting Installation in the General Information section of this chapter 2 Slide coupler onto transmission shaft Lubricate O ring item 3 with grease and position on flange of gear pump IMPORTANT Position gear pump to the transmis sion so that the gear pump s
239. tion Relief Valve Pressure Test Wheel Motor Efficiency Test PTO Pressure Valve Test Implement Relief Pressure Test Gear Pump Flow Test Lift Cylinder Internal Leakage Test Groundsmaster 7200 7210 Chapter 4 Hydraulic System 2 SERVICE AND REPAIRS 43 3 General Precautions for Removing and 3 Installing Hydraulic System Components 43 4 Check Hydraulic Lines and Hoses 43 5 Flush Hydraulic System 44 7 Charge Hydraulic System 45 7 Hydraulic Tank cee eee eee 46 7 Wheel Motors 48 Wheel Motor Service 50 8 Transmission ulus eee eee eee 52 9 Transmission Removal 53 10 Transmission Installation 54 10 Transmission Service 56 12 Transmission Disassembly 57 14 Transmission Assembly 68 16 Gear Pump oa 78 18 Gear Pump Service 80 18 Lift Control Valve 84 18 Lift Control Valve Service 86 19 Polar Trac M Hydraulic Control Valve 88 19 Polar Trac Hydraulic Control Valve Service 90 19 Lift Cylinder _ 92 20 Lift Cylinder Service 94 24 Polar Trac Lift Cylinder 96 25 Polar Trac Lift Cylinder Service 98 26 OI COO sink RR as 100 28 PARKER T
240. tion and the parking brake is disengaged the SCM Parking Brake Off input LED should be illumi nated The parking brake switch and circuit wiring should be tested as a SCM input before performing the following testing procedure Testing 1 Before disconnecting the parking brake switch for testing the switch and its circuit wiring should be tested as a SCM input see Standard Control Module in this section 2 If the SCM verifies that the brake switch and circuit wiring are functioning correctly no further brake switch testing is necessary 3 If the SCM determines that the brake switch and cir cuit wiring are not functioning correctly test switch as follows A Make sure ignition switch is in the OFF position Locate parking brake switch for testing B Disconnect machine wire harness electrical con nector from the parking brake switch C Check the continuity of the switch by connecting a multimeter ohms setting across the connector ter minals D When the switch plunger is extended there should be continuity closed between the switch ter minals E When the switch plunger is depressed there should be no continuity open between the switch terminals F Replace brake switch if necessary G If the brake switch tests correctly and a circuit problem still exists check wire harness see Electri cal Schematics and Circuit Drawings in Chapter 8 Foldout Diagrams H Connect switch connector to machine
241. tion in the Gener al Information section of this chapter Hydraulic System Page 4 44 IMPORTANT Use only hydraulic fluids specified in Operator s Manual Other fluids may cause system damage Use of biodegradable hydraulic fluid in Groundsmaster 7200 and 7210 machines is not rec ommended 8 Fill hydraulic tank with new hydraulic fluid 9 Disconnect wire harness connector from engine fuel stop solenoid to prevent the engine from starting Make sure traction levers and lift control lever are in the neu tral position 10 Turn ignition key switch to START and engage start er for ten 10 seconds to prime the transmission and gear pump Repeat this step again 11 Connect wire harness electrical connector to fuel stop solenoid 12 Start engine and let it run at low idle speed 1500 to 1650 RPM for a minimum of 2 minutes Increase engine speed to high idle 3200 to 3250 RPM for a minimum of 1 minute under no load 13 Raise and lower cutting deck or implement several times 14 Shut off engine and check for hydraulic oil leaks Check oil level in hydraulic tank and add correct amount of oil if necessary 15 Operate the machine for 2 hours under normal oper ating conditions 16 Check condition of hydraulic oil If the new fluid shows any signs of contamination repeat steps 1 through 15 again until oil is clean 17 Assume normal operation and follow recommended maintenance intervals Groundsmaster 7200 7210
242. tion torque see Using a Torque Wrench with an Offset Wrench in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 Ifa torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in b B Mark the swivel nut and fitting body Hold the hose tube with a wrench to prevent it from turning Fitting Dash Size Hose Tube Side Thread Size C Use a second wrench to tighten the nut to the cor rect Flats From Wrench Resistance F F W R The markings on the nut and fitting body will verify that the connection has been properly tightened Size F F W R 4 1 4 in nominal hose or tubing 1 2 to 3 4 6 3 8 in 1 2 to 3 4 8 1 2 in 1 2 to 3 4 10 5 8 in 1 2 to 3 4 12 3 4 in 1 3 to 1 2 16 1 in 1 8 to 1 2 Tube or Hose Figure 1 Mark Nut Final and Bedv s Position Initial Position Extend Line AT WRENCH RESISTANCE AFTER TIGHTENING Figure 2 Installation Torque 9 16 18 18 to 22 ft lb 25 to 29 N m 11 16 16 27 to 33 ft lb 37 to 44 N m 13 16 16 37 to 47 ft lb 51 to 63 N m 1 14 60 to 74 ft Ib 82 to 100 N m 13 16 12 85 to 105 ft lb 116 to 142 N m 1 7 6 12 110 to 136 ft lb 150 to
243. top of cutting deck 4 Loosen jam nuts item 22 that secure idler stop bolt item 21 to cutting deck to allow clearance between idler and stop bolt Remove drive belt from deck pulleys 5 Insert nut driver or small piece of pipe onto the end of the torsion spring for the idler arm Be careful when removing tension from the idler arm torsion spring The spring is under heavy load and may cause personal injury 6 Carefully push the torsion spring end down and away from the idler arm to unhook the spring from the arm 7 Remove snap ring that retains idler arm assembly to cutting deck 8 Remove idler components as needed using Figure 4 as a guide Installation Fig 4 1 Install removed idler components using Figure 4 as a guide Secure idler arm assembly to cutting deck with snap ring 2 Insert nut driver or small piece of pipe onto the end of the torsion spring for the idler arm Be careful when applying tension to the idler arm torsion spring The spring is under heavy load and may cause personal injury 3 Carefully push down on the torsion spring end to get the spring under the idler arm mounting plate Then re lease the spring slowly to lock it into place Groundsmaster 7200 7210 Page 7 9 4 Install drive belt to pulleys 5 If idler arm on right side of cutting deck was removed check that clearance between idler arm and stop bolt is from 0 100 to 0 160 2 5 to 4 0 mm Fig 5 If neces
244. ts Chapter 1 Safety General Safety Instructions 1 1 Jacking Instructions 1 4 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Kubota Diesel Engine Specifications 3 2 General Information 3 4 Adjustments a PAG NG NAL 3 5 Service and Repairs 3 6 KUBOTA WORKSHOP MANUAL DIESEL ENGINE 05 SERIES Chapter 4 Hydraulic System Specifications 4 2 General Information 4 3 Hydraulic Schematics 4 9 Hydraulic Flow Diagrams 4 10 Special Tools 4 18 Troubleshooting 4 20 TOM io a 4 24 Service and Repairs 4 43 PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES Groundsmaster 7200 7210 Chapter 5 Electrical System Electrical Schematics and Diagrams Special Tools o Troubleshooting Electrical System Quick Checks Component Testing Service and Repairs Chapter 6 Chassis Specifications
245. tting performance 6 Height of cut Adjust deck as specified in the Operator s Manual Effective actual height of cut will be different than the bench set height of cut 7 Cutting deck alignment and ground following Check lift arms for wear damage or binding Also inspect for bent or damaged pivot shafts 8 Anti scalp roller condition All anti scalp rollers should rotate freely Replace rollers or roller shafts if worn or damaged 9 Grass conditions Mow when grass is dry for best cutting results Also remove only 1 2 5 cm or 1 3 of the grass blade when cutting Groundsmaster 7200 7210 Page 7 3 Cutting Deck This page is intentionally blank Cutting Deck Page 7 4 Groundsmaster 7200 7210 Service and Repairs Do not start the engine and engage the PTO switch when the PTO drive shaft is discon nected from the cutting deck or implement If the engine is started and the PTO shaft is al lowed to rotate serious personal injury and machine damage could result If the PTO drive shaft is disconnected from the cutting deck or implement remove fuse F1 15 amp from fuse block to prevent unintentional engagement of the PTO clutch Blade Stopping Time The blades of the cutting deck should come to a com plete stop in less than seven 7 seconds after the PTO switch is disengaged NOTE When checking blade stopping time make sure the deck is lowered onto a clean section of turf or hard surface to avo
246. uction port is facing up 3 Position gear pump to the transmission and secure with two 2 cap screws and lock washers 4 Move hydraulic tank toward rear of machine to its proper position and secure with reservoir support see Hydraulic Tank Installation in this section 5 Install parking brake handle to machine see Parking Brake Assembly in the Service and Repairs section of Chapter 6 Chassis Make sure that parking brake switch operation is correct after brake handle is installed 6 Remove plugs that were installed to hydraulic hoses and fittings during the removal procedure Attach hy draulic hoses to fittings on gear pump and hydraulic tank using labels placed during removal see Hydraulic Hose and Tube Installation in the General Information section of this chapter 7 Fill hydraulic tank with new hydraulic oil 8 Install operator seat and seat base see Operator Seat Installation in the Service and Repair section of Chapter 6 Chassis Figure 95 1 Hydraulic tank 4 RH wheel motor 2 Transmission 5 LH wheel motor 3 Gear pump 2 3 L3 cs gt lt Groundsmaster 7200 7210 Page 4 79 Hydraulic System Gear Pump Service 220 in lb 25 N m g 220 in lb 25 N m Figure 96 1
247. ulic System 2 L3 cs gt lt Implement Relief Pressure Test Using Pressure Gauge 91012 Hs LU q 972 ISd 0007 SINIYA 331138 INVA NIHSNT4 INVA SSVdA8 du VMyOW PRESSURE GAUGE INVA SNIHSN14 VIE vic m H INA SSVdA8 QquvwHuod A eq 972 ISd 000 SINIYA 331138 a LHS 2 O1 OF 0 SS OLOW TH3HM H7 01 04 00 HOLOW Cay THSHMHH Figure 21 Page 4 36 Groundsmaster 7200 7210 Hydraulic System The Implement Relief Pressure Test should be per formed if a cutting deck or implement raise and lower problem is identified This test will determine if the imple ment relief valve is operating correctly Procedure for Implement Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature 2 Make sure that traction drive is correctly adjusted for the neutral position Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 3 Park machine
248. undsmaster 7200 7210 Hydraulic Schematic With Polar Trac and Rear Attach Lift Kit Installed All solenoids are _ shown as de energized Page 8 6 PTO pressure test port ATTACHMENT KALAN TRAC KIT SWING OPT GILINDER REPLACES STANDARD DEDOS OPT DECK LIFT VALVE IN WINTER CONFIGURATION P KOMEN A D C REAR HYDRAULIC POWERED REAR ATTACHMENT ATTACHMENT Ko PB T LIFT CYLINDER OPT OPT 3 4 16 UNF Port RELIEF VALVES TR NES 4000 PSI 276 bar FORWARD Hl Ins REAR PORT Q Q Q BYPASS X feral 6 Go VALVE HI lt 5 R m FRONT M2 PORT 2 O X CHARGE PRESSURE TEST PORT L E KATE O NG FLUSHING 18 KITE 3 4 16 UNF PORT VALVE a Pomi 22 PORT 3 4 16 UNF uy 99 TT FORWARD Ca PRESSURE VALVE sv FRONT M L l TEST PORT ave oC PRESSURE VALVE G ee x ru S CHARGE RELIEF 313530 psi M LII sy ay N 86415 psi aes Gg REAR Ful PORT L
249. undsmaster 7200 7210 Page 4 91 Assembly Fig 105 IMPORTANT Do not wipe control valve parts with dry paper towels or rags Lint may cause damage to the hydraulic system CAUTION Use eye protection such as goggles when using compressed air 1 Clean all metal parts with solvent and blow dry with compressed air 2 Replace check poppet item 1 O rings and back up washers with new ones 3 Install new O rings item 12 into the valve body 4 If a spool was disassembled install washer item 14 spool spring item 16 spacer item 3 and retaining ring item 13 to the spool 5 Slide bushings item 8 and new O rings item 12 over the spools 6 Lubricate spools liberally with clean hydraulic fluid and carefully install into their proper bore 7 Install spool caps item 10 into valve body Torque caps from 20 to 25 ft Ib 27 to 33 N m 8 Lubricate both plungers items 2 and 21 liberally with clean hydraulic fluid and install into their proper bore 9 Install new O rings seats item 5 check poppet item 1 and check spring item 9 into the plunger bores 10 Install O rings back up washers and seat retaining plugs items 7 and 15 into their plunger bores Torque plugs from 30 to 35 ft lb 41 to 47 N m 11 Install new O ring back up washer and solid plug item 6 into the bore with the detent plunger Torque plug from 30 to 35 ft Ib 41 to 47 N m 12 Lubricate detent plunger i
250. ure seals and back up rings fit in grooves machined into bearing blocks O rings fit in grooves ma chined in the pump body 8 Carefully remove and discard O rings pressure seals and back up rings from pump body and bearing blocks Do not cause any damage to the machined grooves during the removal process 9 Turn front plate over with seal side up and remove the retaining ring IMPORTANT Make sure to not damage the counter bore when removing the shaft seal from the front plate 10 Carefully remove shaft seal from the front plate 11 If necessary remove implement relief valve from back plate Remove and discard sealing washers Inspection 4h caution Use eye protection such as goggles when using compressed air 1 Clean all pump parts with solvent Dry all parts with compressed air 2 Inspect drive gear idler gear and bearing blocks for the following If damage is found pump replacement is necessary A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sharp edges of gears will mill into bearing blocks and thus must be replaced Groundsmaster 7200 7210 Page 4 81 D Bearing areas of bearing blocks should not have
251. ver 3 Piston 2 Collar 10 Remove two 2 hex plugs from pump body Remove and discard O rings from plugs 11 Remove four 4 socket head plugs from pump body Figure 44 1 Hex plug 2 used 2 Socket plug 4 used Hydraulic System Page 4 58 Groundsmaster 7200 7210 12 Remove three 3 shorter 45 mm and two 2 longer 95 mm flange head screws that secure pump body to center case Remove pump body from center case Figure 45 1 Pump body 2 Center case 13 Remove two 2 pins that locate pump body Remove and discard O rings 2 NY cs gt lt Figure 46 2 Pump body 14 Slide outer and inner charge pump rotors from RH pump shaft Remove key from keyslot in pump shaft Figure 47 3 Inner pump rotor 1 RH pump shaft 2 Outer pump rotor Groundsmaster 7200 7210 Page 4 59 Hydraulic System 15 Remove eight 8 socket head screws that secure center case to transmission pump housing 16 Carefully remove center case assembly from trans mission pump housing 17 Remove two 2 pins from transmission pump hous ing bores Remove and discard gasket 18 Remove bypass valves from center case Remove and discard O rings and backup rings from bypass valves IMPORTANT The forward and reverse relief car tridges are different Label the relief cartridges for assembly purposes 19 Remove forward and reverse relief valve cartridges from center case noting relief cartridge location
252. ving or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic components 3 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 4 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic fittings hoses and tubes Before disconnecting or performing any work on the hydraulic system all pressure in the system must be relieved See Relieving Hydraulic System Pressure in the General Information section 5 Hydraulic oil may be hot Be careful when loosening and removing hydraulic system components Check Hydraulic Lines and Hoses Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or cardboard not hands to search for leaks Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Groundsmaster 7200 7210 Page 4 43 6 Put clean caps or plugs on any hydraulic lines hy draulic fittings a
253. wHOd OW Ca OH3HM HB req 912 ISd 000 Figure 26 Page 4 40 Groundsmaster 7200 7210 Hydraulic System The Lift Cylinder Internal Leakage Test should be per formed if a cutting deck or implement raise and lower problem is identified This test will determine if the lift cyl inder is faulty NOTE Raise lower circuit operation will be affected by lift cylinder binding extra weight on the cutting deck or implement and or binding of lift components Make sure that these items are checked before proceeding with the lift cylinder internal leakage test Procedure for Lift Cylinder Internal Leakage Test 1 Park machine on a level surface with the PTO switch OFF Position the cutting deck or implement in a par tially raised position and turn the engine off Apply the parking brake 2 Under both sides of the cutting deck or implement use a jack to raise the cutting deck or implement slight ly This will remove the load from the lift cylinder and re lieve lift cylinder hydraulic pressure Support both sides of the cutting deck or implement with jack stands to prevent the lift cylinder from retracting 3 Thoroughly clean the area around the hydraulic hose end at the barrel end of the lift cylinder Disconnect the hydraulic hose from the lift cylinder barrel end fitting Fig 27 IMPORTANT When capping the lift cylinder fitting and hydraulic hose end use a steel
254. washer washer O ring solenoid coil and O ring from solenoid valve stem For assembly purposes note that KANZAKI molded into the coil has the I nearest the nut location as coil direction is impor tant for proper solenoid operation 3 Remove solenoid valve stem from transmission pump body 4 Remove pin from spool Remove spool sleeve and solenoid valve spring from transmission pump body For assembly purposes note that step in spool is toward spring location and that sleeve is installed so that holes are closest to the spring location as well Figure 40 4 Spool 5 Sleeve 1 Solenoid coil 2 Solenoid valve stem 3 Pin Groundsmaster 7200 7210 Page 4 57 Hydraulic System 5 Remove filter bypass plug spring and valve from transmission pump body Remove and discard O ring from plug Figure 41 1 Filter bypass plug 2 Bypass valve 6 Remove pressure valve plug spring and valve from transmission pump body Remove and discard O ring from plug 7 Remove charge relief plug spring and valve from transmission pump body Remove and discard O ring from plug Figure 42 1 Pressure valve plug 2 Charge relief plug 8 Remove two 2 bolts that secure accumulator cover to transmission pump body 9 Remove cover gasket collar spring and piston from pump body For assembly purposes note that hole in collar is toward the outside of the pump body Discard gasket Figure 43 1 Accumulator co
255. wire har ness Check brake switch operation Electrical System Page 5 16 Figure 17 1 Front panel 2 Washer head screw Figure 18 1 Brake lever assembly 2 Brake switch 0 015 TO 0 045 0 4 to 1 0 mm DISTANCE BETWEEN TAB AND SWITCH BODY WITH BRAKE APPLIED Figure 19 1 Brake shaft tab 3 Screw 2 Parking brake switch Groundsmaster 7200 7210 Standard Control Module Groundsmaster 7200 7210 machines are equipped with a Standard Control Module SCM to monitor and con trol electrical components required for safe operation The SCM is attached to the control panel cover Fig 20 Inputs from the ignition neutral parking brake PTO seat high temperature warning switch and high temper ature shutdown switch are monitored by the SCM Cur rent output to the PTO engine starter motor and engine run components fuel pump and engine run solenoid are controlled based on the inputs monitored by the SCM The SCM can be used to check operation of machine switches by monitoring the SCM LEDs If a SCM LED does not illuminate e g the In Seat input LED does not illuminate when the seat is occupied and the ignition switch is in the ON position testing of the switch fuses and circuit wiring would be required The SCM does not connect to an external computer or hand held device can not be re programmed and does not record intermittent fault data SCM Inputs Fig 21 The Power input LED sh
256. witch from engine Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns 2 Lower the coolant level in the engine and remove the high temperature shutdown switch from the engine 3 Put the end of the switch in a container of oil with a thermometer and slowly heat the oil Fig 30 Handle the hot oil with extreme care to prevent personal injury or fire 4 Check resistance of the switch with a multimeter ohms setting as the oil temperature increases The high temperature shutdown switch is normally open and should close from 234 to 244 F 112 to 118 C Groundsmaster 7200 7210 Page 5 23 5 Replace shutdown switch if specifications are not met 6 After testing is complete install shutdown switch to the engine housing A Clean threads of housing and switch thoroughly Apply thread sealant to the threads of the switch B Thread switch into the housing Torque switch from 22 to 28 ft lb 29 4 to 39 2 N m C Reconnect harness wire to shutdown switch 7 Fill engine cooling system 8 Lower and secure hood Figure 29 1 High temperature shutdown switch Figure 30 Electrical System E 2 o 2 Lu g 2 D E 7 Dual Temperature Switch Polar Trac Machines On machines equipped with Polar Trac the dual tem perature switch includes two normally open circuits used to monitor engi
257. y position radiator to the radiator frame 3 Secure radiator to the radiator frame with four 4 cap screws and flange nuts 4 Carefully position fan shroud to radiator taking care to not damage fan Secure fan shroud to the radiator with four 4 screws and flat washers 5 Make sure that equal clearance exists at all points between fan shroud and fan A To move fan shroud left or right adjust location of radiator in radiator frame B To move fan shroud up or down adjust location of shroud on radiator 6 Connect following hoses to the radiator A Upper radiator hose to the water pump B Lower radiator hose to the engine block C Coolant hose to the expansion tank D Air inlet hose to the air cleaner assembly 7 Apply thread sealant to threads of radiator plug item 12 Install plug into radiator opening 8 Check that no gaps exist between radiator radiator frame and machine frame If necessary seal gaps with silicone caulk 9 Fill radiator with coolant Make sure that expansion tank coolant level is correct 10 Close and latch hood Kubota Diesel Engine E s3 Su a o lt Y 2 a 25 7 N m Loctite 271 50 to 60 ft Ib 68 to 81 N m 21 39 18 20 Figure 9 1 Flywheel coupling 16 Fuel hose supply 30 Snubbing washer 2 used 2 Cap screw 6 used 17 Hose clamp 31 Cap screw 2 used 3 Cap screw 18 Elbow fitting 2 used 32 Lock washer 4 Muffler bracket 19 Flange head scr
258. ydraulic tank is full Add correct oil if nec essary Figure 100 3 Cap screw 1 Lift control valve 2 Lift lever valve link Hydraulic System 2g 5 EZ 35 Ro Lift Control Valve Service 10 to 15 ft lb 24 to 27 Nom Opa Loctite 242 35 to 40 ft lb 47 to 54 N m 18 to 20 ft lb 24 to 27 N m Loctite 4242 35 to 40 ft Ib 47 to 54 N m 24 to 36 in Ib 2 7 to 4 1 N m Loctite 4242 Figure 101 1 Detent ball 9 Plug 17 Spring 2 Spring 10 Poppet stop 18 O ring 3 Gasket 11 Poppet 19 Detent plunger 4 O ring 12 End cap 20 Spring 5 Screw 13 Spacer 21 O ring 6 Washer 14 Adapter plug 22 Lockout seat 7 Screw and lock washer 2 used 15 O ring 23 O ring 8 Spool 16 Detent plug Disassembly Fig 101 1 Plug all ports and clean the outside of control valve thoroughly 2 Remove two 2 screws with lock washers item 7 that secure end cap item 12 to control valve Remove end cap 3 Retain spool to prevent it from turning Remove screw item 5 spacer item 13 spring item 20 and washer item 6 from control valve 4 Carefully slide spool item 8 from housing bore Hydraulic System Page 4 86 5 Carefully remove O rings item 4 from spool bore Take care to not damage spool bore or O ring cavities during O ring removal 6 Remove detent plug item 16 O ring item 18 spring item 17 and detent ball item 1 7 Remove plug item 9 with O

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