Toro Groundsmaster 7200 Service Manual
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Toro Groundsmaster 7200 Service Manual

Zero turn rotary mower with kubota engine
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Form No. 07150SL Rev D
Groundsmaster
7200/7210
®
(Models with Kubota Engine)
Original Instructions (EN)

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  • Page 1 Form No. 07150SL Rev D Groundsmaster 7200/7210 ® (Models with Kubota Engine) Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 IMPORTANT: The IMPORTANT notice will give im- specifications or this publication without notice. portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2007, 2016, 2018, 2019, 2020...
  • Page 6 This page is intentionally blank. Groundsmaster 7200/7210...

  • Page 7: Table Of Contents

    ..... . . 4 -- 43 PARKER TORQMOTOR SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) Groundsmaster 7200/7210...
  • Page 8 This page is intentionally blank. Groundsmaster 7200/7210...

  • Page 9: General Safety Instructions

    ..... General Safety Instructions Groundsmaster 7200 and 7210 machines meet or ex- ceed safety standard specifications as identified in the WARNING Operator’s Manual.

  • Page 10: Before Operating

    A replacement Operator’s Manual is available B. Do not remove machine fuel tank cap while en- on the Internet at www.Toro.com. gine is hot or running. 2. Keep all shields, safety devices and decals in place.

  • Page 11: Maintenance And Service

    7. When working on the hydraulic system and its com- the machine, use genuine Toro replacement parts and ponents, wear eye protection. accessories. Replacement parts and accessories made by other manufacturers may result in non-conformance 8.

  • Page 12: Jacking Instructions

    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 Groundsmaster 7200/7210...

  • Page 13: Product Records

    ......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...

  • Page 14: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 – 2 Groundsmaster 7200/7210...

  • Page 15: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 16 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 Page 2 – 4 Groundsmaster 7200/7210...
  • Page 17 NOTE: The nominal torque values listed above are based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately + 10% of the nominal torque value. Groundsmaster 7200/7210 Page 2 – 5 Product Records and Maintenance...

  • Page 18: Specifications

    3/8 – 16 UNC 200 + 100 in–lb fasteners. Conversion Factors in–lb X 11.2985 = N–cm N–cm X 0.08851 = in–lb ft–lb X 1.3558 = N–m N–m X 0.7376 = ft–lb Product Records and Maintenance Page 2 – 6 Groundsmaster 7200/7210...
  • Page 19 ......Groundsmaster 7200 ......

  • Page 20: Groundsmaster 7200

    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 Firing Order 1 (fan end) –...

  • Page 21: Groundsmaster 7210

    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...

  • Page 22: General Information

    Kubota D1105 plied through your Authorized Toro Distributor. If no diesel engine used in the Groundsmaster 7200 and parts list is available, be prepared to provide your distrib- 7210. Refer to the Operator’s Manual for engine mainte- utor with the Toro equipment model and serial numbers nance information.

  • Page 23: Adjustments

    4. Make sure that cable jam nuts are fully tightened af- Figure 1 ter adjustment. 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...

  • Page 24: Service And Repairs

    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...
  • Page 25 C. If indicator and nipple were removed from hous- ing, apply sealant to threads of nipple before assem- bly. 2. Close and latch hood. Groundsmaster 7200/7210 Page 3 – 7 Kubota Diesel Engine...

  • Page 26: Exhaust System

    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...
  • Page 27 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–lb (4.3 to 5.4 N–m). 6. Close and latch hood. Groundsmaster 7200/7210 Page 3 – 9 Kubota Diesel Engine...

  • Page 28: Fuel System

    13. Cap screw 28. Flange nut (2 used) 43. Hose clamp (2 used) 14. Fuel filter 29. Toolbox cover 15. Hose clamp 30. Washer head screw (6 used) 44. Strainer fitting (2 used) Kubota Diesel Engine Page 3 – 10 Groundsmaster 7200/7210...

  • Page 29: Check Fuel Lines And Connections

    (50 PSI maximum pressure). hood and operator seat. Fuel Tank Installation (Fig. 7) NOTE: The fuel tanks on Groundsmaster 7200 and 7210 machines are connected to a common tee–fitting 1. If strainer (outlet) fitting was removed from fuel tank, (item 7) under the seat.

  • Page 30: Radiator

    23. Hose 36. Hose 11. Radiator frame 24. Roll pin 37. Radiator cap 12. Pipe plug 25. R–clamp 38. Washer head screw 13. Air inlet hose 26. Flat washer (6 used) Kubota Diesel Engine Page 3 – 12 Groundsmaster 7200/7210...
  • Page 31 9. Fill radiator with coolant. Make sure that expansion 7. Carefully pull radiator from the radiator frame and tank coolant level is correct. machine. 10.Close and latch hood. 8. Plug radiator and hose openings to prevent contami- nation. Groundsmaster 7200/7210 Page 3 – 13 Kubota Diesel Engine...

  • Page 32: Engine

    (or implement), stop engine, engage parking brake and panel to frame (Fig. 10). Remove rear panel. remove key from the ignition switch. 5. Remove air cleaner from the engine (see Air Cleaner Assembly Removal in this section). Kubota Diesel Engine Page 3 – 14 Groundsmaster 7200/7210...
  • Page 33 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 Kubota Diesel Engine...

  • Page 34: Engine Installation

    C. High temperature warning switch and high tem- perature shutdown switch (Fig. 13). 6. Connect lift or hoist to the front and rear engine lift tabs. D. Starter motor, fusible link harness, alternator and oil pressure switch. Kubota Diesel Engine Page 3 – 16 Groundsmaster 7200/7210...
  • Page 35 17.Connect throttle cable to the support bracket and 24.Bleed fuel system. swivel on the speed control lever. 25.Close and latch hood. Lower operator seat. 18.Adjust throttle cable (see Adjust Throttle Cable in the Adjustments section of this chapter). Groundsmaster 7200/7210 Page 3 – 17 Kubota Diesel Engine...
  • Page 36 This page is intentionally blank. Kubota Diesel Engine Page 3 – 18 Groundsmaster 7200/7210...

  • Page 37: Specifications

    Lift Cylinder Internal Leakage Test ... . PARKER TORQMOTOR SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) Groundsmaster 7200/7210 Page 4 - 1 Hydraulic System Rev. A...

  • Page 38: Specifications

    Hydraulic Oil Capacities (Approximate) Hydraulic Oil Change (Hydraulic Tank and Transmission) 10.9 Qt. U.S. (10.3 L) Hydraulic System (All Components and Lines) 16 Qt. U.S. (15.1 L) Hydraulic Oil See Operator’s Manual Hydraulic System Page 4 – 2 Groundsmaster 7200/7210...

  • Page 39: General Information

    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).

  • Page 40: Hydraulic Hose And Tube Installation

    85 to 105 ft–lb (116 to 142 N–m) 1 7/16 – 12 110 to 136 ft–lb (150 to 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...

  • Page 41: Hydraulic Fitting Installation

    202 to 248 ft–lb (274 to 336 N–m) 121 to 149 ft–lb (165 to 202 N–m) 1 5/8 – 12 247 to 303 ft–lb (335 to 410 N–m) 149 to 183 ft–lb (202 to 248 N–m) Figure 5 Groundsmaster 7200/7210 Page 4 – 5 Hydraulic System...
  • Page 42 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 Groundsmaster 7200/7210...

  • Page 43: Operator's Manual

    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.

  • Page 44: Traction Circuit (Closed Loop) Component Failure

    Traction Circuit (Closed Loop) Component Failure The traction system on Groundsmaster 7200 and 7210 Once the filter has been placed in the traction circuit, place the machine on jack stands and operate the trac- machines consists of two identical and independent closed loop traction circuits.

  • Page 45: Hydraulic Schematics

    Hydraulic Schematics The hydraulic schematics for the Groundsmaster 7200 and 7210 are located in Chapter 8 – Foldout Diagrams. Groundsmaster 7200/7210 Page 4 – 9 Hydraulic System...

  • Page 46: Hydraulic Flow Diagrams

    Hydraulic Flow Diagrams Hydraulic System Page 4 – 10 Groundsmaster 7200/7210...

  • Page 47: Traction Circuits

    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 replenished. Groundsmaster 7200/7210 Page 4 – 11 Hydraulic System...
  • Page 48 Hydraulic System Page 4 - 12 Groundsmaster 7200/7210 Rev. A...

  • Page 49: Lift Circuit (Raise)

    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. Groundsmaster 7200/7210 Page 4 - 13 Hydraulic System Rev. A...
  • Page 50 Hydraulic System Page 4 - 14 Groundsmaster 7200/7210 Rev. A...

  • Page 51: Lift Circuit (Lower)

    (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. Groundsmaster 7200/7210 Page 4 - 15 Hydraulic System Rev. A...
  • Page 52 Hydraulic System Page 4 – 16 Groundsmaster 7200/7210...

  • Page 53: Pto Circuit

    PTO Circuit The transmission used on Groundsmaster 7200 and Pressure to the PTO clutch is limited by the pressure 7210 machines includes a hydraulic, multi–plate clutch valve in the transmission. Pressure valve setting is from that is used to engage the PTO. Hydraulic flow for PTO 280 to 340 PSI (19.3 to 23.4 bar).

  • Page 54: Special Tools

    Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Test Kit Toro Part Number: TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools.

  • Page 55: Hydraulic Test Fitting Kit

    Figure 12 High Flow Hydraulic Filter Kit Toro Part Number: TOR6011 NOTE: Replacement filter element is Toro part number TOR6012. Filter element cannister tightening torque is The high flow hydraulic filter kit is designed with large 25 ft- lb (34 N- m).

  • Page 56: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 4 – 20 Groundsmaster 7200/7210...
  • Page 57 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Groundsmaster 7200/7210 Page 4 – 21...
  • Page 58 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 4 – 22 Groundsmaster 7200/7210...
  • Page 59 This page is intentionally blank. Groundsmaster 7200/7210 Page 4 – 23 Hydraulic System...

  • Page 60: Testing

    Contamination can cause excessive wear or binding of hydraulic components. 14.If a PTO circuit problem exists, consider performing the PTO Pressure Valve Test. 2. When conducting tests on the hydraulic system, wear eye protection. Hydraulic System Page 4 – 24 Groundsmaster 7200/7210...

  • Page 61: Traction System Operation Testing

    Traction System Operation Testing Because the Groundsmaster 7200/7210 traction sys- 3. Wheel speed should be the same on both rear tem uses two (2) separate circuits, it can be difficult to wheels. Make sure hydraulic oil is at normal operating identify which circuit is causing a problem and what hy- temperature.

  • Page 62: Charge Relief Valve Pressure Test

    Charge Relief Valve Pressure Test (Using Pressure Gauge) PRESSURE GAUGE Figure 14 Hydraulic System Page 4 – 26 Groundsmaster 7200/7210...
  • Page 63 Figure 15 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 Hydraulic System...

  • Page 64: Transmission Piston Pump Flow Test

    Transmission Piston Pump Flow Test (Using Tester with Pressure Gauges and Flow Me- ter) Port B Port C Port A Port D RIGHT SIDE TRACTION (PISTON) PUMP TESTING SHOWN HYDRAULIC TESTER Figure 16 Hydraulic System Page 4 – 28 Groundsmaster 7200/7210...
  • Page 65 Procedure for Transmission Piston Pump Flow IMPORTANT: Do not run engine at full speed when Test: performing this flow test using Toro Hydraulic Tes- ter (Pressure and Flow) (TOR214678). Traction 1. Make sure hydraulic oil is at normal operating tem- pump output at full engine speed can damage hy- perature.

  • Page 66: Traction Relief Valve Pressure Test

    Traction Relief Valve Pressure Test (Using Tester with Pressure Gauges and Flow Meter) Port B Port C Port A Port D RIGHT SIDE FORWARD TRACTION RELIEF VALVE TESTING SHOWN HYDRAULIC TESTER Figure 17 Hydraulic System Page 4 – 30 Groundsmaster 7200/7210...
  • Page 67 IMPORTANT: Do not run engine at full speed when Procedure for Traction Relief Valve Pressure Test: performing this test using Toro Hydraulic Tester (Pressure and Flow) (TOR214678). Traction pump 1. Make sure hydraulic oil is at normal operating tem- output at full engine speed can damage hydraulic perature.

  • Page 68: Wheel Motor Efficiency Test

    Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter) Port B Port C Port A Port D RIGHT SIDE WHEEL MOTOR EFFICIENCY TESTING SHOWN HYDRAULIC TESTER Figure 18 Hydraulic System Page 4 – 32 Groundsmaster 7200/7210...
  • Page 69 Continued operation with a worn, IMPORTANT: Do not run engine at full speed when inefficient motor can generate excessive heat, cause performing this test using Toro Hydraulic Tester damage to seals and other components in the hydraulic (Pressure and Flow) (TOR214678). Traction pump system and affect overall machine performance.

  • Page 70: Pto Pressure Valve Test

    PTO Pressure Valve Test (Using Pressure Gauge) Figure 19 Hydraulic System Page 4 – 34 Groundsmaster 7200/7210...
  • Page 71 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 Hydraulic System...

  • Page 72: Implement Relief Pressure Test

    Implement Relief Pressure Test (Using Pressure Gauge) PRESSURE GAUGE Figure 21 Hydraulic System Page 4 – 36 Groundsmaster 7200/7210...
  • Page 73 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 7200/7210 Page 4 – 37 Hydraulic System...

  • Page 74: Gear Pump Flow Test

    Gear Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter) HYDRAULIC TESTER Figure 24 Hydraulic System Page 4 – 38 Groundsmaster 7200/7210...
  • Page 75 8. Start engine and run at low idle speed (1500 to 1650 1. Lift control valve 2. Hose from gear pump RPM). Check for any hydraulic leakage from test con- nections and correct before proceeding with test. Groundsmaster 7200/7210 Page 4 – 39 Hydraulic System...

  • Page 76: Lift Cylinder Internal Leakage Test

    Lift Cylinder Internal Leakage Test Figure 26 Hydraulic System Page 4 – 40 Groundsmaster 7200/7210...
  • Page 77 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 Hydraulic System...
  • Page 78 This page is intentionally blank. Hydraulic System Page 4 – 42 Groundsmaster 7200/7210...

  • Page 79: Service And Repairs

    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 Hydraulic System...

  • Page 80: Flush Hydraulic System

    (oil appears milky, black or con- damage. Use of biodegradable hydraulic fluid in tains metal particles). Groundsmaster 7200 and 7210 machines is not rec- ommended. IMPORTANT: If a component failure occurred in the traction circuit, refer to Traction Circuit (Closed 8.

  • Page 81: Charge Hydraulic System

    (do not overfill). Check hydraulic com- CAUTION ponents for leaks. Tighten any loose connections. 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 Hydraulic System...

  • Page 82: Hydraulic Tank

    3. Remove front cover from machine (Fig. 30). 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. Hydraulic System Page 4 – 46 Groundsmaster 7200/7210...
  • Page 83 6 – Chassis). Make sure that parking brake switch op- Figure 31 eration is correct after brake handle is installed. 1. Hydraulic tank 3. Gear pump 2. Transmission 7. Secure front cover to machine (Fig. 30). Groundsmaster 7200/7210 Page 4 – 47 Hydraulic System...

  • Page 84: Wheel Motors

    3. Jack up machine enough to allow the removal of the drive wheel. Support machine with jack stands. 1. Park machine on a level surface, lower cutting deck (or implement), stop engine, engage parking brake and remove key from the ignition switch. Hydraulic System Page 4 – 48 Groundsmaster 7200/7210...
  • Page 85 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 Hydraulic System...

  • Page 86: Wheel Motor Service

    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 Groundsmaster 7200/7210...
  • Page 87 This page is intentionally blank. Groundsmaster 7200/7210 Page 4 – 51 Hydraulic System...

  • Page 88: Transmission

    27. Cap screw 42. Hydraulic hose 13. Hydraulic hose 28. O–ring 43. Hydraulic fitting (4 used) 14. Cap screw (2 used) 29. Hydraulic fitting 15. Lock washer (2 used) 30. O–ring 44. O–ring Hydraulic System Page 4 – 52 Groundsmaster 7200/7210...

  • Page 89: Transmission Removal

    RIGHT FRONT Figure 37 1. LH wheel motor 4. RH wheel motor 6. Transmission 2. Hydraulic tank 5. 8mm threaded boss 7. Flywheel housing 3. Gear pump Groundsmaster 7200/7210 Page 4 – 53 Hydraulic System...

  • Page 90: Transmission Installation

    81 to 99 ft–lb (110 to 134 N–m) 35 to 43 ft–lb (48 to 58 N–m) 58 to 72 ft–lb (79 to 97 N–m) 20 to 26 ft–lb (28 to 35 N–m) Figure 38 Hydraulic System Page 4 – 54 Groundsmaster 7200/7210...
  • Page 91 Secure harness to frame. screws 400 in–lb (45 N–m). 17.Check parking brake and brake switch operation. 9. Install hydraulic tank to machine (see Hydraulic Tank Installation in this section). 18.Adjust traction drive for neutral. Groundsmaster 7200/7210 Page 4 – 55 Hydraulic System...

  • Page 92: Transmission Service

    Transmission Service 13 14 Figure 39 Hydraulic System Page 4 – 56 Groundsmaster 7200/7210...

  • Page 93: Transmission Disassembly

    Figure 40 1. Solenoid coil 4. Spool 2. Solenoid valve stem 5. Sleeve 3. Pin Groundsmaster 7200/7210 Page 4 – 57 Hydraulic System...
  • Page 94 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...
  • Page 95 14.Slide outer and inner charge pump rotors from RH pump shaft. Remove key from keyslot in pump shaft. Figure 47 1. RH pump shaft 3. Inner pump rotor 2. Outer pump rotor Groundsmaster 7200/7210 Page 4 – 59 Hydraulic System...
  • Page 96 1. Bypass valve 4. Forward relief cartridge 2. Center case 5. Valve plate 3. Reverse relief cartridge Figure 50 1. Forward relief cartridge 3. Hex head groove 2. Reverse relief cartridge Hydraulic System Page 4 – 60 Groundsmaster 7200/7210...
  • Page 97 27.Remove socket head screw and nut that secures control arm onto each trunnion shaft. Slide control arm from each trunnion shaft. Figure 53 1. Oil seal 3. Thrust plate bevel 2. Thrust plate 4. Control arm Groundsmaster 7200/7210 Page 4 – 61 Hydraulic System...
  • Page 98 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...
  • Page 99 Discard removed bearings. Remove gear from input shaft. Figure 57 1. RH pump shaft 3. Input shaft 2. LH pump shaft 4. Seal ring Groundsmaster 7200/7210 Page 4 – 63 Hydraulic System...
  • Page 100 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...
  • Page 101 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 62 1. Rod (3 used) 3. PTO gear 2. Clutch assembly Groundsmaster 7200/7210 Page 4 – 65 Hydraulic System...
  • Page 102 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 7200/7210...
  • Page 103 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 Groundsmaster 7200/7210 Page 4 – 67 Hydraulic System...

  • Page 104: Transmission Assembly

    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 69 1. Socket head plug 3. Pump housing 2. Hex plug Hydraulic System Page 4 – 68 Groundsmaster 7200/7210...
  • Page 105 D. Carefully install two (2) seal rings into grooves of PTO shaft. Figure 72 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 Groundsmaster 7200/7210 Page 4 – 69 Hydraulic System...
  • Page 106 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...
  • Page 107 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 77 1. Input shaft 3. LH pump shaft 2. RH pump shaft 4. Pipe assembly Groundsmaster 7200/7210 Page 4 – 71 Hydraulic System...
  • Page 108 Torque hex plugs from 14 to 15 ft–lb (18 to 21 N–m) and socket head plug from 17 to 19 ft–lb (22 to 27 N–m). Figure 79 1. Hex plug 2. Socket head plug Hydraulic System Page 4 – 72 Groundsmaster 7200/7210...
  • Page 109 Install springs and plugs to secure flushing valves. Torque plugs from 17 to 19 ft–lb (22 to Figure 82 27 N–m). 1. Hex plug (6 used) 3. LH flushing valve 2. RH flushing valve 4. Center case Groundsmaster 7200/7210 Page 4 – 73 Hydraulic System...
  • Page 110 (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 85 1. Center case 3. Pin (2 used) 2. Pump housing Hydraulic System Page 4 – 74 Groundsmaster 7200/7210...
  • Page 111 (2) longer flange head screws to secure pump body to center case. Torque screws in a crossing pattern from 17 to 19 ft–lb (22 to 27 N–m). Figure 88 1. Pump body 2. Center case Groundsmaster 7200/7210 Page 4 – 75 Hydraulic System...
  • Page 112 49.Lubricate new O–ring and install O–ring onto plug. Install plug into pump body. Torque plug from 17 to 19 ft–lb (22 to 27 N–m). Figure 92 1. Filter bypass valve 2. Filter bypass plug Hydraulic System Page 4 – 76 Groundsmaster 7200/7210...
  • Page 113 “I” nearest the nut location. Torque nut from 52 to 69 in– lb (5.9 to 7.8 N–m). Figure 93 1. Sleeve 5. Spool step 2. Spool 6. Solenoid valve stem 3. Pin 7. Solenoid coil 4. Sleeve holes Groundsmaster 7200/7210 Page 4 – 77 Hydraulic System...

  • Page 114: Gear Pump

    10.Remove two (2) cap screws and lock washers that 4. Thoroughly clean hydraulic hose ends and fittings on secure gear pump to the transmission. gear pump and hydraulic tank to prevent hydraulic sys- tem contamination. Hydraulic System Page 4 – 78 Groundsmaster 7200/7210...
  • Page 115 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). Groundsmaster 7200/7210 Page 4 – 79 Hydraulic System...

  • Page 116: Gear Pump Service

    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...
  • Page 117 Make sure that C. Inspect gear face edge for sharpness. Sharp these surfaces are clean and dry. edges of gears will mill into bearing blocks and, thus, must be replaced. Groundsmaster 7200/7210 Page 4 – 81 Hydraulic System...
  • Page 118 If input shaft binds, disassemble pump and 13.Install the four (4) socket head screws with lock repeat assembly process. washers and hand tighten. 18.Remove pump from vise. Hydraulic System Page 4 – 82 Groundsmaster 7200/7210...
  • Page 119 This page is intentionally blank. Groundsmaster 7200/7210 Page 4 – 83 Hydraulic System...

  • Page 120: Manual Lift Control Valve

    23. Hydraulic fitting 8. Hydraulic hose (to oil cooler) 16. Cap screw NOTE: Machines with serial number below 313000000 use a manual lift control valve to engage the cutting deck lift circuit. Hydraulic System Page 4 - 84 Groundsmaster 7200/7210 Rev. A...
  • Page 121 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. Figure 100 1. Lift control valve 3. Cap screw 2. Lift lever valve link Groundsmaster 7200/7210 Page 4 - 85 Hydraulic System...

  • Page 122: Below 313000000)

    (item 6) from control valve. 15), poppet stop (item 10), spring (item 2) and poppet (item 11) from control valve body. 4. Carefully slide spool (item 8) from housing bore. Hydraulic System Page 4 - 86 Groundsmaster 7200/7210 Rev. A...
  • Page 123 1. Lift control valve 3. O- ring 2. Plug cure with screw. Retain spool to prevent it from turning and torque screw from 24 to 36 in- lb (2.7 to 4.1 N- m). Groundsmaster 7200/7210 Page 4 - 87 Hydraulic System...

  • Page 124: Lift Control Manifold (Serial Number Above 313000000)

    313000000 use an lift control manifold to engage the cutting deck lift circuit. A switch on the right side traction lever is used to activate the lift system on these ma- chines. Hydraulic System Page 4 - 88 Groundsmaster 7200/7210 Rev. A...
  • Page 125 8. If hydraulic fittings are to be removed from lift control manifold, mark fitting orientation to allow correct assem- bly. Remove hydraulic fittings from manifold as needed. Discard O- rings from removed fittings. Groundsmaster 7200/7210 Page 4 - 89 Hydraulic System Rev. A...

  • Page 126: Lift Control Manifold Service (Serial Number Above 313000000)

    Schematic in Chapter 8 - Foldout Drawings to identify may have been the same manifold as used on machines the function of the hydraulic lines and cartridge valves with a serial number above 315000000. at each manifold port. Hydraulic System Page 4 - 90 Groundsmaster 7200/7210 Rev. A...
  • Page 127 Contamination can become lodged in small valve 9. If problems still exist after manifold assembly, re- orifices or seal areas causing malfunction. move cartridge valve and clean again or replace valve. Groundsmaster 7200/7210 Page 4 - 91 Hydraulic System Rev. A...
  • Page 128 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 - 92 Groundsmaster 7200/7210...
  • Page 129 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. 106). Groundsmaster 7200/7210 Page 4 - 93 Hydraulic System...
  • Page 130 19. Detent plug 30. Back- up washer Check spring 20. Wiper seal 31. Plug 10. Spool cap (2 used) 21. Plunger 32. O- ring 11. Valve body 22. Detent plunger 33. Spool Hydraulic System Page 4 - 94 Groundsmaster 7200/7210...
  • Page 131 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). Groundsmaster 7200/7210 Page 4 - 95 Hydraulic System...

  • Page 132: Lift Cylinder

    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 - 96 Groundsmaster 7200/7210...
  • Page 133 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. 109). Groundsmaster 7200/7210 Page 4 - 97 Hydraulic System...

  • Page 134: Lift Cylinder Service

    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 - 98 Groundsmaster 7200/7210...
  • Page 135 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. Groundsmaster 7200/7210 Page 4 - 99 Hydraulic System...

  • Page 136: Polar Trac Tm Lift Cylinder

    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. Lift arm 8. O- ring 12. Lock nut Hydraulic System Page 4 - 100 Groundsmaster 7200/7210...
  • Page 137 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 - 101 Hydraulic System...
  • Page 138 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 - 102 Groundsmaster 7200/7210...
  • Page 139 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 - 103 Hydraulic System...

  • Page 140: Oil Cooler

    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 - 104 Groundsmaster 7200/7210...
  • Page 141 ......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...

  • Page 142: Special Tools

    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 impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 143 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4 Groundsmaster 7200/7210 Page 5 - 3 Electrical System Rev. A...

  • Page 144: Troubleshooting

    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 Problem Possible Causes Starter solenoid clicks, but starter will not crank.
  • Page 145 Engine starts, but stops when the ignition switch is Engine fuel stop solenoid or circuit wiring is faulty (pull released from the START position. coil operates but hold coil or circuit wiring is faulty). The ignition switch is faulty. Groundsmaster 7200/7210 Page 5 - 5 Electrical System...

  • Page 146: General Run & Transport Problems

    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. Electrical System Page 5 - 6 Groundsmaster 7200/7210...

  • Page 147: Cutting Deck Operating Problems

    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). Groundsmaster 7200/7210 Page 5 - 7 Electrical System...

  • Page 148: Electrical System Quick Checks

    Tool(s) required: Digital multimeter and/or inductive Ammeter (AC/DC Current Transducer). The glow plug system on Groundsmaster 7200 and 7210 machines should have a reading of approximately Test instructions: Properly connect the ammeter to the 27 Amps.

  • Page 149: Check Operation Of Interlock Switches

    Correct problem if machine is not operating properly. Groundsmaster 7200 and 7210 machines are equipped with a Standard Control Module (SCM) which monitors 3. With operator in the seat, the traction control levers interlock switch operation.

  • Page 150: Component Testing

    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. Electrical System Page 5 - 10 Groundsmaster 7200/7210 Rev. A...

  • Page 151: Indicator Lights

    ON position. Testing Indicator Lights 1. Apply 12 VDC to terminals 1A and 2A (Fig. 8). 2. Ground terminals 1B and 2B (Fig. 8). 3. Both indicator lights should illuminate. Groundsmaster 7200/7210 Page 5 - 11 Electrical System...

  • Page 152: 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 9 7. Connect harness electrical connector to the hour meter. Electrical System Page 5 - 12 Groundsmaster 7200/7210...

  • Page 153: Pto Switch

    ON (UP) COM B + NO B COM B + NC B Verify continuity between switch terminals. COM C + NO C COM C + NC C Groundsmaster 7200/7210 Page 5 - 13 Electrical System...

  • Page 154: Neutral Switches

    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.

  • Page 155: Seat Switch

    D. With no pressure on the seat, there should be no continuity between the seat switch harness termi- nals. Figure 15 1. Seat harness connector 2. Machine wire harness Groundsmaster 7200/7210 Page 5 - 15 Electrical System...

  • Page 156: Parking Brake Switch

    Schematics and Circuit Drawings in Chapter 8 - Foldout Diagrams). Figure 18 1. Brake shaft tab 3. Screw I. Connect switch connector to machine wire har- 2. Parking brake switch ness. Check brake switch operation. Electrical System Page 5 - 16 Groundsmaster 7200/7210 Rev. A...

  • Page 157: Parking Brake Switch

    (continuity) to ground. Figure 19 1. Parking brake switch 4. Shaft tab 2. Lock washer (2 used) 5. Brake pedal 3. Jam nut (2 used) Groundsmaster 7200/7210 Page 5 - 17 Electrical System Rev. A...

  • Page 158: Standard Control Module

    Standard Control Module Groundsmaster 7200/7210 machines are equipped with SCM Outputs (Fig. 21) a Standard Control Module (SCM) to monitor and con- The Start output LED should be illuminated when the trol electrical components required for safe operation. ignition key switch is in the START position with the trac- The SCM is attached to the control panel cover (Fig.

  • Page 159: Standard Control Module Logic Chart

    LED OFF - Circuit is open to ground or circuit is de- energized Circuit is not involved with this machine function (LED OFF) 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.

  • Page 160: Pto Solenoid Valve Coil

    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.

  • Page 161: Lift Control Manifold Solenoid Valve Coils

    Above 313000000) in the Service and Repairs section of Chapter 4 - Hydraulic System). 5. After testing the coils, connect wire harness electri- cal connector to the solenoid valve coil. Figure 25 Groundsmaster 7200/7210 Page 5 - 21 Electrical System Rev. A...

  • Page 162: Fusible Link Harness

    Fusible Link Harness The Groundsmaster 7200 and 7210 uses three (3) fus- ible links for circuit protection. These fusible links are lo- FUSIBLE LINK cated in a harness that connects the starter B+ terminal FUSIBLE LINK FUSIBLE LINK to the main wire harness. If any of these links should fail, current to the protected circuit will cease.

  • Page 163: Glow Relay

    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.

  • Page 164: High Temperature Warning Switch

    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 - 24 Groundsmaster 7200/7210...

  • Page 165: High Temperature Shutdown Switch

    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 Groundsmaster 7200/7210 Page 5 - 25 Electrical System...

  • Page 166: Dual Temperature Switch

    3. Put the end of the switch in a container of oil with a thermometer and slowly heat the oil (Fig. 35). CAUTION Handle the hot oil with extreme care to prevent Figure 35 personal injury or fire. Electrical System Page 5 - 26 Groundsmaster 7200/7210...

  • Page 167: Deck Lift/Lower Switch

    8. If testing determines that the deck lift/lower switch is Figure 37 faulty, replace lift/lower switch. 1. RH traction lever 4. Switch wire harness 2. Switch cap 5. Deck lift/lower switch 3. Screw (2 used) Groundsmaster 7200/7210 Page 5 - 27 Electrical System Rev. A...

  • Page 168: Fuel Pump

    8. Connect wire harness electrical connector to the fuel stop solenoid. Machines with serial numbers above 280000000: 9. Bleed fuel system. Pump Capacity 64 fl oz/min (1.9 liters/min) Pressure 7 PSI (48.3 kPa) Current Draw 2.0 amp Electrical System Page 5 - 28 Groundsmaster 7200/7210 Rev. A...

  • Page 169: Fuel Stop Solenoid

    (ground) (Fig. 41). 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. Groundsmaster 7200/7210 Page 5 - 29 Electrical System...

  • Page 170: Glow Controller

    1. Controller top view 2. Controller end view switch to the controller and perform Step 4 again (see Chapter 8 - Foldout Diagrams). Electrical System Page 5 - 30 Groundsmaster 7200/7210...

  • Page 171: Service And Repairs

    3. Connect the wire harness electrical connector to the solenoid valve coil connector. 53 to 69 in- lb (5.9 to 7.8 N- m) Figure 45 1. Hex nut 4. Seal 2. Lock washer 5. Solenoid valve coil 3. Washer Groundsmaster 7200/7210 Page 5 - 31 Electrical System...

  • Page 172: Battery Storage

    (+) cable first. Coat terminals are explosive, keep open flames and electrical with battery terminal protector (Toro Part No. 107- 0392) sparks away from the battery; do not smoke. or a light coat of grease to reduce corrosion after con- Nausea may result if the gases are inhaled.

  • Page 173: Battery Service

    7. Carriage screw A. Check for cracks. Replace battery if cracked or 4. Flange nut 8. Positive cable leaking. B. Check battery terminal posts for corrosion. Use wire brush to clean corrosion from posts. Groundsmaster 7200/7210 Page 5 - 33 Electrical System...
  • Page 174 0.1 amp usually indicates a faulty nals following the manufacturer’s instructions. switch, a shorted circuit or grounded wire. Identify and Connect a digital multimeter to the battery terminals. repair electrical faults before returning machine to ser- vice. Electrical System Page 5 - 34 Groundsmaster 7200/7210...
  • Page 175 8. After connections are made, apply battery terminal 80 or 3.8 hrs 7.5 hrs 11.3 hrs 15 hrs protector (Toro Part No. 107- 0392) or a light coat of less grease on all battery posts and cable connectors to re- 3 amps 3 amps 3 amps 3 amps duce corrosion.
  • Page 176 This page is intentionally blank. Electrical System Page 5 - 36 Groundsmaster 7200/7210...
  • Page 177 ........Groundsmaster 7200/7210 Page 6 – 1...

  • Page 178: Specifications

    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...

  • Page 179: General Information

    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...

  • Page 180: Service And Repairs

    12. Hydraulic fitting 3. Wheel assembly 8. Woodruff key 13. Hydraulic hose 4. Wheel hub 9. O–ring 14. Hydraulic hose 5. Wheel stud (5 used per wheel) 10. Hydraulic fitting 15. Parking brake (LH shown) Chassis Page 6 – 4 Groundsmaster 7200/7210...
  • Page 181 (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 Chassis...

  • Page 182: Polar Trac Tm Wheels

    16. Bogey pivot assembly (LH shown) 5. Wheel assembly (6 used) 11. Parking brake (LH shown) 17. Wheel stud (5 used per hub) 6. Lug nut (5 used per wheel) 12. Screw (4 used per motor) Chassis Page 6 – 6 Groundsmaster 7200/7210...
  • Page 183 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. Figure 3 1. Side access cover 2. Lock nut / flat washer Groundsmaster 7200/7210 Page 6 – 7 Chassis...

  • Page 184: Parking Brakes

    Locate and retrieve two (2) hardened washers from between parking brake and brake support (Figs. 5 and 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 Groundsmaster 7200/7210...
  • Page 185 (item 6) from 300 to 400 ft–lb (407 to 542 1. Brake swivel 4. Hardened washer N–m). Release parking brake. 2. Caliper brake lever 5. Clearance 3. Wheel hub disc 11. Check parking brake and brake switch operation. Groundsmaster 7200/7210 Page 6 – 9 Chassis...

  • Page 186: Parking Brake Service

    6. Hex nut (2 used) 13. Hex nut (2 used) 19. Washer 7. Stationary actuator NOTE: If parking brake wear or damage occurs, brake replacement is necessary. Individual brake components are not available. Chassis Page 6 – 10 Groundsmaster 7200/7210...
  • Page 187 (item 15) and hex nuts (items 5 and 6). plete brake assembly if excessive wear or damage to Torque fasteners to values identified in Figure 8. any component is detected. Groundsmaster 7200/7210 Page 6 – 11 Chassis...

  • Page 188: Parking Brake Assembly

    14. Flat washer (2 used) 22. Brake linkage yoke (2 used) 7. Retaining ring (2 used) 15. Brake switch 23. Clevis spring pin (2 used) 8. Retaining ring (2 used) 16. Switch nut 24. Frame bracket Chassis Page 6 – 12 Groundsmaster 7200/7210...
  • Page 189 3. Flat washer 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 Chassis...

  • Page 190: Front Castor Wheels

    (Fig. 14). Belleville washer orienta- tion is critical for proper castor wheel movement. 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 Groundsmaster 7200/7210...
  • Page 191 Allow grease to fill cavities below lower bearing, between bearings and above upper bearing. Reinstall plug into frame. Groundsmaster 7200/7210 Page 6 - 15 Chassis...

  • Page 192: Polar Trac Tm Wheel Hub Service

    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...
  • Page 193 4. Slide the wheel hub assembly onto the spindle shaft and secure it in place with the slotted hex nut. DO NOT fully tighten the nut or install the cotter pin. Groundsmaster 7200/7210 Page 6 – 17 Chassis...

  • Page 194: Pto Drive Shaft

    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...
  • Page 195 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 Chassis...

  • Page 196: Pto Drive Shaft Cross And Bearing Service

    IMPORTANT: Take care when installing cross into bearing to avoid damaging bearing seal. 1. End yoke 3. Snap ring (4 used) 2. Cross and bearing kit 4. Shaft yoke C. Carefully insert cross into bearing and yoke. Chassis Page 6 – 20 Groundsmaster 7200/7210...
  • Page 197 This page is intentionally blank. Groundsmaster 7200/7210 Page 6 – 21 Chassis...

  • Page 198: Cutting Deck Lift Arms

    (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...
  • Page 199 Install HOC pin 1. Rear lift arm 3. Washer cavity 2. Washer 4. Deck lift shaft into HOC bracket to allow desired height–of–cut (Fig. 22). 18.070 to 18.180 in (45.9 to 46.1 cm) Figure 26 Groundsmaster 7200/7210 Page 6 – 23 Chassis...

  • Page 200: Operator Seat

    22. Washer head screw (2 used) 6. Seat stop lever 14. Grommet 7. Latch lever (2 used) 15. Cap screw 23. Clevis pin 8. Seat plate 16. Seat belt 24. Seat switch harness Chassis Page 6 – 24 Groundsmaster 7200/7210...
  • Page 201 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...

  • Page 202: Operator Seat Service

    24. Seat switch 7. Seat frame assembly 16. Cable (2 used) 25. Seat adjuster 8. Lumbar support knob 17. Weight adjust bar 26. Seat adjuster (slave) 9. Label 18. Label 27. Seat boot Chassis Page 6 – 26 Groundsmaster 7200/7210...
  • Page 203 Secure bolt in position with nut. Groundsmaster 7200/7210 Page 6 – 27 Chassis...

  • Page 204: Hood

    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...
  • Page 205 3. Position hood to machine and slide hood support 6. If necessary, remove hood components using Figure onto frame rods. 31 as a guide. 4. Secure hood to frame rods with hair pin cotter (item 5. Close and latch hood. Groundsmaster 7200/7210 Page 6 – 29 Chassis...
  • Page 206 This page is intentionally blank. Chassis Page 6 – 30 Groundsmaster 7200/7210...
  • Page 207 ........Cutting Deck Pull Links ..... Groundsmaster 7200/7210 Page 7 – 1 Cutting Deck...

  • Page 208: General Information

    The Operator’s Manual provides 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...

  • Page 209: Factors That Can Affect Cutting Performance

    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...
  • Page 210 This page is intentionally blank. Cutting Deck Page 7 – 4 Groundsmaster 7200/7210...

  • Page 211: Service And Repairs

    (7) seconds, the PTO brake assem- surface to avoid dust and debris. bly in the transmission should be inspected. Groundsmaster 7200/7210 Page 7 – 5 Cutting Deck...

  • Page 212: Cutting Deck Removal And Installation

    PTO clutch. 5. To prevent unintentional engagement of the PTO clutch, remove fuse F1 (15 amp) from fuse block. Figure 3 1. Clevis pin 3. Adjustment clevis 2. Deck lift chain Cutting Deck Page 7 – 6 Groundsmaster 7200/7210...
  • Page 213 7. Install fuse F1 (15 amp) into fuse block. 3. Connect end yoke of PTO drive shaft to cutting deck gearbox shaft (see PTO Drive Shaft Installation in the Service and Repairs section of Chapter 6 – Chassis). Groundsmaster 7200/7210 Page 7 – 7 Cutting Deck...

  • Page 214: Idler Assembly

    5. Snap ring 13. Center spindle assembly 20. LH idler arm 6. Flange bushing 14. RH spindle assembly 21. Stop bolt 7. Torsion spring 15. Socket head screw 22. Jam nut 8. Washer Cutting Deck Page 7 – 8 Groundsmaster 7200/7210...
  • Page 215 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 Cutting Deck...

  • Page 216: Blade Spindle

    (Fig. 7). 4. Remove drive belt from deck pulleys (see Operator’s Figure 7 Manual). 1. Idler arm (RH shown) 3. 3/8” square drive 2. 1/2” square drive Cutting Deck Page 7 – 10 Groundsmaster 7200/7210...
  • Page 217 3. Flange nut (8 used) 6. Blade bolt 6. Install belt covers to cutting deck. Lower the footrest. RIGHT FRONT Figure 9 RH spindle grease fitting Center spindle grease fitting LH spindle grease fitting Groundsmaster 7200/7210 Page 7 – 11 Cutting Deck...

  • Page 218: Blade Spindle Service

    2. Spacer ring 5. Outer spacer 3. Large snap ring 2. Install outer spacer into top of spindle housing. The spacer should fit against the snap ring. Cutting Deck Page 7 – 12 Groundsmaster 7200/7210...
  • Page 219 1. Upper seal 3. Flat washer 2. O–ring 4. Lock nut 13.Rotate spindle shaft to make sure that it turns freely. Groundsmaster 7200/7210 Page 7 – 13 Cutting Deck...

  • Page 220: Gearbox

    (or 4. Remove drive belt from deck pulleys. implement), remove fuse F1 (15 amp) from fuse block to prevent unintentional engagement of the PTO clutch. Cutting Deck Page 7 – 14 Groundsmaster 7200/7210...
  • Page 221 12) to deck mounting plate. 2. Dipstick 5. Oil seal 3. Oil cap 6. Plug 7. Secure gearbox assembly to gearbox brackets with four (4) cap screws (item 10) and lock washers (item 11). Groundsmaster 7200/7210 Page 7 – 15 Cutting Deck...

  • Page 222: Cutting Deck Pull Links

    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...
  • Page 223 3. Torsion spring end 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 Cutting Deck...
  • Page 224 This page is intentionally blank. Cutting Deck Page 7 – 18 Groundsmaster 7200/7210...
  • Page 225 ......Serial Number Above 403440001 ... . Groundsmaster 7200/7210 Page 8 - - 1 Foldout Diagrams...

  • Page 226: Electrical Drawing Designations

    SP. The manufac- turing number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1). Foldout Diagrams Page 8 - - 2 Groundsmaster 7200/7210 Rev. A...

  • Page 227: Hydraulic Schematics

    LH WHEEL MOTOR BYPASS 300 to 310 cc VALVE LSHT REAR PORT FLUSHING PORT VALVE 4000 PSI (276 bar) Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 All solenoids are shown as de- - energized. Page 8 - - 3...

  • Page 228: Serial Number Below 313000000

    PORT PORT FLUSHING VALVE OPTIONAL 4000 PSI (276 bar) AUXILIARY HYDRAULIC POWER KIT Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Rear Attach Lift Kit Installed) All solenoids are shown as de- - energized. Page 8 - - 4...

  • Page 229: Serial Number Below 313000000

    300 to 310 cc VALVE LSHT REAR PORT PORT FLUSHING VALVE 4000 PSI (276 bar) Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Polar Trac Installed) All solenoids are shown as de- - energized. Page 8 - - 5...

  • Page 230: Serial Number Below 313000000

    FLUSHING OPTIONAL VALVE 4000 PSI (276 bar) AUXILIARY HYDRAULIC POWER KIT Groundsmaster 7200/7210 Hydraulic Schematic Serial Number Below 313000000 (With Polar Trac and Rear Attach Lift Kit Installed) All solenoids are shown as de- - energized. Page 8 - - 6...

  • Page 231: Serial Number From 313000001 To 314999999

    IMPLEMENT RELIEF Gear Charge Pump 1:0.691 2250 RPM Pump PTO CLUTCH Groundsmaster 7200/7210 Hydraulic Schematic PORT 1 Serial Number From 313000001 to 314999999 Suction Screen 100 Mesh (With Optional Hydraulic Kits Shown) All solenoids are shown as de- - energized.

  • Page 232: Serial Number Above 315000000

    ENGINE RATED SPEED KUBOTA 3250 RPM PTO CLUTCH BREATHER PORT 1 OPTIONAL OVERFLOW TANK Groundsmaster 7200/7210 PTO PRESSURE TEST PORT Hydraulic Schematic Serial Number Above 315000000 (With Optional Hydraulic Kits Shown) All solenoids are shown as de- - energized. Page 8 - - 8...

  • Page 233: Electrical Schematics

    FOR OPTIONAL FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Electrical Schematic Serial Number Below 313000000 All relays and solenoids are shown as de- - energized. FOR ACCESSORY POWER KIT All ground wires are black. Page 8 - - 9...

  • Page 234: Serial Number Below 313000000 (With Optional Electrical Kits Shown)

    Groundsmaster 7200/7210 Electrical Schematic Serial Number Below 313000000 (With Optional Electrical Kits Shown) All relays and solenoids are shown as de- - energized. All ground wires are black. Page 8 - - 10...

  • Page 235: Serial Numbers 313000000 To 403440000

    Groundsmaster 7200/7210 Electrical Schematic Serial Numbers 313000000 to 403440000 (With Optional Electrical Kits Shown) All solenoids are shown as de- - energized. Page 8 - - 11...
  • Page 236 122- -1413 Rev B Groundsmaster 7200/7210 Electrical Schematic All solenoids are shown (Serial numbers above 403440001) as de- -energized. (With Optional Electrical Kits Shown) Page 8 - - 12...

  • Page 237: Glow Circuits

    (OCCUPIED) LH NEUTRAL SWITCH RH NEUTRAL SWITCH (IN NEUTRAL LOCK) (IN NEUTRAL LOCK) FOR OPTIONAL FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Glow Circuits Serial Number Below 313000000 Shown Power Current FOR ACCESSORY Control Current POWER KIT Indication Current Page 8 - - 13...

  • Page 238: Crank Circuits

    LH NEUTRAL SWITCH RH NEUTRAL SWITCH (IN NEUTRAL LOCK) (IN NEUTRAL LOCK) (PTO OFF) FOR OPTIONAL FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Crank Circuits Serial Number Below 313000000 Shown FOR ACCESSORY POWER KIT Power Current Control Current Indication Current Page 8 - - 14...

  • Page 239: Run Circuits

    LH NEUTRAL SWITCH RH NEUTRAL SWITCH (NOT IN NEUTRAL) (NOT IN NEUTRAL) (PTO OFF) FOR OPTIONAL FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Run Circuits Serial Number Below 313000000 Shown FOR ACCESSORY POWER KIT Power Current Control Current Indication Current Page 8 - - 15...

  • Page 240: Run Circuits (Pto Engaged)

    LH NEUTRAL SWITCH RH NEUTRAL SWITCH (NOT IN NEUTRAL) (NOT IN NEUTRAL) (PTO ON) FOR OPTIONAL FOR ACCESSORY POWER KIT Groundsmaster 7200/7210 Run Circuits (PTO Engaged) Serial Number Below 313000000 Shown FOR ACCESSORY POWER KIT Power Current Control Current Indication Current...

  • Page 241: Wire Harness Drawings

    (SERIAL NUMBERS (SERIAL NUMBERS BELOW 28000000) ABOVE 28000000) Groundsmaster 7200/7210 Wire Harness Drawing (Serial Number Below 310000000) Page 8 - - 17...
  • Page 242 VIOLET BROWN BLACK GREEN BLACK BLACK BLACK FUSIBLE LINK WHITE RED/BLACK PINK BLACK RED/BLACK BLACK PINK PINK PINK WHITE ORANGE YELLOW YELLOW PINK Groundsmaster 7200/7210 Wire Harness Diagram (Serial Number Below 310000000) Page 8 - - 18...

  • Page 243: Serial Number From 310000001 To 312999999

    Groundsmaster 7200/7210 Wire Harness Drawing (Serial Number From 310000001 to 312999999) Page 8 - - 19...
  • Page 244 FUSIBLE LINK Groundsmaster 7200/7210 Wire Harness Diagram (Serial Number From 310000001 to 312999999) Page 8 - - 20...
  • Page 245 Groundsmaster 7200/7210 Wire Harness Drawing (Serial Numbers 313000000 to 403440000) Page 8 - - 21...
  • Page 246 FUSIBLE LINK Groundsmaster 7200/7210 Wire Harness Diagram (Serial Numbers 313000000 to 403440000) Page 8 - - 22...
  • Page 247 122- -1414 Rev A Groundsmaster 7200/7210 Wire Harness Drawing (Serial numbers above 403440001) Page 8 - - 23...
  • Page 248 122- -1414 Rev A Groundsmaster 7200/7210 Wire Harness Drawing (Serial numbers above 403440001) Page 8 - - 24...

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Groundsmaster 7210

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