Toro Groundsmaster 7210 Service Manual Download | Manualshive

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Installing the Engine (continued)

5. Support the transmission to prevent it from moving during the engine

installation.

6. Carefully lower the engine into the machine, align the engine with the

transmission input shaft, and move the engine toward the flywheel housing.

IMPORTANT

When installing the engine ensure that you do not damage the
engine, flywheel housing, fuel hoses, hydraulic lines, electrical
harness or other parts. Also, ensure that transmission does not
shift during engine installation.

g035027

Figure 19

1.

Tab

3.

Return hose

2.

Clamp

4.

Fuel supply hose

Groundsmaster 7210

Page 3–25

Diesel Engine: Service and Repairs

16222SL Rev C

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Summary of Contents for Groundsmaster 7210

Page 1: ...No 16222SL Rev D Groundsmaster 7210 Models with Yanmar Engine 2019 The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 Original Instructions EN Contact us at www Toro com All Rights Reser...

Page 2: ...cription A 2016 Initial issue B 2017 Added Foldout Drawings C 03 2018 Updated Engine chapter Added Revision History and published in new format Revision History Page 2 Groundsmaster 7210 16222SL Rev C...

Page 3: ...ely 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 or Mail to Technical Publicatio...

Page 4: ...NOTES Revision History Page 4 Groundsmaster 7210 16222SL Rev C...

Page 5: ...afety symbol means danger When you see this symbol carefully read the instructions that follow Failure to obey the instructions could kill or cause serious permanent injury or disability WARNING This...

Page 6: ...htening sequence component orientation that may not be obvious Critical Torque This icon is used to highlight an assembly torque requirement that is different than what is recommended in the Standard...

Page 7: ...rical Components 5 23 Adjustments 5 54 Service and Repairs 5 56 Chapter 6 Chassis 6 1 Specifications 6 2 General Information 6 3 Service and Repairs 6 4 Chapter 7 Cutting Deck 7 1 General Information...

Page 8: ...ce Materials YANMAR TNV TIER 4 SERIES SERVICE MANUAL YANMAR TNV TIER 4 SERIES TROUBLESHOOTING MANUAL PARKER TORQMOTOR SERVICE PROCEDURE TC TB TE TJ TF TG TH AND TL SERIES Preface Page 8 Groundsmaster...

Page 9: ...ties 1 2 Before Operating the Machine 1 2 While Operating the Machine 1 3 Maintenance and Service 1 4 Jacking Instructions 1 6 Raising the Front of the Machine 1 6 Raising the Rear of the Machine 1 7...

Page 10: ...te survey follow the procedure outlined in the Operator s Manuals Before Operating the Machine Review and understand the contents of the Operator s Manuals and Operator s Training DVD before starting...

Page 11: ...un the engine in a confined area without adequate ventilation 1 Set the parking brake 2 Ensure that the 2 drive handles are in the NEUTRAL LOCK position and the PTO switch is in the OFF disengaged pos...

Page 12: ...e pressure in the system by parking the machine on a level surface lowering the cutting deck or implement completely and then shutting off the engine Use eye protection when working on the hydraulic s...

Page 13: ...n result in non conformance with the safety standards and can void the warranty When changing the attachments tires or performing other service use correct blocks hoists and jacks to raise and support...

Page 14: ...he raised machine Do not use the cutting deck or implement as a jacking point Raising the Front of the Machine g033384 Figure 2 1 Front castor wheel 2 Front jacking point 1 Set the parking brake and b...

Page 15: ...g point 1 Block the 2 front castor wheels with chocks to prevent the machine from moving 2 Position the jack securely under the flat surface of the protection plate Figure 3 3 Lift the rear wheels off...

Page 16: ...unit and cutting units of your Groundsmaster If any decal becomes illegible or damaged install a new decal Decal part numbers are listed in your Parts Catalog Order replacement decals from Authorized...

Page 17: ...tener 2 4 Calculating the Torque Values When Using a Drive Adapter Wrench 2 5 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 2 6 Standard Torque for Dry Zinc Plated and Steel Fast...

Page 18: ...5 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...

Page 19: ...5 Cubic Feet Cubic Meters 0 028 Volume Cubic Inches Cubic Centimeters 16 39 Tons Short Metric Tons 0 908 Pounds Kilograms 0 454 Weight Ounces Avdp Grams 28 349 Pounds Sq In Kilopascal 6 895 Pressure P...

Page 20: ...ardness of the surface underneath the head of the fastener or similar condition which affects the installation As noted in the following tables the torque values should be reduced by 25 for the lubric...

Page 21: ...e lower than the listed torque recommendation Example The measured effective length of the torque wrench distance from the center of the handle to the center of the square drive is 457 mm 18 inches Th...

Page 22: ...4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 1...

Page 23: ...m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m Note The torque values must be reduced when installing the fasteners into threaded aluminum or brass The specified torque value should be d...

Page 24: ...t lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cut...

Page 25: ...he use of a shop supply may appear in figures that support a procedure Always refer to the written procedure for specific information regarding the type and the application of a shop supply IMPORTANT...

Page 26: ...ts into housings or onto shafts When cured bearing and sleeve retaining compound fills the gap between mating parts with a hard resin that increases load distribution and protects against corrosion Ad...

Page 27: ...omponents for flow and pressure capacities The tester flow measurement maximum is 57 LPM 15 GPM This tester includes the following Inlet Hose This hose connects the system circuit to the inlet side of...

Page 28: ...h a gauge rated at 20 to 150 LPM 4 to 40 GPM Note This tester does not include any hydraulic hoses or fittings refer to Hydraulic Hose Kit Toro Part No TOR6007 and Hydraulic Test Fitting Kit Tor Part...

Page 29: ...6 ORFS 11 16 16 TOR4079 18 8 ORFS 13 16 16 TOR4079 19 CAP 2 each 10 ORFS 1 14 TOR4079 20 6 ORFS 11 16 16 to 8 SAE ORB 3 4 16 TOR4079 8 8 ORFS 13 16 16 to 8 SAE ORB 3 4 16 TOR4079 9 UNION 1 each 10 OR...

Page 30: ...Hose Kit page 2 12 Note The replacement filter element is Toro Part No TOR6012 The filter element canister tightening torque is 34 N m 25 ft lb Remote Starter Switch After flushing the hydraulic syste...

Page 31: ...e excess current is not allowed through the meter This excess current can damage the circuits that are not designed to carry it Battery Terminal Protector Toro Part No 107 0392 Use this aerosol spray...

Page 32: ...Specifications and Maintenance Special Tools Page 2 16 Groundsmaster 7210 16222SL Rev C...

Page 33: ...ne Electronic Control Unit ECU 3 3 Yanmar Engine 3 4 Diesel Particulate Filter DPF 3 4 Service and Repairs 3 8 Air Cleaner System 3 8 Exhaust System 3 10 Radiator 3 13 Fuel System 3 17 Engine 3 21 Add...

Page 34: ...sel or Biodiesel fuel up to B7 with ultra low sulfur content Fuel tank capacity 43 5 L 11 5 US gallons Fuel injection pump Yanmar supply pump Fuel injection type Common rail system EPA Tier 4 certifie...

Page 35: ...ooting Manuals The engine that powers your Groundsmaster machine is a Yanmar Model 3TNV88C used on Groundsmaster 7210 Models 30616 30617 30618 30619 30633 and 30695 a Tier 4F compliant engine The Yanm...

Page 36: ...eneration Glow plugs are used to assist starting the engine Numerous engine sensors are used to allow the engine ECU to monitor and control the engine operation for optimum engine performance The engi...

Page 37: ...he traction unit Operator s Manual with the correct DPF regeneration instructions for the machine Types of regeneration that are performed automatically while the machine is operating Type Conditions...

Page 38: ...reases due to soot buildup reaching a critical level Can only be initiated when prompted by the engine ECU For software 122 0127E and up the machine mow function PTO will be disabled at first notifica...

Page 39: ...lt of the regeneration processes The lighter ash is discharged through the exhaust system while the heavier ash collects in the soot filter When enough ash accumulates in the soot filter the engine EC...

Page 40: ...lange nut 4 each 5 Screw 2 each 8 Hose clamp 3 Bracket 6 Hose clamp 9 Air cleaner Assembly Removing the Air Cleaner System Note Refer to the Traction Unit Operator s Manual for the maintenance procedu...

Page 41: ...ents are in good condition and are properly secured during installation 5 Examine the air inlet hoses for wear or damage replace the hose that is worn or damaged 6 Inspect and replace the damaged hood...

Page 42: ...st hose assembly 41 Bolt 2 each 6 DPF unit 18 DPF stiffener 30 Hose clip 2 each 42 Bolt 2 each 7 Temperature sensor 19 DPF stiffener 31 Pressure sensor 43 Bolt 2 each 8 Temperature sensor 20 Bolt 2 ea...

Page 43: ...F The diesel oxidation catalyst DOC has a service life expectancy and requires replacement at recommended intervals Replacement of the DOC will require exhaust system disassembly removal of the existi...

Page 44: ...anifold or header to block tube to muffler muffler to DOC DOC to exhaust tube 3 Install the 2 nuts item 44 in Figure 10 to attach the DPF to the DPF stay torque the nuts to 11 to 21 N m 8 to 15 ft lb...

Page 45: ...radiator hose 18 Rubber grommet 29 Bottle bracket 40 Flange nut 2 each 8 Hose clamp 19 Bulkhead bracket 30 Grommet 2 each 41 Carriage screw 2 each 9 Bulb seal 2 each 20 O ring 31 Carriage screw 2 each...

Page 46: ...waste ordinances 3 Remove the radiator cap item 5 in Figure 13 from the radiator g035023 Figure 13 1 Screw 3 each 5 Radiator cap 2 Flat washer 6 each 6 Pipe plug 3 Lock washer 3 each 7 Radiator 4 Nut...

Page 47: ...12 and replace the bulb seals if damaged Installing the Radiator 1 If removed install the bottom shroud item 42 in Figure 12 2 If separated assemble the radiator to the oil cooler Figure 13 3 Remove t...

Page 48: ...refer to the Traction Unit Operator s Manual Note Ensure that the overflow tank coolant level is correct 16 Add hydraulic fluid to the hydraulic reservoir as necessary to raise the hydraulic fluid le...

Page 49: ...16 Plain washer 2 each 27 Fuel supply hose 38 Cable clamp 6 Instruction decal 17 Flat washer 2 each 28 Right fuel tank 39 Screw 2 each 7 Keps nut 3 each 18 Screw 29 Spacer 40 Fuel return hose 8 Fuel...

Page 50: ...fuel system needs to be primed before starting the engine for the first time after running out of fuel or after fuel system maintenance e g draining the fuel water separator replacing a fuel hose To p...

Page 51: ...fuel tank from the machine 15 Locate and retain the spacer items 29 and 15 in Figure 14 from the fuel tank Note For information regarding the fuel pump testing refer to Testing the Fuel Pump page 5 4...

Page 52: ...nge head screws item 1 in Figure 15 6 Assemble the access cover to the control panel and secure the cover with the 2 swell latches item 5 in Figure 15 7 Install the fuel supply return and vent hoses t...

Page 53: ...r mount 2 each 10 Screw 2 each 17 Screw 3 each 24 Guide bracket 4 Lock washer 8 each 11 Flange nut 4 each 18 Screw 13 each 25 Bolt 8 each 5 Screw 8 each 12 Engine mount 2 each 19 Lock washer 26 Yanmar...

Page 54: ...ery cable g035041 Figure 18 1 Negative eye cable 4 Ground eye cable 2 Yanmar ECU 5 Socket connector 3 Positive eye cable 6 Connector 3 Disconnect both the battery cables at the battery Disconnect the...

Page 55: ...connect the socket connector item 5 in Figure 18 of the terminal receptacle at the coolant temperature sender of the engine wire harness Disconnect the Glow Start and EGR Relays items 1 2 and 3 in Fig...

Page 56: ...igure 16 that secure the flywheel coupling to the engine and remove the flywheel coupling from the engine Installing the Engine IMPORTANT Ensure that all parts removed from the engine during maintenan...

Page 57: ...d move the engine toward the flywheel housing IMPORTANT When installing the engine ensure that you do not damage the engine flywheel housing fuel hoses hydraulic lines electrical harness or other part...

Page 58: ...tem 4 in Figure 19 and return hose to the fuel filter 12 Use the notes that you recorded during removal and connect all the electrical connectors The machine wire harness to the engine wire harness 2...

Page 59: ...attery Connect the positive battery cable item 2 in Figure 17 and then the negative battery cable refer to Servicing the Battery page 5 61 19 Install the hood refer to Installing the Hood page 6 41 20...

Page 60: ...Diesel Engine Service and Repairs Page 3 28 Groundsmaster 7210 16222SL Rev C...

Page 61: ...28 Traction Circuit Problems 4 28 PTO Circuit Problems 4 29 Lift Lower Circuit Problems 4 30 Testing the Hydraulic System 4 31 Testing the Traction System Operation 4 33 Testing the Charge Relief Valv...

Page 62: ...Control Manifold 4 115 Polar Trac Hydraulic Control Valve 4 118 Servicing the Polar Trac Hydraulic Control Valve 4 121 Lift Cylinder 4 124 Servicing the Lift Cylinder 4 126 Polar Trac Lift Cylinder 4...

Page 63: ...r pump Displacement per revolution Implement relief pressure Casappa single section positive displacement gear type pump 6 7 cm 0 41 in 20 700 kPa 3 000 psi Wheel motors Displacement per revolution Pa...

Page 64: ...ight with 1 wrench and tighten the hose swivel nut onto the fitting with the other wrench refer to Installing the Hydraulic Hose and Tube O Ring Face Seal Fitting page 4 5 Note If the hose has an elbo...

Page 65: ...rque wrench to tighten the swivel nut to the recommended torque value within the specified range of torque values refer to the Hose Tube Installation Torque Table page 4 6 This procedure to tighten th...

Page 66: ...es threads per inch Installation Torque 4 9 16 18 25 to 29 N m 18 to 22 ft lb 6 11 16 16 37 to 44 N m 27 to 33 ft lb 8 13 16 16 51 to 63 N m 37 to 47 ft lb 10 1 14 82 to 100 N m 60 to 74 ft lb 12 1 3...

Page 67: ...7 Note It may be necessary to use a drive adapter wrench e g crowfoot wrench to install a hydraulic fitting refer to Calculating the Torque Values When Using a Drive Adapter Wrench page 2 5 5 If a tor...

Page 68: ...20 1 5 8 12 335 to 410 N m 247 to 303 ft lb 202 to 248 N m 149 to 183 ft lb Flat From Finger Tight Table Size FFFT 4 1 4 inch nominal hose or tubing 1 00 0 25 6 3 8 inch 1 50 0 25 8 1 2 inch 1 50 0 2...

Page 69: ...Fitting Installation Torque Table page 4 7 This tightening procedure requires a drive adapter wrench e g crowfoot wrench Note It may be necessary to use a drive adapter wrench e g crowfoot wrench to i...

Page 70: ...clockwise 1 to 2 turns IMPORTANT Pushing the machine faster than 2 mph can damage the drive system If you must move the machine a considerable distance more than a few feet transport it on a truck or...

Page 71: ...vel surface 2 Lower the cutting deck or implement 3 Shut off the engine 4 Turn the key switch to the OFF position and allow the engine to stop Release the hydraulic pressure from the lift circuit as f...

Page 72: ...action circuit component e g wheel motor or transmission piston pump Using a high pressure hydraulic fluid filter will remove contaminates from the hydraulic fluid in the traction circuit thereby prev...

Page 73: ...Hydraulic Schematics Refer to the Hydraulic Schematic in Appendix A Foldout Drawings Groundsmaster 7210 Page 4 13 Hydraulic System Hydraulic Schematics 16222SL Rev C...

Page 74: ...g186588 Figure 27 Hydraulic System Hydraulic Schematics Page 4 14 Groundsmaster 7210 16222SL Rev C...

Page 75: ...or in the forward direction The fluid flow from the wheel motor returns to the transmission port B or D and is continuously pumped while the traction lever is pushed forward As the traction load incre...

Page 76: ...e fluid flow from the wheel motor returns to the transmission port A or C and is continuously pumped while the traction lever is pulled rearward As the traction load increases the reverse traction cir...

Page 77: ...Reverse Direction continued g186586 Figure 28 Groundsmaster 7210 Page 4 17 Hydraulic System Hydraulic Schematics 16222SL Rev C...

Page 78: ...ift cylinder The energized solenoid valve A S1 allows the hydraulic flow from the gear pump to the cylinder head of the lift cylinder The lift cylinder extends causing the cutting deck to raise The fl...

Page 79: ...Electrical Lift Control continued g186585 Figure 29 Groundsmaster 7210 Page 4 19 Hydraulic System Hydraulic Schematics 16222SL Rev C...

Page 80: ...the lift lower switch is pressed detent position the deck will lower fully and then enter the float position When the bottom of the lift lower switch is pressed detent position the solenoid valve A S...

Page 81: ...Cutting Deck Float continued g186587 Figure 30 Groundsmaster 7210 Page 4 21 Hydraulic System Hydraulic Schematics 16222SL Rev C...

Page 82: ...ngagement of the PTO WARNING The Groundsmaster 7210 machine has a hydraulic accumulator built into the transmission that stores energy by compressing a spring This pressure must be released before dis...

Page 83: ...6 900 kPa 1 000 psi 34 500 kPa 5 000 psi and 69 000 kPa 10 000 psi gauges refer to Testing the Hydraulic System page 4 31 15 GPM Hydraulic Tester Kit Pressure and Flow g031765 Figure 32 Toro Part No T...

Page 84: ...ttings An assortment of hydraulic fittings are included with this kit Hydraulic Test Fitting Kit g033394 Figure 33 Toro Part No TOR4079 This kit includes a variety of O ring face seal fittings to let...

Page 85: ...il you remove it Install a high flow hydraulic fluid filter into the circuit when you connect the hydraulic test gauges in order to test the traction circuit components or after you replace a failed t...

Page 86: ...he fittings and hoses that are used to connect high flow hydraulic filter kit TOR6011 to the machine hydraulic traction system components Remote Starter Switch g036604 Figure 37 g186163 Figure 38 Hydr...

Page 87: ...recommended to include a 20 A in line fuse between the battery and switch connector for circuit protection A remote stater switch can also be constructed using the Toro switch 106 2027 a length of 14...

Page 88: ...aulic fluid is contaminated or the fluid viscosity is too light The oil cooler is damaged or plugged The oil cooler air flow is obstructed The transmission bypass valve s is open or damaged The gear p...

Page 89: ...the problem wheel motor are worn or damaged Note If 1 traction circuit component has internal wear or damage it is possible that the other traction components are also damaged The machine does not tra...

Page 90: ...der linkage is binding or broken The lift arm bushings are binding The hydraulic fluid level in the hydraulic tank is low The gear pump pressure or flow is insufficient The gear pump is damaged The im...

Page 91: ...high pressure Do not use your hands to search for leaks use a piece of paper or cardboard Hydraulic fluid escaping under pressure can have sufficient force to penetrate the skin and cause serious inju...

Page 92: ...oss threaded before you tighten them with a wrench 8 Position the tester hoses to prevent the rotating machine parts from contacting and damaging the hoses or tester 9 After you connect the test equip...

Page 93: ...machine in place the parking brake is not applied The machine should remain stationary on the incline or drift slowly backwards in a straight line If 1 of the traction circuits of the transmission is...

Page 94: ...Testing the Charge Relief Valve Pressure Using Pressure Gauge g187016 Figure 40 Hydraulic System Testing the Hydraulic System Page 4 34 Groundsmaster 7210 16222SL Rev C...

Page 95: ...400 rpm Check for hydraulic fluid leaks from the test connections and correct before continuing the test 10 Operate the engine by moving the throttle to full speed 3 000 rpm The pressure gauge readin...

Page 96: ...or damaged Note When a pump is worn or damaged the charge pump cannot keep up with internal leakage in the traction circuit 13 Stop the machine and shut off the engine 14 Release pressure from the hyd...

Page 97: ...Testing the Transmission Piston Pump Flow Using Tester with Pressure Gauges and Flow Meter g187022 Figure 41 Groundsmaster 7210 Page 4 37 Hydraulic System Testing the Hydraulic System 16222SL Rev C...

Page 98: ...hrough the traction circuit Note Ensure that the parking brake is not applied 6 Clean the transmission area around the traction circuit hoses on the top of the transmission Figure 41 Determine which p...

Page 99: ...performance If the flow is less than 41 6 L minute 11 gallons minute or a pressure of 6 900 kPa 1 000 psi cannot be obtained A The traction control lever may need adjustment B If the engine speed dro...

Page 100: ...Testing the Traction Relief Valve Pressure Using Tester with Pressure Gauges and Flow Meter g187021 Figure 42 Hydraulic System Testing the Hydraulic System Page 4 40 Groundsmaster 7210 16222SL Rev C...

Page 101: ...Port D 7 Install a hydraulic tester pressure and flow in series with the pump outlet and disconnected hose Ensure that the tester flow arrow points from the pump outlet port and toward the hose for t...

Page 102: ...elief valves so do not interchange the forward and reverse relief valves 14 If the traction relief valve pressure is not met remove and inspect the relief valve from the transmission refer to Servicin...

Page 103: ...Testing the Wheel Motor Efficiency Using Tester with Pressure Gauges and Flow Meter g187023 Figure 43 Groundsmaster 7210 Page 4 43 Hydraulic System Testing the Hydraulic System 16222SL Rev C...

Page 104: ...this section 5 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 raise the machine and support it with...

Page 105: ...RAL position Shut off the engine and record the test results Rotate the wheel and test it again Note Testing the wheel motor leakage in 3 different wheel positions will give the most accurate test res...

Page 106: ...Testing the PTO Pressure Valve Using Pressure Gauge FO RW ARD FO RW ARD g187020 Figure 44 Hydraulic System Testing the Hydraulic System Page 4 46 Groundsmaster 7210 16222SL Rev C...

Page 107: ...400 rpm Check for hydraulic fluid leaks from the test connections and correct before continuing the test 7 With the engine running move the throttle to full speed 3 000 rpm WARNING Keep away from the...

Page 108: ...Testing the Implement Relief Pressure Using Pressure Gauge g187018 Figure 45 Hydraulic System Testing the Hydraulic System Page 4 48 Groundsmaster 7210 16222SL Rev C...

Page 109: ...EUTRAL position WARNING Before disconnecting or doing any work on the hydraulic system release all the pressure in the system refer to Releasing Pressure from the Hydraulic System page 4 11 g033405 Fi...

Page 110: ...control manifold 10 Monitor the pressure gauge carefully while you press the lift switch to the RAISE position The system pressure should be approximately 20 700 kPa 3 000 psi as the implement relief...

Page 111: ...Testing the Gear Pump Flow Using Tester with Pressure Gauges and Flow Meter g187017 Figure 48 Groundsmaster 7210 Page 4 51 Hydraulic System Testing the Hydraulic System 16222SL Rev C...

Page 112: ...y work on the hydraulic system release all the pressure in the system refer to Releasing Pressure from the Hydraulic System page 4 11 g033408 Figure 49 1 Lift control manifold 2 Hose from the gear pum...

Page 113: ...minute 5 0 gallons minute A lower pump flow may result in reduced circuit performance If the flow is less than 17 0 L minute 4 5 gallons minute or a pressure of 6 900 kPa 1 000 psi cannot be obtained...

Page 114: ...Testing the Lift Cylinder for Internal Leakage FO RW ARD FO RW ARD g187019 Figure 50 Hydraulic System Testing the Hydraulic System Page 4 54 Groundsmaster 7210 16222SL Rev C...

Page 115: ...ack to raise the cutting deck or implement slightly This removes the load from the lift cylinder and releases the lift cylinder hydraulic pressure 3 Support both sides of the cutting deck or implement...

Page 116: ...inder in good usable condition will show minimal rod movement B If the rod movement is more than 6 4 mm 1 4 inch after 4 hours indicates a lift cylinder with internal seal damage or excessive internal...

Page 117: ...tem refer to Releasing Pressure from the Hydraulic System page 4 11 5 The hydraulic fluid may be hot Be careful when you loosen and remove the hydraulic system components 6 Install clean caps or plugs...

Page 118: ...the hydraulic system before performing any work on the system Seek immediate medical attention if hydraulic fluid is injected into your skin IMPORTANT Check the hydraulic lines and hoses daily for le...

Page 119: ...cranking procedure for the second time 5 Disconnect the remote starter switch leads from the starter motor solenoid terminal and positive post of the battery Flushing the Hydraulic System IMPORTANT Fl...

Page 120: ...lling the Hydraulic Hose and Tube O Ring Face Seal Fitting page 4 5 IMPORTANT Using other hydraulic fluids could damage the hydraulic system Use the hydraulic fluids that are specified in the Traction...

Page 121: ...to Priming the Hydraulic Pumps page 4 58 IMPORTANT Before lifting the machine with a jack review and follow Jacking Instructions page 1 6 6 Raise the 2 drive wheels off the ground and place the jack...

Page 122: ...the NEUTRAL position refer to the Traction Unit Operator s Manual 13 Lower the machine to the ground 14 If the transmission or a wheel motor was replaced or rebuilt operate the traction circuit on a l...

Page 123: ...29 Breather 8 Hose clamp 19 O ring 30 Washer head screw 2 each 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 Removing the Hydra...

Page 124: ...l a new lubricated O ring on the strainer Thread the strainer into the tank and torque the strainer to 82 to 90 N m 60 to 66 ft lb 2 Install the fittings that were removed with new lubricated O rings...

Page 125: ...ocket head screw 4 each per motor 13 Hydraulic hose 7 Wheel motor left 14 Hydraulic hose Removing the Wheel Motor WARNING Before disconnecting or doing any work on the hydraulic system release all the...

Page 126: ...e motor shaft 7 Locate and retrieve the woodruff key from the wheel motor shaft g033416 Figure 56 1 Hydraulic tank 3 Right wheel motor 2 Transmission 4 Left wheel motor 8 Clean the hydraulic hose ends...

Page 127: ...ittings into the wheel motor ports refer to Installing the Hydraulic Fittings SAE Straight Thread O Ring Fitting into the Component Port page 4 7 Ensure that the fittings are orientated correctly 6 Us...

Page 128: ...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 the wheel motors on the mach...

Page 129: ...motor fails refer to the Traction Circuit Closed Loop Component Failure page 4 12 for information regarding the importance of removing contamination from the traction circuit Groundsmaster 7210 Page...

Page 130: ...mp 36 Hydraulic hose 7 Bolt 50 mm long 6 each 22 Hydraulic hose 37 Hydraulic hose 2 each 8 Tube 23 O ring 38 Hydraulic hose 2 each 9 Flywheel housing 24 O ring 39 O ring 10 Dowel pin 2 each 25 Hex nut...

Page 131: ...s installed from the outside toward the center of the machine 4 Disconnect the wire harness electrical connector from the transmission solenoid valve coil Position the wire harness away from the trans...

Page 132: ...60 CAUTION Support the transmission assembly when you remove it from the flywheel housing to prevent it from falling and causing personal injury 11 Remove the 7 bolts and 7 lock washers that secure t...

Page 133: ...Installing the Transmission 1 Ensure that the flywheel coupler and flywheel housing are secure on the engine refer to Chapter 3 Diesel Engine page 3 1 2 If the hydraulic fittings were removed from the...

Page 134: ...both sides of the machine attach the pump control rod to the traction control hub with the bolt and locknut Figure 59 Note The bolt is installed from the outside toward the center of the machine 11 R...

Page 135: ...Servicing the Transmission g033422 Figure 62 Groundsmaster 7210 Page 4 75 Hydraulic System Service and Repairs 16222SL Rev C...

Page 136: ...ach 15 Collar 41 Hex plug 8 each 67 Gasket 16 Bolt and washer 2 each 42 Pipe assembly 68 Gear case housing 17 Accumulator cover 43 Seal 2 each 69 Flange head screw 13 each 18 Gasket 44 Washer 2 each 7...

Page 137: ...4 Remove the solenoid valve stem from the transmission pump body 5 Remove the pin from the spool and remove the spool sleeve and solenoid valve spring from the transmission pump body 6 For assembly p...

Page 138: ...rom the transmission pump body 12 Remove and discard the O ring from the charge relief plug g033426 Figure 66 1 Accumulator cover 3 Piston 2 Collar 13 Remove the 2 bolts that attach the accumulator co...

Page 139: ...ard the O rings from the plugs 17 Remove the 4 socket head plugs from the pump body g033428 Figure 68 1 Pump body 2 Center case 18 Remove the 3 shorter 45 mm and 2 longer 95 mm flange head screws that...

Page 140: ...dy 20 Remove and discard the O rings g033430 Figure 70 1 Right pump shaft 3 Inner pump rotor 2 Outer pump rotor 21 Slide the outer and inner charge pump rotors from the right pump shaft and remove the...

Page 141: ...Figure 71 1 Center case 3 Pin 2 each 2 Pump housing g033432 Figure 72 1 Bypass valve 4 Forward relief cartridge 2 Center case 5 Valve plate 3 Reverse relief cartridge Groundsmaster 7210 Page 4 81 Hyd...

Page 142: ...IMPORTANT The forward and reverse relief cartridges are different For assembly purposes label all the relief cartridges 28 Remove the forward and reverse relief valve cartridges from the center case...

Page 143: ...ositions of the cylinder blocks so that you can assemble them in the same position Note Ensure that you do not drop the pistons from the cylinder block 35 Slide the pipe assembly from the bore of the...

Page 144: ...plug 2 Socket head plug 40 Remove the 2 hex plugs and 1 socket head plug from the gear case housing 41 Remove and discard the O rings from the plugs g033438 Figure 78 1 Gear case housing 3 Pin 2 each...

Page 145: ...do not damage the seal bore in the housing g033439 Figure 79 1 Input shaft 3 Left pump shaft 2 Right pump shaft 4 Pipe 47 Remove the input shaft right pump shaft and left pump shaft assemblies from tr...

Page 146: ...ler to remove the bearings from the pump shaft 52 Discard the bearings that were removed and remove the gear from the pump shaft 53 If the input shaft bearing replacement is necessary use a bearing pu...

Page 147: ...ction plate 2 Pump housing 56 Remove the final friction plate from the transmission pump housing Note This friction plate may have been removed with the PTO shaft assembly g033443 Figure 83 1 Bearing...

Page 148: ...slot E Remove the 2 seal rings from the PTO shaft grooves Discard the seal rings F Remove the B plate C plate 3 A plates and 3 friction plates from the PTO shaft G Use a bearing puller to remove the b...

Page 149: ...he bearings that were removed 61 Remove the retaining ring from the groove in the PTO gear bore g033447 Figure 87 1 Socket head plug 3 Pump housing 2 Hex plug 62 Remove the socket head plug and hex pl...

Page 150: ...emove and discard the O rings from the side covers 67 Remove the retaining rings that attach the oil seals into the 2 side covers 68 Remove and discard the oil seals from the side covers g033449 Figur...

Page 151: ...ly install the swash plates into the transmission pump housing g033451 Figure 91 1 Side cover 4 Retaining ring 2 O ring 5 Oil seal 3 Pump housing 3 Press the oil seal into the 2 side covers and secure...

Page 152: ...the plugs into the transmission pump housing torque the plugs to 23 to 26 N m 17 to 19 ft lb g033453 Figure 93 1 Bearing 3 Retaining ring 2 PTO gear 7 Install the retaining ring into the groove in the...

Page 153: ...haft 6 Friction plate 3 each 3 B plate 7 Bearing 4 C plate 10 Assemble the PTO shaft assembly as follows A Press new bearing onto the PTO shaft so that the bearing is flush with the shaft shoulder B A...

Page 154: ...align the rods in the clutch with the holes in the B plate Note Ensure that the slot in the clutch is aligned with the key in the shaft C Place the spacer onto the PTO shaft D Press the bearing onto t...

Page 155: ...housing grooves g033459 Figure 99 1 Right pump shaft 3 Input shaft 2 Left pump shaft 4 Seal ring 14 If the shafts were disassembled install the gear and 2 bearings onto the input shaft right pump sha...

Page 156: ...gear teeth of the input shaft is aligned with the gears on the PTO and pump shafts 17 Lubricate the 2 new O rings and install the O rings into the grooves in the pipe Slide the pipe assembly into the...

Page 157: ...t damage the input shaft oil seal 22 Place the spacer on the oil seal and secure the seal with the retaining ring g033462 Figure 102 1 Hex plug 2 Socket head plug 23 Lubricate new O rings and install...

Page 158: ...the nut to 27 to 31 N m 20 to 23 ft lb g033464 Figure 104 1 Cylinder block assembly 2 Pipe 28 Lubricate all components of the cylinder blocks with a thick layer of clean hydraulic fluid Note Ensure th...

Page 159: ...rings and plugs to secure the flushing valves torque the plugs to 23 to 26 N m 17 to 19 ft lb g033466 Figure 106 1 Bypass valve 4 Forward relief cartridge 2 Center case 5 Valve plate 3 Reverse relief...

Page 160: ...valve plates to hold the valve plates in position during assembly Install the valve plates to the dowel pins in the center plate g033468 Figure 108 1 Center case 3 Pin 2 each 2 Pump housing 38 Install...

Page 161: ...uid Slide the inner pump rotor onto the pump shaft and align the pump rotor with the key Place the outer pump rotor onto the inner pump rotor 42 Install the 2 pins into the bores of the pump body 43 A...

Page 162: ...23 to 26 N m 17 to 19 ft lb in a crossing pattern g033472 Figure 112 1 Hex plug 2 each 2 Socket plug 4 each 45 Lubricate new O rings and install the O rings onto the 2 hex plugs Install the plugs int...

Page 163: ...torque the bolts to 23 to 26 N m 17 to 19 ft lb g033474 Figure 114 1 Charge relief valve 3 Charge relief plug 2 Pressure valve 4 Pressure valve plug 49 Lubricate the charge relief valve and spring wi...

Page 164: ...to 26 N m 17 to 19 ft lb g033476 Figure 116 1 Sleeve 5 Spool step 2 Spool 6 Solenoid valve stem 3 Pin 7 Solenoid coil 4 Sleeve holes 54 Lubricate the solenoid valve spring sleeve and spool with clean...

Page 165: ...o 22 N m 186 to 195 in lb 57 Install the O ring solenoid coil O ring washer lock washer and nut onto the solenoid valve stem torque the nut to 5 9 to 7 8 N m 52 to 69 in lb Note The coil should be ins...

Page 166: ...m refer to Releasing Pressure from the Hydraulic System page 4 11 1 Park the machine on a level surface lower the cutting deck or implement shut off the engine set the parking brake and remove the key...

Page 167: ...ve the 2 bolts and 2 lock washers that secure the gear pump to the transmission and remove the gear pump from the transmission 13 Remove and discard the O ring item 3 in Figure 117 14 Locate and remov...

Page 168: ...ing brake sensor is correct after you install the brake handle 6 Remove the caps or plugs that were installed to the hydraulic hoses and fittings during the removal process 7 Use the labels that you a...

Page 169: ...10 Lock washer 4 each 16 Front bearing block 5 Rear back up ring 11 Back plate 17 Front plate 6 Rear pressure seal 12 Body 18 Retaining ring Disassembling the Gear Pump 1 Install clean plugs in the p...

Page 170: ...not touch the gear surfaces as residue on hands may be corrosive to gear finish 8 Place the pump on its side and push on the rear bearing block to remove the bearing blocks and gear set from the pump...

Page 171: ...he bearing blocks Replace the gears if you find any sharp gear face edge D Bearing areas of the bearing blocks must not have excessive wear or scoring E Face of the bearing blocks that are in contact...

Page 172: ...essure 13 Place a thin sleeve or tape on the pump shaft splines to prevent seal damage 14 Position the pump with back plate downwards 15 Use the marker lines for proper location and carefully slide th...

Page 173: ...hydraulic system release all the pressure in the system Refer to Releasing Pressure from the Hydraulic System page 4 11 1 Park the machine on a level surface lower the cutting deck shut off the engin...

Page 174: ...the O rings Installing the Lift Control Manifold 1 If the hydraulic fittings were removed from the lift control manifold lubricate the new O rings with clean hydraulic fluid position the O rings to t...

Page 175: ...ld valves solenoid coils and plugs are similar on either manifold Note The ports on the lift control manifold are marked for easy identification of the components Refer to the Hydraulic Schematic in A...

Page 176: ...t secure the solenoid coil to the cartridge valve Carefully slide the coil off the valve IMPORTANT Carefully handle the cartridge valve Slight bending or distortion of the stem tube can cause binding...

Page 177: ...l the O rings sealing rings and back up rings correctly on the cartridge valve for proper operation and sealing C Put the assembled cartridge into the clean hydraulic fluid IMPORTANT Carefully handle...

Page 178: ...ng 36 Lever valve link 2 each 7 Regulatory decal 22 Hydraulic fitting 37 O ring 8 Serial plate 23 O ring 2 each 38 Washer 2 each 9 Decal 24 Hydraulic cap 39 Bulkhead nut 10 Pop rivet 2 each 25 O ring...

Page 179: ...system contamination 6 Remove the 2 hairpins that attach the lever valve links to the control valve spools Figure 125 Slide the links from the spools 7 Support the control valve to prevent it from fa...

Page 180: ...ps or plugs that were installed to the hydraulic hoses during the removal process 5 Use the labels that you attached during the removal process to correctly connect the hydraulic hoses to the fittings...

Page 181: ...l spring 27 O ring 6 Solid plug 17 Disc 28 O ring 7 Seat retaining plug 2 each 18 Plug 29 O ring 8 Bushing 19 Detent plug 30 Back up washer 9 Check spring 20 Wiper seal 31 Plug 10 Spool cap 2 each 21...

Page 182: ...om the opposite end of the plunger 8 Remove the detent plug item 19 in Figure 126 and O ring from the valve body and remove the disc spring and detent plunger from the body Inspecting the Polar Trac H...

Page 183: ...ungers into their proper bores 9 Install new O rings seats item 5 in Figure 126 check poppet and check spring into the plunger bores 10 Install the O rings back up washers and seat retaining plugs ite...

Page 184: ...aulic hose 18 Pivot pin Removing the Lift Cylinder WARNING Before disconnecting or doing any work on the hydraulic system release all the pressure in the system refer to Releasing Pressure from the Hy...

Page 185: ...ard the O rings from the fittings Installing the Lift Cylinder 1 If the hydraulic fittings were removed from the lift cylinder lubricate and install new O rings to the fittings Install the fittings in...

Page 186: ...ase fitting 6 Collar 11 O ring 2 Cylinder head 7 Shaft 12 Piston 3 Nut 8 Dust seal 13 Piston seal 4 O ring 9 Rod seal 5 Head 10 Back up ring Disassembling the Lift Cylinder 1 Slowly pump the cylinder...

Page 187: ...efore assembly 2 Put a coating of clean hydraulic fluid on new O rings piston seal rod seal back up ring and dust seal and do the following steps A Install the piston seal and O ring to the piston B I...

Page 188: ...n all internal parts Carefully slide the piston shaft and head assembly into the cylinder head Note Do not damage the seals 6 Use a pipe wrench to install the collar and secure the head in the cylinde...

Page 189: ...ew 6 Lift cylinder 19 Quick disconnect coupler 32 Locknut 2 each 7 O ring 2 each 20 O ring 33 Flange head screw 2 each 8 90 hydraulic fitting 2 each 21 90 hydraulic fitting 34 45 lube fitting 9 O ring...

Page 190: ...orientation of the fittings for assembly purposes 10 Remove and discard the O rings from fittings Installing the Polar Trac Lift Cylinder 1 If the hydraulic fittings were removed from the lift cylinde...

Page 191: ...r 13 Wear ring 4 O ring 9 Seal 5 Head 10 Retaining ring Disassembling the Polar Trac Lift Cylinder 1 Slowly pump the cylinder rod and remove the hydraulic fluid from the lift cylinder into a drain pan...

Page 192: ...and piston from the rod Carefully slide the head off the shaft 6 Remove the cap seal and O ring from the piston If necessary remove the wear ring from the piston Note Do not scratch or damage the pist...

Page 193: ...linder head only to prevent damage 4 Mount the cylinder head correctly in a vise by clamping on the clevis end of the cylinder head IMPORTANT When installing the head into the cylinder head pay carefu...

Page 194: ...and oil cooler from the machine refer to Removing the Radiator page 3 13 4 Remove the 3 screws item 1 in Figure 132 6 flat washers 3 lock washers and 3 nuts that attach the oil cooler to the radiator...

Page 195: ...he outer surface of the cooler Note The oil cooler must be free from corrosion cracked tubes or excessive pitting of tubes Installing the Oil Cooler 1 Install the oil cooler to the radiator with the 3...

Page 196: ...Hydraulic System Service and Repairs Page 4 136 Groundsmaster 7210 16222SL Rev C...

Page 197: ...Problems 5 17 Cutting Deck Operating Problems 5 18 Cutting Deck Lift Lower Problems 5 19 Electrical System Quick Checks 5 20 Testing the Battery Open Circuit Test 5 20 Testing the Charging System 5 20...

Page 198: ...4 Service and Repairs 5 56 PTO Solenoid Valve Coil 5 56 Lift Control Manifold Solenoid Valve Coils 5 58 Battery Storage 5 59 Battery Care 5 60 Servicing the Battery 5 61 Electrical System Adjustments...

Page 199: ...e the SCM to check the operation of the 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 key...

Page 200: ...TO output LED 11 High temperature warning input LED 6 Neutral input LED 12 Backlap input LED The start output LED should be illuminated when the key switch is in the START position with the 2 traction...

Page 201: ...and engine starter is energized IMPORTANT During the operation of the machine if the PTO shuts down and the console temperature warning light illuminates avoid shutting off the engine Under this condi...

Page 202: ...Standard Control Module Logic Chart continued g034737 Figure 135 Electrical System General Information Page 5 6 Groundsmaster 7210 16222SL Rev C...

Page 203: ...the Groundsmaster 7210 machine communicate with each other on a CAN bus system This system allows the traction unit to fully integrate all the different electrical components of the tractor and bring...

Page 204: ...4 wires to operate and communicate to the system CAN High CAN Low B power and ground Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harness Drawings Diagrams in Appendi...

Page 205: ...sistance of a digital meter in the voltage mode ensures that the excess current is not allowed through the meter This excess current can damage the circuits that are not designed to carry it Battery T...

Page 206: ...liberally apply the gel to the component and wire harness connector plug the connector into the component unplug the connector apply the gel to both surfaces again and connect the harness connector to...

Page 207: ...cessary machine communication for the InfoCenter operation Splash Screen g035028 Figure 141 1 Engine coolant temperature 4 Right button 2 Battery voltage 5 Down button 3 Hour meter 6 Menu back button...

Page 208: ...erature 4 Right button 2 Battery voltage 5 Down button 3 Engine RPM 6 Menu back button The 2 InfoCenter main information screens Figure 142 and Figure 143 are displayed after the initial splash screen...

Page 209: ...formation on the main menu and menu item screens refer to the Main Menu Screen page 5 13 Main Menu Screen g035031 Figure 144 1 Main menu 4 Back button 2 Choose menu item 5 Menu items 3 Move to menu it...

Page 210: ...617 30618 30619 30633 and 30695 If the engine ECU identifies that a stationary DPF regeneration is necessary an advisory will occur on the InfoCenter and necessary steps will be listed in the service...

Page 211: ...ains in the RUN position Note The initial PIN will either be 1234 or 0000 If the PIN has been changed and is forgotten you can obtain a temporary PIN from your Toro distributor About Screen g035033 Fi...

Page 212: ...in the interlock circuit The battery charge is low The batteries are discharged The battery cables are loose or corroded The ground connection is loose or corroded The wiring at the starter motor is...

Page 213: ...Control Module is damaged The engine starts but stops when the key switch is released from the START position The circuit wiring is damaged The key switch is damaged General Run and Transport Problem...

Page 214: ...wiring is damaged A hydraulic problem in the mow circuit exists refer to Chapter 4 Hydraulic System page 4 1 The cutting deck run but should not with the PTO switch in the OFF disengage position The P...

Page 215: ...solenoid coil S1 or circuit wiring is damaged A hydraulic problem in the lift lower circuit exists refer to the Troubleshooting page 4 28 None of the cutting units raises The lift control manifold sol...

Page 216: ...stem This is a simple test that determines if a charging system is functioning It tells you if the charging system has an output but not its capacity Tool required Digital multimeter to set the DC vol...

Page 217: ...machine should have a reading of approximately 21 A Checking the Operation of the Interlock Switches CAUTION Check the operation of the interlock switches daily for proper operation Replace any malfu...

Page 218: ...g brake off and the PTO switch in the OFF position the engine must start Lift off the seat and slowly move the traction control levers from the NEUTRAL LOCK position the engine must stop in 1 to 3 sec...

Page 219: ...heck of the switch Note For the engine component testing information refer to the Yanmar Engine Service Manual IMPORTANT When testing the electrical components for continuity with a multimeter ohms se...

Page 220: ...the key switch as follows A Ensure that the key switch is in the OFF position Disconnect the wire harness connector from the key switch B The circuitry of the key switch is shown in the Circuit Logic...

Page 221: ...deck or implement The Standard Control Module SCM monitors the position of the PTO switch up or down Using the inputs from the PTO switch and other switches in the interlock system the SCM controls t...

Page 222: ...tly then test the PTO switch as follows A Ensure that the key switch is in the OFF position and locate the PTO switch for testing B Disconnect the machine wire harness electrical connector from the PT...

Page 223: ...ndard Control Module SCM monitors the status of the neutral switches If the key switch is in the ON position and the 2 traction levers are in the NEUTRAL LOCK position the SCM Neutral input LED should...

Page 224: ...to check the continuity of the switch D When the switch plunger is extended ensure that there is no continuity open between the switch terminals E When the switch plunger is pressed ensure that there...

Page 225: ...follows A Ensure that the key switch is in the OFF position Tilt the seat assembly up to get access to the seat switch electrical connections g033651 Figure 155 1 Seat harness connector 2 Machine wir...

Page 226: ...rness for continuity Repair or replace the components as necessary G If the seat switch testing is correct and the circuit problem still exists check the machine wire harness refer to the Electrical S...

Page 227: ...lower the cutting deck set the parking brake and shut off the engine 2 Ensure that the key switch is in the OFF position 3 Locate the engine oil pressure switch on the engine and disconnect the wire...

Page 228: ...Switch continued 7 After you complete the oil pressure switch testing connect the ECU wire harness connector to the oil pressure switch Electrical System Testing the Electrical Components Page 5 32 G...

Page 229: ...eased the brake latch is not engaged the SCM parking brake sensor input LED should be illuminated Test the parking brake sensor and circuit wiring as a SCM input before you perform the following testi...

Page 230: ...the sensor and return to step 7 B Ensure that the key switch is in the OFF position and disconnect the parking brake sensor connector from the machine wire harness C Use a multimeter check that the ma...

Page 231: ...h is in the OFF position Unplug the wire harness electrical connector from the solenoid valve coil Note Before taking the small resistance readings with a digital multimeter short the multimeter test...

Page 232: ...to Servicing the Battery page 5 61 Locate and unplug the fusible link connector P1 from the machine wire harness Use a multimeter to ensure that the continuity exists between each terminal pin in the...

Page 233: ...s A diode assembly is used to protect the PTO circuit from the voltage spikes that occur when the PTO switch is engaged This diode plugs into the machine wire harness below the operator seat refer to...

Page 234: ...arness near the alternator refer to the Engine Wire Harness Drawing in Appendix A Foldout Drawings The resistor assembly can be identified by its gray color and resistor symbol on the end of the resis...

Page 235: ...he Glow Relay 1 Unlatch the hood and raise it 2 Ensure that the key switch is in the OFF position Disconnect the wire harness electrical connector from the glow relay Note Before taking the small resi...

Page 236: ...nd terminal 85 and apply 12 VDC to terminal 86 The relay must break the continuity between the terminals 30 and 87 as 12 VDC is set and removed from terminal 86 5 Disconnect the voltage and leads from...

Page 237: ...es power to the engine EGR valve when energized by the engine ECU Testing the Start or EGR Relays 1 Park the machine on a level surface lower the cutting deck shut off the engine set the parking brake...

Page 238: ...87 9 Connect the multimeter ohms setting leads to the relay terminals 30 and 87A and apply 12 VDC to the terminal 85 The relay should make and break continuity between the terminals 30 and 87A as 12...

Page 239: ...crossmember of the machine and remove the rear panel and position it away from the machine 4 Unlatch the hood and raise it 5 Disconnect the fuel supply hose pump discharge from the inlet fitting on t...

Page 240: ...l filter 10 Prime the fuel system refer to Priming the Fuel System page 3 18 Fuel Pump Specifications Pump Capacity 700 ml minute 23 5 fl oz minute Pressure 21 5 to 37 3 kPa 3 1 to 5 4 psi Maximum Cur...

Page 241: ...ses This closed circuit provides 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 the engine coola...

Page 242: ...switch in a container of oil with a thermometer and then slowly heat the oil Figure 170 CAUTION The oil is hot and could cause personal injury or fire Handle the hot oil with extreme care g033667 Figu...

Page 243: ...switch 7 Fill the engine cooling system 8 Lower the hood and secure it with the latches Fuses g034750 Figure 171 1 Fuse F4 2 A 3 Fuse F2 10 A 2 Fuse F3 10 A 4 Fuse F1 15 A g034749 Figure 172 1 ECU 2 2...

Page 244: ...meter InfoCenter and parking brake sensor The fuse F4 2 A protects power supply for the SCM logic Testing the Fuses Turn the key switch to the RUN position do not start the engine With the fuse insta...

Page 245: ...plugs into the platform wire harness below the fuel pump near the left fuel tank The resistor can be accessed by removing the operator sear and rear panel Note The insulator wedge in the terminator r...

Page 246: ...e control panel When the top of the lift lower switch is pressed momentary position both of the solenoid valve coils S1 and S2 on the hydraulic lift control manifold are energized causing the valves t...

Page 247: ...switch pressed momentary position there should be continuity closed circuit between the bottom and center switch terminals and no continuity open circuit between the top and center switch terminals 7...

Page 248: ...e is located on the right side of the machine near the rear left wheel When the solenoid coils are energized the valve shift occurs to control the hydraulic fluid flow The electrical testing of the co...

Page 249: ...his value from the measured value of the component that you are testing 4 Use a multimeter ohms setting measure the resistance between the 2 connector terminals on the solenoid valve coil The correct...

Page 250: ...igure 179 1 Parking brake shaft 3 Parking brake sensor 2 Tab 4 Gap The parking brake sensor acts as an input for the SCM controller to determine when the parking brake is set the brake latch engaged T...

Page 251: ...n the sensor with the jam nuts to allow correct gap between the sensor and the tab Tighten the jam nuts to secure the adjustment Tighten the jam nuts to 18 4 to 22 4 N m 162 to 198 in lb After you tig...

Page 252: ...36991 Figure 180 1 Transmission 3 Coil connector 2 Solenoid valve and coil g036300 Figure 181 1 Hex nut 4 Seal 2 Lock washer 5 Solenoid valve coil 3 Washer You can replace the PTO solenoid valve coil...

Page 253: ...stem Figure 181 6 Clean any corrosion or dirt from the valve stem Installing the PTO Solenoid Valve Coil 1 Slide the new coil assembly seals and washers onto the solenoid valve stem Ensure that you c...

Page 254: ...aise the operator seat to get access to the deck lift manifold Figure 182 for the location of solenoid coils on the deck lift manifold 4 Disconnect the wire harness electrical connector from the solen...

Page 255: ...ore the battery on a shelf or on the machine 3 Disconnect the cables if the battery is kept on the machine 4 Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge 5...

Page 256: ...p surface with water after cleaning IMPORTANT Do not remove fill caps while cleaning 3 Tighten the battery cables on the battery terminals to provide a good electrical contact WARNING Connecting the c...

Page 257: ...shield while working with batteries Battery Specifications Battery electrolyte specific gravity Fully Charged 1 265 corrected to 26 7 C 80 F Discharged less than 1 240 Battery specifications BCI Group...

Page 258: ...cleaning the battery tape or block the vent holes of the filler caps and ensure that the caps are tight C Check for the signs of wetness or leakage on the top of the battery which might indicate a lo...

Page 259: ...t these charging conditions replace the battery 3 Do a high discharge test with an adjustable load tester This is 1 of the most reliable means of testing a battery as it simulates the cold cranking te...

Page 260: ...tions are in good condition 4 Place the battery in its compartment Ensure that the battery is level and flat Connect the positive cable connector onto the positive battery post Use 2 wrenches to attac...

Page 261: ...ecific Gravity Open Circuit Voltage 100 1 265 12 68 75 1 225 12 45 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 instructi...

Page 262: ...tery charger manufacturer s instructions connect the charger cables to the battery posts Ensure that you make a good connection 4 Charge the battery following the manufacturer s instructions 5 Occasio...

Page 263: ...cing the Parking Brake 6 13 Parking Brake Assembly 6 15 Front Castor Wheels 6 18 Servicing the Polar Trac Wheel Hub 6 22 PTO Driveshaft 6 25 Servicing the PTO Driveshaft Cross and Bearing 6 27 Cutting...

Page 264: ...Tire pressure machines with Polar Trac 241 kPa 35 psi Rear wheel lug nut torque 102 to 115 N m 75 to 85 ft lb Wheel lug nut torque machines with Polar Trac 88 to 115 N m 65 to 85 ft lb Rear wheel hub...

Page 265: ...tion regarding the operation general maintenance procedures and maintenance intervals for your machine Refer to the Traction Unit Operator s Manual for additional information when servicing the machin...

Page 266: ...ydraulic fitting 15 Parking brake left Removing the Rear Wheel 1 Park the machine on a level surface lower the cutting deck or implement shut off the engine and remove the key from the key switch Note...

Page 267: ...jack stands to support the machine 4 Remove the 5 wheel lug nuts and 5 wheel studs that attach the rear wheel to the wheel hub and remove the rear wheel Installing the Rear Wheel 1 Install the wheel...

Page 268: ...g nut 5 each per wheel 12 Screw 4 each per motor Removing the Polar Trac Wheels Note Refer to the Polar Trac Operator s Manual for additional information regarding the drive track and wheel removal 1...

Page 269: ...ft arm pivot tube 6 Lift the front of the machine with the jack until you support the rear of the machine on the jack stands and the center tire swings back and nearly contacts the rear tire Support t...

Page 270: ...e a second person to lift the center of the track to install the center wheel 5 Install the center wheel to the machine with the 5 wheel lug nuts 6 Lower the front of the machine to the ground Note Wh...

Page 271: ...he Parking Brakes 1 Park the machine on a level surface lower the cutting deck or implement shut off the engine and remove the key from the key switch Note The installation torque of the locknut used...

Page 272: ...Separate the brake rod from the brake lever 5 Remove the 4 bolts and 4 flange nuts that attach the brake support to the frame 6 Slide the brake support with the parking brake assembly attached from t...

Page 273: ...onto the shaft C Install the wheel hub to the motor shaft with the locknut 2 Place the 2 hardened washers on the brake mounting screws Figure 188 and Figure 189 IMPORTANT When installing the brake to...

Page 274: ...ure 190 8 Install the brake rod assembly to the parking brake lever with the flat washer and retaining ring 9 Install the wheel to the machine with the 5 wheel lug nuts 10 Lower the wheel to the groun...

Page 275: ...brake wear or damage occurs brake replacement is necessary Individual brake components are not available Disassembling the Parking Brake 1 Loosen and remove the 2 hex bolts item 4 in Figure 191 2 soc...

Page 276: ...embly with the 2 hex bolts item 4 in Figure 191 2 socket head screws and 4 hex nuts torque the hex bolts to 41 to 54 N m 30 to 40 ft lb and socket head screws to 24 to 31 N m 18 to 23 ft lb Chassis Se...

Page 277: ...nkage yoke 2 each 5 Hex nut 10 each 13 Lock washer 2 each 21 Front brake rod 2 each 6 Swivel assembly 2 each 14 Switch bracket 22 Brake lever grip 7 Flat washer 6 each 15 Brake pivot 2 each 8 Compress...

Page 278: ...D Remove the brake handle and flange bearings from the machine 4 Remove the additional parking brake components as shown in Figure 192 Assembling the Parking Brake Assembly g033687 Figure 194 1 Front...

Page 279: ...he compression spring on the rear brake rod Note Ensure that the length of the spring with the brake applied is 7 4 to 7 6 cm 2 880 to 3 000 inch If necessary adjust the length of the spring with the...

Page 280: ...screw 2 each 11 Bolt 2 each 18 Locknut 2 each 5 Grease fitting 2 each 12 Castor wheel assembly 2 each 19 Grease cap 2 each 6 Castor arm assembly 13 Locknut 2 each 7 Screw 3 each 14 Castor fork 2 each...

Page 281: ...PORTANT Before lifting the machine with a jack review and follow Jacking Instructions page 1 6 2 Block the wheels with chocks Use a jack to lift the front of the machine so that the castor wheel can b...

Page 282: ...o the wheel C Install the seals into the wheel D Carefully install the bearing spacers and then the castor spacer into the wheel 2 If the bearing cups were removed from the carrier frame press new cup...

Page 283: ...tor fork has excessive grease installed 8 Install new grease cap item 19 in Figure 196 so that the cap shoulder is flush with the top of the carrier frame Note There should be no evidence that the cap...

Page 284: ...ach per wheel 10 Pivot pin 3 Flange nut 7 Drive track 11 Shoulder bolt 4 Shoulder screw 8 Pivot pin Disassembling the Polar Trac Wheel Hub Note Refer to the Polar Trac Operator s Manual for additional...

Page 285: ...from the wheel hub and discard the seal 7 Remove the bearing cones from both sides of the wheel hub 8 Clean the bearings in solvent and clean the inside of the wheel hub Note Ensure that the bearings...

Page 286: ...100 in lb to set the bearings and then loosen the nut until the hub has end play 7 While you turn the wheel hub by hand torque the slotted hex nut to 1 7 to 2 3 N m 15 to 20 in lb Also align the hex...

Page 287: ...remove the key from the key switch 2 Remove the fuse F1 15 A from the fuse block to prevent the PTO clutch from engaging accidentally 3 Disconnect the end yoke of the PTO driveshaft from the PTO shaf...

Page 288: ...toward the cutting deck gearbox input shaft 2 Align the splines and roll pin holes of the driveshaft yokes with the transmission and gearbox shafts 3 Slide the PTO driveshaft end yokes onto the transm...

Page 289: ...the following steps A Place a small socket against 1 bearing and a large socket against the yoke on the opposite side B While you support the large socket apply pressure on small socket to partially p...

Page 290: ...nto the yoke bore and onto the cross shaft Press the bearing into the yoke F Install the 4 snap rings to the bearings to secure the bearings in place G Repeat the procedure for the other yoke H Apply...

Page 291: ...16 Lift arm 5 Spherical ball joint 4 each 11 Deck lift chain 4 each 17 Washer 2 each 6 Jam nut 4 each 12 Bearing plate 2 each 18 Retaining ring 2 each Disassembling the Cutting Deck Lift Arms 1 Park t...

Page 292: ...each 6 Cutting deck 2 Note the location of the HOC pin in the HOC bracket for assembly purposes and remove the HOC pin from the HOC bracket Figure 205 3 Start the engine and fully lower the cutting de...

Page 293: ...o not change the link assembly length to adjust the height of cut or for any other reason Note When properly installed the flange nuts item 9 in Figure 204 should have the flange surface against the l...

Page 294: ...sembling the Cutting Deck Lift Arms continued 5 Install the HOC pin into the HOC bracket to allow desired height of cut Figure 205 Chassis Service and Repairs Page 6 32 Groundsmaster 7210 16222SL Rev...

Page 295: ...y 4 Rivet 4 each 9 Nut 2 each 14 Cross member assembly 5 Leaf spring 2 each 10 Double loop hairpin cotter 2 each Removing the Rollover Protection System 1 Park the machine on a level surface lower the...

Page 296: ...screws item 3 in Figure 209 and 4 flange nuts that secure the cross member assembly to the ROPS tubes and remove the cross member assembly Installing the Rollover Protection System 1 Install the cross...

Page 297: ...nge nut 8 each 28 R clamp 2 each 7 Seat support 18 Seat prop 29 Manual tube 8 Nut 2 each 19 Left cover 30 Grommet 9 Rubber bumper 2 each 20 Clevis pin 2 each 31 Flange nut 4 each 10 Shoulder screw 2 e...

Page 298: ...port the seat and latch angles to prevent them from shifting during seat removal 5 Remove the 4 flange nuts that attach the seat and latch angles to the seat plate and remove the seat from the machine...

Page 299: ...aring shaft 23 Label 6 Left armrest mount assembly 15 Hex nut 24 Seat switch 7 Seat frame assembly 16 Cable 2 each 25 Seat adjuster 8 Lumbar support knob 17 Weight adjust bar 26 Seat adjuster slave 9...

Page 300: ...frame 8 Remove the 2 roll pins that attach the bearing shafts to the seat frame and remove the bearing shafts and split nylon bushings from the frame 9 Lift the seat frame from the suspension base 10...

Page 301: ...2 roll pins 8 Position the cables under the seat frame bars and on the top of the suspension base and insert the cable ends in the spring saddle slots 9 Pass the weight adjustment knob shaft through t...

Page 302: ...h 2 each 16 Rubber latch 2 each Removing the Hood 1 Park the machine on a level surface lower the cutting deck or implement shut off the engine set the parking brake and remove the key from the key sw...

Page 303: ...heck the condition of all the seals on the frame and hood Replace the damaged or missing seals 4 Check that no gaps exist between the hood components and the machine frame Note If necessary seal the g...

Page 304: ...Chassis Service and Repairs Page 6 42 Groundsmaster 7210 16222SL Rev C...

Page 305: ...erator s Manual 7 2 Factors That Can Affect Cutting Performance 7 3 Service and Repairs 7 4 Blade Stopping Time 7 4 Cutting Deck 7 5 Idler Assembly 7 6 Blade Spindle 7 9 Servicing the Blade Spindle 7...

Page 306: ...g and repair of 60 62 and 72 inch cutting decks The 100 inch cutting deck information is not covered in this chapter Cutting Deck Operator s Manual The Cutting Deck Operator s Manual provides informat...

Page 307: ...nual 4 Blade condition Sharpen the blades if their cutting edges are dull or nicked Inspect the blade sail for wear or damage Replace the blade if necessary 5 Mower housing condition Ensure that the c...

Page 308: ...ntrol panel cover 2 Fuse block Before servicing the cutting deck remove the fuse F1 15 A from the fuse block Figure 216 Power to the PTO switch will be disconnected after removing the fuse F1 which wi...

Page 309: ...to a complete stop If this time is more than 7 seconds inspect the PTO brake assembly in the transmission refer to PTO Circuit Problems page 4 29 Cutting Deck Refer to specific Cutting Deck Operator...

Page 310: ...each 7 Torsion spring 2 each 16 Locknut 2 each 25 Ribbed neck bolt 24 each 8 Washer 2 each 17 Right idler arm 9 Grease fitting 2 each 18 Drive pulley Removing the Idler Assembly 1 Park the machine on...

Page 311: ...and away from the idler arm to unhook the spring from the arm 8 Remove the snap ring that retains the idler arm assembly to the cutting deck 9 Remove the idler components as shown in Figure 217 Instal...

Page 312: ...he pulleys 5 If the idler arm on the right side of cutting deck was removed check that the clearance between the idler arm and stop bolt is 2 5 to 4 0 mm 0 100 to 0 160 inch Figure 218 Note If necessa...

Page 313: ...lt 7 Left spindle assembly 12 Flange nut 24 each 3 Idler pulley 8 Cutting deck 13 Doubler ring 3 each 4 Ribbed neck bolt 24 each 9 Blade 3 each 14 Center spindle assembly 5 Idler pulley 10 Anti scalp...

Page 314: ...he parking brake and remove the key from the key switch Support the cutting deck so that it cannot fall accidentally 2 Lift the footrest to get access to the top of the cutting deck and support the fo...

Page 315: ...he cutting deck and note the orientation of the grease fitting Figure 220 Attach the spindle assembly to the deck with the 8 ribbed neck bolts and 8 flange nuts 2 Install the cutting blade anti scalp...

Page 316: ...indle shaft while removing the shaft 4 Remove the oil seals from the spindle housing 5 Remove the bearing cones O ring inner bearing spacer and spacer ring from the spindle housing 6 Use an arbor pres...

Page 317: ...large snap ring If the original snap ring is in good condition with no sign 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...

Page 318: ...earing cones with grease Apply a film of grease on the lips of the oil seals and O ring 5 Install the lower bearing cone and oil seal into the bottom of the spindle housing Note The bottom seal must h...

Page 319: ...O ring to the top of the spindle shaft Figure 226 11 Install the pulley hub down special hardened washer and locknut to the spindle shaft Figure 226 torque the locknut to 176 to 203 N m 130 to 150 ft...

Page 320: ...14 Right deck cover 3 Left gearbox bracket 9 Right gearbox bracket 15 Left deck cover 4 Mount 3 each 10 Bolt 4 each 16 Knob 2 each 5 Carriage screw 3 each 11 Lock washer 4 each 17 Set screw 2 each 6 G...

Page 321: ...shut off the engine set the parking brake and remove the key from the key switch 2 Lift the footrest to get access to the top of the cutting deck 3 Support the raised footrest with the prop rod 4 Remo...

Page 322: ...lean the gearbox output shaft pulley ID inner diameter and taper lock bushing 3 Position the woodruff key pulley and then the taper lock bushing to the gearbox output shaft Slide the bushing to the sh...

Page 323: ...levis pin 4 each 17 Torsion spring 2 each 6 Bumper 2 each 12 Flange nut 8 each 18 Bushing 2 each Disassembling the Cutting Deck Pull Links 1 Remove the cutting deck from the machine refer to the Cutti...

Page 324: ...ssembling the Cutting Deck Pull Links Note For 62 inch cutting decks the torsion spring item 17 in Figure 230 is painted red The torsion spring on 72 inch decks is painted black 1 Place the plain spac...

Page 325: ...Drawing Platform 1 of 2 A 8 Wire Harness Drawing Platform 2 of 2 A 9 Wire Harness Drawing Engine 1 of 2 A 10 Wire Harness Drawing Engine 2 of 2 A 11 Wire Harness Drawing Cab Power A 12 Wire Harness Dr...

Page 326: ...es include a line with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a...

Page 327: ...Drawing 105 7260 Rev E Sheet 1 16222SL Rev C Page A 3 Hydraulic Schematic g186843...

Page 328: ...Page A 4 16222SL Rev C Drawing 119 4372 Rev C Sheet 1 Electrical Schematic Platform g186842...

Page 329: ...Drawing 119 4377 Rev C Sheet 1 16222SL Rev C Page A 5 Electrical Schematic Engine g186841...

Page 330: ...Page A 6 16222SL Rev C Drawing 122 0350 Rev C Sheet 1 of 2 Electrical Schematic Cab 1 of 2 g186839...

Page 331: ...Drawing 122 0350 Rev C Sheet 2 of 2 16222SL Rev C Page A 7 Electrical Schematic Cab 2 of 2 g186840...

Page 332: ...Page A 8 16222SL Rev C Drawing 119 4370 Rev E Sheet 1 of 2 Wire Harness Drawing Platform 1 of 2 g186849...

Page 333: ...Drawing 119 4370 Rev E Sheet 2 of 2 16222SL Rev C Page A 9 Wire Harness Drawing Platform 2 of 2 g186846...

Page 334: ...Page A 10 16222SL Rev C Drawing 119 4371 Rev G Sheet 1 of 2 Wire Harness Drawing Engine 1 of 2 g186848...

Page 335: ...Drawing 119 4371 Rev G Sheet 2 of 2 16222SL Rev C Page A 11 Wire Harness Drawing Engine 2 of 2 g186845...

Page 336: ...Page A 12 16222SL Rev C Drawing 119 4386 Rev A Sheet 1 Wire Harness Drawing Cab Power g186851...

Page 337: ...Drawing 122 0723 Rev A Sheet 1 of 2 16222SL Rev C Page A 13 Wire Harness Drawing Cab Headliner g186847...

Page 338: ...Page A 14 16222SL Rev C Drawing 122 0723 Rev A Sheet 2 of 2 Wire Harness Diagram Cab Headliner g186844...

Page 339: ...Drawing 122 0158 Rev A Sheet 1 16222SL Rev C Page A 15 Wire Harness Drawing Cab Power Point Kit g186852...

Page 340: ...Page A 16 16222SL Rev C Drawing 108 2099 Rev C Sheet 1 Wire Harness Drawing Auxiliary Power Model 30382 g186850...

Page 341: ...Drawing 110 1659 Rev A Sheet 1 16222SL Rev C Page A 17 Wire Harness Drawing Light Kit Model 30374 g186853...

Page 342: ......

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