Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table Of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Kubota Diesel Engine
- 4 - Hydraulic System
- Specifications
- General Information
- Hydraulic Schematics
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction System Operation Testing
- Charge Relief Valve Pressure Test (Using Pressure Gauge)
- Transmission Piston Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)
- Traction Relief Valve Pressure Test (Using Tester with Pressure Gauges and Flow Meter)
- Wheel Motor Efficiency Test (Using Tester with Pressure Gauges and Flow Meter)
- PTO Pressure Valve Test (Using Pressure Gauge)
- Implement Relief Pressure Test (Using Pressure Gauge)
- Gear Pump Flow Test (Using Tester with Pressure Gauges and Flow Meter)
- Lift Cylinder Internal Leakage Test
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Flush Hydraulic System
- Charge Hydraulic System
- Hydraulic Tank
- Wheel Motors
- Wheel Motor Service
- Transmission
- Transmission Service
- Gear Pump
- Gear Pump Service
- Manual Lift Control Valve (SN Below 313000000)
- Manual Lift Control Valve Service (SN Below 313000000)
- Lift Control Manifold (SN Above 313000000)
- Lift Control Manifold Service (SN Above 313000000)
- Polar TracTM Hydraulic Control Valve
- Polar TracTM Hydraulic Control Valve Service
- Lift Cylinder
- Lift Cylinder Service
- Polar TracTM Lift Cylinder
- Polar TracTM Lift Cylinder Service
- Oil Cooler
- 5 - Electrical System
- Electrical Schematics and Diagrams
- Special Tools
- Troubleshooting
- Electrical System Quick Checks
- Component Testing
- Ignition Switch
- Indicator Lights
- Hour Meter
- PTO Switch
- Neutral Switches
- Seat Switch
- Parking Brake Switch (SN Below 310000000)
- Parking Brake Switch (SN Above 310000000)
- Standard Control Module
- Standard Control Module Logic Chart
- PTO Solenoid Valve Coil
- Lift Control Manifold Solenoid Valve Coils (SN Above 313000000)
- Fusible Link Harness
- Diode Assembly
- Glow Relay
- High Temperature Warning Switch
- High Temperature Shutdown Switch
- Dual Temperature Switch (Polar TracTM Machines)
- Deck Lift/Lower Switch (SN Above 313000000)
- Fuel Pump
- Fuel Stop Solenoid
- Glow Controller
- Service and Repairs
- 6 - Chassis
- 7 - Cutting Deck
- 8 - Foldout Diagrams
- Electrical Drawing Designations
- Hydraulic Schematics
- Hydraulic Schematic (SN Below 313000000)
- Hydraulic Schematic (SN Below 313000000) with Rear Attach Lift Kit
- Hydraulic Schematic (SN Below 313000000) with Polar Trac Installed)
- Hydraulic Schematic (SN Below 313000000) with Polar Trac and Rear Attach Lift Kit
- Hydraulic Schematic (SN From 313000001 to 314999999)
- Hydraulic Schematic (SN Above 315000000)
- Electrical Schematics
- Circuit Diagrams
- Wire Harness
Groundsmaster 7200/7210Hydraulic System Page 4 – 44
Flush Hydraulic System
IMPORTANT: Flush the hydraulic system any time
there is a severe component failure or if the system
is contaminated (oil appears milky, black or con-
tains metal particles).
IMPORTANT: If a component failure occurred in the
traction circuit, refer to Traction Circuit (Closed
Loop) Component Failure in the General Informa-
tion section for information regarding the impor-
tance of removing contamination from the traction
circuit.
1. Make sure hydraulic oil is at normal operating tem-
perature by operating the machine for at least four (4)
hours.
WARNING
Before disconnecting or performing any work on
the hydraulic system, all pressure in the system
must be relieved. See Relieving Hydraulic System
Pressure in the General Information section.
2. Park machine on a level surface. Lower cutting deck
(or implement), stop engine and engage parking brake.
Remove key from the ignition switch.
IMPORTANT: Make sure to thoroughly clean around
all hydraulic connections that will be disassembled.
3. Drain hydraulic tank and transmission.
4. Drain hydraulic system. Drain all hoses, tubes and
components while the system is warm.
5. Remove and replace hydraulic oil filter.
6. Inspect and clean hydraulic oil tank (see Hydraulic
Tank Inspection in this section).
7. Reconnect all hydraulic hoses, lines and compo-
nents that were disconnected to drain hydraulic system
(see Hydraulic Hose and Tube Installation in the Gener-
al Information section of this chapter).
IMPORTANT: Use only hydraulic fluids specified in
Operator’s Manual. Other fluids may cause system
damage. Use of biodegradable hydraulic fluid in
Groundsmaster 7200 and 7210 machines is not rec-
ommended.
8. Fill hydraulic tank with new hydraulic fluid.
9. Disconnect wire harness connector from engine fuel
stop solenoid to prevent the engine from starting. Make
sure traction levers and lift control lever are in the neu-
tral position.
10.Turn ignition key switch to START and engage start-
er for ten (10) seconds to prime the transmission and
gear pump. Repeat this step again.
11. Connect wire harness electrical connector to fuel
stop solenoid.
12.Start engine and let it run at low idle speed (1500 to
1650 RPM) for a minimum of 2 minutes. Increase engine
speed to high idle (3200 to 3250 RPM) for a minimum
of 1 minute under no load.
13.Raise and lower cutting deck (or implement) several
times.
14.Shut off engine and check for hydraulic oil leaks.
Check oil level in hydraulic tank and add correct amount
of oil if necessary.
15.Operate the machine for 2 hours under normal oper-
ating conditions.
16.Check condition of hydraulic oil. If the new fluid
shows any signs of contamination, repeat steps 1
through 15 again until oil is clean.
17.Assume normal operation and follow recommended
maintenance intervals.