Page 1 Form No. 16222SL Rev D Groundsmaster 7210 (Models with Yanmar Engine) © 2019—The Toro® Company Original Instructions (EN) 8111 Lyndale Avenue South Contact us at www.Toro.com. Bloomington, MN 55420 All Rights Reserved...
Page 2 Revision History Revision Date Description 2016 Initial issue. 2017 Added Foldout Drawings. 03/2018 Updated Engine chapter. Added Revision History and published in new format. Updated Chassis chapter. 03/2019 Revision History Page 2 Groundsmaster 7210 16222SL Rev C...
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: Revision History Page 4 Groundsmaster 7210 16222SL Rev C...
Page 5 The purpose of this publication is to provide the service technician with the information for troubleshooting, testing, and repair of the major systems and components of Groundsmaster 7210 machines that are powered by a Yanmar diesel engine. Refer to the Operator’s Manuals for operating, maintenance, and adjustment instructions.
Page 6 Operator’s Manual. Note: Refer to the service decal on the machine and the machine Operator’s Manual for commonly used fluid specifications and capacities. Preface Page 6 Groundsmaster 7210 16222SL Rev C...
Page 7: Table Of Contents
Wire Harness Diagram - Cab Headliner ............A–14 Wire Harness Drawing - Cab Power Point Kit ..........A–15 Wire Harness Drawing - Auxiliary Power Model 30382 ........A–16 Wire Harness Drawing - Light Kit Model 30374 ...........A–17 Groundsmaster 7210 Page 7 Preface 16222SL Rev C...
Page 8: Preface
Additional Reference 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 7210 16222SL Rev C...
Page 9: Chapter 1: Safety
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 Safety and Instructional Decals ......................1–8 Groundsmaster 7210 Page 1–1 Safety 16222SL Rev C...
Page 10: Safety Instructions
Safety Instructions The Groundsmaster 7210 machine meets or exceeds safety standard specifications as identified in the Operator’s Manuals. Although the hazard control and accident prevention are dependent partially upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
Page 11: While Operating The Machine
Touching a hot engine, radiator, or exhaust system can burn you. Do not touch the engine, radiator, or exhaust system while the engine is running or soon after you stop it. Groundsmaster 7210 Page 1–3 Safety: Safety Instructions 16222SL Rev C...
Page 12: Maintenance And Service
Use eye protection when working on the hydraulic system and its components. • If major repairs are necessary, contact your Authorized Toro Distributor. • Use care when checking or servicing the cutting deck. Wear gloves and use caution when servicing the deck.
Page 13 At the time of manufacture, the machine conformed to the safety standards for riding mowers. To ensure the optimum performance and continued safety certification of the machine, use genuine Toro replacement parts and accessories. The replacement parts and accessories of other manufacturers can result in non-conformance with the safety standards and can void the warranty.
Page 14: Jacking Instructions
3. Use a jack to raise the front of the machine. 4. After raising the front of the machine, use appropriate jack stands under the frame to support the front of the machine. Safety: Jacking Instructions Page 1–6 Groundsmaster 7210 16222SL Rev C...
Page 15: Raising The Rear Of The Machine
2. Position the jack securely under the flat surface of the protection plate (Figure 3. Lift the rear wheels off the ground. 4. Use appropriate jack stands under the frame to support the rear of the machine. Groundsmaster 7210 Page 1–7 Safety: Jacking Instructions 16222SL Rev C...
Page 16: Safety And Instructional Decals
Numerous safety and instruction decals are affixed to the traction unit and cutting units of your Groundsmaster. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog. Order replacement decals from Authorized Toro Distributor. Safety: Safety and Instructional Decals Page 1–8...
Page 17: Chapter 2: Specifications And Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)..........2–6 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) ........2–7 Other Torque Specifications ....................... 2–8 Conversion Factors..........................2–8 Shop Supplies ............................2–9 Special Tools ............................2–11 Groundsmaster 7210 Page 2–1 Specifications and Maintenance 16222SL Rev C...
Page 18: Specifications
61/64 0.953125 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 0.484375 12.303 0.984375 25.003 31/64 63/64 0.5000 12.700 1.000 25.400 1 mm = 0.03937 inch 0.001 inch = 0.0254 mm Specifications and Maintenance: Specifications Page 2–2 Groundsmaster 7210 16222SL Rev C...
Page 19: U.s. To Metric Conversions
1.356 Foot-pounds Kilogram-Meters 0.138 Inch-pounds Kilogram-Centimeters 1.152 Liquid Volume Liters 0.946 Quarts Gallons Liters 3.785 Liquid Flow Gallons/Minute Liters/Minute 3.785 Temperature Fahrenheit Celsius Subtract 32° 2. Multiply by 5/9 Groundsmaster 7210 Page 2–3 Specifications and Maintenance: Specifications 16222SL Rev C...
Page 20: Torque Specifications
Torque Specifications The recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual.
Page 21: Calculating The Torque Values When Using A Drive-Adapter Wrench
If the listed torque recommendation for a fastener is 103 to 127 N∙m (76 to 94 ft-lb), the proper torque when using this torque wrench with a drive-adapter wrench would be 98 to 121 N∙m (72 to 89 ft-lb). Groundsmaster 7210 Page 2–5 Specifications and Maintenance: Torque Specifications...
Page 22: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)
Note: Reduce the 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 a thread sealant, such as Loctite. Specifications and Maintenance: Torque Specifications Page 2–6 Groundsmaster 7210 16222SL Rev C...
Page 23: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Note: Reduce the 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 a thread sealant, such as Loctite. Groundsmaster 7210 Page 2–7 Specifications and Maintenance: Torque Specifications...
Page 24: Other Torque Specifications
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 Specifications and Maintenance: Torque Specifications Page 2–8 Groundsmaster 7210 16222SL Rev C...
Page 25: Shop Supplies
Always refer to the written procedure for specific information regarding the type and the application of a shop supply. IMPORTANT Always follow manufacturers instructions when using or storing shop supplies. Groundsmaster 7210 Page 2–9 Specifications and Maintenance: Shop Supplies 16222SL Rev C...
Page 26 Standard silicone sealants are designed to perform in temperatures from -51°F to 232°C (-60°F to 400°F), while high temperature variants can preform in temperatures up to 343°C (650°F). Specifications and Maintenance: Shop Supplies Page 2–10 Groundsmaster 7210 16222SL Rev C...
Page 27: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools may also be available from a local tool supplier. Hydraulic Pressure Testing Kit Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick...
Page 28 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 No. TOR4079. Hydraulic O-Ring Kit Toro Part No.
Page 29 Hydraulic Test Fitting Kit Toro Part No. TOR4079 This kit includes a variety of O-ring face seal fittings to let you connect the test gauges into the system. FITTING TYPE SIZE PART NUMBER 4 ORFS (9/16–18) TOR4079–3 6 ORFS (11/16–16) TOR4079–12...
Page 30 Note: This kit does not include the hydraulic hoses; refer to Hydraulic 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 system or replacing a hydraulic component (e.g.
Page 31 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 on the battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply the...
Page 32 Specifications and Maintenance: Special Tools Page 2–16 Groundsmaster 7210 16222SL Rev C...
Page 33: Chapter 3: Diesel Engine
Air Cleaner System ..........................3–8 Exhaust System ..........................3–10 Radiator ............................3–13 Fuel System ............................. 3–17 Engine.............................. 3–21 Additional Reference Materials YANMAR TNV (TIER 4) SERIES SERVICE MANUAL YANMAR TNV (TIER 4) SERIES TROUBLESHOOTING MANUAL Groundsmaster 7210 Page 3–1 Diesel Engine 16222SL Rev C...
Page 34: Specifications
Refer to the Traction Unit Operator’s Manual Crankcase-oil capacity 4.7 L (5 qt) Oil pump Yanmar trochoid pump Coolant capacity 6.6 L (7 qt) Alternator/Regulator 12 VDC, 55 A Engine weight (dry) 188 kg (414 lb) Diesel Engine: Specifications Page 3–2 Groundsmaster 7210 16222SL Rev C...
Page 35: General Information
Engine Electronic Control Unit (ECU) The Yanmar engine used in the Groundsmaster 7210 machine uses an electronic control unit (ECU) for engine management and to communicate with operator InfoCenter on the machine.
Page 36: Yanmar Engine
The Yanmar troubleshooting manual and electronic diagnosis tool and should be used to provide assistance in identifying the cause of the problem and the repairs that are necessary. Contact your Toro distributor for assistance in Yanmar engine troubleshooting.
Page 37 • For machines with software 122-0127A thru D: Complete DPF regeneration instructions can be found in the updated traction unit Operator’s Manual for the specific machine. Visit www.toro.com to download the updated traction unit Operator’s Manual for the machine. •...
Page 38 Note: Verify the model and serial number of the engine installed in the machine. 3TNV88C-DTR2 engines below serial number 02254 cannot run a recovery regeneration without first reprogramming the engine ECU. Contact an Authorized Toro Distributor for assistance. Diesel Engine: General Information Page 3–6...
Page 39 Level 2: Engine De-rated to 50% None Exhaust System Warning (page 3–10) Service the DPF; Level 3: Engine Maximum torque De-rated to 50% Exhaust System Warning + 200 rpm (page 3–10) Groundsmaster 7210 Page 3–7 Diesel Engine: General Information 16222SL Rev C...
Page 40: Service And Repairs
Hose clamp Air cleaner Assembly Removing the Air Cleaner System Note: Refer to the Traction Unit Operator's Manual for the maintenance procedures and intervals of the air cleaner. Diesel Engine: Service and Repairs Page 3–8 Groundsmaster 7210 16222SL Rev C...
Page 41 3.4 N·m (30 in-lb), and install the service indicator onto the nipple. 2. Lower the hood and secure it with the latches. Groundsmaster 7210 Page 3–9 Diesel Engine: Service and Repairs...
Page 42: Exhaust System
Nut (4 each) Doc-case Pressure sensor unit Bolt (2 each) Exhaust manifold Soot-case filter Pipe joint bolt (2 each) Clip band DPF silencer Sensor gasket (4 each) 36. Band Diesel Engine: Service and Repairs Page 3–10 Groundsmaster 7210 16222SL Rev C...
Page 43 The engine that powers your Groundsmaster 7210 machine is a Yanmar model 3TNV88C with EPA Tier 4F emission regulations. The engine is equipped with an exhaust system that includes a diesel oxidation catalyst (DOC) and a diesel-particulate filter (DPF). These exhaust components require service or component replacement at regular intervals, refer to the Operator’s Manual.
Page 44 N·m (15 to 23 ft-lb) before you tighten the fasteners that secure the exhaust system to the DPF stays. 8. Install the exhaust tube as shown in Figure 9. Lower the hood and secure it with the latches. Diesel Engine: Service and Repairs Page 3–12 Groundsmaster 7210 16222SL Rev C...
Page 45: Radiator
1. Park the machine on a level surface, lower the cutting deck, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Unlatch the hood and raise it. Groundsmaster 7210 Page 3–13 Diesel Engine: Service and Repairs...
Page 46 5. Disconnect the following hoses from the radiator: • The upper radiator hose (item 35 in Figure 12) that is connected to the water pump. Diesel Engine: Service and Repairs Page 3–14 Groundsmaster 7210 16222SL Rev C...
Page 47 9. Use new O-rings and lubricate the O-rings with clean hydraulic fluid before installing the 90° hydraulic fittings. 10. Install the (2 each) 90° hydraulic fittings into the oil cooler. Groundsmaster 7210 Page 3–15 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 48 18. Check for leaks. Repair any leaks as required. 19. Once at operating temperature, check the coolant level and fill the coolant reservoir as necessary. 20. Lower the hood and secure it with the latches. Diesel Engine: Service and Repairs Page 3–16 Groundsmaster 7210 16222SL Rev C...
Page 49: Fuel System
Flange nut (2 each) Elbow fitting Fuel return hose Strainer fitting (2 each) Screw (4 each) Elbow fitting Left fuel tank Fuel supply hose Elbow fitting Straight fitting Groundsmaster 7210 Page 3–17 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 50 • Use diesel fuel as an engine fuel only, not for any other purpose. Checking the Fuel Lines and Connections Note: The fuel tanks of the Groundsmaster 7210 machine are connected to a hydraulic tee fitting (item 34 in Figure 14) under the operator seat.
Page 51 2. If the elbow and straight fittings (items 43 and 44 in Figure 14) were removed from the fuel/water separator head, apply thread sealant to the fittings before installing. Groundsmaster 7210 Page 3–19 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 52 10. Check the fuel hoses and fittings for leaks. Note: Repair all fuel leaks before operating the machine. 11. Lower the hood and secure it with the latches. 12. Lower the operator seat. Diesel Engine: Service and Repairs Page 3–20 Groundsmaster 7210 16222SL Rev C...
Page 53: Engine
Bolt (8 each) Screw (8 each) Engine mount (2 each) Lock washer Yanmar engine Harness tab Screw (4 each) Rubber grommet (2 each) Lock washer Flywheel coupling Screw (2 each) Groundsmaster 7210 Page 3–21 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 54 17) and then the positive battery cable (item 2 Figure 17); refer to Servicing the Battery (page 5–61). 4. Remove the ROPS assembly; refer to Removing the Rollover Protection System (page 6–33). Diesel Engine: Service and Repairs Page 3–22 Groundsmaster 7210 16222SL Rev C...
Page 55 Support the engine with lift or hoist to prevent the engine from shifting or moving. 12. Remove the 2 screws (item 18 in Figure 16) and 2 lock washers that secure the guide bracket to the flywheel housing. Groundsmaster 7210 Page 3–23 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 56 The engine is very heavy, and a hoist not rated for the weight of the engine may fail, causing possible injury and damage to the engine. Use hoist equipment rated to lift the engine, which is approximately 188 kg (414 lb). Diesel Engine: Service and Repairs Page 3–24 Groundsmaster 7210 16222SL Rev C...
Page 57 Also, ensure that transmission does not shift during engine installation. g035027 Figure 19 Return hose Clamp Fuel supply hose Groundsmaster 7210 Page 3–25 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 58 • The negative battery cable to the engine block (item 3 in Figure 17). 13. Install the radiator to the machine; refer to Installing the Radiator (page 3–15). 14. Install the exhaust tube to the engine (Figure 11). Diesel Engine: Service and Repairs Page 3–26 Groundsmaster 7210 16222SL Rev C...
Page 59 20. Ensure that all the hoses, tubes, and wires are clear of moving parts and secured to their original locations. 21. Operate the machine checking for coolant, hydraulic fluid or fuel leaks before returning the machine to service. Groundsmaster 7210 Page 3–27 Diesel Engine: Service and Repairs 16222SL Rev C...
Page 60 Diesel Engine: Service and Repairs Page 3–28 Groundsmaster 7210 16222SL Rev C...
Page 61 Service and Repairs ........................... 4–57 General Precautions for Removing and Installing the Hydraulic System Components...... 4–57 Checking the Hydraulic Lines and Hoses ..................4–58 Priming the Hydraulic Pumps ......................4–58 Flushing the Hydraulic System......................4–59 Groundsmaster 7210 Page 4–1 Hydraulic System 16222SL Rev C...
Page 62 Servicing the Polar Trac Lift Cylinder ..................... 4–131 Oil Cooler ............................4–134 Additional Reference Materials PARKER TORQMOTOR™ SERVICE PROCEDURE (TC, TB, TE, TJ, TF, TG, TH AND TL SERIES) Hydraulic System: Service and Repairs Page 4–2 Groundsmaster 7210 16222SL Rev C...
Page 63: Chapter 4: Hydraulic System
10.3 L (10.9 US qt) Hydraulic fluid change (hydraulic tank 15.1 L (16 US qt) and transmission) Hydraulic system (all components and lines) Hydraulic fluid Refer to the Traction Unit Operator's Manual Groundsmaster 7210 Page 4–3 Hydraulic System: Specifications 16222SL Rev C...
Page 64: General Information
For more hydraulic hose information; refer to Hydraulic Hose Servicing of the Toro Basics Series Training Books (Part No. 94813SL). WARNING Release all pressure in the hydraulic system before performing any work on the system;...
Page 65: Installing The Hydraulic Hose And Tube (O-Ring Face Seal Fitting)
3.39 N∙m (30 in-lb). B. Put a mark on the swivel nut and body of the fitting. Hold the hose/tube in alignment with a wrench to prevent the hose/tube from turning. Groundsmaster 7210 Page 4–5 Hydraulic System: General Information...
Page 66 6 (3/8 inch) 1/2 to 3/4 8 (1/2 inch) 1/2 to 3/4 10 (5/8 inch) 1/2 to 3/4 12 (3/4 inch) 1/3 to 1/2 16 (1 inch) 1/3 to 1/2 Hydraulic System: General Information Page 4–6 Groundsmaster 7210 16222SL Rev C...
Page 67: Installing The Hydraulic Fittings (Sae Straight Thread O-Ring Fitting Into The Component Port)
47 to 56 N∙m (34 to 42 ft-lb) 28 to 35 N∙m (20 to 26 ft-lb) 3/4—16 79 to 97 N∙m (58 to 72 ft-lb) 48 to 58 N∙m (35 to 43 ft-lb) Groundsmaster 7210 Page 4–7 Hydraulic System: General Information 16222SL Rev C...
Page 68 Back-up washer g212225 Figure 25 1. Ensure that all the threads, the sealing surfaces of fitting, and the component port are free of burrs, nicks, scratches, or unwanted material. Hydraulic System: General Information Page 4–8 Groundsmaster 7210 16222SL Rev C...
Page 69: Traction Unit Operator's Manual
The Traction Unit Operator's Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Traction Unit Operator's Manual for additional information when servicing the machine. Groundsmaster 7210 Page 4–9 Hydraulic System: General Information 16222SL Rev C...
Page 70: Pushing The Traction Unit
Pushing the Traction Unit In case of emergency, push the machine for a very short distance. However, Toro does not recommend this as a standard procedure. g033387 Figure 26 Transmission Bypass valve 1. Find the 2 bypass valves on the transmission (Figure 26).
Page 71: Releasing Pressure From The Hydraulic System
2. Turn the key switch to the O position and allow the engine to stop. 3. After lowering the cutting deck, ensure that the lift cylinder does not support the cutting deck (or implement). Groundsmaster 7210 Page 4–11 Hydraulic System: General Information 16222SL Rev C...
Page 72: Traction Circuit (Closed Loop) Component Failure
Traction Circuit (Closed Loop) Component Failure The traction system of the Groundsmaster 7210 machine consists of 2 identical and independent closed loop traction circuits. If a component failure occurs in 1 of these traction circuits (e.g., wheel motor or transmission piston pump), unwanted material and contamination from the damaged component will circulate throughout the traction circuit.
Page 73: Hydraulic Schematics
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 Figure 27 Hydraulic System: Hydraulic Schematics Page 4–14 Groundsmaster 7210 16222SL Rev C...
Page 75: Traction Circuits
The fluid loss from the closed loop due to the flushing valve is replaced by the charge pump. Groundsmaster 7210 Page 4–15 Hydraulic System: Hydraulic Schematics...
Page 76 The charge circuit functions the same in reverse as it does in the forward direction. Hydraulic System: Hydraulic Schematics Page 4–16 Groundsmaster 7210 16222SL Rev C...
Page 77 Reverse Direction (continued) g186586 Figure 28 Groundsmaster 7210 Page 4–17 Hydraulic System: Hydraulic Schematics 16222SL Rev C...
Page 78: Lift Circuit (Raise)
The de-energized solenoid valve A/S1 prevents the hydraulic flow to and from the lift cylinder to keep the cutting deck in the raised position. Hydraulic System: Hydraulic Schematics Page 4–18 Groundsmaster 7210 16222SL Rev C...
Page 79 Electrical Lift Control (continued) g186585 Figure 29 Groundsmaster 7210 Page 4–19 Hydraulic System: Hydraulic Schematics 16222SL Rev C...
Page 80: Lift Circuit (Lower)
This energized solenoid provides an oil passage to and from the lift cylinder to allow cylinder and cutting deck movement while mowing. Hydraulic System: Hydraulic Schematics Page 4–20 Groundsmaster 7210 16222SL Rev C...
Page 81 Cutting Deck Float (continued) g186587 Page 4–21 Groundsmaster 7210 Hydraulic System: Hydraulic Schematics Figure 30 16222SL Rev C...
Page 82: Pto Circuit
PTO Circuit The transmission of the Groundsmaster 7210 machine consists of a hydraulic, multi-plate clutch that is used to engage the PTO. The hydraulic flow for the PTO clutch engagement is provided by the transmission-charge pump. When the PTO switch is turned on, the transmission solenoid valve is energized to allow the hydraulic flow to engage the PTO clutch.
Page 83: Special Tools
Special Tools You can order these special tools from your Toro Distributor. Some tools are also available from a local tool supplier. Hydraulic Pressure Testing Kit g031764 Figure 31 Toro Part No. TOR47009 Use this kit to take various pressure readings for diagnostic tests. Quick disconnect fittings are provided to attach directly to the mating fittings on the machine test ports without the tools.
Page 84: Hydraulic Test Fitting 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 you connect the test gauges into the system. The kit includes: tees, unions, reducers, plugs, caps, and male test fittings.
Page 85: High Flow Hydraulic Filter Kit
Note: This kit does not include the hydraulic hoses; refer to Hydraulic Hose Kit (page 4–25). Note: The replacement filter element is Toro Part No. TOR6012. The filter element canister tightening torque is 34 N∙m (25 ft-lb). Hydraulic Hose Kit g035152...
Page 86: Remote Starter Switch
Hydraulic Hose Kit (continued) Toro Part No. TOR6007 This kit includes the fittings and hoses that are used to connect high flow hydraulic filter kit (TOR6011) to the machine hydraulic traction system components. Remote Starter Switch g036604 Figure 37 g186163...
Page 87 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 gauge wire, a 20 A in-line fuse, 2 alligator clips, and necessary connectors.
Page 88: Troubleshooting
Neutral is difficult to find. • The external control linkage is incorrectly adjusted, disconnected, binding, or damaged. • The orifice in the transmission-check valve(s) is plugged. • The transmission is worn or damaged. Hydraulic System: Troubleshooting Page 4–28 Groundsmaster 7210 16222SL Rev C...
Page 89: Pto Circuit Problems
• An electrical problem exists; refer to Chapter 5: Electrical System (page 5–1). • The transmission solenoid valve is stuck or damaged. • The PTO brake friction plates are worn or damaged. Groundsmaster 7210 Page 4–29 Hydraulic System: Troubleshooting 16222SL Rev C...
Page 90: Lift/Lower Circuit Problems
• The lift control manifold is damaged. The cutting deck (or implement) raises, but does not stay up. • The lift cylinder is leaking internally. • The lift control manifold is worn or damaged. Hydraulic System: Troubleshooting Page 4–30 Groundsmaster 7210 16222SL Rev C...
Page 91: Testing The Hydraulic System
Before performing the hydraulic tests, check all obvious areas, such as fluid supply, filter, binding linkages, loose fasteners, or improper adjustments before you assume that a hydraulic component is the source of the problem. Groundsmaster 7210 Page 4–31 Hydraulic System: Testing the Hydraulic System 16222SL Rev C...
Page 92 13. If there is a lift circuit problem, perform 1 or more of the following tests: implement relief pressure, gear pump flow, and/or lift cylinder internal leakage. 14. If there is a PTO circuit problem, perform the PTO pressure valve test. Hydraulic System: Testing the Hydraulic System Page 4–32 Groundsmaster 7210 16222SL Rev C...
Page 93: Testing The Traction System Operation
Testing the Traction System Operation Because the traction system of the Groundsmaster 7210 machine uses 2 different circuits, it is difficult to identify which circuit is causing a problem and what hydraulic tests should be performed. Use the following operation tests and suggestions before you perform the hydraulic tests described in this section.
Page 94: Testing The Charge Relief Valve Pressure (Using Pressure Gauge)
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 (Step 10) as the machine is moving (e.g., if the initial charge pressure is 690 kPa (100 psi), charge pressure while the machine is moving should be above 590 kPa (85 psi). Groundsmaster 7210 Page 4–35 Hydraulic System: Testing the Hydraulic System...
Page 96 15. Remove the pressure gauge from the transmission charge-pressure test port. 16. Install the plug into the port and torque the plug to 17.7 to 21.5 N∙m (13 to 15 ft-lb). Hydraulic System: Testing the Hydraulic System Page 4–36 Groundsmaster 7210 16222SL Rev C...
Page 97: Testing The Transmission Piston Pump Flow (Using Tester With Pressure Gauges And Flow Meter)
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 IMPORTANT Do not run the engine at full speed when performing this flow test using Toro hydraulic tester (pressure and flow) (TOR214678). The traction pump output at full engine speed can damage the hydraulic tester.
Page 99 19. Disconnect the tester from the transmission fitting and hose, and connect the hydraulic hose to the transmission port fitting again. 20. If necessary, repeat the flow test for other transmission piston pump. Groundsmaster 7210 Page 4–39 Hydraulic System: Testing the Hydraulic System...
Page 100: Testing The Traction Relief Valve Pressure (Using Tester With Pressure Gauges And Flow Meter)
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 IMPORTANT Do not run the engine at full speed when performing this test using Toro hydraulic tester (pressure and flow) (TOR214678). The traction pump output at full engine speed can damage the hydraulic tester. 9. Use a phototac to measure the engine speed, move the throttle so that the engine speed is 2,800 rpm (not full speed).
Page 102 16. Disconnect the tester from the pump outlet fitting and hydraulic hose, and connect the hose to the pump fitting. 17. If necessary, repeat the pressure test for other traction-relief valves. Hydraulic System: Testing the Hydraulic System Page 4–42 Groundsmaster 7210 16222SL Rev C...
Page 103: Testing The Wheel Motor Efficiency (Using Tester With Pressure Gauges And Flow Meter)
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 10. Start the engine and run it at low-idle speed (1,400 rpm). Check for hydraulic-fluid leaks from test connections and correct before continuing the test. Hydraulic System: Testing the Hydraulic System Page 4–44 Groundsmaster 7210 16222SL Rev C...
Page 105 IMPORTANT Do not run the engine at full speed when performing this test using Toro hydraulic tester (pressure and flow) (TOR214678). The traction pump output at full engine speed can damage the hydraulic tester. 11. Use a phototac to measure the engine speed, move the throttle so that the engine speed is 2,800 rpm (not full speed).
Page 106: Testing The Pto Pressure Valve (Using Pressure Gauge)
Testing the PTO Pressure Valve (Using Pressure Gauge) g187020 Figure 44 Hydraulic System: Testing the Hydraulic System Page 4–46 Groundsmaster 7210 16222SL Rev C...
Page 107 13. Disconnect the test gauge from the pressure valve test port. Install the plug into the port and torque the plug to 19 to 20 N∙m (14 to 15 ft-lb). Groundsmaster 7210 Page 4–47 Hydraulic System: Testing the Hydraulic System...
Page 108: Testing The Implement Relief Pressure (Using Pressure Gauge)
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 Hose to the lift control manifold 3. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, and set the parking brake. Groundsmaster 7210 Page 4–49 Hydraulic System: Testing the Hydraulic System 16222SL Rev C...
Page 110 14. Disconnect the T-connector with test gauge from the lift control manifold fitting and hydraulic hose, and connect the hydraulic hose to the lift control manifold fitting again. Hydraulic System: Testing the Hydraulic System Page 4–50 Groundsmaster 7210 16222SL Rev C...
Page 111: Testing The Gear Pump Flow (Using Tester With Pressure Gauges And Flow Meter)
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 Ensure that the tester flow arrow points from the pump outlet port and toward the disconnected hose. Ensure that the flow-control valve on the tester is fully open. Hydraulic System: Testing the Hydraulic System Page 4–52 Groundsmaster 7210 16222SL Rev C...
Page 113 Hydraulic System (page 4–11). 16. Disconnect the tester from the lift control manifold fitting and hydraulic hose, and connect the hose to the lift control manifold fitting again. Groundsmaster 7210 Page 4–53 Hydraulic System: Testing the Hydraulic System 16222SL Rev C...
Page 114: Testing The Lift Cylinder For Internal Leakage
Testing the Lift Cylinder for Internal Leakage g187019 Figure 50 Hydraulic System: Testing the Hydraulic System Page 4–54 Groundsmaster 7210 16222SL Rev C...
Page 115 5. Install a steel cap on the open lift cylinder fitting to seal the lift cylinder. Also, install a steel plug in the open end of the disconnected hose to prevent leakage or contamination. Groundsmaster 7210 Page 4–55 Hydraulic System: Testing the Hydraulic System...
Page 116 15. Start the engine and operate the lift cylinder through several raise and lower cycles. Shut off the engine and check for any leakage. 16. Check the hydraulic-fluid level in the hydraulic reservoir. Hydraulic System: Testing the Hydraulic System Page 4–56 Groundsmaster 7210 16222SL Rev C...
Page 117: Service And Repairs
4. Use proper tightening procedures when installing the hydraulic hoses and fittings; refer to Installing the Hydraulic Hose and Tube (O-Ring Face Seal Groundsmaster 7210 Page 4–57 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 118: Checking The Hydraulic Lines And Hoses
2. Check the hydraulic-fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. Hydraulic System: Service and Repairs Page 4–58 Groundsmaster 7210 16222SL Rev C...
Page 119: Flushing The Hydraulic System
1. Ensure that the hydraulic fluid is at normal operating temperature by operating the machine for at least 20 minutes. Groundsmaster 7210 Page 4–59 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 120 14. Check the condition of hydraulic fluid. If new fluid shows any signs of contamination, repeat steps through again until the fluid is clean. 15. Assume the normal operation and follow the recommended maintenance intervals. Hydraulic System: Service and Repairs Page 4–60 Groundsmaster 7210 16222SL Rev C...
Page 121: Charging The Hydraulic System
A. The oil filter or suction lines that are loose. B. An incorrect hose routing. C. The suction line that is blocked. D. The implement relief valve that is damaged. Groundsmaster 7210 Page 4–61 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 122 16. Stop the machine. Check the hydraulic-fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. 17. Check the hydraulic components for leaks and tighten any loose connections. Hydraulic System: Service and Repairs Page 4–62 Groundsmaster 7210 16222SL Rev C...
Page 123: Hydraulic Tank
2. Remove the operator seat and seat base; refer to Removing the Operator Seat (page 6–35). Groundsmaster 7210 Page 4–63 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 124 Installing the Operator Seat (page 6–36). 9. Operate the machine. Check the hydraulic-fluid level and adjust if necessary. 10. Check the hydraulic components for leaks. Tighten any loose connections. Hydraulic System: Service and Repairs Page 4–64 Groundsmaster 7210 16222SL Rev C...
Page 125: Wheel Motors
1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. Groundsmaster 7210 Page 4–65 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 126 12. Install clean caps or plugs on the hydraulic hoses and wheel motor ports to prevent system contamination. 13. Support the wheel motor to prevent it from falling during removal. Hydraulic System: Service and Repairs Page 4–66 Groundsmaster 7210 16222SL Rev C...
Page 127 11. Lower the machine to the ground. Torque the locknut (item 1 in Figure 55) to 407 to 542 N∙m (300 to 400 ft-lb). 12. Fill the reservoir with the correct quantity of new hydraulic fluid. Groundsmaster 7210 Page 4–67 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 128: Servicing The Wheel Motor
Body seal (5 each) Stator assembly Note: The 2 wheel motors of the Groundsmaster 7210 machine have the same basic construction. The left wheel motor has a yellow sticker on the port side of the stator. The right wheel motor has a reverse timed manifold.
Page 129 If a wheel motor fails; refer to the Traction Circuit (Closed Loop) Component Failure (page 4–12) for information regarding the importance of removing contamination from the traction circuit. Groundsmaster 7210 Page 4–69 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 130: Transmission
Hydraulic fitting Hydraulic fitting Clip O-ring O-ring Bolt Hydraulic hose Hydraulic hose O-ring Hydraulic fitting (4 each) Bolt (2 each) Hydraulic fitting O-ring Lock washer (2 each) O-ring Hydraulic System: Service and Repairs Page 4–70 Groundsmaster 7210 16222SL Rev C...
Page 131 8. Install clean caps or plugs in the hose and fitting openings to prevent system contamination. 9. Remove the hydraulic tank; refer to Removing the Hydraulic Tank (page 4–63). Groundsmaster 7210 Page 4–71 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 132 12. Move the transmission assembly toward the front of the machine and away from the flywheel housing and coupler on the engine flywheel. Lift the transmission from the machine. Hydraulic System: Service and Repairs Page 4–72 Groundsmaster 7210 16222SL Rev C...
Page 133 Installing the Gear Pump (page 4–107). 4. Slide both the pump control rods onto the transmission control arms and attach them with retaining rings (Figure 59). g033421 Figure 61 Groundsmaster 7210 Page 4–73 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 134 16. Connect the wire harness electrical connectors to the solenoid valve coil and seat switch. Secure the harness to the frame. 17. Check the operation of the parking brake and parking brake sensor. 18. Adjust the traction drive for neutral. Hydraulic System: Service and Repairs Page 4–74 Groundsmaster 7210 16222SL Rev C...
Page 135: Servicing The Transmission
Servicing the Transmission g033422 Figure 62 Groundsmaster 7210 Page 4–75 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 136 IMPORTANT If a transmission 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. Hydraulic System: Service and Repairs Page 4–76 Groundsmaster 7210 16222SL Rev C...
Page 137 Filter bypass plug Bypass valve 7. Remove the filter bypass plug, spring, and valve from the transmission pump body. 8. Remove and discard the O-ring from the plug. Groundsmaster 7210 Page 4–77 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 138 14. Remove the cover, gasket, collar, spring, and piston from the pump body. For assembly purposes, note that the hole in the collar is toward the outside of the pump body. Discard the gasket. Hydraulic System: Service and Repairs Page 4–78 Groundsmaster 7210 16222SL Rev C...
Page 139 18. Remove the 3 shorter (45 mm) and 2 longer (95 mm) flange-head screws that attach the pump body to the center case, and remove the pump body from the center case. Groundsmaster 7210 Page 4–79 Hydraulic System: Service and Repairs...
Page 140 Outer pump rotor 21. Slide the outer and inner charge pump rotors from the right pump shaft, and remove the key from the key slot in the pump shaft. Hydraulic System: Service and Repairs Page 4–80 Groundsmaster 7210 16222SL Rev C...
Page 141 Disassembling the Transmission (continued) g033431 Figure 71 Center case Pin (2 each) Pump housing g033432 Figure 72 Bypass valve Forward relief cartridge Center case Valve plate Reverse relief cartridge Groundsmaster 7210 Page 4–81 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 142 Figure 74 Hex plug (6 each) Left flushing valve Right flushing valve Center case 30. Remove the 6 hex plugs from the center case. Hydraulic System: Service and Repairs Page 4–82 Groundsmaster 7210 16222SL Rev C...
Page 143 37. Remove the retaining ring that secures the PTO shaft oil seal into the housing bore, and remove the spacer and oil seal from the housing. Note: Ensure that you do not damage the housing bore. Groundsmaster 7210 Page 4–83 Hydraulic System: Service and Repairs...
Page 144 43. Carefully remove the gear case housing from the pump housing. 44. Locate and retrieve the 2 pins from the gear case housing holes. 45. Remove and discard the gasket. Hydraulic System: Service and Repairs Page 4–84 Groundsmaster 7210 16222SL Rev C...
Page 145 48. Slide the pipe assembly from the bore of the pump housing. 49. Remove and discard the 2 O-rings from the grooves in the pipe. Groundsmaster 7210 Page 4–85 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 146 54. Discard the bearings that were removed, and remove the gear from the input shaft. g033441 Figure 81 Pump housing PTO shaft assembly Hydraulic System: Service and Repairs Page 4–86 Groundsmaster 7210 16222SL Rev C...
Page 147 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 Bearing Gear PTO shaft Clutch assembly Spacer Groundsmaster 7210 Page 4–87 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 148 58. Slide the 3 rods from the holes in the clutch assembly. 59. Slide the PTO gear assembly from the clutch assembly. Note: Because the individual clutch components are not available, disassembly of the clutch assembly is not necessary. Hydraulic System: Service and Repairs Page 4–88 Groundsmaster 7210 16222SL Rev C...
Page 149 Socket head plug Pump housing Hex plug 62. Remove the socket head plug and hex plug from the transmission pump housing. 63. Remove and discard the O-rings from the plugs. Groundsmaster 7210 Page 4–89 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 150 Washer 69. Carefully remove the swash plates from the transmission pump housing, and remove the washer from each swash plate. 70. Clean and inspect all the transmission components. Hydraulic System: Service and Repairs Page 4–90 Groundsmaster 7210 16222SL Rev C...
Page 151 Note: Ensure that you do not damage the seals. 5. Install the 2 side covers to the transmission pump housing with the 3 socket-head screws; torque the screws to 8.8 to 10.8 N∙m (78 to 95 in-lb). Groundsmaster 7210 Page 4–91 Hydraulic System: Service and Repairs...
Page 152 7. Install the retaining ring into the groove in the PTO gear bore. Press both the bearings into the PTO gear until each bearing contacts the retaining ring that is installed. Hydraulic System: Service and Repairs Page 4–92 Groundsmaster 7210 16222SL Rev C...
Page 153 B. Alternately place the 3 A-plates and 3 friction plates onto the PTO shaft. C. Place the C-plate and then the B-plate onto the shaft. D. Carefully install the 2 seal rings into the grooves of the PTO shaft. Groundsmaster 7210 Page 4–93 Hydraulic System: Service and Repairs...
Page 154 12. Apply clean hydraulic fluid to the friction plate and place it in the transmission pump housing. Note: Ensure that the tabs on the friction plates are placed in the housing grooves. Hydraulic System: Service and Repairs Page 4–94 Groundsmaster 7210 16222SL Rev C...
Page 155 Note: Ensure that the bearings are pressed fully to the shaft shoulder. 15. Lubricate the seal rings and install the seal ring onto the right and left pump shafts. Groundsmaster 7210 Page 4–95 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 156 Figure 101 Gear case housing Pin (2 each) Pump housing 18. Install the 2 pins into the transmission pump housing holes. Align new gasket to the housing. Hydraulic System: Service and Repairs Page 4–96 Groundsmaster 7210 16222SL Rev C...
Page 157 Figure 103 Oil seal Thrust plate bevel Thrust plate Control arm 24. Install the oil seal into the bore of the pump housing at the PTO shaft. Groundsmaster 7210 Page 4–97 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 158 Slide the pipe assembly into the bore of the transmission pump housing. g033465 Figure 105 Hex plug (6 each) Left flushing valve Right flushing valve Center case Hydraulic System: Service and Repairs Page 4–98 Groundsmaster 7210 16222SL Rev C...
Page 159 7 to 9 N∙m (62 to 79 in-lb). 35. Lubricate the sealing washers and install them onto the forward and reverse relief valve cartridges. Groundsmaster 7210 Page 4–99 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 160 40. Assemble the center case to the transmission pump housing with the 8 socket-head screws. Tighten the screws evenly in a crossing pattern and then torque the screws to 23 to 26 N∙m (17 to 19 ft-lb). Hydraulic System: Service and Repairs Page 4–100 Groundsmaster 7210 16222SL Rev C...
Page 161 43. Apply clean grease to the pump body O-rings to hold them in position during assembly. Place the O-rings in the pump body locations. g033470 Figure 110 Pump body Groundsmaster 7210 Page 4–101 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 162 46. Apply sealant to the threads of the 4 socket-head plugs and install them into the pump body; torque the plugs to 8.8 to 10.8 N∙m (78 to 95 in-lb). Hydraulic System: Service and Repairs Page 4–102 Groundsmaster 7210 16222SL Rev C...
Page 163 51. Lubricate new O-rings and install the O-rings onto the charge relief plug and pressure valve plug. Install the plugs into the pump body; torque the plugs to 23 to 26 N∙m (17 to 19 ft-lb). Groundsmaster 7210 Page 4–103 Hydraulic System: Service and Repairs...
Page 164 Note: Ensure that the sleeve is installed so that the holes are closest to the spring location and that the step in the spool is also toward the spring location. Hydraulic System: Service and Repairs Page 4–104 Groundsmaster 7210 16222SL Rev C...
Page 165 5.9 to 7.8 N∙m (52 to 69 in-lb). Note: The coil should be installed so that the "KANZAKI" molded into the coil has the "I" nearest the nut location. Groundsmaster 7210 Page 4–105 Hydraulic System: Service and Repairs...
Page 166: Gear Pump
4. Clean the hydraulic hose ends and fittings on the gear pump and hydraulic tank to prevent contaminants from entering into the system. 5. For assembly purposes, label all the hydraulic hoses and fittings. Hydraulic System: Service and Repairs Page 4–106 Groundsmaster 7210 16222SL Rev C...
Page 167 117) with grease and install the O-ring onto the flange of the gear pump. IMPORTANT Position the gear pump to the transmission so that the gear pump suction port is facing up. Groundsmaster 7210 Page 4–107 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 168 8. Fill the hydraulic tank with the correct quantity of new hydraulic fluid. 9. Install the operator seat and seat base; refer to Installing the Operator Seat (page 6–36). Hydraulic System: Service and Repairs Page 4–108 Groundsmaster 7210 16222SL Rev C...
Page 169: Servicing The Gear Pump
1. Install clean plugs in the pump ports and clean the outer surface of the pump. After cleaning, remove the plugs and drain the hydraulic fluid out of the pump. g033480 Figure 120 Groundsmaster 7210 Page 4–109 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 170 11. Carefully remove the shaft seal from the front plate. 12. If necessary, remove the implement relief valve from the back plate. 13. Remove and discard the sealing washers. Hydraulic System: Service and Repairs Page 4–110 Groundsmaster 7210 16222SL Rev C...
Page 171 Note: The seal should be pressed into place until it reaches the bottom of the bore. 3. Install the retaining ring into the groove of the front plate. Groundsmaster 7210 Page 4–111 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 172 If the input shaft binds, disassemble the pump and repeat the assembly process. 22. Remove the pump from the vise. Hydraulic System: Service and Repairs Page 4–112 Groundsmaster 7210 16222SL Rev C...
Page 173: Lift Control Manifold
Ensure that the cutting deck is fully lowered and supported before loosening the hydraulic lines, cartridge valves, or plugs from the lift control manifold. Groundsmaster 7210 Page 4–113 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 174 6. Connect the wire harness connectors to the solenoid coils on the manifold. 7. Check the hydraulic-fluid level in the hydraulic reservoir and add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. Hydraulic System: Service and Repairs Page 4–114 Groundsmaster 7210 16222SL Rev C...
Page 175: Servicing The Lift Control Manifold
123) installed in the manifold port 4. This plug is not a serviceable part and is used to prevent hydraulic flow from the manifold port 1 to port 4. Groundsmaster 7210 Page 4–115 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 176 B. If the sealing surfaces of the valve are pitted or damaged, the hydraulic system can be too hot or there can be water in the system. Hydraulic System: Service and Repairs Page 4–116 Groundsmaster 7210 16222SL Rev C...
Page 177 6.7 N∙m (60 in-lb). 10. If the problems still exist after manifold assembly, remove the cartridge valve and clean the valve again or replace the cartridge valve. Groundsmaster 7210 Page 4–117 Hydraulic System: Service and Repairs...
Page 178: Polar Trac Hydraulic Control Valve
90° hydraulic fitting Retainer nut (4 each) O-ring Cable tie Carriage screw (2 each) Straight fitting O-ring Ear pivot O-ring (2 each) 90° hydraulic fitting Screw (4 each) Hydraulic System: Service and Repairs Page 4–118 Groundsmaster 7210 16222SL Rev C...
Page 179 O-rings to the fittings. Install the fittings into the valve ports; refer Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fitting into the Component Port) (page 4–7). Use the notes that you recorded during removal to orientate the fittings. Groundsmaster 7210 Page 4–119 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 180 Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–5). 6. Ensure that the hydraulic tank is full. Add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. Hydraulic System: Service and Repairs Page 4–120 Groundsmaster 7210 16222SL Rev C...
Page 181: Servicing The Polar Trac Hydraulic Control Valve
Spool cap (2 each) Plunger O-ring Valve body Detent plunger Spool Disassembling the Polar Trac Hydraulic Control Valve 1. Plug all the ports and clean the outer surface of the valve. Groundsmaster 7210 Page 4–121 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 182 2. Replace the check poppet (item 1 in Figure 126), O-rings, and back-up washers with new ones. 3. Install new O-rings (item 12 in Figure 126) into the valve body. Hydraulic System: Service and Repairs Page 4–122 Groundsmaster 7210 16222SL Rev C...
Page 183 13. Install the O-ring and detent plug (item 19 in Figure 126) into the valve body; torque the plug to 5.4 to 6.8 N∙m (4 to 5 ft-lb). Groundsmaster 7210 Page 4–123 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 184: Lift Cylinder
2. Clean the hydraulic hose ends and fittings on the lift cylinder to prevent contaminants from entering into the hydraulic system. Hydraulic System: Service and Repairs Page 4–124 Groundsmaster 7210 16222SL Rev C...
Page 185 Installing the Hydraulic Hose and Tube (O-Ring Face Seal Fitting) (page 4–5). 7. Lubricate the grease fittings on the lift cylinder and pivot pin. Groundsmaster 7210 Page 4–125 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 186: Servicing The Lift Cylinder
1. Slowly pump the cylinder shaft to remove the hydraulic fluid from the lift cylinder into a drain pan. Plug both the ports and clean the outer surface of the cylinder. Hydraulic System: Service and Repairs Page 4–126 Groundsmaster 7210 16222SL Rev C...
Page 187 When you clamp the cylinder head of the cylinder in a vise, clamp the clevis end of the cylinder head only to prevent damage. 4. Mount the cylinder head in a vise. Groundsmaster 7210 Page 4–127 Hydraulic System: Service and Repairs...
Page 188 Note: Do not damage the seals. 6. Use a pipe wrench to install the collar and secure the head in the cylinder head. Hydraulic System: Service and Repairs Page 4–128 Groundsmaster 7210 16222SL Rev C...
Page 189: Polar Trac Lift Cylinder
Hydraulic hose assembly Bolt (2 each) Hydraulic hose assembly Hydraulic hose Pivot pin (2 each) Lift arm assembly Lock pin Hydraulic hose Locknut (3 each) Slotted roll pin O-ring Hairpin Groundsmaster 7210 Page 4–129 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 190 7. Lubricate the grease fittings on the cylinder pivot pins. 8. Ensure that the hydraulic tank is full. Add correct quantity of fluid if necessary; refer to the Traction Unit Operator’s Manual. Hydraulic System: Service and Repairs Page 4–130 Groundsmaster 7210 16222SL Rev C...
Page 191: Servicing The Polar Trac Lift Cylinder
1. Slowly pump the cylinder rod and remove the hydraulic fluid from the lift cylinder into a drain pan. Plug the 2 ports and clean the outer surface of the cylinder. Groundsmaster 7210 Page 4–131 Hydraulic System: Service and Repairs...
Page 192 2. Put a coating of clean hydraulic fluid on new O-rings, back-up ring, and other seals, and do the following steps: A. Carefully install the cap seal and O-ring to the piston. If removed, install the wear ring on the piston. Hydraulic System: Service and Repairs Page 4–132 Groundsmaster 7210 16222SL Rev C...
Page 193 Groundsmaster 7210 Page 4–133 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 194: Oil Cooler
1. Back flush the oil cooler with cleaning solvent. After cleaning the cooler, ensure that all the solvent is drained from the cooler. CAUTION Use eye protection such as goggles when using compressed air to dry the oil cooler. Hydraulic System: Service and Repairs Page 4–134 Groundsmaster 7210 16222SL Rev C...
Page 195 2. Install the radiator and oil cooler to the machine; refer to Installing the Radiator (page 3–15). 3. Lower the hood and secure it with the latches. 4. Start the engine and check for leaks. Groundsmaster 7210 Page 4–135 Hydraulic System: Service and Repairs 16222SL Rev C...
Page 196 Hydraulic System: Service and Repairs Page 4–136 Groundsmaster 7210 16222SL Rev C...
Page 197 Start and EGR Relays........................5–41 Fuel Pump............................5–43 Dual Temperature Switch ......................... 5–45 Fuses ............................... 5–47 CAN-bus Terminator Resistor ......................5–49 Deck Lift/Lower Switch........................5–50 Lift Control Manifold Solenoid Valve Coil..................5–52 Groundsmaster 7210 Page 5–1 Electrical System 16222SL Rev C...
Page 198 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 5–2 Groundsmaster 7210 16222SL Rev C...
Page 199: General Information
Control panel cover Standard Control Module (SCM) Latch Screw The Groundsmaster 7210 machine is equipped with a Standard Control Module (SCM) to monitor and control the electrical components required for safe operation. The SCM is attached to the control panel cover (Figure 133).
Page 200 The high-temperature warning input LED should be illuminated when the engine dual temperature switch closes due to engine coolant temperature of approximately 105°C (220°F). The backlap input LED is not used on the Groundsmaster 7210 machine. SCM Outputs g033656 Figure 134...
Page 201: Standard Control Module Logic Chart
Allow the engine to be idle for several minutes while it cools to a safe level, and check the cooling system before returning the machine to service. Groundsmaster 7210 Page 5–5 Electrical System: General Information 16222SL Rev C...
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: Yanmar Engine Electronic Control Unit (Ecu)
Battery Electronic Control Unit (ECU) The Yanmar engine that powers the Groundsmaster 7210 machine uses an electronic control unit (ECU) for engine management and to communicate with the InfoCenter display on the machine. If you must disconnect the engine ECU...
Page 204: Electrical Schematics And Diagrams
CAN High, CAN Low, B+ (power), and ground. Electrical Schematics and Diagrams Refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A—Foldout Drawings. Electrical System: General Information Page 5–8 Groundsmaster 7210 16222SL Rev C...
Page 205: Special Tools
Special Tools You can order these special tools from your Authorized Toro Distributor. Some tools are also available from a local supplier. Multimeter g033636 Figure 137 The meter can test the electrical components and circuits for current, resistance, or voltage.
Page 206: Battery Hydrometer
The connectors must be fully packed with gel for effective results. Note: Do not use the dielectric gel on the sealed connection terminals as the gel can unseat the connector seals during assembly. Toro Part No. 107-0342 Electrical System: Special Tools Page 5–10 Groundsmaster 7210...
Page 207: Infocenter Display
InfoCenter for several seconds, the main information screen will be displayed on the InfoCenter. The splash screen can be used to identify the machine battery voltage, hour meter reading, engine coolant temperature, and engine status. Groundsmaster 7210 Page 5–11 Electrical System: InfoCenter Display 16222SL Rev C...
Page 208: Main Information Screen
The 2 InfoCenter main information screens (Figure 142 Figure 143) are displayed after the initial splash screen has been displayed for several seconds. During the normal operation of the machine, the main information screens Electrical System: InfoCenter Display Page 5–12 Groundsmaster 7210 16222SL Rev C...
Page 209: Main Menu Screen
The main menu items include service, settings, and about. These menu items are described below. To return to the main information screen from the main menu screen, press the back button (left button). Groundsmaster 7210 Page 5–13 Electrical System: InfoCenter Display 16222SL Rev C...
Page 210: Service Screen
Protected menus allows the machine PIN to be entered so that the hidden machine service screen items can be viewed and modified. The protected service items include the exhaust system DPF regeneration (Tier 4 engines). Electrical System: InfoCenter Display Page 5–14 Groundsmaster 7210 16222SL Rev C...
Page 211: About Screen
R 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 Figure 146...
Page 212: Troubleshooting
If the machine has any interlock switches that are bypassed, connect the switches for the correct troubleshooting and safety. Note: Use the Standard Control Module input and output LED's when troubleshooting an electrical problem of the Groundsmaster 7210 machine. Starting Problems Problem...
Page 213: General Run And Transport Problems
• The parking brake sensor or circuit approximately 10 seconds before it shuts off wiring is damaged. again. Groundsmaster 7210 Page 5–17 Electrical System: Troubleshooting 16222SL Rev C...
Page 214: Cutting Deck Operating Problems
• The PTO clutch in the transmission is worn or damaged; refer to Chapter 4: Hydraulic System (page 4–1). • The transmission pressure valve or charge pump is damaged; refer to Chapter 4: Hydraulic System (page 4–1). Electrical System: Troubleshooting Page 5–18 Groundsmaster 7210 16222SL Rev C...
Page 215: Cutting Deck Lift/Lower Problems
None of the cutting units raises. • The lift control manifold solenoid coil S1 or circuit wiring is damaged. • A hydraulic problem in the lift/lower circuit exists; refer to the Troubleshooting (page 4–28). Groundsmaster 7210 Page 5–19 Electrical System: Troubleshooting 16222SL Rev C...
Page 216: Electrical System Quick Checks
0.50 V higher than that of the initial battery voltage. Refer to the Battery Voltage Table (page 5–21) for an example of a charging system that is functioning. Electrical System: Electrical System Quick Checks Page 5–20 Groundsmaster 7210 16222SL Rev C...
Page 217: Testing The Glow Plug System
Adjust the meter to read zero (if applicable). Activate the glow plug system and record the multimeter results. The glow plug system of the Groundsmaster 7210 machine should have a reading of approximately 21 A. Checking the Operation of the Interlock Switches...
Page 218 Lift off the seat and slowly move the traction control levers from the N position, the engine must stop in 1 to 3 seconds. EUTRAL LOCK Correct the problem if the machine is not operating properly. Electrical System: Electrical System Quick Checks Page 5–22 Groundsmaster 7210 16222SL Rev C...
Page 219: Testing The Electrical Components
When testing the electrical components for continuity with a multimeter (ohms setting), ensure that you disconnect the power to the circuit. Key Switch g035045 Figure 147 Key switch g033641 Figure 148 Groundsmaster 7210 Page 5–23 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 220 E. Connect the machine wire harness connector to the key switch. Circuit Logic Table Switch Position Normal Circuits Other Circuits None None B+A+I REHEAT B+S+I None TART Electrical System: Testing the Electrical Components Page 5–24 Groundsmaster 7210 16222SL Rev C...
Page 221: Pto Switch
PTO. If the key switch is in the O position and the PTO switch is engaged, the SCM PTO switch input LED should be illuminated. Groundsmaster 7210 Page 5–25 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 222 COM C + NC C COM C + NO C COM B + NO B COM B + NC B COM C + NO C COM C + NC C Electrical System: Testing the Electrical Components Page 5–26 Groundsmaster 7210 16222SL Rev C...
Page 223: Neutral Switches
Figure 153 Traction lever (left) Neutral switch The Groundsmaster 7210 machine uses 2 identical neutral switches. These neutral switches are normally open and close when the traction levers are in the position. The neutral switches are located under the left cover...
Page 224 Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A—Foldout Drawings. H. Connect the machine wire harness connector to the neutral switch. Check the operation of the neutral switch. Electrical System: Testing the Electrical Components Page 5–28 Groundsmaster 7210 16222SL Rev C...
Page 225: Seat Switch
Groundsmaster 7210 Page 5–29 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 226 H. After you complete the seat switch testing, connect the machine wire harness connector to the seat switch electrical lead. Lower the seat assembly. Check the operation of the seat switch. Electrical System: Testing the Electrical Components Page 5–30 Groundsmaster 7210 16222SL Rev C...
Page 227: Engine Oil Pressure Switch
6. If the switch testing is correct and the circuit problem still exists, check the machine wire harness; refer to the Electrical Schematics and Wire Harness Drawings/Diagrams in Appendix A—Foldout Drawings. Groundsmaster 7210 Page 5–31 Electrical System: Testing the Electrical Components...
Page 228 Testing the Engine Oil Pressure Switch (continued) 7. After you complete the oil pressure switch testing, connect the ECU wire harness connector to the oil pressure switch. Electrical System: Testing the Electrical Components Page 5–32 Groundsmaster 7210 16222SL Rev C...
Page 229: Parking Brake Sensor
5. Remove the left cover. 6. Locate the parking brake sensor (Figure 157). Note: Ensure that the parking brake is not set. Groundsmaster 7210 Page 5–33 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 230 Adjust the sensor after installation; refer to Parking Brake Sensor (page 5–54). 10. After you complete the brake sensor testing, ensure that the sensor connector is plugged into the machine wire harness. Electrical System: Testing the Electrical Components Page 5–34 Groundsmaster 7210 16222SL Rev C...
Page 231: Pto Solenoid Valve Coil
Figure 158 Transmission Coil connector Solenoid valve and coil The hydraulic system of the Groundsmaster 7210 machine uses a solenoid valve coil on the front of the transmission (Figure 158). When the solenoid valve coil is energized, hydraulic flow is directed to operate the PTO system.
Page 232: Fusible Link Harness
Figure 160 The Groundsmaster 7210 machine uses 3 fusible links for the circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the main wire harness. If any of these links fail, current to the protected circuit stops;...
Page 233: Diode Assemblies
Several identical diodes are used on the Groundsmaster 7210 machines. The maximum current allowed through any of the diodes is 6 A. The diode assemblies can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 161).
Page 234: Resistor Assembly
Resistor assembly Testing the Resistor Assembly The resistor can be tested using a digital multimeter (ohms setting). Note: The resistance across the resistor terminals should be 1600 ohms. Electrical System: Testing the Electrical Components Page 5–38 Groundsmaster 7210 16222SL Rev C...
Page 235: Glow Relay
Figure 164 The glow relay of the Groundsmaster 7210 machine has 4 terminals and allows electrical current to the engine glow plugs when energized. The glow relay is attached to the ECU bracket that is located above the battery.
Page 236 5. Disconnect the voltage and leads from the relay terminals. 6. Connect the wire harness electrical connector to the glow relay after you complete the testing. 7. Close the hood and secure it with the latches. Electrical System: Testing the Electrical Components Page 5–40 Groundsmaster 7210 16222SL Rev C...
Page 237: Start And Egr Relays
Normally closed term Common terminal The Groundsmaster 7210 machine uses 2 identical relays that have 5 terminals to control power to the starter motor solenoid and EGR valve of the engine. The relays are attached to the ECU bracket above the battery (Figure 165).
Page 238 12. Connect the positive (+) cable to the battery and then connect the negative (-) cable to battery; refer to Servicing the Battery (page 5–61). 13. Lower the hood and secure it with the latches. Electrical System: Testing the Electrical Components Page 5–42 Groundsmaster 7210 16222SL Rev C...
Page 239: Fuel Pump
8. Turn the key switch to the O position and collect the fuel in the graduated cylinder. Allow the pump to run for 30 seconds and then return the switch to the O position. Groundsmaster 7210 Page 5–43 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 240 21.5 to 37.3 kPa (3.1 to 5.4 psi) Maximum Current Draw 0.9 A 11. Lower the operator seat. 12. Lower the hood and secure it with the latches. Electrical System: Testing the Electrical Components Page 5–44 Groundsmaster 7210 16222SL Rev C...
Page 241: Dual Temperature Switch
The Standard Control Module (SCM) monitors the operation of the dual temperature switch. If excessive coolant temperature causes either the switch circuit to close, the appropriate LED on the SCM illuminates. Test the switch Groundsmaster 7210 Page 5–45 Electrical System: Testing the Electrical Components...
Page 242 6. After you complete the testing, install the temperature switch to the engine housing, do the following steps: A. Clean the threads of the housing and switch. Apply thread sealant to the threads of the switch. Electrical System: Testing the Electrical Components Page 5–46 Groundsmaster 7210 16222SL Rev C...
Page 243: Fuses
Fuse F3 (10 A) Fuse F1 (15 A) g034749 Figure 172 25 A fuse The fuse block is located under the controller cover next to the operator seat. Groundsmaster 7210 Page 5–47 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 244 Remove the fuse from the fuse block and check that the fuse has continuity across the fuse terminals. Electrical System: Testing the Electrical Components Page 5–48 Groundsmaster 7210 16222SL Rev C...
Page 245: Can-Bus Terminator Resistor
(Figure 173) using a digital multimeter (ohms setting). The resistance between the terminals A and B of the terminator resistor should be 120 ohms. The terminal C is not used on the Groundsmaster 7210 machine. Groundsmaster 7210 Page 5–49 Electrical System: Testing the Electrical Components...
Page 246: Deck Lift/Lower Switch
S1 on the hydraulic lift control manifold is energized causing the valve to shift and the lift cylinder to retract to lower the cutting deck. Electrical System: Testing the Electrical Components Page 5–50 Groundsmaster 7210 16222SL Rev C...
Page 247 10. Carefully slide the switch cap with the lift/lower switch and the attached wire harness into the right control handle and secure the switch cap with the 2 screws. Groundsmaster 7210 Page 5–51 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 248: Lift Control Manifold Solenoid Valve Coil
When the solenoid coils are energized, the valve shift occurs to control the hydraulic fluid flow. The electrical testing of the coils can be done with the coil installed on the hydraulic valve. Electrical System: Testing the Electrical Components Page 5–52 Groundsmaster 7210 16222SL Rev C...
Page 249 Solenoid Valve Coil Specifications Table Coil Diameter Coil Height Coil Resistance 46.7 mm (1.84 inch) 49.9 mm (1.96 inch) 7.1 ohm 35.8 mm (1.41 inch) 36.3 mm (1.43 inch) 8.8 ohm Groundsmaster 7210 Page 5–53 Electrical System: Testing the Electrical Components 16222SL Rev C...
Page 250: Adjustments
(the brake latch engaged). The brake sensor is a normally open proximity sensor that is installed to the bracket located below the brake shaft (Figure 178). Electrical System: Adjustments Page 5–54 Groundsmaster 7210 16222SL Rev C...
Page 251 4. After adjusting the parking brake sensor, use the SCM to check that the parking brake sensor and circuit wiring are functioning correctly; refer to Parking Brake Sensor (page 5–33). Groundsmaster 7210 Page 5–55 Electrical System: Adjustments 16222SL Rev C...
Page 252: Service And Repairs
Figure 181 Hex nut Seal Lock washer Solenoid valve coil Washer You can replace the PTO solenoid valve coil on the transmission without opening the hydraulic system (Figure 180). Electrical System: Service and Repairs Page 5–56 Groundsmaster 7210 16222SL Rev C...
Page 253 2. Install the hex nut onto the spool assembly and torque the nut to 5.9 to 7.8 N∙m (53 to 69 in-lb). 3. Connect the wire harness electrical connector to the solenoid valve coil connector. 4. Lower and secure the operator seat. Groundsmaster 7210 Page 5–57 Electrical System: Service and Repairs 16222SL Rev C...
Page 254: Lift Control Manifold Solenoid Valve Coils
2. Install the nut onto the valve and torque the nut to 6.8 N∙m (5 ft-lb). Note: Do not overtighten the nut. 3. Connect the machine wire harness connector to the solenoid coil. 4. Lower and secure the seat. Electrical System: Service and Repairs Page 5–58 Groundsmaster 7210 16222SL Rev C...
Page 255: Battery Storage
4. Store the battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5. To prevent the battery from freezing during storage, ensure that you charge it fully; refer to Servicing the Battery (page 5–61). Groundsmaster 7210 Page 5–59 Electrical System: Service and Repairs 16222SL Rev C...
Page 256: Battery Care
(-) cable first. Clean the cable clamps and terminals separately. Connect the cables with the positive (+) cable first. Apply a layer of battery terminal protector (Toro Part No. 107-0392) or a light coat of grease to the terminals to reduce corrosion after you make the connections.
Page 257: Servicing The Battery
Width 17.3 cm (6.8 inches) Height 20.3 cm (8.0 inches) Removing the Battery g033676 Figure 183 Negative cable Flat washer Battery Battery retainer Battery tray Carriage screw Flange nut Positive cable Groundsmaster 7210 Page 5–61 Electrical System: Service and Repairs 16222SL Rev C...
Page 258 A. Use a hydrometer to measure the specific gravity of each cell. Pull the electrolyte in and out of the hydrometer barrel before taking a reading to warm-up the hydrometer. At the same time, take the temperature of the cell. Electrical System: Service and Repairs Page 5–62 Groundsmaster 7210 16222SL Rev C...
Page 259 F. Apply a test load of 1/2 the cranking performance rating of the battery for 15 seconds; refer to Battery Specifications (page 5–61). G. Take a test voltage reading at 15 seconds, then remove the load. Groundsmaster 7210 Page 5–63 Electrical System: Service and Repairs 16222SL Rev C...
Page 260 7. Connect the negative (-) cable connector to the negative (-) battery post. Use the 2 wrenches to attach the cable bolt and locknut. 8. After you make the connections, apply battery terminal protector (Toro Part No. 107-0392) or a light layer of grease on all the battery posts and cable connectors to reduce corrosion.
Page 261 171 to 250 5.8 hrs 11.5 hrs 17.3 hrs 23 hrs above 250 6 hrs 12 hrs 18 hrs 24 hrs 10 A 10 A 10 A 10 A Groundsmaster 7210 Page 5–65 Electrical System: Service and Repairs 16222SL Rev C...
Page 262 Note: The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.003 change in specific gravity for 3 consecutive readings. Electrical System: Service and Repairs Page 5–66 Groundsmaster 7210 16222SL Rev C...
Page 263 Servicing the PTO Driveshaft Cross and Bearing ................6–27 Cutting Deck Lift Arms ........................6–29 Rollover Protection System......................6–33 Operator Seat ..........................6–35 Servicing the Operator Seat ......................6–37 Hood ..............................6–40 Groundsmaster 7210 Page 6–1 Chassis 16222SL Rev C...
Page 264: Specifications
102 to 115 N∙m (75 to 85 ft-lb) Wheel lug nut torque (machines with Polar Trac) 88 to 115 N∙m (65 to 85 ft-lb) Rear wheel hub locknut torque 407 to 542 N∙m (300 to 400 ft-lb) Chassis: Specifications Page 6–2 Groundsmaster 7210 16222SL Rev C...
Page 265: General Information
The Traction Unit Operator’s Manual provides information regarding the operation, general maintenance procedures, and maintenance intervals for your machine. Refer to the Traction Unit Operator’s Manual for additional information when servicing the machine. Groundsmaster 7210 Page 6–3 Chassis: General Information 16222SL Rev C...
Page 266: Service And Repairs
Polar Trac Wheels (page 6–6) for information regarding the wheel removal. 2. Loosen, but do not remove the 5 wheel-lug nuts that attach the rear wheel to the wheel hub. Chassis: Service and Repairs Page 6–4 Groundsmaster 7210 16222SL Rev C...
Page 267 1. Install the wheel to the machine with the 5 wheel-lug nuts and 5 wheel studs. 2. Lower the wheel to the ground and torque the wheel-lug nuts to 102 to 115 N∙m (75 to 85 ft-lb) in a star-like pattern. Groundsmaster 7210 Page 6–5 Chassis: Service and Repairs...
Page 268: Polar Trac Wheels
Note: When removing the wheels from a Polar Trac equipped machine, remove the center wheel first to allow track clearance for the front or rear wheels. Chassis: Service and Repairs Page 6–6 Groundsmaster 7210 16222SL Rev C...
Page 269 9. Once you remove the center wheel, have a second person to lift the track from other wheel(s) as necessary to remove the additional wheel(s) from the machine. Groundsmaster 7210 Page 6–7 Chassis: Service and Repairs 16222SL Rev C...
Page 270 8. Position the side access cover to the frame and attach with the 2 screws. 9. Fully lower the machine to the ground and torque all the wheel-lug nuts to 88 to 115 N∙m (65 to 85 ft-lb) in a crossing pattern. Chassis: Service and Repairs Page 6–8 Groundsmaster 7210 16222SL Rev C...
Page 271: Parking Brakes
3. Remove the rear wheel; refer to Removing the Rear Wheel (page 6–4). Note: Ensure that the machine is correctly supported with jack stands. Groundsmaster 7210 Page 6–9 Chassis: Service and Repairs 16222SL Rev C...
Page 272 7. Remove the 2 locknuts that secure the parking brake assembly to the brake support, and remove the brake from the support. 8. Locate and retrieve the 2 hardened washers from the parking brake and brake support (Figure 188 Figure 189). Chassis: Service and Repairs Page 6–10 Groundsmaster 7210 16222SL Rev C...
Page 273 Note: Ensure that the disc is between the 2 stators (brake pads) in the brake assembly. 6. Install the 4 bolts and 4 flange nuts in the mounting holes of the brake support and frame, but do not fully tighten. Groundsmaster 7210 Page 6–11 Chassis: Service and Repairs 16222SL Rev C...
Page 274 (item 1 in Figure 187) to 407 to 542 N∙m (300 to 400 ft-lb). Release the parking brake. 12. Check the operation of the parking brake and parking brake sensor. Chassis: Service and Repairs Page 6–12 Groundsmaster 7210 16222SL Rev C...
Page 275: Servicing The Parking Brake
Assembling the Parking Brake 1. Position the stationary actuator on the level work surface. 2. Assemble the brake components in order (Figure 191). Groundsmaster 7210 Page 6–13 Chassis: Service and Repairs 16222SL Rev C...
Page 276 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: Service and Repairs Page 6–14 Groundsmaster 7210 16222SL Rev C...
Page 277: Parking Brake Assembly
Disassembling the Parking Brake Assembly 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. Groundsmaster 7210 Page 6–15 Chassis: Service and Repairs 16222SL Rev C...
Page 278 B. Ensure that the screws (item 10 in Figure 192) that are used to attach the flange bearings to the frame are installed from the outside of the frame to the inside. Chassis: Service and Repairs Page 6–16 Groundsmaster 7210 16222SL Rev C...
Page 279 195) on the rear brake rod. 3. Check the operation of the parking brake and parking brake sensor. 4. Install the left cover to the machine with the 2 bolts (Figure 193). Groundsmaster 7210 Page 6–17 Chassis: Service and Repairs 16222SL Rev C...
Page 280: Front Castor Wheels
Castor fork (2 each) Disassembling the Front Castor Wheels Note: The left castor wheel has 2 adjustable positions, 1 is for 60/62 inch deck and the other is for 72 inch deck. Chassis: Service and Repairs Page 6–18 Groundsmaster 7210 16222SL Rev C...
Page 281 5. Remove the grease cap (item 19 in Figure 196) from the carrier frame, and discard the cap. Groundsmaster 7210 Page 6–19 Chassis: Service and Repairs 16222SL Rev C...
Page 282 Allow grease to fill the cavities below the lower bearing, between the bearings, and above the upper bearing. Install the plug again into the frame. Chassis: Service and Repairs Page 6–20 Groundsmaster 7210 16222SL Rev C...
Page 283 Note: There should be no evidence that the cap is indented by the top of the castor fork. 9. Position the castor wheel to the castor fork and secure the wheel with the bolt and locknut. 10. Lower the machine to the ground. Groundsmaster 7210 Page 6–21 Chassis: Service and Repairs 16222SL Rev C...
Page 284: Servicing The Polar Trac Wheel Hub
Shoulder bolt Shoulder screw Pivot pin Disassembling the Polar Trac Wheel Hub Note: Refer to the Polar Trac Operator's Manual for additional information regarding the drive track and wheel removal. Chassis: Service and Repairs Page 6–22 Groundsmaster 7210 16222SL Rev C...
Page 285 IMPORTANT The lip of the seal must be toward the bearing. Press the seal into the wheel hub so that it is flush with the end of the wheel hub. Groundsmaster 7210 Page 6–23 Chassis: Service and Repairs 16222SL Rev C...
Page 286 Note: Ensure that the drive track is installed in the correct direction of rotation. 10. Lower the machine to the ground and torque all the wheel-lug nuts to 88 to 115 N∙m (65 to 85 ft-lb) in a crossing pattern. Chassis: Service and Repairs Page 6–24 Groundsmaster 7210 16222SL Rev C...
Page 287: Pto Driveshaft
4. Disconnect the end yoke of the PTO driveshaft from the cutting deck gearbox shaft as follows: A. Remove the roll pin from the end yoke and gearbox shaft. Groundsmaster 7210 Page 6–25 Chassis: Service and Repairs 16222SL Rev C...
Page 288 PTO shaft; torque the locknuts to 20 to 25 N∙m (175 to 225 in-lb). 5. Lubricate the PTO driveshaft grease fittings. 6. Install the fuse F1 (15 A) into the fuse block. Chassis: Service and Repairs Page 6–26 Groundsmaster 7210 16222SL Rev C...
Page 289: Servicing The Pto Driveshaft Cross And Bearing
A. Apply a coat of grease to the bearing bores of the end yoke and shaft yoke. Also, apply grease to the bearings and seal of the bearing assembly. Groundsmaster 7210 Page 6–27 Chassis: Service and Repairs 16222SL Rev C...
Page 290 If the binding continues, disassemble the joint to identify the source of binding. Note: Ensure that the assembled joint moves without any binding. 6. Install the PTO driveshaft to the machine; refer to Installing the PTO Driveshaft (page 6–26). Chassis: Service and Repairs Page 6–28 Groundsmaster 7210 16222SL Rev C...
Page 291: Cutting Deck Lift Arms
1. Park the machine on a level surface with the cutting deck in fully raised position. Shut off the engine, set the parking brake, and remove the key from the key switch. Groundsmaster 7210 Page 6–29 Chassis: Service and Repairs...
Page 292 3. Start the engine and fully lower the cutting deck. Shut off the engine, and remove the key from the key switch. 4. Remove the lift arm components as shown in Figure 204 Figure 206. Chassis: Service and Repairs Page 6–30 Groundsmaster 7210 16222SL Rev C...
Page 293 3. Lubricate all the lift arm grease fittings after assembly. 4. Start the engine and fully raise the cutting deck. Shut off the engine and remove the key from the key switch. Groundsmaster 7210 Page 6–31 Chassis: Service and Repairs...
Page 294 Assembling 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 C...
Page 295: Rollover Protection System
1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. 2. Raise the operator seat. Groundsmaster 7210 Page 6–33 Chassis: Service and Repairs 16222SL Rev C...
Page 296 6. Insert the 2 fold pins (item 6 in Figure 209) into the ROPS support plate and insert the 2 double loop hairpin cotters. 7. Lower the operator seat. Chassis: Service and Repairs Page 6–34 Groundsmaster 7210 16222SL Rev C...
Page 297: Operator Seat
1. Park the machine on a level surface, lower the cutting deck (or implement), shut off the engine, set the parking brake, and remove the key from the key switch. Groundsmaster 7210 Page 6–35 Chassis: Service and Repairs 16222SL Rev C...
Page 298 3. Connect the wire harness electrical connector to the seat switch harness (Figure 212). 4. Lower the seat and latch it. 5. Check the operation of the operator seat switch. Chassis: Service and Repairs Page 6–36 Groundsmaster 7210 16222SL Rev C...
Page 299: Servicing The Operator Seat
1. Remove the operator seat from the machine; refer to Removing the Operator Seat (page 6–35). 2. Remove the armrest assemblies and then the back panel from the back of the seat. Groundsmaster 7210 Page 6–37 Chassis: Service and Repairs 16222SL Rev C...
Page 300 1. Attach the bottom of the shock absorber to the spring saddle with the nut and bolt. 2. Install the springs to the spring saddle in the same orientation that you noted during removal. Chassis: Service and Repairs Page 6–38 Groundsmaster 7210 16222SL Rev C...
Page 301 15. Assemble the back panel and then the armrest assemblies to the seat. 16. Install the operator seat on the machine; refer to Installing the Operator Seat (page 6–36). Groundsmaster 7210 Page 6–39 Chassis: Service and Repairs 16222SL Rev C...
Page 302: Hood
4. Slide the hood to the left side of the machine to free the hood support from the frame rods. 5. Remove the hood from the machine. 6. If necessary, remove the hood components (Figure 215). Chassis: Service and Repairs Page 6–40 Groundsmaster 7210 16222SL Rev C...
Page 303 5. Position the hood to the machine and slide the hood support onto the frame rods. 6. Secure the hood to the frame rods with the hairpin cotter (item 17 in Figure 215). 7. Close the hood and latch it. Groundsmaster 7210 Page 6–41 Chassis: Service and Repairs 16222SL Rev C...
Page 304 Chassis: Service and Repairs Page 6–42 Groundsmaster 7210 16222SL Rev C...
Page 305 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 ......................7–12 Gearbox ............................7–16 Cutting Deck Pull Links ........................7–19 Groundsmaster 7210 Page 7–1 Cutting Deck 16222SL Rev C...
Page 306: General Information
General Information Specifications Several cutting decks are available for Groundsmaster 7210 machine. Refer to the Cutting Deck Operator's Manual for specifications and optional accessories for the cutting deck used on your machine. Note: This chapter gives information about troubleshooting and repair of 60, 62, and 72 inch cutting decks.
Page 307: Factors That Can Affect Cutting Performance
10. Machine traction speed Mowing at too fast of a traction speed will result in poor after cut appearance and missed patches of grass. Groundsmaster 7210 Page 7–3 Cutting Deck: Factors That Can Affect Cutting Performance...
Page 308: Service And Repairs
To check the blade stopping time, instruct a second person to stay away from the machine at a safe distance and monitor the blades on the cutting deck. Cutting Deck: Service and Repairs Page 7–4 Groundsmaster 7210 16222SL Rev C...
Page 309: Cutting Deck
PTO brake assembly in the transmission; refer to Circuit Problems (page 4–29). Cutting Deck Refer to specific Cutting Deck Operator’s Manual for cutting deck removal and installation procedure. Groundsmaster 7210 Page 7–5 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 310: Idler Assembly
2. Lift the footrest to get access to the top of the cutting deck and support the footrest with the prop rod. 3. Remove the deck covers from the top of the cutting deck. Cutting Deck: Service and Repairs Page 7–6 Groundsmaster 7210 16222SL Rev C...
Page 311 The spring is under heavy load and can cause personal injury. Be careful when applying the tension to the torsion spring of the idler arm. g033712 Figure 218 Idler arm Jam nut Stop bolt Groundsmaster 7210 Page 7–7 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 312 Note: If necessary, adjust the location of the jam nuts on the stop bolt to allow proper clearance. 6. Install the deck covers to the cutting deck. 7. Lower the footrest. Cutting Deck: Service and Repairs Page 7–8 Groundsmaster 7210 16222SL Rev C...
Page 313: Blade Spindle
Flange nut (24 each) Idler pulley Cutting deck Doubler ring (3 each) Ribbed neck bolt (24 each) Blade (3 each) Center spindle assembly Idler pulley Anti-scalp cup (3 each) Drive pulley Groundsmaster 7210 Page 7–9 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 314 Note: When removing the deck drive belt, use the breaker bar in the idler arm square drive holes to rotate the idler pulley away from the belt (Figure 221). Cutting Deck: Service and Repairs Page 7–10 Groundsmaster 7210 16222SL Rev C...
Page 315 4. Install the drive belt to the deck pulleys. 5. Lubricate the spindle grease fittings. 6. Install the belt covers to the cutting deck. 7. Lower the footrest. Groundsmaster 7210 Page 7–11 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 316: Servicing The Blade Spindle
(items 1, 2, and 3 in Figure 223). You cannot purchase these parts separately. Also, do not mix the bearing set components from one deck spindle to the another. Cutting Deck: Service and Repairs Page 7–12 Groundsmaster 7210 16222SL Rev C...
Page 317 Figure 223 Bearing Inner spacer Spacer ring Outer spacer Large snap ring g033719 Figure 224 Bearing cup Arbor press Large snap ring Support Arbor press base Outer spacer Groundsmaster 7210 Page 7–13 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 318 Note: The upper seal must have the lip facing in (down). Also, install upper seal so it is flush to 2.0 mm (0.080 inch) recessed to the housing surface (Figure 225). Cutting Deck: Service and Repairs Page 7–14 Groundsmaster 7210 16222SL Rev C...
Page 319 12. Attach a hand pump grease gun to the grease fitting on the housing and fill the housing cavity with grease until the grease starts to come out of the lower seal. 13. Rotate the spindle shaft to ensure that it turns freely. Groundsmaster 7210 Page 7–15 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 320: Gearbox
Mount (3 each) Bolt (4 each) Knob (2 each) Carriage screw (3 each) Lock washer (4 each) Set screw (2 each) Gearbox Woodruff key Retainer nut (2 each) Cutting Deck: Service and Repairs Page 7–16 Groundsmaster 7210 16222SL Rev C...
Page 321 4. Remove the deck covers from the top of the cutting deck. 5. Remove the drive belt from the deck pulleys. 6. Disconnect the PTO driveshaft from the gearbox; refer to Removing the PTO Driveshaft (page 6–25). Groundsmaster 7210 Page 7–17 Cutting Deck: Service and Repairs 16222SL Rev C...
Page 322 11. Torque the plug in the gearbox to 19.8 N∙m (175 in-lb). Fill the gearbox with approximately 355 ml (12 fl oz) of SAE 80W90 gear lubricant. 12. Lower the footrest. Cutting Deck: Service and Repairs Page 7–18 Groundsmaster 7210 16222SL Rev C...
Page 323: Cutting Deck Pull Links
The pull link torsion springs can cause some rotation of the pull links during the removal process, causing personal injury. Be careful when removing the pull links from the cutting deck. Groundsmaster 7210 Page 7–19 Cutting Deck: Service and Repairs...
Page 324 6. Install the cutting deck to the machine; refer to the Cutting Deck Operator’s Manual. 7. Lubricate the pull link grease fittings. 8. Check the cutting deck mismatch and pitch. Adjust the cutting deck if necessary. Cutting Deck: Service and Repairs Page 7–20 Groundsmaster 7210 16222SL Rev C...
Page 325: Appendix A
Wire Harness Diagram - Cab Headliner ...................A–14 Wire Harness Drawing - Cab Power Point Kit...................A–15 Wire Harness Drawing - Auxiliary Power Model 30382..............A–16 Wire Harness Drawing - Light Kit Model 30374 ................A–17 Groundsmaster 7210 Page A–1 Foldout Drawings 16222SL Rev C...
Page 326: Electrical Drawing Designations
Y or YE YELLOW Numerous harness wires used on the Toro machines 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 black line, OR_BK is an orange wire with a black line).
Page 327: Hydraulic Schematic
Hydraulic Schematic g186843 Drawing 105-7260 Rev E, Sheet 1 16222SL Rev C Page A–3...
Page 328: Electrical Schematic - Platform
Electrical Schematic - Platform g186842 Page A–4 16222SL Rev C Drawing 119-4372 Rev C, Sheet 1...
Page 329: Electrical Schematic - Engine
Electrical Schematic - Engine g186841 Drawing 119-4377 Rev C, Sheet 1 16222SL Rev C Page A–5...
Page 330: Electrical Schematic - Cab (1
Electrical Schematic - Cab (1 of 2) g186839 Page A–6 16222SL Rev C Drawing 122-0350 Rev C, Sheet 1 of 2...
Page 331: Electrical Schematic - Cab (2
Electrical Schematic - Cab (2 of 2) g186840 Drawing 122-0350 Rev C, Sheet 2 of 2 16222SL Rev C Page A–7...
Page 332: Wire Harness Drawing - Platform (1
Wire Harness Drawing - Platform (1 of 2) g186849 Page A–8 16222SL Rev C Drawing 119-4370 Rev E, Sheet 1 of 2...
Page 333: Wire Harness Drawing - Platform (2
Wire Harness Drawing - Platform (2 of 2) g186846 Drawing 119-4370 Rev E, Sheet 2 of 2 16222SL Rev C Page A–9...
Page 334: Wire Harness Drawing - Engine (1
Wire Harness Drawing - Engine (1 of 2) g186848 Page A–10 16222SL Rev C Drawing 119-4371 Rev G, Sheet 1 of 2...
Page 335: Wire Harness Drawing - Engine (2
Wire Harness Drawing - Engine (2 of 2) g186845 Drawing 119-4371 Rev G, Sheet 2 of 2 16222SL Rev C Page A–11...
Page 336: Wire Harness Drawing - Cab Power
Wire Harness Drawing - Cab Power g186851 Page A–12 16222SL Rev C Drawing 119-4386 Rev A, Sheet 1...
Page 337: Wire Harness Drawing - Cab Headliner
Wire Harness Drawing - Cab Headliner g186847 Drawing 122-0723 Rev A, Sheet 1 of 2 16222SL Rev C Page A–13...
Page 338: Wire Harness Diagram - Cab Headliner
Wire Harness Diagram - Cab Headliner g186844 Page A–14 16222SL Rev C Drawing 122-0723 Rev A, Sheet 2 of 2...
Page 339: Wire Harness Drawing - Cab Power Point Kit
Wire Harness Drawing - Cab Power Point Kit g186852 Drawing 122-0158 Rev A, Sheet 1 16222SL Rev C Page A–15...
Page 340: Wire Harness Drawing - Auxiliary Power Model 30382
Wire Harness Drawing - Auxiliary Power Model 30382 g186850 Page A–16 16222SL Rev C Drawing 108-2099 Rev C, Sheet 1...
Page 341: Wire Harness Drawing - Light Kit Model 30374
Wire Harness Drawing - Light Kit Model 30374 g186853 Drawing 110-1659 Rev A, Sheet 1 16222SL Rev C Page A–17...

Toro Groundsmaster 7210 Service Manual

Table of Contents

Chapter 1: Safety

Chapter 2: Specifications and Maintenance

Chapter 3: Diesel Engine

Table of Contents

Chapter 4: Hydraulic System

Table of Contents

Chapter 5 :Electricalsystem

Table of Contents

Chapter 6 :Chassis

Table of Contents

Chapter 7 :Cuttingdeck

Appendix A

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Groundsmaster 7210

Summary of Contents for Toro Groundsmaster 7210