Toro Groundsmaster 7210 User manual

Form No. 16222SL Rev D
Groundsmaster7210
(ModelswithYanmarEngine)
© 2019—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
OriginalInstructions(EN)
Contactusatwww.Toro.com.
AllRightsReserved

RevisionHistory
RevisionDateDescription
A2016Initialissue.
B2017AddedFoldoutDrawings.
C03/2018UpdatedEnginechapter.AddedRevisionHistoryandpublishedinnewformat.
RevisionHistoryPage2Groundsmaster7210
16222SLRevC
D03/2019Updated Chassis chapter.

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usefulness of its publications. To do this effectively, we encourage user feedback. Please comment
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Bloomington, MN 55420-1196
Phone: +1 952-887-8495
Groundsmaster7210Page3RevisionHistory
16222SLRevC

NOTES:
RevisionHistoryPage4Groundsmaster7210
16222SLRevC

Preface
Thepurposeofthispublicationistoprovidetheservicetechnicianwiththe
informationfortroubleshooting,testing,andrepairofthemajorsystemsand
componentsofGroundsmaster7210machinesthatarepoweredbyaYanmar
dieselengine.
RefertotheOperator’sManualsforoperating,maintenance,andadjustment
instructions.SpaceisprovidedinChapter2(page2–1)ofthisbooktoinsertthe
Operator’sManualsandPartsCatalogforyourmachine.Additionalcopiesofthe
Operator’sManualsandPartsCatalogsareavailableatwww.toro.com.
TheToroCompanyreservestherighttochangetheproductspecicationsor
thispublicationwithoutnotice.
DANGER
Thissafetysymbolmeansdanger.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscouldkillorcauseseriouspermanentinjuryordisability.
WARNING
Thissafetysymbolmeanswarning.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinseriousinjury.
CAUTION
Thissafetysymbolmeanscaution.Whenyouseethissymbol,
carefullyreadtheinstructionsthatfollow.Failuretoobeythe
instructionscanresultinminortomoderateinjury.
IMPORTANT
TheImportantnoticewillgivetheimportantinstructionswhichyou
mustfollowtopreventdamagetothesystemsorcomponentson
themachine.
Note:ANotewillgivethegeneralinformationaboutthecorrectoperation,
maintenance,service,testing,orrepairofthemachine.
Groundsmaster7210Page5Preface
16222SLRevC

g034400
Figure1
ServiceProcedureIcons
ThefollowingiconsappearthroughoutthisServiceManualtobringattentionto
specicimportantdetailsofaserviceprocedure.
CriticalProcess
Thisiconisusedtohighlight:
•installingsafetyequipment(shields,guards,seatbelts,brakesandR.O.P .S.
components)thatmayhavebeenremoved
•dimensionsorsettingsthatmustbemaintainedforpropermachineoperation
•aspecicfastenertighteningsequence
•componentorientationthatmaynotbeobvious
CriticalTorque
Thisiconisusedtohighlightanassemblytorquerequirementthatisdifferent
thanwhatisrecommendedintheStandardT orqueTables;refertoTorque
Specications(page2–4).
FluidSpecications
Thisiconisusedtohighlightuidspecicationsandcapacitiesthatareless
common,andmaynotappearonthemachineservicedecalorinthemachine
Operator’sManual.
Note:RefertotheservicedecalonthemachineandthemachineOperator’s
Manualforcommonlyuseduidspecicationsandcapacities.
PrefacePage6Groundsmaster7210
16222SLRevC

TableofContents
Preface................................................................................................................5
Chapter1:Safety............................................................................................1–1
SafetyInstructions.......................................................................................1–2
JackingInstructions.....................................................................................1–6
SafetyandInstructionalDecals....................................................................1–8
Chapter2:SpecicationsandMaintenance....................................................2–1
Specications...............................................................................................2–2
TorqueSpecications...................................................................................2–4
ShopSupplies..............................................................................................2–9
SpecialT ools..............................................................................................2–11
Chapter3:DieselEngine.................................................................................3–1
Specications...............................................................................................3–2
GeneralInformation.....................................................................................3–3
ServiceandRepairs.....................................................................................3–8
Chapter4:HydraulicSystem...........................................................................4–1
Specications...............................................................................................4–3
GeneralInformation.....................................................................................4–4
HydraulicSchematics.................................................................................4–13
SpecialT ools...............................................................................................4–23
Troubleshooting..........................................................................................4–28
TestingtheHydraulicSystem......................................................................4–31
ServiceandRepairs...................................................................................4–57
Chapter5:ElectricalSystem...........................................................................5–1
GeneralInformation.....................................................................................5–3
SpecialTools.................................................................................................5–9
InfoCenterDisplay......................................................................................5–11
Troubleshooting..........................................................................................5–16
ElectricalSystemQuickChecks..................................................................5–20
TestingtheElectricalComponents..............................................................5–23
Adjustments...............................................................................................5–54
ServiceandRepairs...................................................................................5–56
Chapter6:Chassis..........................................................................................6–1
Specications...............................................................................................6–2
GeneralInformation.....................................................................................6–3
ServiceandRepairs.....................................................................................6–4
Chapter7:CuttingDeck..................................................................................7–1
GeneralInformation.....................................................................................7–2
FactorsThatCanAffectCuttingPerformance...............................................7–3
ServiceandRepairs.....................................................................................7–4
AppendixA......................................................................................................A–1
HydraulicSchematic.....................................................................................A–3
ElectricalSchematic-Platform.....................................................................A–4
ElectricalSchematic-Engine.......................................................................A–5
ElectricalSchematic-Cab(1of2)................................................................A–6
ElectricalSchematic-Cab(2of2)................................................................A–7
WireHarnessDrawing-Platform(1of2)......................................................A–8
WireHarnessDrawing-Platform(2of2)......................................................A–9
WireHarnessDrawing-Engine(1of2).......................................................A–10
WireHarnessDrawing-Engine(2of2).......................................................A–11
WireHarnessDrawing-CabPower............................................................A–12
WireHarnessDrawing-CabHeadliner.......................................................A–13
WireHarnessDiagram-CabHeadliner......................................................A–14
WireHarnessDrawing-CabPowerPointKit..............................................A–15
WireHarnessDrawing-AuxiliaryPowerModel30382................................A–16
WireHarnessDrawing-LightKitModel30374...........................................A–17
Groundsmaster7210Page7Preface
16222SLRevC

Chapter1
Safety
TableofContents
SafetyInstructions................................................................................................................................1–2
Supervisor’sResponsibilities.............................................................................................................1–2
BeforeOperatingtheMachine...........................................................................................................1–2
WhileOperatingtheMachine.............................................................................................................1–3
MaintenanceandService...................................................................................................................1–4
JackingInstructions..............................................................................................................................1–6
RaisingtheFrontoftheMachine........................................................................................................1–6
RaisingtheRearoftheMachine........................................................................................................1–7
SafetyandInstructionalDecals............................................................................................................1–8
Groundsmaster7210Page1–1Safety
16222SLRevC

SafetyInstructions
TheGroundsmaster7210machinemeetsorexceedssafetystandard
specicationsasidentiedintheOperator’sManuals.Althoughthehazard
controlandaccidentpreventionaredependentpartiallyuponthedesignand
congurationofthemachine,thesefactorsarealsodependentuponthe
awareness,concernandpropertrainingofthepersonnelinvolvedinthe
operation,transport,maintenance,andstorageofthemachine.Theimproper
useormaintenancebytheoperatororownerofthemachinecanresultininjury.
WARNING
Toreducethepotentialofinjuryordeath,complywiththefollowing
safetyinstructionsaswellasinformationfoundintheOperator’s
Manuals.
Supervisor’sResponsibilities
1.EnsurethattheoperatorsarefullytrainedandfamiliarwiththeOperator’s
Manuals,Operator’sTrainingDVD,andalloftheoperatingandsafetydecals
onthemachine.
2.Establishyourownspecialproceduresandworkrulesforunusualoperating
conditions(e.g.,slopestoosteepformachineoperation).Surveythemowing
sitecompletelytodeterminehillsonwhichyoucanoperatesafely.When
performingthissitesurvey,alwaysunderstandandtakeintoconsideration
theturfconditionandrolloverrisk.T operformasitesurvey,followthe
procedureoutlinedintheOperator’sManuals.
BeforeOperatingtheMachine
•ReviewandunderstandthecontentsoftheOperator’sManualsand
Operator’sTrainingDVDbeforestartingandoperatingthemachine.Become
familiarwiththecontrolsandknowhowtostopthemachineandengine
quickly.AdditionalcopiesoftheOperator’sManualsareavailableat
www.toro.com.
•Keepalltheshields,safetydevices,anddecalsinplace.Ifashield,safety
device,ordecalisillegibleordamaged,repairorreplaceitbeforeoperating
themachine.
•Tightenanyloosenuts,bolts,orscrewstoensurethatthemachineisin
safeoperatingcondition.
•Ensuretheinterlockswitchesareadjustedcorrectlysothattheengine
doesnotstartunlessthe2drivehandlesareintheNEUTRALLOCKposition,
thePTOswitchisintheOFF(disengaged)position,andeithertheseatis
occupiedortheparkingbrakeisapplied.
•Dieselfuelishighlyammable;handleitcarefully.
–Storefuelincontainersspecicallydesignedforstoringfuel.
–Donotremovethefueltankcapofthemachinewhiletheengineishot
orrunning.
–Donotsmokewhilehandlingfuel.
–Fillthefueltankoutdoorsandonlytoalevelwithinaninchofthetopof
thetank,notthellerneck.Donotoverllthefueltank.
–Replacethefueltankandfuelcontainercapssecurelyafterrefuelling
themachine.
Safety:SafetyInstructionsPage1–2Groundsmaster7210
16222SLRevC

BeforeOperatingtheMachine(continued)
–Ifyouspillfuel,donotattempttostarttheenginebutmovethemachine
awayfromthespill.Avoidcreatinganysourceofignitionuntilfuelvapors
havedissipated.Wipeupanyspilledfuel.
WhileOperatingtheMachine
•Sitontheseatwhenstartingandoperatingthemachine.
•Anytimeyouparkthemachine(shortorlongterm),lowerthecuttingdeck
(orimplement)totheground.
IMPORTANT
Whenyoulowerthecuttingdeckfullytotheground,thepressure
fromtheliftcircuitreleasesandpreventsthecuttingdeckfrom
accidentallylowering.
•Ifyouparkthemachineonaslope,blockorchockthewheels.
Beforestartingthemachine
DANGER
Theexhaustfumesarehazardousandhavethepotentialofinjury
ordeath.
Donotruntheengineinaconnedareawithoutadequateventilation.
1.Settheparkingbrake.
2.Ensurethatthe2drivehandlesareintheNEUTRALLOCKpositionandthe
PTOswitchisintheOFF(disengaged)position.
3.Afteryoustarttheengine,releasetheparkingbrakeandkeepthe2drive
handlesintheNEUTRALLOCKposition.Ensurethatthemachinedoesnot
move.
Note:Ifmachinemovementisevident,thetractionlinkageisadjusted
incorrectly;therefore,shutofftheengineandadjustthetractionlinkageuntil
themachinedoesnotmovewhenthe2drivehandlesareintheNEUTRAL
LOCKposition;refertoTractionUnitOperator’sManual.
CAUTION
Runningtheenginecausestheengine,radiator,andexhaustsystem
tobecomehot.Touchingahotengine,radiator,orexhaustsystem
canburnyou.
Donottouchtheengine,radiator,orexhaustsystemwhilethe
engineisrunningorsoonafteryoustopit.
Groundsmaster7210Page1–3Safety:SafetyInstructions
16222SLRevC

Beforestoppingthemachine
1.Ensurethatthe2drivehandlesareintheNEUTRALLOCKposition.
2.Loweranddisengagethecuttingdeck(orimplement)andwaitforallmoving
partstostop.
3.Settheparkingbrake.
4.Shutofftheengineandremovethekeyfromthekeyswitch.
MaintenanceandService
•Beforeservicingormakinganyadjustmentstothemachine,lowerthecutting
deck(orimplement),settheparkingbrake,shutofftheengine,andremove
thekeyfromthekeyswitch.
•Ensurethatthemachineisinsafeoperatingconditionbykeepingallthe
nuts,bolts,andscrewstight.
•Donotstorethemachineorafuelcontainerinsidewherethereisanopen
ame,suchasnearawaterheaterorfurnace.
•Ensurethatallofthehydrauliclineconnectorsaretightandthatallthe
hydraulichosesandlinesareingoodconditionbeforeapplyingpressureto
thehydraulicsystem.
•Keepyourbodyandhandsawayfrompin-holeleaksinthehydrauliclines
thatejecthydraulicuidunderhighpressure.Usecardboardorpapertond
hydraulicleaks.Thehydraulicuidescapingunderpressurecanpenetrate
theskinandcauseinjury.Ifhydraulicuidisaccidentallyinjectedintothe
skin,youmusthaveitsurgicallyremovedwithinafewhoursbyadoctor
familiarwiththistypeofinjury.Otherwise,gangrenemayresult.
•Beforedisconnectingorperforminganyworkonthehydraulicsystem,
releaseallthepressureinthesystembyparkingthemachineonalevel
surface,loweringthecuttingdeck(orimplement)completely,andthen
shuttingofftheengine.
•Useeyeprotectionwhenworkingonthehydraulicsystemandits
components.
•Ifmajorrepairsarenecessary,contactyourAuthorizedT oroDistributor.
•Usecarewhencheckingorservicingthecuttingdeck.Wearglovesand
usecautionwhenservicingthedeck.
•Toreducepotentialrehazards,keeptheengineareafreeofexcessive
grease,grass,leaves,anddirt.Cleantheprotectivescreenonthemachine
frequently.
•Ifyoumustruntheenginetoperformmaintenanceortomakeanadjustment,
keepyourhands,feet,clothing,andotherpartsofthebodyawayfromthe
cuttingdeck(implement)andothermovingparts.Keepbystandersaway.
•Donotoverspeedtheenginebychangingtheenginegovernorsetting.
Toensuresafetyandaccuracy,checkthemaximumenginespeedwitha
tachometer.
•Shutofftheenginebeforecheckingoraddingoiltotheenginecrankcase.
•Disconnectthebatteriesbeforeservicingthemachine.Disconnectthe
negativebatterycableandthenthepositivecable.Ifbatteryvoltageis
necessaryfortroubleshootingortestprocedures,temporarilyconnectthe
battery.Connectthepositivebatterycableandthenthenegativecable.
•Batteryacidispoisonousandcancauseburns.Avoidacidcontactwithskin,
eyes,andclothing.Protectyourface,eyes,andclothingwhenworkingwitha
battery.
•Batterygasescanexplode.Keepcigarettes,sparks,andamesawayfrom
thebattery.
Safety:SafetyInstructionsPage1–4Groundsmaster7210
16222SLRevC

MaintenanceandService(continued)
•Ifweldingonthemachineisnecessary,disconnectallthebatterycablesto
preventdamagetotheelectricalsystem.Disconnectthenegativebattery
cableandthenthepositivecable.
•DisconnectandremovetheengineECUfromthemachine.
•Atthetimeofmanufacture,themachineconformedtothesafetystandards
forridingmowers.Toensuretheoptimumperformanceandcontinued
safetycerticationofthemachine,usegenuineT ororeplacementpartsand
accessories.Thereplacementpartsandaccessoriesofothermanufacturers
canresultinnon-conformancewiththesafetystandardsandcanvoidthe
warranty.
•Whenchangingtheattachments,tires,orperformingotherservice,use
correctblocks,hoists,andjackstoraiseandsupportthemachine.Ensure
thatthemachineisparkedonasolidlevelsurface,suchasaconcreteoor.
Beforeyouliftthemachine,removealltheattachmentsthatmayinterfere
withthesafeandcorrectliftofthemachine.Alwaysblockthewheelswith
chocks.Useappropriatejackstandstosupporttheraisedmachine.Failing
toproperlysupportthemachinewithappropriatejackstandscancausethe
machinetomoveorfallandcanresultinpersonalinjury;refertoJacking
Instructions(page1–6).
Groundsmaster7210Page1–5Safety:SafetyInstructions
16222SLRevC

JackingInstructions
CAUTION
Failingtoproperlysupportthemachinewithappropriatejackstands
cancausethemachinetomoveorfallandcanresultinpersonal
injury.
Whenchangingtheattachments,tires,orperformingotherservices,
dothefollowingsteps:
•Usecorrectblocks,hoists,andjackstoraiseandsupportthe
machine.
•Parkthemachineonasolidlevelsurface,suchasaconcrete
oor.
•Beforeyouliftthemachine,removealltheattachmentsthatmay
interferewiththesafeandcorrectliftofthemachine.
•Alwaysblockthewheelswithchocks.
•Useappropriatejackstandstosupporttheraisedmachine.
•Donotusethecuttingdeck(orimplement)asajackingpoint.
RaisingtheFrontoftheMachine
g033384
Figure2
1.Frontcastorwheel2.Frontjackingpoint
1.Settheparkingbrakeandblockthe2reartireswithchockstopreventthe
machinefrommoving.
2.Positionthejacktothemachine:
A.Onmachineswithcuttingdeck,positionthejackstandsunderthesquare
carrierframetubenearthefrontcastorwheel(Figure2).
B.OnmachineswithPolarTrac™Kit,positionthejacksecurelyunderthe
liftarmpivottubeonthefrontofthemachine.
3.Useajacktoraisethefrontofthemachine.
4.Afterraisingthefrontofthemachine,useappropriatejackstandsunderthe
frametosupportthefrontofthemachine.
Safety:JackingInstructionsPage1–6Groundsmaster7210
16222SLRevC

RaisingtheRearoftheMachine
IMPORTANT
Donotsupportthemachineonthewheelhubs(brakerotors).
g033385
Figure3
1.Protectionplate3.Rearwheel
2.Rearjackingpoint
1.Blockthe2frontcastorwheelswithchockstopreventthemachinefrom
moving.
2.Positionthejacksecurelyundertheatsurfaceoftheprotectionplate
(Figure3).
3.Lifttherearwheelsofftheground.
4.Useappropriatejackstandsundertheframetosupporttherearofthe
machine.
Groundsmaster7210Page1–7Safety:JackingInstructions
16222SLRevC

SafetyandInstructionalDecals
Numeroussafetyandinstructiondecalsareafxedtothetractionunitand
cuttingunitsofyourGroundsmaster.Ifanydecalbecomesillegibleordamaged,
installanewdecal.DecalpartnumbersarelistedinyourPartsCatalog.Order
replacementdecalsfromAuthorizedT oroDistributor.
Safety:SafetyandInstructionalDecalsPage1–8Groundsmaster7210
16222SLRevC

Chapter2
SpecicationsandMaintenance
TableofContents
Specications.......................................................................................................................................2–2
DecimalandMillimeterEquivalents...................................................................................................2–2
U.S.toMetricConversions................................................................................................................2–3
TorqueSpecications...........................................................................................................................2–4
IdentifyingtheFastener......................................................................................................................2–4
CalculatingtheT orqueValuesWhenUsingaDrive-AdapterWrench.................................................2–5
StandardT orqueforDry,ZincPlated,andSteelFasteners(InchSeries)............................................2–6
StandardT orqueforDry,ZincPlated,andSteelFasteners(MetricFasteners)...................................2–7
OtherTorqueSpecications...............................................................................................................2–8
ConversionFactors............................................................................................................................2–8
ShopSupplies......................................................................................................................................2–9
SpecialTools......................................................................................................................................2–11
Groundsmaster7210Page2–1SpecicationsandMaintenance
16222SLRevC

Specications
InsertacopyoftheOperator’sManualsandPartsCatalogsforyourmachineat
theendofthischapter.Additionally,ifanyoptionalequipmentoraccessoriesare
installedtoyourmachine,inserttheInstallationInstructions,Operator’sManuals,
andPartsCatalogsforthoseoptionsattheendofthischapter.
Themaintenanceproceduresandrecommendedserviceintervalsforyour
machinearecoveredintheOperator’sManual.Refertothispublicationwhen
performingtheregularequipmentmaintenance.
DecimalandMillimeterEquivalents
FractionsDecimalsmmFractionsDecimalsmm
1/640.0156250.39733/640.51562513.097
1/320.031250.79417/320.5312513.494
3/640.0468751.19135/640.54687513.891
1/160.06251.5889/160.562514.288
5/640.0781251.98437/640.57812514.684
3/320.093752.38119/320.5937515.081
7/640.1092752.77839/640.60937515.478
1/80.12503.1755/80.625015.875
9/640.1406253.57241/640.64062516.272
5/320.156253.96921/320.6562516.669
11/640.1718754.36643/640.67187517.066
3/160.18754.76211/160.687517.462
13/640.2031255.15945/640.70312517.859
7/320.218755.55623/320.7187518.256
15/640.2343755.95347/640.73437518.653
1/40.25006.3503/40.750019.050
17/640.2656256.74749/640.76562519.447
9/320.281257.14425/320.7812519.844
19/640.2968757.54151/640.79687520.241
5/160.31257.93813/160.812520.638
21/640.3281258.33453/640.82812521.034
11/320.343758.73127/320.8437521.431
23/640.3593759.12855/640.85937521.828
3/80.37509.5257/80.875022.225
25/640.3906259.92257/640.89062522.622
13/320.4062510.31929/320.9062523.019
27/640.42187510.71659/640.92187523.416
7/160.437511.11215/160.937523.812
29/640.45312511.50961/640.95312524.209
15/320.4687511.90631/320.9687524.606
31/640.48437512.30363/640.98437525.003
1/20.500012.70011.00025.400
1mm=0.03937inch0.001inch=0.0254mm
SpecicationsandMaintenance:SpecicationsPage2–2Groundsmaster7210
16222SLRevC

U.S.toMetricConversions
ToConvertIntoMultiplyBy
MilesKilometers1.609
YardsMeters0.914
FeetMeters0.305
FeetCentimeters30.48
InchesMeters0.025
InchesCentimeters2.54
LinearMeasurement
InchesMillimeters25.4
SquareMilesSquareKilometers2.59
SquareFeetSquareMeters0.093
SquareInchesSquareCentimeters6.452
Area
AcreHectare0.405
CubicYardsCubicMeters0.765
CubicFeetCubicMeters0.028
Volume
CubicInchesCubicCentimeters16.39
Tons(Short)MetricTons0.908
PoundsKilograms0.454
Weight
Ounces(Avdp.)Grams28.349
Pounds/Sq.In.Kilopascal6.895
Pressure
Pounds/Sq.In.Bar0.069
Foot-poundsNewton-Meters1.356
Foot-poundsKilogram-Meters0.138
Work
Inch-poundsKilogram-Centimeters1.152
QuartsLiters0.946
LiquidVolume
GallonsLiters3.785
LiquidFlowGallons/MinuteLiters/Minute3.785
TemperatureFahrenheitCelsius1.Subtract32°
2.Multiplyby5/9
Groundsmaster7210Page2–3SpecicationsandMaintenance:Specications
16222SLRevC

TorqueSpecications
Therecommendedfastenertorquevaluesarelistedinthefollowingtables.For
criticalapplications,asdeterminedbyT oro,eithertherecommendedtorqueora
torquethatisuniquetotheapplicationisclearlyidentiedandspeciedinthis
ServiceManual.
Thesetorquespecicationsfortheinstallationandtighteningofthefastenerswill
applytoallthefastenerswhichdonothaveaspecicrequirementidentiedin
thisServiceManual.Thefollowingfactorsmustbeconsideredwhenapplying
thetorque:cleanlinessofthefastener,useofathreadsealant(e.g.,Loctite),
degreeoflubricationonthefastener,presenceofaprevailingtorquefeature
(e.g.,Nylocknut),hardnessofthesurfaceunderneaththeheadofthefastener,
orsimilarconditionwhichaffectstheinstallation.
Asnotedinthefollowingtables,thetorquevaluesshouldbereducedby25%
forthelubricatedfastenerstoachievethesimilarstressasadryfastener.The
torquevaluesmustbereducedwhenthefasteneristhreadedintothealuminum
orbrass.Thespecictorquevalueshouldbedeterminedbasedonthealuminum
orbrassmaterialstrength,fastenersize,lengthofthreadengagement,etc.
Thestandardmethodofcheckingthetorquecanbeperformedbymarkingaline
onthefastener(headornut)andmatingpart,thenbackoffthefastener1/4
ofaturn.Measurethetorquenecessarytotightenthefasteneruntilthelines
matchup.
IdentifyingtheFastener
g206088
Figure4
g206089
Figure5
SpecicationsandMaintenance:TorqueSpecicationsPage2–4Groundsmaster7210
16222SLRevC
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