Groundsmaster® 7200 or 7210 Series Traction Unit

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

Before you start the engine and use the machine, check the cooling system; refer to Checking the Cooling System.

Before you start the engine and use the machine, check the hydraulic system; refer to Checking the Hydraulic System.

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do not use the seat belt when the roll bar is in the lowered position.

Lowering the Roll Bar

Lower the roll bar as shown in Figure 9.

Note: Push the bar forward to relieve pressure on the pins.

Figure 9

Note: Secure the roll bar so that it does not damage the hood.

Raising the Roll Bar

Raise the roll bar as shown in Figure 10.

Figure 10

Important: Always use the seat belt when the roll bar is in the raised and locked position. Do not use the seat belt when the roll bar is in the lowered position.

The seat moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

To adjust, move the lever sideways to unlock the seat (Figure 13).

Figure 13

The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

To adjust it, turn the knob in front either direction to provide the best comfort (Figure 14).

Figure 14

1. Seat-suspension knob

To access the hydraulic and other systems under the seat, unlatch the seat and swing it forward.

1. Use the seat position adjustment lever to slide the seat all the way forward.

2. Pull the seat latch forward and lift up to unlatch the seat (Figure 15).

   

   Figure 15

   1. Seat latch

Always engage the parking brake when you stop the machine or leave it unattended.

Engaging the Parking Brake

Warning

The parking brake may not hold the machine parked on a slope and could cause personal injury or property damage.

Do not park the machine on slopes unless the wheels are chocked or blocked.

Figure 16

Releasing the Parking Brake

Figure 17

Note: The glow plug light illuminates for 6 seconds when you turn the ignition key to the RUN position. Turn the ignition to the START position after the light goes out.

Important: Use starting cycles of no more than 15 seconds per minute to avoid overheating the starter motor.

Important: Operate the machine with the throttle lever in the SLOW position in both the forward and reverse directions for 1 to 2 minutes after changing the engine oil, overhauling either the engine, transmission, or wheel motor, and when you start the engine for the first time. Operate the lift lever and PTO lever to ensure that they operate properly. Shut the engine off, check fluid levels, and check for oil leaks, loose parts, and any other noticeable malfunctions.

Figure 18

Note: Leave the throttle midway between the SLOW and FAST positions until the engine and hydraulic system warm up.

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Always operate in the FAST throttle position when running powered attachments.

1. Release the parking brake.

   Note: The engine shuts off if you move the motion-control levers out of the NEUTRAL-LOCK position with the parking brake engaged.

2. Move the levers to the center, unlocked position.

3. Drive the machine as follows:

   • To move straight forward, slowly push the motion-control levers forward (Figure 19).

   • To move straight rearward, slowly pull the motion-control levers rearward (Figure 19).

   • To turn, slow the machine by pulling back on both levers and then push forward on the lever on the opposite side from which you want to turn (Figure 19).

   • To stop, pull the motion-control levers to the NEUTRAL position.

   Note: The farther you move the motion-control levers in either direction, the faster the machine moves in that direction.

   

   Figure 19

   1. Motion-control lever—NEUTRAL-LOCK position
   2. Center, unlocked position
   3. Forward
   4. Backward
   5. Front of the machine

You can adjust the height of cut from 2.5 to 15.8 cm (1 to 6 inches) in 6 mm (1/4 inch) increments by relocating the stop pin into different hole locations.

1. With the engine running, push the deck-lift switch up until the mower deck is fully raised and release the switch immediately (Figure 21).

2. Rotate the stop pin until the roll pin in it lines up with the slots in the holes in the height-of-cut bracket and remove it (Figure 24).

3. Select a hole in the height-of-cut bracket corresponding to the height of cut desired, insert the pin, and rotate it down to lock it in place (Figure 24).

   Note: There are 4 rows of hole positions (Figure 24). The top row gives you the height of cut listed above the pin. The second row down gives you the height listed plus 6 mm (1/4 inch). The third row down gives you the height listed plus 12 mm (1/2 inch). The bottom row gives you the height listed plus 18 mm (3/4 inch). For the 15.8 cm (6 inch) position, there is only 1 hole, located in the second row. This does not add 6 mm (1/4 inch) to the 15.8 cm (6 inch) position.

   

   Figure 24

   1. Stop pin
   2. Height-of-cut stop

4. Adjust the anti-scalp rollers and skids as required.

In an emergency, you can move the machine a very short distance by actuating the bypass valves in the hydraulic pump and pushing the machine.

Important: Always push the machine by hand and never a long distance. Never tow the machine, because damage to the hydraulic system may occur.

Important: The bypass valves must be open whenever you push or tow the machine. Close the valves once you have pushed or towed the machine to the desired location.

1. Lift the seat; refer to Unlatching the Seat

2. Locate the bypass valves (Figure 25) and rotate each bypass valve counterclockwise 1 turn.

   Note: This allows hydraulic fluid to bypass the pump, enabling the wheels to turn.

   Important: Do not rotate the bypass valves more than 1 turn. This prevents valves from coming out of the body and causing fluid to run out.

   

   Figure 25

   1. Right bypass valve
   2. Left bypass valve

3. Ensure that the parking brake is disengaged and push the machine to the desired location.

4. Close the valves by rotating each valve 1 clockwise turn (Figure 25).

   Note: Do not overtighten the valves.

5. Torque the valves to approximately 8 N∙m (71 in-lb).

   Important: Ensure that the bypass valves are closed before you start the engine. Running the engine with open bypass valves causes the transmission to overheat.

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury.

1. If you are using a trailer, connect it to the towing vehicle, and connect the safety chains.

2. If applicable, connect the trailer brakes.

3. Load the machine onto the trailer or truck; refer to Loading the Machine.

4. Shut off the engine, remove the key, engage the parking brake, and close the fuel valve.

5. Use the tie-down loops on the machine to securely fasten it to the trailer or truck with straps, chains, cable, or ropes (Figure 26).

   

   Figure 26

   1. Traction unit tie-down loops

Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Drive the machine up ramps in reverse and drive it down ramps in a forward direction (Figure 27).

Figure 27

1. Drive the machine up the ramp in reverse.
2. Drive the machine forward down the ramp.

Important: Do not use narrow individual ramps for each side of the machine.

Figure 28

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15°
4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5. “H” indicates the height of the trailer or truck bed to the ground.
6. Trailer

The machine has grease fittings that you must lubricate regularly with No. 2 lithium grease. Lubricate more often in dirty or dusty conditions because dirt can get into the bearings and bushings and cause accelerated wear.

1. Wipe the grease fittings clean so that foreign matter cannot be forced into the bearing or bushing.

2. Pump grease into the fittings.

3. Wipe off excess grease.

Note: Improper wash-down procedures can negatively affect bearing life. Do not wash down the machine when it is still hot and avoid directing high-pressure or high-volume spray at the bearings or seals.

The gear box is designed to operate with SAE EP90W gear lube. Although the gearbox comes from the factory with lubricant, check the level of the lubricant in the cutting unit before operating it and as recommended in the Daily Maintenance Checklist.

1. Check the air-cleaner body for damage, which could possibly cause an air leak. Replace a damaged air-cleaner body.

2. Check the air-intake system for leaks, damage, or loose hose clamps.

3. Service the air-cleaner filter when the air-cleaner indicator shows red or every 400 hours and service it more frequently in extremely dusty or dirty conditions (Figure 30).

   Important: Do not over-service the air filter.

   

   Figure 30

   1. Air-cleaner cover
   2. Gasket
   3. Filter
   4. Air-cleaner body
   5. Air-cleaner indicator
   6. Air-cleaner latch
   7. Rubber outlet valve

4. Be sure that the cover is seated correctly and seals with the air-cleaner body.

Servicing the Air Cleaner

Maintenance Service Interval	Maintenance Procedure
Every 400 hours	Service the air cleaner.

Note: If the foam gasket in the cover is damaged, replace it.

Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract.

Important: Do not clean the used filter to avoid damage to the filter media.

Important: Do not use a damaged filter.

Important: Do not apply pressure to the flexible center of the filter.

Figure 31

Remove and clean the in-line strainers after draining the tank. Use clean diesel fuel to flush out the tank.

Important: Drain and clean the tank if the fuel system becomes contaminated or if you are storing the machine for an extended period.

Inspect the fuel lines for deterioration, damage, chaffing, or loose connections.

1. Park the machine on a level surface. Ensure that the fuel tank is at least half full.

2. Unlatch and raise the hood.

3. Place a rag under the air-bleed screw on the fuel-injection pump and open it (Figure 36).

   

   Figure 36

   1. Fuel-injection-pump bleed screw

4. Turn the ignition key to the ON position.

   Note: The electric fuel pump begins operation, thereby forcing air out at the air-bleed screw.

   Caution

   The engine may start during this procedure. Moving fans and belts in a running engine can severely injure you or bystanders.

   Keep hands, fingers, loose clothing/jewelry, and hair away from the engine fan and belt during this procedure.

5. Leave the key in the ON position until a solid stream of fuel flows out around the screw.

6. Tighten the screw and turn the key to the OFF position.

   Note: Normally, the engine should start after you bleed the fuel system. However, if the engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air from the Injectors.

Note: Use this procedure only if you purged the fuel system through normal priming procedures and the engine does not start; refer to Bleeding the Fuel System.

1. Place a rag under the pipe connection coming from the injection pump to the No. 1 injector nozzle as illustrated in Figure 37.

   

   Figure 37

   1. Pipe connection from the injection pump to the No. 1 injector nozzle

2. Move the throttle to the FAST position.

3. Turn the ignition key to the START position and watch the fuel flow around the connector.

   Caution

   The engine may start during this procedure. Moving fans and belts in a running engine can severely injure you or bystanders.

   Keep hands, fingers, loose clothing/jewelry, and hair away from the engine fan and belt during this procedure.

4. Tighten the pipe connector securely when it attains a solid flow.

5. Turn the key to the OFF position.

6. Repeat this procedure for the remaining nozzles.

Keep the top of the battery clean. If you store the machine in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where the temperature is cool.

Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning it. Do not remove the fill caps while cleaning the battery.

The battery cables must be tight on the terminals to provide good electrical contact.

If corrosion occurs at the terminals, disconnect the cables, negative (-) cable first, and scrape the clamps and terminals separately. Connect the cables, positive (+) cable first, and coat the terminals with petroleum jelly.

If you are storing the machine more than 30 days, remove the battery and charge it fully. Either store it on a shelf or on the machine. Do not connect the cables if you store it on the machine. Store the battery in a cool environment to prevent the battery from discharging rapidly. To prevent the battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.265 to 1.299.

The fuses are located under the control panel. Access them through the side panel cover (Figure 38). To open the side panel cover, release the 2 latches and pull out on it.

If the machine stops or has other electrical system issues, check the fuses. Grasp each fuse in turn and remove them 1 at a time, checking if any are blown.

Important: If you need to replace a fuse, always use the same type and amperage-rated fuse as the one you are replacing, otherwise you could damage the electrical system. Refer to the decal next to the fuses for a diagram of each fuse and its amperage (Figure 39).

Note: If a fuse blows frequently, you may have a short in the electrical system and should have it serviced by a qualified service technician.

Figure 38

1. Side panel cover
2. Latch

Figure 39

Check the pressure after every 50 operating hours or monthly, whichever occurs first (Figure 40).

Maintain the air pressure in the front and rear tires. The correct air pressure is 124 kPa (15 psi) in the rear tires and 103 kPa (25 psi) in the caster wheels. Uneven tire pressure can cause an uneven cut. Check the tires when they are cold to get the most accurate pressure reading.

Figure 40

1. Obtain a new caster-wheel assembly, cone bearings, and bearing seals from your Authorized Toro Distributor.

2. Remove the locknut from the bolt (Figure 41).

   

   Figure 41

   1. Locknut
   2. Bearing spacer
   3. Outer bearing seal
   4. Cone bearing
   5. Inner bearing seal
   6. Spacer
   7. Caster wheel
   8. Axle bolt
   9. Caster fork

3. Grasp the caster wheel and slide the bolt out of the fork or pivot arm.

4. Discard the old caster wheel and bearings.

5. Assemble the caster wheel by pushing the cone bearings and seals, packed with grease, into the wheel hub, positioned as shown in Figure 41.

6. Slide the spacer into the wheel hub through the bearings, captivating the spacer inside the wheel hub with 2 bearing spacers.

   Important: Ensure that the seal lips are not folded inward.

7. Install the caster-wheel assembly between the castor fork and secure it in place with the bolt and locknut.

8. Tighten the locknut until the wheel no longer spins freely, then back it off just until the wheel spins freely.

9. Attach a grease gun to the grease fitting on the caster wheel and fill it with No. 2 lithium grease.

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti freeze. The capacity of the cooling system is 7.5 L (6 US qt).

1. Check the level of the coolant in the expansion tank (Figure 42).

   Note: The coolant level should be between the marks on the side of the tank.

   

   Figure 42

   1. Expansion tank

2. If coolant level is low, remove the expansion-tank cap and replenish the system.

   Important: Do not overfill.

3. Install the expansion-tank cap.

Clean the radiator to prevent the engine from overheating.

Note: If the mower deck or engine shuts off due to overheating, check the radiator for excessive buildup of debris.

Clean the radiator as follows:

1. Open the hood.

2. Working from the fan side of the radiator, blow out debris with low pressure (345 kPa or 50 psi), compressed air. Repeat from the front of the radiator and the other fan side.

   Important: Do not use water.

3. After you thoroughly clean the radiator, clean out debris that may have collected in the channel at the radiator base.

4. Close the hood.

1. Stop the machine, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 43).

   

   Figure 43

   1. Bolt
   2. Control panel

3. Loosen the 2 jam nuts securing the parking-brake interlock switch to the mounting bracket.

   

   Figure 44

   1. Brake-shaft sensor
   2. 4 mm (5/32 inch)
   3. Jam nut
   4. Parking-brake interlock switch

4. Move the switch up or down on the bracket until the distance between the brake-shaft sensor and the switch plunger is 4 mm (5/32 inch) as shown in Figure 44.

   Note: Make sure that the brake-shaft sensor does not contact the switch plunger.

5. Secure the switch jam nuts.

6. Test the adjustment as follows:

   1. Ensure that the parking brake is engaged and you are not sitting on the seat, then start the engine.

   2. Move the control levers out of the NEUTRAL-LOCK position.

      Note: The engine should shut off. If not, check the adjustment that you made to the switch.

7. Install the front panel.

1. Apply 44 N (10 lb) of force to the alternator belt, midway between the pulleys.

2. If the deflection is not 10 mm (3/8 inch), loosen the alternator mounting bolts (Figure 45).

   

   Figure 45

   1. Mounting bolt
   2. Alternator

3. Increase or decrease the alternator-belt tension.

4. Tighten the mounting bolts.

5. Check the deflection of the belt again to ensure that the tension is correct.

1. Stop the machine, move the motion-control levers to the NEUTRAL-LOCK position, engage the parking brake, and remove the ignition key.

2. Remove the bolts securing the front panel and remove the panel (Figure 46).

   

   Figure 46

   1. Bolt
   2. Control panel

3. Loosen the 2 screws securing the interlock switch (Figure 47).

   

   Figure 47

   1. Control lever
   2. Neutral-interlock switch
   3. Screw
   4. 0.4 to 1 mm (0.015 to 0.045 inch)

4. Holding the control lever against the frame, move the switch toward the lever until the distance between the lever and switch body is 0.4 to 1 mm (0.015 to 0.045 inch) as shown in Figure 47.

5. Secure the switch.

6. Repeat steps 3 to 5 for the other lever.

7. Install the front panel.

If the motion-control levers do not align with the neutral slots when released from the REVERSE position, adjustment is required. Adjust each lever, spring, and rod separately.

1. Disengage the PTO, move the control lever to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the bolts securing the front panel and remove the panel (Figure 48).

   

   Figure 48

   1. Bolt
   2. Control panel

4. Move the control lever to the NEUTRAL position but not locked (Figure 50).

5. Pull the lever back until the clevis pin (on an arm above the pivot shaft) contacts the end of the slot (just beginning to put pressure on the spring) as shown in Figure 49.

   

   Figure 49

   1. Clevis pin
   2. Slot
   3. Jam nut
   4. Adjustment bolt
   5. Yoke

6. Check where the control lever is relative to notch in the console (Figure 50).

   Note: The control lever should be centered, allowing lever to pivot outward to the NEUTRAL-LOCK position.

   

   Figure 50

   1. NEUTRAL position
   2. NEUTRAL-LOCK position

7. If adjustment is needed, loosen the nut and jam nut against the yoke (Figure 49).

8. Applying slight rearward pressure on the motion-control lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in the NEUTRAL-LOCK position (Figure 49).

   Note: Rearward pressure on the lever keeps the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.

9. Tighten the nut and jam nut (Figure 49).

10. Repeat steps 4 through 9 for the other control lever.

11. Install the front panel.

Make this adjustment with the drive wheels turning.

1. Raise the frame onto stable jack stands so that the drive wheels can rotate freely.

2. Slide the seat forward, unlatch it, and swing it up and forward.

3. Disconnect the electrical connector from the seat safety switch.

4. Temporarily install a jumper wire across the terminals in the wire harness connector.

5. Start the engine, ensure that the throttle lever is midway between the FAST and SLOW positions, and release the parking brake.

   Note: The motion-control levers must be in the NEUTRAL-LOCK position while you make any adjustments.

6. Adjust the pump rod length on one side by rotating the hex shaft, in the appropriate direction, until the corresponding wheel is still or slightly creeping in reverse (Figure 51).

   

   Figure 51

   1. Right pump rod
   2. Left pump rod
   3. Ball joint
   4. Bolt
   5. Jam nut
   6. Hex shaft
   7. Ball joint

7. Move the motion-control lever forward and reverse, then back to neutral.

   Note: The wheel must stop turning or slightly creep in reverse.

8. Move the throttle lever to the FAST position.

   Note: Make sure that the wheel remains stopped or slightly creeps in reverse; adjust it if necessary.

9. Repeat steps 6 through 8 for the other side of the machine.

10. Tighten the jam nuts at the ball joints (Figure 49).

11. Move the throttle lever to the SLOW position and shut off the engine.

12. Remove the jumper wire from the wire harness connector and plug the connector into the seat switch.

    Warning

    The electrical system does not perform proper safety shutoff with the jumper wire installed.

    • Remove the jumper wire from the wire harness connector and plug the connector into the seat switch when you complete adjustment.

    • Never operate the machine with the jumper installed and the seat switch bypassed.

13. Lower the seat into position.

14. Remove the jack stands.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the bolts securing the front panel and remove the panel (Figure 52).

   

   Figure 52

   1. Bolt
   2. Control panel

4. Loosen the jam nut on the stop bolt for a control lever (Figure 53).

   

   Figure 53

   1. Stop bolt
   2. Control lever
   3. Jam nut
   4. 1.5 mm (0.060 inch)

5. Thread the stop bolt all the way in (away from the control lever).

6. Push the control lever all the way forward until it stops and hold it there.

7. Thread the stop bolt out (toward the control lever) until there is a gap of 1.5 mm (0.060 inch) between the head of the stop bolt and the control lever.

   Note: If you want to reduce the maximum machine speed, back each stop bolt out an equal amount toward the control lever until you reach the desired maximum speed. You may need to test your adjustment several times.

8. Tighten the jam nut to secure the stop bolt in place.

9. Repeat steps 4 through 8 for the other control lever.

10. Install the front panel.

11. Ensure that the machine drives straight and does not turn when both control levers are pushed all the way forward.

    Note: If the machine turns, the stop bolts are not evenly set and you need to adjust them further.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Loosen the bolts securing the control levers (Figure 54).

   

   Figure 54

   1. Control lever
   2. Control-lever post
   3. Bolts

4. Have someone push the control-lever posts (not the control levers) all the way forward into the maximum-speed position and hold them there.

5. Adjust the control levers so that they line up and tighten the bolts, securing the levers to the posts (Figure 55).

   

   Figure 55

Check the level of the hydraulic fluid before you first start the engine and daily thereafter.

1. Position the machine on a level surface.

2. Move the motion-control levers to the NEUTRAL-LOCK position and start the engine.

   Note: Run the engine at the lowest possible rpm to purge the system of air.

   Important: Do not engage the PTO.

3. Raise the deck to extend the lift cylinders, shut off the engine, and remove the key.

4. Raise the seat to access the hydraulic fluid tank.

5. Remove the hydraulic fill cap from the filler neck (Figure 56).

   

   Figure 56

   1. Dipstick
   2. Fill cap

6. Remove the dipstick and wipe it with a clean rag (Figure 56).

7. Place the dipstick into the filler neck; then remove it and check the level of fluid (Figure 56).

   Note: If the level is not within the notched area of the dipstick, add enough high-quality hydraulic fluid to raise the level to within the notched area.

   Important: Do not overfill.

8. Replace the dipstick and thread the fill cap finger-tight onto the filler neck.

9. Check all hoses and fittings for leaks.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Place a large pan under the hydraulic reservoir and transmission case and remove the plugs, draining all of the hydraulic fluid (Figure 57).

   

   Figure 57

   1. Hydraulic-reservoir drain plug
   2. Filter
   3. Transmission-case drain plug

4. Clean the area around the hydraulic fluid filter and remove the filter (Figure 57).

5. Immediately install a new hydraulic fluid filter.

6. Install the hydraulic-reservoir and transmission-case drain plugs.

7. Fill the reservoir to the proper level (approximately 5.7 L or 6 US qt); refer to Checking the Hydraulic System.

8. Start the engine and check for oil leaks. Allow the engine to run for about 5 minutes, then shut it off.

9. After 2 minutes, check the level of the hydraulic fluid; refer to Checking the Hydraulic System.

1. Disengage the PTO, move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake.

2. Move the throttle lever to the SLOW position, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Raise the mower to the transport position.

4. Raise the front of the machine using jack stands.

5. Thoroughly clean the underside of the mower with water.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants. Dispose of these according to your state and local regulations.