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ACCESSORIES AND MISCELLANEOUS REPAIR

4181384 First Edition

9-11

Disassembly and Assembly

Pedal Bracket Assembly

See Figure 9-22.

Figure 9-22

Assembly Notes

• Apply grease to flanged bushings (5) before

installing. (Refer to “Safety, Operation, and
Maintenance Manual” for grease specifications.)

• Apply grease to grease fitting (7). (Refer to “Safety,

Operation, and Maintenance Manual” for grease
specifications.)

Pedal Assembly

See Figure 9-23.

Figure 9-23

Assembly Note

DO NOT overtighten lock nut (4), the mow speed stop
bracket must be able to rotate after assembly.

Countersunk Socket-Head
Screw

Pedal Mounting Bracket

Lock Washer

Screw

Flanged Bushing (2)

Pedal Lever Weldment

Grease Fitting

Pivot Shaft

TN1076

Screw

Washer (3)

Mow Speed Stop Bracket

Lock Nut

Pedal Cover

Traction Pedal

Pedal Cover

TN1077

Summary of Contents for AR3

Page 1: ...AR 3 TR 3 Trim Mowers Technical Repair Manual AR30001 AR30002 TR30001 TR30002...

Page 2: ...s machine can cause severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operat...

Page 3: ......

Page 4: ...parts manual for specific information on these topics THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION JACOBSEN RESERVES THE RIGHT TO CHANGE AN...

Page 5: ...ools and or materials will be listed for reference prior to beginning a procedure Specifications Near the beginning of each chapter is a specifications listing This listing contains any specifications...

Page 6: ...9 2 3 4 5 6 7 8 Table of Contents 5 1 Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Unit Accessories and Miscellaneous Repair...

Page 7: ......

Page 8: ...er Eye and Face Protection 1 7 Park Mower Safely 1 7 Use Lifting Equipment Safely 1 8 Support Machine Securely 1 8 Use Compressed Air and Air Tools Safely 1 8 Service Tires Safely 1 9 Handle Fuel Safe...

Page 9: ...1 2 4181384 First Edition SAFETY 1 Page Intentionally Blank...

Page 10: ...ol before beginning service Prepare proper work space lighting A well lit work area can make the job easier Follow procedures and safety warnings Service procedures are written to be as safe and effic...

Page 11: ...1 4 4181384 First Edition SAFETY 1 Figure 1 1 AR 3 shown TR 3 is similar TN0991 TN0992 4 1 2 3 5 6 6 5 7 8 5 6 9 6...

Page 12: ...justar o reparar este equipo desengranar todas los mandos aplicar el freno de estacionamiento y apagar el motor Mantener las manos los pies y la ropa alejados de las piezas en movimiento No conducir c...

Page 13: ...6 Avoid Fluid Escaping Under Pressure Consult Technical Manual for Service Procedures 7 Do Not Remove Safety Shields While Engine is Running 8 Danger of Explosion if the Battery Terminals are Short C...

Page 14: ...s are present Vented Goggles Goggles offer side protection not offered by safety glasses alone Unvented Goggles Unvented goggles offer protection from chemical splashes and vapors Park Mower Safely Se...

Page 15: ...rotection while using compressed air and air tools When using air tools do not exceed the air pressure rating for the tool When using an impact wrench always use approved impact sockets Never use stan...

Page 16: ...local state or federal ordinances and recommendations from your fuel supplier Never overfill or allow the tank to become empty Use clean fresh fuel Do not fill above the fuel filler neck Store Volatil...

Page 17: ...cts with care Refer to the chemical manufacturer s Material Safety Data Sheet MSDS for information regarding health hazards safe handling and emergency response procedures The hydraulic system is unde...

Page 18: ...with certain types of plastics Make sure the fluid to be stored is compatible with the storage container Never use food or beverage containers to store waste fluids IMPORTANT Dispose of waste fluids...

Page 19: ...1 12 4181384 First Edition SAFETY 1...

Page 20: ...fication Number 2 2 Serial Number 2 2 Engine Serial Number 2 2 Optional Machine Accessories 2 2 Component Location 2 3 AR 3 2 3 TR 3 2 5 Specifications 2 7 Quick Reference Specifications 2 7 General S...

Page 21: ...bota and hydrostatic transmission Serial Number An identification plate like the one shown listing the serial number is attached to the operator platform Always provide the serial number of the unit w...

Page 22: ...and 2 4 CAUTION Figure 2 3 Component Location Right Side Become familiar with operator controls machine components and correct operating procedures before beginning repair procedures 1 Canopy Optiona...

Page 23: ...n SPECIFICATIONS AND GENERAL INFORMATION 2 Figure 2 4 Component Location Left Side 1 Foot Support 5 Left Front Wheel Motor 2 Hood 6 Front Wheel 2 3 Rear Wheel Motor 7 Fuel Tank 4 Rear Center Cutting U...

Page 24: ...rols machine components and correct operating procedures before beginning repair procedures 1 Canopy Optional 8 Right Front Cutting Unit 2 OPS Optional 9 Right Front Wheel Motor 3 Seat 10 Front Wheel...

Page 25: ...n SPECIFICATIONS AND GENERAL INFORMATION 2 Figure 2 6 Component Location Left Side 1 Foot Support 5 Left Front Wheel Motor 2 Hood 6 Front Wheel 2 3 Rear Wheel Motor 7 Fuel Tank 4 Rear Center Cutting U...

Page 26: ...cross Solenoid Coil 24 Volt Solenoid Coils 68 F ohms 41 74 10 Fuel Shutoff Solenoid Resistance between Terminal 1 and Ground ohms 15 58 Fuel Shutoff Solenoid Resistance between Terminal 3 and Ground o...

Page 27: ...heel Motor End Cover Screw Torque lb ft N m 52 70 Rear Wheel Motor Hub Nut Torque lb ft N m 148 7 200 10 Rear Wheel Motor End Cover Screw Torque lb ft N m 55 59 75 80 Test and Adjustment Specification...

Page 28: ...g Torque lb ft N m 2 3 Flushing Valve M5 x 0 50 Diameter Orifice Plug Torque lb ft N m 1 7 2 5 Mow Brake Valve Mow Solenoid Valve Torque lb ft N m 20 27 Mow Brake Valve Brake Solenoid Valve Torque lb...

Page 29: ...etaining Screw Torque lb ft N m 70 95 Fuel Tank Capacity gal L 6 6 25 OPS M10 Mounting Hardware Torque lb ft N m 34 46 M12 Mounting Hardware Torque lb ft N m 58 79 Front Tires Size 20 x 12 00 10 Type...

Page 30: ...3 11 8 Idle Speed 1650 25 rpm Maximum Speed No Load 3150 50 rpm Oil Sump Capacity gal L 1 77 6 7 Alternator 12 volt 30 amp Dry Weight 205 lb 93 kg Turbocharged Engine Manufacturer Model Kubota D1105 T...

Page 31: ...ight lb kg 2293 1040 Width of Cut in m 72 1 83 Overall Width in m 79 2 00 Overall Height in m 52 7 1 34 Overall Length in m 123 3 12 Weights and Dimensions TR 3 Overall Weight lb kg 2050 930 Width of...

Page 32: ...115 156 154 209 1 4 20 in lb Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159...

Page 33: ...2 14 4181384 First Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Page Intentionally Blank...

Page 34: ...Kubota D1105 T 3 6 Repair 3 8 Fan Belt 3 8 Air Cleaner Assembly 3 8 Muffler 3 9 Exhaust Manifold Naturally Aspirated Engine 3 11 Exhaust Manifold and Turbocharger 3 12 Radiator Hydraulic Oil Cooler 3...

Page 35: ...8 Idle Speed 1650 25 rpm Maximum Speed No Load 3150 50 rpm Oil Sump Capacity gal l 1 77 6 7 Alternator 12 Volt 30 Amp Dry Weight 205 lb 93 kg Turbocharged Engine Manufacturer Model Kubota D1105 T Engi...

Page 36: ...ENGINE 4181384 First Edition 3 3 3 Repair Specifications Specifications Nylon Pump Coupler Flange Socket Head Screw Torque lb ft N m 55 75...

Page 37: ...re 3 1 Component Location Right Side 1 Radiator Hydraulic Oil Cooler 7 Muffler and Shield 2 Thermostat 8 Alternator 3 Oil Filler Cap 9 Fan Drive Belt 4 Exhaust Manifold 10 Oil Pressure Sending Unit 5...

Page 38: ...an Drive Belt 2 Air Cleaner Assembly 8 Air Restriction Indicator 3 Air Intake Hose 9 Throttle Cable 4 Coolant Overflow Tank 10 In Line Fuel Filter 5 Coolant Filler Pressure Cap 11 Fuel Pump 6 Radiator...

Page 39: ...cation Right Side 1 Radiator Hydraulic Oil Cooler 7 Exhaust Down Pipe 2 Fan Drive Belt 8 Exhaust Manifold 3 Thermostat 9 Muffler and Shield 4 Oil Filler Cap 10 Alternator 5 Turbocharger 11 Oil Pressur...

Page 40: ...an Drive Belt 2 Air Cleaner Assembly 8 Air Restriction Indicator 3 Air Intake Hose 9 Throttle Cable 4 Coolant Overflow Tank 10 Fuel Pump 5 Coolant Filler Pressure Cap 11 In Line Fuel Filter 6 Radiator...

Page 41: ...ternator 2 toward the engine to loosen the belt 3 Figure 3 6 5 Remove the fan belt 3 from the alternator 4 coolant pump 5 and crankshaft 6 pulleys Installation Notes Install the fan drive belt by reve...

Page 42: ...er of removal Muffler Removal and Installation See Figures 3 9 through 3 13 CAUTION NOTE Turbocharged engine shown naturally aspirated engine is similar 1 Park the mower safely See Park Mower Safely o...

Page 43: ...each end of muffler 15 7 Remove muffler 15 Figure 3 12 8 Remove gasket 17 from down pipe 16 Figure 3 13 9 Remove four screws 20 lock washers 21 and flat washers 22 and remove downpipe 23 and gasket 1...

Page 44: ...downpipe and gaskets 6 and 7 from elbow 1 and muffler 11 Figure 3 15 6 Remove four screws 12 lock washers 13 flat washers 14 elbow 15 and gasket 16 from exhaust manifold 17 Figure 3 16 7 Remove six f...

Page 45: ...13 and 17 and remove hose 12 from turbocharger and air cleaner assembly 6 Remove hose clamps 14 and 16 and hose 15 Figure 3 19 NOTE Vent tube removed for photo clarity Plug oil hose and openings to p...

Page 46: ...similar 1 Park the mower safely See Park Mower Safely on page 1 7 2 Raise the hood WARNING 3 Drain cooling system 4 Drain hydraulic system Figure 3 21 NOTE Label all hoses before removing to ensure c...

Page 47: ...oil cooler 14 Figure 3 23 14 Support the radiator hydraulic oil cooler 20 15 Remove four two each side screws 21 lock washers 22 and flat washers 23 from radiator hydraulic oil cooler 20 16 Remove th...

Page 48: ...adiator support 36 from radiator hydraulic oil cooler 43 24 Remove four lock nuts 46 flat washers 45 screws 49 and lock washers 50 and remove two spacers 35 and 47 left radiator support 44 and cowling...

Page 49: ...two screws 6 and lock washers 7 6 Remove thermostat housing 8 gasket 9 and thermostat 10 from spacer 11 NOTE Perform step 7 if removing the spacer from the engine 7 Remove two socket head screws 14 a...

Page 50: ...tform Figure 3 27 4 Move throttle lever 1 to the slow position Figure 3 28 NOTE Record the location of the spring washers before removing to ensure correct installation 5 Remove screw 5 two spring was...

Page 51: ...e cable during installation Operate throttle lever to ensure proper operation and full range of motion Fuel Pump Naturally Aspirated Engine Removal and Installation See Figure 3 32 1 Park the mower sa...

Page 52: ...e removing to ensure correct installation 8 Remove two lock nuts 8 screws 9 and four flat washers 10 9 Remove fuel pump 3 Installation Note Install the fuel pump by reversing the order of removal Engi...

Page 53: ...ble 14 at injector pump See steps 1 through 6 of Throttle Cable and Control Lever on page 3 17 Figure 3 38 12 Remove flanged nut 17 and disconnect wire 16 from glow plug strip 18 NOTE Plug the fuel ho...

Page 54: ...r and down pipe See Muffler on page 3 9 WARNING 19 Attach a suitable lifting device to the engine Figure 3 40 20 Support the front of the pump assembly 34 21 Remove two socket head screws 31 lock wash...

Page 55: ...39 from engine 38 23 Remove two lock nuts 49 flat washers 36 and 48 and screws 35 from engine mounts 37 and 43 24 Remove the engine 38 from the chassis 25 Remove two isolation mounts 45 and flat wash...

Page 56: ...emove four screws 63 and lock washers 64 and remove left engine mount 52 from engine 61 30 Remove four screws 51 and lock washers 52 and remove right engine mount 53 from engine 61 31 Remove screw 54...

Page 57: ...te engine manual prepared by the engine manufacturer is supplied with this machine Refer to the engine manufacturer s manual for all engine related service Proper attention to the engine manufacturer...

Page 58: ...Operation 4 29 Start Circuit Schematic 4 31 Run Circuit Theory of Operation 4 33 Run Circuit Schematic On Seat 4 34 Run Circuit Schematic Off Seat 4 35 Raise Lower Circuit Theory of Operation 4 36 Ra...

Page 59: ...cuit 4 57 Work Lights Circuit 4 59 Component Testing 4 60 Electrical System and Component Testing 4 60 Fuse Test 4 61 Relay Tests 4 62 Key Switch Test 4 63 Brake Safety Switch Test 4 64 Joystick Test...

Page 60: ...Switch 4 79 Rocker Switches 4 80 Indicator Lamps 4 81 Brake Safety Switch 4 82 Joystick 4 82 Control Module 4 83 Multi Function Gauge 4 83 Seat Switch 4 84 Traction Pedal Neutral Switch 4 84 Solenoid...

Page 61: ...Solenoid Coil 24 Volt Solenoid Coils at 68 F ohms 41 74 10 Fuel Shutoff Solenoid Resistance Between Terminal 1 and Ground ohms 15 58 Fuel Shutoff Solenoid Resistance Between Terminal 3 and Ground ohms...

Page 62: ...Work Lights F4 5A Fuse Park Brake solenoid F5 2A Fuse Multi Function Gauge F6 15A Fuse Start Circuit F7 7 5A Fuse Alternator F8 5A Fuse Mow Switch Light Alternator Light Multi Function Gauge and Setu...

Page 63: ...ew of the many switch configurations Switches are designated by the number of poles circuits controlled and throws actuator positions Unless otherwise specified switches are shown in the Normally Open...

Page 64: ...and Generating Devices Electric Motors may also include AC or DC Stator Alternator Actuating Devices Solenoid Valve PTO Clutch Engine Related Devices Ignition Coil Spark Plug Regulator Lights Single...

Page 65: ...closure cabinet housing etc Wires crossing but not connected Ground to earth Wiring Connections Ground to chassis Coil Direct Current DC as shown on an oscilloscope Battery Alternating Current AC as s...

Page 66: ...4 Over Temperature Light See Figure 4 6 H5 Module Fault Light See Figure 4 6 H6 Alternator Light See Figure 4 6 H7 Alarm See Figure 4 6 K1 Start Relay See Figure 4 2 K2 Glow Plug Relay See Figure 4 2...

Page 67: ...n Red Red Blk Blk Brn Yel Brn Yel Wht Blu Wht Blu Blk Blk Blk Brn Brn Brn Brn Wht Brn Wht Brn Red Brn Red Blk Brn Yel Brn Yel Brn Yel 6 Yel Blk Yel 3 1 2 3 4 1 2 3 4 5 6 M M1 Starter Motor M2 Fuel Pum...

Page 68: ...d Lt Grn Red Lt Grn Red Lt Grn Red Red Blk Red Blk 5 2 Backlap Mow Grn Org Grn Org Lt Grn Brn On Off Grn Brn Grn Brn Grn Blk Grn Blk Blk Grn Grn Blk Mow Gry Yel Yel Blu Yel Blu Off F8 5A Fuse Wht Blk...

Page 69: ...F4 5A Fuse F10 10A Fuse Wht Grn Grn Blk Wht Wht Grn Yel Grn Wht Blk Brn Lt Grn Brn Grn Grn Blk Grn Org Grn Org 11 Grn Brn Grn Brn 17 Yel Blu Yel Blu 4 Wht Blk Brn Blk Brn 12 Lt Grn Brn Lt Grn Brn 10 G...

Page 70: ...Yel Grn Blu Org Brn Brn Yel Blk Vio Yel Grn Blu Org Brn Brn Yel Blk Vio Yel Grn Blu Org Brn On Grn Red Yel Org Yel Red Yel Org Grn Vio Yel Org Yel Red Yel Red Yel Red Off Grn Vio S7 Weight Transfer Sw...

Page 71: ...Wht Grn Grn Brn Yel Brn Yel Brn Yel Blk Brn Yel Blk Blk Vio Yel Vio Yel Vio Yel Vio Yel Vio Yel Vio Yel Grn Blu Grn Blu Grn Blu Org Brn Org Brn Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Wht Brn Yel Grn...

Page 72: ...lk Blk Blk Blk Blk Blk Blk Blk 1 3 7 8 2 2 Blk Grn Wht On Blu Wht Blu Wht Blu Wht Blu Wht Blu Wht Blu Wht Off 1 X1 X6 Accessory Socket 1 X7 Accessory Socket 2 Wht Grn Grn Grn 2 X1 X2 F2 15A Fuse Wht G...

Page 73: ...4 16 4181384 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 74: ...terminal AC to the following components 15A fuse F1 15A fuse F2 10A fuse F3 5A fuse F4 2A fuse F5 7 5A fuse F7 5A fuse F8 5A fuse F9 10A fuse F10 Alternator excitation terminal Fuel pump Mow switch te...

Page 75: ...Brn Brn Wht Brn Wht Brn Brn Brn Brn Blk Brn Brn Red Red Blk Blk Brn Yel Brn Yel Wht Blu Wht Blu Blk Blk Brn Yel Blk Blk Blk Brn Brn Brn Brn Wht Brn Wht Brn Red Brn Red Blk Brn Yel Brn Yel Brn Yel 6 Y...

Page 76: ...ht Blu Wht Blu Lever Engaged Lever Released Lt Grn Red Lt Grn Red Lt Grn Red Red Blk Red Blk 5 2 Backlap Mow Grn Org Grn Org Lt Grn Brn On Off Grn Brn Grn Brn Grn Blk Grn Blk Blk Grn Grn Blk Mow Gry Y...

Page 77: ...Vio 8 3 Grn Vio Grn Vio Power 1 Blk Blk Blk Yel Vio 13 Yel Vio 14 Red Blk 15 Org Blk 6 Grn Blu 7 Vio Yel Vio Yel Grn Blu 18 Org Brn Org Brn Red Blk Org Blk Grn Wht Yel Pnk 9 Grn Wht 5 Yel Pnk Y2 Brake...

Page 78: ...lk Blk Blk Blk Blk 2 8 Yel Vio Yel Vio Vio Yel Grn Blu Org Brn Brn Yel Blk Vio Yel Grn Blu Org Brn Brn Yel Blk Vio Yel Grn Blu Org Brn On Grn Red Yel Org Yel Red Yel Org Grn Vio Yel Org Yel Red Yel Re...

Page 79: ...el Brn Yel Brn Yel Blk Brn Yel Blk Blk Vio Yel Vio Yel Grn Blu Grn Blu Grn Blu Org Brn Org Brn Blk Blk Blk Blk Blk Blk Blk Wht Brn Yel Grn Yel Grn Wht Brn B1 Engine Temperature Switch B2 Engine Oil Pr...

Page 80: ...nd Circuit Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk 1 3 7 8 2 2 Blk Grn Wht On Blu Wht Blu Wht Blu Wht Blu Wht Blu Wht Blu Wht Off 1 X1 X6 Accessory Socket 1 X7 Accessory Socket 2 Wht G...

Page 81: ...is in the run position and with the engine off the voltage regulator detects zero output voltage from the alternator and provides a ground to the alternator light circuit With the alternator light cir...

Page 82: ...itch G1 Battery G2 Alternator Off Heat Run Wht Wht Start 30 AC 19 50 Brn Brn 6 5 X2 X2 Unswitched Power Circuit Switched Power Circuit Ground Circuit Alternator Light Circuit Charging Circuit 6 Brn Ye...

Page 83: ...e key switch is held in the glow position current also flows from key switch terminal 19 to glow plug relay terminal 86 energizing the relay With the relay energized current flows between relay contac...

Page 84: ...Brn Red Brn Blu Brn Red Brn Red Brn Blk Blk Blk Blk Brn Brn Brn Brn Wht Brn Wht Brn Red Brn Red Blk 1 2 3 4 5 6 M1 Starter Motor K2 Glow Plug Relay R1 Glow Plugs H1 Glow Plug Wait Light A2 Glow Plug T...

Page 85: ...4 28 4181384 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 86: ...the seat Park brake switch in the locked position Drive pedal in the neutral position Mow switch in the off position When the operator is on the seat the seat switch contacts close With the seat switc...

Page 87: ...when the starter solenoid is de energized Current also flows from the start circuit to glow plug timer terminal 4 activating the input With the input activated and terminal 6 grounded the glow plug ti...

Page 88: ...2 3 4 5 6 M1 Starter Motor K2 Glow Plug Relay K1 Start Relay R1 Glow Plugs H1 Glow Plug Wait Light A2 Glow Plug Timer F12 F6 15A Fuse M S1 Key Switch G1 Battery Off Heat Run Wht Wht Blk Brn Blk Brn S...

Page 89: ...Brn 12 2 Grn Blk 17 Grn Brn 16 Grn Gry Grn Brn Blk Brn Unswitched Power Circuit Switched Power Circuit 5 Volt Power Circuit Ground Circuit 6 10 X1 X2 A1 Control Module Blk Grn Pnk Grn Vio 8 3 Grn Vio...

Page 90: ...nd the drive pedals are not in their neutral positions The control module will de energize the fuel shutoff solenoid approximately 1 5 seconds after the seat switch contacts open The time delay is to...

Page 91: ...0 X1 X2 Blk Grn Pnk Grn Vio 8 3 10 Grn Vio Power 1 16 Grn Gry 3 Grn Gry Grn Gry 4 5 8 2 To Brake Sol 1 Blk Blk Neutral Pedal Engaged 5V Seat Sw Input 5V Park Brake Sw Input 5 Volt Power Supply Lt Grn...

Page 92: ...10 X1 X2 A1 Control Module Blk Grn Pnk Grn Vio 8 3 10 Grn Vio Power 1 16 Grn Gry 3 Grn Gry Grn Gry 4 5 8 2 To Brake Sol 1 Blk Blk Neutral Pedal Engaged 5V Seat Sw Input 5V Park Brake Sw Input 5 Volt P...

Page 93: ...noid output terminal 9 to the raise solenoid energizing the solenoid With the solenoid energized the cutting units will continue to rise until the raise lower switch is released or until the cutting u...

Page 94: ...rol Module Grn Vio Grn Vio 8 3 Grn Vio Power 1 Blk 12V Raise Sol output 5 Volt Power Supply 12V Lower Sol Output 5V Raise Sw Input 5V Lower Sw Input 1 3 4 6 5 7 8 2 Blk Raise Off 14 15 2 9 2 5 Lower Y...

Page 95: ...control module now provides 5 volts to the mow switch Mow Circuit When the mow switch is in the mow position voltage is provided to the control module 5V mow switch input activating the input When th...

Page 96: ...itch Circuit Unswitched Power Circuit Switched Power Circuit 5 Volt Power Circuit Ground Circuit Ground F10 10A Fuse Grn F8 Wht Grn Blk 2 5 Yel Pnk A1 Control Module Grn Vio Grn Vio 8 3 Grn Vio Power...

Page 97: ...eleased When the park brake switch is in the brake released position current flows to the park brake solenoid energizing the solenoid With the solenoid energized the park brake is released Park Brake...

Page 98: ...rcuit 5 Volt Power Circuit Ground Circuit Ground F10 10A Fuse Grn Blk Grn Blk Grn Blk Grn Pnk F9 5A Fuse Wht 2 Grn Blk 16 Grn Gry Grn Gry Grn Gry Grn Gry A1 Control Module Blk Grn Pnk Grn Vio 8 3 Grn...

Page 99: ...wer Circuit 5 Volt Power Circuit Ground Circuit Ground F10 10A Fuse Grn Blk Grn Blk Grn Blk Grn Pnk F9 5A Fuse Wht 2 Grn Blk 16 Grn Gry Grn Gry Grn Gry Grn Gry A1 Control Module Blk Grn Pnk Grn Vio 8...

Page 100: ...enoid output terminal 10 to the backlap switch See Run Circuit Theory of Operation on page 4 33 When the backlap switch is in the backlap position voltage is provided to control module 12V backlap inp...

Page 101: ...r Circuit Ground Circuit Ground F10 10A Fuse Grn F8 Wht Grn Blk 2 5 Yel Pnk Grn Vio Grn Vio 8 3 Grn Vio Power 1 Blk Blk Blk 12V Mow Sol Output 5V Mow Sw Input 5 Volt Power Supply 12V Fuel Shutoff Outp...

Page 102: ...control module now provides 5 volts to the raise lower switch Weight Transfer Circuit When the raise lower switch is momentarily placed in the lower position control module 12V lower solenoid output...

Page 103: ...und F10 10A Fuse Grn BlK Grn BlK 13 Yel Vio A1 Control Module Grn Vio Grn Vio 8 3 Grn Vio Power 1 Blk 5 Volt Power Supply 12V Lower Sol Output 5V Raise Sw Input 5V Lower Sw Input 1 3 6 4 5 7 8 2 Blk R...

Page 104: ...control module over temp input terminal activating the input With the input activated current flows from 12V over temp light output to the over temp light turning on the light Current also flows from...

Page 105: ...t Light 7 6 Blk Setup Switch Circuit t On Off Grn Gry Red To Alternator Blk Wht Blk Wht S9 Setup Switch Blk Wht 1 Grn 2 Gry Red 6 Ground Battery Discharge Input Switched Power Hour Meter Enable Setup...

Page 106: ...rom the switch to the work lights turning on the lights Work Lights Circuit Schematic See Figure 4 27 Figure 4 27 Wht Blk S1 Key Switch G1 Battery Off Heat Run Wht Start 30 AC 19 50 Brn Brn Brn Unswit...

Page 107: ...el pump grn wire terminal and ground Voltage must be approximately 12 VDC Open fuel pump ground circuit Check continuity between fuel pump blk wire terminal and ground Continuity must be indicated Fau...

Page 108: ...k continuity between battery negative terminal and ground Continuity must be indicated Faulty battery Check specific gravity of the individual battery cells Probable Cause Remedy Open fuse 7 5A fuse F...

Page 109: ...al 86 Continuity must be indicated Open glow plug relay ground circuit Check continuity between glow plug relay terminal 85 and ground Continuity must be indicated Faulty glow plug relay output circui...

Page 110: ...position measure voltage between control module 5V park brake input terminal and ground Voltage must be approximately 5 VDC Faulty 5V seat switch input circuit With the key switch in the run position...

Page 111: ...dule with a known good control module Probable Cause Remedy Park brake switch is in the released position and or mow switch is in the mow position Place the park brake switch in the locked position an...

Page 112: ...lower solenoid yel red wire terminal and ground Voltage must be approximately 12 VDC Open lower solenoid ground circuit Check continuity between lower solenoid blk wire terminal and ground Continuity...

Page 113: ...al and ground Continuity must be indicated Probable Cause Remedy Raise lower switch was not momentarily placed in the lower position Momentarily place the raise lower switch in the lower position to a...

Page 114: ...e indicated Probable Cause Remedy Faulty engine oil pressure light Check light bulb Open 5A Fuse F9 Test fuse See Fuse Test on page 4 61 Faulty engine oil pressure switch With the key switch in the of...

Page 115: ...ature switch Faulty over temp light input circuit Check continuity between control module over temp light input terminal and engine temperature switch connector Continuity must be indicated Faulty 12V...

Page 116: ...ht switched power circuit With the key switch in the run position measure voltage between alternator light grn wire terminal and ground Voltage must be approximately 12 VDC Faulty hour meter enable in...

Page 117: ...erator s manual for more information 2 If using a multimeter set to read ohms or set meter to continuity setting 3 Disconnect the ends of the wire being tested 4 Touch meter leads to the ends of the w...

Page 118: ...4 30 1 Park the mower safely See Park Mower Safely on page 1 7 2 Disconnect the battery negative cables at the battery 3 Open the engine hood Figure 4 29 4 Open the fuse holder cover 1 Figure 4 30 5...

Page 119: ...e relay Glow Plug Relay See Figure 4 32 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove the glow plug relay See Glow Plug Relay on page 4 79 Figure 4 32 3 Connect one test lead to t...

Page 120: ...faulty replace the switch NO Proceed to step 11 11 Connect one test lead to terminal 4 12 Place and hold the key switch in the heat position 13 Connect the other test lead to terminal 3 Is continuity...

Page 121: ...om the instrument panel See Joystick on page 4 82 Figure 4 35 3 Connect test leads to terminals 2 and 3 and check continuity Is continuity indicated YES The switch is faulty replace the joystick assem...

Page 122: ...continuity Is continuity indicated YES The switch is good NO The switch is faulty replace the switch Seat Switch Test See Figure 4 48 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove...

Page 123: ...ce the switch in the off position 9 Connect one test lead to terminal 6 10 Connect the other test lead to terminal 5 and check for continuity Is continuity indicated YES Proceed to step 11 NO The swit...

Page 124: ...The switch is faulty replace the switch 8 Connect one test lead to terminal 1 9 Connect the other test lead to terminal 2 and check for continuity Is continuity indicated YES Proceed to step 10 NO The...

Page 125: ...volt Figure 4 42 NOTE On some meters it will be necessary to select a range for the component being tested 3 Using a multimeter or ohmmeter measure ohms resistance between terminals 1 and 2 Refer to t...

Page 126: ...imately 0 375 ohms YES The solenoid is good NO The solenoid is faulty replace the solenoid Backlap Switch Test See Figure 4 44 1 Park the mower safely See Park Mower Safely on page 1 7 2 Identify and...

Page 127: ...the key switch 2 to the run position Does the engine oil pressure warning light 1 come on YES Proceed to step 4 NO Check the instrumentation circuit See Instrumentation Circuit Schematic on page 4 48...

Page 128: ...ove the float 3 in the empty position and read the resistance value Is the resistance value approximately 180 ohms YES Proceed to step 6 NO The sender unit is faulty replace the sender unit 6 Move the...

Page 129: ...nd flat washers 15 and retainer bracket 16 from the battery tray 12 NOTICE 7 Remove the battery 11 NOTE Perform steps 8 through 11 if the battery tray is to be removed Battery posts terminals and rela...

Page 130: ...lat washer 18 from the inside of the frame rail 17 and battery tray 21 10 Remove two countersunk socket head screws 22 from the battery tray 21 and the outside of the frame rail 17 11 Remove the batte...

Page 131: ...installation 5 Remove lock nut 2 and disconnect wire 1 from terminal 6 Disconnect wiring connector block 4 from the alternator 3 Figure 4 52 7 Loosen screw 7 and push the alternator 10 toward the engi...

Page 132: ...move nut 5 and lock washer 6 and disconnect wires 2 and 3 from terminal 6 Disconnect wiring connector 7 from the starter motor 1 Figure 4 54 7 Remove socket head screw 9 lock washer 10 and flat washer...

Page 133: ...and support the seat platform Figure 4 56 NOTES Seat removed for photo clarity If moving the instrument panel aside use caution to prevent stretching or kinking of the cables 5 Remove six screws 1 and...

Page 134: ...Remove fuse s 3 by pulling the fuse s straight out of the fuse holder Installation Note Install plug in fuse s by reversing the order of removal Strip Fuses Removal and Installation See Figures 4 61...

Page 135: ...module 1 from the harness 2 Installation Note Install the diode module by reversing the order of removal Start Relay Removal and Installation See Figure 4 64 1 Park the mower safely See Park Mower Sa...

Page 136: ...ow plug relay by reversing the order of removal Key Switch Removal and Installation See Figures 4 66 and 4 67 1 Park the mower safely See Park Mower Safely on page 1 7 2 Disconnect the battery negativ...

Page 137: ...ly See Park Mower Safely on page 1 7 2 Disconnect the battery negative cables at the battery 3 Remove instrument panel See Instrument Panel on page 4 76 Figure 4 69 NOTE Label all wiring connectors be...

Page 138: ...shown 1 Park the mower safely See Park Mower Safely on page 1 7 2 Disconnect the battery negative cables at the battery 3 Remove instrument panel See Instrument Panel on page 4 76 Figure 4 72 NOTE La...

Page 139: ...the brake safety switch by reversing the order of removal Joystick Removal and Installation See Figures 4 75 and 4 76 1 Park the mower safely See Park Mower Safely on page 1 7 2 Disconnect the batter...

Page 140: ...ttery negative cables at the battery 3 Remove instrument panel See Instrument Panel on page 4 76 Figure 4 77 4 Disconnect the control module wiring connector 2 from the harness 3 5 Remove the control...

Page 141: ...removal and installation is included in the seat and mounting plate removal and installation procedure See Seat and Mounting Plate on page 9 16 Traction Pedal Neutral Switch Removal and Installation...

Page 142: ...e Figure 4 83 NOTE The mow solenoid is shown all solenoids are removed and installed the same way 1 Park the mower safely See Park Mower Safely on page 1 7 2 Raise and support the seat platform mow an...

Page 143: ...ws 1 and washers 2 Installation Note Install the fuel shutoff solenoid by reversing order of removal Backlap Switch Removal and Installation See Figure 4 85 1 Park the mower safely See Park Mower Safe...

Page 144: ...g to ensure correct installation 4 Remove screw 1 and disconnect wire 3 from the oil pressure switch 2 5 Remove the oil pressure switch 2 from the engine block The hydraulic system is under pressure a...

Page 145: ...turn to relieve pressure in cooling system Figure 4 89 NOTE Label all wires before disconnecting to ensure correct installation 5 Disconnect wiring connector 2 from the engine temperature switch 4 6...

Page 146: ...alarm 3 4 Remove lock nut 4 screw 5 and two flat washers 6 and remove the alarm 3 Installation Note Install the alarm by reversing the order of removal Glow Plug Timer Removal and Installation See Fig...

Page 147: ...4 90 4181384 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 148: ...t Reverse Schematic 5 7 Troubleshooting 5 8 Field Test Procedures 5 10 Preliminary Checks 5 10 Charge Pump Test 5 10 Traction System Test 5 10 Rear Wheel Motor Test 5 10 Instrument Test Procedures 5 1...

Page 149: ...static Pump Flow gpm lpm 20 76 at 3150 rpm Forward System Relief Pressure psi bar 3046 210 Reverse System Relief Pressure psi bar 3046 210 Charge Pressure psi bar 160 11 Hydraulic Leakage Percentage R...

Page 150: ...4181384 First Edition 5 3 5 Component Location See Figure 5 2 Figure 5 2 Power Train Component Location 1 Rear Wheel Motor 2 Hydrostatic Pump 3 Left Front Wheel Motor 4 Right Front Wheel Motor TN0991...

Page 151: ...e valve to the brake pistons in the front wheel motors to release the parking brakes When the park brake release lever is moved to the released position the oil passage from the mow and brake valve is...

Page 152: ...ing Circuit TN1185 Operating Pressure Oil Charge Pressure Oil Return Oil Mow and Brake Valve M2 MP BR DR1 DR M1 CP Load Control Valve Relief Valve Brake Solenoid Valve Mow Solenoid Valve 1 2 3 4 Park...

Page 153: ...ve is normally in the operating position directing the charge oil from the mow and brake valve to the brake pistons in the front wheel motors to release the parking brakes When the park brake release...

Page 154: ...ing Circuit TN1186 Mow and Brake Valve M2 MP BR DR1 DR M1 CP Load Control Valve Relief Valve Brake Solenoid Valve 1 2 3 4 Park Brake Release Valve Hydraulic Oil Filter Front Wheel Motors Rear Wheel Mo...

Page 155: ...ual for the correct oil specifications Tow valve open Close tow valve Oil filter plugged Replace filter find source of contamination Air bubbles in hydraulic oil Check suction line for air leaks Incor...

Page 156: ...rt or debris in fins Clean oil cooler fins of dirt and debris Incorrect charge pressure relief setting Test charge pressure relief valve setting See Transmission Neutral Adjustment on page 5 18 Faulty...

Page 157: ...rward Does the engine labor or stall YES The traction pump is not faulty NO A fault exists in the hydrostatic drive circuit including the traction pump or wheel motors Proceed to instrument test See I...

Page 158: ...ear wheel motor Although all the components lend to the overall system leakage only the left front wheel motor which is at the extreme end of the marginal range would be considered for repair replacem...

Page 159: ...stall all hoses and fittings as noted prior to removal 8 Check hydraulic oil level Add oil as needed Refer to Safety Operation and Maintenance Manual for correct oil specifications Traction System Tes...

Page 160: ...ely by turning clockwise 9 Disconnect and plug hose 4 10 Install a cap to fitting 3 11 Disconnect hoses 5 and 8 Figure 5 12 12 Connect test hose 14 of flow meter inlet to fitting 6 13 Connect test hos...

Page 161: ...nal Additional testing is required NO Proceed to next question Is traction system leakage 21 or more YES Test individual components in traction system for leakage 25 Disconnect and remove test equipme...

Page 162: ...epair or replace traction pump See Traction Pump on page 5 22 CAUTION 13 Continue to close flow meter valve 2 until zero flow is obtained Record forward system relief valve pressure 14 Stop engine and...

Page 163: ...5 12 3 See Figure 5 13 Remove the blocking disks from locations 1 and 3 4 Connect hoses back to flow meter as outlined in traction system test See Traction System Test on page 5 12 The hydraulic syst...

Page 164: ...pump to produce 10 gpm 37 8 lpm in the forward direction 13 Slowly close flow meter valve until pressure reaches 2300 psi 159 bar Read and record loaded flow 14 Stop engine and return flow lock tool...

Page 165: ...Verify engine rpm is within specification 3150 rpm 50 to ensure accurate hydraulic test results 30 Start engine and run at full throttle 3150 rpm 50 31 Adjust flow lock tool 3 to allow pump to produce...

Page 166: ...nance Manual Figure 5 19 WARNING CAUTION 7 Manually move the pump control lever 7 until the wheels stop rotating 8 Stop the engine Prevent personal injury Use properly rated lifting devices Always be...

Page 167: ...ent is noted 15 Stop the engine 16 Adjust the neutral switch See TR 3 and Early Model 30001 AR 3 Traction Pedal Neutral Switch Adjustment on page 5 20 TR 3 and Early Model 30001 AR 3 Traction Pedal Ne...

Page 168: ...ch Adjustment See Figure 5 24 1 Park the mower safely See Park Mower Safely on page 1 7 2 Allow the traction pedal to return to the neutral position NOTE Late Model 30002 AR3 traction pedal neutral sw...

Page 169: ...YDROSTATIC POWER TRAIN 5 Repair Traction Pump Removal and Installation See Figure 5 25 Figure 5 25 26 4 1 32 22 23 38 23 30 37 2 5 10 24 27 21 25 29 34 33 39 40 3 35 28 6 7 8 9 11 12 13 14 15 16 17 18...

Page 170: ...et 22 and frame 25 17 Remove two socket head screws 19 lock washers 18 and flat washers 17 top and bottom from the hydrostatic pump 38 and bell housing 18 Slide pump 38 away from engine to disengage p...

Page 171: ...ing 37 O Ring 2 2 Trunnion Cover Assembly 14 Lip Seal 26 Retaining Ring 38 Hex Plug 2 3 O Ring 2 15 O Ring 27 Valve Plate 39 O Ring 2 4 Lip Seal 16 Internal Retaining Ring 28 Pin 40 SCR Valve 5 Shim 3...

Page 172: ...safely See Park Mower Safely on page 1 7 2 Remove the front cutting unit on the side where the motor is being removed 3 Remove front wheel See Front Wheels on page 9 19 Figure 5 27 NOTES Label all hy...

Page 173: ...l Apply anti seize compound to the motor shaft threads Be careful not to apply anti seize compound to the motor shaft 20 Tighten castle nut 19 to 332 7 lb ft 450 10 N m Install a new cotter pin 21 in...

Page 174: ...ven screws 3 from the end cover 4 Figure 5 33 NOTE The spacer 9 may remain with the disk valve 6 when the valve housing is removed 3 Remove the end cover assembly 8 and spacer 9 from the disk valve 6...

Page 175: ...nit Do not disassemble the gear wheel set If replacement is necessary replace the entire assembly 9 Remove the gear wheel set 15 from the mounting flange bearing housing assembly 16 Figure 5 36 10 Rem...

Page 176: ...eplace the stator rings 26 if the surfaces are worn or damaged or if any other damage is noted Figure 5 40 15 Inspect the disks for any scratches on the mating surfaces 29 front and rear Replace the d...

Page 177: ...haft assembly 19 Remove the shaft assembly 44 from the bearing housing 42 using a press NOTE Record the orientation of the dust 41 and shaft 43 seals before removing to ensure correct installation 20...

Page 178: ...the inner and outer surfaces of the dust 1 and shaft 3 seals NOTE Install the seals using a seal and driver set and press 2 Install the shaft seal 3 in the bearing housing 2 3 Install the dust seal 1...

Page 179: ...O rings 9 and 10 and install O rings on the brake piston 8 9 Install the brake piston 8 in the mounting flange 12 in the same orientation as recorded during removal Figure 5 50 10 Install the brake d...

Page 180: ...m jelly to O ring 20 and install an O ring in the mounting flange assembly 22 IMPORTANT The motor must be timed correctly Figure 5 53 14 Install the gear wheel set 24 on the mounting flange bearing ho...

Page 181: ...away from the gear wheel set 21 Install an O ring 29 on the valve plate 30 Figure 5 57 NOTE Install the backing rings in the same locations as record during removal 22 Install O ring 34 and two backi...

Page 182: ...of disk valve 42 Figure 5 60 27 Install the disk valve 42 on the valve drive 43 and valve plate 44 28 Install the end cover assembly 45 over the disk valve 42 and valve plate 44 Figure 5 61 29 Instal...

Page 183: ...ee hoses 1 2 and 3 Figure 5 63 4 Remove hydraulic fittings 5 10 and 11 5 Remove four motor mounting nuts 6 bolts 7 and eight washers 8 6 Remove hydraulic motor 4 from bracket 9 Figure 5 64 7 Remove se...

Page 184: ...the flats are not covering set screw 20 hole Apply Locite 242 Blue Thread Sealant to set screw threads 20 before installing set screw Figure 5 67 Before tightening the hose connections 23 24 and 25 po...

Page 185: ...the valve housing 4 Figure 5 70 NOTE The spacer 8 may remain with the disk valve 5 when the valve housing is removed 3 Remove the valve housing assembly 7 and spacer 8 from the channel plate 6 4 Remov...

Page 186: ...hannel plate 18 Figure 5 73 NOTES Do not disassemble the gear wheel set If replacement is necessary replace the entire assembly Record the orientation of all components before removing to ensure corre...

Page 187: ...or stored in a clean environment until assembly Assembly See Figures 5 76 trough 5 86 NOTICE NOTE Always install new seals and O rings for assembly Used parts may leak TN1298 26 29 27 28 TN1306 30 31...

Page 188: ...g 6 in the bearing housing 7 Figure 5 78 6 Install a new O ring 12 in the intermediate plate 11 7 Install the intermediate plate 11 on the bearing housing assembly 9 8 Install cardan shaft 13 in the i...

Page 189: ...ends of the valve drive 17 13 Line up mark on gear wheel set rotor 18 with mark on thinner gear face of valve drive 17 Figure 5 80 14 Install the valve drive 17 in the gear wheel set 19 positioning th...

Page 190: ...r the valve drive 27 Figure 5 84 19 Install alignment pin 29 in valve housing if removed 20 Install new O rings 33 and 34 on the balance plate 28 21 Install balance plate 28 spacer 30 and spring washe...

Page 191: ...5 44 4181384 First Edition HYDROSTATIC POWER TRAIN 5 Figure 5 86 23 Install four screws 39 in the valve housing 40 Tighten screw using an alternating pattern to 55 59 lb ft 75 80 N m TN1294 39 40 39...

Page 192: ...uit Schematic 6 21 Weight Transfer Circuit Schematic and Theory of Operation 6 22 Weight Transfer Circuit Schematic 6 23 Mow Circuit Schematic and Theory of Operation 6 24 Mow Circuit Schematic 6 25 B...

Page 193: ...dem Pump 6 44 Cutting Unit Motor 6 46 Lift Valve 6 46 Flushing Valve 6 48 Mow Brake Valve 6 50 Brake Release Valve 6 52 Hydraulic Filter 6 53 Hydraulic Manifold 6 53 Backlap Valve 6 54 Lift Cylinder 6...

Page 194: ...Pressure Setting AR 3 Model 30002 psi bar 3626 250 Mow Brake Relief Valve Pressure Setting TR 3 psi bar 3046 210 Hydraulic Leakage Percentage Ranges 0 10 Good 11 20 Marginal 21 and Beyond Bad Lift Ste...

Page 195: ...0 Flushing Valve Sequence Valve Torque lb ft N m 37 50 Flushing Valve M5 x 1 00 Diameter Orifice Plug Torque lb ft N m 2 3 Flushing Valve M5 x 0 50 Diameter Orifice Plug Torque lb ft N m 1 7 2 5 Mow B...

Page 196: ...1 Hydraulic Oil Filter 2 Mow and Brake Valve 3 Hydraulic Oil Manifold 4 Tandem Pump Assembly 5 Lift Valve 6 Brake Release Valve 7 Left Front Lift Cylinder 8 Left Front Cutting Unit Drive Motor 9 Right...

Page 197: ...n HYDRAULICS 6 Figure 6 2 Component Location Left Side 1 Flushing Valve 2 Radiator Hydraulic Oil Cooler 3 Rear Center Cutting Unit Drive Motor 4 Rear Center Cutting Unit Lift Cylinder 5 Hydraulic Oil...

Page 198: ...ulic Oil Filter 2 Mow and Brake Valve 3 Hydraulic Oil Manifold 4 Tandem Pump Assembly 5 Lift Valve 6 Brake Release Valve 7 Left Front Cutting Unit Drive Motor 8 Right Front Cutting Unit Drive Motor 9...

Page 199: ...ICS 6 Figure 6 4 Component Location Left Side 1 Flushing Valve 2 Backlap Valve If Equipped 3 Radiator Hydraulic Oil Cooler 4 Rear Center Cutting Unit Lift Cylinder 5 Hydraulic Oil Filter 6 Left Front...

Page 200: ...HYDRAULICS 4181384 First Edition 6 9 6 Page Intentionally Blank...

Page 201: ...fer Solenoid 1 2 363 psi 25 bar Lift Cylinders Lift Valve Steering Cylinder Oil Cooler Cutting Unit Pump 9 6 GPM at 3150 RPM Steering Pump 2 6 GPM at 3150 RPM Hydraulic Oil Tank Lift and Steer Relief...

Page 202: ...Release Valve Hydraulic Oil Filter Front Wheel Motors Rear Wheel Motor Flushing Valve Traction Pump 20 GPM at 3150 RPM Check Valve M2 MP BR DR1 DR M1 CP M1 M2 B A L1 E L2 M3 System Relief Valves 3046...

Page 203: ...ift Valve Steering Valve Steering Cylinder Oil Cooler Cutting Unit Pump 9 6 GPM at 3150 RPM Steering Pump 2 6 GPM at 3150 RPM Hydraulic Oil Tank Lift and Steer Relief Valve 1595 psi 110 bar L R P T E...

Page 204: ...Filter Front Wheel Motors Rear Wheel Motor Flushing Valve Traction Pump 20 GPM at 3150 RPM Check Valve M2 MP BR DR1 DR M1 CP M1 M2 B A L1 E L2 M3 System Relief Valves 3046 psi 210 bar Charge Pressure...

Page 205: ...3150 RPM 2 4 363 psi 110 bar Lift Cylinders Lift Valve Steering Cylinder Oil Cooler Steering Pump 2 6 GPM at 3150 RPM Hydraulic Oil Tank Lift and Steer Relief Valve 1595 psi 110 bar L R P T E L CR T...

Page 206: ...ushing Valve Traction Pump 20 GPM at 3150 RPM Check Valve M2 MP BR DR1 DR M1 CP M1 M2 B A L1 E L2 M3 System Relief Valves 3046 psi 210 bar Charge Pressure Relief 160 psi 11 bar RW1 RW2 PP DR Backlap V...

Page 207: ...valve body and returns to the hydraulic oil tank When the steering cylinder reaches the end of its travel or if the steering mechanism movement is stopped with the steering wheel turned pressure in th...

Page 208: ...action Drive Circuit 2 Return Oil from Raise Lower Circuit 5 Return Oil from Brake Release Valve 3 Operating Pressure Oil to Mow Circuit TN1182 Inlet Oil Operating Pressure Oil Return Oil 1 2 3 Steeri...

Page 209: ...by the steering circuit and oil flows to the primary weight transfer valve in the lift valve With the primary weight transfer valve de energized and the raise valve energized high pressure oil flows...

Page 210: ...re Oil from Steering Circuit TN1183 Operating Pressure Oil Lift Cylinders Lift Valve L CR SP Secondary Weight Transfer Solenoid Primary Weight Transfer Solenoid Lower Raise Oil Cooler Hydraulic Oil Ta...

Page 211: ...ght transfer valve and is directed to the raise lower valve With the raise lower valve in the lower position the pressurized oil unseats the check valve once oil pressure is built against the 0 052 in...

Page 212: ...ering Circuit TN1184 Operating Pressure Oil Metered Oil Return Oil 363 psi 110 bar Lift Cylinders Lift Valve L CR SP Secondary Weight Transfer Solenoid Primary Weight Transfer Solenoid Lower Raise Oil...

Page 213: ...ransfer valve Operating pressure oil is then routed to the check valve closing the valve Operating pressure oil is also routed to the rod side of the lift cylinders placing upward pressure to the lift...

Page 214: ...il from Steering Circuit TN1187 Operating Pressure Oil Return Oil 363 psi 110 bar Lift Cylinders Lift Valve CR SP Secondary Weight Transfer Solenoid Primary Weight Transfer Solenoid Lower Raise Oil Co...

Page 215: ...he right front motor and then to the rear center motor before returning to the mow and brake valve at port M2 Each AR 3 cutting unit motor also has a check valve that is forced closed by the incoming...

Page 216: ...t 2 Charge Pressure Oil to Traction Drive Circuit TN1189 Operating Pressure Oil Charge Pressure Oil Return Oil Cutting Unit Pump Steering Pump Hydraulic Oil Tank Mow and Brake Valve M2 MP BR DR1 DR M1...

Page 217: ...er models Operating pressure oil flows to the pilot line of the cutting circuit relief valve against the check valve in the mow valve closing the relief valve and to the pilot line end of the load con...

Page 218: ...rive Circuit TN1188 Operating Pressure Oil Charge Pressure Oil Return Oil Inlet or Drain Oil Cutting Unit Pump Steering Pump Hydraulic Oil Tank Mow and Brake Valve M2 MP BR DR1 DR M1 CP Load Control V...

Page 219: ...3 from the lift valve body 5 11 Clean and inspect check valve for damage Replace as necessary 12 If lift cylinders continue to drift down remove lift solenoid valve 4 from lift valve body 5 13 Clean...

Page 220: ...seconds 9 Stop the engine and remove the ignition key 10 Measure the amount of oil that flowed from the case drain The amount x 4 amount per minute Is the oil captured from the case drain within a hal...

Page 221: ...d Flow from mow brake valve test 9 gpm 10 9 9 5 x 100 Mow Brake Valve Leakage 5 Left Cutting Unit Motor Test Loaded Flow from mow brake valve test 9 gpm Loaded Flow from left cutting unit motor test 7...

Page 222: ...loaded flow 16 Open flow meter valve 4 and stop engine 17 Calculate cutting unit system leakage Step 14 Step 15 Step 14 x 100 Leak Percentage Is cutting unit system leakage 10 or less YES The cutting...

Page 223: ...er valve until pressure reaches 2300 psi 159 bar Read and record the cutting unit charge pump loaded flow 8 Stop engine 9 Calculate cutting unit charge pump leakage Step 15 of previous test Step 7 Ste...

Page 224: ...C open valve fully after operating temperature is reached 9 Engage cutting unit switch 10 Slowly close flow meter valve 2 until pressure reaches 2300 psi 159 bar Read and record the cutting unit charg...

Page 225: ...t and remove test equipment Install all hoses and fittings as noted prior to removal 15 Check hydraulic oil level Add oil as needed Refer to Safety Operation and Maintenance Manual for correct oil spe...

Page 226: ...fely on page 1 7 2 Before performing this test perform cutting unit system test leaving flow meter connected as outlined 3 Raise seat platform 4 Bypass seat switch Figure 6 28 5 Remove blocking disk f...

Page 227: ...tting unit switch 20 Slowly close flow meter valve 3 until pressure reaches 2300 psi 159 bar Read and record the right cutting unit motor loaded flow 21 Open flow meter valve 3 and stop engine 22 Calc...

Page 228: ...the mower safely See Park Mower Safely on page 1 7 2 Before performing this test perform cutting unit system test leaving flow meter connected as outlined 3 Raise seat platform 4 Bypass seat switch F...

Page 229: ...age cutting unit switch 20 Slowly close flow meter valve 3 until pressure reaches 2300 psi 159 bar Read and record the left cutting unit motor loaded flow 21 Open flow meter valve 3 and stop engine 22...

Page 230: ...al for correct oil specifications Lift Steer System Relief Valve Pressure Test See Figures 6 32 and 6 33 WARNING 1 Operate hydraulic system until oil temperature is at 120 150 F 49 65 C 2 Park the mow...

Page 231: ...aise seat platform 3 Bypass seat switch Figure 6 34 4 Disconnect hose 2 from fitting 1 Figure 6 35 5 Install tee fitting 5 to fitting 1 6 Connect flow meter inlet test hose 6 and hose 2 to tee fitting...

Page 232: ...s Lift Steer Pump Test See Figures 6 34 and 6 35 WARNING 1 Park the mower safely See Park Mower Safely on page 1 7 2 Raise seat platform 3 Bypass seat switch 4 Before performing this test perform lift...

Page 233: ...nect hose to tee fitting 3 Bypass seat switch and raise seat platform Figure 6 36 4 Install blocking disk at fitting 1 on lift valve preventing oil flow from entering lift cylinders Figure 6 37 5 Open...

Page 234: ...ve leakage 11 to 20 YES The lift valve is marginal Repair or replace as needed NO Proceed to next question Is lift valve leakage 21 or more YES Repair or replace lift valve See Lift Valve on page 6 46...

Page 235: ...s with caps or plugs to prevent contamination 4 Disconnect hydraulic hoses 3 5 Support the tandem pump 4 6 Remove mounting bolts 2 and washers 1 7 Remove the tandem pump 4 Installation Notes Install t...

Page 236: ...ove parts and place in assembly order on a clean work area 4 Discard seals as they are removed NOTICE 5 Clean all parts using clean solvent and dry using compressed air 6 Inspect all parts for wear or...

Page 237: ...Disassembly Inspection and Assembly NOTE See Chapter 8 Cutting Units for cutting unit motor service information AR 3 See Deck Drive Motor on page 8 25 TR 3 See Reel Drive Motor on page 8 33 Lift Valv...

Page 238: ...al for oil specifications Start engine and check lift valve operation Check for leaks and repair as necessary Disassembly Inspection and Assembly See Figure 6 42 Figure 6 42 1 Remove inspect and repla...

Page 239: ...g valve 5 from mower NOTE Record the location and orientation of fittings on lift valve to ensure correct installation 5 Remove fittings 3 4 and 9 from flushing valve 5 Installation Notes Install flus...

Page 240: ...n 3 N m Tighten M5 x 0 50 diameter orifice plug 1 to 1 7 lb ft 20 lb in 2 5 N m 1 Orifice Plug 4 Sequence Valve 2 Check Valve 5 Orifice Plug 3 Flushing Valve Block It is important that all components...

Page 241: ...ve mow brake valve 3 from bracket 7 Figure 6 46 NOTE Record the location and orientation of fittings on lift valve to ensure correct installation 6 Remove fitting 14 from mow brake valve 19 7 Remove e...

Page 242: ...N m Tighten hollow hex plugs 5 to 37 lb ft 50 N m 1 Solenoid Coil 2 5 Hollow Hex Plug 2 Relief Valve 6 Hollow Hex Plug 6 3 Brake Solenoid Valve 7 Mow Brake Valve Block 4 Load Control Valve 8 Mow Sole...

Page 243: ...reversing the order of removal Ensure new O rings are in place before installing hoses on fittings Insert orifice disc in proper hose connection Replace hydraulic filter Refill hydraulic tank Refer t...

Page 244: ...ill hydraulic tank Refer to Safety Operation and Maintenance Manual for oil specifications Start engine Check hydraulic filter for leaks and repair as necessary Hydraulic Manifold Removal and Installa...

Page 245: ...nstalling hoses on fittings Replace hydraulic filter Refill hydraulic tank Refer to Safety Operation and Maintenance Manual for oil specifications Start engine and check backlap valve operation Check...

Page 246: ...ydraulic hose fittings 9 from cylinder barrel 3 Installation Notes Install lift cylinder by reversing the order of removal Ensure new O rings are in place before installing hoses on fittings Replace h...

Page 247: ...lvent and dry using compressed air 7 Inspect all parts for excessive wear cracks broken parts and scoring of the cylinder barrel piston and rod Assembly Notes NOTICE Lubricate all parts O rings seals...

Page 248: ...nk drain plug 3 Remove drain plug from bottom of hydraulic oil tank to drain tank Figure 6 54 NOTES Label all hydraulic hoses before disconnecting to ensure correct installation Close all openings wit...

Page 249: ...6 58 4181384 First Edition HYDRAULICS 6 Page Intentionally Blank...

Page 250: ...cifications 7 3 Component Location 7 4 Tests and Adjustments 7 5 Steering Leakage Test 7 5 Steer System Relief Valve Pressure Test 7 6 Repair 7 7 Steering Wheel 7 7 Steering Valve 7 7 Steering Tower 7...

Page 251: ...7 2 4181384 First Edition STEERING 7 Page Intentionally Blank...

Page 252: ...pecifications Test Specifications Steering System Leakage Test Cylinder Leakage pt L Zero Nominal Amount Repair Specifications Steering Wheel Nut Torque lb ft N m 25 34 Steering Cylinder to Rear Wheel...

Page 253: ...Component Location See Figure 7 1 Figure 7 1 1 Steering Unit Pump 2 Steering Tower 3 Steering Column 4 Steering Valve 5 Tilt Bracket 6 Steering Wheel 7 Rear Wheel Support 8 Steering Cylinder TN0991 T...

Page 254: ...l amount of oil or less YES Go to step 10 NO Repair or replace steering cylinder See Steering Cylinder on page 7 10 10 Disconnect and plug hose 3 11 Start the engine and set engine speed to full throt...

Page 255: ...er system relief valve is good Proceed to step 9 NO Replace steering valve See Steering Valve on page 7 7 9 Disconnect and remove test equipment Install all hoses and fittings as noted prior to remova...

Page 256: ...oil resistant thread locker to the threads on the steering column Tighten nut 2 to 25 lb ft 34 N m Steering Valve Removal and Installation See Figures 7 6 through 7 8 1 Park the mower safely See Park...

Page 257: ...ing valve port E 10 10 Disconnect hose 8 from steering valve port T 11 Figure 7 8 11 Remove four socket head screws 14 and lock washers 15 and remove the steering column 16 from the steering valve 21...

Page 258: ...30 Hex Screw 6 M10 x 15 9 x 2 5 Lock Washer 7 M6 Speednut 6 8 Steering Tower Weldment 9 M5 x 12 Countersunk Screw 10 Tilt Spring Actuator 11 Tilt Cable 12 M8 x 25 Carriage Bolt 4 13 M8 Lock Nut 14 Ste...

Page 259: ...heel slightly to allow the screw 2 securing the rod end of the steering cylinder 4 to align with the hole 1 in the wheel pivot weldment 3 Remove nut 5 and lock washer 6 from screw 2 NOTE Record the lo...

Page 260: ...Replace as needed Installation Notes Install the steering cylinder by reversing the order of removal Figure 7 13 Install tighten screw 25 fully into the rear wheel support 28 before installing the nut...

Page 261: ...14 Assembly Notes NOTE Assemble the steering cylinder by reversing the order of disassembly Always install new seals and O rings for assembly used parts may leak Figure 7 19 Install seal 16 in the low...

Page 262: ...ck washer 6 from screw 2 NOTE Record the location of washers before removing to ensure correct installation 6 Remove screw 2 and four flat washers 3 from the rear wheel support 7 and the rod end of th...

Page 263: ...nance Manual for grease specifications 4 Install the Nilos ring 7 over the shaft of the rear wheel support 6 5 Install the rear wheel support 6 in the wheel pivot weldment using a screw 1 lock washer...

Page 264: ...STEERING 4181384 First Edition 7 15 7 Page Intentionally Blank...

Page 265: ...7 16 4181384 First Edition STEERING 7...

Page 266: ...al Troubleshooting TR 3 8 14 Quality of Cut Troubleshooting TR 3 8 15 Repair AR 3 8 25 Rotary Cutting Unit 8 25 Deck Drive Motor 8 25 Cutter Blade 8 28 Front Deck Yoke 8 29 Rear Deck Yoke 8 29 Deck Ca...

Page 267: ...First Edition CUTTING UNITS 8 Specifications Rotary Cutting Units AR 3 Repair Specification Deck Drive Motor Housing to Front Cover Screw Torque lb ft N m 37 50 Cutter Blade Retaining Screw Torque lb...

Page 268: ...3 8 Component Location AR 3 See Figure 8 1 Figure 8 1 1 Rear Center Cutting Unit 2 Left Front Cutting Unit 3 Right Front Cutting Unit 4 Drive Motor 5 Deck Roller 6 Yoke 7 Deck Frame 8 Caster Wheels 2...

Page 269: ...3 See Figure 8 2 Figure 8 2 1 Rear Center Cutting Unit 2 Left Front Cutting Unit 3 Right Front Cutting Unit 4 Yoke Assembly 5 Front Roller 6 Cutting Reel 7 Drive Motor 8 Rear Roller 9 Bedknife Shoe As...

Page 270: ...eat before engaging mower Cutting unit s do not lower completely to ground Cutting unit s movement is restricted Check remove cutting unit restriction Lift lower circuit is faulty Test lift lower circ...

Page 271: ...n area should be available where test cuts can be made This area should provide known and consistent turf conditions to allow accurate evaluation of the mower s performance Another test cut should be...

Page 272: ...iations in the turf Probable Cause Remedy Mowing ground speed is too fast Reduce mowing ground speed Grass build up on roller Clean the roller and scraper Roller is out of round Replace roller See Dec...

Page 273: ...cutting units Refer to Safety Operation and Maintenance Manual Worn roller bearings or deck caster wheels Check replace roller bearings See Deck Roller on page 8 31 and or deck caster wheels See Deck...

Page 274: ...rown patch This is usually caused by an excessively low height of cut setting and or uneven turf Probable Cause Remedy HOC height of cut settings are lower than normal Check and adjust the HOC setting...

Page 275: ...ttered blades of uncut or poorly cut grass Probable Cause Remedy Dull cutting blade s Sharpen blade s Refer to Safety Operation and Maintenance Manual Mowing ground speed is too fast Reduce mowing gro...

Page 276: ...e s See Cutter Blade on page 8 28 Turning too aggressively Cutting units don t overlap during turns or on side hills Turn less aggressively to allow cutting units to overlap Change mowing direction or...

Page 277: ...at one end of cutting unit s or between cutting units forming line s in the direction of travel Probable Cause Remedy Grass is too tall Mow more often Mowing while grass is wet Mow when grass is dry G...

Page 278: ...o another Check adjust HOC on cutting units to same height Refer to Safety Operation and Maintenance Manual Check condition of deck and or frame Repair or replace as needed Difference in rotary cuttin...

Page 279: ...Cutting unit s movement is restricted Check remove cutting unit restriction Lift lower circuit is faulty Test lift lower circuit See Symptom Lower solenoid does not energize on page 4 55 Cutting unit...

Page 280: ...ea should provide known and consistent turf conditions to allow accurate evaluation of the mower s performance Another test cut should be performed after the completion of the repairs and or adjustmen...

Page 281: ...use Remedy Mowing ground speed is too fast Reduce mowing ground speed Grass build up on roller Clean the roller and use scrapers or brushes Roller is out of round Replace roller See Front Roller on pa...

Page 282: ...conditions Check adjust HOC to turf conditions Refer to Safety Operation and Maintenance Manual Cutting reel diameter is worn Check cutting reel diameter and replace if worn below minimum diameter Ref...

Page 283: ...Maintenance Manual Worn front roller bearings Check replace front roller bearings See Front Roller on page 8 42 Reel to bedknife contact is different from one side of the cutting unit to the other or...

Page 284: ...ut HOC setting and or uneven turf Probable Cause Remedy HOC height of cut settings are lower than normal Check adjust the HOC settings Refer to Safety Operation and Maintenance Manual Improper reel to...

Page 285: ...adjusted Adjust reel to bedknife setting Refer to Safety Operation and Maintenance Manual Dull reel or bedknife cutting edges Sharpen or replace reel blade and bedknife as necessary See Reel Blade on...

Page 286: ...Blade on page 8 41 Loose or missing bedknife fasteners Check bedknife screws Tighten loose screws replace missing screws See Bedknife on page 8 37 Turning too aggressively Cutting units don t overlap...

Page 287: ...cutting unit s or between two cutting units forming a line in the direction of travel Probable Cause Remedy Grass is too tall Mow more often Mowing while grass is wet Mow when grass is dry Grass built...

Page 288: ...t points across a reel and or bedknife Probable Cause Remedy Reel and or bedknife unevenly worn Inspect bedknife and reel Sharpen or replace reel blade and bedknife as necessary See Reel Blade on page...

Page 289: ...cutting unit to another Probable Cause Remedy HOC inconsistent from one cutting unit to another Check adjust HOC on cutting units Refer to Safety Operation and Maintenance Manual Difference in mower r...

Page 290: ...ot shaft 13 6 Roll cutting unit 12 forward and slide deck yoke 8 forward until it clears the lift arm pivot shaft 13 Retain lift arm shaft bushings inside deck yoke 8 Installation Notes Install the cu...

Page 291: ...bolts 4 from the deck motor 1 8 Remove the deck motor 1 Installation Notes Install deck drive motor by reversing the order of removal Install the motor on the deck making sure that it is in proper or...

Page 292: ...ressed air 1 Support Shaft 7 Shaft Seal 13 Screw 4 19 Seal 2 2 Sleeve Bearing 8 Sleeve Bearing Holder 14 Pump Body 20 Thrust Plate 3 Retaining Ring 9 Seal 2 15 Check Valve Body 21 Dowel Pin 2 4 Shaft...

Page 293: ...steps to a final torque of 37 lb ft 50 N m Cutter Blade Removal and Installation See Figure 8 8 1 Park the mower safely See Park Mower Safely on page 1 7 2 Raise and support the cutting units Refer t...

Page 294: ...om the deck yoke 11 and the outer side of the cutting unit frame Figure 8 11 Inner Side of Cutting Unit 6 Remove screws 19 flat washers 18 deck pivot 16 and bushing 15 from frame bracket 17 from inner...

Page 295: ...Apply grease on lift arm pivot shaft bushings and lift arm pivot shaft before installation Refer to Safety Operation and Maintenance Manual for grease specifications Deck Caster Wheels Removal Inspect...

Page 296: ...4 Remove three snap ring lock pins 2 and spacers 4 from cutting height spindles 3 of cutting unit frame 5 5 Lift mower deck 1 up and away from cutting unit frame 5 Installation Note Install the mower...

Page 297: ...he roller by reversing the order of removal Disassembly Inspection and Assembly See Figure 8 21 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove deck roller from cutting unit See Dec...

Page 298: ...ng 7 5 Disconnect hose 9 from elbow fitting 10 6 Disconnect hose 11 from motor OUT port NOTE Record the location of fittings before removing to ensure correct installation 7 Remove fitting 8 from moto...

Page 299: ...eight flat washers 5 and remove the rear cover 4 from the pump housing 3 4 Remove seal 9 backing seal 8 and thrust plate 10 from the pump housing 3 5 Remove retaining ring 17 from drive shaft 7 6 Remo...

Page 300: ...eals and O rings during assembly used parts may leak Assemble the reel motor by reversing the order of disassembly When installing the drive shaft 7 and driven gear 11 match the mating gear teeth usin...

Page 301: ...n Notes Install the cutting unit by reversing the order of removal Inspect O rings on fittings before installation Replace O rings if damaged or missing Use a new gasket for installation Apply grease...

Page 302: ...ct Refer to Safety Operation and Maintenance Manual Bedknife Removal and Installation See Figure 8 33 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove the bedknife shoe assembly See...

Page 303: ...8 4181384 First Edition CUTTING UNITS 8 Reel Bearing Housing Assemblies Removal and Installation Drive Side See Figure 8 34 Figure 8 34 TN1269 1 2 3 6 5 4 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23...

Page 304: ...der bolt 23 CAUTION 11 Rotate the bearing housing 18 up so that the shoulder bolt 23 is at the top of the adjustment slot 22 and remove the shoulder bolt from the bearing housing 18 and cutting unit f...

Page 305: ...23 and spacer 24 from reel shaft 5 NOTE Do not remove bearing cone 26 unless it is necessary to replace the bearing 25 Always replace the bearing and bearing cone as a set 5 Remove bearing 25 from be...

Page 306: ...nd Maintenance Manual Reel Blade Removal Inspection and Installation See Figure 8 36 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove bedknife shoe assembly See Bedknife Shoe on page...

Page 307: ...Figure 8 39 NOTE Record location of roller bracket hardware to ease assembly 7 Remove screw 9 nut 10 and lock washer 11 from roller bracket 8 8 Remove screw 12 nut 13 lock washer 14 and flat washer 1...

Page 308: ...t 4 5 Rotary Lip Seal 2 9 Seal Ring 2 13 Grease Fitting 2 2 Shield 2 6 Spring 2 10 Taper Roller Bearing 2 14 Shaft 3 Seal Journal 2 7 Washer 2 11 O Ring 4 15 Plain Roller 4 Bearing Housing 2 8 Ring Ca...

Page 309: ...t See Cutting Unit on page 8 36 Figure 8 42 3 Remove two socket head cap screws 1 and lock washers 2 4 Remove skid 3 from cutting unit Figure 8 43 NOTE Record location of roller bracket hardware 5 6 a...

Page 310: ...bly Removal and Installation See Figures 8 45 and 8 46 1 Park the mower safely See Park Mower Safely on page 1 7 2 Remove the cutting unit See Cutting Unit on page 8 36 Figure 8 45 3 Remove two one ea...

Page 311: ...8 46 4181384 First Edition CUTTING UNITS 8 Page Intentionally Blank...

Page 312: ...aneous Repair Specifications 9 2 Repair Specifications 9 2 Component Location 9 3 Repair 9 4 Canopy 9 4 OPS 9 4 Hood 9 6 Fuel Tank 9 6 Traction Pedal 9 10 Traction Pedal Damper 9 12 Seat and Mounting...

Page 313: ...ounting Hardware Torque lb ft N m 34 46 M12 Mounting Hardware Torque lb ft N m 58 79 Front Tires Size 20 x 12 00 10 Type Turf Trac 4 Ply Air Pressure psi kPa 14 20 97 138 Mounting Bolt Torque lb ft N...

Page 314: ...n 9 3 9 Component Location Figure 9 1 Component Location AR 3 Shown 1 Canopy Optional 2 Seat and Seat Platform 3 Fuel Tank 4 Traction Pedal 5 Work Lights Optional 6 Traction Pedal Damper 7 Front Wheel...

Page 315: ...the two rear nuts 4 screws 5 and four washers 6 5 Remove the canopy 2 Installation Notes Center the canopy before tightening the mounting hardware Install the canopy by reversing the order of removal...

Page 316: ...ssembly Figure 9 7 Figure 9 8 6 Remove two M10 lock nuts 5 screws 6 and four flat washers 7 from the top of the bracket on each side of the OPS assembly 7 Remove the OPS assembly Installation Notes In...

Page 317: ...hers 3 Figure 9 10 4 Remove the hood 4 Installation Note Install the hood by reversing the order of removal Fuel Tank Removal and Installation See Figures 9 11 through 9 16 CAUTION 1 Park the mower sa...

Page 318: ...drain plug 3 and allow fuel to drain into container 7 Replace the fuel filler cap 1 and drain plug 3 8 Remove screw 4 lock washer 5 and flat washer 6 from fuel tank 2 Figure 9 13 9 Support the fuel ta...

Page 319: ...installation 12 Loosen hose clamp 19 and disconnect the return hose 18 from the fuel sender 15 13 Loosen hose clamp 16 and disconnect the supply hose 17 from the fuel sender 15 Figure 9 16 NOTE One fl...

Page 320: ...el sender 9 gasket 10 and collar 8 before removing to ensure correct installation Inspect fuel tank 2 for wear or damage Replace as needed Assembly Notes Install new gasket 10 Install new O ring 3 1 F...

Page 321: ...l assembly 3 Figure 9 19 4 Remove lock nut 9 screw 7 and three flat washers 8 and disconnect rod end 5 from pedal weldment 6 Figure 9 20 5 Remove two lock nuts 10 flat washers 11 and carriage bolts 12...

Page 322: ...to Safety Operation and Maintenance Manual for grease specifications Pedal Assembly See Figure 9 23 Figure 9 23 Assembly Note DO NOT overtighten lock nut 4 the mow speed stop bracket must be able to...

Page 323: ...eplacing the damper assembly Figure 9 25 5 Measure and record the distance 8 between the face of the damper and the end of the rod end 6 Loosen the jam nut 10 and remove the rod end 9 7 Remove the jam...

Page 324: ...gure 9 29 NOTE The end cap is a tight fit To aid in removal place a length of metal tubing or a deep well socket over the piston rod and against the face of the end cap and tap with a hammer to dislod...

Page 325: ...igures 9 32 through 9 39 Figure 9 32 NOTE Install the reaction sleeves in the same orientation as recorded during removal 1 Install the reaction sleeve 2 inner 6 and outer 7 springs reaction sleeve 5...

Page 326: ...n the piston rod until the assembly bottoms in the cylinder Release pressure on the rod and allow the piston assembly to find its free position Figure 9 35 7 Install new O rings 12 and 13 on the end c...

Page 327: ...1 7 2 Raise and support the seat platform Figure 9 40 3 Disconnect the seat switch wiring harness 7 from the machine harness 6 4 Support the seat 1 5 Remove four lock nuts 4 and flat washers 5 6 Remo...

Page 328: ...from the seat frame 20 13 Remove the seat cushion 18 routing the seat switch wiring harness 19 through the seat frame 20 Figure 9 44 14 Disconnect the wiring harness 22 from the seat switch 21 Figure...

Page 329: ...rk lights to project the desired distance in front of the mower before tightening the lock nuts 4 Rear Wheel Removal and Installation See Figure 9 48 WARNING 1 Park the mower safely See Park Mower Saf...

Page 330: ...he left wheel See Rotary Cutting Unit on page 8 25 or Removal and Installation on page 8 36 2 Loosen but do not remove the four bolts 1 3 Lift the mower using a suitable lifting device 4 Remove four b...

Page 331: ...9 20 4181384 First Edition ACCESSORIES AND MISCELLANEOUS REPAIR 9 Page Intentionally Blank...

Page 332: ...ake Solenoid Coil Removal and Installation 4 85 Test 4 68 C Canopy Removal and Installation 9 4 Charging Circuit Schematic Electrical 4 25 Theory of Operation Electrical 4 24 Troubleshooting 4 51 Chem...

Page 333: ...stallation 8 45 D Deck Drive Motor AR 3 Disassembly and Assembly 8 27 Removal and Installation 8 25 Deck Roller AR 3 Disassembly Inspection and Assembly 8 32 Removal and Installation 8 31 Diagnostic I...

Page 334: ...lation 9 6 Hydraulic Component Location AR 3 6 5 Component Location TR 3 6 7 Repair 6 44 Schematic AR 3 Model AR30001 6 10 Schematic AR 3 Model AR30002 6 12 Schematic TR 3 6 14 Specifications 6 3 Test...

Page 335: ...Symbols 4 7 Mow Circuit Schematic Electrical 4 39 Schematic Hydraulic 6 25 Theory of Operation Electrical 4 38 Theory of Operation Hydraulic 6 24 Troubleshooting 4 56 Mow Solenoid Coil Removal and Ins...

Page 336: ...l Removal and Installation 9 18 Rear Wheel Motor Assembly 5 40 Disassembly 5 38 Removal and Installation 5 36 Rear Wheel Support Installation 7 14 Removal 7 13 Reel Bearing Housing Assemblies TR 3 Rem...

Page 337: ...rcuit 4 18 Raise Lower Circuit 4 37 Run Circuit Off Seat 4 35 Run Circuit On Seat 4 34 Start Circuit 4 31 Weight Transfer Circuit 4 46 Work Light Circuit 4 49 Schematic Hydraulic Backlap Circuit TR 3...

Page 338: ...3 17 Tires Service Safety 1 9 Torque Values Standard Inch Fastener Torque Values 2 13 Metric Fastener Torque Values 2 13 TR 3 Component Location 2 5 Traction Circuit Forward Schematic Hydraulic 5 5 T...

Page 339: ...ht Removal and Installation 9 18 Work Light Circuit Schematic Electrical 4 49 Theory of Operation Electrical 4 49 Troubleshooting 4 59 Work Light Switch Removal and Installation 4 80 Test 4 66 Y Yoke...

Page 340: ......

Page 341: ...ipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technicians back...

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