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3-44

4271491-Second Edition

GENSET AND BATTERY PACK

Battery Charger

Removal and Installation

See Figure 3-73.

Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

Raise the hood.

Figure 3-73

NOTE

Label all wires before disconnecting to ensure correct
installation.

TN4555

Summary of Contents for Eclipse 322 62800

Page 1: ...Eclipse 322 Riding Greens Mower Technical Repair Manual 62800 62801 62802 62803 62804 62805 62825 62826 Second Edition...

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Page 3: ...proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine 2012 Jacobsen A Textron Company All rights reserved When Performan...

Page 4: ......

Page 5: ...nual 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 ANY OF THIS...

Page 6: ...hese tools 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 specific...

Page 7: ...2 3 4 5 6 7 Table of Contents 4271491 Rev A 7 1 Safety Specifications and General Information Genset and Battery Pack Electrical Chassis Cutting Units Accessories and Miscellaneous Repair...

Page 8: ......

Page 9: ...6 Use Proper Eye and Face Protection 1 6 Park Mower Safely 1 6 Use Lifting Equipment Safely 1 7 Support Machine Securely 1 7 Use Compressed Air and Air Tools Safely 1 8 Service Tires Safely 1 8 Handle...

Page 10: ...n get hot during operation Be sure to allow enough time for components to cool before beginning service Prepare proper work space lighting A well lit work area can make the job easier Follow procedure...

Page 11: ...dition 1 3 1 Safety Label Locations Become familiar with machine safety labels and locations The following illustrations show safety label locations on the machine See Figure 1 1 Figure 1 1 10 11 8 3...

Page 12: ...1 4 4271491 Second Edition SAFETY 1 6 7 105dB LWA 4181861 4181860 4181862 5 2 4 3 1 4216820 Rev A...

Page 13: ...SAFETY 4271491 Second Edition 1 5 1 9 41 8 1 8 64 8 4127335 10 4181865 11...

Page 14: ...s to offer a higher level of protection when sparks and flying debris are present Vented Goggles Goggles offer side protection not offered by safety glasses alone Unvented Goggles Unvented goggles off...

Page 15: ...he load When using a lifting device always connect the load so it is balanced Always use a lifting device on a hard level surface Lower the lifting device to the lowest point before moving Move the lo...

Page 16: ...en dismounting or mounting tires use a wheel holder or tire machine Use proper tire mounting tools and equipment Never use screwdrivers or makeshift tools to force a tire on or off a wheel Be sure tir...

Page 17: ...edures Contact the chemical manufacturer to obtain an MSDS for the chemical product Service Cooling System Safely WARNING WARNING Always dispose of used engine coolant properly See Dispose of Waste Ma...

Page 18: ...ls known to the State of California to cause cancer and reproductive harm Wash your hands after handling The electrolyte in a storage battery is a dilute acid which can cause severe burns to the skin...

Page 19: ...storage container Never use food or beverage containers to store waste fluids IMPORTANT Dispose of waste fluids properly at approved local recycling centers If recycling facilities are not available...

Page 20: ...1 12 4271491 Second Edition SAFETY 1...

Page 21: ...Engine Serial Number Diesel Models 2 2 Engine Identification Number Gasoline Models 2 3 Optional Machine Accessories 2 3 Component Location 2 4 All Models 2 4 Electric Models 2 6 Specifications 2 7 Q...

Page 22: ...or requesting service information Engine Serial Number Diesel Models See Figure 2 3 Figure 2 3 The engine serial number 1 is attached to the top of the rocker arm cover The plate also includes the en...

Page 23: ...tification number 1 is located on the side of the engine and identifies the engine model 2 type 3 and code number 4 Optional Machine Accessories This manual is structured to cover all basic machine co...

Page 24: ...Right Side Become familiar with operator controls machine components and correct operating procedures before beginning repair procedures 1 OPS 5 Steering Tower 9 Front Wheel 2 2 Seat 6 Traction Pedal...

Page 25: ...2 5 2 Figure 2 6 Component Location Left Side 1 Brake Pedal Assembly 4 Rear Axle Assembly 7 Front Axle Assembly 2 Steering Chain and Gear 5 Starter Battery 8 Left Cutting Unit 3 Rear Wheel 6 Buffer B...

Page 26: ...2 6 4271491 Second Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Electric Models Figure 2 7 Component Location Left Side 1 Battery Charger 2 Battery Filling System 3 Battery Pack TN2311 3 1 2...

Page 27: ...e x Stroke in mm 2 64 x 2 68 67 x 68 Power Output hp kW 13 3 9 9 3600 rpm Cooling System liquid cooled Cooling System Capacity qt L 3 2 8 Speed Range 950 3600 rpm Lubrication Capacity With Filter qt L...

Page 28: ...orque Diesel Models lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Generator Assembly Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Throttle Act...

Page 29: ...Fuel Shutoff Hold In Coil at 68 F 20 C Diesel Modes ohms 10 10 Resistance Across Fuel Shutoff Coil at 68 F 20 C Gasoline Models ohms 40 10 Resistance Across Throttle Actuator Coil at 68 F 20 C Diesel...

Page 30: ...N m 53 6 3WD Traction Controller Wire Connection Screw Torque lb in N m 53 6 Contactor Nut 4 Torque See page 4 167 lb in N m 35 4 Contactor Nut 5 Torque See page 4 167 lb in N m 15 1 7 Fuse Mounting F...

Page 31: ...span of chain Repair Specifications Front Wheel Hub Castle Nut Torque lb ft N m 95 115 10 7 13 0 Front Axle Assembly Mounting Screw Torque lb ft N m 65 88 Front Axle Assembly Axle Housing Face to Axl...

Page 32: ...0 25 4 Reel Leveling Rod Rod End to Collar Face Measurement spring side in mm 5 250 133 4 Reel Leveling Rod Rod End to Nut Face Measurement spring side in mm 0 125 3 2 Repair Specifications Reel Motor...

Page 33: ...Shaft to Bearing Rotational Resistance lb in N m 0 1 0 0 11 with No End Play Grooved Front Roller Assembly Rotational Resistance lb in N m 6 0 68 Maximum with No End Play Grooved Disc Roller Assembly...

Page 34: ...rooved Machined Steel Roller PN 068613 lb kg 18 8 16 22 Inch Grooved Machined Aluminum Roller PN 068614 lb kg 8 3 63 Weights Working Weight Less Operator Model 62800 3WD Electric lb kg 1697 770 Model...

Page 35: ...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 36: ...2 16 4271491 Second Edition SPECIFICATIONS AND GENERAL INFORMATION 2...

Page 37: ...esel Models 3 13 Air Filter Assembly Diesel Models 3 14 Muffler Diesel Models 3 15 Alternator Diesel Models 3 16 Radiator Diesel Models 3 17 Thermostat Diesel Models 3 19 Throttle Actuator Diesel Mode...

Page 38: ...d Edition GENSET AND BATTERY PACK 3 Repair Batteries 3 39 Battery Pack Battery Pack Tray and Battery Filling System 3 39 Buffer Battery Pack and Buffer Battery Pack Tray 3 42 Starter Battery 3 43 Batt...

Page 39: ...67 x 68 Power Output hp kW 13 3 9 9 3600 rpm Cooling System liquid cooled Cooling System Capacity qt L 3 2 8 Speed Range 950 3600 rpm Lubrication Capacity With Filter qt L 3 4 3 2 Alternator 12 volt 4...

Page 40: ...8 11 3 Genset Carrier Mounting Screw Torque Diesel Models lb ft N m 65 0 88 0 Coupling Shaft Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Mode...

Page 41: ...PACK 4271491 Second Edition 3 5 3 Component Location Diesel Models See Figures 3 1 and 3 2 Figure 3 1 Component Location Right Side 1 Fuel Tank 2 Muffler 3 Throttle Actuator 4 Fuel Filter 4 2 TN2436...

Page 42: ...ottle 13 Fan Belt 2 Air Cleaner Assembly 8 Fuel Shutoff Solenoid 14 Oil Pressure Switch 3 Radiator 9 Oil Fill Cap 15 Genset 4 12 Volt Connector 10 Thermostat 16 Starter Motor 5 Buffer Battery Pack 11...

Page 43: ...4271491 Second Edition 3 7 3 Gasoline Models See Figures 3 3 and 3 4 Figure 3 3 Component Location Right Side 1 Fuel Tank 3 Throttle Actuator 5 Oil Filter 2 Muffler 4 Oil Pressure Switch 6 Genset 4 3...

Page 44: ...ACK 3 Figure 3 4 Component Location Left Side 1 48 Volt Connector 4 Buffer Battery Pack 7 Oil Fill Cap 2 Air Cleaner Assembly 5 Starter Battery 8 Fuel Filter 3 12 Volt Connector 6 Oil Dipstick 9 Start...

Page 45: ...GENSET AND BATTERY PACK 4271491 Second Edition 3 9 3 Electric Models See Figure 3 5 Figure 3 5 Component Location 1 Battery Filling System 2 48 Volt Connector 3 Battery Pack 3 TN2804 1 2...

Page 46: ...se two turns Place a suitable container under the filter to catch the fuel that will flow from the screw hole 4 Turn the ignition switch to the on position to allow the fuel pump to operate 5 When the...

Page 47: ...wer safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 3 9 NOTES Manually retract and extend the actuator shaft checking for smooth operation throughout the entire range of motion If the...

Page 48: ...tor movement Verify full stroke of the actuator Replace actuator as necessary 3 Disconnect engine throttle linkage 2 and spring 3 from throttle link 1 Pull engine throttle linkage 2 away from engine u...

Page 49: ...tor 2 toward the engine to loosen the fan belt 1 Figure 3 12 4 Remove fan belt 1 from the alternator 2 coolant pump 5 and crankshaft pulley 4 Installation 1 Install fan belt by reversing the order of...

Page 50: ...tion purposes note orientation of air inlet 3 before removing the air filter dust cap 1 3 Release retaining clips 2 and remove the air filter dust cap 4 Using damp lint free cloths thoroughly clean th...

Page 51: ...ler clamp and hardware 5 from exhaust pipe 6 6 Remove four nuts 3 and lock washers 4 7 Remove muffler 7 from exhaust manifold 2 8 Inspect the exhaust system for cracks holes and distortion Replace exh...

Page 52: ...harness aside to provide clearance for alternator removal Figure 3 18 4 Disconnect wire connector 7 5 Remove nut 8 lock washer 9 and wire connector 10 6 Loosen screws 12 and 15 push the alternator 11...

Page 53: ...er NOTE Label all hoses before removing to ensure correct installation Figure 3 19 7 Loosen hose clamp 5 and remove lower radiator hose 6 from radiator 8 Remove screws 1 lock washers 2 flat washers 3...

Page 54: ...hose removed from radiator flush the inside of the radiator with fresh water 2 Install radiator by reversing the order of removal CAUTION 3 Fill radiator with a 50 50 mixture of good quality ethylene...

Page 55: ...3 24 8 Remove two screws 7 two lock washers 8 and bracket 9 9 Remove thermostat housing 6 gasket and thermostat Installation Notes Install thermostat by reversing the order of removal Clean gasket su...

Page 56: ...er of removal Apply Loctite 242 Blue to two governor linkage arm nuts 8 prior to assembly Tighten governor linkage arm nuts 32 to 40 lb in 4 5 N m Adjust throttle actuator linkage See Throttle Actuato...

Page 57: ...bottoms lightly 12 Plug fuel hose 4 to prevent leakage and contamination Figure 3 28 13 Loosen hose clamps 6 and remove air intake hose 15 14 Cut cable tie 14 15 Tag and disconnect wire connector 12 1...

Page 58: ...an the inside and outside of filter head 2 Lightly lubricate O rings 6 and 7 with clean oil Install fuel filter by reversing the order of removal Tighten cup retaining nut 3 hand tight Open fuel shuto...

Page 59: ...of removal Inspect the fuel pump gasket for any damage and replace if necessary Fuel Shutoff Solenoid Diesel Models Removal and Installation See Figures 3 31 and 3 32 1 Park the mower safely See Park...

Page 60: ...ressure switch and glow plug Figure 3 33 8 Tag and disconnect genset to main harness connectors 1 and 2 9 Tag and disconnect throttle actuator connector 4 10 Cut cable ties 3 Figure 3 34 11 Tag and di...

Page 61: ...ne harness to main harness connectors 19 and 20 Figure 3 39 22 Turn the fuel outlet hose shutoff valve clockwise until valve bottoms lightly Valve is located on the bottom of the fuel tank 23 Remove f...

Page 62: ...ake hose 31 Figure 3 41 30 Disconnect overflow hose 37 and secure out of the way 31 Remove two screws 33 lock washers 34 and flat washers 35 32 Remove air cleaner bracket assembly 32 33 Remove radiato...

Page 63: ...lug hose to prevent leakage and contamination 45 Remove nuts 56 screws 57 and radiator overflow bottle 60 WARNING 46 Using an engine hoist support the genset 59 and remove nuts 54 and genset carrier m...

Page 64: ...installation Tighten genset carrier mounting screws 55 to 65 0 lb ft 88 N m Use new gaskets when installing the exhaust system Use new cable ties to secure wire connectors and wire harnesses Apply di...

Page 65: ...nge 13 L S Engine Mount 22 Screw 2 31 Screw 40 Hose Clamp 2 5 Blind Coupling 14 Screw 8 23 R S Engine Mount 32 Nut 2 41 Hose 6 Screw 5 15 Isolation Mount 2 24 Nut 2 33 Governor Linkage Arm 42 Lock Was...

Page 66: ...rior to assembly Tighten six generator flange mounting screws 43 to 13 0 lb ft 17 6 N m Apply Loctite 242 Blue to four generator assembly mounting screws 34 prior to assembly Tighten four generator as...

Page 67: ...s oil in a clean absorbent cloth Replace air filter pre cleaner if it remains dirty or is damaged Do not use petroleum solvents such as kerosene to clean air filter cartridge Do not use pressurized ai...

Page 68: ...3 49 4 Rotate clip 5 on throttle plate and disengage engine throttle linkage 2 5 Disengage engine throttle linkage 2 from throttle link 1 6 Disengage spring 3 from hook 6 on throttle plate 7 Remove sp...

Page 69: ...p to provide a vent for draining fuel 8 Open the fuel shutoff valve 1 at the bottom of the fuel tank 9 When fuel tank is completely empty tighten fuel cap 10 Close fuel shutoff valve 1 Turn clockwise...

Page 70: ...the order of removal Make sure the flow arrow on the side of the fuel filter is aligned with the fuel tank to fuel pump flow direction Genset Gasoline Models Removal and Installation See Figures 3 55...

Page 71: ...arefully guide the cables away from the PDU and position the cables to be unrestricted during genset removal Figure 3 57 18 Tag and disconnect the generator negative output cable 8 from ground stud 9...

Page 72: ...om the genset Figure 3 60 26 Remove four screws 18 and nuts 20 and remove fuel tank bracket 19 Figure 3 61 27 Remove four screws 21 and flat washers 22 and remove rear controller cover 23 Figure 3 62...

Page 73: ...See the Parts and Maintenance Manual for additional information and illustrations Installation Notes I Inspect engine mounts and replace if necessary Install the genset by reversing the order of remov...

Page 74: ...rew 19 Gas Throttle Link 27 Screw 8 35 Screw 8 4 Nut 4 12 Flat Washer 20 Gas Throttle Actuator 28 Screw 9 36 Screw 5 O Ring 13 Hose Clamp 2 21 Screw 4 29 Engine Plate 6 Screw 4 14 Air Cleaner Stud 22...

Page 75: ...to assembly Tighten engine coupler screw 16 to 32 lb ft 43 4 N m Engine Service Gasoline Models A separate engine manual prepared by the engine manufacturer is supplied with this machine Refer to the...

Page 76: ...akage and contamination 12 Remove upper tray mat 19 Figure 3 67 13 Remove screw 21 nut 22 and battery bracket 20 Figure 3 68 NOTE Direction of arrow indicates front of machine 14 Disconnect battery ca...

Page 77: ...25 and screws 26 22 Repeat step 21 for other side of machine 23 Remove battery pack tray 27 NOTICE Installation Note Install battery pack battery pack tray and battery filling system by reversing the...

Page 78: ...ove two screws 13 flat washers 12 lock washers 11 and nuts 110 10 Remove buffer battery pack tray 14 Installation Notes Install buffer battery pack and buffer battery pack tray by reversing the order...

Page 79: ...Notes Install starter battery by reversing the order of removal Route battery cables between the starter battery and the machine avoiding pinch points Be sure that the key switch is off all electrica...

Page 80: ...PACK 3 Battery Charger Removal and Installation See Figure 3 73 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 3 73 NOTE Label all wires before disconnecting to ensu...

Page 81: ...ger 3 Installation Notes Install battery charger by reversing the order of removal Route battery charger cables between the battery pack and the machine avoiding pinch points Be sure that the key swit...

Page 82: ...3 46 4271491 Second Edition GENSET AND BATTERY PACK 3...

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