Jacobsen Eclipse 322 Repair Manual Download Page 329

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INDEX

4222983 First Edition

IX-11

Steering Yoke

Removal and Installation . . . . . . . . . . . . . . .

5-11

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11

Switches

Component Symbols . . . . . . . . . . . . . . . . . . .

4-9

Switching Devices

Component Symbols . . . . . . . . . . . . . . . . . . .

4-9

System Diagnostic Trouble Codes

12 Volt System Low . . . . . . . . . . . . . . . . . . .

4-95

48 Volt System High . . . . . . . . . . . . . . . . . .

4-95

48 Volt System Low . . . . . . . . . . . . . . . . . . .

4-95

Low Fuel Warning . . . . . . . . . . . . . . . . . . . .

4-95

Oil pressure Alarm . . . . . . . . . . . . . . . . . . . .

4-94

Temperature High Alarm . . . . . . . . . . . . . . .

4-94

TCU

Removal and Installation . . . . . . . . . . . . . .

4-142

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-142

TCU Fan

Removal and Installation . . . . . . . . . . . . . .

4-141

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-141

Temperature High Alarm

System Diagnostic Trouble Codes . . . . . . . .

4-94

Test

150A and 300A Fuses . . . . . . . . . . . . . . . .

4-127

3WD Fault 4310 and 4210 . . . . . . . . . . . . . .

4-82

3WD Fault 7310 . . . . . . . . . . . . . . . . . . . . . .

4-82

Accessory Socket Fuse . . . . . . . . . . . . . . .

4-128

Brake Coil . . . . . . . . . . . . . . . . . . . . . . . . .

4-133

Brake Pedal Switch . . . . . . . . . . . . . . . . . .

4-132

Circuit Breakers . . . . . . . . . . . . . . . . . . . . .

4-127

Extremely Slow Traction, No Fault . . . . . . . .

4-80

Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . .

4-128

Fault

48 Volt System Low or Short Run Time – All

Electric Units Only . . . . . . . . . . . .

4-74

Actuator Fault/Short Circuit . . . . . . . . . . .

4-78

Check Actuator . . . . . . . . . . . . . . . . . . . . .

4-79

Check Reel . . . . . . . . . . . . . . . . . . . . . . . .

4-77

Engine RPM Does Not Increase With Load

Changes – Gas and Diesel Hybrid Units
Only . . . . . . . . . . . . . . . . . . . . . . .

4-75

Engine RPM Fluctuates (Hunting) – Gas and

Diesel Hybrid Units Only . . . . . . .

4-75

Miniscule Change in Steering Angle without

Operator Input (Ghost Steering) .

4-83

Traction Surge or Hesitation During Mow

4-80

Vehicle Will Not Start – Gas and Diesel Hybrid

Units Only . . . . . . . . . . . . . . . . .

4-74

Fuel Shutoff Solenoid (Diesel) . . . . . . . . .

4-133

Fuel Shutoff Solenoid (Gas) . . . . . . . . . . .

4-134

Key Switch . . . . . . . . . . . . . . . . . . . . . . . .

4-129

LCD Display CAN Bus Status . . . . . . . . . . .

4-85

LCD Display Lift Actuator Amps . . . . . . . . .

4-78

LCD Display Maintenance Mode . . . . . . . .

4-73

LCD Display Reel Motor Amps . . . . . . . . . .

4-76

LCD Display Reel Motor Speed . . . . . . . . .

4-76

LCD Display Reel Motor Temperature . . . .

4-77

LCD Display Switch Test . . . . . . . . . . . . . .

4-85

LCD Display System Volts . . . . . . . . . . . . .

4-73

LCD Display Taction Motor Amps . . . . . . . .

4-82

LCD Display TCU and Traction Motor

Temperature . . . . . . . . . . . . . . . . . . . . .

4-80

Mow Switch . . . . . . . . . . . . . . . . . . . . . . . .

4-129

No Steering, No Fault

Traction Operational . . . . . . . . . . . . . . . .

4-83

No Traction, No Fault . . . . . . . . . . . . . . . . .

4-79

Raise/Lower Switch Assembly . . . . . . . . .

4-131

Rocker Switches . . . . . . . . . . . . . . . . . . . .

4-130

Seat Switch . . . . . . . . . . . . . . . . . . . . . . . .

4-131

Software Revision Level . . . . . . . . . . . . . . .

4-85

Steering Fault

2310, 2340, 4210, 4310, 7310 . . . . . . . .

4-83

6211 - Both TPS and Proximity Versions

4-84

7380 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-84

Throttle Actuator (Diesel) . . . . . . . . . . . . .

4-134

Throttle Actuator (Gas) . . . . . . . . . . . . . . .

4-135

Traction Fault 6211 . . . . . . . . . . . . . . . . . . .

4-81

Traction Fault 6212 (OLM and BRC) . . . . .

4-81

Traction Fault 6214 . . . . . . . . . . . . . . . . . . .

4-82

Traction Surging During Mow/Transport, No Fault

4-81

Theory of Operation—Electrical

Diesel Engine . . . . . . . . . . . . . . . . . . . . . . .

4-31

Electrical Sub-Circuits . . . . . . . . . . . . . . . . .

4-28

Gas Engine Circuit . . . . . . . . . . . . . . . . . . .

4-37

Genset Circuit . . . . . . . . . . . . . . . . . . . . . . .

4-68

Horn and Work Light Circuit . . . . . . . . . . . .

4-28

Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . .

4-49

Raise/Lower Circuit . . . . . . . . . . . . . . . . . . .

4-41

Steering Circuit . . . . . . . . . . . . . . . . . . . . . .

4-63

Traction Circuit . . . . . . . . . . . . . . . . . . . . . .

4-55

Thermostat (Diesel)

Removal and Installation . . . . . . . . . . . . . . .

3-17

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17

Throttle Actuator (Diesel)

Removal and Installation . . . . . . . . . . . . . . .

3-18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-18

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-134

Summary of Contents for Eclipse 322

Page 1: ...Eclipse 322 Riding Greens Mower Technical Repair Manual 62801 62803 62805 Second Edition...

Page 2: ......

Page 3: ...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 operate...

Page 4: ......

Page 5: ...or s manual and 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 RIG...

Page 6: ...se 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 specificat...

Page 7: ...2 3 4 5 6 7 Table of Contents 4222983 Second Edition 5 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 7 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 4222983 Second Edition SAFETY 1 4181861 4181860 4181862 5 2 4 3 1 105dB LWA 6 4216820 Rev A 7...

Page 13: ...SAFETY 4222983 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: ...to handle the 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...

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 4222983 Second Edition SAFETY 1 Page Intentionally Blank...

Page 21: ...ne Serial Number Model 62805 Diesel 2 2 Engine Identification Number Model 62803 Gas 2 3 Optional Machine Accessories 2 3 Component Location 2 4 All Models 2 4 Model 62801 Electric 2 6 Specifications...

Page 22: ...g replacement parts or requesting service information Engine Serial Number Model 62805 Diesel See Figure 2 3 Figure 2 3 The engine serial number 1 is attached to the top of the rocker arm cover The pl...

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: ...e Model 62805 Shown 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 Tracti...

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 4222983 Second Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Model 62801 Electric Figure 2 7 Component Location Left Side 1 Battery Charger 2 Battery Filling System 3 Battery Pack TN2311 3 1 2...

Page 27: ...0 Bore 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...

Page 28: ...l Model lb ft N m 65 0 88 0 Coupling Shaft Mounting Screw Torque Diesel Model lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Model lb ft N m 13 0 17 6 Generator Assembly Mounting Sc...

Page 29: ...edal Adjustment Voltage volts 4 3 4 4 Repair Specifications Brake Coil Mounting Screw Torque lb in N m 65 7 3 AC Traction Motor Mounting Screw Torque lb in N m 93 10 5 PDU Flange Nut 15 Torque See pag...

Page 30: ...Check and Adjustment Specifications Bedknife Front Face Height in mm 0 0625 1 59 Bedknife Front Face Angle degrees 5 Bedknife Top Face Angle rear relief degrees 8 10 Super Tournament Bedknife Top Fac...

Page 31: ...heel Lug Nut Torque lb ft N m 80 108 5 Mower Speed Transport mph km h 0 9 0 0 14 5 Mowing mph km h 0 5 0 0 8 9 Reverse mph km h 0 4 0 0 6 4 Weights and Dimensions Model 62805 Diesel Overall Weight lb...

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: ...11 Throttle Actuator Adjustment Gas 3 11 Repair Model 62805 Diesel 3 12 Fan Belt Diesel 3 12 Air Filter Assembly Diesel 3 13 Muffler Diesel 3 13 Alternator Diesel 3 14 Radiator Diesel 3 15 Thermostat...

Page 34: ...SET AND BATTERY PACK 3 Repair Batteries 3 36 Battery Pack Battery Pack Tray and Battery Filling System 3 36 Buffer Battery Pack and Buffer Battery Pack Tray 3 38 Starter Battery 3 39 Starter Battery T...

Page 35: ...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 3 4 3 2 Alternato...

Page 36: ...ft N m 65 0 88 0 Coupling Shaft Mounting Screw Torque Diesel Model lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Model lb ft N m 13 0 17 6 Generator Assembly Mounting Screw Torque...

Page 37: ...ACK 4222983 Second Edition 3 5 3 Component Location Model 62805 Diesel 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 TN24...

Page 38: ...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 39: ...4222983 Second Edition 3 7 3 Model 62803 Gas 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 40: ...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 41: ...GENSET AND BATTERY PACK 4222983 Second Edition 3 9 3 Model 62801 Electric 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 42: ...uel 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 bubbles disappear from fuel coming out of the air vent screw hole tigh...

Page 43: ...e throttle lever 3 should contact full throttle stop 5 Checks and Adjustments Model 62803 Gas Throttle Actuator Adjustment Gas See Figure 3 10 1 Park the mower safely See Park Mower Safely on page 1 6...

Page 44: ...or 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 r...

Page 45: ...ap 4 Using damp lint free cloths thoroughly clean the inside of the dust cap Figure 3 14 5 Slide air filter 4 out of the assembly Installation Note Install air filter assembly in the reverse order of...

Page 46: ...order of removal Install new gaskets during installation Tighten nuts 2 to 7 2 8 3 lb ft 9 8 11 3 N m Alternator Diesel Removal and Installation See Figures 3 17 and 3 18 1 Park the mower safely See P...

Page 47: ...k Mower Safely on page 1 6 2 Allow the engine to cool completely 3 Raise the hood 4 Remove cowlings See Cowlings on page 7 18 5 Remove starter battery See Starter Battery on page 3 39 WARNING 6 Drain...

Page 48: ...34 and secure out of the way 16 Loosen hose clamps 26 and remove air intake hoses 24 and 25 from air cleaner and bracket assembly 27 17 Remove screws 28 lock washers 29 and flat washers 30 18 Remove a...

Page 49: ...ly See Park Mower Safely on page 1 6 2 Allow the engine to cool completely 3 Raise the hood WARNING 4 Drain cooling system 3 qt 2 8 L Open petcock located on bottom of radiator remove radiator cap and...

Page 50: ...e antifreeze and clean fresh water Throttle Actuator Diesel Removal and Installation See Figure 3 26 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 3 26 2 Tag and disconnect throttle...

Page 51: ...to 6 gal 23 L of fuel 6 Loosen hose clamp 3 7 Tag and disconnect fuel hose 4 from fuel filter assembly 5 Cap fitting to prevent leakage and contamination 8 Place fuel hose 4 into a suitable container...

Page 52: ...l a new fuel filter at this time See Fuel Filter Diesel on page 3 20 Purge the fuel system See Purging the Fuel System Diesel on page 3 10 Fuel Filter Diesel Removal and Installation See Figure 3 30 C...

Page 53: ...Turn the fuel shutoff valve clockwise until valve bottoms lightly Valve is located on fuel filter Figure 3 31 5 Loosen fuel hose clamps 2 and 4 6 Disconnect fuel hoses 1 and 3 from fuel pump 6 Use a s...

Page 54: ...etely before attempting to service the engine 3 Swing center cutting unit from beneath the machine 4 Raise the hood 5 Remove cowlings See Cowlings on page 7 18 6 Remove starter battery See Starter Bat...

Page 55: ...output cable 8 from ground stud 9 Carefully guide the cable away from the frame and position the cable to be unrestricted during genset removal Figure 3 37 14 Tag and disconnect rectifier connector 10...

Page 56: ...5 and secure diesel inlet duct 36 out of the way 29 Loosen hose clamps 29 and remove air intake hoses 27 and 28 from air cleaner and bracket assembly 30 30 Remove screws 31 lock washers 32 and flat wa...

Page 57: ...t on a suitable stand or workbench that will support the full weight in a safe manner while preventing damage to the genset NOTE If the engine is being replaced some components must be removed and ins...

Page 58: ...6 Screw 2 6 Generator Flange 17 Screw 8 27 Screw 37 Screw 47 Coupling Shaft 7 Blind Coupling 18 Isolation Mount 2 28 Isolation Washer 2 38 Nut 2 48 Hose Clamp 2 8 Screw 5 19 L S Engine Carrier 29 R S...

Page 59: ...s 51 prior to assembly Tighten four generator assembly mounting screws 51 to 13 0 lb ft 17 6 N m Secure bell housing cover plate 10 to engine bell housing using 3MTM VHBTM double sided tape trim exces...

Page 60: ...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 61: ...throttle plate 7 Remove spring 3 from small hole 4 in throttle link 1 8 Remove engine throttle linkage 2 Figure 3 50 9 Tag and disconnect throttle actuator connector 12 10 Remove four nuts 11 lock wa...

Page 62: ...n Figure 3 53 12 Tag and disconnect wire connector 17 13 Loosen hose clamps 5 and 10 14 Tag and disconnect tank to canister hose 8 from the rollover valve 19 Cap fitting and plug hose to prevent leaka...

Page 63: ...Park the mower safely See Park Mower Safely on page 1 6 2 Allow the engine to cool completely before attempting to service the engine 3 Swing center cutting unit from beneath the machine 4 Raise the h...

Page 64: ...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 65: ...Figure 3 60 26 Remove four screws 18 flat washers 19 flat washers 21 nuts 22 and fuel tank bracket 20 Figure 3 61 27 Remove four screws 23 flat washers 24 nuts 25 and SCU cover 26 Figure 3 62 28 Remo...

Page 66: ...ced some components must be removed and installed on the new engine See the Parts and Maintenance Manual for additional information and illustrations Installation Notes I Inspect engine mounts and rep...

Page 67: ...O Ring 35 Lock Washer 18 45 Engine Intake Duct 6 Flat Washer 4 16 Screw 26 Gas Throttle Link 36 Nut 18 46 Screw 4 7 Lock Washer 4 17 Flat Washer 27 Gas Throttle Actuator 37 Screw 8 47 Engine Plate 8 N...

Page 68: ...coupler 23 flush with face of crankshaft Tighten engine coupler screw 22 to 30 lb ft 40 6 N m Engine Service Gas A separate engine manual prepared by the engine manufacturer is supplied with this mach...

Page 69: ...ation 12 Remove upper tray mat 19 Figure 3 68 13 Remove screw 21 lock washer 22 flat washer 23 nut 24 and battery bracket 20 Figure 3 69 NOTE Direction of arrow indicates front of machine 14 Disconnec...

Page 70: ...he mower safely See Park Mower Safely on page 1 6 2 Swing the center cutting unit out from the machine and lock into position Figure 3 71 NOTE Label all wires before disconnecting to ensure correct in...

Page 71: ...moval and Installation See Figure 3 73 NOTE The diesel model is shown the gas model is similar WARNING WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 3 73 NOTE Label all wire...

Page 72: ...Battery on page 3 39 Figure 3 74 3 Remove four screws 2 lock washers 3 and nuts 4 4 Remove starter battery tray 1 Installation Note Install starter battery tray by reversing the order of removal Model...

Page 73: ...41 3 Battery Charger Removal and Installation See Figure 3 76 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 3 76 NOTE Label all wires before disconnecting to ensure...

Page 74: ...nstallation 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 switch is o...

Page 75: ...Schematics 4 28 Horn and Work Light Circuit Theory of Operation 4 28 Horn and Work Light Circuit Schematic 4 29 Diesel Engine Circuit Theory of Operation 4 31 Diesel Engine Circuit Schematic 4 33 Gas...

Page 76: ...22 Work Light Circuit 4 122 Glow Plug Circuit 4 122 Start Circuit 4 123 Charging Circuit 4 123 Raise Lower Circuit 4 124 Mow Circuit 4 125 Component Tests and Adjustments 4 126 Electrical System and C...

Page 77: ...lt Connector 4 151 Instrument Panel 4 151 LCD 4 152 Rocker Switches 4 153 Key Switch 4 153 Raise Lower Switch Assembly 4 154 12 VDC Accessory Plug 4 154 Horn 4 155 Brake Pedal Switch 4 156 Brake Pedal...

Page 78: ...rew Torque lb in N m 65 7 3 AC Traction Motor Mounting Screw Torque lb in N m 93 10 5 PDU Flange Nut 15 Torque See Disassembly and Assembly on page 4 140 lb in N m 150 16 9 PDU Flange Nut 16 Torque Se...

Page 79: ...nt Location Right Side 1 TCU Traction Control Unit Fan 4 Steering Input Device 7 Brake Coil 2 TCU Traction Control Unit 5 RCU Reel Control Unit 8 Traction Pedal Position Sensor 3 OLM Over Limit Monito...

Page 80: ...ICAL 4 Figure 4 2 Component Location Left Side 1 MCU Main Control Unit 3 GCU Genset Control Unit 5 LCD Liquid Crystal Display 2 PDU Power Distribution Unit 4 SCU Steering Control Unit 6 Ground TN2746...

Page 81: ...222983 Second Edition 4 7 4 J79 Interface Connector Location See Figure 4 3 Figure 4 3 J79 Interface Connector Location 1 J79 Interface Connector disconnected 2 J79 Interface Connector connected TN282...

Page 82: ...rness Splice Identification and Locations See Figure 4 4 Figure 4 4 Main Harness Splice Identification and Location 1 Splice A 5 Splice H 2 Splice B 6 Splice O 3 Splice C 7 Splice T 4 Splice E 8 Reel...

Page 83: ...few 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 Ope...

Page 84: ...rs and Generating Devices Electric Motor 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 85: ...nclosure 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...

Page 86: ...Figure 4 10 F4 12A Circuit Breaker MCU 48V Power Brake Coil Traction Pedal Sensor Steering Input Device Work Light See Figures 4 11 and 4 12 F6 30A Circuit Breaker Steering Control 48V Power See Figu...

Page 87: ...Figure 4 16 J104 Power Distribution Unit Connector See Figures 4 6 through 4 14 J105 Right Steering Proximity Switch Connector See Figure 4 13 J122 Power Distribution Unit Connector RCU 48V Power See...

Page 88: ...4 8 Y2 Fuel Shutoff Solenoid Gas Engine See Figure 4 9 Y3 Brake Coil See Figure 4 11 Reel Motor Connector Pin Locations See Figure 4 5 NOTE The right left and center reel motor connectors are configur...

Page 89: ...CAN Shield CAN Low CAN High 48V Unswitched Power 48V Power Bus 48V Switched Power 48V Power Bus 48V Switched Power 12V Switched Power 12V Switched Power 60 Red 61 Red J11 5 Ignition J12 2 Start J11 9...

Page 90: ...Gry 145 Gry 144 Vio 144 Vio 131 Red 134 Red 132 Red 140 Grn 137 Brn 146 Wht J15 3 J15 2 On Off S3 Horn Switch 147 Lt Blu J14 3 J14 2 133 Red On On Off Off S2 Work Light Switch 71 Drk Grn 128 Red 129...

Page 91: ...ow CAN High CAN Shield CAN Low CAN High 71 Drk Grn 71 Drk Grn 71 Drk Grn 71 Drk Grn 282 Brn 281 Lt Blu 18 Brn Wht 279 Red 6A Red J83B 283 Blu 284 Org M1 Starter Motor A3 48V Battery Pack M P B1 Engine...

Page 92: ...CAN Low CAN High 71 Drk Grn 71 Drk Grn 71 Drk Grn 71 Drk Grn 13 Wht Red 276 Vio 273 Red 312 Brn 13 Wht Red 14 Wht Brn J1 9 J1 6 J26 2 To M1 Starter Motor J66 1 To Glow Plugs 109 Brn Yel J26 2 To K4 St...

Page 93: ...Fuel Level J3 7 Oil Pressure J2 1 Magneto Work Light Output J3 5 48V Power Input J2 7 Traction Contactor Output J3 6 Genset Fault Input J3 10 11 Wht Blu 11 Wht Blu 20 Wht Blu 20 Wht Blu 81C Brn Brake...

Page 94: ...Center Work Light J123 Optional Rops Work Light 81C Brn 20 Wht Blu 20 Wht Blu 20 Wht Blu Shield Blk Gnd Block 92F Grn 91F Yel J43 B CAN Shield J44 8 CAN Low J44 15 CAN High J44 23 A5 Traction Control...

Page 95: ...208 Red 209 Grn 202 Grn 203 Yel 204 Blu 213 Wht 215 Vio 214 Gry 48V Switched Power 48V Switched Power 12V Switched Power 12V Switched Power CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN...

Page 96: ...J64 1 48V Input B 48V To Stud 5 J50 W 48 AC Motor J64 16 Motor Temperature Sensor J64 5 Encoder 1 J50 V 48 AC Motor J50 U 48 AC Motor J64 3 5V Supply J64 6 Encoder 2 J64 7 Brake Sensor J64 20 Reverse...

Page 97: ...sor 1B J65 17 Steering Sensor 2A J65 20 Steering Sensor 2B 87 Wht 87A Blk 84 Wht 84A Blk J65 2 Steering Brake Output 82 Brn Yel 88 Wht Grn 88 Wht Grn F6 30A Circuit Breaker K7 48V Steering Relay 48V S...

Page 98: ...CCW Signal Output J6 9 Center Reel Motor CW CCW Signal Ground J6 12 32 Blu 42 Brn 45 Yel 38 Blk 22 Wht 6 Red J122 46 Org 43 Grn 47A Wht 47 Blk 44 Blu 50 Blk 54 Brn 57 Yel 55 Grn 56 Blu 59A Wht 59 Blk...

Page 99: ...Ground 42 Brn 45 Yel 46 Org 43 Grn 47A Wht 44 Blu M6 Right Reel Motor 23 Wht 50 Blk 54 Brn 57 Yel J22 1 48V Power Input J69 2 Tachometer Output J69 8 Temperature Output J69 3 Speed Signal Input J69 4...

Page 100: ...e Limit Monitor OLM 107 Org Grn 102 Brn 105 Grn Blk 106 Yel Wht 101 Red 101A Red J100 1 48V Input J102 Connects to TCU 48V B Terminal J100 2 48V Input J100 3 Resistor Output 1 J100 12 Resistor Output...

Page 101: ...Current 116 Wht 116B Blk From J97 3 MCU J35 F2 Gnd 116A Wht J35 C1 Gen Current 114 Red 114 Red J35 A2 V Bat 125 Org 95 Blk 94 Red Org Org J37 3 J35 F1 Gnd Pack 115 Blk 125 Org 115 Blk 120 Gry 119 Gry...

Page 102: ...breaker F4 to splice A From splice A 48 volts is supplied to work light terminal J28 1 and to optional OPS work light terminal J123 2 Voltage is provided from the LCD 12 volt power supply terminal J1...

Page 103: ...Grn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Switched Power 48V Switched Power 12V Switched Power 12V Switched Power 60 Red 61...

Page 104: ...Switch 125 Red A1 Power Distribution Unit PDU J104 G CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High 48V Switched Power 48V Switched Pow...

Page 105: ...the key switch status in the start position 12 volts is provided from the MCU fuel hold output terminal J2 4 to the fuel shutoff solenoid s hold in coil Current also momentarily flows from the MCU fue...

Page 106: ...oduces three phase alternating current AC The AC voltage is provided to voltage regulator N1 When the battery voltage is low the voltage regulator supplies a regulated voltage to charge the battery Wh...

Page 107: ...eld Shield 42 Blk Wht 1G Blk 92C Grn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Power Bus 48V Switched Power 48V Power Bus 48V Swi...

Page 108: ...er CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High 13 Wht Red 13 Wht Red 14 Wht Brn J1 9 J1 6 J26 2 J66B 1 109 Brn Yel 15 Wht Yel J1 7 J...

Page 109: ...Wht Brn 14 Wht Brn 9A Pnk 9B Pnk 5A Red Blk 16 Red Grn 9 Pnk Splice E J3 7 Oil Pressure 48V Power Input J2 7 J2 5 Fuel Pull In J2 4 Fuel Hold J2 2 Start 1 7 3 4 12 10 J2 3 Glow Plug 66 Lt Blu J3 8 Eng...

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Page 111: ...spark when the engine is turning The MCU start output terminal J2 2 provides 12 volts to start relay terminal 86 energizing the relay With the start relay energized voltage is switched between relay t...

Page 112: ...ield Shield 42 Blk Wht 1G Blk 92C Grn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Power Bus 48V Switched Power 48V Power Bus 48V Sw...

Page 113: ...CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High 13 Wht Red 13 Wht Red J1 9 J1 6 J26 2 15 Wht Yel K4 Start Relay 87 87A 85 86 30 V4 A1 Power Distribution Unit PDU 27...

Page 114: ...ctor 13 Wht Red 13 Wht Red J2 8 12V Power Input 65 Brn 61 Vio 62 Red Org 9A Pnk 5A Red Blk 16 Red Grn 9 Pnk Splice E J3 7 Oil Pressure J2 1 Magneto 48V Power Input J2 7 J2 4 Fuel Hold J2 2 Start 1 4 6...

Page 115: ...12 volts to right reel enable switch terminal J18 2 The right center and left reel enable switches allow the operator to choose which reels to operate Each reel can be operated independently from the...

Page 116: ...ransport the RCU lowers the selected reels to the pre programmed fully lowered position When the machine is in mow mode with the reels engaged the MCU instructs the RCU to lower the selected reels to...

Page 117: ...itched Power 48V Switched Power 48V Switched Power 12V Switched Power 12V Switched Power 60 Red J11 5 Ignition J12 2 Start J11 10 Switched Power Contactor Output J11 8 48V Right Reel Enable J12 6 12V...

Page 118: ...3 J16 2 125 Red On Off S7 Left Reel Enable Switch 139 Yel J18 3 J18 2 S4 Right Reel Enable Switch On Off 138 Org J17 3 J17 2 130 Red S5 Center Reel Enable Switch 127 Red 126 Red 125 Red A4 Main Contr...

Page 119: ...tuator 5V Supply J6 5 Center Lift Sensor Signal Input J6 4 Center Lift Sensor Signal Ground 48V Switched Power 48V Switched Power A10 Left Reel Lift Actuator 48V Motor Terminal B 48V Motor Terminal A...

Page 120: ...44 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Switched Power 48V Switched Power 12V Switched Power 12V Switched Power 60 Red J11 5 Ignition J12 2 Start J11 10 Switched Power Cont...

Page 121: ...3 J16 2 125 Red On Off S7 Left Reel Enable Switch 139 Yel J18 3 S4 Right Reel Enable Switch On Off 138 Org J17 3 J17 2 130 Red S5 Center Reel Enable Switch 127 Red 126 Red 125 Red A4 Main Control Unit...

Page 122: ...nal Ground 48V Switched Power 48V Switched Power A10 Left Reel Lift Actuator A11 Center Reel Lift Actuator J8 2 Right Lift Motor Control Output J8 1 Right Lift Motor Control Output J8 6 Right Lift Act...

Page 123: ...allows the reel motors to operate With the operator on the seat voltage is provided from seat switch terminal J41 2 to MCU seat switch input terminal J4 10 activating the input When the raise lower s...

Page 124: ...cutting and reverse for backlapping With no output to the reel motor the reel operates in the forward direction When the output is providing a signal to the reel motor the motor operates in the rever...

Page 125: ...Switched Power 48V Switched Power 12V Switched Power 12V Switched Power 60 Red J11 5 Ignition J12 2 Start J11 10 Switched Power Contactor Output J11 8 48V Right Reel Enable J12 6 12V Power Supply J11...

Page 126: ...S4 Right Reel Enable Switch On Off 138 Org J17 3 J17 2 130 Red S5 Center Reel Enable Switch 127 Red 126 Red 125 Red A4 Main Control Unit MCU J2 11 CAN High J2 12 CAN Low J2 10 CAN Shield 1F Blk GC2 J...

Page 127: ...Speed Signal Input J69 3 Speed Signal Ground J69 4 Reel Direction Input J69 7 CW CCW Signal Input J69 1 CW CCW Signal Ground J69 5 1C Blk Ground J22 2 J6 10 Center Reel Motor Speed Signal Output J6 11...

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Page 129: ...input activated MCU traction contactor output terminal J3 6 provides a ground to PDU 48 volt traction contactor terminal J1 3 energizing the contactor With the 48 volt traction contactor energized vol...

Page 130: ...TCU motor temperature sensor input terminal J44 16 If the motor temperature rises above 356 F 180 C the TCU communicates this condition to the MCU Now the MCU instructs LCD to turn on the alarm and d...

Page 131: ...rn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Power Bus 48V Switched Power 48V Power Bus 48V Switched Power 12V Switched Power 12V...

Page 132: ...Yel 92 Grn Shield J79 B J79 C R12 02 Ohm Resistor J1 10 J2 8 12V Power Input J2 6 12V Power Input 16 Red Grn 128 Red J41 1 60 Drk Grn J91 3 J41 2 71 Drk Grn On Off S6 Seat Switch J4 10 Seat Switch F4...

Page 133: ...3 A5 Traction Control Unit TCU J44 1 48V Input J47 A J75 1 Splice O J75 2 J47 B To Splice B 48V AC Motor J43 W Motor Temperature Sensor J44 16 Encoder 1 J44 6 48V AC Motor J43 V 48V AC Motor J43 U 5V...

Page 134: ...202 Grn 203 Yel 204 Blu 213 Wht 215 Vio 214 Gry 48V Switched Power 48V Switched Power CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High CAN Shield CAN Low CAN High B...

Page 135: ...A7 3WD Traction Control Unit Optional Third Wheel Drive J64 1 48V Input B 48V To Stud 5 J50 W 48V AC Motor J64 16 Motor Temperature Sensor J64 5 Encoder 1 J50 V 48V AC Motor J50 U 48V AC Motor J64 3 5...

Page 136: ...91E Yel Ground J100 4 CAN Shield J100 9 CAN Low J100 8 CAN High J100 5 A15 Overvoltage Limit Monitor OLM 107 Org Grn 102 Brn 105 Grn Blk 106 Yel Wht 101 Red 101A Red J100 1 48V Input J102 Connects to...

Page 137: ...before the main control unit MCU allows the steering control unit SCU to operate the steering motor when the steering wheel is turned With the operator on the seat voltage is provided from seat switc...

Page 138: ...and J53 W to steering motor AC motor terminals J54 U J54 V and J54 W To control the speed of the steering motor the SCU varies the frequency of the AC voltage applied to the AC motor terminals To Con...

Page 139: ...ttery 52 Wht 12 Wht Grn 245 Shield Shield 42 Blk Wht 1G Blk 92C Grn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Switched Power 48V...

Page 140: ...rn Splice E 9 Pnk 9A Pnk J1 5 5A Red Blk 5A Red Blk 48V Power Input J2 7 R17 CAN Termination Resistor 120 Ohms J79 A 91 Yel 92 Grn Shield J79 B J79 C R12 02 Ohm Resistor J1 10 J2 8 12V Power Input J2...

Page 141: ...Sensor J65 5 Encoder 1 J65 3 5V Supply J65 6 Encoder 2 J65 19 Left Proximity Switch Input 90 Wht Pnk 3B Red Wht Splice B Splice C 111 Red J65 13 Right Proximity Switch Input S10 Left Steering Proximit...

Page 142: ...oduces three phase alternating current AC The AC current is rectified by the diode blocks and direct current DC is provided to PDU terminal stud 3 The generator control unit GCU monitors the speed of...

Page 143: ...ht 12 Wht Grn 245 Shield Shield 42 Blk Wht 1G Blk 92C Grn 91C Yel J91 6 J90 C J90 B J90 A J91 1 J91 2 244 Grn 243 Yel CAN Shield CAN Low CAN High 48V Unswitched Power 48V Power Bus 48V Switched Power...

Page 144: ...t MCU CAN High J2 11 CAN Low J2 12 CAN Shield J2 10 1F Blk J2 9 Ground 91A Yel Shield 92A Grn Splice E 9 Pnk 9A Pnk J1 5 5A Red Blk 5A Red Blk 48V Power Input J2 7 R17 CAN Termination Resistor 120 Ohm...

Page 145: ...sper Mode Circuit Temperature Sensor Circuit Tachometer Circuit GC1 12V Switched Power 12V Switched Power 12V Switched Power 20 Wht Blu 110 Blu 20 Wht Blu A1 Power Distribution Unit PDU A1 Power Distr...

Page 146: ...Grn J37 4 J37 8 J37 1 J37 6 19 Red 19A Red 19B Red 113 Brn 113 Brn 28 Red 13 Brn J35 C2 Gen Current 116 Wht 116B Blk J35 F2 Gnd 116A Wht J35 C1 Gen Current 114 Red 114 Red J35 A2 V Bat 125 Org 95 Blk...

Page 147: ...maintenance mode Change Retrieve Maintenance Mode PIN When servicing a machine that contains an unknown maintenance mode PIN or the PIN was forgotten use the following procedure to retrieve the unknow...

Page 148: ...be 38 4 If run time is still diminished after performing all the above procedures please contact Technical Support immediately Fault Vehicle Will Not Start Gas and Diesel Hybrid Units Only 1 Fault Sy...

Page 149: ...ngs are correct check generator coupler Replace GCU If issue is corrected reinstall old GCU to verify fault returns i Measure continuity DMV Ohms should be less than 0 5 Ohms and no crossover between...

Page 150: ...Left Reel Overcurrent on page 4 98 See DTC Center Reel Overcurrent on page 4 98 See DTC Right Reel Overcurrent on page 4 99 Reel Motor Speed See Figure 4 52 Figure 4 52 Cycle through the LCD menu unti...

Page 151: ...r f Motor controller is faulty Split motor design ONLY i Swap motor controller with known good motor controller g Jumper cable or Molex connector between motor and motor controller is faulty or pinche...

Page 152: ...the actuator that is enabled Compare the three actuator readings if one actuator has a higher current draw than the others this may indicate a mechanical problem or a faulty actuator If the current i...

Page 153: ...not installed ii Physically verify traction pedal is not mechanically held out of neutral Also verify voltage is between 0 3 and 0 8VDC with pedal in neutral iii Physically verify brake pedal is retu...

Page 154: ...ossible root cause s and troubleshooting procedure a Motor speed sensor signal not reaching TCU i Visually inspect for damaged cable or connectors between traction motor and TCU ii Faulty motor speed...

Page 155: ...blem is corrected after test wire is added contact Technical Support 4 If unit still does not operate after performing all the above procedures please contact Technical Support immediately Traction Fa...

Page 156: ...r 3WD Fault 7310 1 Fault No traction in 3WD mode with a 7310 fault shown in LDU 2 Possible root cause s and troubleshooting procedure Speed sensor signal not reaching 3WD controller Visually inspect f...

Page 157: ...ately Fault Miniscule Change in Steering Angle without Operator Input Ghost Steering 1 Fault Operator reports intermittent minimal steering angle changes with no input to steering wheel No loss of ste...

Page 158: ...turns c For issue 2 c Replace steering input device If issue is corrected reinstall old steering input device to verify fault returns 4 If unit still does not operate after performing all the above pr...

Page 159: ...troller name indicates CAN communication has been detected from controller within the last 2 seconds A flashing controller name indicates CAN communication has not been detected from the controller Sw...

Page 160: ...switch is faulty Check connections at switch and or bench test switch and replace as needed 3 Move the raise lower switch to the raise position and observe the digit at position 2 Move the raise lowe...

Page 161: ...ement Does the multimeter display 48VDC or in both switch positions YES The wire harness is good Proceed to the next step NO Wire harness or connections are faulty Perform continuity test and repair r...

Page 162: ...to the next step NO The left reel motor output signal is faulty Turn the key switch off disconnect the left reel motor connectors Turn the key switch on and repeat steps 7 and 8 If results remain unc...

Page 163: ...chanical failure Repair or replace as needed NO The brake assembly is good Proceed to the next step 6 Sit in the seat Observe the traction contactor output LED 3 on the main control unit MCU Does the...

Page 164: ...ons 13 With key on and traction pedal in neutral measure AC voltage at traction motor terminals U V and W Does multimeter indicate 48VAC 10 at all terminals YES The TCU is good Replace traction motor...

Page 165: ...ing motor terminals U V and W Does multimeter indicate 33VAC 10 at all terminals YES The SCU is good Replace steering motor as needed NO The SCU is faulty Replace SCU as needed Start Circuit Diesel En...

Page 166: ...noid output LED YES The MCU fuel pull and hold solenoid outputs are good Proceed to the next step NO MCU is faulty Replace as needed 9 With the key switch in the start position measure voltage at the...

Page 167: ...solenoid output is good Proceed to the next step NO MCU is faulty Replace as needed 7 Place the key switch in the start position and observe the start relay output LED 1 Does the start relay output L...

Page 168: ...n corrosion torque water ii Disconnect and reconnect both BLUE ANDERSON battery plugs b Check main power and chassis ground connections for corrosion and proper torque c Check all circuit breakers and...

Page 169: ...arged Faulty 48V power cables hybrid models Check positive 48V cable between the genset and the PDU Check positive 48V cable between 48V battery pack and PDU Faulty 48V battery pack ground circuit Mak...

Page 170: ...or with a known good reel motor If issue is corrected reinstall old motor to verify fault returns NOTE If vehicle has split motor motor and or motor controller will need to be reinstalled to verify fa...

Page 171: ...bable Cause Remedy Jammed cutting unit Clear cutting unit of all debris Make sure cutting unit rotates without excessive resistance Faulty connections Check connections make sure connections are dry c...

Page 172: ...brush belt over tightened Check belt adjustment Faulty connections Check connections make sure connections are dry clean of corrosion and tight Shorted wiring harness Make sure reel motor wiring harne...

Page 173: ...n good reel motor If issue is corrected reinstall old motor to verify fault returns NOTE If vehicle has split motor motor and or motor controller will need to be reinstalled to verify fault returns Pr...

Page 174: ...the cutting unit rotates without excessive resistance Low voltage Charge batteries Faulty connections Check connections make sure connections are dry clean of corrosion and tight Wiring harness Check...

Page 175: ...to verify fault returns Probable Cause Remedy Lift arm mechanical binding Check lift arm pivot points for binding Check up stop transport lock or bumper adjustments Faulty wiring connections Check all...

Page 176: ...Make sure reel motor wiring harness is free of nicks and cuts and not pinched to machine frame Faulty connections Check connections make sure connections are dry clean of corrosion and tight Faulty li...

Page 177: ...lt returns Probable Cause Remedy Lift arm mechanical binding Check lift arm pivot points for binding Up stop adjustments Check up stop adjustments Incorrect cut position Calibrate actuator Faulty conn...

Page 178: ...tall old component to verify fault returns Probable Cause Remedy Faulty connections Check connections make sure connections are dry clean of corrosion and tight Shorted wiring harness Make sure tracti...

Page 179: ...Probable Cause Remedy Differential Check for excessive mechanical resistance in the differential Faulty brake coil Check brake coil Faulty connections Check connections make sure connections are dry...

Page 180: ...harness is free of nicks and cuts and not pinched to machine frame Traction pedal position sensor out of adjustment Check traction pedal position sensor adjustment See Traction Pedal Adjustment on pag...

Page 181: ...sensor wiring harness is free of nicks and cuts and not pinched to machine frame Faulty brake sensor Verify pedal in neutral position Voltage on signal wire reads above 0 37 VDC DTC will only occur w...

Page 182: ...ow works re install old component to verify fault returns Probable Cause Remedy Moisture in steering motor connector Make sure steering motor connectors are clean and dry Loose steering control unit t...

Page 183: ...it Substitute the steering control unit with a known good steering control unit If system now works re install old component to verify fault returns Faulty OLM BRC unit Substitute the OLM BRC unit wit...

Page 184: ...erify fault returns Probable Cause Remedy Faulty connections Check SCU 23 pin connector make sure connections are dry clean of corrosion and tight Check steering motor connections make sure connection...

Page 185: ...ce and turn off when metal is brought near the sensor surface If a sensor LED does not operate check the connector and make sure the connection is dry clean of corrosion and tight Substitute the proxi...

Page 186: ...fy 5VDC from SCU 23 pin connector is present Faulty steering motor Substitute the steering motor with a known good steering motor If system now works re install old component to verify fault returns P...

Page 187: ...bable Cause Remedy Faulty wiring harness Check wiring between steering input device and steering control unit Steering wheel input device Substitute the steering wheel input device with a known good s...

Page 188: ...esistor terminals A and B Resistance must be 120 ohms Faulty wiring or connections Check CAN termination resistor connector make sure connector is clean and tight Make sure CAN termination resistor wi...

Page 189: ...g frame Check ring terminal connection Faulty resistor Measure resistance between the resistor terminals Resistance must be approximately 2 ohms Faulty throttle actuator Test actuator See Throttle Act...

Page 190: ...or with a known good overvoltage limit monitor If system now works re install old component to verify fault returns Probable Cause Remedy Faulty connection Check the resistor for loose terminals Make...

Page 191: ...ar debris Ring terminal touching frame Check ring terminal connection Faulty resistor Measure resistance between the resistor terminals Resistance must be approximately 2 ohms Probable Cause Remedy Fa...

Page 192: ...s free of nicks and cuts and not pinched to machine frame Faulty fan relay Test relay See Fan Relay Test on page 4 128 Faulty genset fan Substitute the genset fan with a known good genset fan If syste...

Page 193: ...ot pinched to machine frame Faulty fan relay Test relay See Fan Relay Test on page 4 128 Faulty genset fan Substitute the genset fan with a known good genset fan If system now works re install old com...

Page 194: ...y fault returns Probable Cause Remedy Faulty connections Check steering motor connections make sure connections are dry clean of corrosion and tight Faulty wiring harness Make sure wiring harness is f...

Page 195: ...rator control unit If system now works re install old component to verify fault returns Probable Cause Remedy 48V battery pack fully discharged Measure voltage between 48V battery pack connector termi...

Page 196: ...ight switch in the on position and check the main control unit MCU headlight output LED If the LED turns on work light output circuit is good replace work light If the LED does not turn on MCU work li...

Page 197: ...ing no higher than 14VDC output to battery Check continuity between starter battery terminal and battery positive terminal Continuity must be indicated Faulty battery ground circuit Make sure battery...

Page 198: ...ht Faulty wiring harness Make sure wiring harness is free of nicks and cuts and not pinched to machine frame Probable Cause Remedy Actuator Not Calibrated Complete maintenance mode calibration or fact...

Page 199: ...h Test right reel enable switch using LCD display Switch Test See Switch Test on page 4 85 If the right reel enable switch does not activate during the LCD Switch Test bench test the switch See Rocker...

Page 200: ...meters may have a continuity tester setting that uses a buzzer to indicate continuity See the meter Operator s Manual for more information 2 If using a multimeter set to read ohms or set meter to cont...

Page 201: ...eft side cowling See Cowlings on page 7 18 3 Remove MCU See MCU on page 4 138 Figure 4 79 4 Remove top cover from the PDU 5 5 Set the meter to read ohms 6 Touch meter leads to each other and confirm a...

Page 202: ...an relay See Fan Relay on page 4 150 Figure 4 81 3 Set the meter to read ohms 4 Touch meter leads to each other and confirm a resistance value of 0 0 ohms 5 Measure the resistance between terminal 30...

Page 203: ...Test See Figure 4 83 NOTE Test the component utilizing the LCD switch status menu before performing the component bench test See Switch Test on page 4 85 1 Park the mower safely See Park Mower Safely...

Page 204: ...See Rocker Switches on page 4 153 Figure 4 84 3 Move rocker switch to the ON position 4 Set the meter to read ohms 5 Touch meter leads to each other and confirm a resistance value of 0 0 ohms 6 Measur...

Page 205: ...mbly to the center neutral position 8 Measure the resistance between terminals 4 and 5 Is the resistance value 0 02 ohms or less YES Switch is faulty replace raise lower switch assembly NO Proceed to...

Page 206: ...s 3 and 4 Is the resistance value 0 02 ohms or less YES Switch is good NO Switch is faulty replace switch Brake Pedal Switch Test See Figure 4 88 1 Park the mower safely See Park Mower Safely on page...

Page 207: ...Is the resistance value approximately 25 5 ohms at 68 F YES Brake coil is good NO Brake coil is faulty replace brake coil Fuel Shutoff Solenoid Test Diesel See Figures 4 90 and 4 91 1 Park the mower s...

Page 208: ...92 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 4 92 2 Tag and disconnect the fuel shutoff solenoid wire connector 2 3 Set the meter to read ohms 4 Touch meter leads to each other...

Page 209: ...smooth operation throughout the entire range of motion If the actuator shaft sticks or binds replace the actuator 7 Connect the throttle actuator wire connector 1 Cycle the key switch while observing...

Page 210: ...traction pedal connector 5 4 Turn ignition switch to the RUN position Do not start mower 5 Press traction pedal for full forward movement 6 Measure the voltage between the orange and black wires on t...

Page 211: ...esent in each unused wire opening Figure 4 99 Inspect pins 10 and sockets 11 for wear damage corrosion and loose wire connection Replace as necessary Inspect connectors 3 and 8 and seal 13 for wear or...

Page 212: ...gaging connector threads Do not force the connectors Position wire harness to relieve excessive strain on the connector Be sure threads are fully engaged more than three full threads Do NOT apply diel...

Page 213: ...quipped 6 Disconnect the 48 VDC BATT POS connector 6 at stud 1 7 Disconnect the 48 VDC REEL POS connector 4 8 Remove screws 9 and lock washers 10 9 Remove PDU 3 Installation Notes Install PDU by rever...

Page 214: ...ontactor 3 Glow Plug Relay 10 12 Volt Contactor 17 Screw 3 24 PDU Case 31 48 Volt Busbar 4 Start Relay 11 Seal 13 18 Flat Washer 3 25 Traction Contactor 32 PDU Seal 5 Printed Circuit Board 12 Flat Was...

Page 215: ...N m Tighten flange nut 20 to 40 lb in 4 5 N m Tighten flange nut 21 to 80 lb in 9 N m TCU Fan Removal and Installation See Figure 4 106 1 Park the mower safely See Park Mower Safely on page 1 6 2 Rem...

Page 216: ...lectric grease Jacobsen PN 365422 to any connectors removed Tighten nuts at wire connectors 1 and 2 to 132 lb in 14 9 N m SCU Removal and Installation See Figures 4 109 and 4 110 WARNING 1 Park the mo...

Page 217: ...e 1 6 2 Remove covers See Front Cover on page 7 16 and Rear Cover on page 7 16 Figure 4 111 NOTE Label all wires before disconnecting to ensure correct installation 3 Disconnect RCU connectors 5 6 8 a...

Page 218: ...d remove from machine NOTE For Eclipse 322 Model 62805 Diesel lift air intake hose 1 up to allow sufficient clearance for GCU shield removal Figure 4 113 7 Remove screws 7 washers 8 lock washers 9 and...

Page 219: ...4 116 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove covers See Front Cover on page 7 16 and Rear Cover on page 7 16 3 Remove steering wheel See Steering Wheel on page 7 14 Figure...

Page 220: ...any connectors removed Resistor Bank Assembly and Jumper Harness Removal and Installation See Figures 4 117 and 4 118 WARNING CAUTION 1 Park the mower safely See Park Mower Safely on page 1 6 2 Swing...

Page 221: ...r bank assembly and remove resistor bank jumper harness 11 Installation Notes Install resistor bank assembly by reversing the order of removal Apply dielectric grease Jacobsen PN 365422 to any connect...

Page 222: ...removed Contactors Removal and Installation See Figures 4 121 through 4 123 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove PDU See PDU on page 4 139 Figure 4 121 3 Remove s...

Page 223: ...12 22 and 24 from PDU 21 IMPORTANT Flange nuts 16 8 and 10 are the same part number however torque values vary depending on location Installation Notes Install contactors by reversing the order of rem...

Page 224: ...llation Notes Install fuses by reversing the order of removal Apply dielectric grease Jacobsen PN 365422 to fuse socket prior to installation Tighten nuts 2 and 3 to 80 lb in 9 N m Fan Relay Removal a...

Page 225: ...t is not necessary to completely remove the instrument panel In most cases the instrument panel can be moved aside for access to components 1 Park the mower safely See Park Mower Safely on page 1 6 Fi...

Page 226: ...n PN 365422 to any connectors removed Use new cable ties to secure wire connectors and wire harness Install the instrument panel by reversing the order of removal LCD Removal and Installation See Figu...

Page 227: ...onnect the wire connectors 8 on the rocker switch 7 4 Depress tabs 9 on each side of the rocker switch and remove from the instrument panel Installation Notes Apply dielectric grease Jacobsen PN 36542...

Page 228: ...tation of the raise lower switch assembly Label all wires before disconnecting to ensure correct installation 3 Remove four screws 1 nuts 2 and washers 3 4 Tag and disconnect wire connector 4 5 Remove...

Page 229: ...rder of removal Apply dielectric grease Jacobsen PN 365422 to any connectors removed Horn Removal and Installation See Figures 4 139 and 4 140 1 Park the mower safely See Park Mower Safely on page 1 6...

Page 230: ...oved Brake Pedal Position Sensor Removal and Installation See Figures 4 142 and 4 143 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove front splash shield See Axle Shield and Front S...

Page 231: ...146 NOTE The left steering proximity switch is shown the right steering proximity switch is installed the same way 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 4 145 NOTE Clean an...

Page 232: ...he mower safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 4 148 3 Remove nut 2 and washer 3 4 Tag and disconnect wire connector 4 from the engine temperature switch 1 5 Remove engine t...

Page 233: ...Tag and disconnect wire connector 9 NOTE Raise the right side of the floorboard mat to access the heads of screws 7 8 Support the traction pedal position sensor assembly 10 with a suitable lifting de...

Page 234: ...e 4 152 4 Remove four screws 1 and cover 2 5 Proceed to step 7 Figure 4 153 6 Remove four screws 3 and cover 4 7 Replace rectifier repair kit components as needed See Disassembly and Assembly on page...

Page 235: ...Rectifier Temperature Sensor 10 Black Cable 14 150A Shunt 2 Red Cable 7 Rectifier Harness 11 Bus Bar 15 3 8 Cable Grip 3 Screw 2 8 Generator Output 12 Rectifier Diode 16 Housing 4 Rectifier Shunt Cab...

Page 236: ...otor Assembly Removal and Installation See Figures 4 156 and 4 157 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 WARNING IMPORTANT It is important to lift and support the machine o...

Page 237: ...ire harnesses Tighten screws 5 to 93 lb in 10 5 N m Tighten nuts at wire connectors 1 to 132 lb in 14 9 N m Brake Coil Removal and Installation See Figure 4 158 WARNING 1 Park the mower safely See Par...

Page 238: ...162 3 Remove brake coil from AC traction motor assembly See Brake Coil on page 4 163 Figure 4 159 4 Clean AC traction motor assembly of any debris 5 Remove snap ring 1 and spacer 2 6 Remove screws 3 a...

Page 239: ...See Figures 4 163 through 4 166 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 4 163 2 Remove screws 1 lock washers 2 nuts 3 and steering cover 4 Figure 4 164 NOTE Label all...

Page 240: ...ear 12 7 Use the appropriate gear puller and remove the steering motor gear 8 Support the steering motor with a suitable lifting device 9 Remove four screws 13 washers 14 lock washers 15 and nuts 16 1...

Page 241: ...ELECTRICAL 4222983 Second Edition 4 167 4 Page Intentionally Blank...

Page 242: ...4 168 4222983 Second Edition ELECTRICAL 4...

Page 243: ...ks and Adjustments 5 5 Steering Chain Tension Adjustment 5 5 Repair 5 6 Reel Lift Actuators 5 6 Right and Left Lift Arms 5 6 Center Lift Arm 5 9 Steering Yoke 5 11 Steering Chain and Gears 5 12 Front...

Page 244: ...ush at mid span of chain Specification 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 A...

Page 245: ...Figure 5 1 Component Location Right Side 1 Floorboard Assembly 3 Left Cutting Unit 5 Right Lift Arm 7 Front Axle Assembly 9 Center Cutting Unit 2 Traction Pedal 4 Right Reel Lift Actuator 6 Right Cutt...

Page 246: ...983 Second Edition CHASSIS 5 Figure 5 2 Component Location Left Side 1 Brake Pedal Assembly 3 SteeringYoke 5 Left Lift Arm 2 Steering Chain and Gear 4 Left Fender 6 Left Reel Lift Actuator TN2746 3 2...

Page 247: ...shers 2 and nuts 3 4 Remove SCU cover 4 Figure 5 4 5 Loosen two screws 5 6 Adjust position of steering motor 7 to obtain 0 0625 0 250 in 1 6 6 4 mm deflection with 2 10 lb 9 45 N push at mid span of c...

Page 248: ...he reel lift actuator 7 4 Remove cotter pin 5 and flat washer 6 5 Remove the reel lift actuator Installation Notes Install reel lift actuator by reversing the order of removal Apply dielectric grease...

Page 249: ...es Pre adjust the reel leveling rod before installation See Reel Leveling Rod Pre Adjustment on page 6 22 Install lift arm by reversing the order of removal Use new cable ties to secure the wire conne...

Page 250: ...t 2 Flat Washer 6 Stop Bracket 10 Link Arm 14 Left Front Lift Arm 18 Grease Fitting 3 Lock Washer 7 Bushing 11 Flat Washer 15 Polygon Bushing 19 Right Front Lift Arm 4 Screw 8 Flat Washer 12 Lock Wash...

Page 251: ...Center Lift Arm Removal and Installation See Figures 5 9 and 5 10 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove reel lift actuator See Reel Lift Actuators on page 5 6 3 Remove ree...

Page 252: ...at Washer 22 Center Reel Steering Pivot 28 Screw 4 Bushing 11 Flat Washer 17 Cotter Pin 23 Shim Washer as required 29 Flat Washer 5 Center Swing Arm 12 Locking Pin Bracket 18 Center Stop Bracket 24 Po...

Page 253: ...Figures 5 12 through 5 14 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 5 12 2 Swing out and lock the center cutting unit 1 from under the machine WARNING IMPORTANT It is i...

Page 254: ...ge 5 5 Steering Chain and Gears Removal and Installation See Figures 5 15 through 5 17 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 5 15 2 Remove four screws 1 flat washers...

Page 255: ...seize compound to keys 11 and 14 prior to installation Install the gears and chain by reversing the order of removal When installing the steering motor gear install to the measurement taken prior to r...

Page 256: ...of removal Brake Pedal Assembly Removal and Installation See Figures 5 20 and 5 21 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove brake pedal switch See Brake Pedal Switch on page...

Page 257: ...cess screws 7 10 Support brake pedal assembly 6 and remove screws 7 lock washers 8 and flat washers 9 11 Rotate and lower the brake pedal assembly to remove the brake pedal assembly from the machine I...

Page 258: ...Figure 5 22 Figure 5 22 1 Screw 4 5 Brake Arm Weldment 8 Switch Arm 11 Spring 2 Brake Pedal Position Sensor 6 Spring Roll Pin 2 9 Brake Pedal Switch 12 Spacer 4 3 Brake Plate 2 7 Pedal Grip 10 Screw...

Page 259: ...ly on page 1 6 Figure 5 23 2 Remove four lock nuts 5 four screws 1 and shield mounting strap 2 3 Remove axle shield 6 4 Remove four panel fasteners 3 5 Remove front splash shield 4 Installation Notes...

Page 260: ...tion pedal position sensor See Traction Pedal Position Sensor on page 4 159 6 Remove brake pedal assembly See Brake Pedal Assembly on page 5 14 7 Remove axle shield and front splash shield See Axle Sh...

Page 261: ...Installation See Figures 5 28 through 5 30 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove axle shield and front splash shield See Axle Shield and Front Splash Shield on pa...

Page 262: ...s 5 two lock washers 6 four flat washers 7 and two screws 8 10 Repeat step 9 for other side of machine 11 Remove front axle assembly 11 Installation Notes Install front axle assembly by reversing the...

Page 263: ...e shaft bearing 2 from right side axle shaft using a suitable press 8 Repeat steps 3 through 7 for the left side axle shaft and bearing assembly 11 and 2 1 Snap Ring 6 O Ring 11 Left Side Axle Shaft 1...

Page 264: ...ver 17 from axle housing 10 NOTE Bearing caps 12 are marked with letters or numbers in horizontal and vertical positions Note position of bearing caps and replace in original position during assembly...

Page 265: ...ings 7 and 9 for wear or damage Replace as needed Lubricate input shaft ball bearings 7 and 9 with Mobilfluid 424 or SAE 30 oil prior to installation Install input shaft ball bearings on input shaft u...

Page 266: ...5 24 4222983 Second Edition CHASSIS 5 Page Intentionally Blank...

Page 267: ...tment 6 18 Reel Bearing Pre Load Adjustment 6 18 Right and Left Reel Stop Bracket Adjustment 6 20 Right and Left Reel Bumper Adjustment 6 20 Center Reel Bumper Adjustment 6 21 Reel Leveling Rod Pre Ad...

Page 268: ...e Gap in mm 0 001 0 003 0 025 0 076 Reel Bearing Pre Load in mm 0 040 1 27 Right Left Reel Leveling Rod Rod End to Nut Face Measurement non spring side in mm 1 625 41 3 Center Reel Leveling Rod Rod En...

Page 269: ...el Assembly 12 Yoke 15 Cutting Unit Rear Roller 2 Grass Catchers 6 Center Reel Leveling Rod 10 Counterweight 13 Lift Arm 16 Bedknife Backing Assembly 3 Right Reel Leveling Rod 7 Drive Motor 11 Grass S...

Page 270: ...cate the blades and leads to early dulling of the blades In most cases information provided by the user customer will provide the basis for the repairs and adjustments that may be required However it...

Page 271: ...blades Probable Cause Remedy Incorrect cutting height adjustment Adjust to the proper height of cut Incorrect bedknife to reel clearance Adjust the bedknife to reel clearance See Reel Bearing Housing...

Page 272: ...ion is found mostly on mowers with multiple suspended cutting units Washboarding may also be caused by variations in the turf Probable Cause Remedy Mowing ground speed is too fast Reduce mowing ground...

Page 273: ...n is usually caused by an incorrect frequency of clip Probable Cause Remedy Incorrect frequency of clip Check and adjust frequency of clip Frequency of clip must be equal to or less than height of cut...

Page 274: ...C Adjustment on page 6 17 Worn roller bearings Check replace roller bearings See Roller Bearings on page 6 32 Worn reel bearings Check replace adjust reel bearings See Reel Bearing Housing Assembly on...

Page 275: ...sively 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 settings See Height of Cut HOC Adjustment on page 6...

Page 276: ...just bedknife See Bedknife to Reel Clearance Adjustment on page 6 16 Dull cutting edges Sharpen reel and bedknife Refer to Safety Operation and Maintenance Manual Mowing ground speed is too fast Reduc...

Page 277: ...ce missing screws See Bedknife on page 6 27 Incorrect roller Install correct roller for application See Front Roller on page 6 31 or Rear Roller on page 6 32 Bedknife is matting the grass down Install...

Page 278: ...ted 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 d...

Page 279: ...o another Probable Cause Remedy HOC inconsistent from one cutting unit to another Check adjust HOC on cutting units to same height See Height of Cut HOC Adjustment on page 6 17 Check condition of cutt...

Page 280: ...pattern of varying cutting heights resulting in a wave like cut appearance usually due to heavy contact points across the reel and or bedknife Probable Cause Remedy Reel and or bedknife unevenly worn...

Page 281: ...reel enable switch See Rocker Switches Test on page 4 130 Mow switch faulty Test mow switch See Mow Switch Test on page 4 129 Reel motor coupler or key missing Check for missing coupler or key and rep...

Page 282: ...een the reel blade and bedknife using the upper adjuster 7 and the lower adjuster 8 on both the leading and trailing edges of reel NOTES The key consideration for bedknife to reel adjustment is to mov...

Page 283: ...d of the gauge screw over the bedknife 3 6 Turn adjusting knob 1 to close the gap between the front and rear rollers 7 and 5 and height of cut bar 6 7 Tighten lock nut 9 8 Repeat steps 2 through 7 on...

Page 284: ...Tighten nuts 2 on both sides of cutting unit Reel Bearing Pre Load Adjustment See Figures 6 8 through 6 12 1 Park the mower safely See Park Mower Safely on page 1 6 2 Back bedknife away from reel See...

Page 285: ...s or until there is 0 040 in 1 27 mm side to side movement of the reel Figure 6 11 6 Install spacer 10 washer 11 lock washer 13 and screw 12 Figure 6 12 7 Install counterweight 14 screws 15 and lock w...

Page 286: ...he fully up position NOTE The cutting unit should stop against bumper 5 4 Position reel stop bracket 3 against the up stop shaft 1 and tighten nuts 2 Right and Left Reel Bumper Adjustment See Figure 6...

Page 287: ...Eclipse 322 Models 62803 Gas and 62805 Diesel see figure 6 15 For Eclipse 322 Model 62801 Electric see figure 6 16 3 Loosen two screws 1 4 Engage the mow switch and raise the center cutting unit 3 to...

Page 288: ...en the set screw on collar 3 6 Measure distance between end of the leveling rod and face of nut 5 The measurement should be 0 125 in 3 2 mm If the measurement does not meet specifications turn nut 4 a...

Page 289: ...Installation Notes Apply marine lubrication grease to I D of rod connecting pin 3 and reel leveling rod 5 at area beneath the springs Apply Loctite 242 Blue to set screw 4 Pre adjust the reel leveling...

Page 290: ...Installation See Figures 6 23 and 6 24 1 Park the mower safely See Park Mower Safely on page 1 6 NOTE If a grass catcher is fitted to the cutting unit remove it before swinging cutting unit out from u...

Page 291: ...a hand grease gun only Pump the gun slowly until a slight amount of pressure is felt then stop do not over grease Do not use compressed air gun Level the cutting unit See Cutting Unit Leveling Adjustm...

Page 292: ...edknife adjuster screws 1 and 2 on both sides of the cutting unit Figure 6 28 5 Support bedknife backing assembly 3 6 Remove bedknife backing mounting screw 4 on both sides of cutting unit 7 Remove be...

Page 293: ...bedknife front face angle and an 8 10 bedknife top face angle rear relief 5 7 if equipped with a Super Tournament bedknife Adjust the bedknife to reel clearance See Bedknife to Reel Clearance Adjustm...

Page 294: ...LB specifications Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only Pump the gun slowly until a slight amount of pressure is felt then stop do not...

Page 295: ...eded See Reel Assembly on page 6 30 Disassembly and Assembly See Figure 6 34 Figure 6 34 Assembly Notes Install new grease seal 2 Inspect bearing cup and cone 1 for wear or damage Replace as needed Pa...

Page 296: ...ng unit front roller See Front Roller on page 6 31 11 Install cutting unit to mower See Center Cutting Unit on page 6 24 or Right and Left Cutting Units on page 6 25 Reel Assembly Removal and Installa...

Page 297: ...ise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller Figure 6 38 3 Remove nuts 3 and screws 4 4 Remove adjuster knobs 1 5 Remove adj...

Page 298: ...Bearings Removal See Figure 6 40 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove roller See Front Roller on page 6 31 or Rear Roller on page 6 32 Figure 6 40 3 Using a suitable ham...

Page 299: ...ion 7 3 Repair 7 4 Work Light Assembly 7 4 Dome Light 7 5 OPS Light 7 5 OPS 7 6 Hood 7 6 Armrest Assembly 7 7 Seat and Seat Platform 7 8 Seat Switch 7 10 Rear Fender 7 11 Rear Wheel and Axle Assembly...

Page 300: ...g Nut Torque lb ft N m 150 203 Steering Tower Mounting Screw Torque lb ft N m 55 60 75 81 Front Tires Size 18 x 10 5 8 Type 4 ply Air Pressure psi bar 16 1 10 Front Wheel Lug Nut Torque lb ft N m 80 1...

Page 301: ...ure 7 1 Figure 7 1 Component Location 1 OPS Operator Protective Structure 5 Steering Tower 9 Front Wheel 2 2 Seat and Seat Platform 6 Left Side Cowling 10 Right Side Cowling 3 Armrest Assembly 7 Work...

Page 302: ...ounting bracket 4 5 Remove work light assembly 2 Installation Notes Install work light assembly by reversing the order of removal Adjust the work light to project the desired distance in front of the...

Page 303: ...5 Remove dome light 3 Installation Notes Install dome light by reversing the order of removal Use new cable tie to secure wire harness and wire connector OPS Light Removal and Installation See Figure...

Page 304: ...3 lock washers 4 and flat washers 5 on each side of machine 7 Remove OPS 2 Installation Notes Install OPS by reversing the order of removal Tighten OPS mounting screws 3 to 25 lb ft 39 N m Hood Remova...

Page 305: ...prevent stretching or pinching the wires 2 Loosen the lock collar screw 2 and set screw 3 from the armrest assembly 1 3 Remove cable ties securing wire connectors and wire harness Figure 7 10 4 Discon...

Page 306: ...dard seat proceed to step 8 5 Tilt the seat back rest 1 forward 6 Raise rear of seat 3 and slide seat forward 7 Remove seat 3 Figure 7 12 8 Remove nuts 4 lock washers 5 and carriage bolts 6 9 Remove l...

Page 307: ...witch Harness 17 Seat Adjuster Rod 22 Armrest and Seat Base 3 Flat Washer 8 8 Nut 2 13 Latching Seat Track 18 Seat Adjuster Handle 23 Cable Tie 2 4 Product Literature Bag 9 Lock Washer 2 14 Push Nut 4...

Page 308: ...wo lock washers 2 and seat switch 3 Installation Notes Install seat switch by reversing the order of removal Use new cable ties to secure wire harness and wire harness connector Optional Seat See Figu...

Page 309: ...the order of removal Use new cable ties to secure wire harness and wire connector Rear Fender Removal and Installation See Figure 7 19 1 Park the mower safely See Park Mower Safely on page 1 6 Figure...

Page 310: ...hers 2 and flat washers 5 6 Remove the rear wheel and axle assembly from the machine 7 Remove four lug nuts 3 8 Remove rear axle assembly 4 from wheel 6 9 Inspect tread area for tears or other damage...

Page 311: ...xle Disassembly and Assembly See Figure 7 21 Figure 7 21 Rear Axle Assembly 1 Seal 3 Axle Tube 5 Axle Shaft 7 Wheel Bolt 4 9 Bearing Adjuster Nut 2 Bearing Cup and Cone 4 Bearing Backing Ring 6 Flat W...

Page 312: ...r other damage 7 Replace tire if damage is excessive Installation Notes Inspect and clean any rust from hub 1 or wheel mounting area Install front wheel by reversing the order of removal Tighten lug n...

Page 313: ...on the bottom of the steering wheel 12 with the top of the jaws resting on the bottom of the steering wheel 6 Tighten screw 10 until the steering wheel disengages from the steering column shaft 7 Rem...

Page 314: ...ove front cover 1 Installation Note Install front cover by reversing the order of removal Rear Cover Removal and Installation See Figure 7 28 1 Park the mower safely See Park Mower Safely on page 1 6...

Page 315: ...2 and lock washer 6 10 Disengage choke cable 3 from steering tower 7 11 Remove grommet 1 Figure 7 30 12 Disengage gas spring cable 25 from bracket 24 13 Remove nut 18 lock washer 19 spacer 20 and scr...

Page 316: ...disconnect hose 4 from plenum 2 4 Remove screw 1 spacer 6 rubber washer 5 and plenum 2 Figure 7 32 NOTE The left side cowling is shown the right side cowling is similar 5 Move seat forward 6 Remove s...

Page 317: ...e 7 33 Left Side Cowling 1 Cup Holder 5 Support Plate 9 Eclipse 322 Decal 13 Cover Gasket 2 Left Side Cowling 6 Flat Washer 10 Cup Holder Drain Hose 14 Access Cover 3 Left Side Cowling Molding 7 Lock...

Page 318: ...ion ACCESSORIES AND MISCELLANEOUS REPAIR 7 Figure 7 34 Right Side Cowling 1 Right Side Cowling Molding 2 Right Side Cowling 3 Body Cover Plug Not used on Model 62805 Diesel 4 Eclipse 322 Decal 5 Plug...

Page 319: ...Safety 1 8 Alarm Oil Pressure 4 94 Temperature High 4 94 Alternator Diesel Removal and Installation 3 14 Repair 3 14 Armrest Assembly Removal and Installation 7 7 Repair 7 7 Axle Shield and Front Spla...

Page 320: ...Checks and Adjustments Model 62803 Gas Genset and Battery Pack 3 11 Checks and Adjustments Model 62805 Diesel Genset and Battery Pack 3 10 Chemical Products Safe Handling 1 9 Circuit Breakers Removal...

Page 321: ...s and Adjustments 4 126 Continuity Test 4 126 J79 Interface Connector Location 4 7 Repair 4 137 Resistance Test 4 126 Specifications 4 4 Theory and Diagnostic Information 4 9 Troubleshooting 4 73 Elec...

Page 322: ...ult 14 4 118 Generator Fault 15 4 118 Generator Fault 21 4 118 Generator Fault 22 4 118 Generator Fault 23 4 119 Generator Fault 31 4 119 Generator Fault 54 4 119 Generator Fault 55 4 119 Generator Fa...

Page 323: ...em Diagnostic Trouble Codes 4 95 Lower Circuit Schematic Electrical 4 46 M Machine Identification Engine Identification Number Gas 2 3 Engine Serial Number Diesel 2 2 Machine Serial Number 2 2 Optiona...

Page 324: ...or Specifications 2 7 Genset and Battery Pack 2 8 Specifications 2 7 R Radiator Diesel Installation 3 17 Removal 3 15 Repair 3 15 Raise Circuit Schematic Electrical 4 43 Raise Lower Circuit Theory of...

Page 325: ...Right Reel 4 101 L Actuator Fault 4 102 L Actuator Overcurrent 4 101 Left Reel Fault 4 97 Left Reel Overcurrent 4 98 Left Reel Temperature 4 96 Left Reel Volts Low 4 99 R Actuator Fault 4 102 R Actuat...

Page 326: ...Switch 4 162 Fuel Pump Diesel 3 21 Fuel Shutoff Solenoid Diesel 3 22 Fuel Tank Diesel 3 19 Fuel Tank Gas 3 29 Fuses 4 150 GCU 4 144 Genset Diesel 3 22 Genset Gas 3 31 Genset Fan Diesel and Gas 3 27 Gr...

Page 327: ...1 10 Eye and Face Protection 1 6 Fuel Handling 1 9 Introduction 1 2 Job Preparation 1 2 Keep Work Area Clean 1 6 Keep Work Area Well Ventilated 1 6 Lifting Equipment 1 7 Machine Support 1 7 Park Mower...

Page 328: ...y 62803 Gas Removal and Installation 3 40 Starter Battery Tray Model 62805 Diesel Removal and Installation 3 40 Steering Chain and Gears Removal and Installation 5 12 Repair 5 12 Steering Chain Tensio...

Page 329: ...ill Not Start Gas and Diesel Hybrid Units Only 4 74 Fuel Shutoff Solenoid Diesel 4 133 Fuel Shutoff Solenoid Gas 4 134 Key Switch 4 129 LCD Display CAN Bus Status 4 85 LCD Display Lift Actuator Amps 4...

Page 330: ...s and Diesel Hybrid Units Only 4 75 Miniscule Change in Steering Angle without Operator Input Ghost Steering 4 83 Traction Surge or Hesitation During Mow 4 80 Vehicle Will Not Start Gas and Diesel Hyb...

Page 331: ...nnectors Inspection 4 137 V Volatile Materials Storage 1 9 W Waste Materials Safe Disposal 1 11 Work Area Cleanliness 1 6 Ventilation 1 6 Work Light Assembly Disassembly and Assembly 7 4 Removal and I...

Page 332: ...IX 14 4222983 First Edition INDEX IX...

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Page 334: ...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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Jacobsen Eclipse 322, Repair Manual

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