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Jacobsen HR 5111, Service And Repair Instructions

The Jacobsen HR 5111 Operation Manual is a comprehensive guide to help you operate and maintain your lawn mower efficiently. You can download this manual for free from our website. This manual includes step-by-step instructions and diagrams to assist you in getting the most out of your equipment.

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Hydraulic Charge Filter Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-18

Field Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-18
Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-18

Hydraulic Return Oil Filter Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-19

Field Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-19
Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-19

Engine Oil Pressure Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-20

Field Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-20
Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-20

Hydraulic Oil Temperature  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-21
Engine Cooling Water Temperature Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-21

Field Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-21
Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-21

Air Cleaner Service Indicator Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-22

Field Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-22
Switch Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-22

Implement (Mower) Switch Test (Later)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10G-23

10H. Relay  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-1

Engine (Fuel) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-1
Horn  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-1
Cruise Engage  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-1
Cab  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-1
Cruise Disengage (Brake Relay)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-2
Seat Delay Relay Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10H-3

10I.

Solenoids  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-1
Fuel Solenoid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-1

Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-1
Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-2

Differential Lock  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-3
4 Wheel Drive  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-3
Glow Plug Solenoid Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-5
Deck Motor Valve Solenoid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10I-6

10J. Circuit Breakers and Fuse  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10J-1

Circuit Breaker Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10J-1
Fuse Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10J-2

10K. Gauges  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10K-1

General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10K-1
Water Temperature Gauge Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10K-1

10L. Glow Plugs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10L-1

Glow Plug Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10L-1

10M. Diode Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10M-1

Diode Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10M-1

10N. Wiring Diagrams and Component Location Illustrations  . . . . . . . . . . . . . . . . . . . . . . . . . 10N-1

Wiring Diagram  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10N-1
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10N-2

Summary of Contents for HR 5111

Page 1: ...aintain the machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine Copyright 1997 Jacobse...

Page 2: ......

Page 3: ...14 2 3 4 5 6 7 8 9 10 11 12 13 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOU...

Page 4: ......

Page 5: ...Numbers 1A 1 Replacement Parts 1A 1 Serial Numbers 1A 1 General Cleaning 1A 2 Safety 1A 2 Torque Values 1A 2 Torque Specifications 1A 3 Standard SAE Grade 5 Screws 1A 3 Metric 1A 3 Fenders and Hood Re...

Page 6: ......

Page 7: ...ughout this manual refer to the operator s left or right when standing in the normal operating position INDEX NUMBERS Illustrations showing removal disassembly reassembly and installation may have ind...

Page 8: ...stalled as shown in Section 14 of this manual TORQUE VALUES Torque values are given in the following Torque Spe cification Chart Special torque values are called out on illustrations and text through...

Page 9: ...447 N m 3 8 16 27 33 ft lbs 37 45 N m 7 8 9 360 440 ft lbs 488 597 N m 3 8 24 31 39 ft lbs 42 53 N m 7 8 14 396 484 ft lbs 537 656 N m 7 16 14 45 55 ft lbs 61 75 N m 1 8 522 638 ft lbs 708 865 N m 7...

Page 10: ...111 can be accom plished by opening the hood and or seat pan For bet ter access the hood floor pan and engine compart ment cowling can be removed Figure 1A 2 Mark all attaching hardware to simplify in...

Page 11: ...1 General 2C 1 Throttle 2C 1 Traction Pedal 2C 2 Traction Pedal Neutral Adjustment 2C 3 Speed Limit Adjustment 2C 4 Reverse 2C 4 Forward 2C 4 Reverse Sensing Switch 2C 4 Adjustment 2C 4 Parking Brake...

Page 12: ......

Page 13: ...equired Standard automotive hand tools Cleaning materials Stoddard or equivalent solvent Detergent and water Lubricants Refer to Section 11 CONTROLS SECTION 2A REPAIR AND SERVICE TOOLS AND MATERIALS 2...

Page 14: ......

Page 15: ...on pedal is in not adjusted neutral b Binding in the linkage b Repair lubricate Sections 2C and 11B 4 Parking brake does not a Brake not adjusted a Adjust Section 2C hold b Worn brake shoes b Replace...

Page 16: ...l c Faulty cruise magnet c Replace 12 Cruise control does not a Faulty holding relay a Test replace Section 10H shut OFF 13 No 4 wheel drive a 4 wheel drive switch not ON a Turn ON b Reverse sensing s...

Page 17: ...s not a Mower not on the ground a Lower come on b Arm interlock switch not closing b Check switch Section 10G c Check solenoid plug LED c See Section 10B ON Push manual override Mower comes ON Faulty...

Page 18: ...hen operator leaves seat implement switch ON 22 Panel lights do not come a 10 amp gauge panel light circuit a Reset test Section 10J on when test switch is breaker tripped pushed to the ON b Battery d...

Page 19: ...lacement of de fective parts and hardware THROTTLE See Figure 2C 1 Located to the right of the operator s seat the throttle control is used to regulate engine speed Replace a defective throttle as sho...

Page 20: ...nected by linkage to the hy drostatic pump Depending on which way the pedal is depressed it controls forward or reverse Repair of the traction pedal and linkage is limited to replacement of damaged or...

Page 21: ...lace a small amount of lubricating oil on pedal linkage pivot points to ease movement 1 Raise the tractor so all four wheels are off the ground Put jack stands under frame to prevent accidental loweri...

Page 22: ...fore reaching its maximum forward position 2 Adjust stud 7 until the head touches the traction pedal then turn the stud one revolution counter clockwise out against the pedal 3 Tighten nut 6 REVERSE S...

Page 23: ...terclockwise until a smooth but firm action is obtained SERVICE BRAKE See Figure 2C 5 The service brake pedal should have a minimum of 1 8 3 17 mm free play before the plunger contacts piston in the m...

Page 24: ...onent as follows 1 Remove fuel tank to gain access 2 Disconnect battery ground black cable 3 Label wires for proper identification and discon nect wiring 4 Remove attaching hardware and replace faulty...

Page 25: ...on 3C 1 3D Diesel Engine 3D 1 General 3D 1 Air Cleaner 3D 1 Radiator 3D 2 Changing Coolant 3D 2 Cleaning Radiator Core 3D 2 Removal 3D 2 Installation 3D 2 Muffler Removal and Installation 3D 3 Exhaust...

Page 26: ......

Page 27: ...ing materials Stoddard or equivalent solvent Detergent and water Anti rust Never Seize Lubricants Refer to Section 11 Other service items Compressed Air Source Engine Hoist Loctite 242 Blue Engine Ser...

Page 28: ......

Page 29: ...an and or replace filter smoothly Section 3D b Faulty engine component b See Engine Manufacturer s Service Manual 3 Engine dies down a Throttle adjustment a Adjust Section 3D under load b Binding in g...

Page 30: ......

Page 31: ...the engine manufacturer s instructions for engine service and repair The engine manual is available from your Jacobsen Dealer or Distributor NOTE Tests for alternators starters and regulator are inclu...

Page 32: ......

Page 33: ...Remove the baffle 3 and empty dust from the cover Wipe clean with a clean damp cloth NOTE It is not recommended to remove element to clean If element is to be removed replace with a new one 2 Remove...

Page 34: ...ove radiator cap 2 and drain the coolant 4 Disconnect the inlet and outlet hoses by loosen ing hose clamps 3 5 Disconnect overflow tube at radiator cap 6 Remove attaching hardware 4 and 5 7 Inspect we...

Page 35: ...CTION 1 Clean all sections of the exhaust system of dirt dust or other foreign material 2 Inspect exhaust system for cracks holes distor tion or deformation ENGINE SECTION 3D DIESEL ENGINE 3D 3 3D CAU...

Page 36: ...clockwise two turns Use a suit able container to catch fuel which will flow from screw hole 3 Turn ignition switch ON to allow electric fuel pump to operate 4 When bubbles disappear from fuel coming o...

Page 37: ...ure 3D 6 4 Disconnect the throttle cable at the fuel injection pump Figure 3D 7 5 Remove the exhaust pipe and radiator shroud de scribed in preceding paragraphs see Figure 3D 2 and 3D 3 6 Tag and remo...

Page 38: ...lockwashers 5 and flat washers 6 that secure the engine to the frame 4 Install the radiator shroud and exhaust pipe as described in preceding paragraphs of this section 5 Tighten mounting bolts 4 afte...

Page 39: ...1 Assembly 4D 2 4E Axle 4E 1 General 4E 1 Differential Lock Assembly 4E 2 Input Bevel Pinion 4E 2 General 4E 2 Disassembly 4E 3 Reassembly 4E 4 Break Away Torque Adjustment 4E 5 Reduction Gear and Dri...

Page 40: ......

Page 41: ...lent Lubricants Refer to Section 11 Special tools Bucher Guyer AG CH 8166 Niederweningen FAX 01 857 26 55 Adjusting tool 150 10511 0 Special circlip pliers 150 16789 0 Loctite Master Gasket Sealant or...

Page 42: ......

Page 43: ...erential lock d Repair Section 4E e Differential lock collar jammed e Repair Section 4E 3 Wheel scuffs turf a Differential lock engaged a Release on turns b Differential not disengaging b See 1 above...

Page 44: ......

Page 45: ...5 Repeat Steps 3 and 4 for the remaining bearings ASSEMBLY See Figure 4C 1 NOTE During reassembly be sure all the parts are clean and free of dirt 1 Start one bearing in yoke ear and position center...

Page 46: ......

Page 47: ...Figure 4D 1 1 Remove drive shaft assembly from tractor 2 Position the joint in a vise as shown 3 Remove the four snap rings 4 With a soft face hammer strike the top ear of the yoke This will drive th...

Page 48: ...sing a socket or mandrel the same diameter as the bushing drive the bush ing slightly past the snap ring groove 4 Install the snap ring 5 Repeat Steps 3 and 4 for the other bushings 6 After assembly e...

Page 49: ...GENERAL See Figure 4E 1 DRIVE TRAIN SECTION 4E AXLE 4E 1 4E Figure 4E 1 Axle Assembly...

Page 50: ...parts To repair the sliding differential lock collar refer to Differential Disassembly for removal and Reassembly for installation INPUT BEVEL PINION GENERAL The input bevel pinion and ring gear are...

Page 51: ...bevel pinion assembly from axle 3 If the original pinion shaft is to be used remove the shim pack tag and mark it for reassembly If the shims are damaged replace them with shims equal to the thicknes...

Page 52: ...leeve and press bearing cone against sleeve 5 With the bearing inner race supported press out er bearing cone into housing until it just contacts the collapsible sleeve be careful not to collapse the...

Page 53: ...housing 3 Install O ring and shims pack on pinion housing REDUCTION GEAR AND DRIVE AXLE GENERAL Bearings in the reduction gear case are press fitted The large gear is splined to the shaft The axle pin...

Page 54: ...race of the bearing and press drive axle shaft into bearing Step 3 for right axle ONLY 3 Remove the differential lock assembly housing 4 Press drive axle with bearing into axle housing right axle ONL...

Page 55: ...ts to 37 ft lbs 51 N m DIFFERENTIAL GENERAL Separate the axle housing only if bearings pinion gear ring gear differential lock collar and or differen tial are worn or damaged If the differential and o...

Page 56: ...ring bore of gear case 3 Measure the distance between the special tool and end of pinion 4 Subtract this dimension from 0 689 17 5 mm 5 Build a shim pack equal to the final dimension ob tained in Step...

Page 57: ...and input bevel pinion Apply Loctite 242 Blue to the pinion housing bolts and torque them to 37 ft lbs 51 N m 8 Measure the distance from the side of the differ ential bearing to the gear case flange...

Page 58: ...Build a shim pack equal to 0 030 0 76 mm and install it in the bearing bore of the right axle 9 Assemble both axle halves together 10 Snug the bolts evenly do not tighten 11 Using a feeler gauge meas...

Page 59: ...and Materials 5A 1 5B Failure Analysis 5B 1 5C Parking Brake 5C 1 Repair 5C 1 Adjustment 5C 1 5D Service Brake 5D 1 Repair 5D 1 Bleeding System 5D 1 5E Master Cylinder 5E 1 Repair 5E 1 Bleeding Syste...

Page 60: ......

Page 61: ...ND SERVICE TOOLS AND MATERIALS 5A 1 5A Tools required Standard automotive hand tools Metric tools Cleaning materials Stoddard solvent or equivalent Lubricants Refer to Section 11 Other service items B...

Page 62: ......

Page 63: ...ngs c Replace Section 5D 3 Service brake pedal a Worn brake pads a Replace Section 5D fades when pushed b Brake line leaks b Repair c Air in line c Bleed 4 Service brake does not a Binding pedal a Fre...

Page 64: ......

Page 65: ...n and turn knob in a clockwise direction apply and re lease brake lever every quarter turn until a defi nite snap over center action is achieved 2 Over adjustment causes hard lever action but does not...

Page 66: ......

Page 67: ...luid see Section 11 2 At the brake calipers open both bleed screws 3 Slowly push the brake pedal several times until all the air has been bled from the brake lines NOTE At the end of each pedal downwa...

Page 68: ......

Page 69: ...fluid see Section 11 2 At the brake calipers open both bleed screws 3 Slowly push the brake pedal several times until all the air has been bled from the brake lines NOTE At the end of each pedal down...

Page 70: ......

Page 71: ...Unit 6C 1 General 6C 1 Removal 6C 1 Disassembly 6C 2 Inspection 6C 4 Assembly 6C 5 Installation 6C 11 6D Steer Wheel Adjustments 6D 1 Toe In 6D 1 Turn Stop 6D 1 6E Steering Cylinder 6E 1 Removal 6E 1...

Page 72: ......

Page 73: ...aning materials Stoddard solvent or equivalent Other service items O ring and kin ring tool SJ 150 9000 11 Cardan shaft tool SJ 150 9000 3 Above tool can be purchased from Danfoss Inc 1696 Northrock C...

Page 74: ......

Page 75: ...Replace leaf springs Section 6C steering go to neutral position 4 Backlash a Splines of cardan shaft worn or a Cardan shaft to be replaced broken Section 6C b Leaf springs b Replace worn spring Secti...

Page 76: ......

Page 77: ...al steering REMOVAL See Figure 6C 1 1 Remove steering wheel cap 1 nut 2 flat wash er 3 and steering wheel 4 NOTE Insert 5 should come off with steering wheel 2 Remove steering unit cover 6 3 Label and...

Page 78: ...ve end cover screws 1 and washers 2 NOTE There are seven screws one is a special screw note its position 3 Slide cover 3 sideways from gear wheel set 4 4 Lift gear wheel set 4 off housing 5 Remove car...

Page 79: ...ing unit housing See Figure 6C 5 10 Remove O ring 22 kin ring 21 thrust bearing and washers 20 ring 19 and dust ring 23 11 Push cross pin 15 out of sleeve 16 12 Carefully push spool 17 from sleeve 16...

Page 80: ...NOTE Steps 14 and 15 describe the removal of one of two shock valve assemblies Repeat Steps 14 and 15 for the other shock valve 16 Using a 8 mm hex socket wrench remove pres sure relief valve plug 30...

Page 81: ...o flat neutral position springs 18 into slot of spool 17 4 Slide two curved springs 18 between the flat springs 5 Press springs together and push into slots of sleeve 16 6 Line up springs 18 and cente...

Page 82: ...6 NOTE Ring 19 should rotate free of springs 18 8 Install cross pin 15 through sleeve and spool 9 Install thrust bearing and washers 20 being sure inside chamber of heavy washer goes on spool first ST...

Page 83: ...ng 22 and kin ring 21 Place them on the guide tool as shown 12 Using the inner tool push and turn the guide through the outer tool sleeve until O ring 22 and kin ring 21 properly seat in the housing 1...

Page 84: ...ert sleeve assembly 14 NOTE Sleeve to housing fit is very close Do not force together 16 Push sleeve 14 into housing pushing out the O ring and kin ring guide tool 17 Insert ball 11 into hole as shown...

Page 85: ...24 Install gear wheel set 5 Engage the splines so the valley of the inner rotor is in line with the pin slot of the cardan shaft as shown 25 Install cover 3 flat washers 2 and screws 1 NOTE Be sure t...

Page 86: ...tractor hydraulics and adjust as described in Section 8S 28 Install relief valve spool 34 spring 33 and us ing an 8 mm hex socket wrench plug 32 29 Install washer 31 and plugs 30 snug After adjusting...

Page 87: ...3 Install insert 5 flat washer 3 steering wheel 4 and nut 1 Torque nuts to 25 30 ft lbs 34 41 N m 4 If steering unit was disassembled adjust shock valve and relief valve pressure settings as de scribe...

Page 88: ......

Page 89: ...ompletely to the right and left 3 In each direction the steering arms should con nect the stop bolts If they do not proceed with Step a a Remove the cylinder b Loosen the cylinder clamps on each end o...

Page 90: ......

Page 91: ...set the parking brake 2 Tag and remove hydraulic lines Cap the cylinder ports and plug the lines 3 Remove attaching hardware and remove cylinder STEERING SECTION 6E STEERING CYLINDER 6E 1 6E Figure 6E...

Page 92: ...l the oil from the cylinder Disassemble following the steps as illustrated INSPECTION Inspect all parts for excessive wear cracks and broken parts Discard all O rings seals and backup rings STEERING S...

Page 93: ...before assembly 4 Follow the steps as illustrated in Figure 6E 4 and reassembly INSTALLATION See Figure 6E 1 1 Install cylinder and secure with attaching hardware 2 Connect hydraulic hoses 3 Start tr...

Page 94: ...STEERING SECTION 6E STEERING CYLINDER 6E 4 Figure 6E 4 Steering Cylinder Assembly...

Page 95: ...7 7A Repair and Service Tools and Materials 7A 1 7B Failure Analysis 7B 1 7C Tire Service 7C 1 General 7C 1 Service 7C 1 SECTION 7 WHEELS AND TIRES...

Page 96: ......

Page 97: ...eaning materials Stoddard solvent or equivalent Other service items Commercially available tire sealant Non hardening Tire pressure gauge Compressed air with tire valve fitting WHEELS TIRES SECTION 7A...

Page 98: ......

Page 99: ...Under inflated tires a Inflate tires to 20 to 24 psi 1 4 to 1 6 bars front and 6 to 10 psi 41 to 68 bars rear b Steering malfunctioning b Steering test Refer to Sections 8M 8N c Wheel nuts loose c Tig...

Page 100: ......

Page 101: ...hen it is replaced This assures proper seating of the tire bead to the rim Then reduce the pressure to the desired level before using NOTE Never use grease or oil on the rim when mount ing a tire Bead...

Page 102: ......

Page 103: ...Face Seal Torque Recommendations 8C 3 8D Traction Pump 8D 1 General 8D 1 Removal 8D 1 Repair 8D 2 Inspection 8D 2 Installation 8D 3 8E Implement Pump 8E 1 General 8E 1 Removal 8E 1 Repair 8E 2 Disasse...

Page 104: ...em 8Q 6 8R Instrument Test 8R 1 General 8R 1 Relief Valve Test 8R 2 Charge Relief Test 8R 2 Steering System Relief Test 8R 3 Adjustment 8R 3 Lift System Relief 8R 4 Adjustment 8R 4 Traction System Rel...

Page 105: ...r Test 8R 17 Wing Mowers 8R 18 Pump Test 8R 18 Right Wing Motor Valve Test 8R 19 Right Wing Motor Tests 8R 19 Left Wing Motor Valve Test 8R 20 Left Wing Motor Tests 8R 20 Hydraulic Instrument Test Dat...

Page 106: ......

Page 107: ...ls Stoddard or equivalent solvent Detergent and water Loctite Locquic Primer T Lubricants Refer to Section 11 Grease Sunray DX671 or Gulf Supreme No 0 Other service items Seal and Repair Kits availabl...

Page 108: ...HYDRAULICS SECTION 8A REPAIR AND SERVICE TOOLS AND MATERIALS 8A 2 Figure 8A 1 Wheel Restraint...

Page 109: ...everse OK out of adjustment b Faulty traction loop relief b Test Section 8R valve s 4 No reverse or slow a Traction linkage damaged or a Repair adjust Section 2C forward OK out of adjustment b Faulty...

Page 110: ...energize d Insufficient charge pressure to d Test Section 8R activate differential lock e Differential collar return spring e Repair Section 4E broken LIFT SYSTEM 1 Mowers will not lower a Engine RPM...

Page 111: ...der leaking internally a Repair Section 8L themselves b Valve detent poppet not seating b Repair Section 8H or leaking c Detent spool not retracting c Repair Section 8H completely sticking 10 Mower s...

Page 112: ...aulty pump section e Test Section 8R NO see a YES see c e OFF See a 5 Right wing mower doesn t a Faulty electrical circuit a See Section 10B run b Faulty motor control valve b Test Section 10I Check L...

Page 113: ...mallet is recommended unless otherwise specified in the repair instruction Unless otherwise indicated apply a light coat of clean hydraulic fluid to parts as each is reassembled Ap ply clean grease to...

Page 114: ...for O Ring Boss Fittings NOTE O rings should be lubricated with the fluid to be used in the system prior to assembly HYDRAULICS SECTION 8C GENERAL INSTRUCTIONS 8C 2 FIgure 8C 1 Reference Marking SAE...

Page 115: ...e Size O D In Lbs 3 3 8 24 0 188 96 120 4 7 16 20 0 250 168 192 5 1 2 20 0 312 216 240 6 9 16 18 0 375 288 312 8 3 4 16 0 500 600 720 10 7 8 14 0 625 864 960 12 11 16 12 0 750 1500 1620 14 13 8 12 0 8...

Page 116: ......

Page 117: ...until a hydro pump test described in Section 8Q and or 8R is performed 1 Remove the seat and seat pan 2 Thoroughly clean area around entire pump with a suitable cleaning solvent Do not use material th...

Page 118: ...gouged marks 2 Inspect piston shoes for excessive wear cracks or shoes that fall off pistons 3 Inspect shaft for excessive wear or damage 4 If any component condition is questionable replace hydrostat...

Page 119: ...fasten the mounting plate 2 Connect all control linkage See Section 2 for prop er adjustments 3 Install the implement pump 4 Connect all hydraulic hoses and tubes 5 Install seat and seat pan 6 Start...

Page 120: ......

Page 121: ...p section 4 supplies oil for steering lift and lower charge oil for the traction pump differ ential lock and the 4 wheel drive valve REMOVAL See Figure 8E 1 1 Using a suitable solution clean the pump...

Page 122: ...Recommended method of marking body sections is to use a fine point metal punch making one indentation in line on each section HYDRAULICS SECTION 8E IMPLEMENT PUMP 8E 2 CAUTION Never pry pump sections...

Page 123: ...ng up from cover section 3 Use a new seal kit during assembly Use clean grease to keep seals in position 4 Remove alignment mark from gear sets after they have been installed with teeth in mesh 5 Rota...

Page 124: ......

Page 125: ...REPAIR Repairs are limited to replacing the 4 wheel drive pilot cartridge or changing O rings HYDRAULICS SECTION 8F 4 WHEEL DRIVE CONTROL VALVE 8F 1 8F Figure 8F 1 4 Wheel Drive Control Valve...

Page 126: ......

Page 127: ...ited to cleaning only Use a punch manu ally push poppet off its seat and flush with cleaning solvent If the problem still exists replace valve HYDRAULICS SECTION 8G ANTI SIPHON VALVE 8G 1 8G Figure 8G...

Page 128: ......

Page 129: ...r the three front cutting units REMOVAL 1 Drain and remove the fuel line 2 Tag and mark hydraulic lines on valve 3 Remove hydraulic lines 4 Disconnect lever linkage and remove 5 Remove valve DISASSEMB...

Page 130: ...HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H 2 Figure 8H 3 Spool Assembly Removal Figure 8H 4 Relief Valve Removal...

Page 131: ...rts as necessary 3 Inspect poppet seats for burrs or roughness 4 Discard old O rings and replace with new ones REASSEMBLY See Figures 8H 5 to 8H 7 HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H...

Page 132: ...HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H 4 Figure 8H 7 Detent and Lockout Reassembly...

Page 133: ...REPAIR HYDRAULICS SECTION 8I TRACTION MOTOR 8I 1 8I Figure 8I 1 Traction Motor Disassembly Figure 8I 2 Drive Shaft Disassembly...

Page 134: ...nd shoes Pistons should be snug and shoes should be flat and have no signs of flaking NOTE Do not tap piston shoes 4 Inspect piston block Make sure the flat surface is free of score marks NOTE Do not...

Page 135: ...HYDRAULICS SECTION 8I TRACTION MOTOR 8I 3 8I Figure 8I 4 Drive Shaft Reassembly Figure 8I 5 Traction Motor Reassembly...

Page 136: ......

Page 137: ...REPAIR HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 1 8J Figure 8J 1 Rear Traction Motor...

Page 138: ...HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 2 Figure 8J 2 Seal Assembly...

Page 139: ...HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 3 8J Figure 8J 3 O Rings and Seals...

Page 140: ......

Page 141: ...REPAIR Repair of the control valve is limited to changing car tridges or renewing O ring on each cartridge HYDRAULICS SECTION 8K CONTROL VALVE 8K 1 8K Figure 8K 1 Control Valve...

Page 142: ......

Page 143: ...re the same FRONT CYLINDERS DISASSEMBLY See Figure 8L 1 1 Clean and air dry exterior of cylinder 2 Drain all the oil from the cylinder 3 Disassemble following the steps in Figure 8L 1 HYDRAULICS SECTI...

Page 144: ...eals and seal ring REASSEMBLY 1 Lightly lubricate O rings seal ring and seals 2 Install seal kit as shown in Figure 8L 2 3 Lubricate all parts before assembly 4 Follow the steps as illustrated in Figu...

Page 145: ...HYDRAULICS SECTION 8L LIFT CYLINDER 8L 3 8L Figure 8L 3 Lift Cylinder Assembly...

Page 146: ...air dry exterior of cylinder 2 Drain all the oil from the cylinder 3 Disassemble following the steps in Figure 8L 4 4 Disassemble remainder of cylinder as shown in Fig ure 8L 4 HYDRAULICS SECTION 8L...

Page 147: ...EMBLY 1 Lightly lubricate O rings backup rings and seals 2 Install seal kit as shown in Figure 8L 5 NOTE Do not install rod O ring at this time 3 Lubricate all parts before assembly 4 Follow the steps...

Page 148: ...HYDRAULICS SECTION 8L LIFT CYLINDER 8L 6 Figure 8L 6 Wing Cylinder Assembly...

Page 149: ...The following illustration shows one of the three valves REPAIR See Figure 8M 1 Repair of the valve consists of installing a new O ring kit for changing a coil 1 Follow the sequence as illustrated to...

Page 150: ...sure it slides easily in the outer flux sleeve 5 Check for broken or cracked return spring INSTALLATION Install control valve to frame with attaching hardware SOLENOID COIL REPLACEMENT Refer to Secti...

Page 151: ...erclockwise CCW rotating have the letter A stamped on the motor housing Prior to disassembly mark the position of the check valve in the cover to motor housing REPAIR See Figure 8N 2 Repair of the mot...

Page 152: ...aning an indication of damage to motor or other hydraulic component 2 Inspect all parts for cracks nicks burrs and exces sive wear Replace entire motor if found damaged or worn REASSEMBLY See Figure 8...

Page 153: ...s is located at the bottom left side of the hydraulic tank Repair is limited to cleaning only Disassemble and flush with a cleaning solvent HYDRAULICS SECTION 8O OIL COOLER COLD OIL BYPASS 8O 1 8O Fig...

Page 154: ......

Page 155: ...REPAIR Repair of the flotation control is renewing O ring or replacing the control cartridge HYDRAULICS SECTION 8P FLOTATION CONTROL 8P 1 8P Figure 8P 1 Back Pressure Control Valve...

Page 156: ......

Page 157: ...nce Always change the filter when changing the oil The filter should be changed after the initial 25 hours of operation Thereafter the filter should be changed approximately every 250 hours 2 Check al...

Page 158: ...With the engine throttle wide open 2 wheel drive and cutting units lowered slowly step on the trac tion pedal If the engine labors or the tractor drive tires brake traction the traction motor is okay...

Page 159: ...r steer ing the maximum right and or left the steering unit is okay If the steering wheel continues to turn proceed to Step 2 2 Remove both hydraulic lines from the steering cylin der plug the lines c...

Page 160: ...HYDRAULICS SECTION 8Q HYDRAULIC FIELD TEST PROCEDURES 8Q 4...

Page 161: ...Wing Remove hydraulic lines as shown in Figure 8Q 4 Plug line and cap port Left Wing Remove hydraulic lines as shown in Figure 8Q 4 Plug line and cap port 3 Pull lift control lever raising the mower...

Page 162: ...plement mower switches ON engine not running and the reel directional switch in CUT check the plastic connector on the motor control valve the red LED should be on If the red LED is on proceed with St...

Page 163: ...HYDRAULICS SECTION 8Q HYDRAULIC FIELD TEST PROCEDURES 8Q 7 Figure 8Q 5 Reel System 8Q...

Page 164: ...motor If the case drain line feels warmer than the remaining motor it may have excessive internal leakage see Section 8N If only the right motor is affected check its case drain line If the case drai...

Page 165: ...afe manner It is important to follow the instructions accurately and completely Make sure to plug lines and cap ports when so instructed Also read and follow the Preliminary Checks provided in Section...

Page 166: ...advance throt tle to 2800 engine rpm Charge relief should read 190 250 psi NOTE The charge relief cartridge should not be adjusted If the charge relief pressure is higher or lower than 190 250 psi ad...

Page 167: ...psi is obtained relief valve is okay If 1500 psi cannot be obtained proceed with relief valve adjustment Adjustment See Figure 8R 3 1 Shut the engine down before making the adjust ment 2 Remove the s...

Page 168: ...be obtained proceed with re lief valve adjustment Adjustment See Figure 8R 4 1 Be sure engine is shut down 2 Remove relief valve cap from lift valve 3 Shims are used to adjust the pressure setting Ad...

Page 169: ...5 1 Use a 0 5000 psi gauge with test adapter P N 551433 2 Plug gauge into port BD located on the top of the 4 wheel drive valve 3 Set the parking brake start the engine advance throttle to 2800 engine...

Page 170: ...rt of the left motor Plug line cap motor port 4 Set the brake start the engine advance the throttle to 2800 engine rpm Engage the front motor circuit If 3000 psi is obtained relief valve is okay If 30...

Page 171: ...er load valve start engine advance throt tle to 2800 engine rpm 5 Read record no load flow It should be 7 5 gpm 6 Slowly close tester load valve until 1500 psi is obtained and allow oil to heat up to...

Page 172: ...t the engine slowly advance the throttle Flow should increase to approximately 4 5 5 0 gpm at approximately 1900 2000 engine rpm At this point flow should stop increasing as engine rpm continues to be...

Page 173: ...he front mower NOTE DO NOT start engine If mower s come down and no oil leaks from disconnected tee the lift valve may be faulty repair valve see Section 8H NOTE A small amount of static oil may leak...

Page 174: ...down and oil contin ues to leak from cylinder port cylinder is faulty repair cylinder see Section 8L RIGHT WING CYLINDER AND LIFT VALVE ISOLATION EST See Figure 8R 10 15 Raise right wing mower and lo...

Page 175: ...charge pressure is not affected after changing the charge relief cartridge proceed with an in strument test implement pump section 4 11 Slowly close tester load valve until 3000 psi is obtained and al...

Page 176: ...Open tester load valve start engine advance throt tle to 2800 engine rpm 19 Set parking brake apply and hold foot brake 20 Slowly close tester load valve until 3000 psi is obtained and allow oil to h...

Page 177: ...Open tester load valve start engine advance throt tle to 2800 engine rpm 25 Engage 4 wheel drive switch 26 Set parking brake apply and hold foot brake 27 Slowly close tester load valve until 3000 psi...

Page 178: ...or hose to L1 port 30 Install rear wheel restraints to the right and left rear wheels 31 Open tester load valve start engine advance throt tle to 2800 engine rpm 32 Engage 4 wheel drive switch 33 Set...

Page 179: ...er load valve start engine advance throt tle to 2800 engine rpm 5 Read record no load flow It should be 10 0 gpm 6 Slowly close tester load valve until 2300 psi is ob tained and allow oil to heat up t...

Page 180: ...ith Step 20 If flow drop is 1 2 1 gpm valve is marginal If flow drops more than 1 gpm valve has exces sive internal leakage Left Motor Test NOTE A pump and valve test must be performed be fore proceed...

Page 181: ...wer reel switch into CUT and pull implement switch ON 35 Slowly close tester valve until 2500 psi is obtained 36 Read record gpm flow Subtract from flow obtained in CENTER MOTOR test If flow drops 1 2...

Page 182: ...tester to the pump out let port and plug pump outlet line 3 Put the hose from the OUT port of tester into the hydraulic tank 4 Open tester load valve start engine advance throt tle to 2800 engine rpm...

Page 183: ...ief valve adjustments reel system wing mowers adjustment Figure 8R 6 18 Slowly open tester load valve until 2500 psi is obtained 19 Read record gpm flow Subtract from flow obtained in PUMP test If low...

Page 184: ...faulty Readjust see relief valve adjustments reel system wing mowers adjustment Figure 8R 6 18 Slowly open tester load valve until 2500 psi is obtained 19 Read record gpm flow Subtract flow obtained...

Page 185: ...HYDRAULICS SECTION 8R INSTRUMENT TEST 8R 21 8R Figure 8R 19 Left Wing Motor Circuit Tests...

Page 186: ...HYDRAULICS SECTION 8R INSTRUMENT TEST 8R 22 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 187: ..._ Conclusion ________ gpm drop engine rpm drop ________ LIFT SYSTEM TESTS Front Mower and Lift Valve Isolation Test check correct Conclusion _____ No oil leakage mower does not come down _____ No oil...

Page 188: ...gine rpm ________ 4 Wheel Drive Test ________ gpm 3000 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Right Motor NO LOAD ________ gpm engine rpm ________ L...

Page 189: ...AD ________ gpm engine rpm ________ 2500 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Right Wing Motor Valve NO LOAD ________ gpm engine rpm ________ Pump...

Page 190: ...pm engine rpm ________ Pump Test ________ gpm 2500 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Left Wing Inside Motor NO LOAD ________ gpm engine rpm ___...

Page 191: ...HYDRAULICS 8S 1 8S Figure 8S 1 Flow Diagram...

Page 192: ...HYDRAULICS 8S 3 Figure 8S 2 Schematic Early...

Page 193: ...HYDRAULICS 8S 5 8S Figure 8S 3 Schematic Later...

Page 194: ...3000 psi T p A B C 4 3 2 1 Inside Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge R...

Page 195: ...e Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift...

Page 196: ...e Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift...

Page 197: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Page 198: ...ide Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lif...

Page 199: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Page 200: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Page 201: ...TR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Valve LH Center RH 4WD Valve...

Page 202: ...HYDRAULICS 8S 7 Figure 8S 4 Traction System 1 of 4...

Page 203: ...HYDRAULICS 8S 9 8S Figure 8S 5 Power Steering System 2 of 4...

Page 204: ...HYDRAULICS 8S 11 Figure 8S 6 Lift System 3 of 4...

Page 205: ...HYDRAULICS 8S 13 8S Figure 8S 7 Mower System 4 of 4...

Page 206: ......

Page 207: ...allation 9C 1 9D Hydraulic Tank 9D 1 General 9D 1 Removal and Installation 9D 1 9E Seat 9E 1 Removal and Installation 9E 1 9F Deck Lift Assembly 9F 1 Lift Assembly 9F 1 Wings Transport Lock Mechanism...

Page 208: ......

Page 209: ...en orange Paint Jacobsen black Anti rust Never Seize Lubricants Grease gun grease eg Sunray DX671 or Gulf Supreme No 0 Lithium based grease Other oil options Jacobsen Part No 502693 5 gal 19 liter Jac...

Page 210: ......

Page 211: ...ove 2000 a Increase engine rpm not occur when lever is b Lever linkage is worn b Repair or replace linkage actuated Section 2C c Mechanical binding c Lubricate repair d Hydraulics faulty d Test Sectio...

Page 212: ......

Page 213: ...D INSTALLATION See Figure 9C 1 1 Place a suitable container under tank and open tank drain valve 2 Remove fuel vent outlet and return lines from tank 3 Remove tank mounting hardware and tank 4 Remove...

Page 214: ......

Page 215: ...rance or air noted by a foamy appear ance or other contaminants a rancid odor indicating excessive heat or after a major component failure the hydraulic fluid should be changed NOTE The cap on the hyd...

Page 216: ......

Page 217: ...e from the slide mounting brackets 2 Lift the seat and slide mounts off seat pan To install the seat secure the seat assembly with at taching hardware Lubricate as described in Section 11 CHASSIS SECT...

Page 218: ......

Page 219: ...CHASSIS SECTION 9F DECK LIFT ASSEMBLY 1 9F Figure 9F 1 Lift Assembly LIFT ASSEMBLY See Figure 9F 1 1 Lower implement to ground...

Page 220: ...e adjustments unless the arms have been disassembled Repair is limited to replacing damaged or worn parts NOTE When installing the center lock nut do not tight en against latch hook Latch hook must mo...

Page 221: ...steering cylinder and hydraulic motors Cap or plug all fittings 4 Remove cotter pin and slotted nut 5 Remove capscrew 6 Making sure tractor and axle are well supported remove pivot shaft and thrust w...

Page 222: ...5 Inspect steering assembly components for signs of wear and replace as necessary 6 Replace lower thrust bearing and thrust washers and spindle bushings as needed 7 Install thrust bearings and thrust...

Page 223: ...oid 10F 1 Starter Motor 10F 2 10G Switches 10G 1 General 10G 1 Seat Switch Test 10G 1 Ignition Switch Test Early 10G 2 Ignition Switch Test Later 10G 4 Implement Mower Switch Test Early 10G 6 Wing Mow...

Page 224: ...est Later 10G 23 10H Relay 10H 1 Engine Fuel Solenoid 10H 1 Horn 10H 1 Cruise Engage 10H 1 Cab 10H 1 Cruise Disengage Brake Relay 10H 2 Seat Delay Relay Test 10H 3 10I Solenoids 10I 1 Fuel Solenoid 10...

Page 225: ...timeter Jumper wires 60 amp ammeter Cleaning materials Baking soda and water Other service items Electrical insulation compound P N 365422 ELECTRICAL SYSTEM SECTION 10A REPAIR AND SERVICE TOOLS AND MA...

Page 226: ......

Page 227: ...L c Faulty glow plug switch c Test Section 10G d 30 amp implement fuel circuit d Reset test Section 10J breaker tripped e Faulty fuel solenoid relay e Test replace Section 10H f Faulty fuel solenoid f...

Page 228: ...C c Reverse sensing switch not c Adjust Section 2C adjusted d Faulty reverse sensing switch d Test Section 10G e Faulty 4 wheel drive switch e Test Section 10G f Faulty 4 wheel drive valve f See Secti...

Page 229: ...Test replace Section 10H immediately when oper b Faulty wiring or bad electrical b Test Section 10C ator leaves seat Imple ground ment switch ON 6 Engine does not shut a Faulty time delay relay a Test...

Page 230: ...e Faulty wiring or bad electrical e Test Section 10C ground 6 Hourmeter does not work a 10 amp gauge panel light circuit a Reset test Section 10J breaker tripped b Faulty hourmeter b Replace c Faulty...

Page 231: ...i Test Section 10C ground 2 Cruise control drops off a Faulty holding relay a Test replace Section 10H after being set b Service brake switch not adjusted b Adjust Section 2C c Faulty cruise control...

Page 232: ...10C ground 8 Cab heater and wipers do a Ignition switch OFF a Turn ON not work b Faulty cab relay b Test Section 10H c Faulty wiring or bad electrical c Test Section 10C ground 9 Heater fan does not...

Page 233: ...y check as described below NOTE Before performing any component or wiring test check for corrosion and loose or missing con nections If a component switch relay etc is removed for test or replacement...

Page 234: ...ings are above 0 5 the switch or wire is questionable ELECTRICAL SYSTEM SECTION 10C GENERAL INSTRUCTIONS 10C 2 Figure 10C 2 Resistance Test Ohms POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2...

Page 235: ...performance or early failure due to loss of electrolyte 2 Keep terminals and top of battery clean Wash with baking soda and rinse with clear water Do not al low soda solution to enter cells as this w...

Page 236: ...DC multimeter to battery terminals 2 Set voltmeter to 20 VDC 3 Crank the engine if battery voltage falls below 9 volts while cranking the battery is run down or faulty Charge and perform test again EL...

Page 237: ...oltage should increase to a maximum 14V at 1500 engine rpm Current output should also increase to a maxi mum 35 amps at 2500 engine rpm NOTE Charge condition of battery will affect current amp output...

Page 238: ...meter to 20 VDC and connect POS lead to terminal F and NEG to terminal E 3 Turn on the ignition switch The multimeter should read battery voltage If no voltage registers continue with voltage reg ulat...

Page 239: ...inal 4 Set the multimeter to 200 VDC 5 Start and run engine at approximately 1500 rpm 6 Disconnect the battery NEG cable Voltage should be about 17 VDC Voltage should increase to 32 VDC as the en gine...

Page 240: ...alternator 2 Set the multimeter to 200 ohms range 3 Connect the multimeter POS lead to terminal F and the NEG lead to terminal E The resistance should be approximately 6 5 10 ohms ELECTRICAL SYSTEM SE...

Page 241: ...emove the NEG battery cable 5 Gradually accelerate the engine and watch the multimeter Voltage should rise as engine rpm increases Voltage should read 13 8 to 14 8 VDC If voltage does not increase wit...

Page 242: ...EGULATOR TEST See Figure 10E 6 The regulator regulates the output voltage and current according to the electrical demand ELECTRICAL SYSTEM SECTION 10E CHARGING SYSTEM 10E 6 Figure 10E 6 Regulator Test...

Page 243: ...switch is turned to the start position a click should be heard from the coil If no click is heard the coil or electrical supply may be defective Continue with the next step 4 Remove the PUR WHT soleno...

Page 244: ...ct cable to POS terminal of battery 6 Touch the NEG cable to the NEG terminal on the battery The starter motor should turn If the starter does not turn or turns slow con nect a multimeter set at 20 VD...

Page 245: ...EAT SWITCH TEST See Figure 10G 1 1 Disconnect seat switch connector 2 Set VOM to 200 ohms scale 3 Connect meter leads to connector terminals There should be no reading no continuity on VOM 4 Depress s...

Page 246: ...ld be a reading of 0 0 5 ohms on the multimeter d Connect black NEG lead to terminal X and red POS lead to terminal Y There should be a reading of 0 0 5 ohms on the multimeter e Hold switch in START p...

Page 247: ...tinuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms STEP 4C STEP 4E STEP 4F STEP 4A STEP 4D STEP 4B Position Continuity...

Page 248: ...0 5 ohms in any of the following tests the switch is faulty and must be replaced b With key switch in RUN position connect black NEG test lead to terminal B and red POS lead to terminal I There should...

Page 249: ...ELECTRICAL SYSTEM SECTION 10G SWITCHES 10G 5 10G Figure 10G 5 Ignition Switch Test Step 4...

Page 250: ...om binations of terminals with switch in the OFF position There should be no reading on the multimeter 4 Place switch in ON position and test as follows a Check for continuity by connecting one multi...

Page 251: ...position and test as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Connect one multim...

Page 252: ...test as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Check for continuity across rem...

Page 253: ...as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Check for continuity across remaini...

Page 254: ...lows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal A There should be 0 0 5 ohms on the mul timeter b Check for continuity across remaining term...

Page 255: ...ld switch in the ON position There should be a reading of 0 0 5 ohms on the multimeter Replace a switch that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL S...

Page 256: ...est leads to switch terminals There should be a reading of 0 0 5 ohms on the multimeter 5 Lift and hold switch lever up in OFF position There should be no reading on the multimeter NOTE Switch must be...

Page 257: ...button down There should be a reading of 0 0 5 ohms at multimeter Replace a switch that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL SYSTEM SECTION 10G SW...

Page 258: ...ading on the multimeter no continuity 7 Depress switch lever There should be a reading on multimeter conti nuity Replace a switch that does not meet all the above test results or has resistance of 0 5...

Page 259: ...om the switch 2 Set multimeter to 200 ohms scale 3 Connect leads to switch as shown There should be no continuity through the switch 4 Depress switch There should be a reading of 0 0 5 ohms at multime...

Page 260: ...continuity through the switch 3 Actuate switch push switch in There should be a reading of 0 0 5 ohms at multimeter NOTE RED switch lead is not used Replace a switch that does not meet all the above...

Page 261: ...t come on check circuit wiring and or bulb Hydraulic charge pressure light does not go off when engine is started At the switch disconnect the plug Light goes off proceed with switch test Step 1 Light...

Page 262: ...s turned on and stays ON when engine is started Remove BLU wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circuit wiring for ground SWITCH TEST 1...

Page 263: ...d on and stays ON when engine is started Remove TAN wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circuit wiring for ground SWITCH TEST 1 Set mul...

Page 264: ...ring and or bulb Engine oil pressure light does not go off when engine is started Remove BLU wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circui...

Page 265: ...water temperature light does not come on Check circuit wiring and or bulb SWITCH TEST 1 Using a suitable container fill it with engine or hydraulic oil 2 Heat the oil to 230 F 110 C 3 Set multimeter...

Page 266: ...comes ON proceed with switch test Step 1 Air filter light does not come on check circuit wiring and or bulb SWITCH TEST 1 Set multimeter to 200 ohms scale 2 Connect test leads as shown There should b...

Page 267: ...terminal 5 and the other to terminal 6 There should be 0 0 5 ohms on the mul timeter b Connect one multimeter test lead to terminal 2 and the other lead to terminal 3 c Check for continuity across al...

Page 268: ......

Page 269: ...nuity on both terminals 87 If there is continuity replace relay 4 Connect 12V across terminals 85 and 86 There should be an audible click 5 Connect black NEG lead from the multimeter to terminal 30 6...

Page 270: ...inals 85 and 86 There should be an audible click 6 Connect black NEG lead from multimeter to terminal 30 7 Connect red POS lead from multimeter to ter minal 87a Open when coil is energized 8 Move red...

Page 271: ...volts If not replace relay 5 Disconnect white wire from 12V Bat After a 1 to 2 second delay voltage reading on DMM should drop out if not replace relay ELECTRICAL SYSTEM SECTION 10H RELAY 10H 3 10H P...

Page 272: ......

Page 273: ...age is not present check wiring for an open or high resistance 5 Connect red POS lead of multimeter to termi nal of WHT wire No voltage should register proceed with Step 6 If battery voltage is presen...

Page 274: ...RUN position 3 Adjust and connect rod at stop lever as necessary so that there is a gap between lever and stop with solenoid engaged 4 After adjustment turn ignition switch to OFF NOTE If not adjuste...

Page 275: ...Hirshman connector from solenoid 4 Set multimeter to 20 VDC range 5 Connect black NEG multimeter lead to con nector as shown 6 Connect red POS lead of multimeter to con nector as shown Multimeter read...

Page 276: ...ultimeter leads to coil as shown Coil ohms reading should be approximately 10 ohms if reading is correct Valve car tridge may be faulty Coil ohm reading not to specification change coil ELECTRICAL SYS...

Page 277: ...ohms Replace a solenoid that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL SYSTEM SECTION 10I SOLENOIDS 10I 5 10I POWER OFF ON 200m 2 20 200 1000 750 200 20...

Page 278: ...hman connector from solenoid 4 Set multimeter to 20 VDC range 5 Connect black NEG multimeter lead to con nector as shown 6 Connect red POS lead of multimeter to con nector as shown Multimeter reads ba...

Page 279: ...leads to coil as shown Coil ohms reading should be approximately 2 98 3 65 ohms if reading is correct Valve cartridge may be faulty Coil ohms reading is not to specification change coil ELECTRICAL SY...

Page 280: ......

Page 281: ...meter scale Replace a circuit breaker that does not meet these test results ELECTRICAL SYSTEM SECTION 10J CIRCUIT BREAKERS AND FUSE 10J 1 10J POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M...

Page 282: ...AL SYSTEM SECTION 10J CIRCUIT BREAKERS AND FUSE 10J 2 POWER OFF ON 200m 2 20 200 1000 750200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV ACV ACA 200 2m 200m 2 2 200m 20m 10A 2m 200 DCA 20m 10A COM A 10A...

Page 283: ...OTE See Section 10N for the location of all instru ments and gauges WATER TEMPERATURE GAUGE TEST See Figure 10K 1 Test the water temperature gauge as follows 1 Turn ignition switch to RUN ON 2 Disconn...

Page 284: ......

Page 285: ...be approximate ly 0 8 ohms cold If the reading is at infinity or 0 ohms the glow plug is defective and must be replaced ELECTRICAL SYSTEM SECTION 10L GLOW PLUGS 10L 1 10L POWER OFF ON 200m 2 20 200 1...

Page 286: ......

Page 287: ...diode is faulty If there is no continuity in either direction diode is also faulty ELECTRICAL SYSTEM SECTION 10M DIODE TEST 10M 1 10M POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M 200M 20K...

Page 288: ......

Page 289: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 1 10N Fogire 10N 1 Wiring Diagram 1 of 2...

Page 290: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 3 Figure 10N 2 Wiring Diagram 1 of 2...

Page 291: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 5 10N Figure 10N 3 Wiring Diagram for Figures 10N 1 and 10N 2 2 of 2...

Page 292: ......

Page 293: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Page 294: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Page 295: ...K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse Switch Rd Pu Wh B...

Page 296: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Page 297: ...ory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse Switch R...

Page 298: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 7 Figure 10N 4 Component Location 1 of 3...

Page 299: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 9 10N Figure 10N 5 Component Location 2 of 3...

Page 300: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 11 Figure 10N 6 Component Location 3 of 3...

Page 301: ...nd Charts 11B 1 General 11B 1 Lubrication Schedules 11B 1 Tractor Grease Chart 11B 1 Tractor Oil Chart 11B 1 Tractor Lubrication Chart 11B 1 Mower Lubrication Chart 11B 2 11C Maintenance Schedules 11C...

Page 302: ......

Page 303: ...pe of equip ment and the type of environment in which it operates While performing preventive maintenance tasks the individual should always be alert to conditions that may seem abnormal If an abnorma...

Page 304: ...kit QTY KITS ORDERED __________ Kit consists of 10 ea 8476 TS Maintenance Summary Sheets 20 ea 8477 TS Service Order Sheets 5 ea 8478 TS Folders check color desired ____Orange Turf Tractors ____Gray...

Page 305: ...footnotes on page 11C 3 letters a thru k give more detailed information PREVENTIVE MAINTENANCE SECTION 11B LUBRICATION SCHEDULES AND CHARTS 11B 1 11B Ref Qty Description Remarks 40 HOURS Every Week 1...

Page 306: ...TION SCHEDULES AND CHARTS 11B 2 Ref Qty Description Remarks 40 HOURS Every Week 1 8 a Hydraulic lift cylinder ends 2 4 a Mower arm pivots 4 8 a Wing mower unit pivots 5 8 a Caster wheel pivots 6 10 a...

Page 307: ...oil X Change every 500 hours 17 1 j Charge filter Change the first 25 hours Change every 250 hours thereafter 18 1 j Return filter 19 1 Tank strainer X 20 1 g Front drive wheel lube X X Change every...

Page 308: ...re X Check clean f Radiator coolant X Check when cooled X Change Hood screen X Check clean Ensure trap door is closed X Close Ensure sealing foam on top of radiator and on trap door is in place X Inst...

Page 309: ...9 quarts Use MIL L 214OC or API Classification CC CD CE Grade oil Recommended Oils Above 77 F use SAE 30 32 F to 77 F use SAE 20 Below 32 F Use SAE 10 or SAE 10W 30 e System capacity 8 oz heavy duty b...

Page 310: ......

Page 311: ...ration for Repair 12C 1 12D Mowers 12D 1 Pivot Housing and Push Arms 12D 1 Carrier Assembly 12D 2 Deck Fittings 12D 3 Blade Spindle Assembly 12D 4 General 12D 4 Disassembly 12D 6 Reassembly 12D 6 12E...

Page 312: ......

Page 313: ...ddard or equivalent solvent Detergent and water Lubricants Non metallic additive wheel bearing grease eg Sunray DX 692 or Enco Fibrox 280 Grease gun grease eg Sunray DX 671 or Gulf Supreme No 0 SAE 30...

Page 314: ......

Page 315: ...d Repair replace Sections 8L 8M 8N e Tractor hydraulic system e Test Sections 8M 8N malfunctioning 3 Uneven cutting a Deck not adjusted level a Adjust deck see Operator s Manual b Blades loose b Tight...

Page 316: ......

Page 317: ...s It may be necessary to use bearing pullers and or wooden blocks and hammer to free up some parts When such force is required to remove parts those parts should be replaced rather than reinstalled on...

Page 318: ......

Page 319: ...VOT HOUSING AND PUSH ARMS Removal and installation of the pivot housings and push arms are illustrated in Figure 12D 1 ATTACHMENTS SECTION 12D MOWERS 12D 1 12D Figure 12D 1 Pivot Housings and Push Arm...

Page 320: ...CARRIER ASSEMBLY Repair of the carrier assemblies consist of replacing bushings and worn or damaged components see Fig ure 12D 2 ATTACHMENTS SECTION 12D MOWERS 12D 2 Figure 12D 2 Carrier Assembly...

Page 321: ...DECK FITTINGS Removal and installation of deck fittings are illustrated in Figure 12D 3 ATTACHMENTS SECTION 12D MOWERS 12D 3 12D Figure 12D 3 Deck Fittings...

Page 322: ...r see Figure 12D 5 In this section service of the motors consists only of the spindle assembly For service of the hydraulic mo tor see Section 8O In most cases the spindle housing and motor do not hav...

Page 323: ...ATTACHMENTS SECTION 12D MOWERS 12D 5 12D Figure 12D 5 Motor Rotation By Code Letter...

Page 324: ...bearing is to be changed 10 Remove motor assembly from spindle housing Do not disassemble motor 11 Remove spindle shaft bearing REASSEMBLY See Figure 12D 6 1 Install spindle bearing if removed 2 Inst...

Page 325: ...ng the blades DO NOT follow the original angle of grind A Figure 12E 2 1 Grind new cutting edges on a diagonal as shown in B 2 Do not exceed 1 2 12 7 mm total metal removed at end of bar 3 Make sure t...

Page 326: ...lling blades make sure blade is positioned correctly Torque center blade mounting screw to 75 ft lbs 102 N m and the two blade mounting adapter screws to 35 40 ft lbs 47 54 N m ATTACHMENTS SECTION 12E...

Page 327: ...Repair of the caster wheels consist of replacing bush ings and worn or damaged components See Figure 12F 2 ATTACHMENTS SECTION 12F CASTER WHEELS 12F 1 12F Figure 12F 1 Caster Wheels...

Page 328: ...ATTACHMENTS SECTION 12F CASTER WHEELS 12F 2 Figure 12F 2 Caster Wheel Repair...

Page 329: ...13 THIS SECTION INTENTIONALLY LEFT BLANK SECTION 13 OPTIONS...

Page 330: ......

Page 331: ...Locations 14A 1 Tractor 14A 1 Mower 14A 3 14B Conversion Charts 14B 1 Millimeters to Decimals 14B 1 Decimals to Millimeters Fractions to Decimals to Millimeters 14B 2 U S to Metric Conversions 14B 3 S...

Page 332: ......

Page 333: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 1 14A TRACTOR Part No 964907 1 Part No 365339 2 Part No 365919 3...

Page 334: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 2 Part No 361175 4 Part No 861883 9 Part No 339237 5 Part No 365956 6 Part No 339460 7 Part No 363134 8 Part No 366160 10 Part No 366527 11...

Page 335: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 3 14A MOWER Part No J T338141 1...

Page 336: ......

Page 337: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 1 14B MILLIMETERS TO DECIMALS...

Page 338: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 2 DECIMALS TO MILLIMETERS FRACTIONS TO DECIMALS TO MILLIMETERS...

Page 339: ...re Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp G...

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