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Jacobsen SLF 1880, Technical/Repair Manual

The Jacobsen SLF 1880 Technical/Repair Manual is a comprehensive resource for anyone seeking to maintain or repair this powerful machine. This invaluable manual, available for free download at manualshive.com, provides step-by-step instructions and detailed diagrams to ensure optimal performance and longevity of the SLF 1880.

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HYDRAULICS

--1

SECTION 8

HYDRAULICS

8A

Repair, Service Tools, and Materials .............................................................................................................. 3

Materials Required ................................................................................................................................... 3
Specifications ........................................................................................................................................... 5

8B

Failure Analysis .............................................................................................................................................. 7

General .................................................................................................................................................... 7

8C

General Instructions........................................................................................................................................ 9

General .................................................................................................................................................... 9
Hydraulic Tube and Hose Fittings ............................................................................................................ 9
37° Flare Fittings .................................................................................................................................... 10
Hose Installation Instructions ................................................................................................................. 10
ORS (Face Seal) Fittings ........................................................................................................................11

8D

Hydraulic Schematics ................................................................................................................................... 13

General .................................................................................................................................................. 13
Schematic - 2011 & Prior........................................................................................................................ 14
Schematic- 2011 & Later ........................................................................................................................ 19

8E

Traction Circuit Theory of Operation............................................................................................................. 25

Traction Circuit—Neutral Schematic and Theory of Operation .............................................................. 25
Traction Circuit—Forward 2WD Schematic and Theory of Operation.................................................... 29
Traction Circuit—Reverse 2WD Schematic and Theory of Operation ................................................... 33
Traction Circuit—Forward 4WD Schematic and Theory of Operation.................................................... 37

8F

Traction Circuit Field Test ............................................................................................................................. 41

General .................................................................................................................................................. 41
As a Safety Reminder ............................................................................................................................ 41
Preliminary Checks ................................................................................................................................ 41
Hydrostatic Charge Pump Test .............................................................................................................. 41
Hydrostatic Traction System Test........................................................................................................... 41
Front Traction Motor Test ....................................................................................................................... 42

8G

Traction Circuit Instrument Tests .................................................................................................................. 43

General .................................................................................................................................................. 43
Pressure Tests ....................................................................................................................................... 44
Charge Pressure Test  ........................................................................................................................... 44
Flow Tests .............................................................................................................................................. 46
Charge Pump Flow Test......................................................................................................................... 46
Steering Circuit Test ............................................................................................................................... 47
Traction Circuit Flow Test ....................................................................................................................... 48
Traction Pump Flow Test........................................................................................................................ 49
Front Traction Motor Flow Test............................................................................................................... 51
4WD Valve Flow Test ............................................................................................................................. 53
Rear Traction Motor Flow Test ............................................................................................................... 54
Charge Pump Test Record..................................................................................................................... 57
Traction Circuit Test Record ................................................................................................................... 58

8H

Traction Pump Repair ................................................................................................................................... 59

General ................................................................................................................................................. 59
Removal ................................................................................................................................................. 61
Disassembly........................................................................................................................................... 61
Inspection............................................................................................................................................... 64
Assembly................................................................................................................................................ 65
Installation .............................................................................................................................................. 68

8I

Front Traction Motor Repair.......................................................................................................................... 69

8

Summary of Contents for SLF 1880

Page 1: ...Technical Repair Manual SLF 1880 ...

Page 2: ...Page Intentionally Blank ...

Page 3: ...hose 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 adjust or service the machine Litho in the U S A 5 2011 Part Number 4171721 Rev B 2011 Jacobsen A Textron Company All rights reserved ...

Page 4: ...Page Intentionally Blank ...

Page 5: ...rts manual for specific information on these topics THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UO TO THE TIME OF PUBLICATION JACOBSEN RESERVES THE RIGHT TO CHANGE ANY OF THIS INFORMATION WITHOUT NOTICE California Proposition 65 Warning Trademark Acknowledgement Jacobsen acknowledges the following trademarks for company names or products mentioned within this pub lic...

Page 6: ...ning a procedure Specifications Near the beginning of each chapter is a specifications listing this listing contains any specifications contained within the chapter Quick Reference Specifications A list of all machine specifications can be found in Chapter 1 Specifications This is a list of all general specifications Detailed specifications will be listed in the front of each chapter under Specifi...

Page 7: ...TRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS AND TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 8: ...Page Intentionally Blank ...

Page 9: ...INTRODUCTION 1 SECTION 1 INTRODUCTION 1A General Information 1 Contents 1 Index Numbers 1 Replacement Parts 1 Specifications 2 Serial Numbers 4 General Cleaning 4 Safety 4 Torque Values 10 1 ...

Page 10: ...INTRODUCTION 0 Page Intentionally Blank ...

Page 11: ...for each section of the man ual are given at the start of that section The designations L H left hand and R H right hand are used throughout this manual and refer to the oper ator s left or right when sitting in the normal operating position INDEX NUMBERS Illustrations showing removal disassembly reassem bly and illustration may have index numbers to call out the sequence of procedures Where the s...

Page 12: ...th service indicator Alternator 40 amp Cooling system Liquid Cooled Kubota D1105 TE Engine 67938 Make Kubota Model D1105 TE Horsepower 33 hp 24 6 kW 3000 rpm NOTE Actual sustained horsepower will likely be lower than listed in specifications due to operating limi tations and environmental factors Displacement 68 5 cu In 1123 cc Torque 60 ft lbs 81 Nm 2200 rpm Fuel Type No 2 Diesel Rating Cetane Ra...

Page 13: ...tor Alternator 40 amp Cooling system Liquid Cooled Cutting Units Reel 5 Reels 18 in 457 mm wide Reel Diameter 5 in 127 mm Blade Options 8 or 11 blades Cutting Height 0 30 to 0 70 in 7 6 to 18mm Cutting Width 80 in 2032 mm Cutting Frequency 8 Blade 0 067 in mph 1 06 mm kph 11 Blade 0 049 in mph 0 77 mm kph Tractor Tires Front 24 x 13 12 2 ply Rear 18 x 9 5 8 2 ply Pressure 10 12 psi 69 83 kPa Batte...

Page 14: ...iesel Engine Parts Catalog 4160162 Operator Training Video 4102141 Service Repair Manual 4171721 SERIAL NUMBERS See Figure 1A 2 for location of tractor assembly series number Figure 1A 2 Serial Number Location GENERAL CLEANING Improper cleaning and lubrication of your machine results in equipment failures Before any repairs are undertaken thoroughly clean the exterior of the com ponent to be remov...

Page 15: ...ome familiar with these words and their meaning Take all precautions to avoid the hazards described Inspect Machine Safety Decals Decals on the machine denote cautions warnings and dangers These cautions warnings and danger decals must be on the machine at all times If they become worn torn or painted over new decals should be installed as shown in Section 14A of this manual DANGER Imminent hazard...

Page 16: ...quipment Safely Always use a lifting deice with a lifting capacity greater than the weight of the item being lifted Secure the load to the lifting device using cables chains or slings rated to handle the load being lifted Fasteners being used to connect lifting devices must be strong enough to handle the load Also be sure the mounting point of the load is strong enough to handle the load When usin...

Page 17: ...keshift tools to force a tire on or off a wheel Be sure tire irons and mounting tools are free of grease and oil grip them firmly Inspect wheel parts for rust damage cracks or distortion never use wheels that ar out of round rusted or cracked Never hammer on wheels with a steel hammer Use rubber covered hammers When inflating tires always use an inflation cage Always stand away from the valve stem...

Page 18: ...ervice Electrical Components Safely Always remove jewelry prior to servicing a machine and or machine electrical system Jewelry can come in contact with electrical components resulting in death or serious injury WARNING Never remove the fuel cap from the fuel tank or add fuel when the engine is running or while the engine is hot Do not smoke when handling fuel Never fill or drain the fuel tank ind...

Page 19: ...nt Collect fluids in well marked approved storage con tainers Some waste fluids can react with certain types of plastics Make sure the fluid to be stored is compati ble with the storage container Never use food or bev erage containers to store waste fluids Dispose of waste fluids properly at approved local recycling centers If recycling facilities are not available contact your local community for...

Page 20: ...10 234 286 ft lbs 317 388 Nm 5 16 24 17 21 ft lbs 23028 Nm 3 4 16 270 330 ft lbs 366 447 Nm 3 8 16 27 33 ft lbs 37 45 Nm 7 8 9 360 440 ft lbs 488 597 Nm 3 8 24 31 39 ft lbs 42 53 Nm 7 8 14 396 484 ft lbs 537 656 Nm 7 16 14 45 55 ft lbs 61 75 Nm 1 8 522 638 ft lbs 708 865 Nm 7 16 20 49 61 ft lbs 66 83 Nm 1 12 576 704 ft lbs 780 954 Nm NOTE These torque values are to be used for all hardware excludi...

Page 21: ... Specifications 1 2B Failure Analysis 3 General 3 2C Control Adjustments 5 General 5 Throttle 5 Neutral And Reverse Sensing Switches 6 Traction Pedal Speed Limiter 7 Maximum Transport Speed 7 Parking Brake 8 Brake Interlock Switch 10 Lift Limit Switch 10 2D Gauges And Instruments 13 Repair 13 2 ...

Page 22: ... 0 Page Intentionally Blank ...

Page 23: ...lly Closed air gap 0 094 to 0 125 in 2 4 3 mm Switches Early Magnetic Proximity Switch Neutral switch Normally Open 0 15 amp air gap 0 098 to 0 125 in 2 4 3 mm Reverse sensing switch Normally Open 0 15 amp air gap 0 098 to 0 125 in 2 4 3 mm Parking brake switch Normally Open 0 15 amp air gap 0 098 to 0 125 in 2 4 3 mm Lift limit switch Normally Open 0 15 Amp air gap 0 098 to 0 125 in 2 4 3 mm Swit...

Page 24: ...2A 2 Page Intentionally Blank ...

Page 25: ...ent a Adjust traction Section 2C 4 Parking brake fails a Brake not adjusted b Worn brake shoes c Damaged or broken linkage a Adjust brake Section 2C b Replace pads Section 5C c Repair as necessary 5 Reel does not lift or lower properly as joystick is acti vated a Joystick faulty b Control valve leaking or defective c Relief too low d System relief valve too low e Faulty lift cylinder f Faulty char...

Page 26: ...2B 4 Page Intentionally Blank ...

Page 27: ...ace the engine throttle lever on injection pump against the max speed screw 4 Adjust the throttle cable nuts until the cable eyelet is positioned on the pin as shown 5 Replace the side cover Figure 2C 1 Throttle Control Adjustment WARNING To prevent injury lower implements to the ground disengage all drives engage parking brake stop engine and remove the key from the ignition switch before making ...

Page 28: ...e to the traction pedal 7 Check the Interlock system and operation of trac tion pedal after adjustment 4WD Reverse Sensing Switch A four wheel drive reverse sensing switch is included on machines equipped with four wheel drive The switch stops four wheel drive operation when the machine is placed in reverse or neutral The switch is located on the same mounting bracket as the neutral switch Figure ...

Page 29: ... throttle is adjusted correctly Figure 2C 5 Traction Pedal Linkage 1 Check the neutral adjustment and adjust if neces sary 2 Place the traction pedal speed limiter in the trans port position 3 Disconnect the rod end from the traction pedal 4 Push the traction pedal forward until it touches the floor panel 5 Push the return arm on the drive pump back until it hits the internal stop on the pump hous...

Page 30: ...arking Brake 4 Pull the cable behind the lower cable adjusting nut Figure 2C 9 away from the pedal until brake pads just contact the brake disc Thread the lower adjusting nut up until it contacts the mounting plate Tighten the upper adjusting nut while hold ing the cable in place Tighten the upper adjusting nut to 20 ft lbs 27 Nm NOTICE Additional adjustment may be made on the rod end at the pump ...

Page 31: ...2C 9 Figure 2C 9 Parking Brake Cables 5 Connect the brake return spring Repeat for the second cable Upper Adjusting Nut Lower Adjusting Nut NOTICE Do not overtighten or turn the cable ...

Page 32: ...ont axle directly behind the lift arm If the reels continue to run when lifted or do not run when lowered inspect the switch Adjust or replace the switch as needed Figure 2C 12 1 Park the tractor on a flat level surface 2 Remove the center reel from the lift arm 3 Place the ignition switch in the OFF position and remove the ignition key 4 Add or remove shims as needed to obtain correct air gap bet...

Page 33: ...the lift arm The switch contact should close when the lift arm drops below 30 Figure 2C 13 Figure 2C 13 Lift Switch Mounting NOTICE Use a multimeter to check for continuity between the switch wires Continuity should be available when the lift arm passes just below 30 from horizontal NOTICE The lift limit switch sets the point where the switch turns off the reel drive not how high the reels raise T...

Page 34: ...2D 12 Page Intentionally Blank ...

Page 35: ...d dis connect wiring 3 Remove the attached hardware and replace the component 4 Using the labels created in Step 2 install the hard ware and connect the wiring 5 Connect the battery ground black cable Figure 2D 1 Gauges and Instrument NOTICE Refer to Section 10 for test and repair procedures of switches Reel Switch 4WD Switch Horn Switch Hydraulic Oil Temperature Gauge Ignition Switch Hour Meter L...

Page 36: ...2D 14 Page Intentionally Blank ...

Page 37: ...terials Required 1 3B Failure Analysis 3 General 3 3C General Instructions 5 Contents 5 Cleaning Lubrication 5 3D Engine 7 General 7 Engine Belt 7 Engine Oil 8 Air Cleaner 8 Radiator Service 10 Exhaust System 12 Fuel System 13 Engine Removal 15 Engine Installation 16 3 ...

Page 38: ... 0 Page Intentionally Blank ...

Page 39: ... Torque 60 ft lbs 81Nm 2200 rpm 33 hp 24 6 kW 3000 rpm Kubota D1105 E3B Torque 52 7 ft lbs 71 5 Nm 2200 rpm 24 8 hp 18 5 kW 3000 rpm Kubota D1105 T E3B Torque 65 ft lbs 88 1 Nm 2200rpm 32 9 hp 24 5 kW 3000 rpm Engine Lubrication Engine Oil Capacity 5 4 quarts 5 1 liters Oil Type SAE 10W30 API Classification CD CE Cooling System Fan Belt Deflection 0 250 to 0 312 in 6 to 8 mm Radiator Cap 15 psi 1 ...

Page 40: ...3A 2 Page Intentionally Blank ...

Page 41: ...the pedal h Adjust or replace the switch Section 2C and Section 10J 2 Engine is hard to start or runs poorly a Fuel level low fuel or fuel fil ter dirty b Faulty glow plug c Air cleaner dirty d Injectors fuel pump faulty e Engine problem a Fill with fresh fuel Change the fuel filter Bleed fuel lines Section 3D b Replace faulty glow plug c Inspect and replace the air fil ter Section 3D d Consult th...

Page 42: ...3B 4 Page Intentionally Blank ...

Page 43: ...iator Removal and installation of the engine is cov ered in this manual Engine repair is not included in this manual refer to the manufacturer s instructions CLEANING LUBRICATION Thoroughly cleaning the engine on a regular basis will provide better conditions for component removal repair and inspection A clean engine also aids in trou bleshooting coolant and engine oil leaks Thoroughly clean compo...

Page 44: ...3C 6 Page Intentionally Blank ...

Page 45: ... alternator pulleys to 0 25 to 0 31256 in 6 to 8 mm with a deflection of 20 lbs Push at the midpoint between pulleys Figure 3D 1 See the engine manufacturer s manual Figure 3D 1 Alternator Mounting 2 Adjust the belt tension by loosening the alternator mounting bolts and pulling the alternator against the belt until the proper tension is achieved Figure 3D 2 Figure 3D 2 Engine Drive Belt WARNING To...

Page 46: ...and dirt into a rubber dust evacu ator The dust evacuator then dumps the debris The valve should be checked daily for contaminants Squeeze the sides of the valve together to release debris trapper inside When the restriction gauge indicates a need for air filter service clean the outside of the air cleaner assembly and gently remove the filter element using the following procedure Ambient Temperat...

Page 47: ...s Ensure the hose clamps secure the hoses without leaks 4 Inspect the new filter element Do not use a dam aged element especially the open end seal 5 Install the new filter element making sure it is properly seated and secured in the housing 6 Install the end cover with the dust evacuator located at the bottom of the assembly Secure with spring clips 7 Reset the air filter restriction gauge by pre...

Page 48: ...st screen Using low pressure compressed air blow dust and debris from the radiator core Figure 3D 6 CAUTION Never remove the radiator cap when the coolant is hot The engine must be shut off and cooled before the radiator cap is removed Very hot coolant will be sprayed from the radiator if the cap is loosened before the engine has cooled Serious personal injury can occur NOTICE It is illegal to dis...

Page 49: ...d secure with three bolts on each side 2 Position the shroud and coolant reservoir on the radiator Secure with three bolts on each side 3 Install the upper and lower radiator hoses Secure the hoses with hose clamps 4 Ensure the drain petcock is closed and fill with a 50 50 mixture of ethylene glycol based antifreeze and clean fresh water 5 Carefully inspect the radiator cap for wear and damage rep...

Page 50: ...t System Removal and Installation Remove and install the exhaust system components as shown in Figure 3D 8 Figure 3D 8 Exhaust System CAUTION Do not attempt to service the exhaust system when the engine is hot Serious personal injury can occur NOTICE If a change in the color or sound of the exhaust occurs stop the engine immediately identify the problem and repair as necessary NOTICE Tighten all e...

Page 51: ...hat will fit inside the fuel filler neck Avoid using unapproved containers to transport fuel Keep all fuel containers clean and closed when not in use CAUTION Never remove the fuel cap from the fuel tank or add fuel when the engine is running Do not smoke when handling fuel Never fill or drain the fuel tank indoors Do not spill fuel and always clean fuel spills Never handle or store fuel container...

Page 52: ... appropriate container 6 Remove the o rings 7 Clean the inside and outside of the fuel bowl and mounting 8 Lightly lubricate the new o rings with clean diesel fuel and install in the mounting 9 Install the filter element and bowl securely Secure with a clamp ring 10 Open the fuel filter valve Figure 3D 11 Figure 3D 11 Closed Fuel Valve 11 Purge any air from the fuel system after installing the new...

Page 53: ...on key Allow the engine to cool completely before attempting to service the engine 2 Disconnect the negative battery clamp first then remove the positive clamp Remove the battery hold down clamp and battery 3 Using a suitable container drain the radiator engine block and engine oil 4 Remove the upper and lower radiator hoses 5 Close the fuel filter valve and disconnect the fuel outlet hose from th...

Page 54: ...new gaskets install the exhaust system 8 Install the air cleaner assembly 9 Using the procedures in Section 2 connect the throttle cable on the injection pump and cable housing clamp 10 Connect the fuel outlet hose to the fuel filter and open the fuel valve 11 Install and tighten the upper and lower radiator hoses Secure the hoses with clamps 12 Clean and install the battery and hold down clamp In...

Page 55: ...3D 17 Figure 3D 13 Engine Components Fuel Filter Throttle Cable and Housing Clamp Air Clean Assembly Battery Fuel Hose Clamp and Engine Mount Alternator Radiator Hoses Drive Shaft ...

Page 56: ...3D 18 Page Intentionally Blank ...

Page 57: ...DRIVE TRAIN 1 SECTION 4 DRIVE TRAIN 4A Repair and Service Tools and Materials 1 Materials Required 1 Specifications 1 4B Failure Analysis 3 General 3 4C Traction Pump Drive Shaft 5 General 5 Service 5 4 ...

Page 58: ... 0 Page Intentionally Blank ...

Page 59: ...S REQUIRED l SPECIFICATIONS Tools required Standard automotive hand tools Cleaning materials Stoddard solvent or equivalent Lubricants Refer to Section 11 Driveshaft Total Length 11 144 in 283 mm Balance 2 oz in 3200 rpm Flange Bolt Torque 35 40 ft lbs 47 54 Nm 4A ...

Page 60: ...4A 2 Page Intentionally Blank ...

Page 61: ...detailed descriptions of remedial procedures PROBLEM PROBABLE CAUSE REMEDY 1 Drive shaft loose a Universal joints worn a Change Section 4C 2 Metallic rattling sound when load is reduced on drive line a Universal joints worn a Change Section 4C 3 Vibration a Universal joints worn b Driveshaft out of balance a Change Section 4C b Replace driveshaft 4B ...

Page 62: ...4B 4 Page Intentionally Blank ...

Page 63: ...2 Slide the drive shaft off the drive pump splined shaft Disassembly 1 Position the u joint on a vise as shown in Figure 4C 2 Figure 4C 2 Drive Shaft Disassembly 2 Using a soft face hammer strike the top ear of the yoke driving the upper bearing upward and out of the ear 3 Grip the loose bearing in the vise and drive the yoke off the bearing 4 Repeat Step 1 through Step 3 for the remaining bearing...

Page 64: ...vers the cross shaft 5 Remove the yoke from the vise and check for free movement of the bearing in the yoke Installation 1 Slide the front yoke over the drive pump shaft 2 Place the rear yoke over the engine drive plate and install four socket head screws NOTICE During assembly make sure all parts especially the caps are clean inside and outside NOTICE If the bearing seems tight in the bearing cap...

Page 65: ...BRAKE SYSTEM 1 SECTION 5 BRAKE SYSTEM 5A Repair and Service Tools and Materials 1 Materials Required 1 Specifications 1 5B Failure Analysis 3 General 3 5C Parking Brake 5 General 5 Cables 5 5 ...

Page 66: ... 0 Page Intentionally Blank ...

Page 67: ...ubricants Refer to Section 11 Other service items Brake pads Brakes Brake Pedal Free Travel 1 5 in 38 mm Brake Disc Diameter 10 7 in 271 7 mm Brake Disc Thickness 0 187 in 4 7mm Brake Pad Thickness Inside Pad 0 530 in 13 5mm Brake Pad Thickness Outside Pad 0 310 in 7 8mm Brake Cable Spring Free Length Inside Hooks 3 25 in 82 5 mm Brake Return Spring Free Length Inside Hooks 8 in 203mm 5A ...

Page 68: ...5A 2 Page Intentionally Blank ...

Page 69: ...brake does not hold tractor in position when the engine is off a Brake is misadjusted b Worn brake pads c Broken or work brake cable a Adjust brake Section 5C b Replace pads Section 5C c Replace cable Section 5C 2 Parking brake does not hold tractor in position when the engine is on a Brake is misadjusted b Worn brake pads c Traction control needs adjust ing a Adjust brake Section 5C b Replaced pa...

Page 70: ...5B 4 Page Intentionally Blank ...

Page 71: ... the actuating lever When pushed the brake pedal pulls on the cables which pulls the actuat ing lever The actuating lever has a cam type lobe which pushes the inner support plate and pad against the brake disc stopping the tractor As the pads wear the cables can be adjusted to com pensate for the wear When released a return spring moves the actuating lever to the released position Figure 5C 1 Park...

Page 72: ...spect the cables and cable mounting for wear and damage Replace as necessary 5 Inspect the brake disc and hub for grooves excessive wear and damage Replace the hub and brake disc as necessary Assembly 1 Assemble the caliper actuating lever spring retainer pads and support plate Figure 5C 2 2 Install the caliper assembly over the brake disc and secure with the brake bracket and four bolts 3 Install...

Page 73: ...hould just touch the inner support plate 2 Check the brake pedal free travel Figure 5C 2 The pedal free travel should be approximately 1 5 in 38 mm 3 Use the cable nuts to adjust free travel and actuat ing lever position 4 Repeat the procedure for the other side ...

Page 74: ...5C 8 Page Intentionally Blank ...

Page 75: ...Analysis 3 General 3 6C Steering valve 5 General 5 Removal 5 Steering Valve Disassembly 6 Steering Valve Inspection 7 Steering Valve Assembly 7 Installation 10 6D Steering Cylinder 11 General 11 Removal 11 Disassembly 12 Inspection 12 Assembly 13 Installation 13 6E Steering Wheel Adjustment 15 Steering Adjustments 15 6 ...

Page 76: ... 0 Page Intentionally Blank ...

Page 77: ...s required Standard automotive hand tools Cleaning materials Stoddard solvent or equivalent Lubricants Refer to Section 11 Other service items 6 pieces 0 007 in 0 18 mm shim stock 0 5 in 13 mm wide and 1 5 in 38 mm long Portable hydraulic filtering unit Vacuum pump Service fixture for Power Steering Valve Figure 6A 1 6A ...

Page 78: ...n 22 8 cm Steering Axle Rear Wheel Toe in 0 0625 to 0 125 in 1 6 to 3 2 mm Tire Pressure Tire Pressure Front 10 12 psi 69 83 kPa Tire Pressure Rear 8 10 psi 55 69 kPa Torques Steering Valve Cover Nuts 20 24 ft lbs 27 33 Nm Steering Cylinder Castle Nut 50 55 ft lbs 68 75 Nm Steering Cylinder Bolt 70 75 ft lbs 95 101 Nm Tie Rod Castle Nuts 30 35 ft lbs 40 48 Nm Front Wheel Bolt 85 95 ft lbs 115 128N...

Page 79: ...en or repair Section 6E or Section 9F c Repair Section 6D d Adjust Section 6E 3 Shimmy a Tire mounting nuts loose b Loose or worn steering link age c Steering cylinder internal leakage d Steering wheels out of adjust ment a Tighten Section 7C b Tighten or repair Section 6E or Section 9F c Repair Section 6D d Adjust Section 6E 4 Hard steering in one direc tion a Internal failure of steering valve b...

Page 80: ...il a Tighten b Tighten or repair Section 6E or Section 9F c Repair Section 6D d Repair Section 6C e Check oil cooler and clean if necessary 7 No steering a Steering relief stuck open b Steering valve excessive internal leakage c Steering cylinder faulty d Charge pump failure a Test Section 8N b Test Section 8N c Test Section 8N d Test charge pump Section 8G PROBLEM PROBABLE CAUSE REMEDY ...

Page 81: ... wheel Figure 6C 1 6 Tag and remove the hoses from the bottom of the steering valve Immediately plug the hoses and valve to prevent contamination of the hydraulic system Figure 6C 1 7 While supporting the steering valve remove the steering valve mounting nuts at the mounting bracket Figure 6C 1 8 Remove the steering valve from the steering tower Figure 6C 1 Figure 6C 1 Steering Valve Removal and I...

Page 82: ...raulic com ponents NOTICE Scribe a line from the top to the bottom of the steer ing valve assembly not including the steering tube Use the scribed line for reference when assembling the valve sections WARNING Wear eye protection when assembling and disas sembling the steering valve Springs and other objects may be propelled into the air causing eye injury NOTICE The following steps reference Figur...

Page 83: ...lot edges and surface for nicks scor ing and rounding 4 Inspect the hex drive 11 for wear 5 Inspect the isolation manifold 13 for nicks scratches and scoring A polished wear pattern due to valve plate rotation is normal 6 Inspect the drive link 14 for wear and damage 7 Inspect the thrust bearing 19 for brinelling spal ling and missing rollers 8 Discard all seals and seal rings 9 Inspect the commut...

Page 84: ...im shock 0 5 in 13 mm wide by 1 5 in 38 mm long in three places equal distance apart between the metering ring and metering package Figure 6C 6 16 Tighten the capscrews 1 twice in sequence Figure 6C 6 to 11 13 in lbs 1 2 1 5 Nm torque 17 Remove the metering package and shims Place the drive link 14 large tang into the rotor 7 Figure 6C 6 Turn the metering package by hand to make sure there is no b...

Page 85: ...stall the seal ring 3 25 Place three 0 75 in 19 mm springs 7 in the port manifold 6 as shown 26 Carefully place the port manifold 6 springs down onto the valve ring 8 Figure 6C 6 27 Install the o rings 4 and seal ring 3 on the port cover 2 28 Install the needle rollers 5 in the port manifold 6 29 Install the port manifold 6 1 2 3 4 5 6 7 3 8 9 10 3 11 13 14 3 15 3 16 17 18 19 20 21 22 23 24 26 27 ...

Page 86: ... steering valve in the steering valve bracket with the four studs protruding through the bracket 2 Install the steering valve mounting nuts 3 Install the steering wheel lockwasher and nut Tighten the nut to 25 30 ft lbs 34 41 Nm torque 4 Remove the plugs from the steering valve and hydraulic hoses Using the tags created during disassembly connect the hoses to the steering valve 5 Install the steer...

Page 87: ... clean the area surrounding the steer ing cylinder especially the hydraulic hose fittings 4 Tag and remove hydraulic hoses from the steering cylinder Immediately plug the hose ends and cyl inder to prevent contamination of the hydraulic system 5 Remove the cotter pin and castle nut from the steering cylinder ball joint at the steering arm Figure 6D 2 6 Using a ball joint removal tool remove the ba...

Page 88: ...r Disassembly WARNING Use appropriate eye protection when using com pressed air for cleaning or drying purposes Com pressed air can cause serious personal injury Use safety reduction valves to reduce the air pressure to a safe level before use NOTICE When removing the ball joint count the number of turns for removal This will aid in replacing the ball joint Barrel Rod Piston Ring Piston Nut Step 1...

Page 89: ...t washers spacer and nut 3 Install the ball joint on the steering arm and secure with the castle nut and cotter pin 4 Using the tags created during disassembly con nect the hydraulic hoses to the cylinder NOTICE Install the ball joint using the same number of turns as noted during removal Barrel Rod Piston Ring Piston Nut Step 1 Step 4 Lubricate assembly and push rod into barrel Using a spanner wr...

Page 90: ...top to stop in both directions to purge air from cylinder 6 Check for hydraulic leaks and cylinder operation Repair as necessary 7 Check the steering toe in and turn stop adjust ments as described in this section and in the Parts and Maintenance manual ...

Page 91: ...mm S Figure 6E 1 Align the ball joints and tighten the jam nuts on the tie rod 4 After adjusting the tie rod adjust the steering cyl inder by threading the ball joint T in or out so the spindle arm clears the stop on the axle by 0 0625 to 0 125 in 1 5 to 3 mm when the cylinder is fully extended Figure 6E 1 Figure 6E 1 Steering Adjustments Torque Values Steering Adjustment Nuts Torque Tie Rod Castl...

Page 92: ...6E 16 Page Intentionally Blank ...

Page 93: ...WHEELS AND TIRES 1 SECTION 7 WHEELS AND TIRES 7A Repair Service Tools and Materials 1 Materials Required 1 Specifications 1 7B Failure Analysis 3 General 3 7C Tire Service 5 General 5 Service 5 7 ...

Page 94: ...WHEELS AND TIRES 0 Page Intentionally Blank ...

Page 95: ...ard solvent or equivalent Lubricants Refer to Section 11 Other service items Commercial tire sealant Tire pressure gauge Compressed air source with inflation tool Tire Pressure Tire Pressure Front 10 12 psi 69 83 kPa Tire Pressure Rear 8 10 psi 55 69 kPa Torques Front Wheel Bolt 85 95 ft lbs 115 128Nm Rear Wheel Bolt 85 95 ft lbs 115 128Nm SPECIFICATIONS 7A ...

Page 96: ...WHEELS AND TIRES 7A 2 Page Intentionally Blank ...

Page 97: ... Reduce tire pressure to 10 12 psi 69 83 kPa 2 Tractor wanders a Under inflated tires b Malfunctioning tractor motor c Steering malfunctioning d Wheel nuts loose e Steer wheels out of adjust ment a Inflate tires to 10 12 psi 69 83 kPa b Repair traction motor Section 8I and Section 8J c Steering test Section 8M and Section 8N d Tighten wheel bolts to 88 to 95 ft lbs 115 to 128 Nm e Adjust Section 6...

Page 98: ...WHEELS AND TIRES 7B 4 Page Intentionally Blank ...

Page 99: ...re to the desired level for opera tion Figure 7C 1 Mounting leaks around the tire bead can be repaired using commercial sealants available at tire repair shops Apply the sealant using the procedure below 1 Inject sealant through the valve stem or break one bead loose and pull the tire past the rim flange 2 Pour sealant into tire cavity 3 Seat bead on the rim by inflating the tire to 22 psi 152 kPa...

Page 100: ...WHEELS AND TIRES 7E 6 Page Intentionally Blank ...

Page 101: ...tic and Theory of Operation 33 Traction Circuit Forward 4WD Schematic and Theory of Operation 37 8F Traction Circuit Field Test 41 General 41 As a Safety Reminder 41 Preliminary Checks 41 Hydrostatic Charge Pump Test 41 Hydrostatic Traction System Test 41 Front Traction Motor Test 42 8G Traction Circuit Instrument Tests 43 General 43 Pressure Tests 44 Charge Pressure Test 44 Flow Tests 46 Charge P...

Page 102: ...t Procedures 89 General 89 As a Safety Reminder 89 Preliminary Checks 89 Lift System Test 89 Power Steering System Test 90 Mower Reel Motor System Test 91 8N Hydraulic Instrument Tests 93 General 93 Pressure Tests 94 Steering Circuit Pressure Test 94 Lift Circuit Pressure Test 95 Reel Motor Pressure Test 98 Flow Tests 99 Steering Circuit Flow Test 99 Front Reel Circuit Flow Test 101 Rear Reel Circ...

Page 103: ...allation 125 8R Reel Valve Repair 127 General 127 Removal 127 Installation 127 8S Reel Motor Repair 129 General 129 Removal 129 Installation 129 8T Oil Cooler Repair 131 General 131 Removal 131 Installation 131 8U Component Locations 133 ...

Page 104: ... 2 Page Intentionally Blank ...

Page 105: ...igure 8A 2 Cleaning materials Stoddard solvent or equivalent Detergent and water Loctite Locquic Primer T Lubricants Refer to Section 11 Other service items Seal and Repair Kits available from Jacobsen deal ers Liquid gasket Special bearing mandrel Front Traction Motor Repair JAC 5052 Rear Traction Motor Repair JAC 5053 Blind hole puller Traction motors Hydraulic fitting kit available from Jacobse...

Page 106: ...8A 4 Figure 8A 2 Wheel Restraint 12 1 2 2 12 14 16 36 12 2 1 Pipe 13 1 2 Long 1 Pipe Cut to Fit Between Runners 3 4 NC Ready Rod 15 Long 2 3 4 NC Nuts Two Cargo Straps 3 Wide 12 Long ...

Page 107: ... rev Rear Traction Motor Displacement 8 ci rev 131 cc rev Steering Steering Valve Displacement 6 6 ci rev 108 cc rev Steering Cylinder Bore 1 5 in 38 1 mm Steering Cylinder Rod Diameter 0 750 in 19mm Auxiliary Gear Pump Reel Lift Pump Displacement Each Section 0 39 ci rev 6 4 cc rev Pump Volume 3150 RPM Each Section 5 3 gpm 20 lpm Reel Motors Reel Motor Displacement 0 6 ci rev 9 8 cc rev Reel Circ...

Page 108: ...low 10 Micron Return Filter Bypass Pressure 25 psi 172 kpa Charge Filter 2011 Units and Later Charge Filter Element Full Flow 10 Micron Charge Filter Bypass Differential Pressure 25 psid 172 kpa Reservoir Reservoir Cap Pressure 3 psi 20 6 kpa Reservoir Cap Vent 10 Micron Foam Vent Reservoir Capacity 8 U S Gal 30 28 liters Fluid Type Biodegradeable Jacobsen GreensCare 68 ...

Page 109: ...over relief valve g Internal damage of hydro h Hydro control arm loose a Add oil Section 11A b Check charge pressure Section 8G Replace Section 8H c Check charge pressure Section 8G Repair Section 8H d Close tow valve e Isolate repair Section 8I and Section 8J f Repair Section 8H g Repair Section 8H h Repair Section 2C 3 Traction in one direction only a Internal check valve in hydro b Pedal linkag...

Page 110: ...ver relief valve c Rear traction motor faulty d Low charge pressure a Repair Section 8K b Repair Section 8H c Repair Section 8J d Check charge pressure Section 8G Charge pump relief faulty or Internal charge pump dam aged replace Section 8H PROBLEM PROBABLE CAUSE REMEDY ...

Page 111: ...n tools Do not force or pry components apart or together Light tapping with a plastic mallet is recommended unless otherwise specified in the repair instructions Unless otherwise indicated apply a light coat of clean hydraulic fluid to parts as each is reassembled Apply clean grease to o rings if necessary to hold them in position during reassembly Hydraulic hose and tube lines should be inspected...

Page 112: ...ing seal When tightening a hose do not permit it to twist hold it in a normal straight position 2 When installing mower hoses place the fittings at angles to avoid contact with fixed parts when turn ing Make sure hoses are assembled to proper A and B ports on components SAE Dash Size Thread Size Tube O D Torque In lbs of Flat Rotations 3 3 8 24 0 188 95 105 1 1 2 1 3 4 4 7 16 20 0 250 135 145 2 1 ...

Page 113: ...8 5 16 24 459290 3 16 3 8 24 459291 1 4 7 16 339896 5 16 1 2 20 459293 1 2 3 4 16 339898 5 8 7 8 14 339899 3 4 1 1 16 12 339900 7 8 1 3 16 12 459296 1 1 5 18 12 339901 1 1 4 1 5 8 12 339902 1 1 2 1 7 8 12 339903 2 2 1 2 12 459300 NOTICE O rings should be lubricated with the fluid to be used in the system prior to assembly Figure 8C 2 B A SAE Dash Size Thread Size Tube O D Torque In lbs 3 3 8 24 0 ...

Page 114: ...6 12 339909 8 14 339910 10 16 339911 12 18 339912 16 21 339913 20 25 339914 24 29 339915 SAE Dash Size Thread Size Tube O D Torque In lbs 3 N A N A 4 9 16 0 250 120 144 5 N A N A 6 11 16 0 375 216 240 8 13 16 0 500 384 420 10 1 14 0 625 552 600 12 1 3 16 12 0 750 780 840 16 1 7 16 12 1 000 1104 1200 20 1 11 16 12 1 250 1500 1680 24 2 12 1 500 1800 3960 ...

Page 115: ...ed a hardened charge pump coupling hardened charge relief valve poppet and seat increased charge pressure from 58 102 psi 400 703 kpa to 145 203 psi 1000 1400 kpa and a charge filter was added to the hydraulic circuit NOTICE The above changes were implemented in 2011 beginning with the following serial numbers 6795501837 6795601797 and 6795701716 8D ...

Page 116: ...si Crack Bypass 10 Micron Filter Tank Fill Cap Assembly Forward Relief Valve 3045 psi Reverse Relief Valve 3045 psi Check Valve Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Charge Relief Valve 58 102 psi Gear Pump 0 39 ci 0 39 ci 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump 25 psi Crack Bypass 1 2 3 4 5 6 7 8 9 TN2502 ...

Page 117: ...c Schematic 2011 Prior Units Reverse 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 11 9 ci 7 97 ci 7 97 ci Left Rear Wheel Motor Check Valve Check Valve Forward 1 1 2 2 3 3 4 4 5 5 6 7 7 8 9 9 10 11 TN2503 ...

Page 118: ...8D 16 Schematic 2011 Prior Figure 8D 3 Hydraulic Schematic 2011 Prior Units In Out RT LT Steering Unit Steering Cylinder 6 6 ci Check Valve Steering Valve 1 2 3 1 2 3 4 5 7 9 10 11 7 9 10 11 TN2504 ...

Page 119: ...nt Cylinder Left Rear Cylinder Right Rear Cylinder One Way Orifice 0 032 0 040 in Check Valve Lift Valve Relief Valve 1750 psi Relief Valve 450 psi Test Port T P G T Solenoid Valve 3 4 2 1 6 10 9 8 1 2 3 1 2 3 9 One Way Orifice 0 032 One Way Orifice 0 032 One Way Orifice 0 026 One Way Orifice 0 026 One Way Orifice 0 026 Check Valve Check Valve ...

Page 120: ...el Valve A B P T Test Port Test Port T P A B Backlap Valve Solenoid Valve Solenoid Valve Relief Valve 2200 psi Relief Valve 2200 psi Backlap Valve 0 60 ci G G Left Rear Reel Motor Right Rear Reel Motor Left Front Reel Motor Center Reel Motor Right Front Reel Motor 0 60 ci 1 2 3 0 60 ci 0 60 ci 0 60 ci TN2506 ...

Page 121: ... Crack Bypass 10 Micron Filter Tank Fill Cap Assembly Forward Relief Valve 3045 psi Reverse Relief Valve 3045 psi Check Valve Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Charge Relief Valve 145 203 psi Gear Pump 0 39 ci 0 39 ci 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump 25 psi Crack Bypass 1 2 3 4 5 6 7 8 9 TN2502 A ...

Page 122: ...raulic Schematic 2011 Later Units Reverse 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 11 9 ci 7 97 ci 7 97 ci Left Rear Wheel Motor Check Valve Check Valve Forward 1 1 2 2 3 3 4 4 5 5 6 7 7 8 9 9 10 11 TN2503 ...

Page 123: ...011 Later Figure 8D 8 Hydraulic Schematic 2011 Later Units 5 In Out RT LT Steering Unit Steering Cylinder 6 6 ci Check Valve Steering Valve 1 2 3 1 2 3 4 5 7 9 10 11 7 9 10 11 TN2504 A Charge Filter 10 Micron Filter 25 psi Bypass ...

Page 124: ...Left Front Cylinder Left Rear Cylinder Right Rear Cylinder One Way Orifice 0 032 0 040 in Check Valve Lift Valve Relief Valve 1750 psi Relief Valve 450 psi Test Port T P G T Solenoid Valve 3 4 2 1 6 10 9 8 1 2 3 1 2 3 9 One Way Orifice 0 032 One Way Orifice 0 032 One Way Orifice 0 026 One Way Orifice 0 026 One Way Orifice 0 026 Check Valve Check Valve ...

Page 125: ...ont Reel Valve A B P T Test Port Test Port T P A B Backlap Valve Solenoid Valve Solenoid Valve Relief Valve 2200 psi Relief Valve 2200 psi Backlap Valve 0 60 ci G G Left Rear Reel Motor Right Rear Reel Motor Left Front Reel Motor Center Reel Motor Right Front Reel Motor 0 60 ci 1 2 3 0 60 ci 0 60 ci 0 60 ci TN2506 A ...

Page 126: ...8D 24 Page Intentionally Blank ...

Page 127: ...ge pressure applied to the traction pump and traction circuit When the incom ing charge oil reaches the relief valve setting the relief valve will open releasing excess flow to the hydraulic tank Traction Pump Circuit With the traction pedal in the NEUTRAL position charge pressure oil flows to the combination check valves 3045 psi 210 bar relief valves each side of the traction pump rotating group...

Page 128: ...WD Valve Port A 4 Charge Pressure Oil to Front Wheel Motors and Check Valve Charge Pressure Oil Inlet or Drain Oil Return Oil TN2517 A Hydraulic Oil Tank Check Valve Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Gear Pump 0 39 ci 0 39 ci 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump Reverse Relief Valve 3045 psi Forward Relief Valve 3045 psi Charge Relief Valve...

Page 129: ...m Traction Pump Port B 5 Front Wheel Motor Case Drain Oil to Lift Valve Port T 6 Front Wheel Motor Case Drain Oil to Lift Valve Port T Inlet or Drain Oil TN2518 5 6 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 11 9 ci 7 97 ci 7 97 ci Left Rear Wheel Motor Check Valve Check Valve Forward Reverse 3 4 Charge Pressure Oil ...

Page 130: ...8E 28 Page Intentionally Blank ...

Page 131: ...en the traction pedal is moved to the FORWARD position operating pressure oil from the traction pump rotating group is routed to the combination check valves 3045 psi 210 bar relief valves and the tow valve and exits the traction pump at port A The oil is then routed to the front wheel motors driving the motors Oil exiting the front wheel motors is routed to port B of the traction pump to replenis...

Page 132: ... and 4WD Valve Port A 4 Charge Pressure Oil from Front Wheel Motors Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil Return Oil TN2519 A Hydraulic Tank Forward Relief Valve 3045 psi Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Charge Relief Valve 145 203 psi Gear Pump 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump Reverse Relief Valve 3045 psi Chec...

Page 133: ...static Traction Pump Port B 5 Front Wheel Motor Case Drain Oil to Lift Valve Port T 6 Front Wheel Motor Case Drain Oil to Lift Valve Port T 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 7 97 ci Left Rear Wheel Motor Check Valve 3 4 5 6 Forward Reverse 11 9 ci Check Valve 7 97 ci Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil TN2520 ...

Page 134: ...8E 32 Page Intentionally Blank ...

Page 135: ...pedal is moved to the REVERSE position operating pressure oil from the traction pump rotating group is routed to the combination check valves 3045 psi 210 bar relief valves and the tow valve and exits the traction pump at port B The oil is then routed to the front wheel motors driving the motors Oil exiting the front wheel motors is routed to port A of the traction pump to replenish the intake sid...

Page 136: ... and 4WD Valve Port A 4 Charge Pressure Oil from Front Wheel Motors Hydraulic Tank Forward Relief Valve 3045 psi Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Charge Relief Valve 145 203 psi Gear Pump 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump 0 39 ci 0 39 ci 1 2 3 4 Check Valve Reverse Relief Valve 3045 psi Operating Pressure Oil Charge Pressure Oil Inlet o...

Page 137: ...static Traction Pump Port B 5 Front Wheel Motor Case Drain Oil to Lift Valve Port T 6 Front Wheel Motor Case Drain Oil to Lift Valve Port T 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 7 97 ci 7 97 ci Left Rear Wheel Motor Check Valve 3 4 11 9 ci Forward Reverse Check Valve 5 6 TN2522 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil ...

Page 138: ...8E 36 Page Intentionally Blank ...

Page 139: ...oved to the FORWARD position operating pressure oil from the traction pump rotating group is routed to the combination check valves 3045 psi 210 bar relief valves and the tow valve and exits the traction pump at Port A The oil is then routed to the front wheel motors driving the motors Oil exiting the front wheel motors is routed to port B of the traction pump to replenish the intake side of the t...

Page 140: ...nd 4WD Valve Port A 4 Charge Pressure Oil from Front Wheel Motors Hydraulic Oil Tank Forward Relief Valve 3045 psi Check Valve 0 425 ci 1 35 ci 3150 50 rpm Hydrostatic Traction Pump Tow Valve Charge Relief Valve 145 203 psi Gear Pump 0 39 ci Relief Valve 1160 psi 3 2 1 A B Charge Pump TN2523 A Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil Return Oil 0 39 ci 0 39 ci 1 2 3 4 Check Va...

Page 141: ...static Traction Pump Port B 5 Front Wheel Motor Case Drain Oil to Lift Valve Port T 6 Front Wheel Motor Case Drain Oil to Lift Valve Port T 4WD Valve A B M2 M2 M1 M1 Right Rear Wheel Motor Front Wheel Motors 4WD Solenoid 11 9 ci 7 97 ci 7 97 ci Left Rear Wheel Motor Check Valve 3 4 5 6 Forward Reverse 11 9 ci Check Valve TN2524 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil ...

Page 142: ...8E 40 Page Intentionally Blank ...

Page 143: ... the above symptoms appear or if the hydraulic oil becomes contaminated or after a major component failure the system should be flushed the oil changed and a new filter installed 2 Check all lines and fittings for leakage and tighten as necessary Section 8C 3 Eliminate all possible mechanical problems before starting the hydraulic tests HYDROSTATIC CHARGE PUMP TEST The charge pump supplies oil for...

Page 144: ...set engine to high idle speed and in two wheel drive push the traction pedal forward for 15 seconds 7 Shut off the engine and remove the ignition key 8 Measure the amount of oil collected from the case drain leakage from the 15 second test and multiply x 4 to get gallon per minute of oil internally bypassing the wheel motor Conclusion If oil from the case drain is less than 0 5 gpm 1 9 lpm the mot...

Page 145: ... provided at the end of this sec tion Make copies of the record for future use Use the form to record test results Page 8G 49 Figure 8G 13 CAUTION If interlock safety features are bypassed during a test use extreme caution when performing tests and make sure the interlock system is functional after the test has been completed CAUTION When using a plug to block a pressure line the plug must be able...

Page 146: ...clusion If charge pressure is within range charge relief setting is correct If charge pressure is not within range the charge relief valve may need cleaning or replacement Charge Relief Valve 6 Remove charge relief valve plug spring and cone Inspect for debris and damage Clean or replace as necessary If the relief valve is not clogged or damaged Charge pump may be faulty Traction circuit may have ...

Page 147: ...8G 45 Figure 8G 2 Charge Pressure Test Steering Unit Auxiliary Port 0 to 500 psi 0 to 3447 kPa Gauge Tee Charge Relief Valve ...

Page 148: ... charge pump no load flow indication C on Charge Circuit Test Record Figure 8G 12 6 Slowly close tester load valve until a reading of 850 psi 5860 kPa is obtained 7 Record loaded flow indication D on Charge Cir cuit Test Record Figure 8G 12 8 Subtract flow indication D from flow indication C on the Charge Circuit Test Record The result is the charge pump leakage Figure 8G 12 Conclusion If leakage ...

Page 149: ...cylinder remove both hydraulic lines plug the lines and cap the cylinder ports 14 Set the parking brake start the engine and advance the throttle to high idle speed 15 Turn the steering wheel to the right then to the left until it stops and hold record pressure readings If relief pressure is 1160 psi 7992 kPa 10 steering cylinder is at fault If relief pressure is not within range in one or both di...

Page 150: ...and Steering Flow Test TRACTION CIRCUIT FLOW TEST Load Valve In Out Charge Pump Outlet Hose Charge Pump Outlet NOTICE Before performing this test be sure tow valve located on the underside of the traction pump is closed Figure 8F 1 ...

Page 151: ...raction lines as shown in Figure 8G 5 6 To perform traction pump flow test install blocking disc on test meter hoses connected to the T fit tings on lines going to the front wheel motors behind the front axle Figure 8G 5 In Out Blocking Disc Traction Pump Flow Test Top Hydro Port Reverse Bottom Hydro Port Forward Top Hydraulic Line Reverse Bottom Hydraulic Line Forward NOTICE It is important that ...

Page 152: ...ose the load valve on the flow meter until flow reaches 0 0 gpm lpm 16 Read record forward high pressure relief valve pressure on Traction Circuit Test Record Figure 8G 13 17 Open tester load valve slow engine to idle speed and shut off engine CAUTION When using a plug to block a pressure line the plug must be able to withstand the pressure developed in the circuit CAUTION If interlock safety feat...

Page 153: ... until 2200 psi 152 Bar is obtained 23 Read record gpm lpm flow on Traction Circuit Test Record Figure 8G 13 If flow drops 0 5 gpm 1 9 lpm or less right front traction motor is okay proceed to Left Front Traction Motor Test If flow drops 0 5 to 1 5 gpm 1 9 to 5 6 lpm the right front traction motor is marginal If flow drops more than 2 gpm 7 6 lpm perfor mance will be noticeably reduced The right N...

Page 154: ... off start engine and advance throttle to high idle position 28 Slowly close tester load valve until 2200 psi 152 Bar is obtained 29 Read record gpm lpm flow on Traction Circuit Test Record Figure 8G 13 If flow drops 0 5 gpm 1 9 lpm or less right front traction motor is okay proceed to 4WD Valve Flow Test NOTICE Before performing this test a traction pump flow test must be performed Flow meter con...

Page 155: ... Test 33 Open flow meter load valve set parking brake reel switch off start engine and advance throttle to high idle position 34 Slowly close tester load valve until 2200 psi 152 Bar is obtained 35 Read record gpm lpm flow on Traction Circuit Test Record Figure 8G 13 If flow drops 0 5 gpm 1 9 lpm or less 4WD valve is okay proceed to Rear Traction Motor Flow Test NOTICE Before performing this test ...

Page 156: ...ction motor Figure 8G 10 Right Rear Traction Motor Flow Test 39 Open flow meter load valve set parking brake reel switch off start engine and advance throttle to high idle position 40 Slowly close tester load valve until 2200 psi 152 Bar is obtained 41 Read record gpm lpm flow on Traction Circuit Test Record Figure 8G 13 NOTICE Before performing this test a traction pump flow test front traction m...

Page 157: ...igure 8G 9 44 All blocking disc are removed to test the left rear traction motor Figure 8G 10 NOTICE Before performing this test a traction pump flow test front traction motor test 4WD valve test and right rear traction motor test must be performed Flow meter connections are maintained from traction pump flow test with the exception of the blocking disc being relocated The flow lock tool should re...

Page 158: ... motor is marginal If flow drops more than 2 gpm 7 6 lpm perfor mance will be noticeably reduced The left rear traction motor will require repair or replace ment 48 Open tester load valve slow engine to idle speed and shut off engine 49 Remove flow test meter and hoses and install the traction pump hydraulic lines to the lines on the front axle 50 Remove the flow lock tool from the traction pump c...

Page 159: ...speed ____________ Charge Circuit Pressure Test A Step 4 Page 8G 38 Charge pressure 54 to 66 psi 372 to 455 kPa ____________ B Step 9 Page 8G 40 Steering relief pressure 1160 psi 7992 kPa 10 ____________ Step 8 Result 1 C Minus D Equals Charge pump leakage ____________ Charge Pump Flow Test Page 8G 40 C Step 5 Traction pump no load Flow ____________ D Step 7 Traction Pump Flow 850 psi 5860 kPa ___...

Page 160: ...___ Left Front Traction Motor Test 8G 45 D From Previous Test ____________ E Step 29 Left front traction motor flow 2200 psi 151 7 Bar ____________ Result 3 D Minus E Equals left front traction motor leakage ____________ 4WD Valve Test Page 8G 46 E From Previous Test ____________ F Step 35 4WD Valve flow 2200 psi 151 7 Bar ____________ Result 4 E Minus F Equals 4WD Valve leakage ____________ Right...

Page 161: ...ed in the opposite direc tion oil flows to the opposite side of the traction motors turning the motor and attached wheels The direction of swashblock swivel is controlled by the traction pedal and pump control arm A charge pump is mounted between the rotating group and rear valve plate assembly The pump draws fluid from the hydraulic tank and supplies hydraulic pressure to the steering unit and th...

Page 162: ...y Control Housing Rear Cover Not Used on LF 1880 Rear Valve Plate Assembly PTO Coupling Main Case Input Shaft Gerotor Pump Valve Plate Charge Pump Assembly Rotating Group Swashblock Rear Valve Plate Assembly Valve Plate Charge Pump Main Case and Input Shaft Input Shaft ...

Page 163: ...uts washers and mounting bracket 8 Remove the traction pump and reel pump from the frame 9 Remove the two socket head capscrews that secure the reel pump to the traction pump 10 Remove the reel pump and o ring from the trac tion pump Discard the o ring DISASSEMBLY Control Group and Valve Plate 1 Position traction pump on a workbench with con trol shaft down 2 Completely loosen but do not remove so...

Page 164: ...ing Relief Valve Rear Valve Plate Bypass Pressure Relief Valve Bushing O Rings Coupler Gerotor Pump Retaining Ring Valve Plate Tow Valve Cross Port Relief Valve Cross Port Relief Valve CAUTION Use extreme care to avoid damaging parts and wear surfaces of rotating group and associated parts ...

Page 165: ...roup Figure 8H 5 Rotating Group Disassembly Drive Shaft Group Figure 8H 6 Drive Shaft Group Disassembly Cylinder Barrel Shoe Retainer Spring Ball Fulcrum Shoe Retainer Pistons Retaining Ring Hydrodynamic Bearing O Ring ...

Page 166: ...play A good piston shoe fit will have no end play with the shoe free to rotate and pivot on the piston ball Check each shoe for proper thickness Figure 8H 8 All shoes must be equal within 0 001 0 025 mm The shoes should be replaced as a set Inspect swashblock for wear scoring or damage Replace if worn or damaged Figure 8H 8 Piston and Shoe Thickness Compare saddle bearing thickness in the wear are...

Page 167: ...ation Figure 8H 9 Swashblock Group Assembly Drive Shaft Group Figure 8H 10 Figure 8H 10 Drive Group Assembly Retaining Ring Hydrodynamic Bearing Swashblock Saddle Bearings Main Case Shaft Seal Flush with Housing NOTICE When installing the bearing press on the outer face Install with numbers on bearing to the outside Shaft Shaft Retaining Ring Bearing Retaining Ring Bearing Seal Retainer ...

Page 168: ...um ball Figure 8H 11 Figure 8H 11 Rotating Group Assembly Valve Plate Gerotor Pump Rear Plate Assembly Figure 8H 12 Figure 8H 12 Valve Plate Gerotor Pump and Rear Plate Assembly NOTICE Do not force pistons into barrel The pistons should fit loosely Pistons Shoe Retainer Cylinder Barrel Main Case Assembly ...

Page 169: ...8H 67 Control Group Assembly Figure 8H 13 Figure 8H 13 Control Group Assembly Gasket Control Pin O Ring Control Housing O Ring Arm and Pintle Traction Pump Assembly ...

Page 170: ...ng tags created during disassembly remove plugs and connect hoses to the traction pump and reel pump 4 Install the drive shaft on the traction pump input shaft and engine 5 Replace the hydraulic oil filter and fill the hydraulic tank with hydraulic oil 6 Install the seat and seat pan 7 Start the engine and check component operation and for leaks If necessary perform tests and checks as needed Figu...

Page 171: ...aulic fittings 8 Tag and disconnect the hydraulic hoses from the motor Immediately plug the hoses and motor to prevent contamination of the hydraulic system 9 While supporting the motor remove four mounting bolts and lock washers 10 Remove the motor from the axle Figure 8I 2 Figure 8I 2 Traction Motor Mounting REPAIR 1 Disassemble motor as shown in Figure 8I 3 2 Press the shaft and bearing assembl...

Page 172: ... Manifold Cover Balance Ring Valve Valve Plate Seals Drive Link Gerotor Drive Shaft Wear Plate Shaft Bearing Assembly Backup Ring Shaft Seal Dust Seal NOTICE During assembly position the seals seal rings and backup ring properly Figure 8I 4 Wear Plate Backup Ring Shaft Seal Dust Seal Shaft Face Seal Seal Ring ...

Page 173: ...all the shaft face seal as shown in Figure 8I 6 Place the wear plate on the flange end Figure 8I 6 Installation of Face Seal 9 Continue to assemble as shown in Figure 8I 7 Figure 8I 7 O Rings and Seals Dust Seal Shaft Seal Mounting Flange Backup Ring Shaft Bearing Assembly Seal Wear Plate Shaft Face Seal Shaft Face Springs Pins Port Manifold Cover Tighten Capscrews to 36 to 37 ft lbs 49 to 50 Nm ...

Page 174: ...lock washers 3 Remove the plugs from the hydraulic hoses and motor Using tags created during disassembly connect the hoses to the motor fittings 4 Install key in motor output shaft 5 Clean shaft taper and hub taper so that they are clean and dry Taper fit must be assembled free of lubricants and anti seize 6 Position hub over the output shaft and secure with nut and cotter pin Torque the front whe...

Page 175: ...aulic hoses 7 Tag and disconnect the hydraulic hoses from the motor Immediately plug the hoses and motor to prevent contamination of the hydraulic system 8 While supporting the motor remove the four mounting bolts and lock washers Figure 8J 2 9 Remove the motor from the motor mount Figure 8J 2 Traction Motor Mounting REPAIR 1 Disassemble motor as shown in Figure 8J 3 2 Press the shaft and bearing ...

Page 176: ...Manifold Cover Balance Ring Valve Valve Plate Seals Drive Link Gerotor Drive Shaft Wear Plate Shaft Bearing Assembly Backup Ring Shaft Seal Dust Seal NOTICE During assembly position the seals seal rings and backup ring properly Figure 8J 4 Wear Plate Backup Ring Shaft Seal Dust Seal Shaft Face Seal Seal Ring ...

Page 177: ...all the shaft face seal as shown in Figure 8J 6 Place the wear plate on the flange end Figure 8J 6 Installation of Face Seal 9 Continue to assemble as shown in Figure 8J 7 Figure 8J 7 O rings and Seals Dust Seal Shaft Seal Mounting Flange Backup Ring Shaft Bearing Assembly Seal Wear Plate Shaft Face Seal Shaft Face Springs Pins Port Manifold Cover Tighten Capscrews to 36 to 37 ft lbs 49 to 50 Nm ...

Page 178: ... using the tags created dur ing removal connect the hydraulic hoses to the motor 3 Install the key in the motor output shaft 4 Clean shaft taper and hub taper so that they are clean and dry Taper fit must be assembled free of lubricants and anti seize 5 Position the hub over the output shaft and key secure with nut and cotter pin Torque the rear wheel hub nut to 200 ft lbs 25 ft lbs 6 Install the ...

Page 179: ...ers securing the bracket to the valve 7 Remove the valve REPAIR The 4 wheel valve repairs are limited to changing o rings backup rings and coil The valve can be replaced as an assembly Figure 8K 1 INSTALLATION 1 Position the valve and bracket in the frame for mounting 2 Install three bracket mounting screws and lock washers 3 Position the mounting bracket on the frame and secure with two mounting ...

Page 180: ...8K 78 Page Intentionally Blank ...

Page 181: ...l to the hydrostatic traction pump With the steering wheel turned to the left the steering valve is moved allowing oil to flow through the valve to the gerotor metering section Oil is then routed out port LT of the steering unit to the steering cylinder for a left turn Oil from the rod end of the cylinder is forced out of the cylinder and routed back to port RT of the steering unit and back throug...

Page 182: ...c 1 Operating Pressure Oil from Charge Pump Outlet 2 Charge Pressure Oil to Hydrostatic Traction Pump 1 2 Steering Unit In Out Check Valve Steering Valve LT RT Return Oil Metered Oil Charge Pressure oil Operating Pressure Oil TN2512 ...

Page 183: ...linders Oil also flows through the 0 040 in 1 0 mm orifice while bypassing the three one way 0 026 in 0 66 mm orifices and is routed to the rod end of the rear lift cylinders Oil flow to the rod side of the lift cylin ders raises the cutting units Oil is forced from the piston end of the lift cylinders and is routed back to the lift valve and returned to the hydraulic tank Circuit Relief The lift ...

Page 184: ...1 2 3 4 5 Test Port G P T T Solenoid Valve Relief Valve 1750 psi Relief Valve 450 psi Lift Valve Check Valve Check Valve Check Valve 3 4 2 1 6 10 9 8 0 040 in One Way Orifice 0 026 in One Way Orifice 0 026 in One Way Orifice 0 026 in Left Rear Cylinder Right Rear Cylinder Right Front Cylinder Left Front Cylinder Center Cylinder One Way Orifice 0 032 in One Way Orifice 0 032 in One Way Orifice 0 03...

Page 185: ...lief valve will shift dumping excess oil to the hydraulic tank With operating pressure oil built up at the check valve pilot lines the check valves open Gravity pulls the cut ting units down pulling against the lift cylinders The oil from the rod end of the front and center lift cylinders flows through the 0 032 in 0 8 mm orifices which dampen the lowering of the reels to prevent damage to the cut...

Page 186: ...eel Motors 1 2 3 Operating Pressure Oil Metered Oil Return Oil TN2514 Relief Valve 450 psi Lift Valve Test Port One Way Orifice 0 026 in One Way Orifice 0 026 in One Way Orifice 0 026 in 0 040 in Right Rear Cylinder Left Rear Cylinder One Way Orifice 0 032 in One Way Orifice 0 032 in One Way Orifice 0 032 in Right Front Cylinder Center Cylinder Left Front Cylinder 3 4 2 1 6 10 9 8 G P T T Relief V...

Page 187: ...motors Circuit Relief The mow circuit is protected by the 2200 psi 152 bar pilot operated relief valves located in the reel valves The relief valves will open if the oil pressure in the mow circuit reaches 2200 psi 152 bar routing the oil through port T of the reel valves to the oil cooler return filter and then the hydraulic tank Oil Return Return oil from the reel motors enters the reel valves a...

Page 188: ...Lift Valve Port T 6 Case Drain Oil from Front Wheel Motors C 5 6 Operating Pressure Oil Inlet or Drain Oil Return Oil 5 Charge Pressure Oil Rear Reel Valve Front Reel Valve A B P T Test Port Test Port T P A B Backlap Valve Solenoid Valve Solenoid Valve Relief Valve 2200 psi 2200 psi Relief Valve Backlap Valve 0 60 ci G G Left Rear Reel Motor Right Rear Reel Motor Left Front Reel Motor Center Reel ...

Page 189: ... flow will regulate reverse rotational speed and maintain reverse motor speed as load is applied to the reel motors Speed adjustment settings can be main tained and will not affect mowing operation when motors are shifted to mow rotation Circuit Relief The backlap circuit is protected by the 2200 psi 152 bar pilot operated relief valves located in the reel valves The relief valves will open if the...

Page 190: ...o Lift Valve Port T 6 Case Drain Oil from Front Wheel Motors 5 Rear Reel Valve Front Reel Valve A B P T Test Port T P A B Backlap Valve Solenoid Valve Solenoid Valve Relief Valve 2200 psi Relief Valve 2200 psi Backlap Valve 0 60 ci G G Left Rear Reel Motor Right Rear Reel Motor Left Front Reel Motor Center Reel Motor Right Front Reel Motor 0 60 ci 0 60 ci 0 60 ci 0 60 ci 1 2 3 4 5 6 Operating Pres...

Page 191: ...ar or if the hydraulic oil becomes contaminated or after a major component failure the system should be flushed the oil changed and a new filter installed 2 Check all lines and fittings for leakage and tighten as necessary Section 8C 3 Eliminate all possible mechanical problems before starting the hydraulic tests LIFT SYSTEM TEST The purpose of this test is to determine if the lift cylin ders are ...

Page 192: ...clusion If the steering wheel becomes hard to turn or stops turning and a hissing sound is heard after steering the maximum right and or left the steering unit is not at fault If the steering wheel continues to turn proceed with the test 2 With the engine off remove both hydraulic hoses from the steering cylinder plug the hoses and cap the cylinder ports 3 With the engine on turn the steering whee...

Page 193: ...se from the reel motor to be tested Figure 8M 3 Immediately plug the hose 3 Position a drain pan minimum capacity 1 gallon 3 8 liters near the reel motor 4 Install a separate hose on the case drain fitting on the motor and place the free end in the container 5 Block the reel so that the reel cannot turn 6 Set the parking brake start the engine and place the reel switch in the forward ON position R...

Page 194: ...n 8N If the oil from the case drain is 0 5 to 1 gpm 1 9 to 3 8 lpm the motor is marginal If the oil from the case drain is over 1 gpm 3 8 lpm the motor should be repaired or replaced 9 Remove the separate test hose from the motor and plug from the case drain hose Connect the case drain hose to the reel motor 10 Remove the blocking device from the reel 11 Repeat this test procedure for each reel mo...

Page 195: ...ord has been provided at the end of this sec tion Make copies of the record for future use Use the form to record test results CAUTION If interlock safety features are bypassed during a test use extreme caution when performing tests and make sure the interlock system is functional after the test CAUTION When using a plug to block a pressure line the plug must be able to withstand the pressure deve...

Page 196: ...valve plug spring and cone Inspect for sediment or debris and dam age Clean or replace as necessary If the relief valve is not clogged or damaged 8 Remove the hydraulic lines from the steering cyl inder Cap the cylinder ports and plug the hydrau lic hoses 9 Set the parking brake start engine and advance engine speed to full throttle 10 Slowly turn the steering wheel to the full left and right posi...

Page 197: ...the relief valve opens within range relief valve and lift circuit are not at fault If the relief valve exceeds range replace the relief valve If the relief valve does not reach range the reel auxiliary hydraulic pump may be at fault Proceed with pressure test 6 Shut off the engine and remove the ignition key 7 Remove the hydraulic hoses from the lift cylinders Figure 8N 3 and plug the hoses Cap th...

Page 198: ... hold in the lowering position 11 While watching the pressure gauge Figure 8N 4 place the joystick in the lower position The lower relief valve should open at approximately 450 psi 3102 kPa Conclusion If the relief valve opens within range the lower relief valve is not faulty If the relief valve does not open within range replace the lower relief valve 12 Remove the gauge and cover the quick conne...

Page 199: ...8N 97 Figure 8N 4 Lower Circuit Testing Quick Connect Fitting 0 to 2000 psi 0 to 13790 kPa ...

Page 200: ...ot at fault A reel motor may be at fault Remove the plugs and connect the hose to the reel valve Add motors one at a time to the circuit and repeat steps 4 through 7 If the relief valve does not open within range replace the relief valve If the relief valve does not develop pressure within range perform a flow test on the reel auxiliary hydraulic pump 8 Shut off the engine remove the gauge place t...

Page 201: ...elief valve pressure is not in the specified range in one or both positions proceed with Step 3 3 At the steering cylinder remove both hydraulic lines plug the lines and cap the cylinder ports 4 Set the parking brake start the engine and advance the throttle to high idle speed 5 Turn the steering wheel to the right then to the left until it stops and hold record pressure readings Conclusion If rel...

Page 202: ...8N 100 Figure 8N 7 Charge Pump and Steering Flow Test Load Valve In Out Charge Pump Outlet Hose Charge Pump Outlet Fitting ...

Page 203: ...N 8 Front Reel Pump Section Flow Test 4 Insert blocking disc on flow meter hose connected to the reel valve hydraulic line 5 Fully open the load valve on the flow meter Figure 8N 8 Front Reel Pump Section Flow Test 6 Set parking brake start engine and advance engine speed to full throttle 7 Record pump section three no load flow indication A on Front Reel Circuit Test Record Figure 8N 13 CAUTION D...

Page 204: ... A from flow indication B The result is section one pump leakage Conclusion If leakage is less that gpm 1 9 lpm pump is not at fault If leakage is to 1 gpm 1 9 to 3 8 lpm pump is marginal If leakage is over 1 gpm 3 8 lpm pump may be faulty 10 Open load valve on flow meter and slow engine to low idle speed 11 Shut off the engine and remove the ignition key 12 Proceed to Front Reel Valve Flow Test ...

Page 205: ...eel Valve Flow Test 16 Set parking brake start engine and advance engine speed to full throttle 17 Slowly close tester load valve until 1600 psi 110 Bar is indicated on the pressure gauge Record flow indication C on Front Reel Circuit Test Record Figure 8N 13 18 Subtract flow indication C from flow indication B The result is front reel valve leakage Conclusion If leakage is less that gpm 1 9 lpm v...

Page 206: ...onclusion Early models reel relief valve pressure was 3000 psi 307 Bar Late models 2009 reel relief valve pressure was 2200 psi 152 Bar 21 Open flow meter load valve and slow engine to low idle speed 22 Shut off the engine and remove the ignition key 23 Proceed to Front Right Reel Motor Flow Test ...

Page 207: ...t reel motor flow test must be performed before performing this test 33 Flow meter connections remain the same from the previous valve test Carefully follow the steps to set up for this test I 34 Install suitable blocking device or tool in right front cutting unit preventing cutting unit from turning 35 Fully open the flow meter load valve 36 Set parking brake start engine and advance engine speed...

Page 208: ...throttle 45 Slowly close tester load valve until 1600 psi 110 Bar is indicated on the pressure gauge Record flow indication d on Front Reel Circuit Test Record Figure 8N 13 46 Subtract flow indication d from flow indication c The result is left front reel motor leakage Conclusion If leakage is less that gpm 1 9 lpm motor is not at fault If leakage is to 1 gpm 1 9 to 3 8 lpm motor is marginal If le...

Page 209: ...voir Figure 8N 10 Rear Reel Pump Section Flow Test 4 Insert blocking disc on flow meter hose connected to the rear reel valve hydraulic line 5 Fully open the load valve on the flow meter Figure 8N 10 Rear Reel Pump Section Flow Test 6 Set parking brake start engine and advance engine speed to full throttle 7 Record pump section two no load flow indication A on Rear Reel Circuit Test Record CAUTION...

Page 210: ... B from flow indication A The result is section two pump leakage Conclusion If leakage is less that gpm 1 9 lpm pump is not at fault If leakage is to 1 gpm 1 9 to 3 8 lpm pump is marginal If leakage is over 1 gpm 3 8 lpm pump may be faulty 10 Open load valve on flow meter and slow engine to low idle speed 11 Shut off the engine and remove the ignition key 12 Proceed to Rear Reel Valve Flow Test ...

Page 211: ...w meter load valve Figure 8N 11 Rear Reel Valve Flow Test 16 Set parking brake start engine and advance engine speed to full throttle 17 Slowly close tester load valve until 1600 psi 110 Bar is indicated on the pressure gauge Record flow indication C on Rear Reel Circuit Test Record Figure 8N 14 18 Subtract flow indication C from flow indication B The result is front reel valve leakage Conclusion ...

Page 212: ...tion D on the Rear Reel Circuit Test Record Figure 8N 14 Conclusion Early models reel relief valve pressure was 3000 psi 307 Bar Late models 2009 reel relief valve pressure was 2200 psi 152 Bar 21 Open flow meter load valve and slow engine to low idle speed 22 Shut off the engine and remove the ignition key 23 Proceed to Rear Left Reel Motor Flow Test ...

Page 213: ...rformed before performing this test 33 Flow meter connections remain the same from the previous valve test Carefully follow the steps to set up for this test 34 Install suitable blocking device or tool in right front cutting unit preventing cutting unit from turning 35 Fully open the flow meter load valve 36 Set parking brake start engine and advance engine speed to full throttle 37 Slowly close t...

Page 214: ...3 8 lpm motor may be faulty 39 Open flow meter load valve and slow engine to low idle speed 40 Shut off the engine and remove the ignition key 41 Remove blocking disc and flow test meter and restore hydraulic hose and line connections ...

Page 215: ...ction three no load flow indication g 5 Slowly close tester load valve until 1000 psi 6894 kPa is indicated on the pressure gauge Record flow indication h 6 Subtract flow indication h from flow indication g The result is section three pump leakage Conclusion If leakage is less that gpm 1 9 lpm pump is not at fault If leakage is to 1 gpm 1 9 to 3 8 lpm pump and or reel valve circuit relief is margi...

Page 216: ...Front Reel Valve Flow Test Page 8N 95 B From Pump Test ____________ C Step 17 Front reel valve flow 1600 psi 110 Bar ____________ Result 2 B Minus C Equals front reel valve leakage ____________ Right Front Reel Motor Test 8N 97 C From Previous Test ____________ E Step 28 Right front reel motor flow 1600 psi 110 Bar ____________ Result 3 C Minus E Right front reel motor leakage ____________ Center ...

Page 217: ... pump leakage ____________ D Step 20 Rear reel valve relief valve pressure ____________ Rear Reel Valve Flow Test Page 8N 101 B From Pump Test ____________ C Step 17 Rear reel valve flow 1600 psi 110 Bar ____________ Result 2 B Minus C Equals rear reel valve leakage ____________ Left Rear Reel Motor Test 8N 103 C From Previous Test ____________ E Step 28 Left rear reel motor flow 1600 psi 110 Bar ...

Page 218: ...8N 116 Page Intentionally Blank ...

Page 219: ...roughly clean the auxiliary pump especially the area surrounding the hydraulic hoses tubes and fittings 4 Tag and disconnect the hydraulic hoses and tubes from the auxiliary pump Immediately plug the hoses and pump to prevent contamination of the hydraulic system 5 Remove the mounting bracket bolts and nuts Figure 8O 2 6 While supporting the pump remove the two socket head capscrews securing the a...

Page 220: ... studs and bolts disassemble pump one section at a time Before removing gear set mark a line across the meshing teeth to ensure that the gears are reassembled in the same position Figure 8O 4 Bolt Stud Section 3 Section 2 Section 1 Spacer Plate O Ring Seal Backup Washer Bushing Set Body Gear Set Bushing Set Seal Backup Washer O Ring Flange Seal Retaining Ring CAUTION Never pry pump sections apart ...

Page 221: ...er assembling each sec tion to make sure there is no binding between parts 6 Use extreme care when installing the shaft seal The shaft seal must sit squarely in the seal bore Lubricate seal and use care when inserting shaft through the shaft seal 7 Install the studs bolts and nuts finger tight and rotate the drive shaft to make sure it turns freely Tighten the tie bolts evenly and in steps to a fi...

Page 222: ...8O 120 Page Intentionally Blank ...

Page 223: ...5 Tag and disconnect the wiring harness connectors from both solenoids 6 While supporting the valve remove two mounting screws and lock washers from the bottom of the valve 7 Remove the valve from the mower INSTALLATION 1 Position the valve on the front axle mounting and secure with two screws and lock washers 2 Remove plugs and using the tags created during removal connect the hydraulic hoses and...

Page 224: ...8P 122 Page Intentionally Blank ...

Page 225: ... air dry exterior of cylinder 2 Drain the oil from the cylinder 3 Disassemble the lift cylinder Figure 8Q 1 Figure 8Q 1 Lift Cylinder Disassembly a Remove rod guide lock ring Figure 8Q 2 Figure 8Q 2 Guide Lock Ring b Push rod guide into cylinder approximately 0 75 in Figure 8Q 3 Figure 8Q 3 Rod Guide CAUTION During repair of the cylinder use extreme care not to damage the barrel rod and sealing su...

Page 226: ...mbly from the cylinder body Figure 8Q 7 Figure 8Q 7 Rod Assembly ASSEMBLY 1 Lightly lubricate o rings backup rings and seals with clean hydraulic oil 2 Install seal kit as shown in Figure 8Q 8 3 Lubricate all parts with clean hydraulic oil before assembly Figure 8Q 8 Lift Cylinder Assembly Nylon Spacer Lock Ring Lock Ring Groove NOTICE Do not install rod o ring at this time Rod Assembly Nut Piston...

Page 227: ...ssembly d Push the rod guide into the cylinder approxi mately 0 75 in Figure 8Q 12 Figure 8Q 12 Rod Guide e Install the large snap ring Figure 8Q 13 Figure 8Q 13 Lock Ring f Pull the rod and guide out Install a spacer and small snap ring Figure 8Q 14 Figure 8Q 14 Nylon Spacer and Snap Ring INSTALLATION Section 9E and Figure 8Q 15 Figure 8Q 15 Seal Kit Installation Nylon Spacer Lock Ring Lock Ring ...

Page 228: ...8Q 126 Page Intentionally Blank ...

Page 229: ...rom the valve Immediately plug the hoses tubes and valve to prevent contamination of the hydrau lic system 4 Tag and disconnect both solenoid wiring harness connectors 5 While supporting the valve remove two mounting screws and lock washers from the bottom of the valve 6 Remove the valve from the mower INSTALLATION 1 Position the valve on the mount and secure with two mounting screws and lock wash...

Page 230: ...8R 128 Figure 8R 1 Reel Valve Mounting Front Reel Valve Center Reel Valve Solenoid Valve Coil Port Plug Coil Nut Relief Valve Flow Control Knob ...

Page 231: ... motor fittings Immediately plug the hoses and motor to prevent contamination of the hydraulic system INSTALLATION 1 Remove plugs and using tags created during removal connect the hydraulic hoses to the motor fittings 2 Check the reel mounting area for dirt and debris Clean as necessary 3 Position the motor to reel coupler on the reel 4 Install the motor on the reel and over the mounting pins Secu...

Page 232: ...8S 130 Page Intentionally Blank ...

Page 233: ... area 4 Carefully remove the oil cooler rubber iso mounts 5 Tag and disconnect the oil cooler hydraulic hoses Immediately plug the hoses and oil cooler to pre vent contamination of the hydraulic system 6 Remove the oil cooler INSTALLATION 1 Position the oil cooler for installation of the hydraulic hoses 2 Remove plugs and using the tags created during removal connect the hydraulic hoses to the oil...

Page 234: ...8T 132 Page Intentionally Blank ...

Page 235: ...raction Motor Oil Cooler Traction Pump Reel Auxiliary Pump Hydraulic Tank Hydraulic Return Filter Front Traction Motor Front Traction Motor Steering Unit Lift Lower Valve Reel Valve 4WD Valve Hydraulic Charge Filter SECTION 8U COMPONENT LOCATIONS 8U ...

Page 236: ...8U 134 Figure 8U 1 Component Locations Page Intentionally Blank ...

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