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Textron JACOBSEN GP400, Technical/Repair Manual

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IX-8

4252490-Rev A

Index

IX

Repair

12V Accessory Socket . . . . . . . . . . . . . . . . .  4-59
Air Filter Assembly (Diesel)  . . . . . . . . . . . . . .  3-8
Air Filter Assembly (Gasoline)  . . . . . . . . . . .  3-18
Alarm Light . . . . . . . . . . . . . . . . . . . . . . . . . .  4-63
Alternator  . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-51
Backlap Switch . . . . . . . . . . . . . . . . . . . . . . .  4-56
Battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-51
Battery Cover . . . . . . . . . . . . . . . . . . . . . . . .  4-50
Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . .  8-33
Bedknife Backing Assembly . . . . . . . . . . . . .  8-32
Canister (Gasoline)  . . . . . . . . . . . . . . . . . . .  3-18
Center Lift Arm . . . . . . . . . . . . . . . . . . . . . . .  8-26
Center Lift Cylinder . . . . . . . . . . . . . . . . . . . .  6-52
Choke Cable (Gasoline) . . . . . . . . . . . . . . . .  3-20
Control Arm  . . . . . . . . . . . . . . . . . . . . . . . . . .  7-5
Coolant Recovery Bottle (Diesel) . . . . . . . . .  3-10
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . .  8-22
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-50
Engine (Diesel) . . . . . . . . . . . . . . . . . . . . . . .  3-15
Engine (Gasoline) . . . . . . . . . . . . . . . . . . . . .  3-21
Engine Oil Pressure Light . . . . . . . . . . . . . . .  4-63
Engine Oil Pressure Switch (Diesel) . . . . . . .  4-57
Engine Oil Pressure Switch (Gasoline)  . . . .  4-57
Engine Service (Diesel)  . . . . . . . . . . . . . . . .  3-17
Engine Service (Gasoline)  . . . . . . . . . . . . . .  3-22
Engine Stop Relay (gasoline) . . . . . . . . . . . .  4-60
Engine Temperature Sensor  . . . . . . . . . . . .  4-61
Fan Belt (Diesel) . . . . . . . . . . . . . . . . . . . . . . .  3-7
Floorboard Assembly . . . . . . . . . . . . . . . . . .  9-17
Flushing Valve  . . . . . . . . . . . . . . . . . . . . . . .  5-55
Front Reel Valve . . . . . . . . . . . . . . . . . . . . . .  6-48
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . .  8-38
Front Wheel  . . . . . . . . . . . . . . . . . . . . . . . . .  9-19
Front Wheel Hub  . . . . . . . . . . . . . . . . . . . . .  9-22
Fuel Filter (Diesel)  . . . . . . . . . . . . . . . . . . . .  3-14
Fuel Filter (Gasoline)  . . . . . . . . . . . . . . . . . .  3-21
Fuel Pump (Diesel) . . . . . . . . . . . . . . . . . . . .  3-15
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . .  4-63
Fuel Shutoff Timer  . . . . . . . . . . . . . . . . . . . .  4-64
Fuel Tank (Diesel)  . . . . . . . . . . . . . . . . . . . . .  9-7
Fuel Tank (Gasoline)  . . . . . . . . . . . . . . . . . . .  9-9
Fuel Tank Support Pan  . . . . . . . . . . . . . . . .  9-10
Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-60
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . .  6-43
Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . .  4-60
Grass Shield . . . . . . . . . . . . . . . . . . . . . . . . .  8-32
Horn  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-65
Horn Switch  . . . . . . . . . . . . . . . . . . . . . . . . .  4-54
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . .  4-65
Hydraulic Oil Charge Filter Assembly . . . . . .  6-59
Hydraulic Oil Charge Filter Pressure Switch  4-58
Hydraulic Oil Cooler (Diesel)  . . . . . . . . . . . .  6-60
Hydraulic Oil Cooler (Gasoline)  . . . . . . . . . .  6-61
Hydraulic Oil Pressure Light . . . . . . . . . . . . .  4-63
Hydraulic Oil Tank (Diesel) . . . . . . . . . . . . . .  6-57

Hydraulic Oil Tank (Gasoline) . . . . . . . . . . .   6-58
Hydraulics  . . . . . . . . . . . . . . . . . . . . . . . . . .   6-42
Hydrostatic Power Train  . . . . . . . . . . . . . . .   5-50
Instrument Panel . . . . . . . . . . . . . . . . . . . . .   4-52
Instrument Panel Cover . . . . . . . . . . . . . . . .   9-13
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . .   4-54
Left and Right Front Lift Cylinders . . . . . . . .   6-54
Lift Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . .   6-46
Lift Yoke  . . . . . . . . . . . . . . . . . . . . . . . . . . .   8-23
Lower Solenoid  . . . . . . . . . . . . . . . . . . . . . .   4-61
MCU  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-50
Mow Solenoid  . . . . . . . . . . . . . . . . . . . . . . .   4-62
Mow/Transport Switch . . . . . . . . . . . . . . . . .   4-56
Muffler (Diesel)  . . . . . . . . . . . . . . . . . . . . . .   3-10
Muffler Assembly (Gasoline) . . . . . . . . . . . .   3-19
OPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   9-7
Park Brake Cables  . . . . . . . . . . . . . . . . . . .   9-20
Park Brake Caliper Assembly  . . . . . . . . . . .   9-20
Park Brake Lever . . . . . . . . . . . . . . . . . . . . .   9-14
Radiator (Diesel) . . . . . . . . . . . . . . . . . . . . .   3-12
Raise Solenoid  . . . . . . . . . . . . . . . . . . . . . .   4-62
Raise/Lower Switch Assembly  . . . . . . . . . .   4-55
Rear Roller  . . . . . . . . . . . . . . . . . . . . . . . . .   8-38
Rear Wheel and Steering Axle—2WD Units 

(Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . .   9-22

Rear Wheel and Steering Axle—2WD Units 

(Gasoline) . . . . . . . . . . . . . . . . . . . . . . . .   9-24

Rear Wheel Hub—3WD Units . . . . . . . . . . .   9-26
Rear Wheel—3WD Units . . . . . . . . . . . . . . .   9-25
Reel Assembly  . . . . . . . . . . . . . . . . . . . . . .   8-37
Reel Bearing Housing Assembly—Drive Side . . . .  

8-34

Reel Bearing Housing Assembly—Non-Drive Side  

8-36

Reel Leveling Rod . . . . . . . . . . . . . . . . . . . .   8-23
Reel Motor . . . . . . . . . . . . . . . . . . . . . . . . . .   8-28
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-60
Right and Left Lift Arms . . . . . . . . . . . . . . . .   8-24
Rocker Switches  . . . . . . . . . . . . . . . . . . . . .   4-53
Roller Bearings  . . . . . . . . . . . . . . . . . . . . . .   8-39
Seat and Seat Plate  . . . . . . . . . . . . . . . . . .   9-15
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . .   9-16
Soft Drop Valve . . . . . . . . . . . . . . . . . . . . . .   6-50
Splash Shield  . . . . . . . . . . . . . . . . . . . . . . .   9-18
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . .   4-52
Starter Relay . . . . . . . . . . . . . . . . . . . . . . . .   4-60
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   7-4
Steering Axle—2WD Units (Diesel) . . . . . . .   9-23
Steering Axle—2WD Units (Gasoline) . . . . .   9-25
Steering Column Covers . . . . . . . . . . . . . . . .   7-4
Steering Cylinder . . . . . . . . . . . . . . . . . . . . .   7-14
Steering Unit  . . . . . . . . . . . . . . . . . . . . . . . . .   7-6
Steering Wheel  . . . . . . . . . . . . . . . . . . . . . . .   7-4
Steering Yoke Assembly . . . . . . . . . . . . . . .   7-17
Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . .   8-27
Thermostat (Diesel) . . . . . . . . . . . . . . . . . . .   3-11

Summary of Contents for JACOBSEN GP400

Page 1: ...GP400 Riding Greens Mower Technical Repair Manual USAG004 USAD004...

Page 2: ......

Page 3: ...e 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 2011 Jacobsen A Textron Company All righ...

Page 4: ......

Page 5: ...erator s manual and parts manual for specific information on these topics THE INFORMATION CONTAINED IN THIS MANUAL IS BASED ON MACHINES MANUFACTURED UP TO THE TIME OF PUBLICATION JACOBSEN RESERVES THE...

Page 6: ...tools and or materials will be listed for reference prior to beginning a procedure Specifications Near the beginning of each chapter is a specifications listing This listing contains any specification...

Page 7: ...4 5 6 7 8 Table of Contents 4252490 Rev A 7 1 Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous R...

Page 8: ......

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

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

Page 11: ...SAFETY 4252490 Rev A 1 3 1 Figure 1 1 TN3769 11 9 5 10 1 2 4 6 7 8 3...

Page 12: ...1 4 4252490 Rev A SAFETY 1 7 1 6 11 8 5...

Page 13: ...SAFETY 4252490 Rev A 1 5 1 Pb 4 2 3 14 10 4127335 SRC 9...

Page 14: ...ed Goggles Goggles offer side protection not offered by safety glasses alone Unvented Goggles Unvented goggles offer protection from chemical splashes and vapors Park Mower Safely See Figure 1 2 WARNI...

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

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

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

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

Page 19: ...Serial Number 2 2 Optional Machine Accessories 2 2 Component Location 2 3 Specifications 2 4 Quick Reference Specifications 2 4 Standard Torque Values 2 11 Inch Fastener Torque Values 2 11 Metric Fast...

Page 20: ...er plate 1 is attached to the top of the rocker arm cover The plate also includes the engine model number and the engine code number An engine data tag 2 is attached to the side of the rocker arm cove...

Page 21: ...come familiar with operator controls machine components and correct operating procedures before beginning repair procedures 1 Fuel Tank 4 Park Brake Lever 7 Steering Wheel 10 Right Cutting Unit 2 Hydr...

Page 22: ...t hp kW 17 7 13 2 3200 rpm Cooling System Liquid Cooled Cooling System Capacity qt L 4 3 8 50 50 Water Ethylene Glycol Mix Maximum Speed No Load rpm 3400 50 Oil Sump Capacity qt L 3 4 3 2 Alternator 1...

Page 23: ...22 C ohms 5 6 10 Resistance Across Solenoid Coil Lower Solenoid Coil at 72 F 22 C ohms 5 6 10 Resistance Across Fuel Shutoff Pull In Coil ohm 1 0 10 Resistance Across Carb Solenoid Coil at 68 F 20 C o...

Page 24: ...Relief Valve Torque lb ft N m 44 60 Flushing Valve Check Valve Torque lb ft N m 44 60 Flushing Valve Port RW1 Fitting Torque lb ft N m 77 105 Flushing Valve Port RW2 Fitting Torque lb ft N m 77 105 F...

Page 25: ...Relief Valve Torque lb ft N m 20 25 27 34 Lift Valve Check Valve Torque lb ft N m 30 35 41 47 Lift Valve Solenoid Valve Torque lb ft N m 25 30 34 40 Lift Valve Port P Fitting Torque lb ft N m 55 74 Li...

Page 26: ...4252490 Rev A SPECIFICATIONS AND GENERAL INFORMATION 2 Steering Repair Specifications Steering Wheel Nut Torque lb ft N m 28 30 38 41 Steering Unit End Cover to Housing Screw Torque lb ft N m 20 24 27...

Page 27: ...lar Face Measurement Spring Side in mm 4 606 117 Reel Leveling Rod Rod End to Nut Face Measurement Spring Side in mm 0 094 2 4 Repair Specifications Reel Motor Mounting Nut Torque lb ft N m 18 24 Reel...

Page 28: ...g Nut Torque lb ft N m 48 63 65 85 2WD Mounting Bolt Torque lb ft N m 48 63 65 85 3WD Lug Nut Torque lb ft N m 55 63 75 85 Front Wheel Hub Castle Nut Torque lb ft N m 162 220 Rear Wheel Hub 3WD Castle...

Page 29: ...156 154 209 1 4 20 in lb Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159 215...

Page 30: ...hose to twist hold the hose in a normal straight position When installing hoses place fittings at angles to avoid contact with fixed parts when turning Make sure hoses are assembled to proper A and B...

Page 31: ...Air Filter Assembly Diesel 3 8 Throttle Cable Diesel 3 9 Muffler Diesel 3 10 Coolant Recovery Bottle Diesel 3 10 Thermostat Diesel 3 11 Radiator Diesel 3 12 Fuel Filter Diesel 3 14 Fuel Pump Diesel 3...

Page 32: ...System Liquid Cooled Cooling System Capacity qt L 4 3 8 50 50 Water Ethylene Glycol Mix Maximum Speed No Load rpm 3400 50 Oil Sump Capacity qt L 3 4 3 2 Alternator 12 volt 150W Dry Weight lb kg 139 63...

Page 33: ...Plate 5 Air Cleaner Assembly 9 Starter 13 Thermostat 2 Fuel Shutoff Solenoid 6 Coolant Recovery Bottle 10 Engine Oil Pressure Switch 14 Engine Temperature Sensor 3 Radiator Drain Plug 7 Alternator 11...

Page 34: ...3 4 4252490 Rev A ENGINE 3 Figure 3 2 Component Location Right Side 1 Radiator 2 Glow Plug 3 Fuel Pump 4 Fuel Filter TN3767 TN3948 4 3 1 2...

Page 35: ...oline Models See Figure 3 33 Figure 3 3 Component Location 1 Air Filter Assembly 4 Muffler 7 Fuel Pump 2 Throttle Cable 5 Engine Oil Dipstick 8 Fuel Filter 3 Choke 6 Engine Oil Fill Cap 9 Engine Oil C...

Page 36: ...y turning it counterclockwise two turns Place a suitable container under the filter to catch fuel that will flow from the screw hole 5 When bubbles no longer appear in fuel coming out of the air vent...

Page 37: ...igure 3 7 4 Remove fan belt 1 from the alternator 3 coolant pump 5 and crankshaft pulley 4 Installation 1 Install fan belt by reversing the order of removal 2 Adjust belt tension by loosening alternat...

Page 38: ...allation 2 Release retaining clips 1 and remove air filter dust cap 2 3 Using damp lint free cloth thoroughly clean the inside of the dust cap Figure 3 9 4 Slide air filter 4 out of the assembly 5 Rai...

Page 39: ...See Park Mower Safely on page 1 6 2 Raise the hydraulic oil fuel tank See Raise Hydraulic Oil Fuel Tank on page 9 4 3 Remove throttle lever See Throttle Lever on page 9 14 Figure 3 12 4 Loosen screw 1...

Page 40: ...tall muffler by reversing the order of removal Install new gasket 4 during installation Coolant Recovery Bottle Diesel Removal and Installation See Figure 3 14 CAUTION 1 Park the mower safely See Park...

Page 41: ...ngine cooling system Figure 3 16 7 Loosen hose clamp 2 and disconnect hose 3 8 Remove two screws 4 and lock washers 5 9 Remove thermostat housing 8 gasket 6 and thermostat 7 Installation Notes Install...

Page 42: ...and drain coolant Figure 3 18 7 Remove two screws 4 and flat washers 5 8 Remove nine screws 2 and flat washers 3 and remove radiator cover 6 NOTE Label all hoses before removing to ensure correct ins...

Page 43: ...bushings 30 21 Remove radiator 28 from mounting frame 35 Installation 1 Flush the inside of the radiator with fresh water 2 Install radiator by reversing the order of removal 3 Use new cable tie to s...

Page 44: ...allation Notes Clean the inside and outside of filter head 2 Lightly lubricate O rings 6 and 7 with clean oil Install fuel filter by reversing the order of removal Tighten cup retaining nut 3 hand tig...

Page 45: ...to installation Do not overtighten these screws or tank may crack and cause a leak Apply dielectric grease Jacobsen PN 365422 to any wire connectors disconnected Engine Diesel Removal and Installation...

Page 46: ...emove hydraulic lines 12 15 Remove seven screws 8 and lock washers 9 and remove OPS bracket 7 Figure 3 27 16 Loosen hose clamp 13 and disconnect fuel hose 14 Figure 3 28 17 Remove screws 16 and discon...

Page 47: ...r of removal Tighten engine mounting screws 17 and 20 to 44 lb ft 60 N m If necessary remove components from the engine and install the components on the new engine Use new gaskets when installing the...

Page 48: ...ze dry in a clean cloth Saturate in clean engine oil and squeeze out excess oil in a clean absorbent cloth Replace air filter pre cleaner if it remains dirty or is damaged Do not use petroleum solvent...

Page 49: ...ure 3 33 4 Remove screw 3 5 Remove two nuts 13 four flat washers 1 two lock washers 15 and exhaust cover 4 6 Remove two nuts 6 and clamp 5 and disconnect exhaust pipe 7 from muffler 8 7 Remove screw 1...

Page 50: ...rottle cable 2 Installation Note Install throttle cable by reversing the order of removal Choke Cable Gasoline Removal and Installation See Figures 3 35 and 3 36 1 Park the mower safely See Park Mower...

Page 51: ...the engine to cool completely 3 Tag and disconnect the negative battery cable 4 Remove fuel tank See Fuel Tank Gasoline on page 9 9 5 Remove fuel tank support pan See Fuel Tank Support Pan on page 9 1...

Page 52: ...information and illustrations Installation Notes Inspect engine isolation mounts and replace if necessary Tighten engine isolation mount screws 4 to 44 lb ft 60 N m Install the engine by reversing the...

Page 53: ...soline Engine Circuit Schematic 4 20 Raise Lower Circuit Theory of Operation 4 23 Raise Circuit Schematic 4 24 Lower Circuit Schematic 4 25 Mow Circuit Theory of Operation 4 26 Mow Circuit Schematic 4...

Page 54: ...asoline 4 48 Mow Transport Switch Adjustment 4 49 Repair 4 50 Control Module 4 50 Battery Cover 4 50 Battery 4 51 Alternator 4 51 Starter Motor 4 52 Instrument Panel 4 52 Rocker Switches 4 53 Horn Swi...

Page 55: ...at 72 F 22 C ohms 5 6 10 Resistance Across Solenoid Coil Lower Solenoid Coil at 72 F 22 C ohms 5 6 10 Resistance Across Fuel Shutoff Pull In Coil ohm 1 0 10 Resistance Across Carb Solenoid Coil at 68...

Page 56: ...tch configurations Switches are designated by the number of poles circuits controlled and throws actuator positions Unless otherwise specified switches are shown in the Normally Open N O position Sing...

Page 57: ...Electric Motors may also include AC or DC Stator Alternator Actuating Devices Solenoid Valve PTO Clutch Engine Related Devices Ignition Coil Spark Plug Regulator Fuel Shutoff Solenoid Lights Single E...

Page 58: ...ure cabinet housing etc Wires crossing but not connected Ground to earth Wiring Connections Ground to chassis Coil Direct Current DC as shown on an oscilloscope Battery Alternating Current AC as shown...

Page 59: ...t See Figure 4 4 H5 Hydraulic Filter Pressure Light See Figure 4 4 H6 Engine Temperature Gauge See Figure 4 4 J1 Control Module Connector See Figure 4 2 J2 Control Module Connector See Figure 4 2 J3 P...

Page 60: ...r F7 40A Fuse Y1 Fuel Shutoff Solenoid F4 10A Fuse Brn Red Brn Blu Lt Grn Blk K2 Glow Plug Relay A2 Fuel Shutoff Timer R1 Glow Plugs 87 87A 85 86 30 Lt Grn Red Lt Grn Red Lt Grn Unswitched Power Circu...

Page 61: ...rake Input J1 11 Mow Switch Input J1 5 Yel Blu Yel Blu A1 Control Module Yel Brn Yel Brn Seat Switch Input J1 7 Wht Blk Wht Blk Lower Solenoid Output J2 8 Wht Blu Wht Blu Mow Solenoid Ountput J2 9 Wht...

Page 62: ...lk Y3 Mow Solenoid Y4 Raise Solenoid Y5 Lower Solenoid Raise Off Lower 6 Yel 1 Yel 5 2 S3 Raise Lower Switch Yel Blk Yel Blk Splice 6 Splice 7 Splice 3 Splice 7 Yel S5 Horn Switch On Off S6 Park Brake...

Page 63: ...ure Switch P P Blu Brn Grn B1 Engine Oil Pressure Switch H4 Engine Oil Pressure Light H5 Hydraulic Filter Pressure Light Splice 3 Splice 7 Splice 3 Splice 7 Blk N O S8 Mow Transport Switch Grn 1 3 6 4...

Page 64: ...Blk B3 Engine Temperature Sensor Diesel Blu Grn 2 6 Signal Gnd 3 5 12V 1 Back Light 12V H6 Engine Temperature Gauge Diesel 1 3 6 4 5 7 8 2 Blk Blk Blk Blk Blu On BLu Blu Red Blu Red Blu Red Blu Red B...

Page 65: ...ELECTRICAL 4252490 Rev A 4 13 4 Page Intentionally Blank...

Page 66: ...diesel Switched Power Circuit When the key switch is turned to the run position voltage is provided from key switch terminal B to splice 3 Splice 3 provides voltage to the following fuse block fuses...

Page 67: ...second intervals while activating the glow plug circuit Start Circuit With the key switch held in the start position the control module start relay output terminal J2 4 provides voltage to start relay...

Page 68: ...d Brn Brn Red Grn G2 Alternator F7 40A Fuse Y1 Fuel Shutoff Solenoid F4 10A Fuse Brn Red Brn Blu Lt Grn Blk K2 Glow Plug Relay A2 Fuel Shutoff Timer R1 Glow Plugs 87 87A 85 86 30 Lt Grn Red Lt Grn Red...

Page 69: ...Input J1 11 A1 Control Module Yel Blu Mow Switch Input J1 5 J2 5 Engine Run Output F3 20A Fuse Blk Splice 7 H2 Alarm Light Grn Gry S6 Park Brake Switch On Off Grn 1 Grn Gry 2 Grn Gry Blk 3 Blu Grn B3...

Page 70: ...4 18 4252490 Rev A ELECTRICAL 4 Page Intentionally Blank...

Page 71: ...inal J2 5 provides voltage to the carb solenoid energizing the solenoid With the solenoid energized the carb solenoid plunger retracts allowing fuel to flow The control module engine run output termin...

Page 72: ...ed Y2 Carb Solenoid F4 10A Fuse Lt Grn Red Lt Grn Red Wht Red Wht Red Brn Lt Grn Brn 12V Gnd H1 Hour Meter Yel Brn S4 Seat Switch On Off Yel S1 Key Switch Off Run Start A B C D Wht Wht Red Blk M M2 Fu...

Page 73: ...at Switch Input Park Brake Input J1 11 A1 Control Module Yel Blu Mow Switch Input J1 5 J2 5 Engine Run Output F3 20A Fuse Splice 7 Grn Gry S6 Park Brake Switch On Off Grn 1 Grn Gry 2 Grn Gry Blk 3 Blk...

Page 74: ...4 22 4252490 Rev A ELECTRICAL 4 Page Intentionally Blank...

Page 75: ...ith the solenoid energized the cutting units will continue to rise until the raise lower switch is released When the raise lower switch is momentarily placed in the raise position the control module e...

Page 76: ...Raise Solenoid Output J2 7 Yel Pnk Yel Pnk Raise Switch Input J2 2 Lower Switch Input J1 12 A1 Control Module Yel Brn Yel Brn Seat Switch Input J1 7 Wht Blk Wht Blk Brn F3 20A Fuse S4 Seat Switch On...

Page 77: ...Lower Solenoid Output J2 8 Yel Pnk Yel Pnk Raise Switch Input J2 2 Lower Switch Input J1 12 A1 Control Module Yel Brn Yel Brn Seat Switch Input J1 7 Wht Blu Wht Blu Brn F3 20A Fuse S4 Seat Switch On...

Page 78: ...the switch to the control module park brake switch input terminal J1 11 indicating the switch is in the off position When the cutting units are placed in the lowered position the control module allows...

Page 79: ...Switch Input J1 7 Wht Pnk Wht Pnk Brn F3 20A Fuse S4 Seat Switch On Off Wht Pnk Y3 Mow Solenoid Splice 7 Yel S1 Key Switch Off Run Start A B C D Wht Blk Unswitched Power Circuit Switched Power Circui...

Page 80: ...al J1 11 activating the input When the cutting units are placed in the lowered position the control module allows activation of the mow circuit The control module records the last position of the cutt...

Page 81: ...Seat Switch On Off Wht Pnk Y3 Mow Solenoid Splice 7 Yel S1 Key Switch Off Run Start A B C D Wht Blk Unswitched Power Circuit Switched Power Circuit 5V Power Circuit Mow Circuit Interlock Circuit Groun...

Page 82: ...ed from key switch terminal B to the light switch See Power Circuit Theory of Operation on page 4 14 Work Light Circuit When the light switch is placed in the on position voltage is provided to the wo...

Page 83: ...Key Switch Off Run Start A B C D Wht Blu 12 6 Wht F6 15A Fuse Blk 2 6 Signal Gnd 3 5 12V 1 Backlight 12V H6 Engine Temperature Gauge Diesel 1 3 6 4 5 7 8 2 Blk Blk Blk Blu On BLu Blu Red Blu Red Blu R...

Page 84: ...4 32 4252490 Rev A ELECTRICAL 4 Page Intentionally Blank...

Page 85: ...Coolant Temp Light Diesel The engine temperature sensor resistance changes in relationship to the engine coolant temperature As the engine temperature sensor is heated the resistance of the sensor ch...

Page 86: ...ce 7 Splice 7 S1 Key Switch Off Run Start A B C D Wht Unswitched Power Circuit Switched Power Circuit Horn Circuit Engine Temperature Gauge Circuit Start Circuit Hour Meter Circuit Alarm Light Circuit...

Page 87: ...mperature Gauge Circuit Ground Circuit Blk Blk Brn B2 Hydraulic Filter Pressure Switch P P Blu Brn Grn B1 Engine Oil Pressure Switch H4 Engine Oil Pressure Light H5 Hydraulic Filter Pressure Light Spl...

Page 88: ...plug relay Test the glow plug relay See Relays Test on page 4 41 Faulty glow plugs Substitute the glow plugs with known good glow plugs Probable Cause Remedy Faulty battery Replace battery with a kno...

Page 89: ...volts substitute the alternator with a known good alternator Probable Cause Remedy Open 10A fuse Test the 12V accessory socket fuse See Fuses Test on page 4 41 Faulty accessory socket Substitute the a...

Page 90: ...15A fuse Test the 15A light switch fuse See Fuses Test on page 4 41 Faulty work light switch Test the work light switch See Rocker Switches Test on page 4 43 Probable Cause Remedy Low engine oil press...

Page 91: ...wn good engine temperature gauge Probable Cause Remedy Faulty hour meter Substitute the hour meter with a known good hour meter Probable Cause Remedy Faulty horn switch Test the horn switch See Horn S...

Page 92: ...See the meter operator s manual for more information 2 If using a multimeter set to read ohms or set meter to continuity setting 3 Disconnect the ends of the wire being tested 4 Touch meter leads to t...

Page 93: ...1 6 2 Remove relay See Relays on page 4 60 3 Set the meter to read ohms 4 Touch meter leads to each other and confirm a resistance value of 0 0 ohms Figure 4 18 5 Measure the resistance between termin...

Page 94: ...YES The relay is good NO The relay is faulty replace the relay Key Switch Test See Figure 4 20 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove key switch See Key Switch on page 4 5...

Page 95: ...The rocker switch is faulty replace the rocker switch 7 Place rocker switch in the off position 8 Measure the resistance between terminals 1 and 2 Is the resistance value 0 02 ohm or less YES The roc...

Page 96: ...faulty replace the backlap switch NO The backlap switch is good Horn Switch Test See Figure 4 23 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove horn switch See Horn Switch on page...

Page 97: ...e between terminals 2 and 3 Is the resistance value 0 02 ohm or less YES Proceed to step 7 NO The switch is faulty replace the raise lower switch assembly 7 Return the raise lower switch assembly to t...

Page 98: ...Lower Solenoid Test See Figure 4 26 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove solenoid See Lower Solenoid on page 4 61 or Raise Solenoid on page 4 62 3 Set the meter to read...

Page 99: ...solenoid is faulty replace the solenoid Fuel Shutoff Solenoid Test See Figure 4 28 1 Park the mower safely See Park Mower Safely on page 1 6 2 Set the meter to read ohms 3 Touch meter leads to each ot...

Page 100: ...Measure the voltage between terminals 3 and 4 Is approximately 12 volts indicated YES Proceed to step 10 NO The fuel shutoff timer is faulty replace the fuel shutoff timer 10 Wait approximately 7 seco...

Page 101: ...trument panel cover See Instrument Panel Cover on page 9 13 Figure 4 31 4 Position the traction lever 1 in the mow position Figure 4 32 5 Loosen nuts 2 and 3 Figure 4 33 6 Adjust mow transport switch...

Page 102: ...4 Disconnect control module wire connectors 4 and 5 5 Remove screws 2 and nuts 3 6 Remove control module 1 Installation Notes Apply dielectric grease Jacobsen PN 365422 to any wire connectors disconn...

Page 103: ...Raise Hydraulic Oil Fuel Tank on page 9 4 Figure 4 37 NOTE Label all wires before disconnecting to ensure correct installation 4 Disconnect wire connectors 4 and 5 5 Support alternator 6 6 Remove scr...

Page 104: ...motor by reversing the order of removal Instrument Panel Removal and Installation See Figure 4 39 NOTE If servicing individual components it is not always necessary to completely remove the instrumen...

Page 105: ...battery cable at the battery 3 Remove instrument panel cover See Instrument Panel Cover on page 9 13 Figure 4 41 4 Disconnect wire connector 4 5 Depress taps 3 on each side of rocker switch and remove...

Page 106: ...5 6 Disconnect wires 2 and 3 7 Remove horn retainer nut 1 and remove horn from instrument panel Installation Note Install horn switch by reversing the order of removal Key Switch Removal and Installa...

Page 107: ...Safely on page 1 6 2 Disconnect the negative battery cable at the battery 3 Remove instrument panel cover See Instrument Panel Cover on page 9 13 4 Remove instrument panel See Instrument Panel on page...

Page 108: ...re wire connectors and wire harness Install mow transport switch assembly by reversing the order of removal Adjust the mow transport switch See Mow Transport Switch Adjustment on page 4 49 Backlap Swi...

Page 109: ...the threads of the oil pressure switch before installing Install engine oil pressure switch by reversing the order of removal Engine Oil Pressure Switch Gasoline Removal and Installation See Figure 4...

Page 110: ...pressure switch 2 Installation Notes Apply dielectric grease Jacobsen PN 365422 to any wire connectors disconnected Apply Teflon tape to the threads of the hydraulic oil charge filter pressure switch...

Page 111: ...Figure 4 53 NOTE Label all wires before disconnecting to ensure correct installation 5 Disconnect wire connector 3 Figure 4 54 NOTE Note orientation of the 12V accessory socket insert to ensure corre...

Page 112: ...gure 4 56 4 Remove fuse cover 1 5 Locate correct fuse 6 Remove fuse Installation Note Install fuse s by reversing the order of removal Relays Removal and Installation See Figure 4 57 Figure 4 57 NOTES...

Page 113: ...engine temperature sensor by reversing the order of removal Lower Solenoid Removal and Installation See Figure 4 59 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative...

Page 114: ...isconnect wire connector 2 5 Remove raise solenoid 1 Installation Notes Apply dielectric grease Jacobsen PN 365422 to any wire connectors disconnected Use new cable ties to secure wire connectors and...

Page 115: ...dielectric grease Jacobsen PN 365422 to any wire connectors disconnected Use new cable ties to secure wire connectors and wire harness Install fuel shutoff solenoid by reversing the order of removal W...

Page 116: ...Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery 3 Remove instrument panel cover See Instrument Panel Cover on page 9 13 Figure 4 65 NOTE Label all wires before disconne...

Page 117: ...sen PN 365422 to any wire connectors disconnected Use new cable ties to secure wire connectors and wire harness Install hour meter by reversing the order of removal Horn Removal and Installation See F...

Page 118: ...4 66 4252490 Rev A ELECTRICAL 4...

Page 119: ...Traction Circuit Forward Schematic 2WD Models 5 12 Traction Circuit Reverse Schematic and Theory of Operation 2WD Models 5 15 Traction Circuit Reverse Schematic 2WD Models 5 16 Traction Circuit Neutr...

Page 120: ...ocedures 5 35 Instrument Test Overview 5 35 Charge Pressure Test 5 36 Traction System Test 5 37 Traction Pump Tests 5 41 Wheel Motors Tests 5 43 Flushing Valve Check Valve Test 5 48 Repair 5 50 Tracti...

Page 121: ...ve Relief Valve Torque lb ft N m 44 60 Flushing Valve Check Valve Torque lb ft N m 44 60 Flushing Valve Port RW1 Fitting Torque lb ft N m 77 105 Flushing Valve Port RW2 Fitting Torque lb ft N m 77 105...

Page 122: ...twist hold the hose in a normal straight position When installing hoses place fittings at angles to avoid contact with fixed parts when turning Make sure hoses are assembled to proper A and B ports on...

Page 123: ...tered In the event of a traction system component failure it is recommended that all traction system components be disassembled and cleaned or filtered using a portable in line filter available throug...

Page 124: ...5 6 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Component Location See Figure 5 2 Figure 5 2 Component Location 1 Traction Pump 2 Gear Pump 3 Front Wheel Motor 2 TN3767 3 2 1...

Page 125: ...lates the charge pressure applied to the traction pump circuit When the incoming charge pressure oil reaches 150 210 psi 10 15 bar the charge pressure relief valve will open venting excess flow back t...

Page 126: ...rt T 3 Charge Pressure Oil to Front Wheel Motors 6 Return Oil from Right and Left Reel Motor Case Drains TN3082 Traction Pump Suction Strainer Hydraulic Tank 125 Micron Check Valve A B Engine 3400 rpm...

Page 127: ...ressure Oil from Traction Pump Port A 8 Return Oil from Steering Unit Port T 4 Charge Pressure Oil from Traction Pump Port B 9 Return Oil from Lift Valve Port T 5 Return Oil to Oil Cooler TN3083 Charg...

Page 128: ...5 10 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 129: ...bar implement relief valve is used to allow intermittent operation of the charge pump at 800 psi 55 bar Traction Drive Circuit The traction pedal is linked to the traction pump by cable Movement of th...

Page 130: ...3 Operating Pressure Oil to Front Wheel Motors 6 Return Oil from Right and Left Reel Motor Case Drains TN3084 Traction Pump Suction Strainer Hydraulic Tank 125 Micron Check Valve A B Engine 3400 rpm O...

Page 131: ...action Pump Port A 8 Return Oil from Steering Unit Port T 4 Charge Pressure Oil from Traction Pump Port B 9 Return Oil from Lift Valve Port T 5 Return Oil to Oil Cooler TN3085 10 37 ci Left Front Whee...

Page 132: ...5 14 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 133: ...ar implement relief valve is used to allow intermittent operation of the charge pump at 800 psi 55 bar Traction Drive Circuit The traction pedal is linked to the traction pump by cable Movement of the...

Page 134: ...T 3 Charge Pressure Oil to Front Wheel Motors 6 Return Oil from Right and Left Reel Motor Case Drains TN3086 Traction Pump Suction Strainer Hydraulic Tank 125 Micron Check Valve A B Engine 3400 rpm O...

Page 135: ...ion Pump Port A 8 Return Oil from Steering Unit Port T 4 Operating Pressure Oil from Traction Pump Port B 9 Return Oil from Lift Valve Port T 5 Return Oil to Oil Cooler TN3087 10 37 ci Left Front Whee...

Page 136: ...5 18 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 137: ...raulic tank via the steering unit and oil cooler The excess charge pump supply is used to operate the steering circuit The 800 psi 55 bar implement relief valve is used to allow intermittent operation...

Page 138: ...Motor Case Drain 3 Charge Pressure Oil to Front Wheel Motors 6 Return Oil from Steering Unit Port T and Lift Valve Port T TN3076 Charge Pressure Oil Inlet or Drain Oil Traction Pump Suction Strainer H...

Page 139: ...Pressure Oil from Traction Pump Port A 4 Charge Pressure Oil from Traction Pump Port B 5 Return Oil to Hydraulic Tank TN3077 Charge Pressure Oil 10 37 ci Left Front Wheel Motor Check Valve Shuttle Val...

Page 140: ...5 22 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 141: ...0 psi 55 bar implement relief valve is used to allow intermittent operation of the charge pump at 800 psi 55 bar Traction Drive Circuit The traction pedal is linked to the traction pump by cable Movem...

Page 142: ...rain 3 Operating Pressure Oil to Front Wheel Motors 6 Return Oil from Steering Unit Port T and Lift Valve Port T TN3078 Traction Pump Suction Strainer Hydraulic Tank 125 Micron Check Valve A B Engine...

Page 143: ...action Pump Port A 4 Charge Pressure Oil from Traction Pump Port B 5 Return Oil to Hydraulic Tank TN3079 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 37 ci Left Front Wheel Motor C...

Page 144: ...5 26 4252490 Rev A HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 145: ...rcuit The 800 psi 55 bar implement relief valve is used to allow intermittent operation of the charge pump at 800 psi 55 bar Traction Drive Circuit The traction pedal is linked to the traction pump by...

Page 146: ...e Drain 3 Charge Pressure Oil to Front Wheel Motors 6 Return Oil from Steering Unit Port T and Lift Valve Port T TN3080 Traction Pump Suction Strainer Hydraulic Tank 125 Micron Check Valve A B Engine...

Page 147: ...ion Pump Port A 4 Operating Pressure Oil from Traction Pump Port B 5 Return Oil to Hydraulic Tank TN3081 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 37 ci Left Front Wheel Motor C...

Page 148: ...Remedy Hydraulic oil not at correct level in reservoir Fill reservoir to correct level Refer to Parts and Maintenance Manual for correct oil specifications Tow valve open Close tow valve Refer to Safe...

Page 149: ...page 5 35 Faulty charge pressure relief valve Test charge pressure relief valve See Charge Pressure Test on page 5 36 Repair or replace charge pressure relief valve as needed See Traction Pump and Co...

Page 150: ...n are off the ground 4 Close the tow valve completely by turning it clockwise Figure 5 16 5 Remove nut 2 and disconnect traction control cable 3 from cam plate 4 6 Release park brake 7 Start engine an...

Page 151: ...7 is positioned in the V shaped notch in the cam plate 11 Tighten screws 5 12 Proceed to Fine Adjustment Fine Adjustment 13 Loosen lock nut 8 just enough to allow rotation of eccentric screw 6 14 Rota...

Page 152: ...d traction pump If faults exist in the charge pump proceed with an instrument test for the charge pump See Charge Pressure Test on page 5 36 Traction System Test See Figure 5 19 NOTE Be sure tow valve...

Page 153: ...mp 20 in the right front wheel motor 5 3 in the left front wheel motor 4 1 in the rear wheel motor and 2 9 in the flushing valve check valve Although all the components lend to the overall system leak...

Page 154: ...ssure gauge 5 to traction pump tee fitting 4 at port B NOTE Verify engine rpm is within specification 3400 rpm 50 to ensure accurate hydraulic test results 5 Start engine and run at full throttle 3400...

Page 155: ...remove test equipment Install all hoses and fittings as noted prior to removal 12 Install and connect all components as noted prior to test 13 Check hydraulic oil level Add oil as needed Refer to Par...

Page 156: ...rt the machine with jackstands 5 Disconnect traction pump control cable from pump control arm Figure 5 25 6 Install flow lock tool 2 and secure to pump control arm 7 Close tow valve completely by turn...

Page 157: ...29 Figure 5 30 Traction Pump Fittings 3WD Models 15 Disconnect hoses 15 and 16 from tee fitting 17 16 Remove tee fitting 17 from port A of traction pump 17 Reconnect hoses 15 and 16 to tee fitting 17...

Page 158: ...allow pump to produce 7 gpm 27 lpm in the forward direction Read and record no load flow 28 Slowly close flow meter valve until a reading of 2500 psi 172 bar is reached Read and record loaded flow 29...

Page 159: ...flow meter and front wheel restraints connected as outlined See Traction System Test on page 5 37 3 For 3WD models proceed to step 8 Figure 5 32 Traction Pump Fittings 2WD Models 4 Install blocking di...

Page 160: ...5 35 Traction Pump Test 2WD Models Blocking Disks Blocking Oil to Wheel Motors Figure 5 36 Traction Pump Test 3WD Models Blocking Disks Blocking Oil to Wheel Motors NOTE Verify engine rpm is within sp...

Page 161: ...igures 5 38 through 5 45 IMPORTANT Performing this test will isolate the wheel motors from the rest of the hydrostatic system This test works together with the traction system test traction pump tests...

Page 162: ...king disk at location 1 to block oil to left front wheel motor inlet 7 Open flow meter valve completely before starting engine Figure 5 39 Right Front Wheel Motor Test 2WD Models Blocking Disk Blockin...

Page 163: ...o allow pump to produce 7 gpm 27 lpm in the forward direction 12 Slowly close flow meter valve until a reading of 2500 psi 172 bar is reached Read and record loaded flow 13 Stop engine apply park brak...

Page 164: ...e and run at full throttle 3400 rpm 50 18 Adjust flow lock tool 1 to allow pump to produce 7 gpm 27 lpm in the forward direction 19 Use the flow meter to warm the hydraulic oil Turn flow meter valve u...

Page 165: ...e 5 57 then proceed to step 24 24 Lower rear of machine to the ground 25 Remove front wheel restraints 26 For 3WD models proceed to step 30 27 For 2WD models testing is complete Disconnect and remove...

Page 166: ...tep 21 x 100 Leak Percentage Is rear wheel motor leakage 10 or less YES The rear wheel motor is good Proceed to Flushing Valve Check Valve Test on page 5 48 NO Proceed to next question Is rear wheel m...

Page 167: ...0 F 49 65 C open valve fully after operating temperature is reached 8 After warming the hydraulic oil verify flow lock tool is adjusted to allow pump to produce 7 gpm 27 lpm in the forward direction 9...

Page 168: ...ct installation Close all openings with caps or plugs to prevent contamination 4 For 3WD models proceed to step 8 Figure 5 48 5 Disconnect hoses 2 and 3 6 Disconnect cross fitting 1 at the traction pu...

Page 169: ...ance Manual for correct oil specifications Start engine Check for leaks and repair as necessary Perform neutral adjustment See Neutral Adjustment on page 5 32 Disassembly Inspection and Assembly See F...

Page 170: ...nd replace fitting 15 for port V1 as necessary 6 Remove inspect and replace fitting 16 for port S as necessary 7 Remove inspect and replace fitting 17 for port L1 as necessary 8 Remove inspect and rep...

Page 171: ...sing 24 Shim A R Implement Relief 29 Seal 34 Poppet Charge Relief 19 Seal 2 25 Spring Implement Relief 30 Bearing 35 Spring Charge Relief 20 Washer 2 26 Poppet Implement Relief 31 Charge Pump Gerotor...

Page 172: ...ppet 26 from traction pump housing 18 Note the number of shims 24 2 Inspect poppet 26 and the seat in housing 18 for damage and remove any foreign material Replace components as needed WARNING NOTICE...

Page 173: ...installing the charge pump housing to prevent damaging the seals 19 Apply a thin film of clean hydraulic oil to seals 19 before assembly Flushing Valve Removal and Installation See Figure 5 55 1 Park...

Page 174: ...emoving to ensure correct installation 2 Remove inspect and replace fittings 2 for ports RW1 and RW2 as necessary 3 Remove inspect and replace fitting 5 for port DR as necessary 4 Remove inspect and r...

Page 175: ...draulic tubes before disconnecting to ensure correct installation Close all openings with caps or plugs to prevent contamination 4 Disconnect tubes 1 and 2 5 Support front wheel motor 5 and remove fou...

Page 176: ...le In Line Filter on page 5 5 Check hydraulic oil level Add oil as needed Refer to Parts and Maintenance Manual for correct oil specifications Rear Wheel Motor See Figures 5 61 and 5 62 1 Park the mow...

Page 177: ...ng screws 6 to 59 66 lb ft 80 90 N m Tighten inlet and outlet port fittings 4 and 5 to 77 lb ft 105 N m Pressure filter the traction system upon start up if metal debris is found in system oil or moto...

Page 178: ...Commutator 2 Bearing Outer 7 Thrust Bearing 12 Thrust Washer 2 17 Vane 14 2 2 In motors with one piece stator housings seven vanes are used 22 Commutator Ring 3 Housing 8 Bearing Inner 13 Rotor Set 1...

Page 179: ...must be replaced as a matched set 9 Inspect commutator ring 22 for cracks or burrs 10 Inspect commutator 20 for cracks burrs wear scoring spalling or brinelling NOTES The manifold is constructed of pl...

Page 180: ...orrosion Clean shaft as needed 25 Remove coupling shaft 9 from housing 3 Figure 5 66 NOTES Minor shaft wear in the seal area 30 is allowed If wear exceeds 0 020 in 0 51 mm replace the coupling shaft A...

Page 181: ...ean solvent and dry using compressed air 33 Inspect all parts for wear or damage Replace parts as needed 34 Apply a thin film of clean hydraulic oil to all parts to prevent corrosion Keep parts covere...

Page 182: ...or 2 Bearing Outer 7 Thrust Bearing 12 Thrust Washer 2 17 Vane 14 2 2 In motors with one piece stator housings seven vanes are used 22 Commutator Ring 3 Housing 8 Bearing Inner 13 Rotor Set 18 Rotor 2...

Page 183: ...jaws firmly clamping each side of the housing mounting flange Figure 5 68 8 Install a new backup ring 4 backup washer 5 and seal 6 into housing 3 working the ring washer and seal around the thrust be...

Page 184: ...ake sure that drive link splines engage with rotor splines 18 Apply a thin film of petroleum jelly to seal ring 14 and install seal ring in the groove on the side of the manifold 19 facing the rotor s...

Page 185: ...ator housing 23 End Cover Assembly 3 Housing 10 Thrust Bearing 17 Vane 14 2 2 In motors with one piece stator housings seven vanes are used 24 Plug Shuttle Valve 4 Backup Ring 11 Drive Link 18 Rotor 2...

Page 186: ...equires inspection of the end cover commutator manifold and rotor set Replace as needed Figure 5 72 NOTICE 8 Remove two shuttle valve plugs 24 and 27 and O rings 30 and 32 9 Remove shuttle valve 31 an...

Page 187: ...e rotor assembly 21 Place rotor set 13 and wear plate 15 on a flat surface with the rotor 18 positioned in the stator so that two rotor lobes 180 apart and the rotor vane 17 center line are on the sam...

Page 188: ...e bearing counterbore before removing the bearing 34 Inspect inner bearing 8 and outer bearing 2 All roller elements must be firmly retained in the bearing cages and orbit freely All rollers must be f...

Page 189: ...ing 23 End Cover Assembly 3 Housing 10 Thrust Bearing 17 Vane 14 2 2 In motors with one piece stator housings seven vanes are used 24 Plug Shuttle Valve 4 Backup Ring 11 Drive Link 18 Rotor 25 Screw 7...

Page 190: ...jaws firmly clamping each side of the housing mounting flange Figure 5 76 8 Install a new backup ring 4 backup washer 5 and seal 6 into housing 3 working the ring washer and seal around the thrust bea...

Page 191: ...n film of petroleum jelly to seal ring 14 and install seal ring in the groove on the side of the manifold 19 facing the rotor set NOTE The manifold surface that must make contact with the rotor set ha...

Page 192: ...5 74 4252490 Rev A HYDROSTATIC POWER TRAIN 5...

Page 193: ...of Operation 6 20 Raise Circuit Schematic 6 21 Lower Circuit Schematic and Theory of Operation 6 22 Lower Circuit Schematic 6 23 Mow Circuit Schematic and Theory of Operation 6 24 Mow Circuit Schemat...

Page 194: ...lve Unit 6 48 Soft Drop Valve 6 50 Top and Bottom Sequence Valves 6 51 Center Lift Cylinder 6 52 Left and Right Front Lift Cylinders 6 54 Hydraulic Oil Tank Diesel 6 57 Hydraulic Oil Tank Gasoline 6 5...

Page 195: ...ve Relief Valve Torque lb ft N m 20 25 27 34 Lift Valve Check Valve Torque lb ft N m 30 35 41 47 Lift Valve Solenoid Valve Torque lb ft N m 25 30 34 40 Lift Valve Port P Fitting Torque lb ft N m 55 74...

Page 196: ...hold the hose in a normal straight position When installing hoses place fittings at angles to avoid contact with fixed parts when turning Make sure hoses are assembled to proper A and B ports on compo...

Page 197: ...igures 6 1 and 6 2 Figure 6 1 Component Location Front 1 Center Lift Cylinder 4 Lift Valve 7 Right Front Lift Cylinder 2 Reel Valve Unit 5 Soft Drop Valve 3 Hydraulic Oil Charge Filter Assembly 6 Left...

Page 198: ...4252490 Rev A HYDRAULICS 6 Figure 6 2 Component Location Rear 1 Hydraulic Oil Cooler 3 Traction Pump 5 Top Sequence Valve 2 Gear Pump 4 Bottom Sequence Valve 6 Hydraulic Oil Tank 2 6 TN3767 TN3769 3 1...

Page 199: ...ck Valve A B Engine 3400 rpm Oil Cooler 2 psi Crack Bypass Gear Pump TN3026 Charge Relief Valve 150 210 psi Tow Valve 0 33 ci M1 1 2 3 4 5 6 Tank Fill Cap Assembly 0 40 ci 0 92 ci Implement Relief Val...

Page 200: ...chematic 3WD Continued Figure 6 4 10 37 ci Left Front Wheel Motor TN3027 Check Valve Shuttle Valve 1 2 3 4 5 6 7 8 Rear Wheel Motor Right Front Wheel Motor 10 37 ci 20 75 ci 0 040 in RW2 DR Flushing V...

Page 201: ...HYDRAULICS 4252490 Rev A 6 9 6 Hydraulic Schematic 3WD Continued Figure 6 5 Steering Cylinder Steering Unit Steering Valve Check Valve TN3028 3 84 ci 1 2 9 10 7 8 R L T P 2 10 7 8...

Page 202: ...ontinued Figure 6 6 Lift Valve TN3029 Right Lift Cylinder Relief Valve 1250 psi 2 10 7 8 2 11 7 8 Left Lift Cylinder Center Lift Cylinder P T Solenoid Valve Check Valve A B B A B B A A Lift Lift Lift...

Page 203: ...Continued Figure 6 7 Reel Valve Unit Relief Valve 3020 psi TN3030 Right Reel Motor T B 2 11 7 8 0 020 in Check Valve Reel Valve Backlap Enable Switch 145 Micron Filter P A Left Reel Motor Center Reel...

Page 204: ...heck Valve A B Engine 3400 rpm Oil Cooler 2 psi Crack Bypass Gear Pump TN3031 Charge Relief Valve 150 210 psi Tow Valve 0 33 ci M1 1 2 3 4 5 Tank Fill Cap Assembly 0 40 ci 0 92 ci Implement Relief Val...

Page 205: ...RAULICS 4252490 Rev A 6 13 6 Hydraulic Schematic 2WD Continued Figure 6 9 10 37 ci Left Front Wheel Motor TN3032 Shuttle Valve 1 2 3 4 5 6 7 Right Front Wheel Motor 10 37 ci 1 2 8 9 6 7 1 3 gpm 0 052...

Page 206: ...6 14 4252490 Rev A HYDRAULICS 6 Hydraulic Schematic 2WD Continued Figure 6 10 Steering Cylinder Steering Unit Steering Valve Check Valve TN3028 3 84 ci 1 2 8 9 6 7 R L T P 2 9 6 7...

Page 207: ...ontinued Figure 6 11 Lift Valve TN3029 Right Lift Cylinder Relief Valve 1250 psi 2 9 6 7 2 10 6 7 Left Lift Cylinder Center Lift Cylinder P T Solenoid Valve Check Valve A B B A B B A A Lift Lift Lift...

Page 208: ...Continued Figure 6 12 Reel Valve Unit Relief Valve 3020 psi TN3030 Right Reel Motor T B 2 10 6 7 0 020 in Check Valve Reel Valve Backlap Enable Switch 145 Micron Filter P A Left Reel Motor Center Reel...

Page 209: ...HYDRAULICS 4252490 Rev A 6 17 6 Page Intentionally Blank...

Page 210: ...t ahead position the steering valve routes all of the operating pressure oil out of the steering unit through port T to the oil cooler and then to the hydraulic tank With the steering wheel turned to...

Page 211: ...igure 6 13 Figure 6 13 1 Operating Pressure Oil from Charge Pump Traction Pump Port V1 2 Return Oil to Oil Cooler and Hydraulic Tank Steering Cylinder Steering Unit Steering Valve Check Valve TN3069 3...

Page 212: ...stricted through the check valve exits port A of the top sequence delay valve and flows to the piston side of the center lift cylinder Oil flow to the piston side of the center lift cylinder raises th...

Page 213: ...nd Hydraulic Tank 2 Operating Pressure Oil from Reel Valve Unit Port T Lift Valve TN3070 Right Lift Cylinder Relief Valve 1250 psi 1 2 Left Lift Cylinder Center Lift Cylinder P T Solenoid Valve Check...

Page 214: ...the rod side of the center lift cylinder lowers the center cutting unit Oil entering port A of the soft drop valve flows against the check valve through the orifice and exits port B of the soft drop v...

Page 215: ...nd Hydraulic Tank 2 Operating Pressure Oil from Reel Valve Unit Port T Lift Valve Right Lift Cylinder Relief Valve 1250 psi 1 2 Left Lift Cylinder Center Lift Cylinder P T Solenoid Valve Check Valve A...

Page 216: ...routed to the pilot of the reel valve and against the check valve With oil pressure applied to the reel valve pilot the reel valve shifts routing operating pressure oil through port A to the reel mot...

Page 217: ...Tank 2 Return Oil to Lift Valve Port P 4 Center Reel Motor Case Drain Oil to Hydraulic Tank Reel Valve Unit Relief Valve 3020 psi Right Reel Motor T B 1 2 3 4 0 020 in Check Valve Reel Valve Backlap E...

Page 218: ...0 5 mm orifice is routed to the pilot of the reel valve and against the check valve With the reel valve in the backlap position operating pressure oil is routed through port B to the reel motors in s...

Page 219: ...c Tank 2 Return Oil to Lift Valve Port P 4 Center Reel Motor Case Drain Oil to Hydraulic Tank Reel Valve Unit Relief Valve 3020 psi Right Reel Motor T B 1 2 3 4 0 020 in Check Valve Reel Valve Backlap...

Page 220: ...il temperature is 120 150 F 49 65 C 2 Raise cutting units 3 Park the mower safely See Park Mower Safely on page 1 6 4 Support all cutting unit lift arms Figure 6 18 5 Disconnect hose 2 from lift cylin...

Page 221: ...fall YES Check valve 6 is bypassing oil Repair or replace check valve then proceed to step 17 NO The check valve is not faulty Proceed to step 17 17 Disconnect and remove test equipment Install all ho...

Page 222: ...the key 3 Remove case drain hose from reel motor Immediately plug the hose 4 Place a drain pan with a minimum capacity of 1 gallon 3 8 L near the reel motor 5 Install a separate hose on the case drai...

Page 223: ...calculate and record leakage percentages The results from this test reveal leakage of 5 in the gear pump 5 3 in the reel valve unit 20 in the right reel motor 5 6 in the left reel motor and 4 4 in th...

Page 224: ...hose end is under oil level in hydraulic tank to prevent aeration of oil 5 Secure flow meter outlet hose 3 to hydraulic tank fillneck WARNING 6 Install suitable blocking device or tool in right cuttin...

Page 225: ...e cutting units circuit is good Proceed to Reel Motors Test on page 6 36 NO Proceed to next question Is cutting units circuit leakage 11 20 YES The cutting units circuit is marginal Additional testing...

Page 226: ...full throttle 3400 rpm 50 CAUTION 8 Use the flow meter to warm the hydraulic oil Turn flow meter valve until a reading of 1500 psi 103 bar or 50 of the relief valve rating is reached Warm oil to 120...

Page 227: ...MPORTANT Performing this test will isolate the reel valve unit from the rest of the cutting units circuit This test works together with the cutting units circuit test gear pump test and reel motors te...

Page 228: ...ext question Is reel valve unit leakage 11 20 YES The reel valve unit is marginal Additional testing is required Proceed to step 13 NO Proceed to next question Is reel valve unit leakage 21 or more YE...

Page 229: ...e flow meter valve until pressure reaches 2200 psi 152 bar or 75 of the relief valve rating is reached Read and record the right reel motor loaded flow 11 Open flow meter valve disengage mow switch an...

Page 230: ...gine 21 Calculate left reel motor leakage Step 10 Step 19 Step 10 x 100 Leak Percentage Is left reel motor leakage 10 or less YES The left reel motor is good Proceed to step 22 NO Proceed to next ques...

Page 231: ...then proceed to step 31 NO Proceed to next question Is center reel motor leakage 21 or more YES Repair or replace center reel motor See Reel Motor on page 8 28 then proceed to step 31 31 Remove block...

Page 232: ...op engine Is implement relief pressure 800 10 psi 55 10 bar YES Implement relief valve is good Proceed to step 12 NO Test charge pressure See Charge Pressure Test on page 5 36 Test steer cylinder See...

Page 233: ...nect test hose and pressure gauge 2 to test port 1 5 Apply park brake Figure 6 40 Lift Relief Valve Pressure Test NOTE Verify engine rpm is within specification 3400 rpm 50 to ensure accurate hydrauli...

Page 234: ...nance Manual for correct oil specifications Repair Hydraulic Oil Tank Drain Procedure See Figure 6 41 1 Park the mower safely See Park Mower Safely on page 1 6 2 Block each side of front wheels using...

Page 235: ...m 4 and cutting unit out 6 Lower the cutting units 7 Drain hydraulic oil tank See Hydraulic Oil Tank Drain Procedure on page 6 42 Figure 6 43 NOTES Label all hydraulic hoses and tubes before disconnec...

Page 236: ...ee fitting 4 as necessary 2 Remove inspect and replace outlet port fitting 1 as necessary 3 Remove inspect and replace inlet port fitting 2 as necessary Figure 6 45 TN3867 2 1 3 4 5 Body Seal 2 8 Rear...

Page 237: ...k from gear sets after gears have been installed with teeth in proper mesh Make sure that bushing sets are correctly installed to properly position the high pressure seals Rotate drive shaft by hand a...

Page 238: ...stallation Notes Install lift valve by reversing the order of removal Ensure new O rings are in place before installing hoses on fittings Apply dielectric grease Jacobsen PN 365422 to any wire connect...

Page 239: ...1 47 N m Tighten fittings for ports P 2 and T 1 to 55 lb ft 74 N m Tighten fittings for ports A 4 and B 3 to 17 lb ft 23 N m 5 Check Valve 8 Solenoid Valve 6 Relief Valve 9 Nut 7 Lift Valve Block 10 C...

Page 240: ...rect installation Close all openings with caps or plugs to prevent contamination 6 Disconnect hydraulic tubes 2 and 3 Figure 6 51 7 Disconnect backlap switch wire connector 8 Support the reel valve un...

Page 241: ...clean solvent and dry using compressed air 17 Inspect all parts for wear or damage Replace parts as necessary 1 Reel Valve Unit Block 5 Check Valve 2 Speed Control Valve 6 Pressure Compensating Valve...

Page 242: ...port B fitting 9 to 77 lb ft 105 N m Tighten port P fitting 7 to 77 lb ft 105 N m Tighten port T fitting 8 to 133 lb ft 180 N m Apply dielectric grease Jacobsen PN 365422 to any wire connectors discon...

Page 243: ...59 Start engine Check hydraulic system for leaks Repair as necessary Check hydraulic oil level and add if necessary Top and Bottom Sequence Valves Removal and Installation See Figure 6 57 NOTE The top...

Page 244: ...TION 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove grass catchers if equipped NOTE Do not swing the arm out or in with cutting units in the lowered position 3 Raise the cutting un...

Page 245: ...filter See Hydraulic Oil Charge Filter Assembly on page 6 59 Refill hydraulic tank Refer to Parts and Maintenance Manual for correct oil specifications Start engine Check hydraulic system for leaks Re...

Page 246: ...or plugs to prevent contamination 4 Disconnect hydraulic hoses 2 and 4 from fittings 1 and 3 Use appropriate eye protection when using compressed air for cleaning or drying purposes Compressed air can...

Page 247: ...raulic Oil Charge Filter Assembly on page 6 59 Refill hydraulic tank Refer to Parts and Maintenance Manual for correct oil specifications Start engine Check hydraulic system for leaks Repair as necess...

Page 248: ...propriate eye protection when using compressed air for cleaning or drying purposes Compressed air can cause serious personal injury Use safety reduction valves to reduce the air pressure to a safe lev...

Page 249: ...Lower hydraulic oil fuel tank 8 to operating position Figure 6 72 11 Remove hydraulic oil tank 16 Installation Notes Install hydraulic oil tank by reversing the order of removal CAUTION Apply anti sei...

Page 250: ...crew 12 lock washer 13 and clip 14 NOTES Label all hydraulic hoses and tubes before disconnecting to ensure correct installation Close all openings with caps or plugs to prevent contamination 7 Discon...

Page 251: ...6 75 NOTE Label wire connectors before disconnecting to ensure correct installation 5 Disconnect wire connector 4 NOTES Label all hydraulic hoses and tubes before disconnecting to ensure correct insta...

Page 252: ...disconnecting to ensure correct installation Close all openings with caps or plugs to prevent contamination 6 Disconnect hydraulic hoses 8 and 10 7 Remove four screws 4 washers 5 and mounting blocks...

Page 253: ...iner bracket 3 7 Remove two nuts 9 and washers 8 and remove the bottom screen retainer bracket 10 8 Thoroughly clean the valve especially the area surrounding the hydraulic hoses tubes and fittings NO...

Page 254: ...cooler frame 23 from the machine Installation Notes Install oil cooler by reversing the order of removal Make sure new O rings are in place before installing hoses and fittings Replace hydraulic oil...

Page 255: ...ev A 7 1 Chapter 7 Steering Specifications 7 2 Component Location 7 3 Repair 7 4 Steering Wheel 7 4 Steering Column Covers 7 4 Control Arm 7 5 Steering Unit 7 6 Steering Cylinder 7 14 Steering Yoke As...

Page 256: ...7 2 4252490 Rev A STEERING 7 Specifications Repair Specifications Steering Wheel Nut Torque lb ft N m 28 30 38 41 Steering Unit End Cover to Housing Screw Torque lb ft N m 20 24 27 33...

Page 257: ...490 Rev A 7 3 7 Component Location See Figure 7 1 Figure 7 1 Component Location 1 Control Arm 4 Control Arm Lock Lever 2 Steering Wheel 5 Steering Cylinder 3 Steering Unit 6 Steering Yoke TN3653 TN371...

Page 258: ...ing column 4 Installation Notes Install steering wheel by reversing the order of removal Tighten the steering wheel nut 3 to 28 30 lb ft 38 41 N m Steering Column Covers Removal and Installation See F...

Page 259: ...7 7 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove steering unit See Steering Unit on page 7 6 Figure 7 6 3 Lower the lift lever 5 and control arm 6 to the lowest position 4 Suppo...

Page 260: ...rsing the order of removal Steering Unit Removal and Installation See Figures 7 8 and 7 9 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove steering wheel See Steering Wheel on page 7...

Page 261: ...ct and replace fitting 10 from steering unit port R as necessary 12 Remove inspect and replace fitting 11 from steering unit port P as necessary 13 Remove inspect and replace fitting 12 from steering...

Page 262: ...nts and work area A clean work area is essential to satisfactory operation of hydraulic components Utilize steering unit service fixture for disassembly See Steering Unit Service Fixture on page 7 7 F...

Page 263: ...gearwheel to distributor plate is a tight fit Tap the side of the gearwheel rim with a soft faced hammer to loosen 6 Remove the gearwheel rim 11 gearwheel 13 and two O rings 12 and 14 as a unit keepin...

Page 264: ...g when the spool and sleeve assembly is removed 12 Remove spring retaining ring 22 13 Remove spring set 21 from spool 20 14 Remove cross pin 24 from spool 23 and sleeve 20 and remove spool from sleeve...

Page 265: ...n 5 in the spool and sleeve assembly NOTES See Figure 7 21 When installing spring set insert the curved springs between the flat springs and push in place Spring retaining ring must be able to rotate...

Page 266: ...e ball 8 into port T Figure 7 23 9 Wrap tape around the threaded and splined area 13 of the spool and sleeve assembly 12 to prevent damaging the seal during installation 10 While holding the cross pin...

Page 267: ...e distributor plate in the same orientation as noted during removal 18 Install a new O ring 21 Figure 7 28 19 Align end cover 24 to housing and install special screw 28 with nut 27 and washer 29 into...

Page 268: ...Swing the rear swing arm out to allow access to the steering cylinder Figure 7 30 6 Support the steering cylinder 4 7 Remove lock nut 9 washers 10 13 and 14 and screw 15 8 Remove steering cylinder 4 a...

Page 269: ...ry Disassembly Inspection and Assembly See Figures 7 32 through 7 37 Figure 7 32 NOTES Record the location and orientation of fittings before removing to ensure correct installation Record the number...

Page 270: ...rsing the order of disassembly Lubricate all parts with clean hydraulic oil before assembly Install new seals and O rings Use appropriate eye protection when using compressed air for cleaning or dryin...

Page 271: ...heel Motors on page 5 57 For 2WD models remove rear wheel and steering axle See Rear Wheel and Steering Axle 2WD Units Diesel on page 9 22 Figure 7 38 4 Remove lock nut 3 from ball joint 1 5 Disconnec...

Page 272: ...7 18 4252490 Rev A STEERING 7...

Page 273: ...8 18 Grass Shield Adjustment 8 18 Reel Bearing Pre Load Adjustment 8 19 Reel Leveling Rod Pre Adjustment 8 20 Cutting Unit Leveling Adjustment 8 21 Repair 8 22 Cutting Unit 8 22 Lift Yoke 8 23 Reel L...

Page 274: ...ace Measurement Spring Side in mm 4 606 117 Reel Leveling Rod Rod End to Nut Face Measurement Spring Side in mm 0 094 2 4 Repair Reel Motor Mounting Nut Torque lb ft N m 18 24 Reel Motor Rear Cover to...

Page 275: ...el Motor 9 Grass Shield 13 Cutting Unit Rear Roller 2 Lift Lerveling Rods 6 Counterweight 10 Yoke 14 Bedknife Backing Assembly 3 Right Cutting Unit 7 Reel Assembly 11 Lift Arm 15 Cutting Unit Frame 4...

Page 276: ...bricate the blades and leads to early dulling of the blades In most cases information provided by the user customer will provide the basis for the repairs and adjustments that may be required However...

Page 277: ...e Height of Cut HOC Adjustment on page 8 18 Incorrect bedknife to reel clearance Adjust the bedknife to reel clearance See Bedknife to Reel Clearance Adjustment on page 8 17 Worn or damaged reel beari...

Page 278: ...mowers with multiple suspended cutting units Washboarding may also be caused by variations in the turf Probable Cause Remedy Mowing ground speed is too fast Reduce mowing ground speed Grass buildup on...

Page 279: ...used by an incorrect frequency of clip Probable Cause Remedy Incorrect frequency of clip Check and adjust frequency of clip Frequency of clip must be equal to or less than height of cut Verify proper...

Page 280: ...of Cut HOC Adjustment on page 8 18 Worn roller bearings Check replace roller bearings See Roller Bearings on page 8 39 Worn reel bearings Replace reel bearings See Reel Bearing Housing Assembly on pag...

Page 281: ...an excessively low height of cut setting and or uneven turf Probable Cause Remedy HOC height of cut settings are lower than normal Check and adjust the HOC settings See Height of Cut HOC Adjustment on...

Page 282: ...justed Adjust bedknife See Bedknife to Reel Clearance Adjustment on page 8 17 Dull cutting edges Sharpen reel and bedknife Refer to Parts and Maintenance Manual Mowing ground speed is too fast Reduce...

Page 283: ...ws Tighten loose screws replace missing screws See Bedknife on page 8 33 Incorrect roller Install correct roller for application See Front Roller on page 8 38 or Rear Roller on page 8 38 Bedknife is m...

Page 284: ...at one end of cutting unit s or between cutting units forming line s in the direction of travel Probable Cause Remedy Grass is too tall Mow more often Mowing while grass is wet Mow when grass is dry G...

Page 285: ...bable Cause Remedy HOC inconsistent from one cutting unit to another Adjust HOC on cutting units to same height See Height of Cut HOC Adjustment on page 8 18 Check condition of cutting unit frame and...

Page 286: ...attern of varying cutting heights resulting in a wave like cut appearance usually due to heavy contact points across the reel and or bedknife Probable Cause Remedy Reel and or bedknife unevenly worn I...

Page 287: ...or stems usually due to mowing in one direction or constant traffic in one direction Probable Cause Remedy Mowing in the same direction all the time Mow against the grain or change the mowing pattern...

Page 288: ...e Reel Motor on page 8 28 Reel drive does not reach full speed Reel motor faulty Repair or replace reel motor See Reel Motor on page 8 28 Bedknife to reel contact too tight Check bedknife to reel clea...

Page 289: ...n reel blade and bedknife using upper adjuster 4 and lower adjuster 5 on both leading and trailing edges of reel NOTES Move the adjusting screws in very small increments when making bedknife to reel a...

Page 290: ...bedknife 3 6 Turn adjusting knob 1 to close the gap between the front roller 7 and rear roller 5 and the height of cut bar 6 7 Tighten lock nut 9 8 Repeat steps 2 through 7 on opposite end of front ro...

Page 291: ...el Clearance Adjustment on page 8 17 Figure 8 6 3 Remove two screws 1 two lock washers 2 and counterweight 3 Figure 8 7 4 Remove screw 6 lock washer 7 washer 5 and spacer 4 Figure 8 8 5 Tighten adjust...

Page 292: ...pin 8 as needed to obtain proper distance 1 c Tighten nut 7 4 Measure distance 3 between end of leveling rod and face of collar The measurement should be 4 606 in 117 mm If the measurement does not m...

Page 293: ...ustment on page 8 20 Figure 8 12 Figure 8 13 NOTE Ensure grass catcher is installed if equipped 3 Fully lower cutting unit to a level solid surface then raise cutting unit until slightly above surface...

Page 294: ...in 2 and release latch 3 5 Grasp handle 1 and swing the rear swing arm 4 and cutting unit out 6 Lower the cutting units Figure 8 15 7 Loosen two nuts 5 and rotate reel motor 8 clockwise NOTE In some c...

Page 295: ...ssed air gun Lift Yoke Removal and Installation See Figure 8 18 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove the cutting unit See Cutting Unit on page 8 22 Figure 8 18 3 Remove t...

Page 296: ...rings Install reel leveling rod by reversing the order of removal Adjust leveling rod See Cutting Unit Leveling Adjustment on page 8 21 Right and Left Lift Arms Removal and Installation See Figures 8...

Page 297: ...two flat washers 10 from lift cylinder 8 and frame 9 6 Move lift cylinder 8 aside Figure 8 23 7 Remove cotter pin 15 and flat washer 16 from lift arm shaft 14 8 Remove lift arm Disassembly and Assembl...

Page 298: ...Safely on page 1 6 2 Remove cutting unit See Cutting Unit on page 8 22 Figure 8 25 3 Remove cotter pin 5 and two flat washers 6 4 Remove pin 2 and flat washer 3 from lift cylinder 1 and lift arm 4 Fig...

Page 299: ...at Washer 2 19 Nyloc Nut 27 Spring Pin 4 Nut 12 Flat Washer 20 Hose Clamp 28 Pivot Shaft 5 Link Arm Assembly 13 Nyloc Nut 2 21 Tube Clamp Top Plate 29 Lift Arm 6 Pivot Bushing 14 Swing Arm 22 Bolt 30...

Page 300: ...aged or have excessive wear Reel Motor Removal and Installation See Figure 8 28 NOTE The right reel motor is shown the left and center reel motors are similar 1 Park the mower safely See Park Mower Sa...

Page 301: ...lic tank Refer to Parts and Maintenance Manual for correct oil specifications Start engine Check hydraulic system for leaks Repair as necessary Check hydraulic oil level and add if necessary Disassemb...

Page 302: ...faced hammer and gently tap body and drive shaft to separate reel motor body 5 O Ring 2 10 Retaining Screw 4 15 Driven Gear 20 Shaft Seal 6 Dowel Pin 2 11 Drive Shaft 16 Thrust Plate 21 Snap Ring 7 P...

Page 303: ...hand after assembling to make sure there is no binding between parts do not force Use extreme care when installing shaft seal Seal must seat squarely in seal bore Install retaining screws 10 finger ti...

Page 304: ...shield by reversing the order of removal Adjust the grass shield See Grass Shield Adjustment on page 8 18 Bedknife Backing Assembly Removal and Installation See Figures 8 33 and 8 34 1 Park the mower...

Page 305: ...dknife backing assembly See Bedknife Backing Assembly on page 8 32 Figure 8 35 3 Remove screws 2 and bedknife 3 from bedknife backing 1 Installation Notes Install bedknife by reversing the order of re...

Page 306: ...reel bearing housing assembly onto reel shaft Inspect bearing 5 for wear or damage Replace as needed Pack bearing 5 with grease that meets or exceeds NLGI Grade 2 LB specifications before assembly Tig...

Page 307: ...t on page 8 22 3 Remove grass shield See Grass Shield on page 8 32 Figure 8 38 4 Remove two screws 1 and lock washers 2 5 Remove counterweight 3 Figure 8 39 6 Remove grease fitting 11 7 Remove screw 1...

Page 308: ...reel bearing housing assembly 8 using bearing assembly tool Jacobsen PN JAC5084 2 Install seal 5 using mounting screws 6 washers 7 and nuts 9 3 Tighten mounting screws 6 to 18 22 lb ft 24 4 29 8 N m...

Page 309: ...e cutting unit from mower See Cutting Unit on page 8 22 3 Remove bedknife backing assembly See Bedknife Backing Assembly on page 8 32 4 Remove front roller See Front Roller on page 8 38 5 Remove grass...

Page 310: ...tings before lubricating and apply grease to the fittings with a hand grease gun only Pump the gun slowly until a slight amount of pressure is felt then stop do not over grease Do not use compressed a...

Page 311: ...ove bearing 2 and seal 1 from shaft 3 5 Repeat steps 3 and 4 for other end of roller Installation NOTES Clean and inspect bearings for wear or damage Replace if necessary Pack bearings 2 with grease t...

Page 312: ...8 40 4252490 Rev A CUTTING UNITS 8...

Page 313: ...0 Traction Pedal Assembly 9 11 Instrument Panel Cover 9 13 Traction Lever Assembly 9 13 Throttle Lever 9 14 Park Brake Lever 9 14 Seat and Seat Plate 9 15 Seat Switch 9 16 Tool Box 9 17 Floorboard Ass...

Page 314: ...ar 10 0 70 Mounting Bolt Torque lb ft N m 55 75 Rear Tire Size 20 x 10 10 Type 2 Ply OTR Smooth Air Pressure psi bar 10 0 70 2WD Lug Nut Torque lb ft N m 48 63 65 85 2WD Mounting Bolt Torque lb ft N m...

Page 315: ...Location 1 OPS Operator Protective Structure 6 Floorboard Assembly 11 Instrument Panel Cover 2 Seat and Seat Plate 7 Splash Shield 12 Fuel Tank 3 Traction Pedal 8 Front Wheel 2 13 Traction Lever 4 Too...

Page 316: ...e 1 6 Figure 9 2 2 Remove screws 1 lock washers 2 and flat washers 3 3 Rotate seat 4 forward Raise Hydraulic Oil Fuel Tank See Figures 9 3 and 9 4 NOTE Diesel model is shown gasoline model is similar...

Page 317: ...5 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 9 5 NOTE Adjusting transport speed stop clockwise increases transport speed Adjusting transport speed stop counterclockwise decreases...

Page 318: ...op 1 3 Tighten lock nuts 2 Park Brake Adjustment See Figure 9 7 NOTE Right park brake shown left park brake is similar To access left park brake remove tool box See Tool Box on page 9 17 1 Park the mo...

Page 319: ...device Figure 9 9 10 Remove four OPS mounting bolts 9 and flat washers 10 11 Remove OPS Installation Notes Install OPS by reversing the order of removal Tighten OPS mounting bolts 9 to 37 lb ft 50 N...

Page 320: ...tank 1 and connect fuel line 4 8 Disconnect fuel lines 2 and 3 Plug lines and cap fittings to prevent leakage and contamination Figure 9 11 NOTE Label all wires before disconnecting to ensure correct...

Page 321: ...ve battery cable from the battery 3 Remove hydraulic oil tank See Hydraulic Oil Tank Gasoline on page 6 58 Figure 9 14 4 Support fuel tank 1 using a suitable lifting device NOTE Fuel system capacity i...

Page 322: ...ghten these screws or tank may crack and cause a leak Install fuel tank by reversing the order of removal Fuel Tank Support Pan Removal and Installation See Figures 9 17 and 9 18 1 Park the mower safe...

Page 323: ...ssembly Removal and Installation See Figures 9 19 through 9 22 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 9 19 2 Disconnect rod 2 3 Remove nut 3 steel bushing 4 nylon bearing 5 a...

Page 324: ...p Adjustment on page 9 6 Disassembly and Assembly Mow Speed Stop Bracket Assembly See Figure 9 23 Figure 9 23 Disassembly Note Clean and inspect all moving parts checking for wear damage and binding A...

Page 325: ...on Note Install instrument panel cover by reversing the order of removal Traction Lever Assembly Removal and Installation See Figures 9 25 and 9 26 1 Park the mower safely See Park Mower Safely on pag...

Page 326: ...le lever by reversing the order of removal Park Brake Lever Removal and Installation See Figure 9 28 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable f...

Page 327: ...sure correct installation 5 Disconnect the operator s seat switch wire connector 8 6 Remove nuts 5 flat washers 6 and screws 7 7 Using a lifting device remove seat and seat plate Installation Notes In...

Page 328: ...e seat and seat plate by reversing the order of disassembly Seat Switch Removal and Installation Standard Seat See Figure 9 34 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 9 34 NOT...

Page 329: ...f removal Floorboard Assembly Removal and Installation See Figures 9 36 through 9 39 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove splash shield See Splash Shield on page 9 18 3 R...

Page 330: ...reversing the order of removal Adjust transport speed stop See Transport Speed Stop Adjustment on page 9 5 Adjust mow speed stop See Mow Speed Stop Adjustment on page 9 6 Splash Shield Removal and In...

Page 331: ...obsen PN 365422 to any wire connectors disconnected Adjust work lights to project desired distance in front of the mower Front Wheel Removal and Installation See Figure 9 42 1 Park the mower safely Se...

Page 332: ...tion Note Install park brake caliper assembly by reversing the order of removal Disassembly and Assembly See Figure 9 44 Figure 9 44 1 Remove caliper housing 2 from caliper bracket 3 2 Remove pin 9 an...

Page 333: ...cement of cable ties to ensure correct installation 8 Disconnect two cables 6 from machine frame 9 Remove all cable ties from cables 6 Figure 9 48 10 Remove clip 11 and pin 12 11 Loosen two lock nuts...

Page 334: ...order of removal Apply anti seize compound Jacobsen PN 360652 to key Key must be bottomed in slot Do not lubricate or apply anti seize on the tapers hub must be installed dry Tighten castle nut to 16...

Page 335: ...ure to 10 psi 0 70 bar Steering Axle 2WD Units Diesel Disassembly and Assembly See Figure 9 52 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove rear wheel and steering axle See Rear...

Page 336: ...assembly 6 from steering yoke 5 6 Remove four mounting bolts 1 and remove wheel 2 from axle 3 7 Inspect tread area for tears or other damage 8 Replace tire if damage is excessive Installation Notes In...

Page 337: ...the mower safely See Park Mower Safely on page 1 6 Figure 9 56 2 Loosen but do not remove four lug nuts 2 WARNING IMPORTANT It is important to lift and support the machine or the machine will move 3 R...

Page 338: ...WD Units on page 9 25 Figure 9 57 3 Loosen but do not remove castle nut 3 4 Loosen the wheel hub 4 from the motor shaft 2 using a suitable puller 5 Remove castle nut 3 and wheel hub 4 6 Remove key 1 f...

Page 339: ...Repair 8 33 Bedknife Backing Assembly Removal and Installation 8 32 Repair 8 32 Bedknife to Reel Clearance Adjustment Checks and Adjustments 8 17 C Canister Gasoline Removal and Installation 3 18 Rep...

Page 340: ...cation 8 3 Leveling Adjustment 8 21 Removal and Installation 8 22 Repair 8 22 Specifications 8 2 Troubleshooting 8 4 Cutting Units Circuit Test Instrument Test Procedures 6 32 D Definition of Terms Gr...

Page 341: ...Installation 9 17 Repair 9 17 Flushing Valve Disassembly Inspection and Assembly 5 56 Removal and Installation 5 55 Repair 5 55 Flushing Valve Check Valve Test 5 48 Front Reel Valve Disassembly Inspe...

Page 342: ...ir 6 60 Hydraulic Oil Cooler Gasoline Removal and Installation 6 61 Repair 6 61 Hydraulic Oil Pressure Light Removal and Installation 4 63 Repair 4 63 Hydraulic Oil Tank Drain Procedure 6 42 Hydraulic...

Page 343: ...n 6 54 Repair 6 54 Left Front Wheel Motor Assembly 5 64 Disassembly and Inspection 5 60 Removal and Installation 5 57 Test 5 43 Lift Cylinder Leakage Test Field Test Procedures 6 28 Lift Relief Valve...

Page 344: ...ion 4 14 Troubleshooting 4 36 Preliminary Checks Field Test Procedures 5 34 6 28 Prepare for the Job Safety 1 2 Purging the Fuel System Diesel Checks and Adjustments Diesel Models 3 6 Q Quality of Cut...

Page 345: ...e Side Disassembly and Assembly 8 34 Removal and Installation 8 34 Repair 8 34 Reel Bearing Housing Assembly Non Drive Side Disassembly and Assembly 8 36 Installation 8 36 Removal 8 35 Repair 8 36 Ree...

Page 346: ...essure Switch 4 58 Hydraulic Oil Cooler Diesel 6 60 Hydraulic Oil Cooler Gasoline 6 61 Hydraulic Oil Pressure Light 4 63 Hydraulic Oil Tank Diesel 6 57 Hydraulic Oil Tank Gasoline 6 58 Hydraulics 6 42...

Page 347: ...Hydraulic System Service 1 9 Introduction 1 2 Keep Work Area Well Ventilated 1 6 Lifting Equipment 1 7 Parking Mower 1 6 Prepare for the Job 1 2 Safety Label Locations 1 2 Safety Notices 1 2 Support...

Page 348: ...nstallation 4 52 Repair 4 52 Starter Relay Removal and Installation 4 60 Repair 4 60 Steering Component Location 7 3 Repair 7 4 Specifications 7 2 Steering Axle 2WD Units Diesel Disassembly and Assemb...

Page 349: ...nd Sub Circuit Schematics Hydraulics 6 18 Hydrostatic Power Train 5 7 Thermostat Diesel Removal and Installation 3 11 Repair 3 11 Throttle Cable Diesel Removal and Installation 3 9 Repair 3 9 Throttle...

Page 350: ...Circuit 4 38 Lower Circuit 4 37 Mechanical Troubleshooting 8 16 Mow Circuit 4 37 Power Circuit 4 36 Quality of Cut Troubleshooting 8 4 Raise Circuit 4 37 Start Circuit 4 36 Work Light Circuit 4 38 V V...

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Page 352: ...ipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations A worldwide dealer network and factory trained technicians back...

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