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HR-5111™

Rotary Mower

Technical/Repair Manual

69116

Summary of Contents for Jacobsen HR-5111

Page 1: ...HR 5111 Rotary Mower Technical Repair Manual 69116...

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Page 3: ...cause severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or s...

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Page 5: ...anual 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 RIGHT TO...

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

Page 7: ...6 7 8 Table of Contents 4203780 First Edition 5 1 Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneo...

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

Page 10: ...e beginning 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...

Page 11: ...SAFETY 4203780 First Edition 1 3 1 Figure 1 1 TN1767 TN1770 5 2 4 15 14 11 16 17 1 6 7 8 10 12 9 3 13...

Page 12: ...1 4 4203780 First Edition SAFETY 1 2 6 3 9 7 5 8 1 4...

Page 13: ...SAFETY 4203780 First Edition 1 5 1 10 11 12 13 14 16 15 17...

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

Page 15: ...rotection 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 stan...

Page 16: ...local 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 Volatil...

Page 17: ...ts with 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...

Page 18: ...with 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...

Page 19: ...n Mower Identification 2 2 Serial Number 2 2 Engine Serial Number 2 3 Optional Machine Accessories 2 3 Component Location 2 3 Specifications 2 5 Quick Reference Specifications 2 5 Standard Torque Valu...

Page 20: ...ial number 3 is attached to the frame of the tractor and is located just ahead of the rear axle on the right side Always provide the serial number of the unit when ordering replacement parts or reques...

Page 21: ...on engine idle speed and engine displacement Optional Machine Accessories This manual is structured to cover all basic machine components and repair The addition of accessories can affect certain trou...

Page 22: ...781 First Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Figure 2 7 Component Location Left Side 1 OPS 4 4WD Valve 2 Hydraulic Oil Tank 5 Front Differential 3 Rear Wheel Motor 2 6 Battery TN1770 6 4...

Page 23: ...ohms 8 8 10 Fuel Level Sender Resistance Between Terminals at Full Position ohms 32 10 Fuel Level Sender Resistance Between Terminals at Empty Position ohms 256 10 Resistance Across Fuel Shutoff Pull...

Page 24: ...ew Torque lb ft N m 37 51 Rear Wheel Motor Valve Housing Screw Torque lb ft N m 36 37 49 50 Rear Wheel Motor Hub Nut Torque lb ft N m 175 200 237 271 Test and Adjustment Specifications Front Cutting U...

Page 25: ...ominal Amount Rear Axle Alignment Toe In Measurement in mm 0 0625 1 6 Rear Axle Spindle Arm to Axle Stop Measurement in mm 0 030 0 060 0 76 1 5 Repair Specifications Steering Wheel Nut lb ft N m 28 30...

Page 26: ...dal Mounting Bracket Nut Torque lb ft N m 25 34 Traction Pedal Ball Joint Nut Torque lb ft N m 50 68 Engine Manufacturer Model Kubota Tier 2 V2203 DI B Engine Type 4 stroke diesel Fuel Requirement No...

Page 27: ...1 First Edition 2 9 2 Weights and Dimensions Overall Weight lb kg 3780 1718 Width of Cut in mm 134 3404 Overall Width in mm 139 3531 Overall Height with OPS in mm 81 2057 Overall Height with OPS Canop...

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

Page 29: ...SPECIFICATIONS AND GENERAL INFORMATION 4203781 First Edition 2 11 2 Page Intentionally Blank...

Page 30: ...2 12 4203781 First Edition SPECIFICATIONS AND GENERAL INFORMATION 2...

Page 31: ...ota V2203 DI B 3 3 Checks and Adjustments 3 5 Throttle Cable 3 5 Fuel Solenoid Rod 3 6 Purging the Fuel System 3 6 Repair 3 7 Fan Belt 3 7 Air Cleaner Assembly 3 8 Muffler 3 9 Exhaust Manifold 3 10 Ra...

Page 32: ...on 4 in line Displacement cu in cc 131 1 2148 Bore x Stroke in mm 3 43 x 3 64 87 x 92 4 Power Output hp kW 49 36 5 2500 rpm Firing Order 1 3 4 2 Compression Ratio 19 1 Injection Timing Before T D C 18...

Page 33: ...mponent Location Right Side 1 Hydraulic Oil Cooler 7 Oil Pressure Sending Unit 2 Radiator 8 Starter Motor 3 Thermostat 9 Alternator 4 Air Cleaner Assembly 10 Fan Drive Belt 5 Coolant Overflow Reservoi...

Page 34: ...ENGINE 3 Figure 3 2 Component Location Left Side 1 Hydraulic Tank 5 Oil Filler Cap 2 Air Cleaner Service Switch 6 Oil Filter 3 Radiator Cap 7 Fuel Filter 4 Throttle Cable 8 Fuel Shutoff Solenoid TN20...

Page 35: ...n Figure 3 5 7 Loosen clamp nuts 18 and position cable in clamp so that governor throttle lever 15 contacts the idle screw 14 Tighten nuts 18 8 Push throttle lever to full open position and check to s...

Page 36: ...ned between fuel solenoid bracket 6 and casting boss 5 when the ignition key is in the off position Purging the Fuel System Adjustment See Figure 3 7 CAUTION NOTE Whenever the fuel filter or fuel line...

Page 37: ...purged and the engine is running listen to the engine If the engine is misfiring repeat steps 9 and 10 for all the fuel injector lines Repair Fan Belt Removal and Installation See Figures 3 8 and 3 9...

Page 38: ...and Installation See Figures 3 10 and 3 11 CAUTION NOTES The air cleaner on this engine is a dry type never apply oil to it It is recommended to remove and clean the dust cap daily in dusty condition...

Page 39: ...ool completely 3 Raise the hood Figure 3 12 4 Remove the muffler clamp and hardware 2 from the exhaust pipe 1 5 Remove four nuts 4 isolation mounts 5 screws 7 and eight flat washers 3 Remove the muffl...

Page 40: ...6 2 Allow the engine to cool completely 3 Raise the hood 4 Remove the muffler See Muffler on page 3 9 Figure 3 14 5 Remove eight nuts 1 and lock washers 2 6 Tilt exhaust manifold 3 upward and remove f...

Page 41: ...ulic Oil Cooler Pivot Plate 4 Radiator Shroud 13 Radiator Support Bracket 2 22 Petcock 5 Seal 2 14 Hydraulic Oil Cooler 23 Weather Strip 6 Base Seal 15 Carriage Bolt 2 24 Screw 2 7 Hose Clamp 16 Lock...

Page 42: ...e the two lock nuts 10 flat washers 11 and hydraulic oil cooler spacers 12 6 Remove the hydraulic oil cooler 13 Installation Note Install the hydraulic oil cooler by reversing the order of removal Rad...

Page 43: ...pporting the radiator remove the two screws 17 lock washers 18 and nuts 19 11 Carefully remove the radiator 20 Radiator Installation 1 Install the radiator by reversing the order of removal 2 Inspect...

Page 44: ...ethylene glycol base antifreeze and clean fresh water Throttle Cable and Control Lever Removal and Installation See Figures 3 22 through 3 25 1 Park the mower safely See Park Mower Safely on page 1 6...

Page 45: ...able route the same as the old cable Secure using existing cable clamps After replacing follow the adjustment procedure See Throttle Cable on page 3 5 Fuel Filter Removal and Installation See Figures...

Page 46: ...he battery 3 Turn the fuel outlet hose shutoff valve clockwise until valve bottoms lightly Valve is located on the bottom of the fuel tank Figure 3 28 4 Disconnect the positive lead 1 from the wiring...

Page 47: ...t hose shutoff valve clockwise until valve bottoms lightly Valve is located on the bottom of the fuel tank Figure 3 29 9 Disconnect and remove fuel hose 1 from inlet of fuel filter 3 and from fuel pum...

Page 48: ...r filter assembly from air cleaner support 31 21 Remove four nuts 34 lock washers 33 flat washers 32 and screws 37 and remove clamp 36 and mounting bracket clamp 35 to remove air cleaner support from...

Page 49: ...24 Check for any connected wires and components and carefully remove the engine from the machine 25 Place the engine on a suitable stand or workbench that will support the full weight in a safe manner...

Page 50: ...e engine and install the components on the new engine Use new gaskets when installing the exhaust system Fill the radiator with a 50 50 mixture of ethylene glycol base antifreeze and clean fresh water...

Page 51: ...y of Operation 4 30 Run Circuit Schematic On Seat 4 31 Run Circuit Schematic Off Seat 4 32 Charging Circuit Theory of Operation 4 34 Charging Circuit Schematic 4 35 Mow Circuit Theory of Operation 4 3...

Page 52: ...ting 4 72 Circuit Breakers Test 4 73 Thermal Circuit Breakers Test 4 73 Relays Test 4 74 Time Delay Relay Test 4 74 Key Switch Test 4 75 Horn Test Switch Test 4 75 Seat Switch Test 4 76 Glow Plug Swit...

Page 53: ...Front Limit Switch 4 97 Rocker Switches 4 98 Reverse Kick Out Switch 4 99 Diff Lock Switch 4 100 Air Filter Pressure Switch 4 100 Return Filter Pressure Switch 4 101 Hyd Oil Temp Switch 4 101 Charge...

Page 54: ...s 8 8 10 Resistance Across Solenoid Coil Diff Lock Solenoid Coil at 68 F ohms 8 8 10 Resistance Across Solenoid Coil 4WD Rev Solenoid Coil at 68 F ohms 8 8 10 Fuel Level Sender Resistance Between Term...

Page 55: ...switch configurations Switches are designated by the number of poles circuits controlled and throws actuator positions Unless otherwise specified switches are shown in the Normally Open N O position...

Page 56: ...ices 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 Sing...

Page 57: ...closure 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 s...

Page 58: ...Meter See Figure 4 4 H3 Engine Temperature Gauge See Figure 4 4 H4 Tachometer See Figure 4 5 H5 Hour Meter See Figure 4 5 H6 Fuel Gauge See Figure 4 5 J4 Cab Canopy Connector See Figure 4 7 K1 Glow P...

Page 59: ...ELECTRICAL 4203780 First Edition 4 9 4 Y6 4WD Rev Solenoid See Figure 4 3 Y7 Diff Lock Solenoid See Figure 4 3 Y8 Cruise Control Magnet See Figure 4 4...

Page 60: ...Accessory Relay K3 Fuel Pull In Relay Red R1 Glow Plugs M S1 Key Switch G1 12V Battery G2 Alternator Pur Org Org Pur Red Red Yel Yel Red Brn Red Brn Red Brn Red Org Org F3 50A Circuit Breaker F1 50A...

Page 61: ...Breaker K8 Right Wing Relay K9 Left Wing Relay On Off S4 Park Brake Switch Pur Wht Brn Wht Brn K4 Time Delay Relay Yel Blk Output Gnd Enable 12V 1 Sec Off Delay On Off S5 Seat Switch On Off S3 PTO Sw...

Page 62: ...f Lock Switch Brn Red Brn Red On Off S8 Front Limit Switch Pur Pur Org Org Org Forward Reverse S12 Reverse Kick Out Switch Lt Grn Org On Off Off S10 Wing Mow Enable Switch Red Wht S11 4WD Switch Pnk 6...

Page 63: ...t Grn 12V Signal Gnd H3 Engine Temperature Gauge Wht Red Org Wht Org S15 Cruise Control Switch Wht Grn Wht Grn Wht Red Enable Disable Off Mom Sw Wht Wht Lt Blu Red Lt Blu Red Red K7 Horn Relay H1 Horn...

Page 64: ...Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org B2 Engine Speed Sensor Blk Blk Brn Brn 12V Signal Gnd H4 Tachometer Org Org Org Org B3 Fuel Level Sensor E1 Right Turn Indicator E10 Left Turn Indicator E...

Page 65: ...tch P Org Org Grn Wht Grn Wht Grn Wht Wht Grn Wht Grn Wht Grn Wht Org Wht Grn Wht Grn Grn Wht Wht Blk E5 Hyd Oil Temp Light B6 Hyd Oil Temp Switch V1 V2 V6 V7 V5 V4 V3 t Org Org Gry Wht Gry Wht Gry Wh...

Page 66: ...Blk Lt Grn Lt Blu Wht Wht Wht Gry Gry Gry Wht Red Red Red Tan Red Tan Red Tan Red Wht Wht Wht Work Road Off S17 Light Switch Optional Work Lights E12 Work Light E13 Work Light E11 Tail Light Org Blu...

Page 67: ...ELECTRICAL 4203780 First Edition 4 17 4 Page Intentionally Blank...

Page 68: ...ust occur before the key switch is provided with 12 volts PTO switch in the off position Park brake switch in the on position With the PTO switch in the off position and park brake switch in the on po...

Page 69: ...Red R1 Glow Plugs M S1 Key Switch G1 12V Battery G2 Alternator Pur Org Org Pur Red Red Yel Yel Red Brn Red Brn Red Brn Red Org Org F3 50A Circuit Breaker F1 50A Circuit Breaker F2 30A Circuit Breaker...

Page 70: ...ng Relay On Off S4 Park Brake Switch Pur Wht Brn Wht Brn K4 Time Delay Relay Yel Blk Output Gnd Enable 12V 1 Sec Off Delay On Off S5 Seat Switch On Off S3 PTO Switch Pur Org Red Blu Red Wht Red Yel Re...

Page 71: ...n Red Pur Pur Org Org Org Forward Reverse S12 Reverse Kick Out Switch Lt Grn Org On Off Off S10 Wing Mow Enable Switch S11 4WD Switch Pnk 66A Pnk Pnk 66A Pnk Pur Grn Blu Mom ON On Off Pnk Wht Blk Wht...

Page 72: ...e Temperature Gauge Wht Red Org Wht Org S15 Cruise Control Switch Wht Grn Wht Grn Wht Red Enable Disable Off Mom Sw Wht Wht Lt Blu Red Lt Blu Red Red K7 Horn Relay H1 Horn 87 30 87 85 86 Wht Blk Lt Bl...

Page 73: ...5 Hour Meter Org B2 Engine Speed Sensor Blk Blk Brn Brn 12V Signal Gnd H4 Tachometer Org Org Org Org B3 Fuel Level Sensor E1 Right Turn Indicator E10 Left Turn Indicator E2 Glow Plug Light Blk Blk Blk...

Page 74: ...Grn Wht Wht Grn Wht Grn Wht Grn Wht Org Wht Grn Wht Grn Grn Wht Wht Blk E5 Hyd Oil Temp Light B6 Hyd Oil Temp Switch V1 V2 V6 V7 V5 V4 V3 t Org Org Gry Wht Gry Wht Gry Wht Wht Blk E6 Charge Filter Ser...

Page 75: ...t Gry Gry Gry Wht Red Red Red Tan Red Tan Red Tan Red Wht Wht Wht Work Road Off S17 Light Switch Optional Work Lights E12 Work Light E13 Work Light E11 Tail Light Org Blu Org Blu Org Blu Org Blu Org B...

Page 76: ...lay battery terminal Interlock Circuit The interlock circuit provides 12 volts to the key switch The following must occur before the key switch is provided with 12 volts PTO switch in the off position...

Page 77: ...50A Circuit Breaker Org Org Red Brn F E B A C F5 10A Circuit Breaker On Off S4 Park Brake Switch On Off S3 PTO Switch Interlock Circuit Unswitched Power Circuit Switched Power Circuit Ground Circuit O...

Page 78: ...d from key switch terminal I to accessory relay terminal 86 energizing the relay With the relay energized switched power is provided from accessory relay terminal 87 to fuel shutoff hold in coil and t...

Page 79: ...Red Brn Red Brn Red Org Org F1 50A Circuit Breaker F2 30A Circuit Breaker Blk Off Run Start B X I S A Y Red Red Wht Org Y1 Fuel Shutoff Solenoid Pull In Hold In 87 87 85 86 30 87 30 87 85 86 Org Red...

Page 80: ...terminal I continues to energize the accessory relay The accessory relay continues to provide voltage to the fuel shutoff hold in coil keeping the fuel shutoff solenoid plunger retracted With the sole...

Page 81: ...2 30A Circuit Breaker Off Run Start B X I S A Y Red Org Y1 Fuel Shutoff Solenoid Pull In Hold In 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park B...

Page 82: ...2 30A Circuit Breaker Off Run Start B X I S A Y Red Org Y1 Fuel Shutoff Solenoid Pull In Hold In 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park B...

Page 83: ...ELECTRICAL 4203780 First Edition 4 33 4 Page Intentionally Blank...

Page 84: ...rcuit The interlock circuit provides 12 volts to the key switch The following must occur before the key switch is provided with 12 volts PTO switch in the off position Park brake switch in the on posi...

Page 85: ...ay M S1 Key Switch G1 12V Battery G2 Alternator Red Brn Red Brn Red Brn Red Org Org F1 50A Circuit Breaker F2 30A Circuit Breaker Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker On...

Page 86: ...releasing the park brake or placing the PTO switch in the on position See Run Circuit Theory of Operation on page 4 30 Mow Circuit When the PTO switch is placed in the on position voltage is provided...

Page 87: ...Red Org Org F1 50A Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker On Off S4 Park Brake Switch Wht Brn On Off S5 Se...

Page 88: ...g Relay K9 Left Wing Relay Brn Red Brn Red Lt Grn Org On Off Off S10 Wing Mow Enable Switch Red Blu Red Wht Red Yel Red Lt Blu Red Yel Red Wht Red Lt Blu Red Yel Red Wht Red Wht Blk Pnk 87 30 87 85 86...

Page 89: ...ELECTRICAL 4203780 First Edition 4 39 4 Page Intentionally Blank...

Page 90: ...elay terminal 87 to PTO switch terminal B and from terminal B to the seat switch Accessory relay terminal 87 also provides switched power to 10 amp circuit breaker F6 Circuit breaker F6 provides volta...

Page 91: ...Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park Brake Switch Wht Brn On Off S5 Seat Switch Wht On Off S13 Diff Lock Switch On Off S3 PTO Switch Pur Pur Pur Brn S...

Page 92: ...5 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park Brake Switch Wht Brn On Off S5 Seat Switch Wht On Off S13 Diff Lock Switch On Off S3 PTO Switch Pur Pur Pur...

Page 93: ...ELECTRICAL 4203780 First Edition 4 43 4 Page Intentionally Blank...

Page 94: ...n the seat before releasing the park brake See Run Circuit Theory of Operation on page 4 30 Cruise Control Circuit When the brake pedal switch is in the on position voltage is provided to the cruise c...

Page 95: ...Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park Brake Switch Wht Brn On...

Page 96: ...Wht Grn Wht Grn Wht Red Enable Disable Off Mom Sw Wht Wht Lt Blu Red Lt Blu Red Wht On Off S14 Brake Pedal Switch Wht Gry Red Gry Red K6 Cruise Relay 87 30 87 85 86 Wht Grn Wht Red Blk Blk Blk 5B Blk...

Page 97: ...50A Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Breaker On Off S4 Park Brake Switch Wht Brn...

Page 98: ...t Grn Wht Grn Wht Red Enable Disable Off Mom Sw Wht Wht Lt Blu Red Lt Blu Red Wht On Off S14 Brake Pedal Switch Wht Gry Red Gry Red K6 Cruise Relay 87 30 87 85 86 Wht Grn Wht Red Blk Blk Blk 5B Blk Bl...

Page 99: ...ELECTRICAL 4203780 First Edition 4 49 4 Page Intentionally Blank...

Page 100: ...ht switch and to cab canopy connector J4 terminal 5 Interlock Circuit The interlock circuit provides 12 volts to the key switch The following must occur before the key switch is provided with 12 volts...

Page 101: ...Red Brn Red Brn Red Brn Red Org Org F1 50A Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur F6 10A Circuit Brea...

Page 102: ...Switch Optional Work Lights E12 Work Light E13 Work Light E11 Tail Light Org Blu Org Blu Org Blu Org Blu Org Blu Red F7 30A Circuit Breaker Tan Red Blk Blk J4 Cab Canopy Option Connector 6 8 4 5 1 2...

Page 103: ...ates the condition of the battery Engine Temperature Gauge The engine temperature sensor resistance changes in relationship to the engine coolant temperature As the engine temperature sensor is heated...

Page 104: ...lant temp light turning on the light Ground is also provided from the hyd temp switch through diode V2 to horn relay terminal 85 energizing the relay With the relay energized voltage is provided from...

Page 105: ...g F1 50A Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur Pur Red Red Pnk Blu Pnk Blu Org F6 10A Circuit Breaker...

Page 106: ...rature Gauge Red Lt Blu Red Red K7 Horn Relay H1 Horn 87 30 87 85 86 Wht Blk Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org B2 Engine Speed Sensor Blk Blk Brn Brn 12V Signal Gnd H4 Tachometer Org Org O...

Page 107: ...emp Light B6 Hyd Oil Temp Switch V1 V2 V6 V7 V5 V4 V3 t Org Org Gry Wht Gry Wht Gry Wht Wht Blk E6 Charge Filter Service Light B7 Charge Filter Pressure Switch P Grn Wht Grn Org Org Gry Red E7 Low Cha...

Page 108: ...relay terminal 86 energizing the relay With the relay energized switched power is provided from accessory relay terminal 87 to 10 amp circuit breaker F6 and 10 amp circuit breaker F4 Switched power i...

Page 109: ...1 50A Circuit Breaker F2 30A Circuit Breaker Off Run Start B X I S A Y Red Org 87 30 87 85 86 Org Red Brn F E B A C F5 10A Circuit Breaker Pur Pur Red Red Pnk Blu Pnk Blu Org F6 10A Circuit Breaker F4...

Page 110: ...H3 Engine Temperature Gauge Red Lt Blu Red Red K7 Horn Relay H1 Horn 87 30 87 85 86 Wht Blk Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org B2 Engine Speed Sensor Blk Blk Brn Brn 12V Signal Gnd H4 Tacho...

Page 111: ...t Grn Wht Grn Wht Grn Org Wht Grn Wht Grn Grn Wht Wht Blk E5 Hyd Oil Temp Light B6 Hyd Oil Temp Switch V1 V2 V6 V7 V5 V4 V3 t Org Org Gry Wht Gry Wht Gry Wht Wht Blk E6 Charge Filter Service Light B7...

Page 112: ...p Clean and tighten ring terminal connector Probable Cause Remedy Faulty 50A circuit breaker Test 50A circuit breaker F1 See Thermal Circuit Breakers Test on page 4 73 Tripped 30A circuit breaker Rese...

Page 113: ...tight Check continuity between battery negative terminal and ground Continuity must be indicated Faulty battery Check specific gravity of the individual battery cells Probable Cause Remedy Faulty PTO...

Page 114: ...le switch and the right mow solenoid Continuity must be indicated Measure continuity between ground and the right mow solenoid ground terminal Continuity must be indicated Probable Cause Remedy Faulty...

Page 115: ...ure continuity between ground and the 4WD solenoid ground terminal Continuity must be indicated Probable Cause Remedy Faulty 4WD switch Test 4WD switch See 4WD Switch Test on page 4 81 Faulty wire har...

Page 116: ...cruise control switch Continuity must be indicated Measure continuity between the cruise control switch and cruise relay terminal 30 wht wire Continuity must be indicated Measure continuity between t...

Page 117: ...ust be approximately 12 VDC Faulty engine oil pressure switch circuit Check continuity between engine oil pressure switch terminal and engine oil pressure light terminal blu wire Continuity must be in...

Page 118: ...g full scale replace the engine temperature sensor Faulty engine temperature circuit Check continuity between engine temperature gauge lt grn wire terminal and the engine temperature sensor terminal C...

Page 119: ...light If the light turns on replace the air pressure switch Faulty wiring Check continuity between return filter pressure switch tan wire terminal and the return filter service light Continuity must...

Page 120: ...y wiring Check continuity between tachometer brn wire terminal and the engine speed sensor Continuity must be indicated Probable Cause Remedy Faulty fuel level sensor With a jumper wire connect the fu...

Page 121: ...oes not sound test horn switch Faulty horn Connect a test light between horn terminals pnk blk and blk wires With the key switch in the run position press the horn switch If the test light turns on an...

Page 122: ...e 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 the...

Page 123: ...Set the multimeter to 20 volts DC 4 Connect the black test lead to the negative battery terminal Figure 4 37 Glow Plug and Work Lights 50 Amp Thermal Circuit Breaker Test 5 Connect the red test lead...

Page 124: ...e relay Time Delay Relay Test See Figure 4 39 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove relay See Time Delay Relay on page 4 89 Figure 4 39 3 Connect one test lead to terminal...

Page 125: ...ch is faulty replace the switch Horn Test Switch Test See Figure 4 41 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove horn test switch See Horn Test Switch on page 4 92 Figure 4 41...

Page 126: ...ower safely See Park Mower Safely on page 1 6 2 Remove glow plug switch See Glow Plug Switch on page 4 93 Figure 4 43 3 Connect test leads to terminals 1 and 3 4 With the switch lever 2 in the OFF pos...

Page 127: ...6 2 Remove PTO switch See PTO Switch on page 4 96 Figure 4 45 3 Place the switch in the OFF locked position 4 Connect test leads to the switch terminals 1 and 2 5 Check for continuity Is continuity in...

Page 128: ...tinuity Is continuity indicated YES The switch is faulty replace the switch NO Proceed to step 6 6 Place the switch in the 2 position 7 Check for continuity Is continuity indicated YES Proceed to step...

Page 129: ...O The switch is faulty replace the switch 12 Place the switch in the OFF middle position 13 Check for continuity Is continuity indicated YES The switch is faulty replace the switch NO Proceed to step...

Page 130: ...e the switch in the 2 position 7 Check for continuity Is continuity indicated YES Proceed to step 8 NO The switch is faulty replace the switch 8 Place and hold the switch in the 1 position 9 Check for...

Page 131: ...y Is continuity indicated YES Proceed to step 13 NO The switch is faulty replace the switch 13 Place the switch in the OFF middle position 14 Check for continuity Is continuity indicated YES The switc...

Page 132: ...place the switch Diff Lock Switch Test See Figure 4 51 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove diff lock switch See Diff Lock Switch on page 4 100 Figure 4 51 3 Connect test...

Page 133: ...tance value approximately 32 ohms YES Proceed to step 6 NO The sensor is faulty replace fuel level sensor 6 Move the float 2 to the empty position and read the resistance value Is the resistance value...

Page 134: ...enoid is faulty replace the solenoid Fuel Shutoff Solenoid Test See Figure 4 54 1 Park the mower safely Figure 4 54 2 Connect the black test lead to the fuel shutoff solenoid black wire terminal 1 3 C...

Page 135: ...re reversed YES The diode is good NO The diode is faulty replace the diode Fuel Pump Test See Figure 4 56 1 Park the mower safely See Park Mower Safely on page 1 6 2 Allow engine to cool completely Fi...

Page 136: ...to avoid pinch points Alternator Removal and Installation See Figure 4 58 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise the hood 3 Disconnect the negative battery cable at the bat...

Page 137: ...to ensure correct installation 4 Disconnect wire connectors 4 5 6 and 7 from the starter motor 1 5 Support the starter motor 1 6 Remove screw 3 and nut 2 7 Remove starter motor Installation Note Inst...

Page 138: ...ts 2 and 3 and disconnect wires 5 5 Remove screws and nuts 1 and 4 and the thermal breaker Main 50 Amp Thermal Circuit Breaker Figure 4 63 6 Remove nuts 7 and 8 and disconnect wires 10 7 Remove screws...

Page 139: ...of removal Time Delay Relay Removal and Installation See Figure 4 66 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery 3 Remove instrume...

Page 140: ...cable at the battery Figure 4 67 3 Remove right cover screws 1 Figure 4 68 4 Remove left cover screws 2 and pull down cover 3 Figure 4 69 5 Remove key switch cover 4 Figure 4 70 6 Remove retaining nu...

Page 141: ...removal Brake Pedal Switch Removal and Installation See Figure 4 72 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery Figure 4 72 NOTE La...

Page 142: ...4 for proper switch height if necessary Install horn switch by reversing the order of removal Seat Switch Removal and Installation See Figures 4 75 through 4 77 1 Park the mower safely See Park Mower...

Page 143: ...switch by reversing the order of removal Use new cable ties to secure wire harness and wire connector Glow Plug Switch Removal and Installation See Figures 4 78 through 4 81 1 Park the mower safely S...

Page 144: ...Installation Note Install the glow plug switch by reversing the order of removal Engine Temperature Gauge Removal and Installation See Figures 4 82 through 4 84 1 Park the mower safely See Park Mower...

Page 145: ...icator lights Right Turn Indicator 1 Glow Plug Light 10 Air Filter Service Light 2 Return Filter Service Light 9 Hyd Oil Temp Light 3 Charge Filter Service Light 8 Low Charge Pressure Light 4 Engine C...

Page 146: ...2 Disconnect the battery negative cable at the battery 3 Remove instrument panel See Instrument Panel on page 4 110 Figure 4 89 Figure 4 90 NOTE Label all wires before disconnecting to ensure correct...

Page 147: ...versing the order of removal Use new cable tie to secure wire connector Front Limit Switch Removal and Installation See Figures 4 93 and 4 94 1 Park the mower safely See Park Mower Safely on page 1 6...

Page 148: ...nect the battery negative cable at the battery 3 Remove instrument panel See Instrument Panel on page 4 110 Figure 4 96 NOTE Label all wires before disconnecting to ensure correct installation 4 Disco...

Page 149: ...e Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery Figure 4 100 NOTE Remove floorboard plug to access switch NOTE Label all wires before disconnecting to ensure cor...

Page 150: ...ve diff lock switch 1 and switch cover 2 Installation Note Install the diff lock switch by reversing the order of removal Air Filter Pressure Switch Removal and Installation See Figure 4 102 1 Park th...

Page 151: ...relieve pressure in the hydraulic system before performing service Always use appropriate safety equipment and clothing to protect exposed skin and eyes from high pressure oil Tighten all connections...

Page 152: ...ly See Park Mower Safely on page 1 6 2 Raise the hood 3 Disconnect the negative battery cable at the battery Figure 4 105 4 Remove nut 1 and disconnect wire 2 from the charge filter pressure switch 3...

Page 153: ...stall the engine oil pressure switch by reversing the order of removal Apply Teflon tape to the threads of the oil pressure switch before installing Engine Temperature Sensor Removal and Installation...

Page 154: ...e Switch Removal and Installation See Figure 4 109 WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery Required Materials Telfon Ta...

Page 155: ...ure switch by reversing the order of removal Install cover 1 Mow Solenoids See Figures 4 110 through 4 112 Figure 4 110 Left Mow Solenoid Figure 4 111 Right Mow Solenoid Figure 4 112 Front Mow Solenoi...

Page 156: ...m the valve 7 Installation Notes Clean cartridge of any debris or surface rust and apply dielectric grease Jacobsen PN 365422 to cartridge before installation Install the solenoid by reversing the ord...

Page 157: ...6 and remove the solenoid 7 from the valve 5 Installation Notes Clean cartridge of any debris or surface rust and apply dielectric grease Jacobsen PN 365422 to cartridge before installation Install t...

Page 158: ...e Install the fuel shutoff solenoid by reversing the order of removal Cruise Control Magnet Removal and Installation See Figures 4 119 through 4 121 1 Park the mower safely See Park Mower Safely on pa...

Page 159: ...the battery 3 Remove seat See Seat and Seat Platform on page 9 13 4 Remove instrument panel See Instrument Panel on page 4 110 Figure 4 122 5 Remove screws 2 lock washers 3 flat washers 4 and trim 8 6...

Page 160: ...rews 8 lock washers 9 and flat washers 10 8 Slide steering console cover 11 away from instrument panel 7 9 Lift the instrument panel 7 to clear the edge of the console wall 6 and rotate the instrument...

Page 161: ...er safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery 3 Remove instrument panel See Instrument Panel on page 4 110 Figure 4 127 4 Remove nuts 5 lock washer...

Page 162: ...ion 5 Disconnect wire terminals 8 6 Remove tachometer 5 Installation Note Install the tachometer by reversing the order of removal Horn Removal and Installation See Figure 4 130 1 Park the mower safel...

Page 163: ...the battery 3 Drain fuel until level is below fuel level sensor mount opening Figure 4 131 4 Remove fuel level sensor cover 1 Figure 4 132 NOTE Label all wires before disconnecting to ensure correct i...

Page 164: ...4 114 4203780 First Edition ELECTRICAL 4...

Page 165: ...ion 5 15 Traction Circuit Reverse 2WD Differential Unlocked Schematic 5 16 Traction Circuit Forward 4WD Schematic and Theory of Operation 5 19 Traction Circuit Forward 4WD Differential Locked Schemati...

Page 166: ...n Pump U Joint 5 48 Traction Pump 5 50 4WD Valve 5 53 Control Valve 5 55 Front Axle Motor 5 58 Front Drive Axle Assembly 5 60 Differential Lock Assembly 5 64 Input Bevel Pinion Assembly 5 65 Drive Axl...

Page 167: ...Motor Backplate Assembly Screw Torque lb ft N m 15 18 20 24 Differential Lock Assembly Fork Screw Torque lb ft N m 19 26 Differential Lock Assembly Housing Screw Torque lb ft N m 37 51 Input Bevel Pin...

Page 168: ...filtered 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 thr...

Page 169: ...First Edition 5 5 5 Component Location See Figures 5 2 and 5 3 Figure 5 2 Component Location Left Side 1 Hydrostatic Pump 3 Front Axle Motor 5 4WD Valve 2 Gear Pump 4 Front Axle U Joint 6 Front Axle T...

Page 170: ...5 6 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Figure 5 3 Component Location Right Side 1 Control Valve 2 Right Rear Wheel Motor 3 Left Rear Wheel Motor 3 4 2 TN1769 TN1921 2 3 1...

Page 171: ...lter to remove debris from the oil In the event of the charge filter becoming plugged a 25 psi pressure switch will activate the Charge Filter light on the control panel and a bypass valve will open t...

Page 172: ...Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN1730 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 Micron Hydrostatic Traction Pump IN Steering Cylinder...

Page 173: ...xle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN1731 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 2 48 ci Secondary 4WD Shuttle Valve 3 Hydraulic Oil Tank 4 5 4WD Rever...

Page 174: ...5 10 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 175: ...125 psi The control valve also includes a charge relief valve that will open to dump oil to the hydraulic tank when the charge pressure reaches 250 psi Traction Drive Circuit When the traction pedal i...

Page 176: ...4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN1722 10 Micron Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 65 ci 3500 psi 1 08 ci Suction Stra...

Page 177: ...nt Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN1723 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 2 48 ci Secondary 4WD Shuttle Valve 3 Hydraulic Oil Tank 4 5 4WD R...

Page 178: ...5 14 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 179: ...alve and the traction pump The control valve also incorporates a charge pressure switch that will activate the Charge Pressure light on the control panel if the charge oil pressure drops below 125 psi...

Page 180: ...A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN1724 10 Micron Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 65 ci 3500 psi 1 08 ci Suction Str...

Page 181: ...ont Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN1725 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 2 48 ci Secondary 4WD Shuttle Valve 3 Hydraulic Oil Tank 4 5 4WD...

Page 182: ...5 18 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 183: ...osition the swash plate is moved stroking the pump This change of the swash plate angle produces an increase of oil flow on one side of the pump Oil at operating pressure is then routed against the ch...

Page 184: ...A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN1726 10 Micron Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 65 ci 3500 psi 1 08 ci Suction St...

Page 185: ...ont Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN1727 4WD Valve L1 1 Right Wheel Motor 2 2 48 ci Secondary 4WD Shuttle Valve 3 Hydraulic Oil Tank 4 5 4WD Reverse...

Page 186: ...5 22 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 187: ...rops below 125 psi The control valve also includes a charge relief valve that will open to dump oil to the hydraulic tank when the charge pressure reaches 250 psi Traction Drive Circuit When the tract...

Page 188: ...ort A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN1728 10 Micron Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 65 ci 3500 psi 1 08 ci Suction...

Page 189: ...ront Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN1729 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 2 48 ci Secondary 4WD Shuttle Valve 3 Hydraulic Oil Tank 4 5 4WD...

Page 190: ...r front axle See Front Drive Axle Assembly on page 5 60 Probable Cause Remedy Hydraulic oil not at correct level in reservoir Fill reservoir to correct level Refer to Safety Operation and Maintenance...

Page 191: ...aulic oil to operating temperature Air in hydraulic system air bubbles in hydraulic oil Check suction line for air leaks Repair as needed Operate various hydraulic systems until hydraulic system is fr...

Page 192: ...assembly sticking Repair or replace 4WD shuttle valve See 4WD Valve on page 5 53 Low charge pressure Test charge pump See Charge Pressure Test on page 5 34 Probable Cause Remedy 4WD solenoid in contro...

Page 193: ...the linkage 7 Start the engine and set the throttle in the fast idle position WARNING 8 Loosen the jam nut 1 on the traction pump centering cylinder 3 and turn the adjustment nut 2 moving the threade...

Page 194: ...neutral position The reverse kick out switch should not indicate continuity when the traction pedal is in the reverse position If adjustment is required proceed to step 4 If no adjustment is required...

Page 195: ...gement delay 14 Start the engine and set the throttle in the fast idle position 15 Place the 4WD switch in the ON position NOTE Four wheel drive rear wheels will not engage unless the 4WD switch is he...

Page 196: ...stop stud 13 before reaching the maximum forward position adjust the stop stud position 2 Loosen jam nut 16 and lock nut 15 3 Adjust turn the stop stud 13 in clockwise 4 Move the traction pedal 14 to...

Page 197: ...cuit and 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 34 Traction System Test See Figure 5 21 NOTE Be sure to...

Page 198: ...ercentages The results from this test reveal leakage of 6 7 in the traction pump and 32 9 in the front axle motor Although both the components lend to the overall system leakage only the front axle mo...

Page 199: ...replace charge pump as needed 9 Disconnect and remove test equipment Install all hoses and fittings as noted prior to removal 10 Install and connect all components as noted prior to test 11 Check hyd...

Page 200: ...4 until pressure reaches 1125 psi 78 bar Read and record the charge pump loaded flow 12 Open flow meter valve 4 and stop engine 13 Calculate charge pump leakage Step 10 Step 11 Step 10 x 100 Leak Per...

Page 201: ...mower safely See Park Mower Safely on page 1 6 2 Remove the seat and seat platform See Seat and Seat Platform on page 9 13 Figure 5 27 3 Install wheel restraint 1 to all four wheels 4 Disconnect tract...

Page 202: ...o 120 150 F 49 65 C open valve fully after operating temperature is reached 18 After warming the hydraulic oil verify flow lock tool is adjusted to allow pump to produce 15 gpm 57 Lpm in the forward d...

Page 203: ...Read and record no load flow 31 Slowly close flow meter valve 7 until pressure reaches 2625 psi 181 bar Read and record loaded flow 32 Open flow meter valve 7 stop engine and set park brake Return fl...

Page 204: ...6 Bypass the seat switch Figure 5 34 Traction Pump Test Blocking Disks Between Flow Meter and Front Axle Motor All Wheels Restrained NOTE Verify engine rpm is within specification 2800 rpm 50 to ensu...

Page 205: ...e flow meter to warm the hydraulic oil Turn the flow meter valve 2 until a reading of 1750 psi 121 bar or one half of the relief valve rating is reached Warm oil to 120 150 F 49 65 C 19 Continue to cl...

Page 206: ...p and front axle motor to be good proceed to step 15 If performing this test to determine which component in system is at fault front axle motor secondary 4WD shuttle valve right rear wheel motor left...

Page 207: ...gine and set park brake Return flow lock tool back to neutral position 13 Calculate front axle motor leakage Step 12 of traction pump test Step 11 Step 12 of traction pump test x 100 Leak Percentage I...

Page 208: ...7 Lpm in the forward direction 22 Engage 4WD switch in the forward position 23 Slowly close flow meter valve until pressure reaches 2625 psi 181 bar Read and record loaded flow 24 Open flow meter valv...

Page 209: ...After warming the hydraulic oil verify flow lock tool is adjusted to allow pump to produce 15 gpm 57 Lpm in the forward direction 32 Engage 4WD switch in the forward position 33 Slowly close flow mete...

Page 210: ...42 Engage 4WD switch in the forward position 43 Slowly close flow meter valve until pressure reaches 2625 psi 181 bar Read and record loaded flow 44 Open flow meter valve stop engine and set park brak...

Page 211: ...Mower Safely on page 1 6 2 Remove park brake See Park Brake on page 9 11 3 Remove front axle motor 2 See Front Axle Motor on page 5 58 4 Disconnect front axle U joint 1 from front axle 3 5 Remove fro...

Page 212: ...5 48 4203780 First Edition HYDROSTATIC POWER TRAIN 5 Traction Pump U Joint Removal and Installation See Figure 5 45 Figure 5 45 TN2032 1 1 2 2 3 1 2 1 2 4 5 6 5 5 5 6 6 6 7 8 9 10 11 12...

Page 213: ...2 nuts 6 and lock washers 5 and carefully move the engine to the rear of the mower as far as possible 6 Slide the U joint off the traction pump input shaft and remove the U joint pump drive flange ass...

Page 214: ...from tee fitting 13 Figure 5 47 11 Remove two screws 16 and lockwashers 17 Remove top block 15 and traction arm 23 from the pump control shaft WARNING 12 Attach a suitable lifting device to the tract...

Page 215: ...et 19 Screw Bottom 2 27 Retaining Ring 2 4 O Ring 12 Plug 2 20 Backplate 28 Thrust Race 2 5 Washer 2 13 Spring 2 21 Dowel Pin 2 29 Thrust Bearing 6 O Ring Cover 14 Relief Valve 2 22 Key Trunnion 30 Wa...

Page 216: ...ic component Inspect all parts for cracks nicks burrs and excessive wear Inspect for scoring galling and scratches on surfaces Replace parts as necessary Assembly Notes Assemble the pump by reversing...

Page 217: ...4WD valve 13 Installation Notes Install the 4WD valve by reversing the order of removal Lubricate all O rings prior to assembly Make sure new O rings are in place before installing hoses on fittings...

Page 218: ...17 Clean all parts using clean solvent and dry using compressed air 18 Inspect all parts for wear or damage Replace parts as needed Assembly Notes NOTICE Assemble the 4WD valve by reversing the order...

Page 219: ...d nuts 7 10 Remove the control valve 8 Installation Notes Install the control valve by reversing the order of removal Lubricate all O rings prior to assembly Make sure new O rings are in place before...

Page 220: ...e block 25 15 Remove O rings 26 28 and 29 and backup rings 27 from priority valve 30 16 Remove nut 35 and solenoid coil 34 from 4WD valve 33 17 Remove 4WD valve 33 from the control valve 25 18 Remove...

Page 221: ...are absolutely clean as contamination can result in serious damage and or improper operation Never use shop towels or rags to dry parts after cleaning as lint may clog passages Dry parts using compre...

Page 222: ...able lifting device 7 Remove two nuts 12 and 16 lock washers 11 and 17 and screws 1 and 8 8 Remove front axle motor 9 from frame 10 and front axle U joint 14 NOTE Record the location and orientation o...

Page 223: ...housing 8 must be replaced 1 Disassemble front wheel motor as shown 2 Place parts in assembly order on a clean work area as they are removed 1 Retaining Ring 5 Thrust Bearing 9 Cam Plate Insert 13 Scr...

Page 224: ...ess shaft seal 2 into the housing until the seal is approximately 7 32 inch 5 5 mm below the surface of the housing Install cam plate insert 9 making sure the lettering is facing toward the housing 8...

Page 225: ...ake pedal switch wire harness connector 13 from the wire harness connector 12 8 Cut cable ties 10 as needed 9 Move the lift arm limit switch and harness 7 and wire harnesses 11 aside Figure 5 60 10 Re...

Page 226: ...5 63 15 Disconnect hydraulic line 35 16 Disconnect hydraulic hose 34 at tee fitting 17 Remove four screws 31 lock washers 32 and flat washers 33 and remove the platform support 30 Figure 5 64 Figure 5...

Page 227: ...ort 52 from frame Figure 5 67 30 Remove four screws 67 and lock washers 66 and remove front axle assembly 68 from the frame Installation Notes Install the front axle by reversing the order of removal...

Page 228: ...ct for scoring galling and scratches on surfaces Replace parts as necessary Assembly Notes NOTICE Assemble the differential lock assembly by reversing the order of disassembly Lubricate all O rings pr...

Page 229: ...Figure 5 69 Figure 5 69 1 Screw 4 5 Nut Elastic Stop 9 Collapsible Spacer 13 O Ring 2 Bearing Cup Outer 6 Seal Outer 10 Bearing Cup Inner 14 Shim As Required 3 Bearing Cone Outer 7 O Ring 11 Bearing C...

Page 230: ...hims for assembly 2 Remove four screws 1 and remove the input bevel pinion assembly 2 12 O ring 13 and shims 14 from the axle assembly 15 3 Support the pinion housing 8 and inner bearing cone 11 Press...

Page 231: ...5 70 1 Screw 4 5 Nut Elastic Stop 9 Collapsible Spacer 13 O Ring 2 Bearing Cup Outer 6 Seal Outer 10 Bearing Cup Inner 14 Shim As Required 3 Bearing Cone Outer 7 O Ring 11 Bearing Cone Inner 15 Axle...

Page 232: ...it just contacts the collapsible spacer 9 NOTE Lubricate all O rings prior to assembly 6 Install O ring 7 in spacer 4 Install spacer in the housing positioning the O ring against the outer bearing con...

Page 233: ...e right reducer shaft the differential lock collar will slide off the reducer shaft 4 Remove four screws 4 and 6 and remove the reducer assembly 5 from the differential housing 10 5 Remove two dowel s...

Page 234: ...parts in assembly order clean and air dry each item for inspection Inspect for worn or defective parts Inspect all parts for cracks nicks burrs and excessive wear Inspect for scoring galling and scrat...

Page 235: ...tial Lock Assembly on page 5 64 4 Press the reducer shaft 2 bearing 1 assembly into the differential housing 4 sliding the reducer shaft through the differential lock collar 5 Install the differential...

Page 236: ...ousing 23 Make sure the surfaces are dry Apply Loctite Ultra Blue gasket material in a continuous bead around the mating surface making sure to go around each hole 13 Install the dowel sleeves 22 in t...

Page 237: ...Differential Housing Right 5 Differential Lock Collar 9 Ball Bearing 2 13 Differential 2 Screw 8 6 Shim As Required 10 Plug 2 14 Differential Housing Left 3 Breather 7 Shim As Required 11 Hex Head Bol...

Page 238: ...ht hex head bolts 4 Apply Loctite 242 to hex head bolts 4 before assembly Install hex head bolts and tighten to 37 lb ft 51 N m 2 Press ball bearings 1 onto the differential assembly Figure 5 82 3 Ins...

Page 239: ...ings 15 Apply Loctite 242 to eight screws 11 before assembly Install screws and tighten to 37 lb ft 51 N m 16 Install plugs 16 drain plug 19 and seal 18 if removed 17 Install breather 12 If removed 18...

Page 240: ...al housings step 11 of Assembly on page 5 74 Method B See Figure 5 87 Figure 5 87 1 Build a temporary shim pack 2 equal to 0 030 in 0 76 mm and place it on the bearing bore of the right differential h...

Page 241: ...lve 2 Figure 5 89 4 Disconnect hoses 5 and 6 from wheel motor 7 5 Disconnect hose 4 from fitting 8 6 Remove fitting 8 from wheel motor 7 Figure 5 90 7 Remove cotter pin 10 CAUTION 8 Loosen but do not...

Page 242: ...er of removal Apply anti seize compound to the motor shaft threads 14 Be careful not to apply anti seize compound to the motor shaft Tighten castle nut 11 to 175 200 lb ft 237 271 N m Install a new co...

Page 243: ...manifold cover 18 1 Disassemble rear wheel motor as shown 2 Place parts in assembly order on a clean work area as they are removed 1 Seal Exclusion 6 Shaft and Bearing Kit 11 Valve Drive 16 Pin 2 2 B...

Page 244: ...n the outer geroler ring if they are loose 3 Install the valve drive 2 in geroler 1 4 Lubricate the seal and install it in the valve plate 3 5 Align the case drain hole 6 in the valve plate 3 with the...

Page 245: ...Screw 5 Screw 15 Screw 2 25 Traction Pump 35 Tube Traction Return 6 Bracket Traction Return 16 Traction Damper 26 Lock Nut Center 36 Washer 4 7 Nut 3 17 Screw 27 Rod Traction Pump Adjusting 37 Spring...

Page 246: ...ds 24 and 29 from traction pump adjusting rod 27 record the number of turns needed to remove the rod ends to ensure correct assembly 4 Place parts in assembly order on a clean work area as they are re...

Page 247: ...of Operation 6 14 Raise Circuit Schematic 6 15 Lower Circuit Schematic and Theory of Operation 6 16 Lower Circuit Schematic 6 17 Mower Deck Float Circuit Schematic and Theory of Operation 6 18 Mower D...

Page 248: ...alve Pressure 6 42 Right Wing Cutting Unit Motors Test 6 43 Left Wing Cutting Unit Circuit Test 6 46 Left Wing Cutting Unit Pump Test 6 47 Left Wing Cutting Unit Deck Valve Test 6 49 Adjust Left Wing...

Page 249: ...Relief Valve Pressure Setting psi bar 2700 3300 186 228 Left Wing Cutting Unit Deck Valve System Relief Valve Pressure Setting psi bar 2700 3300 186 228 Right Wing Cutting Unit Deck Valve System Reli...

Page 250: ...ght Deck Valve 2 Hydraulic Oil Cooler 3 Hydraulic Oil Tank 4 Charge Pressure Filter 5 Hydraulic Oil Return Filter 6 Gear Pump 7 Left Deck Valve 8 Front Lift Cylinder 2 9 Front Cutting Unit Motor 3 10...

Page 251: ...HYDRAULICS 4203780 First Edition 6 5 6 Figure 6 2 Component Location Right Side 13 Lift Valve 14 Right Wing Cutting Unit Motor 2 15 Right Wing Lift Cylinder 3 4 2 1 TN1769 13 15 14...

Page 252: ...Pump 0 65 ci 3500 psi 1 08 ci 3 Suction Screen 100 Mesh 25 psi Switch Hydraulic Oil Tank 25 psi Crack Bypass Tank Fill Cap Assembly 40 Micron Filter 1 08 ci 1 08 ci 2 48 ci 3500 psi 560 Micron Straine...

Page 253: ...9 ci Right Wheel Motor 2 48 ci Secondary 4WD Shuttle Valve 4WD Reverse Solenoid R1 4WD R2 L2 B C Left Wheel Motor 11 9 ci T Charge Pressure Relief Valve 250 psi Charge Pressure Light Switch 4WD Soleno...

Page 254: ...rst Edition HYDRAULICS 6 Hydraulic Schematic Continued Figure 6 5 TN1734 2 3 4 9 10 11 12 13 14 2 3 4 12 13 10 11 IN Steering Cylinder Relief Valve 1450 psi Steering Unit OUT LT 6 6 ci RT Steering Val...

Page 255: ...lve Front Lift Valve Right Lift Valve Detent Valve Detent Valve Detent Valve TN1735 2 3 4 12 13 10 11 2 3 4 12 10 11 IN 0 060 Orifice OUT 0 060 Orifice 0 060 Orifice 0 060 Orifice Left Wing Cylinder F...

Page 256: ...1 04 ci 1 04 ci 1 04 ci 0 67 0 67 0 67 0 67 0 67 0 67 CCW Inside Right Wing Motor CW Inside Left Wing Motor CCW Outside Left Wing Motor CCW Left Front Motor CW Center Front Motor CW Right Front Motor...

Page 257: ...HYDRAULICS 4203780 First Edition 6 11 6 Page Intentionally Blank...

Page 258: ...teering valve before allowing oil flow to the lift valve to ensure maximum steering control at any engine rpm range Steering Circuit Operating pressure oil enters the steering unit at IN port and is r...

Page 259: ...8 Figure 6 8 1 Operating Pressure Oil from Control Valve Port ST 2 Charge Pressure Oil to Charge Filter TN1716 Operating Pressure Oil Charge Pressure Oil Relief Valve 1450 psi Steering Unit IN OUT LT...

Page 260: ...pens to supply oil to the lift valve The priority valve will supply oil flow to the steering valve before allowing oil flow to the lift valve to ensure maximum steering control at any engine rpm range...

Page 261: ...tch IN 4WD Solenoid 1 Weight Transfer Valve 4WD 2 Differential Lock 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Left Lift Valve Control Valve 165 psi N C Differential Lock Solenoid Priority Va...

Page 262: ...gine rpm range Lower Circuit Operating pressure oil enters the lift valve body at the IN port and flows to the relief valve 1500 psi and to each of the spool valves With the lift lower levers in the L...

Page 263: ...ch IN 4WD Solenoid 1 Weight Transfer Valve 4WD 2 Differential Lock 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Control Valve 165 psi N C Differential Lock Solenoid Priority Valve 4 5 gpm T F C...

Page 264: ...NEUTRAL position oil from the lift cylinders can flow freely in both directions through the detent and spool valves As the cutting units move along the ground they rise and fall with the contour of t...

Page 265: ...t Switch IN 4WD Solenoid 1 Weight Transfer Valve 4WD 2 Differential Lock 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Control Valve 165 psi N C Differential Lock Solenoid Priority Valve 4 5 gpm...

Page 266: ...valve 630 psi Operating pressure oil flows out of the valve body through port A driving the motors Circuit Relief The mow circuit is protected by a pilot operated relief valve The relief valve will o...

Page 267: ...0 psi CW Outside Right Wing Motor P 1 Right Deck Valve 2 1 04 ci 3 Hydraulic Oil Tank 0 67 D 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 0 67 0 67 0 67 0 67 0 67 0 67 CCW Inside Right Wing Motor C...

Page 268: ...i and the solenoid valve With the mow switch es in the OFF position the solenoid valves are de engerized opening the valves Oil can then flow through the valves returning to the hydraulic tank With th...

Page 269: ...0 psi CW Outside Right Wing Motor P 1 Right Deck Valve 2 1 04 ci 3 Hydraulic Oil Tank 0 67 D 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 0 67 0 67 0 67 0 67 0 67 0 67 CCW Inside Right Wing Motor C...

Page 270: ...Install cap on lift cylinder fitting 1 8 Remove support from front cutting unit After 15 minutes does cutting unit drift down YES Cylinder is bypassing oil Replace lift cylinder See Front Lift Cylinde...

Page 271: ...hose 2 7 Install cap on lift cylinder fitting 1 8 Remove support from wing cutting unit After 15 minutes does cutting unit drift down YES Cylinder is bypassing oil Replace lift cylinder See Wing Lift...

Page 272: ...r The right wing cutting unit circuit consists of the right wing cutting unit pump right deck valve right wing inside cutting unit motor and right wing outside cutting unit motor This test determines...

Page 273: ...the front cutting unit pump 10 5 in the front deck valve 20 in the right front cutting unit motor 5 6 in the center front cutting unit motor and 4 4 in the left front cutting unit motor Although all t...

Page 274: ...let and hydraulic line 1 to tee fitting 5 NOTE Make sure hose end is under oil level in hydraulic tank to prevent aeration of oil 6 Secure flow meter outlet hose 3 to the hydraulic tank fillneck WARNI...

Page 275: ...ak Percentage Is front cutting units circuit leakage 10 or less YES The front cutting units circuit is good Proceed to Front Cutting Unit Motors Test on page 6 34 NO Proceed to next question Is front...

Page 276: ...itch NOTE Verify engine rpm is within specification 2800 rpm 50 to ensure accurate hydraulic test results 7 Start engine and run at full throttle 2800 rpm 50 8 Use the flow meter to warm the hydraulic...

Page 277: ...utting unit pump See Gear Pump on page 6 58 Then proceed to Front Cutting Unit Deck Valve Test on page 6 31 Front Cutting Unit Deck Valve Test See Figures 6 22 through 6 24 WARNING 1 Park the mower sa...

Page 278: ...eed to step 12 NO Proceed to next question Is front cutting unit deck valve leakage 11 to 20 YES The front cutting unit deck valve is marginal Additional testing is required Proceed to step 12 NO Proc...

Page 279: ...decrease the pressure setting Turn the screw out counterclockwise 5 Tighten nut 1 Could relief valve be adjusted to 2700 psi 186 bar to 3300 psi 228 bar YES Front cutting unit deck valve system relie...

Page 280: ...ft front cutting unit motor preventing left front cutting unit motor from turning Figure 6 26 5 Open flow meter valve 1 completely Figure 6 27 Front Cutting Unit Motors Test Left Cutting Unit Motor Bl...

Page 281: ...t motor leakage 21 or more YES Repair or replace front cutting unit left motor See Deck Motors on page 6 61 Then proceed to step 12 12 Remove device or tool from front cutting unit left motor WARNING...

Page 282: ...t right motor from turning 24 Open flow meter valve 1 completely Figure 6 29 Front Cutting Unit Motors Test Right Cutting Unit Motor Blocked 25 Bypass seat switch and set park brake NOTE Verify engine...

Page 283: ...test 35 Check hydraulic oil level Add oil as needed Refer to Safety Operation and Maintenance Manual for correct oil specifications Right Wing Cutting Unit Circuit Test See Figures 6 30 through 6 32...

Page 284: ...tion 2800 rpm 50 to ensure accurate hydraulic test results 10 Start engine and run at full throttle 2800 rpm 50 11 Use the flow meter to warm the hydraulic oil Turn the flow meter valve 4 until a read...

Page 285: ...ts in right wing cutting unit circuit for leakage Proceed to Right Wing Cutting Unit Pump Test on page 6 39 Right Wing Cutting Unit Pump Test See Figures 6 33 through 6 35 WARNING 1 Park the mower saf...

Page 286: ...100 Leak Percentage Is right wing cutting unit pump leakage 10 or less YES The right wing cutting unit pump is good Proceed to Right Wing Cutting Unit Deck Valve Test on page 6 40 NO Proceed to next...

Page 287: ...5 Bypass seat switch and set park brake NOTE Verify engine rpm is within specification 2800 rpm 50 to ensure accurate hydraulic test results 6 Start engine and run at full throttle 2800 rpm 50 7 Use t...

Page 288: ...ief valve pressure 2700 psi 186 bar to 3300 psi 228 bar YES Right wing cutting unit deck valve system relief valve is good Proceed to Right Wing Cutting Unit Motors Test on page 6 43 NO Adjust right w...

Page 289: ...tors Performing this test will isolate the right wing cutting unit motors from the rest of the right wing cutting units circuit WARNING 1 Park the mower safely See Park Mower Safely on page 1 6 2 Befo...

Page 290: ...alve test Step 9 Step 9 of right wing cutting unit deck valve test x 100 Leak Percentage Is right wing cutting unit outside motor leakage 10 or less YES The right wing cutting unit outside motor is go...

Page 291: ...1 Calculate right wing cutting unit inside motor leakage Step 9 Step 19 Step 9 x 100 Leak Percentage Is right wing cutting unit inside motor leakage 10 or less YES The right wing cutting unit inside m...

Page 292: ...ose 1 to tee fitting 5 NOTE Make sure hose end is under oil level in hydraulic tank to prevent aeration of oil 6 Secure flow meter outlet hose 3 to the hydraulic tank fillneck WARNING 7 Install suitab...

Page 293: ...Is left wing cutting unit circuit leakage 10 or less YES The left wing cutting unit circuit is good Proceed to Left Wing Cutting Unit Motors Test on page 6 52 NO Proceed to next question Is left wing...

Page 294: ...ke NOTE Verify engine rpm is within specification 2800 rpm 50 to ensure accurate hydraulic test results 6 Start engine and run at full throttle 2800 rpm 50 7 Use the flow meter to warm the hydraulic o...

Page 295: ...mp leakage 21 or more YES Repair or replace left wing cutting unit pump See Gear Pump on page 6 58 Then proceed to Left Wing Cutting Unit Deck Valve Test on page 6 49 Left Wing Cutting Unit Deck Valve...

Page 296: ...disengage switches and stop engine 11 Calculate left wing cutting unit deck valve leakage Step 9 of previous test Step 9 Step 9 of previous test x 100 Leak Percentage Is left wing cutting unit deck va...

Page 297: ...it Deck Valve Test on page 6 49 Figure 6 52 3 Loosen nut 1 4 Rotate screw 2 to adjust the relief valve pressure setting To increase the pressure setting Turn the screw in clockwise To decrease the pre...

Page 298: ...NING 4 Install suitable blocking device or tool in left wing cutting unit inside motor preventing left wing cutting unit inside motor from turning Figure 6 53 5 Open flow meter valve 1 completely Figu...

Page 299: ...ep 12 NO Proceed to next question Is left wing cutting unit inside motor leakage 21 or more YES Repair or replace left wing cutting unit inside motor See Deck Motors on page 6 61 Then proceed to step...

Page 300: ...pment Install all hoses and fittings as noted prior to removal 24 Install and connect all components as noted prior to test 25 Check hydraulic oil level Add oil as needed Refer to Safety Operation and...

Page 301: ...accurate hydraulic test results 11 Start engine and run at full throttle 2800 rpm 50 CAUTION 12 Turn the steering wheel fully right against stop 13 Record pressure reading 14 Stop engine Is steer syst...

Page 302: ...er outlet test hose 3 to hose 1 6 Open flow meter valve 4 completely Figure 6 60 Lift Steer Pump Test 7 Set park brake NOTE Verify engine rpm is within specification 2800 rpm 50 to ensure accurate hyd...

Page 303: ...Percentage Is lift steer pump leakage 10 or less YES The lift steer pump is good Proceed to step 14 NO Proceed to next question Is lift steer pump leakage 11 to 20 YES The lift steer pump is marginal...

Page 304: ...on Notes Ensure new O ring is in place before installing hose on fitting Connect hose 1 Replace hydraulic oil return filter See Hydraulic Oil Return Filter on page 6 67 Replace charge pressure filter...

Page 305: ...new O rings are in place before installing hoses on fittings Replace hydraulic oil return filter See Hydraulic Oil Return Filter on page 6 67 Replace charge pressure filter See Charge Pressure Filter...

Page 306: ...Ring 8 5 Coupling 3 9 Screw 8 13 Front Cover Flange 2 Pre Load Seal 4 6 Gear Set 3 10 Dowel Pin 8 14 Shaft Seal 3 Load Seal 4 7 Gear Plate 4 11 Body 3 4 Wear Plate 8 8 Rear Cover Assembly 12 Gear Set...

Page 307: ...pump one section at a time building up from flange section Remove alignment mark from gear sets after gears have been installed with teeth in proper mesh Rotate drive shaft by hand after assembling ea...

Page 308: ...gs with caps or plugs to prevent contamination 5 Disconnect hydraulic tube 4 6 Disconnect hydraulic hoses 5 8 7 Support lift valve 2 8 Remove nuts lock washers and mounting screws 1 9 Remove lift valv...

Page 309: ...ug 3 16 Retaining Ring 3 23 Detent Plunger 3 3 Spring 3 10 Plug 17 Spacer 3 24 Detent Spring 3 4 Poppet 3 11 Shim 3 18 Spring 3 25 O Ring 3 5 Seat 3 12 Spring 19 Washer 3 26 Plug 3 6 Plunger 13 Poppet...

Page 310: ...connector 3 from solenoid NOTES Label all hydraulic hoses and tubes before disconnecting to aid in installation Close all openings with caps or plugs to prevent contamination 5 Disconnect hydraulic ho...

Page 311: ...oses and tubes before disconnecting to aid in installation Close all openings with caps or plugs to prevent contamination 5 Disconnect hydraulic hoses 1 3 6 Disconnect hydraulic hoses 8 and 9 7 Suppor...

Page 312: ...nnect hydraulic hoses 1 3 and 4 6 Disconnect hydraulic tube 9 7 Support the deck valve 2 8 Remove the mounting screws 5 washers 6 and nuts 7 9 Remove the deck valve 2 Installation Notes Install the de...

Page 313: ...ic Oil Return Filter Removal and Installation See Figure 6 72 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise engine hood 3 Drain hydraulic oil tank See Hydraulic Oil Tank Drain Proc...

Page 314: ...on See Figure 6 73 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise engine hood 3 Drain hydraulic oil tank See Hydraulic Oil Tank Drain Procedure on page 6 58 Figure 6 73 4 Disconnect...

Page 315: ...with caps or plugs to prevent contamination 3 Disconnect hydraulic hoses 3 4 Support lift cylinder 1 5 Remove pins 2 and 4 6 Remove lift cylinder 1 Installation Notes Install lift cylinder by reversi...

Page 316: ...her a threaded gland or snap ring gland Determine which type of cylinder was used and disassemble as needed Figure 6 75 Threaded Gland 1 Grease Fitting 2 5 Seal 9 O Ring 13 Piston 2 Barrel 6 Rod Guide...

Page 317: ...d 1 Grease Fitting 2 5 Piston 9 Rod 13 Rod Seal 2 Barrel 6 O Ring 2 10 Lock Ring 14 Rod Guide 3 Nut 7 Backup Washer 11 Lock Ring 15 O Ring 4 Seal Ring 8 Spacer 12 Wiper 16 O Ring TN1840 7 5 11 15 8 14...

Page 318: ...ydraulic oil before assembly Assemble the lift cylinder by reversing the order of disassembly Torque nut to 50 lb ft 68 N m During repair of the cylinder use extreme care not to damage the barrel pist...

Page 319: ...caps or plugs to prevent contamination 2 Disconnect hydraulic hoses 3 and 5 3 Support lift cylinder 2 4 Remove pins 1 and 4 5 Remove lift cylinder 2 Installation Notes Install lift cylinder by revers...

Page 320: ...her a threaded gland or snap ring gland Determine which type of cylinder was used and disassemble as needed Figure 6 78 Threaded Gland 1 Grease Fitting 2 5 Seal 9 O Ring 13 Piston 2 Barrel 6 Rod Guide...

Page 321: ...d 1 Grease Fitting 2 5 Piston 9 Rod 13 Rod Seal 2 Barrel 6 O Ring 2 10 Lock Ring 14 Rod Guide 3 Nut 7 Backup Washer 11 Lock Ring 15 O Ring 4 Seal Ring 8 Spacer 12 Wiper 16 O Ring TN1840 7 5 11 15 8 14...

Page 322: ...ydraulic oil before assembly Assemble the lift cylinder by reversing the order of disassembly Torque nut to 95 lb ft 129 N m During repair of the cylinder use extreme care not to damage the barrel pis...

Page 323: ...age 9 13 4 Drain hydraulic oil tank See Hydraulic Oil Tank Drain Procedure on page 6 58 Figure 6 80 NOTES Label all hydraulic hoses and tubes before disconnecting to aid in installation Close all open...

Page 324: ...DRAULICS 6 Figure 6 82 13 Remove charge pressure filter bracket 14 14 Remove tank straps 17 15 Support the hydraulic oil tank 16 16 Remove hydraulic oil tank back supports 15 17 Remove the hydraulic o...

Page 325: ...il Return Filter on page 6 67 Refill hydraulic oil tank Refer to Safety Operation and Maintenance Manual for oil specifications Start engine Check hydraulic oil tank for leaks and repair as necessary...

Page 326: ...6 80 4203780 First Edition HYDRAULICS 6 Page Intentionally Blank...

Page 327: ...ent Location 7 3 Tests and Adjustments 7 4 Steering Linkage Adjustments 7 4 Steering Relief Valve Pressure Test 7 6 Steering Leakage Test 7 7 Repair 7 8 Steering Wheel 7 8 Steering Valve 7 8 Steering...

Page 328: ...xle Stop Measurement in mm 0 030 0 060 0 76 1 5 Repair Specifications Steering Wheel Nut lb ft N m 28 30 38 41 Steering Valve Rotor to Stator Clearance in mm 0 003 0 08 Steering Valve Metering Assembl...

Page 329: ...203780 First Edition 7 3 7 Component Location See Figure 7 1 Figure 7 1 1 Tie Rod 3 Steering Cylinder 5 Steering Wheel 2 Steering Axle 4 Tilt Lever 6 Steering Valve 7 Steering Console 4 5 7 TN1767 185...

Page 330: ...nd 4 on both sides of the tie rod 3 b Turn the tie rod 3 as needed to obtain proper toe in 1 c Retighten the tie rod clamp bolts nuts 2 and 4 d Proceed to Turning Radius Equal Angle Adjustment Turning...

Page 331: ...ning radius equal angle adjustments have been performed See Tie Rod Adjustment on page 7 4 and Turning Radius Equal Angle Adjustment on page 7 4 1 Park the mower safely See Park Mower Safely on page 1...

Page 332: ...14 NO Proceed to next step 12 Raise the decks and hold the joystick in the raise position 13 Record pressure reading Is lift steer system relief pressure 1500 psi 103 bar reached YES Relief valve is...

Page 333: ...O Repair or replace steering cylinder See Steering Cylinder on page 7 21 8 Disconnect and plug hose 1 9 Start the engine and set engine speed to full throttle 2850 50 rpm 10 Turn the steering wheel fu...

Page 334: ...val Tighten the steering wheel nut 3 to 28 30 lb ft 38 41 N m Steering Valve Removal and Installation See Figures 7 12 through 7 17 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove t...

Page 335: ...oses and record their locations to ensure correct installation Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil 9 Disconnect hydraulic hose 9 from steering valve port LT 10 Di...

Page 336: ...14 Figure 7 17 Installation Notes Install the steering valve by reversing the order of removal When installing the tilt lever 19 screw the lever in until tight and then back the lever off to the posi...

Page 337: ...he steering valve to the service fixture using four nuts 3 IMPORTANT Scribe a line from the top to the bottom of the steering valve assembly not including the steering tube Use the scribed line for re...

Page 338: ...r 38 Input Shaft 6 Ball 9 32 inch 17 Spring 3 28 Drive Plate 39 Retaining Ring 7 Port Manifold 18 Seal Ring 29 Spacer Thrust Bearing 40 Upper Cover and Jacket Assembly 8 Seal Ring 4 19 Metering Ring 3...

Page 339: ...package 20 28 and commutator seal 31 The metering package is serviced as an assembly kit Refer to the Parts Maintenance Manual NOTE The metering package should be disassembled for inspection purposes...

Page 340: ...Stator 38 Input Shaft 6 Ball 9 32 inch 17 Spring 3 28 Drive Plate 39 Retaining Ring 7 Port Manifold 18 Seal Ring 29 Spacer Thrust Bearing 40 Upper Cover and Jacket Assembly 8 Seal Ring 4 19 Metering R...

Page 341: ...rive link 14 for wear and damage 7 Inspect the thrust bearing 30 for dents spalling and missing rollers 8 Discard all seals and seal rings 9 Inspect the commutator cover 21 and drive plate 28 for wear...

Page 342: ...ft 6 Ball 9 32 inch 17 Spring 3 28 Drive Plate 39 Retaining Ring 7 Port Manifold 18 Seal Ring 29 Spacer Thrust Bearing 40 Upper Cover and Jacket Assembly 8 Seal Ring 4 19 Metering Ring 30 Thrust Beari...

Page 343: ...h the aligning pin holes facing up Place a few drops of oil in each recess of the commutator 48 NOTE Make sure the alignment pins 49 are pressed below the surface of the commutator 48 11 Align the fiv...

Page 344: ...gs Install the seal ring 18 Figure 7 26 26 Place the three springs 17 in the port manifold 7 27 Carefully place the port manifold 7 springs down onto the valve ring 9 28 Install the O ring 5 and seal...

Page 345: ...ocations to ensure correct installation 10 Disconnect console harness connector 18 from wiring harness NOTES Label all hydraulic hoses and record their locations to ensure correct installation Plug hy...

Page 346: ...console 25 17 Remove nut 27 lock washer 26 and bolt 24 Remove the console 25 from the support 29 18 Remove the console cover assembly 28 from the support 29 19 Inspect the bushing 31 Replace as neede...

Page 347: ...s 7 35 through 7 37 1 Park the mower safely See Park Mower Safely on page 1 6 2 Thoroughly clean the area surrounding the steering cylinder especially the hydraulic hose fittings Figure 7 35 NOTES Lab...

Page 348: ...nd clamps 14 and 16 from steering cylinder 15 10 Inspect ball joints Replace as needed Installation Notes Install the steering cylinder by reversing the order of removal Using information recorded dur...

Page 349: ...backup rings 5 from piston 4 6 Remove O ring 7 rod seal 9 and rod wiper 10 from rod guide 12 7 Remove O ring 14 from rod 15 WARNING 1 Barrel 5 Backup Ring 2 9 Rod Seal 13 Snap Ring Small 2 Nut 6 O Rin...

Page 350: ...embly 1 Installation Notes Install the tie rod by reversing the order of removal Before installing the tie rod assembly verify that the ball joint tapers and the mating tapered surfaces in the steerin...

Page 351: ...versing the order of disassembly Using information recorded during disassembly install ball joints into tie rod with the correct number of turns Apply grease to grease fittings 9 1 Castle Nut 5 Tie Ro...

Page 352: ...1 Cotter Pin 5 Hose Left 9 Lock Washer 13 Steering Axle Assembly 2 Castle Nut 6 Hex Head Bolt 10 Nut 14 Hose Right 3 Thrust Washer 3 7 Frame Bracket Rear 11 Pivot Steering Axle 15 Steering Cylinder 4...

Page 353: ...11 and rear frame bracket 7 6 Remove cotter pin 1 and castle nut 2 and remove steering axle pivot 11 and thrust washers 3 from steering axle assembly 13 and frame brackets 4 and 7 7 Remove steering a...

Page 354: ...ushing Mount Pivot 4 12 Cotter Pin 4 17 Axle 3 Socket Head Screw 2 8 Grease Fitting 2 13 Motor Mount 2 18 Castle Nut 2 4 Hex Nut 2 9 Thrust Bearing 2 14 Steering Arm Left 19 Steering Cylinder 5 Bushin...

Page 355: ...lation Before installing the steering cylinder assembly verify that the ball joint tapers and the mating tapered surfaces in the steering arm and rear axle are free of burrs dirt and debris DO NOT app...

Page 356: ...7 30 4203780 First Edition STEERING 7 Page Intentionally Blank...

Page 357: ...k Leveling Adjustment 8 4 Deck Rake Adjustment 8 4 Final Adjustments 8 6 Troubleshooting 8 7 Mechanical Troubleshooting 8 7 Quality of Cut Troubleshooting 8 8 Repair 8 16 Deck Motor 8 16 Blade 8 18 Fr...

Page 358: ...8 2 4203780 First Edition CUTTING UNITS 8 Specifications Repair Specifications Specifications Blade Retaining Screw lb ft N m 75 100 Adapter Screws lb ft N m 35 40 47 54...

Page 359: ...er Wing Caster Arm 2 10 Fixed Caster Wheel Assembly 2 2 Deck Motor 7 6 Wing Lift Arm 2 11 Anti Scalp Wheel 4 3 Right Wing Deck Assembly 7 Outer Wing Caster Arm 2 12 Front Deck Assembly 4 Front Deck Li...

Page 360: ...s should be level and parallel to the deck shell as shown This will bring the decks close to the actual height of cut range Tighten all caster wheel arms in this leveled position Deck Rake Adjustment...

Page 361: ...right push arms Wing Decks See Figure 8 5 Figure 8 5 NOTE Each swiveling caster wheel is assembled with at least two 1 8 inch flat washers 1 along with the 1 2 inch height of cut spacers 2 1 Install...

Page 362: ...f cut spacer Add 1 8 inch shim to lift arm to maintain proper deck rake 3 If front deck is cutting higher you may have to loosen the caster wheel arms and lower the deck to the next position Retighten...

Page 363: ...witch is faulty Test front mow enable switch See Front Mow Enable Switch Test on page 4 78 Front right or left mow solenoid is faulty Test mow solenoids See Solenoids Test on page 4 83 See Mow Circuit...

Page 364: ...available where test cuts can be made This area should provide known and consistent turf conditions to allow accurate evaluation of the mower s performance Another test cut should be performed after...

Page 365: ...the turf Probable Cause Remedy Mowing ground speed is too fast Reduce mowing ground speed Improper tire pressure Set front machine tires at 20 psi rear machine tires at 10 psi and caster tires at 23...

Page 366: ...HOC adjustment of cutting units Front deck and wing deck are not level Level decks See Deck Leveling Adjustment on page 8 4 Worn deck caster wheels or deck swivel caster wheels Check replace caster wh...

Page 367: ...hine tires at 10 psi and caster tires at 23 psi HOC height of cut settings are lower than normal Check and adjust the HOC settings See Deck Leveling Adjustment on page 8 4 Front deck and wing deck are...

Page 368: ...d blades of uncut or poorly cut grass Probable Cause Remedy Dull cutting blade s Replace or sharpen blade s Refer to Safety Operation and Maintenance Manual Mowing ground speed is too fast Reduce mowi...

Page 369: ...lade s Replace blade s See Blade on page 8 18 Turning too aggressively Cutting units don t overlap during turns or on side hills Turn less aggressively to allow cutting units to overlap Change mowing...

Page 370: ...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...

Page 371: ...res at 23 psi HOC inconsistent from one cutting unit to another Check adjust HOC on cutting units to same height Refer to Safety Operation and Maintenance Manual Check condition of deck and or frame R...

Page 372: ...e all openings with caps or plugs to prevent contamination 4 Remove hydraulic hoses 1 2 and 7 Close all openings using caps and plugs 5 Remove the six nuts 3 lock washers 4 flat washers 5 and carriage...

Page 373: ...r on page 8 16 CAUTION 4 After removing screws disassemble motor 5 Place parts in assembly order on a clean work area as they are removed 1 Cover 5 Motor Body 9 Shaft Key 13 Small Snap Ring 2 Backing...

Page 374: ...Park Mower Safely on page 1 6 2 Raise and support the cutting units Refer to Safety Operation and Maintenance Manual 3 Disconnect the negative battery cable at the battery Figure 8 8 CAUTION 4 Remove...

Page 375: ...eck Motor on page 8 16 3 Remove torsion clip 1 clevis pin 2 and bushing 3 4 Remove height of cut adjustment pins 4 5 Roll the cutting unit forward away from machine Repair as needed Installation Notes...

Page 376: ...Screw 30 Shaft 3 Flat Washer 2 10 Motor 3 17 Lock Nut 24 Plate 31 Lock Washer 4 Caster Arm 11 Decal 5 18 Key 3 25 Carriage Bolt 32 Nut 5 Lock Washer 3 12 Rubber Stop 19 Adapter 3 26 Screw 33 Front Dec...

Page 377: ...n left side is similar 1 Lower front deck to the ground and park the mower safely See Park Mower Safely on page 1 6 2 Remove front deck See Front Deck on page 8 19 Figure 8 11 3 Remove screw 2 lock wa...

Page 378: ...9 Lock Washer 2 16 Flat Washer 2 23 Bumper 30 Screw 3 Pin 2 10 Washer 17 Lift Cylinder 24 Screw 31 Shaft 4 Screw 11 Bracket 18 Grease Fitting 25 Actuator Arm 32 Pin 5 Bracket 12 Flat Washer 2 19 Lift...

Page 379: ...ock washer 7 nut 8 and lock pin 2 NOTE The deck pivot pin contains two shim washers not shown at both ends of the pin between the mounting brackets 4 and pivot casting 3 Be sure to note the shim locat...

Page 380: ...ew 2 10 Reflector 17 Carriage Bolt 24 Screw 2 31 Screw 4 Flat Washer 4 11 Decal 3 18 Key 2 25 Carriage Bolt 32 Wing Deck 5 Lock Washer 4 12 Lock Washer 19 Nut 4 26 Lock Nut 33 Motor 2 6 Nut 2 13 Nut 2...

Page 381: ...the mower safely See Park Mower Safely on page 1 6 2 Remove wing deck See Wing Decks on page 8 23 Figure 8 16 3 Remove screw 8 collar 7 and nut 6 4 Remove pivot 1 from the lift arm 5 along with two sp...

Page 382: ...crew 30 Screw 4 Wing Deck Lift Arm 13 Magnet 22 Shaft 31 Rubber Stop 2 5 Nut 2 14 Flat Washer 23 Pin 32 Grease Fitting 3 6 Lock Washer 15 Lock Washer 24 Pin 33 Screw 7 Flat Washer 16 Screw 25 Lock Was...

Page 383: ...and support cutting deck using jackstands Figure 8 19 3 Support caster wheel assembly 6 4 Remove lock pin 2 5 Slide the top flat washers 3 caster wheel spacer 4 and height of cut spacers 5 off yoke 1...

Page 384: ...Removal and Installation See Figure 8 21 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise and support cutting deck using jackstands Figure 8 21 3 Remove screw 1 lock washer 2 and nut...

Page 385: ...tallation See Figure 8 23 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise and support cutting deck using jackstands Figure 8 23 3 Remove screw 1 lock washer 2 and nut 3 4 Remove cott...

Page 386: ...r or damage Replace as necessary Assembly Notes Inspect cotter pin for damage before assembly Assemble anti scalp wheel in reverse order of disassembly 1 Anti Scalp Wheel 2 7 Cotter Pin 2 Spacer 2 8 B...

Page 387: ...ents 9 4 Park Brake Adjustment 9 4 Brake Pedal Adjustment 9 4 Bleed Brake System 9 5 Repair 9 5 Canopy 9 5 OPS 9 6 Hood 9 6 Fuel Tank 9 7 Traction Pedal 9 9 Park Brake 9 11 Seat and Seat Platform 9 13...

Page 388: ...162 Rear Tires Size 23 x 10 50 12 Type 4 Ply Air Pressure psi bar 8 10 55 69 Mounting Bolt Torque lb ft N m 40 50 54 68 Mower Speed Transport 2WD mph km h 0 15 0 24 Transport 4WD mph km h 0 8 4 0 13 5...

Page 389: ...Component Location See Figure 9 1 Figure 9 1 1 OPS Operator Protective Structure 6 Front Wheel 2 2 Seat and Seat Platform 7 Differential Lock Switch 3 Hood 8 Brake Pedal 4 Park Brake 9 Traction Pedal...

Page 390: ...stment knob If a scale is not available for measuring place tractor in 2WD mode and adjust brake until motor cannot overcome the park brake NOTES If the knob on the park brake has been turned to its m...

Page 391: ...se brake pedal slowly 7 Repeat steps 2 through 5 until all the air has been bled from the brake line 8 Repeat steps 2 through steps 7 for the other caliper bleed screw 9 Repeat steps 2 through steps 8...

Page 392: ...6 and slide toward rear of mower until OPS clears the end of the mower Installation Notes Install OPS by reversing the order of removal Tighten OPS mounting bolts to 135 165 lb ft 183 224 N m Hood Rem...

Page 393: ...uel cap to provide a vent for draining fuel 5 When fuel tank is completely empty close tank drain valve and tighten fuel cap 6 Close fuel outlet hose shutoff valve 1 Turn clockwise until valve bottoms...

Page 394: ...the mower Installation Notes Apply anti seize to the fuel tank screws 11 Install the fuel tank by reversing the order of removal Use only clean diesel fuel of the correct type 2 diesel from a clean se...

Page 395: ...2 5 Flat Washer 2 16 Flat Washer 2 27 Nut 2 6 Traction Pedal Mounting Bracket 17 Bushing 2 28 Ball Joint 2 7 Traction Pedal Pivot Rod 18 Traction Bell Crank 29 Traction Pedal Adjusting Rod 8 Cotter P...

Page 396: ...spect ball joints for binding or excess free play replace as necessary 8 Unplug reverse kick out switch 22 and remove two nuts 23 lock washers 24 and flat washers 11 to remove reverse kick out switch...

Page 397: ...ar Cable Guide Pulley Bracket 5 Park Brake Caliper 15 Screw 2 25 Spacer 5 35 Lock Washer 4 6 Park Brake Release Spring 16 Flat Washer 2 26 Park Brake Lever 36 Nut 4 7 Park Brake Caliper Bracket 17 Par...

Page 398: ...able pulley 32 flat washer 31 and screw 18 from the rear cable guide pulley bracket Inspect the park brake cable pulley and spacer for wear replace as necessary 16 Remove the nut 36 lock washer 35 spa...

Page 399: ...ont wheels and disengage park brake 3 to allow clearance for seat removal Figure 9 18 5 Tag and disconnect the operator s seat switch wire harness connector 5 6 Using a suitable lifting device slide s...

Page 400: ...19 Roll Pin 27 Lock Washer 4 Armrest Right Hand 12 Seat Suspension Mini 20 Knob 28 Flat Washer 5 Seat Switch 13 Spacer 21 Seat Pan 29 Trim Seal 6 Lock Washer 14 Flat Washer 22 Foam Top 30 Spring 7 Sc...

Page 401: ...st Edition 9 15 9 Figure 9 20 Mini Seat Suspension 1 Push Nut 4 6 Spring Hanger 11 Nut 2 Pivot Shaft 2 7 Lock nut 12 Spring Kit 3 Knob 8 Spring 2 13 Screw 4 Flat Washer 9 Bearing 4 5 Bumper 2 10 Lock...

Page 402: ...Brake Pedal on page 9 19 7 Remove park brake See Park Brake on page 9 11 8 Remove diff lock switch See Diff Lock Switch on page 4 100 9 Remove work light kit if equipped See Work Light Kit on page 9 1...

Page 403: ...ctor Adjust the work lights to project the desired distance in front of the mower Rear Wheels Removal and Installation See Figure 9 25 1 Park the mower safely See Park Mower Safely on page 1 6 Figure...

Page 404: ...4 Raise and support front of mower with jackstands 5 Remove lug nuts 3 6 Remove wheel 2 and inspect tread area for tears or other damage 7 Replace tire if damage is excessive Installation Notes Inspe...

Page 405: ...brake lever Clean grease fitting 5 before and after lubricating Lubricate grease fitting with grease that meets or exceeds NLGI Grade 2 LB specifications Apply grease with a manual grease gun and fill...

Page 406: ...tes Install the master cylinder by reversing the order of removal Bleed the brake system See Bleed Brake System on page 9 5 Brake Caliper Removal and Installation See Figure 9 30 1 Park the mower safe...

Page 407: ...31 NOTE Inspect and clean any rust from pad retaining pins 3 Apply anti seize compound to pad retaining pins and ensure pad retaining pins slide freely 1 Brake Caliper 4 Brake Pad Set 2 Caliper Seal...

Page 408: ...9 22 4203780 First Edition ACCESSORIES AND MISCELLANEOUS REPAIR 9 Page Intentionally Blank...

Page 409: ...p Wheels Disassembly and Assembly 3 30 Removal and Installation 3 29 Repair 3 29 B Battery Removal and Installation 4 85 Repair 4 85 Blade Removal and Installation 3 18 Repair 3 18 Brake Caliper Disas...

Page 410: ...shooting 4 66 Cruise Control Disable Schematic 4 47 Cruise Control Magnet Removal and Installation 4 108 Repair 4 108 Cruise Control Switch Removal and Installation 4 98 Repair 4 97 Test 4 80 Cutting...

Page 411: ...03 Engine Service Repair 3 20 Engine Speed Sensor Removal and Installation 4 110 Repair 4 110 Engine Temperature Gauge Removal and Installation 4 94 Repair 4 94 Engine Temperature Sensor Removal and I...

Page 412: ...15 Repair 3 15 Fuel Gage Removal and Installation 4 111 Repair 4 111 Fuel Level Sensor Removal and Installation 4 113 Repair 4 113 Test 4 82 Fuel Pump Removal and Installation 3 16 Repair 3 16 Test 4...

Page 413: ...ction Linkage Adjustments 5 29 Traction Pedal Neutral Adjustment 5 29 Troubleshooting 5 26 I Indicator Lights Removal and Installation 4 95 Repair 4 95 Input Bevel Pinion Assembly Assembly 5 67 Disass...

Page 414: ...ls 4 6 Mow Circuit Schematic 4 37 Theory of Operation 4 36 Troubleshooting 4 63 Mower Identification Engine Serial Number 2 3 Optional Machine Accessories 2 3 Serial Number 2 2 Specifications and Gene...

Page 415: ...ir 3 11 Rear Axle Disassembly Inspection and Assembly 2 28 Removal and Installation 2 26 Repair 2 26 Rear Wheel Motor Disassembly Inspection and Assembly 5 79 Motor Timing Assembly 5 80 Removal and In...

Page 416: ...nable Switch 4 97 Front Mow Solenoid 4 105 Front Wheels 4 18 Fuel Filter 3 15 Fuel Gage 4 111 Fuel Level Sensor 4 113 Fuel Pump 3 16 Fuel Shutoff Solenoid 4 108 Fuel Tank 4 7 Gear Pump 6 58 Glow Plug...

Page 417: ...ucts Handling 1 9 Compressed Air and Air Tools 1 7 Cooling System Safety 1 9 Electrical Components 1 10 Fuel Handling 1 8 Hydraulic System Service 1 9 Introduction 1 2 Keep Work Area Clean 1 6 Keep Wo...

Page 418: ...General Information 2 10 Start Circuit Schematic 4 29 Theory of Operation 4 28 Troubleshooting 4 62 Starter Motor Removal and Installation 4 86 Repair 4 86 Steering Component Location 2 3 Repair 2 8...

Page 419: ...ge Adjustments 5 29 Weight Transfer Adjustment 5 32 Theory of Operation Charging Circuit 4 34 Cruise Control 4 44 Four Wheel Drive Circuit 4 40 Glow Plug Circuit 4 26 Horn Test Circuit 4 58 Instrument...

Page 420: ...Alert Circuit 4 71 Hydrostatic Power Train 5 26 Instrumentation Circuit 4 67 Mechanical Troubleshooting 3 7 Mow Circuit 4 63 Quality of Cut Troubleshooting 3 8 Run Circuit 4 63 Start Circuit 4 62 Wor...

Page 421: ......

Page 422: ...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...

Page 423: ......

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