Textron JACOBSEN R-311 69166 Technical/Repair Manual Download Page 219

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4203781 First Edition

HYDROSTATIC POWER TRAIN

NOTICE

• Assemble the control valve by reversing the order of

disassembly.

• Lubricate all O-rings prior to assembly.

• It is important that all component parts 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 compressed air.

Required Materials

• Seal Kit, Relief Valve (Jacobsen PN 5003579)

• Seal Kit, Flow Control Valve (Jacobsen PN 556845)

• Seal Kit, Solenoid Valve—4WD

(Jacobsen PN 5003578)

Summary of Contents for JACOBSEN R-311 69166

Page 1: ...R 311 Rotary Mower Technical Repair Manual 69166...

Page 2: ...se 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 servi...

Page 3: ......

Page 4: ...nual 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 C...

Page 5: ...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 6: ...6 7 8 Table of Contents 4203781 First Edition 5 1 Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneo...

Page 7: ......

Page 8: ...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 9: ...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 10: ...SAFETY 4203781 First Edition 1 3 1 Figure 1 1 TN2166 TN2167 6 7 8 9 2 5 4 10 1 2 3...

Page 11: ...1 4 4203781 First Edition SAFETY 1 4181865 5 1 2 4181863 3 NOTICE Do NOT fold this ROPS if a canopy is attached Damage to the mower hood could result 4...

Page 12: ...SAFETY 4203781 First Edition 1 5 1 4181862 4199140 Fill fuel tank to 2 inches below filler neck DO NOT OVERFILL CAUTION 365919 8 10 6 9 4181861 7...

Page 13: ...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 from...

Page 14: ...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 15: ...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 16: ...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 17: ...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 18: ...n Mower Identification 2 2 Serial Number 2 2 Engine Serial Number 2 3 Optional Machine Accessories 2 3 Component Location 2 4 Specifications 2 6 Quick Reference Specifications 2 6 Standard Torque Valu...

Page 19: ...the serial number 3 is attached to the frame of the mower 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 r...

Page 20: ...de number There is also an engine data tag 6 attached to the top of the rocker arm cover and information that can be found on the plate includes valve adjustment specifications injector timing informa...

Page 21: ...ent Location Right Side Become familiar with operator controls machine components and correct operating procedures before beginning repair procedures 1 Seat 6 Left Cutting Unit 2 Instrument Panel 7 Ce...

Page 22: ...ATIONS AND GENERAL INFORMATION 4203781 First Edition 2 5 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 TN2167 6 4...

Page 23: ...nce 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 In Coil at 68 F ohms 0 5 10 Resistanc...

Page 24: ...46 2 at 2800 rpm Lift Steer Pump Flow gpm lpm 9 1 34 5 at 2800 rpm Hydraulic Leakage Percentage Ranges 0 10 Good 11 20 Marginal 21 and beyond Bad Lift System Relief Valve Pressure Setting psi bar 1500...

Page 25: ...b in N m 7 5 10 10 13 Steering Unit End Cover to Housing Screw Torque lb ft N m 20 24 27 33 Steering Cylinder Ball Joint to Steering Arm Torque lb ft N m 40 54 Tie Rod Ball Joint to Steering Arm Torqu...

Page 26: ...l Pivot Screw Torque lb ft N m 9 12 2 Engine Manufacturer Model Kubota Tier 3 V2203 M E3B Engine Type 4 stroke diesel Fuel Requirement No 2 D diesel fuel Cetane Rating 45 Number of Cylinders Configura...

Page 27: ...GENERAL INFORMATION 2 Weights and Dimensions Overall Weight lb kg 3970 1801 Width of Cut in mm 134 3404 Overall Width in mm 139 3531 Overall Height with OPS in mm 84 2134 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: ...2 12 4203781 First Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Page Intentionally Blank...

Page 30: ...ocation 3 3 Kubota V2203 M E3B 3 3 Checks and Adjustments 3 5 Throttle Cable 3 5 Purging the Fuel System 3 6 Repair 3 7 Fan Belt 3 7 Air Cleaner Assembly 3 8 Muffler 3 8 Exhaust Manifold 3 9 Radiator...

Page 31: ...4 in line Displacement cu in cc 134 1 2198 Bore x Stroke in mm 3 43 x 3 64 87 x 92 Power Output hp kW 44 9 33 5 2600 rpm Firing Order 1 3 4 2 Compression Ratio 22 1 Injection Timing Before T D C 18 Co...

Page 32: ...de 1 Hydraulic Oil Cooler 6 Coolant Overflow Reservoir 11 Engine Coolant Temp Switch 2 Engine Oil Cooler 7 Hydraulic Oil Filter 2 12 Fan Drive Belt 3 Radiator 8 Oil Pressure Sending Unit 13 Engine Tem...

Page 33: ...First Edition ENGINE 3 Figure 3 2 Component Location Left Side 1 Hydraulic Tank 3 Engine Oil Fill Cap 5 Oil Filter 7 Fuel Filter 2 Air Cleaner Service Switch 4 Radiator Cap 6 Throttle Cable TN2124 1...

Page 34: ...n 1 mm of clearance between the top of the throttle cable slot 8 and the throttle handle stud 9 8 Tighten nuts 11 Figure 3 5 9 Check throttle for ease of movement and adjust throttle tension with lock...

Page 35: ...the air vent screw hole tighten air vent screw and turn ignition switch to the off position 6 Open the air vent plug 2 on the fuel injection pump 7 Turn the ignition switch to the ON position to allo...

Page 36: ...the engine to loosen the belt 1 Figure 3 9 5 Remove the fan belt 1 from the alternator 3 coolant pump 6 and crankshaft pulley 5 Installation Note Install the fan drive belt by reversing the order of...

Page 37: ...embly Installation Notes Install air cleaner in the reverse order of removal If a new element is installed use a new gasket 4 Muffler Removal Inspection and Installation See Figures 3 12 and 3 13 CAUT...

Page 38: ...the reverse order of removal Install new gaskets during installation Exhaust Manifold Removal and Installation See Figure 3 14 CAUTION 1 Park the mower safely See Park Mower Safely on page 1 6 2 Allow...

Page 39: ...4 Screw 5 12 Oil Cooler Spacer 4 20 Engine Oil Filter Head 29 Washer 5 Radiator Shroud 13 Radiator Cap 21 Engine Oil Filter 30 Lower Radiator Hose 6 Remote Filter Bracket 2 14 Engine Oil Cooler 22 Ada...

Page 40: ...r 13 Remote Oil Cooler Bracket 2 2 Nut 2 6 Oil Cooler Spacer 4 10 Carriage Bolt 2 14 Screw 2 3 Lock Washer 10 7 Nut 8 11 Lock Nut 2 15 Screw 6 4 Flat Washer 4 8 Radiator Support Bracket 2 12 Flat Wash...

Page 41: ...nd fitting 4 Remove two wing nuts 8 lock washers 9 flat washers 5 hydraulic oil cooler spacers 6 and screws 7 Figure 3 18 5 While supporting the hydraulic oil cooler remove the two lock nuts 11 flat w...

Page 42: ...Radiator Removal See Figures 3 20 through 3 22 1 Remove the hydraulic oil cooler See Hydraulic Oil Cooler Removal on page 3 12 2 Remove the engine oil cooler See Engine Oil Cooler Removal on page 3 1...

Page 43: ...ator cap and start the engine following the instructions in the Safety Operation Manual CAUTION 5 When the engine reaches normal operating temperature check and fill the coolant reservoir to the hot f...

Page 44: ...emoval and Installation See Figures 3 24 through 3 27 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove the instrument panel See Instrument Panel on page 4 87 Figure 3 24 3 Remove thr...

Page 45: ...ter replacing follow the adjustment procedure See Throttle Cable on page 3 5 Fuel Filter Removal and Installation See Figures 3 28 and 3 29 CAUTION 1 Park the mower safely See Park Mower Safely on pag...

Page 46: ...attery 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 30 4 Disconnect the positive lead 1 from the wiring harn...

Page 47: ...the engine 5 Remove the muffler and exhaust assembly See Muffler on page 3 8 6 Remove the radiator See Radiator Oil Coolers on page 3 10 7 Remove 4WD valve See 4WD Valve on page 5 51 8 Turn the fuel...

Page 48: ...ir filter assembly 16 from the air cleaner supports 27 16 Remove four nuts 23 lock washers 22 flat washers 21 and screws 26 to remove clamp 25 mounting bracket clamp 24 and air cleaner supports 27 fro...

Page 49: ...engine mounting bolts 31 flat washers 32 isolator washers 34 lock washers 35 and nuts 36 19 Check for any connected wires and components and carefully remove the engine from the machine Prevent perso...

Page 50: ...plate screws to 37 lb ft 51 N m If necessary remove components from the engine and install the components on the new engine Use new gaskets when installing the exhaust system Fill the radiator with a...

Page 51: ...3 22 4203781 First Edition ENGINE 3 Page Intentionally Blank...

Page 52: ...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 53: ...Component Testing 4 73 Circuit Breakers Test 4 74 Thermal Circuit Breakers Test 4 74 Relays Test 4 75 Time Delay Relay Test 4 75 Key Switch Test 4 76 Horn Test Switch Test 4 76 Seat Switch Test 4 77 G...

Page 54: ...imit Switch 4 96 Rocker Switches 4 97 Reverse Kick Out Switch 4 98 Air Filter Pressure Switch 4 99 Return Filter Pressure Switch 4 99 Hyd Oil Temp Switch 4 100 Charge Filter Pressure Switch 4 101 Engi...

Page 55: ...oid Coil 4WD 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 Terminals at Full Position ohms 32 10 Fuel...

Page 56: ...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 57: ...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 58: ...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 59: ...Horn See Figure 4 4 H2 Volt Meter See Figure 4 4 H3 Engine Temperature Gauge See Figure 4 4 H5 Hour Meter See Figure 4 5 H6 Fuel Gauge See Figure 4 5 J1 Deluxe Seat Connector See Figure 4 1 J2 12V Ac...

Page 60: ...ELECTRICAL 4203781 First Edition 4 9 4 Y4 Left Mow Solenoid See Figure 4 3 Y5 4WD Solenoid See Figure 4 3 Y6 4WD Rev Solenoid See Figure 4 3 Y8 Cruise Control Magnet See Figure 4 4...

Page 61: ...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 F8 10A Circuit Breaker F9 10A Circuit Brea...

Page 62: ...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 63: ...it Breaker 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 66A...

Page 64: ...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 87 30...

Page 65: ...n Wht Grn Wht Lt Grn Lt Blu Wht Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org Org Org B3 Fuel Level Sensor E1 Right Turn Indicator E10 Left Turn Indicator E2 Glow Plug Light Blk Blk Blk Blk Blk Blk Ta...

Page 66: ...g 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 Wht Wht Bl...

Page 67: ...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 68: ...ELECTRICAL 4203781 First Edition 4 17 4 Page Intentionally Blank...

Page 69: ...er F9 provides protection to 12V accessory socket J2 Interlock Circuit The interlock circuit provides 12 volts to the key switch The following must occur before the key switch is provided with 12 volt...

Page 70: ...nator 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 F8 10A Circuit Breaker F9 10A Circuit Breaker J1 Deluxe Seat Connector F2 30A Ci...

Page 71: ...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 72: ...rn 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 73: ...erature 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 87 30 87 85 86 Lt Blu Red Wht On Off S14 B...

Page 74: ...ht Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org Org Org B3 Fuel Level Sensor E1 Right Turn Indicator E10 Left Turn Indicator E2 Glow Plug Light Blk Blk Blk Blk Blk Blk Tan 12V Signal Gnd H6 Fuel Gaug...

Page 75: ...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 Service Li...

Page 76: ...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 77: ...plug relay 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 p...

Page 78: ...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 79: ...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 80: ...ternator Red Brn 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 8...

Page 81: ...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 82: ...ircuit Breaker F2 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...

Page 83: ...ircuit Breaker F2 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...

Page 84: ...ELECTRICAL 4203781 First Edition 4 33 4 Page Intentionally Blank...

Page 85: ...lock 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 Park brake switch in the...

Page 86: ...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 87: ...4 36 4203781 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 88: ...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 89: ...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 90: ...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 91: ...4 40 4203781 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 92: ...izing the relay With the relay energized switched power is provided from accessory relay terminal 87 to PTO switch terminal B and from terminal B to the seat switch Accessory relay terminal 87 also pr...

Page 93: ...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 Off S5 Seat Switch On Off S3 PTO Switch Pur Pur...

Page 94: ...rt 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 Off S5 Seat Switch On Off S3 PTO Switch Pur Pur Pur...

Page 95: ...4 44 4203781 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 96: ...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 97: ...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 98: ...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 99: ...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 100: ...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 101: ...4 50 4203781 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 102: ...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 103: ...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 104: ...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 105: ...Voltage is provided from 10 amp circuit breaker F4 to the volt meter The volt meter indicates the condition of the battery Engine Temperature Gauge The engine temperature sensor resistance changes in...

Page 106: ...horn Engine Coolant Temp Light When the engine coolant temp switch is closed a ground is provided to the engine coolant temp light turning on the light Ground is also provided from the hyd temp switch...

Page 107: ...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 108: ...Blk Lt Grn 12V Signal Gnd 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 Org Org B3 Fuel Level Sensor Blk Ta...

Page 109: ...emp Light B6 Hyd Oil Temp Switch V1 V2 V6 V7 V9 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...

Page 110: ...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 111: ...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 112: ...Meter Blk Lt Grn 12V Signal Gnd H3 Engine Temperature Gauge Red Lt Blu Red Red K7 Horn Relay 87 30 87 85 86 Org Org Blk Blk Blk 12V Gnd H5 Hour Meter Org Org Org B3 Fuel Level Sensor Blk Tan 12V Signa...

Page 113: ...rn 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 Charge Filt...

Page 114: ...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 74 Tripped 30A circuit breaker Rese...

Page 115: ...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 116: ...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 117: ...ated Measure continuity between the 4WD switch and the reverse kick out switch blu wire Continuity must be indicated Measure continuity between the reverse kick out switch and the 4WD solenoid grn wir...

Page 118: ...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 119: ...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 120: ...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 121: ...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 122: ...icating full scale replace the fuel level sensor Faulty fuel level circuit Check continuity between fuel gauge brn wire terminal and the fuel level sensor terminal Continuity must be indicated Faulty...

Page 123: ...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 124: ...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 125: ...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 126: ...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 90 Figure 4 39 3 Connect one test lead to terminal...

Page 127: ...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 128: ...ower safely See Park Mower Safely on page 1 6 2 Remove glow plug switch See Glow Plug Switch on page 4 94 Figure 4 43 3 Connect test leads to terminals 1 and 3 4 With the switch lever 2 in the OFF pos...

Page 129: ...6 2 Remove PTO switch See PTO Switch on page 4 95 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 130: ...for continuity Is continuity indicated YES Proceed to step 8 NO The switch is faulty replace the switch 8 Place the switch in the 1 position 9 Check for continuity Is continuity indicated YES The swi...

Page 131: ...ep 14 14 Place the switch in the 5 position 15 Check for continuity Is continuity indicated YES The switch is faulty replace the switch NO Proceed to step 16 16 Connect test leads to the switch termin...

Page 132: ...and hold the switch in the 1 position 12 Check for continuity 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...

Page 133: ...continuity Is continuity indicated YES Proceed to step 20 NO The switch is faulty replace the switch 20 Place and hold the switch to the OFF middle position 21 Check for continuity Is continuity indic...

Page 134: ...2 to the empty position and read the resistance value Is the resistance value approximately 256 ohms YES The sensor is good NO The sensor is faulty replace fuel level sensor Solenoids Test See Figure...

Page 135: ...d is faulty replace the solenoid Fuel Shutoff Solenoid Test See Figures 4 53 and 4 54 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 4 53 2 Disconnect the fuel shutoff solenoid wire...

Page 136: ...when the leads are 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 c...

Page 137: ...attery cable at the battery Figure 4 58 NOTE Label all wires before disconnecting to ensure correct installation 4 Disconnect wire connectors 1 and 2 5 Loosen screw 8 and push the alternator 3 toward...

Page 138: ...NOTE If servicing individual components it is not necessary to completely remove the instrument panel In most cases the instrument panel can be moved aside for access to components 1 Park the mower s...

Page 139: ...l wires before disconnecting to ensure correct installation 5 Disconnect wire connectors 2 and 4 6 Remove circuit breaker 3 Installation Note Install the circuit breaker by reversing the order of remo...

Page 140: ...llowing relays Left Wing Relay 2 Right Wing Relay 1 Cruise Cancel Relay 3 Cruise Relay 4 Fuel Pull In Relay 5 Horn Relay 6 Accessory Relay 7 NOTE For time delay relay see Time Delay Relay on page 4 90...

Page 141: ...move nut 6 lock washer 7 and ground wire terminal 8 6 Remove two nuts 1 lock washers 2 and screws 3 7 Remove time delay relay 5 Installation Note Install the time delay relay by reversing the order of...

Page 142: ...wer Safely on page 1 6 2 Disconnect the negative battery cable at the battery Figure 4 71 NOTE Label all wires before disconnecting to ensure correct installation 3 Disconnect the wire connector 4 Rem...

Page 143: ...l Position the brake pedal switch so contacts are closed with the brake pedal disengaged and open as soon as the brake pedal is pressed Horn Test Switch Removal and Installation See Figure 4 73 1 Park...

Page 144: ...battery cable at the battery Figure 4 74 3 Tilt seat back 1 to forward position 4 Cut cable ties 2 NOTE Label all wires before disconnecting to ensure correct installation 5 Lift rear of seat 3 slide...

Page 145: ...itch Removal and Installation See Figures 4 79 and 4 80 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery 3 Remove instrument panel See I...

Page 146: ...Panel on page 4 87 Figure 4 81 Figure 4 82 NOTE Label all wires before disconnecting to ensure correct installation 4 Disconnect wire connector 4 5 Remove boot 2 from PTO switch 5 6 Remove two nuts 1...

Page 147: ...and flat washers 2 5 Remove proximity switch 3 Installation Notes Install the proximity switch by reversing the order of removal Use new cable tie to secure wire connector Front Limit Switch Removal a...

Page 148: ...igures 4 88 through 4 91 NOTE Front mow enable switch shown 1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the battery negative cable at the battery 3 Remove instrument panel S...

Page 149: ...1 Park the mower safely See Park Mower Safely on page 1 6 2 Disconnect the negative battery cable at the battery Figure 4 92 NOTE Label all wires before disconnecting to ensure correct installation 3...

Page 150: ...hood 3 Disconnect the negative battery cable at the battery Figure 4 94 NOTE Label all wires before disconnecting to ensure correct installation TN2027 2 1 3 The hydraulic system is under pressure an...

Page 151: ...oil return filter See Hydraulic Oil Return Filter on page 6 67 Replace charge pressure filter See Charge Pressure Filter on page 6 67 Refill hydraulic tank Refer to Safety Operation and Maintenance Ma...

Page 152: ...s before disconnecting to ensure correct installation 4 Remove screw 3 and disconnect wire 2 from the engine oil pressure switch 1 5 Remove engine oil pressure switch The hydraulic system is under pre...

Page 153: ...re sensor by reversing the order of removal Apply Teflon tape to the threads of the engine temperature sensor before installing Engine Coolant Temp Switch Removal and Installation See Figure 4 99 WARN...

Page 154: ...correct installation 3 Remove cover 1 4 Disconnect wire connector 3 5 Remove low charge pressure switch 2 Installation Notes Install the low charge pressure switch by reversing the order of removal I...

Page 155: ...Solenoid 3 The left mow solenoid is located on the left deck valve The right mow solenoid is located on the right deck valve The front mow solenoid is located on the front deck valve Removal and Inst...

Page 156: ...installation Install the solenoid by reversing the order of removal Tighten nut 7 to 5 7 lb ft 6 8 9 5 N m 4WD Solenoids See Figures 4 105 and 4 106 Figure 4 105 4WD Solenoid Figure 4 106 4WD Rev Sol...

Page 157: ...artridge of any debris or surface rust and apply dielectric grease Jacobsen PN 365422 to cartridge before installation Install the solenoid by reversing the order of removal Tighten nut 7 to 4 5 lb ft...

Page 158: ...he fuel shutoff solenoid by reversing the order of removal Cruise Control Magnet Removal and Installation See Figures 4 110 through 4 112 1 Park the mower safely See Park Mower Safely on page 1 6 2 Di...

Page 159: ...r Service Light 8 Low Charge Pressure Light 4 Engine Coolant Temp Light 7 Engine Oil Pressure Light 5 Left Turn Indicator 6 Removal and Installation See Figure 4 114 1 Park the mower safely See Park M...

Page 160: ...ore disconnecting to ensure correct installation 8 Remove diode 6 from diode holder 7 Installation Note Install the diode by reversing the order of removal Engine Temperature Gauge Removal and Install...

Page 161: ...ting to ensure correct installation 5 Disconnect wire terminals 4 6 Remove gauge 1 Installation Note Install the gauge by reversing the order of removal Hour Meter Removal and Installation See Figure...

Page 162: ...the horn by reversing the order of removal Horn must not touch any adjacent parts Fuel Level Sensor Removal and Installation See Figures 4 122 and 4 123 1 Park the mower safely See Park Mower Safely o...

Page 163: ...4 112 4203781 First Edition ELECTRICAL 4 Page Intentionally Blank...

Page 164: ...c and Theory of Operation 5 15 Traction Circuit Reverse 2WD Schematic 5 16 Traction Circuit Forward 4WD Schematic and Theory of Operation 5 19 Traction Circuit Forward 4WD Schematic 5 20 Traction Circ...

Page 165: ...TATIC POWER TRAIN 5 Repair 5 46 Front Axle U Joint 5 46 Traction Pump U Joint 5 47 Traction Pump 5 48 4WD Valve 5 51 Control Valve 5 53 Front Axle Motor 5 57 Front Drive Axle Assembly 5 60 Rear Wheel...

Page 166: ...1 20 Marginal 21 and beyond Bad Specification Front Axle Motor Backplate Assembly Screw Torque lb ft N m 15 18 20 24 Front Drive Axle Assembly U Bolt Nut Torque lb ft N m 50 67 8 Front Axle Ring Gear...

Page 167: ...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 168: ...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 Gear Pump 5 Front Axle Motor 2 4WD Valve 4 Front Axle U Joint 6 Front Axle T...

Page 169: ...5 6 4203781 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 TN2263 TN2168 2 3 1...

Page 170: ...o remove debris from the oil In the event of the charge filter becoming plugged a 25 psi 1 7 bar pressure switch will activate the Charge Filter light on the control panel and a bypass valve will open...

Page 171: ...Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN2314 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 Micron Filter Hydrostatic Traction Pump P...

Page 172: ...ssure Oil from Front Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN2317 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 5 04 ci Secondary 4WD Shuttle Valve 3 Hydraulic...

Page 173: ...5 10 4203781 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 174: ...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 25 psi 1 7 bar The control v...

Page 175: ...A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN2318 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 Micron Filter Hydrostatic Traction Pum...

Page 176: ...e Pressure Oil from Front Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN2319 Operating Pressure Oil Inlet or Drain Oil Charge Pressure Oil Metered Oil Return Oil 4...

Page 177: ...5 14 4203781 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 178: ...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 25 psi 1 7 bar The control valve...

Page 179: ...A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN2326 10 Micron Filter Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 77 ci 3500 psi 1 04 ci Suct...

Page 180: ...ing Pressure Oil to Front Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN2327 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 5 04 ci Secondary 4WD Shuttle Valve 3 Hydra...

Page 181: ...5 18 4203781 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 182: ...ill open to dump oil to the hydraulic tank when the charge pressure reaches 160 psi 11 bar Traction Drive Circuit When the traction pedal is moved to FORWARD position the swash plate is moved stroking...

Page 183: ...t A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN2318 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil 10 Micron Filter Hydrostatic Traction P...

Page 184: ...e Pressure Oil from Front Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN2329 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 5 04 ci Secondary 4WD Shuttle Valve 3 Hydra...

Page 185: ...5 22 4203781 First Edition HYDROSTATIC POWER TRAIN 5 Page Intentionally Blank...

Page 186: ...ntrol valve also includes a charge relief valve that will open to dump oil to the hydraulic tank when the charge pressure reaches 160 psi 11 bar Traction Drive Circuit When the traction pedal is moved...

Page 187: ...A 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve Port ST TN2326 10 Micron Filter Hydrostatic Traction Pump IN Steering Cylinder Gear Pump 0 77 ci 3500 psi 1 04 ci Suc...

Page 188: ...ing Pressure Oil to Front Axle Motor and 4WD Valve Port B 6 Charge Pressure Oil from Control Valve Port ST TN2330 4WD Valve L1 11 9 ci 1 Right Wheel Motor 2 5 04 ci Secondary 4WD Shuttle Valve 3 Hydra...

Page 189: ...5 61 Probable Cause Remedy Hydraulic oil not at correct level in reservoir Fill reservoir to correct level Refer to Safety Operation and Maintenance Manual for the correct oil specifications Tow valve...

Page 190: ...ems until hydraulic system is free of air Traction pump worn or damaged Repair or replace pump as needed See Traction Pump on page 5 49 Probable Cause Remedy 4WD solenoid in control valve does not eng...

Page 191: ...ount of oil to the pedal linkage pivot points before adjusting to ensure free movement of the linkage 7 Start the engine and set the throttle in the fast idle position WARNING 8 Loosen the jam nuts 1...

Page 192: ...proceed to step 4 If no adjustment is required proceed to Speed Limit Adjustment on page 5 30 4 Loosen nuts 4 5 Position reverse kick out switch 6 to achieve continuity when the traction pedal is in t...

Page 193: ...tion pedal 8 to the required reverse position and hold 7 Adjust turn the rear stop stud 9 counterclockwise until it touches the traction pedal 8 then one additional turn 8 Tighten nuts 10 9 Tighten lo...

Page 194: ...45 bar of upward force on the cutting unit lift cylinders Increased upward pressure on the cutting unit cylinders will transfer additional weight to the machine drive wheels improving traction and red...

Page 195: ...Figure 5 19 NOTE Be sure tow valve is closed before beginning traction system test 1 Operate hydraulic system until oil temperature is at 120 150 F 49 65 C 2 Set park brake Figure 5 19 3 Install whee...

Page 196: ...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 197: ...ipment Install all hoses and fittings as noted prior to removal 10 Install and connect all components as noted prior to test 11 Check hydraulic oil level Add oil as needed Refer to Safety Operation an...

Page 198: ...es 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 Percentage Is charge pump...

Page 199: ...fely See Park Mower Safely on page 1 6 2 Raise the seat and seat platform Figure 5 25 3 Install wheel restraint 1 to all four wheels 4 Disconnect traction pump control rod from pump control arm Figure...

Page 200: ...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 direction 19...

Page 201: ...rward direction 30 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 pa...

Page 202: ...ure 5 32 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 ensure accurate hydraulic test re...

Page 203: ...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 204: ...after performing the traction system test and the test results have proven the pump and front axle motor to be good proceed to step 16 If performing this test to determine which component in system i...

Page 205: ...is adjusted to allow pump to produce 15 gpm 57 lpm in the forward direction 12 Slowly close flow meter valve until pressure reaches 2625 psi 181 bar Read and record loaded flow 13 Open flow meter val...

Page 206: ...ool is adjusted to allow pump to produce 15 gpm 57 lpm in the forward direction 23 Engage 4WD switch in the forward position 24 Slowly close flow meter valve until pressure reaches 2625 psi 181 bar Re...

Page 207: ...After warming the hydraulic oil verify flow lock tool is adjusted to allow pump to produce 15 gpm 57 lpm in the forward direction 33 Engage 4WD switch in the forward position 34 Slowly close flow mete...

Page 208: ...in the forward position 44 Slowly close flow meter valve until pressure reaches 2625 psi 181 bar Read and record loaded flow 45 Open flow meter valve stop engine and set park brake Return flow lock t...

Page 209: ...ly on page 1 6 2 Remove the front axle motor 3 See Front Axle Motor on page 5 58 3 Remove screws 2 and U joint straps 1 4 Disconnect front axle U joint 4 from front axle 5 5 Remove front axle U joint...

Page 210: ...ation See Figure 5 43 Figure 5 43 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove the 4WD valve See 4WD Valve on page 5 52 NOTE It may be necessary to rotate the flywheel to access...

Page 211: ...ications Start engine Check hydraulic system for leaks Repair as necessary Check hydraulic oil level and add if necessary Traction Pump Removal and Installation See Figures 5 44 and 5 45 1 Park the mo...

Page 212: ...traction pump from the frame 22 Installation Notes Install the hydrostatic pump by reversing the order of removal Lubricate all O rings prior to assembly Make sure new O rings are in place before ins...

Page 213: ...lve 13 Cam Plate 22 Drive Shaft 31 Housing 5 Top Screw 2 14 Washer 6 23 Retaining Ring 2 32 Valve Plate 6 O Ring 15 Screw 24 Thrust Bearing 33 Housing Gasket 7 Coupler 16 Control Arm Cover Plate 25 Vi...

Page 214: ...afely on page 1 6 2 Drain hydraulic oil tank See Hydraulic Oil Tank Drain Procedure on page 6 58 NOTE The 4WD valve is located on the bottom center of machine 3 Thoroughly clean the valve especially t...

Page 215: ...e location and orientation of the all fittings before removing to ensure correct installation 1 Remove straight adapter 1 from port B 2 Remove 90 adapter 2 from port R1 3 Remove straight adapter 3 fro...

Page 216: ...NOTE Label connectors before disconnecting to ensure correct installation 5 Disconnect electrical connectors 8 and 10 NOTES Label all hydraulic hoses and tubes before disconnecting to aid in installat...

Page 217: ...y Inspection and Assembly See Figures 5 51 and 5 52 NOTE Repair of the control valve is limited to replacing cartridges or replacing O rings on each cartridge Figure 5 51 NOTE Record the location and...

Page 218: ...ontrol valve 29 15 Remove nut 34 and solenoid coil 33 from 4WD valve 32 16 Remove 4WD valve 32 from the control valve 24 17 Remove O rings 30 and 31 and backup rings 35 from 4WD valve 32 NOTICE 18 Cle...

Page 219: ...all component parts 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 Dr...

Page 220: ...k washers 2 and screws 4 and 11 7 Remove front axle motor 3 and front axle motor shims 12 if installed from frame 13 NOTE Record the location and orientation of all fittings before removing to ensure...

Page 221: ...der 23 Key 3 Housing Assembly 10 Rotating Kit Assembly 17 Pilot 24 Drive Shaft 4 Bearing Race 2 11 Thrust Race if equipped 18 Spring 25 O Ring 5 Thrust Bearing 12 Bearing Race 19 Washer if equipped 26...

Page 222: ...g parts Lubricate all O rings and seals prior to assembly Lubricate the pilot 17 spider 16 piston assemblies 15 connector plate 14 and thrust race 11 prior to assembly Install the drive shaft 24 into...

Page 223: ...re 5 55 10 Cut cable ties 2 and move hydraulic hoses 1 3 and 4 aside Figure 5 56 11 Support the front axle assembly 8 with a suitable lifting device 12 Remove six nuts 5 six flat washers 6 three U bol...

Page 224: ...Left Side Axle Shaft 32 Roller Bearing Cup 45 Differential Cover Screw 10 7 Inner Shaft Seal 20 Inner Shaft Seal 33 Roller Bearing Cone 46 Oil Level Fill Plug 8 Machined Screw 4 21 Collar 34 Ring Gear...

Page 225: ...lb ft 61 81 N m Tighten pinion nut 16 to 200 220 lb ft 271 298 N m Pinion rotation torque 20 40 lb in 2 3 4 5 N m Tighten screws 31 and 48 to 70 90 lb ft 95 122 N m Backlash tolerance is 0 005 0 008 i...

Page 226: ...lve 2 Figure 5 59 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 60 7 Remove cotter pin 10 CAUTION 8 Loosen but do not...

Page 227: ...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 228: ...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 229: ...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 230: ...w 5 Screw 16 Screw 2 26 Traction Pump 36 Traction Return Tube 6 Traction Return Bracket 17 Traction Damper 27 Center Lock Nut 37 Washer 4 7 Nut 3 18 Screw 28 Traction Pump Adjusting Rod 38 Compression...

Page 231: ...ds 25 and 30 from traction pump adjusting rod 28 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 232: ...ation 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 Deck Flo...

Page 233: ...ef Valve 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 W...

Page 234: ...stem 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...

Page 235: ...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 236: ...HYDRAULICS 4203781 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 14 15...

Page 237: ...ci 3 Suction Screen 100 Mesh 25 psi Switch Hydraulic Oil Tank 25 psi Crack Bypass Tank Fill Cap Assembly 40 Micron Filter 1 04 ci 1 04 ci 2 48 ci 3500 psi 560 Micron Strainer Charge Filter Check Valve...

Page 238: ...Valve L1 11 9 ci Right Wheel Motor 5 04 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 160 psi Charge Pressure Light Swit...

Page 239: ...1 First Edition HYDRAULICS 6 Hydraulic Schematic Continued Figure 6 5 TN2066 2 3 4 9 10 11 12 13 2 3 4 12 10 11 P Steering Cylinder Relief Valve 1500 psi Steering Unit T LT 6 1 ci RT Steering Valve Ch...

Page 240: ...Valve Front Lift Valve Right Lift Valve Detent Valve Detent Valve Detent Valve TN2067 2 3 4 12 10 11 2 3 4 10 11 IN 0 060 Orifice OUT 0 060 Orifice 0 060 Orifice 0 060 Orifice Left Wing Cylinder Fron...

Page 241: ...067 0 067 0 067 0 067 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 A B Left Deck Valve Front Deck...

Page 242: ...HYDRAULICS 4203781 First Edition 6 11 6 Page Intentionally Blank...

Page 243: ...steering 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 port P and is r...

Page 244: ...8 Figure 6 8 1 Operating Pressure Oil from Control Valve Port ST 2 Charge Pressure Oil to Charge Filter TN2186 Relief Valve 1500 psi Steering Unit P T LT 6 1 ci 1 Steering Cylinder RT 2 Steering Valv...

Page 245: ...s 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 Ra...

Page 246: ...Pressure Light Switch IN Primary 4WD Solenoid 1 Weight Transfer Valve 4WD 2 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Left Lift Valve Control Valve 125 psi N C Priority Valve 4 5 gpm T F CP...

Page 247: ...rpm range Lower Circuit Operating pressure oil enters the lift valve body at the IN port and flows to the 1500 psi 103 bar relief valve and to each of the spool valves With the lift lower levers in th...

Page 248: ...0 psi Charge Pressure Light Switch IN Primary 4WD Solenoid 1 Weight Transfer Valve 4WD 2 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Control Valve 125 psi N C Priority Valve 4 5 gpm T F CP SW...

Page 249: ...rs in the 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 con...

Page 250: ...lve 250 psi Charge Pressure Light Switch IN Primary 4WD Solenoid 1 Weight Transfer Valve 4WD 2 300 psi 0 060 Orifice Hydraulic Oil Tank Lift Valve Control Valve 125 psi N C Priority Valve 4 5 gpm T F...

Page 251: ...opens the 630 psi 43 bar brake valve 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 T...

Page 252: ...Right Deck Valve 2 1 04 ci 3 Hydraulic Oil Tank 0 067 D 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 0 067 0 067 0 067 0 067 0 067 0 067 CCW Inside Right Wing Motor CW Inside Left Wing Motor CCW O...

Page 253: ...elief valve 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 ta...

Page 254: ...67 D 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 1 04 ci 0 067 0 067 0 067 0 067 0 067 0 067 CCW Inside Right Wing Motor CW Inside Left Wing Motor CCW Outside Left Wing Motor CCW Left Front Motor CW Cente...

Page 255: ...ll cylinders pass test the problem may be in the lift valve Proceed to step 9 9 Support front cutting unit 10 Connect tee fitting 2 to lift cylinder fitting 1 11 Start the engine and lower cutting uni...

Page 256: ...does it not turn YES Steering cylinder is faulty repair or replace as needed See Steering Cylinder on page 7 17 With steady pressure in one direction does the steering wheel make one complete revolut...

Page 257: ...er minute Is the oil captured from the case drain within a half pint per minute YES The motor shaft and or bearings are not faulty proceed with an instrument test See Instrument Test Procedure on page...

Page 258: ...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 259: ...e 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 suitable...

Page 260: ...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 33 NO Proceed to next question Is front...

Page 261: ...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 the flow meter to warm the hydrauli...

Page 262: ...tting 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 saf...

Page 263: ...roceed 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 P...

Page 264: ...RTANT This test works together with the front cutting units circuit test to isolate a problem with the front cutting units circuit Performing this test will isolate the front cutting unit motors from...

Page 265: ...flow meter to warm the hydraulic oil Turn the flow meter valve 1 until a reading of 1500 psi 103 bar or one half of the relief valve rating is reached Warm oil to 120 150 F 49 65 C open valve fully a...

Page 266: ...r preventing front cutting unit center motor from turning 14 Open flow meter valve 1 completely Figure 6 28 Front Cutting Unit Motors Test Center Cutting Unit Motor Blocked 15 Bypass seat switch and s...

Page 267: ...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 268: ...nts as noted prior to 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 Figur...

Page 269: ...ion 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 readi...

Page 270: ...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 271: ...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 272: ...ypass 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 the...

Page 273: ...m relief valve pressure 2700 3300 psi 186 228 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 wing cu...

Page 274: ...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 Before pe...

Page 275: ...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 276: ...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 277: ...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 suitable blocking device o...

Page 278: ...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 279: ...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 280: ...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 281: ...2 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...

Page 282: ...eck 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 pressur...

Page 283: ...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 284: ...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 62 Then proceed to step...

Page 285: ...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 Maint...

Page 286: ...step 15 NO Test lift steer pump See Lift Steer Pump Test on page 6 55 Test steer cylinder See Steering Leakage Test on page 7 7 Repair or replace steer relief valve See Steering Relief Valve Pressure...

Page 287: ...ults 8 Start engine and run at full throttle 2800 rpm 50 CAUTION 9 Use the flow meter to warm the hydraulic oil Turn the flow meter valve 4 until a reading of 750 psi 52 bar or one half of the relief...

Page 288: ...is marginal Additional testing is required See Field Test Procedures on page 6 24 NO Proceed to next question Is lift steer pump leakage 21 or more YES Repair or replace lift steer pump See Gear Pump...

Page 289: ...raining oil Installation 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 c...

Page 290: ...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 on page 6 6...

Page 291: ...Seal 5 Wear Plate 8 9 Gear Plate 4 13 Gear Set 3 2 Front Cover Flange 6 Seal Ring 8 10 Body 3 14 Screw 8 3 Pre Load Seal 4 7 Gear Set Drive Shaft 11 Rear Cover Assembly 4 Load Seal 4 8 Dowel Pin 8 12...

Page 292: ...coat of clean hydraulic oil to all parts to ease assembly Assemble pump one section at a time building up from flange section Remove alignment mark from gear sets after gears have been installed with...

Page 293: ...nect electrical connectors 3 NOTES Label hydraulic hoses to aid in installation Close all openings with caps or plugs to prevent contamination 7 Disconnect hydraulic tube 4 8 Disconnect hydraulic hose...

Page 294: ...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 295: ...al 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...

Page 296: ...alve 9 8 Remove mounting screws 5 and washers 6 9 Remove the deck valve 9 Installation Notes Install the deck valve by reversing the order of removal Make sure new O rings are in place before installi...

Page 297: ...rn filter See Hydraulic Oil Return Filter on page 6 67 Refill hydraulic tank Refer to Safety Operation and Maintenance Manual for oil specifications Start engine Check hydraulic system for leaks Repai...

Page 298: ...move two screws 2 lock washers 3 and flat washers 4 8 Remove oil filter assembly 6 Installation Notes Install oil filter assembly by reversing the order of removal Replace hydraulic oil filter Refill...

Page 299: ...wer Safely on page 1 6 Figure 6 74 NOTES Label all hydraulic hoses before disconnecting to ensure correct installation All of the lift cylinders have an orifice installed between the hose and the cyli...

Page 300: ...er a threaded gland or a 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 Guid...

Page 301: ...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 302: ...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 303: ...caps or plugs to prevent contamination 3 Disconnect hydraulic hoses 3 and 4 4 Support lift cylinder 1 5 Remove pins 2 and 5 6 Remove lift cylinder 1 Installation Notes Install lift cylinder by revers...

Page 304: ...er a threaded gland or a 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 Guid...

Page 305: ...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 306: ...and Installation NOTE The hydraulic oil cooler is in close proximity to the radiator and uses the engine cooling fan to cool the hydraulic oil Removal and installation of the radiator hydraulic oil c...

Page 307: ...c oil tank 6 Disconnect electrical connector 3 located on the bottom of hydraulic tank 7 Disconnect hoses 4 through 7 from hydraulic oil tank Figure 6 81 8 Disconnect electrical connectors 10 and 12 9...

Page 308: ...isconnect glow plug solenoid 15 and fuel pump 16 from hydraulic oil tank back supports 14 16 Remove tank straps 18 17 Support the hydraulic oil tank 17 18 Remove hydraulic oil tank back supports 14 19...

Page 309: ...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 310: ...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 Tower Cover 7 8 Steering Wheel 7 8 Steering Unit 7 9 Steerin...

Page 311: ...5 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 25 30 34 41 Steering Column to Steering Unit Screw Torque lb ft N m 7...

Page 312: ...tion 7 3 7 Component Location See Figure 7 1 Figure 7 1 1 Tie Rod 4 Tilt Lever 7 Steering Unit 2 Steering Axle 5 Steering Wheel 8 Steering Column 3 Steering Cylinder 6 Steering Tower Cover TN2166 TN21...

Page 313: ...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 314: ...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 315: ...ring relief pressure 1500 psi 103 bar YES Steering relief valve is good Proceed to step 12 NO Relief valve is faulty Repair or replace relief valve See Steering Unit on page 7 9 12 Stop engine 13 Disc...

Page 316: ...NO Repair or replace steering cylinder See Steering Cylinder on page 7 17 8 Disconnect and plug hose 1 9 Start the engine and set engine speed to full throttle 2800 50 rpm 10 Turn the steering wheel...

Page 317: ...teering Wheel Removal and Installation See Figure 7 12 1 Park the mower safely See Park Mower Safely on page 1 6 Figure 7 12 2 Remove unsnap the cap 1 from the steering wheel 4 3 Remove nut 2 and inte...

Page 318: ...hose 1 from steering unit port R 5 Disconnect hydraulic hose 2 from steering unit port L 6 Disconnect hydraulic hose 3 from steering unit port T 7 Disconnect hydraulic hose 4 from steering unit port P...

Page 319: ...to the service fixture using four M6 1 x 20 mm screws and M6 lock washers 3 and 4 Required Tools or Equipment Steering Unit Service Fixture 1 0 165 in 4 2 mm 6 2 0 in 50 8 mm 2 0 250 in 6 35 mm Hole...

Page 320: ...3 Thin Bearing Race 10 Spring Set 17 Gearwheel Rim 23 Housing 4 Bearing 11 Check Valve Ball 18 Gearwheel 24 Name Plate 5 Thick Bearing Race 12 Special Screw 4 19 Distributor Plate 25 Steering Relief...

Page 321: ...16 4 Remove distributor plate 19 5 Remove spacer 21 and cardan shaft 22 6 Remove O ring 20 from housing 23 7 Remove spool 6 cross pin 8 and sleeve 9 as an assembly 8 Remove thin bearing race 3 bearing...

Page 322: ...Shaft 3 Thin Bearing Race 10 Spring Set 17 Gearwheel Rim 23 Housing 4 Bearing 11 Check Valve Ball 18 Gearwheel 24 Name Plate 5 Thick Bearing Race 12 Special Screw 4 19 Distributor Plate 25 Steering Re...

Page 323: ...place guide the spool and sleeve assembly into housing 23 6 Place emergency steering ball 1 in port P 7 Place ball stop 2 in port P 8 Place check valve ball 11 in port P 9 Install O ring 20 in housing...

Page 324: ...Figure 7 22 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove the steering wheel See Steering Wheel on page 7 8 Figure 7 22 3 Using the tilt lever tilt the steering column forward 4...

Page 325: ...witch on page 4 91 5 Remove the horn See Horn on page 4 110 Figure 7 23 6 Remove two screws 1 and tilt cable 2 7 Remove two nuts 8 lock washers 7 and screws 3 and remove weight transfer valve bracket...

Page 326: ...eering cylinder 5 Figure 7 25 6 Remove cotter pin 8 and castle nut 9 from steering cylinder 7 7 Using a ball joint removal tool remove the ball joint from the steering arm Remove the steering cylinder...

Page 327: ...ring 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 apply lubricant of any kind to these...

Page 328: ...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 329: ...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 330: ...ball joints into tie rod with the correct number of turns Lubricate grease fittings with grease that meets or exceeds NLGI Grade 2 LB specifications Apply grease with a manual grease gun and fill slo...

Page 331: ...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 332: ...g axle pivot 11 and thrust washers 3 from steering axle assembly 13 and frame brackets 4 and 7 7 Remove steering axle assembly 13 from mower Installation Notes Install the rear axle assembly by revers...

Page 333: ...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 334: ...tapers and the mating tapered surfaces in the steering arm and rear axle are free of burrs dirt and debris DO NOT apply lubricant of any kind to these surfaces Tighten castle nuts 18 to 40 lb ft 54 N...

Page 335: ...7 26 4203781 First Edition STEERING 7 Page Intentionally Blank...

Page 336: ...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 337: ...8 2 4203781 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 338: ...g Lift Arm 2 11 Anti Scalp Wheel 4 2 Deck Motor 7 7 Outer Wing Caster Arm 2 12 Front Deck Assembly 3 Right Wing Deck Assembly 8 Left Wing Deck Assembly 13 Front Caster Arm 2 4 Front Deck Lift Push Arm...

Page 339: ...the deck The caster arms 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 positi...

Page 340: ...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 341: ...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 342: ...witch is faulty Test front mow enable switch See Front Mow Enable Switch Test on page 4 79 Front right or left mow solenoid is faulty Test mow solenoids See Solenoids Test on page 4 83 See Mow Circuit...

Page 343: ...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 344: ...se Remedy Mowing ground speed is too fast Reduce mowing ground speed Improper tire pressure Set front machine tires at 16 20 psi 110 138 kPa rear machine tires at 10 12 psi 69 83 kPa and caster tires...

Page 345: ...it to another Check 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 Che...

Page 346: ...res at 10 12 psi 69 83 kPa and caster tires at 20 25 psi 138 172 kPa HOC height of cut settings are lower than normal Check and adjust the HOC settings See Deck Leveling Adjustment on page 8 4 Front d...

Page 347: ...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 348: ...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 349: ...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 350: ...ter tires at 20 25 psi 138 172 kPa 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 o...

Page 351: ...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 352: ...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 353: ...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 354: ...n page 8 16 Figure 8 9 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 355: ...haft 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 Deck 6 Nut 13...

Page 356: ...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 wash...

Page 357: ...1 Screw 19 Lift Arm Pivot Shaft 2 26 Cotter Pin 4 33 Flat Washer 4 4 Connector 12 Bracket 20 Lift Cylinder Pin 2 27 Lift Cylinder Pin 2 34 Screw 4 5 Front Limit Switch 13 Flat Washer 21 Bushing 2 28 N...

Page 358: ...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 359: ...ector 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 20 Lock Washe...

Page 360: ...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 s...

Page 361: ...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 362: ...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 6 R...

Page 363: ...r Wheels 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...

Page 364: ...and Installation 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 Rem...

Page 365: ...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 366: ...Adjustment 9 4 Repair 9 4 Canopy 9 4 Front Cowling 9 5 OPS 9 6 Hood 9 6 Fuel Tank 9 7 Traction Pedal 9 9 Seat and Seat Platform 9 10 Footrest Floor 9 13 Floorboard 9 14 Utility Box 9 15 Left Fender 9...

Page 367: ...Rear Tires Size 23 x 10 50 12 Type 4 Ply Air Pressure psi bar 10 12 0 69 0 83 Mounting Bolt Torque lb ft N m 40 50 54 68 Mower Speed Transport 2WD mph km h 0 14 9 0 24 Transport 4WD mph km h 0 7 8 0...

Page 368: ...tion See Figure 9 1 Figure 9 1 1 OPS Operator Protective Structure 5 Hood 9 Right Side Fender 2 Seat and Seat Platform 6 Left Side Fender 10 Traction Pedal 3 Front Cowling 7 Rear Wheel 2 11 Fuel Tank...

Page 369: ...ng nut 3 clockwise until it contacts the mounting plate 2 5 Tighten adjusting nut 1 to 20 lb ft 27 N m 6 Connect brake return spring 7 Repeat steps 2 through 6 for the second brake cable 8 Start machi...

Page 370: ...and nut 2 3 Remove nut 3 and washer 4 and remove deck latch cable 6 from front cowling 5 4 Repeat steps 2 and 3 for other side of machine Figure 9 6 5 Remove hose clamp 8 and fuel breather filter 7 6...

Page 371: ...or other side of machine 7 Remove OPS 1 Installation Notes Install OPS by reversing the order of removal Tighten OPS mounting bolts to 135 165 lb ft 183 224 N m Hood Removal and Installation See Figur...

Page 372: ...el 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 373: ...k from the machine Installation Notes Apply anti seize to the fuel tank screws 12 Install the fuel tank by reversing the order of removal Use only clean diesel fuel of the correct type 2 diesel from a...

Page 374: ...2 9 Flange Nut 2 16 Switch Shim As Required 23 Mow Speed Stop 3 Traction Pedal 10 Nylon Bearing 2 17 Reverse Kick Out Switch 24 Flat Washer 4 Reverse Pedal Grip 11 Flat Washer 18 Flat Washer 2 25 Scr...

Page 375: ...der of disassembly Apply grease that meets or exceeds NLGI Grade 2 LB specifications to all pivot points Do not overtighten lock nut 22 The mow speed stop bracket 23 must be able to rotate after assem...

Page 376: ...nd 9 18 Figure 9 17 1 Seat 7 Screw 4 13 Rear Seat Stop 2 2 Screw 4 8 Nut 4 14 Seat Rail 3 Seat Riser 4 9 Rubber Stop 15 Spacer 3 4 Nut 4 10 Nut 16 Screw 4 5 Screw 4 11 Warning Decal 6 Seat Rail with H...

Page 377: ...Kit 9 Air Spring Kit 13 Seat Belt 2 Right Side Adjustable Arm Rest Kit 6 Left Side Cover 10 Shock Absorber Kit 14 OPS Switch Kit 3 Document Net Kit 7 Backrest Adjustment Kit 11 12V Compressor 15 Righ...

Page 378: ...assembly 6 Remove nut 8 washer 2 spacer 7 spring 3 flat washer 6 screw 5 and park brake lever 1 7 Remove pedal grip 4 Figure 9 20 8 Support brake pedal 17 and remove four carriage bolts 9 and flange n...

Page 379: ...ee Figures 9 23 through 9 27 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove seat and seat platform See Seat and Seat Platform on page 9 10 3 Remove instrument panel See Instrument...

Page 380: ...loorboard clears the footrest floor 11 Remove floorboard from the machine Installation Note Install the floorboard by reversing the order of removal Utility Box Removal and Installation See Figures 9...

Page 381: ...moval and Installation See Figures 9 30 and 9 31 1 Park the mower safely See Park Mower Safely on page 1 6 2 Remove utility box See Utility Box on page 9 15 Figure 9 30 3 Remove three nuts 4 lock wash...

Page 382: ...and screws 3 6 Remove right fender 4 Installation Note Install the right fender by reversing the order of removal Work Light Kit Removal and Installation See Figure 9 33 1 Park the mower safely See Pa...

Page 383: ...rn Set tire pressure to 10 12 psi 0 69 0 83 bar Front Wheels Removal and Installation See Figure 9 35 1 Park the mower safely See Park Mower Safely on page 1 6 2 Block both sides of rear wheels using...

Page 384: ...ck Washer 4 22 Grease Fitting 2 Lock Nut 9 Screw 16 Nut 4 23 Lock Washer 4 3 Park Brake Lever 10 Pedal Grip 17 Brake Pedal Switch 24 Nut 8 4 Flat Washer 11 Screw 3 18 Screw 2 25 Right Brake Arm 5 Bush...

Page 385: ...on page 1 6 2 Remove front wheel See Front Wheels on page 9 18 Figure 9 37 3 Disengage return spring 8 from caliper lever 9 4 Remove cotter pin 2 clevis pin 3 and brake cable 1 5 Remove screw 5 lock w...

Page 386: ...caliper assembly See Brake Caliper Assembly on page 9 20 Figure 9 40 4 Remove eight screws 1 and remove rotor 2 from hub 3 5 Remove cotter pin 4 6 Loosen but do not remove castle nut 5 7 Loosen the w...

Page 387: ...9 22 4203781 First Edition ACCESSORIES AND MISCELLANEOUS REPAIR 9 Page Intentionally Blank...

Page 388: ...sassembly and Assembly 8 30 Removal and Installation 8 29 Repair 8 29 B Battery Removal and Installation 4 85 Repair 4 85 Blade Removal and Installation 8 18 Repair 8 18 Brake Caliper Assembly Removal...

Page 389: ...l Switch Removal and Installation 4 96 Repair 4 96 Test 4 80 Cutting Units Component Location 8 3 Repair 8 16 Specifications 8 2 Tests and Adjustments 8 4 Troubleshooting 8 7 D Deck Leveling Adjustmen...

Page 390: ...32 Wing Lift Cylinders Leakage Test 6 24 Final Adjustments Tests and Adjustments 8 6 Fixed Caster Wheels Disassembly and Assembly 8 29 Removal and Installation 8 28 Repair 8 28 Floorboard Removal and...

Page 391: ...58 Repair 6 58 Glow Plug Circuit Schematic 4 27 Theory of Operation 4 26 Troubleshooting 4 62 Glow Plug Solenoid Removal and Installation 4 105 Repair 4 105 Glow Plug Switch Removal and Installation...

Page 392: ...it Deck Valve System Relief Valve Pressure 6 51 Adjust Right Wing Cutting Unit Deck Valve System Relief Valve Pressure 6 42 Charge Pressure Test 5 33 Charge Pump Test 5 34 Front Cutting Unit Motors Te...

Page 393: ...Serial Number 2 2 Specifications and General Information 2 2 Muffler Removal Inspection and Installation 3 8 Repair 3 8 O OPS Removal and Installation 9 6 Repair 9 6 P Park Brake Switch Removal and I...

Page 394: ...eel Motor Disassembly Inspection and Assembly 5 65 Rear Wheel Motor Timing Assembly 5 66 Removal and Installation 5 63 Repair 5 63 Rear Wheels Removal and Installation 9 18 Repair 9 18 Relays Removal...

Page 395: ...Rotors 9 21 Front Wheels 9 18 Fuel Filter 3 16 Fuel Gauge 4 109 Fuel Level Sensor 4 110 Fuel Pump 3 17 Fuel Shutoff Solenoid 4 106 Fuel Tank 9 7 Gear Pump 6 58 Glow Plug Solenoid 4 105 Glow Plug Switc...

Page 396: ...y Chemical Products 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 Cl...

Page 397: ...tions and General Information 2 11 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 7 3 Re...

Page 398: ...nsfer Adjustment 5 31 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 Instrumentation Circuit 4 53 Mow Circuit...

Page 399: ...wer Train 5 26 Instrumentation Circuit 4 67 Mechanical Troubleshooting 8 7 Mow Circuit 4 63 Quality of Cut Troubleshooting 8 8 Run Circuit 4 63 Start Circuit 4 62 Work Light Circuit 4 66 U Utility Box...

Page 400: ......

Page 401: ...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 402: ......

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