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GENSET AND BATTERY PACK

4271491-Second Edition

3-13

Repair—Diesel Models

Fan Belt (Diesel Models)

Removal

See Figures 3-11 and 3-12.

NOTE

Inspect and adjust the new engine belt after the first 50
hours of operation. Check and adjust annually thereafter.

Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

Raise the hood.

Figure 3-11

Loosen screws (3) and push the alternator (2) toward
the engine to loosen the fan belt (1).

Figure 3-12

Remove fan belt (1) from the alternator (2), coolant
pump (5), and crankshaft pulley (4).

Installation

Install fan belt by reversing the order of removal.

Adjust belt tension by loosening alternator mounting
screws (3) and pulling alternator (2) against the belt
(1) until proper tension is achieved.

Measure belt tension at the midpoint between
pulleys. Adjust fan belt to 0.28–0.35 in.
(7–9 mm) deflection with a tension of 22 lb (98 N).

NOTE

See the engine manufacturer’s manual for further
information.

TN2444

TN1113

Содержание Eclipse 322 62800

Страница 1: ...Eclipse 322 Riding Greens Mower Technical Repair Manual 62800 62801 62802 62803 62804 62805 62825 62826 Second Edition...

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Страница 3: ...proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine 2012 Jacobsen A Textron Company All rights reserved When Performan...

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Страница 5: ...nual 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 CHANGE ANY OF THIS...

Страница 6: ...hese 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 specific...

Страница 7: ...2 3 4 5 6 7 Table of Contents 4271491 Rev A 7 1 Safety Specifications and General Information Genset and Battery Pack Electrical Chassis Cutting Units Accessories and Miscellaneous Repair...

Страница 8: ......

Страница 9: ...6 Use Proper Eye and 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 8 Service Tires Safely 1 8 Handle...

Страница 10: ...n get hot during operation Be sure to allow enough time for components to cool before beginning service Prepare proper work space lighting A well lit work area can make the job easier Follow procedure...

Страница 11: ...dition 1 3 1 Safety Label Locations Become familiar with machine safety labels and locations The following illustrations show safety label locations on the machine See Figure 1 1 Figure 1 1 10 11 8 3...

Страница 12: ...1 4 4271491 Second Edition SAFETY 1 6 7 105dB LWA 4181861 4181860 4181862 5 2 4 3 1 4216820 Rev A...

Страница 13: ...SAFETY 4271491 Second Edition 1 5 1 9 41 8 1 8 64 8 4127335 10 4181865 11...

Страница 14: ...s to offer a higher 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 off...

Страница 15: ...he load When using a lifting device always connect the load so it is balanced Always use a lifting device on a hard level surface Lower the lifting device to the lowest point before moving Move the lo...

Страница 16: ...en dismounting or mounting tires use a wheel holder or tire machine Use proper tire mounting tools and equipment Never use screwdrivers or makeshift tools to force a tire on or off a wheel Be sure tir...

Страница 17: ...edures Contact the chemical manufacturer to obtain an MSDS for the chemical product Service Cooling System Safely WARNING WARNING Always dispose of used engine coolant properly See Dispose of Waste Ma...

Страница 18: ...ls known to the State of California to cause cancer and reproductive harm Wash your hands after handling The electrolyte in a storage battery is a dilute acid which can cause severe burns to the skin...

Страница 19: ...storage container Never use food or beverage containers to store waste fluids IMPORTANT Dispose of waste fluids properly at approved local recycling centers If recycling facilities are not available...

Страница 20: ...1 12 4271491 Second Edition SAFETY 1...

Страница 21: ...Engine Serial Number Diesel Models 2 2 Engine Identification Number Gasoline Models 2 3 Optional Machine Accessories 2 3 Component Location 2 4 All Models 2 4 Electric Models 2 6 Specifications 2 7 Q...

Страница 22: ...or requesting service information Engine Serial Number Diesel Models See Figure 2 3 Figure 2 3 The engine serial number 1 is attached to the top of the rocker arm cover The plate also includes the en...

Страница 23: ...tification number 1 is located on the side of the engine and identifies the engine model 2 type 3 and code number 4 Optional Machine Accessories This manual is structured to cover all basic machine co...

Страница 24: ...Right Side Become familiar with operator controls machine components and correct operating procedures before beginning repair procedures 1 OPS 5 Steering Tower 9 Front Wheel 2 2 Seat 6 Traction Pedal...

Страница 25: ...2 5 2 Figure 2 6 Component Location Left Side 1 Brake Pedal Assembly 4 Rear Axle Assembly 7 Front Axle Assembly 2 Steering Chain and Gear 5 Starter Battery 8 Left Cutting Unit 3 Rear Wheel 6 Buffer B...

Страница 26: ...2 6 4271491 Second Edition SPECIFICATIONS AND GENERAL INFORMATION 2 Electric Models Figure 2 7 Component Location Left Side 1 Battery Charger 2 Battery Filling System 3 Battery Pack TN2311 3 1 2...

Страница 27: ...e x Stroke in mm 2 64 x 2 68 67 x 68 Power Output hp kW 13 3 9 9 3600 rpm Cooling System liquid cooled Cooling System Capacity qt L 3 2 8 Speed Range 950 3600 rpm Lubrication Capacity With Filter qt L...

Страница 28: ...orque Diesel Models lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Generator Assembly Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Throttle Act...

Страница 29: ...Fuel Shutoff Hold In Coil at 68 F 20 C Diesel Modes ohms 10 10 Resistance Across Fuel Shutoff Coil at 68 F 20 C Gasoline Models ohms 40 10 Resistance Across Throttle Actuator Coil at 68 F 20 C Diesel...

Страница 30: ...N m 53 6 3WD Traction Controller Wire Connection Screw Torque lb in N m 53 6 Contactor Nut 4 Torque See page 4 167 lb in N m 35 4 Contactor Nut 5 Torque See page 4 167 lb in N m 15 1 7 Fuse Mounting F...

Страница 31: ...span of chain Repair Specifications Front Wheel Hub Castle Nut Torque lb ft N m 95 115 10 7 13 0 Front Axle Assembly Mounting Screw Torque lb ft N m 65 88 Front Axle Assembly Axle Housing Face to Axl...

Страница 32: ...0 25 4 Reel Leveling Rod Rod End to Collar Face Measurement spring side in mm 5 250 133 4 Reel Leveling Rod Rod End to Nut Face Measurement spring side in mm 0 125 3 2 Repair Specifications Reel Motor...

Страница 33: ...Shaft to Bearing Rotational Resistance lb in N m 0 1 0 0 11 with No End Play Grooved Front Roller Assembly Rotational Resistance lb in N m 6 0 68 Maximum with No End Play Grooved Disc Roller Assembly...

Страница 34: ...rooved Machined Steel Roller PN 068613 lb kg 18 8 16 22 Inch Grooved Machined Aluminum Roller PN 068614 lb kg 8 3 63 Weights Working Weight Less Operator Model 62800 3WD Electric lb kg 1697 770 Model...

Страница 35: ...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...

Страница 36: ...2 16 4271491 Second Edition SPECIFICATIONS AND GENERAL INFORMATION 2...

Страница 37: ...esel Models 3 13 Air Filter Assembly Diesel Models 3 14 Muffler Diesel Models 3 15 Alternator Diesel Models 3 16 Radiator Diesel Models 3 17 Thermostat Diesel Models 3 19 Throttle Actuator Diesel Mode...

Страница 38: ...d Edition GENSET AND BATTERY PACK 3 Repair Batteries 3 39 Battery Pack Battery Pack Tray and Battery Filling System 3 39 Buffer Battery Pack and Buffer Battery Pack Tray 3 42 Starter Battery 3 43 Batt...

Страница 39: ...67 x 68 Power Output hp kW 13 3 9 9 3600 rpm Cooling System liquid cooled Cooling System Capacity qt L 3 2 8 Speed Range 950 3600 rpm Lubrication Capacity With Filter qt L 3 4 3 2 Alternator 12 volt 4...

Страница 40: ...8 11 3 Genset Carrier Mounting Screw Torque Diesel Models lb ft N m 65 0 88 0 Coupling Shaft Mounting Screw Torque Diesel Models lb ft N m 13 0 17 6 Generator Flange Mounting Screw Torque Diesel Mode...

Страница 41: ...PACK 4271491 Second Edition 3 5 3 Component Location Diesel Models See Figures 3 1 and 3 2 Figure 3 1 Component Location Right Side 1 Fuel Tank 2 Muffler 3 Throttle Actuator 4 Fuel Filter 4 2 TN2436...

Страница 42: ...ottle 13 Fan Belt 2 Air Cleaner Assembly 8 Fuel Shutoff Solenoid 14 Oil Pressure Switch 3 Radiator 9 Oil Fill Cap 15 Genset 4 12 Volt Connector 10 Thermostat 16 Starter Motor 5 Buffer Battery Pack 11...

Страница 43: ...4271491 Second Edition 3 7 3 Gasoline Models See Figures 3 3 and 3 4 Figure 3 3 Component Location Right Side 1 Fuel Tank 3 Throttle Actuator 5 Oil Filter 2 Muffler 4 Oil Pressure Switch 6 Genset 4 3...

Страница 44: ...ACK 3 Figure 3 4 Component Location Left Side 1 48 Volt Connector 4 Buffer Battery Pack 7 Oil Fill Cap 2 Air Cleaner Assembly 5 Starter Battery 8 Fuel Filter 3 12 Volt Connector 6 Oil Dipstick 9 Start...

Страница 45: ...GENSET AND BATTERY PACK 4271491 Second Edition 3 9 3 Electric Models See Figure 3 5 Figure 3 5 Component Location 1 Battery Filling System 2 48 Volt Connector 3 Battery Pack 3 TN2804 1 2...

Страница 46: ...se two turns Place a suitable container under the filter to catch the fuel that will flow from the screw hole 4 Turn the ignition switch to the on position to allow the fuel pump to operate 5 When the...

Страница 47: ...wer safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 3 9 NOTES Manually retract and extend the actuator shaft checking for smooth operation throughout the entire range of motion If the...

Страница 48: ...tor movement Verify full stroke of the actuator Replace actuator as necessary 3 Disconnect engine throttle linkage 2 and spring 3 from throttle link 1 Pull engine throttle linkage 2 away from engine u...

Страница 49: ...tor 2 toward the engine to loosen the fan belt 1 Figure 3 12 4 Remove fan belt 1 from the alternator 2 coolant pump 5 and crankshaft pulley 4 Installation 1 Install fan belt by reversing the order of...

Страница 50: ...tion purposes note orientation of air inlet 3 before removing the air filter dust cap 1 3 Release retaining clips 2 and remove the air filter dust cap 4 Using damp lint free cloths thoroughly clean th...

Страница 51: ...ler clamp and hardware 5 from exhaust pipe 6 6 Remove four nuts 3 and lock washers 4 7 Remove muffler 7 from exhaust manifold 2 8 Inspect the exhaust system for cracks holes and distortion Replace exh...

Страница 52: ...harness aside to provide clearance for alternator removal Figure 3 18 4 Disconnect wire connector 7 5 Remove nut 8 lock washer 9 and wire connector 10 6 Loosen screws 12 and 15 push the alternator 11...

Страница 53: ...er NOTE Label all hoses before removing to ensure correct installation Figure 3 19 7 Loosen hose clamp 5 and remove lower radiator hose 6 from radiator 8 Remove screws 1 lock washers 2 flat washers 3...

Страница 54: ...hose removed from radiator flush the inside of the radiator with fresh water 2 Install radiator by reversing the order of removal CAUTION 3 Fill radiator with a 50 50 mixture of good quality ethylene...

Страница 55: ...3 24 8 Remove two screws 7 two lock washers 8 and bracket 9 9 Remove thermostat housing 6 gasket and thermostat Installation Notes Install thermostat by reversing the order of removal Clean gasket su...

Страница 56: ...er of removal Apply Loctite 242 Blue to two governor linkage arm nuts 8 prior to assembly Tighten governor linkage arm nuts 32 to 40 lb in 4 5 N m Adjust throttle actuator linkage See Throttle Actuato...

Страница 57: ...bottoms lightly 12 Plug fuel hose 4 to prevent leakage and contamination Figure 3 28 13 Loosen hose clamps 6 and remove air intake hose 15 14 Cut cable tie 14 15 Tag and disconnect wire connector 12 1...

Страница 58: ...an the inside and outside of filter head 2 Lightly lubricate O rings 6 and 7 with clean oil Install fuel filter by reversing the order of removal Tighten cup retaining nut 3 hand tight Open fuel shuto...

Страница 59: ...of removal Inspect the fuel pump gasket for any damage and replace if necessary Fuel Shutoff Solenoid Diesel Models Removal and Installation See Figures 3 31 and 3 32 1 Park the mower safely See Park...

Страница 60: ...ressure switch and glow plug Figure 3 33 8 Tag and disconnect genset to main harness connectors 1 and 2 9 Tag and disconnect throttle actuator connector 4 10 Cut cable ties 3 Figure 3 34 11 Tag and di...

Страница 61: ...ne harness to main harness connectors 19 and 20 Figure 3 39 22 Turn the fuel outlet hose shutoff valve clockwise until valve bottoms lightly Valve is located on the bottom of the fuel tank 23 Remove f...

Страница 62: ...ake hose 31 Figure 3 41 30 Disconnect overflow hose 37 and secure out of the way 31 Remove two screws 33 lock washers 34 and flat washers 35 32 Remove air cleaner bracket assembly 32 33 Remove radiato...

Страница 63: ...lug hose to prevent leakage and contamination 45 Remove nuts 56 screws 57 and radiator overflow bottle 60 WARNING 46 Using an engine hoist support the genset 59 and remove nuts 54 and genset carrier m...

Страница 64: ...installation Tighten genset carrier mounting screws 55 to 65 0 lb ft 88 N m Use new gaskets when installing the exhaust system Use new cable ties to secure wire connectors and wire harnesses Apply di...

Страница 65: ...nge 13 L S Engine Mount 22 Screw 2 31 Screw 40 Hose Clamp 2 5 Blind Coupling 14 Screw 8 23 R S Engine Mount 32 Nut 2 41 Hose 6 Screw 5 15 Isolation Mount 2 24 Nut 2 33 Governor Linkage Arm 42 Lock Was...

Страница 66: ...rior to assembly Tighten six generator flange mounting screws 43 to 13 0 lb ft 17 6 N m Apply Loctite 242 Blue to four generator assembly mounting screws 34 prior to assembly Tighten four generator as...

Страница 67: ...s oil in a clean absorbent cloth Replace air filter pre cleaner if it remains dirty or is damaged Do not use petroleum solvents such as kerosene to clean air filter cartridge Do not use pressurized ai...

Страница 68: ...3 49 4 Rotate clip 5 on throttle plate and disengage engine throttle linkage 2 5 Disengage engine throttle linkage 2 from throttle link 1 6 Disengage spring 3 from hook 6 on throttle plate 7 Remove sp...

Страница 69: ...p to provide a vent for draining fuel 8 Open the fuel shutoff valve 1 at the bottom of the fuel tank 9 When fuel tank is completely empty tighten fuel cap 10 Close fuel shutoff valve 1 Turn clockwise...

Страница 70: ...the order of removal Make sure the flow arrow on the side of the fuel filter is aligned with the fuel tank to fuel pump flow direction Genset Gasoline Models Removal and Installation See Figures 3 55...

Страница 71: ...arefully guide the cables away from the PDU and position the cables to be unrestricted during genset removal Figure 3 57 18 Tag and disconnect the generator negative output cable 8 from ground stud 9...

Страница 72: ...om the genset Figure 3 60 26 Remove four screws 18 and nuts 20 and remove fuel tank bracket 19 Figure 3 61 27 Remove four screws 21 and flat washers 22 and remove rear controller cover 23 Figure 3 62...

Страница 73: ...See the Parts and Maintenance Manual for additional information and illustrations Installation Notes I Inspect engine mounts and replace if necessary Install the genset by reversing the order of remov...

Страница 74: ...rew 19 Gas Throttle Link 27 Screw 8 35 Screw 8 4 Nut 4 12 Flat Washer 20 Gas Throttle Actuator 28 Screw 9 36 Screw 5 O Ring 13 Hose Clamp 2 21 Screw 4 29 Engine Plate 6 Screw 4 14 Air Cleaner Stud 22...

Страница 75: ...to assembly Tighten engine coupler screw 16 to 32 lb ft 43 4 N m Engine Service Gasoline Models A separate engine manual prepared by the engine manufacturer is supplied with this machine Refer to the...

Страница 76: ...akage and contamination 12 Remove upper tray mat 19 Figure 3 67 13 Remove screw 21 nut 22 and battery bracket 20 Figure 3 68 NOTE Direction of arrow indicates front of machine 14 Disconnect battery ca...

Страница 77: ...25 and screws 26 22 Repeat step 21 for other side of machine 23 Remove battery pack tray 27 NOTICE Installation Note Install battery pack battery pack tray and battery filling system by reversing the...

Страница 78: ...ove two screws 13 flat washers 12 lock washers 11 and nuts 110 10 Remove buffer battery pack tray 14 Installation Notes Install buffer battery pack and buffer battery pack tray by reversing the order...

Страница 79: ...Notes Install starter battery by reversing the order of removal Route battery cables between the starter battery and the machine avoiding pinch points Be sure that the key switch is off all electrica...

Страница 80: ...PACK 3 Battery Charger Removal and Installation See Figure 3 73 1 Park the mower safely See Park Mower Safely on page 1 6 2 Raise the hood Figure 3 73 NOTE Label all wires before disconnecting to ensu...

Страница 81: ...ger 3 Installation Notes Install battery charger by reversing the order of removal Route battery charger cables between the battery pack and the machine avoiding pinch points Be sure that the key swit...

Страница 82: ...3 46 4271491 Second Edition GENSET AND BATTERY PACK 3...

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