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GENERAL

Repair of the electrical system, for the most part, is
limited to the replacement of faulty components or wir-
ing. Wiring diagrams and Component Location illus-
trations are provided in Section 10N for troubleshoot-
ing and/or testing the electrical system. Specific repair
and replacement instructions, where applicable, are
also provided in this section.

NOTE

The test instrument shown in the illustrations for
this section is a digital multimeter (DMM). How-
ever, any test instrument capable of measuring
voltage, current resistance, and continuity val-
ues specified for each test is acceptable.

NOTE

See Engine Manufacturer’s Service Manual for
information on engine electrical components not
covered in this section.

In addition to testing a suspected faulty component it
may be necessary to check for shorts or breaks in the
wiring to the component. A common method of testing
wires or circuits is to perform a continuity check as
described below.

NOTE

Before performing any component or wiring test,
check for corrosion and loose or missing con-
nections.

If a component (switch, relay, etc.) is removed for test
or replacement make sure to identify and label wires
so that the component can be installed correctly.

WIRE CONTINUITY TEST
(See Figure 10C-1)

1. Identify and locate the wire to be checked on the

appropriate “Electrical System” illustration, locat-
ed in Section 10N.

2. Set multimeter to

Ω

(ohms)

scale and touch

leads to end of wire.

•

There should be a reading (continuity) on the
multimeter. If not, proceed to 3.

3. Perform a second check by using a jumper wire to

bypass the wiring being tested. If the component
in question now functions normally, replace the
original wire.

ELECTRICAL SYSTEM

SECTION 10C. GENERAL INSTRUCTIONS

10C-1

10C

POWER

OFF

ON

200m

2

20

200

1000 750200

20

2

200m

20M

2M

200M

20K

2K

200

200

DCV

ACV

ACA

200µ

2m

200m

2

2

200m

20m

10A

2m

200µ

DCA

20m

10A

COM

A

10A

!

1000V

750V

MAX

!

!

2A

MAX

10A MAX

500V

MAX

20M

2M

200M

20K

2K

200

200

ACA

200µ

2m

200m

2

2

200m

20m

10A

2m

200µ

DCA

20m

10A

-

COM

A

!

2A

MAX

V -

Figure 10C-1. Wire Continuity Test

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Содержание HR 5111

Страница 1: ...aintain the machine should be trained in its proper use warned of its dangers and should read the entire manual before attempting to set up operate adjust or service the machine Copyright 1997 Jacobse...

Страница 2: ......

Страница 3: ...14 2 3 4 5 6 7 8 9 10 11 12 13 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOU...

Страница 4: ......

Страница 5: ...Numbers 1A 1 Replacement Parts 1A 1 Serial Numbers 1A 1 General Cleaning 1A 2 Safety 1A 2 Torque Values 1A 2 Torque Specifications 1A 3 Standard SAE Grade 5 Screws 1A 3 Metric 1A 3 Fenders and Hood Re...

Страница 6: ......

Страница 7: ...ughout this manual refer to the operator s left or right when standing in the normal operating position INDEX NUMBERS Illustrations showing removal disassembly reassembly and installation may have ind...

Страница 8: ...stalled as shown in Section 14 of this manual TORQUE VALUES Torque values are given in the following Torque Spe cification Chart Special torque values are called out on illustrations and text through...

Страница 9: ...447 N m 3 8 16 27 33 ft lbs 37 45 N m 7 8 9 360 440 ft lbs 488 597 N m 3 8 24 31 39 ft lbs 42 53 N m 7 8 14 396 484 ft lbs 537 656 N m 7 16 14 45 55 ft lbs 61 75 N m 1 8 522 638 ft lbs 708 865 N m 7...

Страница 10: ...111 can be accom plished by opening the hood and or seat pan For bet ter access the hood floor pan and engine compart ment cowling can be removed Figure 1A 2 Mark all attaching hardware to simplify in...

Страница 11: ...1 General 2C 1 Throttle 2C 1 Traction Pedal 2C 2 Traction Pedal Neutral Adjustment 2C 3 Speed Limit Adjustment 2C 4 Reverse 2C 4 Forward 2C 4 Reverse Sensing Switch 2C 4 Adjustment 2C 4 Parking Brake...

Страница 12: ......

Страница 13: ...equired Standard automotive hand tools Cleaning materials Stoddard or equivalent solvent Detergent and water Lubricants Refer to Section 11 CONTROLS SECTION 2A REPAIR AND SERVICE TOOLS AND MATERIALS 2...

Страница 14: ......

Страница 15: ...on pedal is in not adjusted neutral b Binding in the linkage b Repair lubricate Sections 2C and 11B 4 Parking brake does not a Brake not adjusted a Adjust Section 2C hold b Worn brake shoes b Replace...

Страница 16: ...l c Faulty cruise magnet c Replace 12 Cruise control does not a Faulty holding relay a Test replace Section 10H shut OFF 13 No 4 wheel drive a 4 wheel drive switch not ON a Turn ON b Reverse sensing s...

Страница 17: ...s not a Mower not on the ground a Lower come on b Arm interlock switch not closing b Check switch Section 10G c Check solenoid plug LED c See Section 10B ON Push manual override Mower comes ON Faulty...

Страница 18: ...hen operator leaves seat implement switch ON 22 Panel lights do not come a 10 amp gauge panel light circuit a Reset test Section 10J on when test switch is breaker tripped pushed to the ON b Battery d...

Страница 19: ...lacement of de fective parts and hardware THROTTLE See Figure 2C 1 Located to the right of the operator s seat the throttle control is used to regulate engine speed Replace a defective throttle as sho...

Страница 20: ...nected by linkage to the hy drostatic pump Depending on which way the pedal is depressed it controls forward or reverse Repair of the traction pedal and linkage is limited to replacement of damaged or...

Страница 21: ...lace a small amount of lubricating oil on pedal linkage pivot points to ease movement 1 Raise the tractor so all four wheels are off the ground Put jack stands under frame to prevent accidental loweri...

Страница 22: ...fore reaching its maximum forward position 2 Adjust stud 7 until the head touches the traction pedal then turn the stud one revolution counter clockwise out against the pedal 3 Tighten nut 6 REVERSE S...

Страница 23: ...terclockwise until a smooth but firm action is obtained SERVICE BRAKE See Figure 2C 5 The service brake pedal should have a minimum of 1 8 3 17 mm free play before the plunger contacts piston in the m...

Страница 24: ...onent as follows 1 Remove fuel tank to gain access 2 Disconnect battery ground black cable 3 Label wires for proper identification and discon nect wiring 4 Remove attaching hardware and replace faulty...

Страница 25: ...on 3C 1 3D Diesel Engine 3D 1 General 3D 1 Air Cleaner 3D 1 Radiator 3D 2 Changing Coolant 3D 2 Cleaning Radiator Core 3D 2 Removal 3D 2 Installation 3D 2 Muffler Removal and Installation 3D 3 Exhaust...

Страница 26: ......

Страница 27: ...ing materials Stoddard or equivalent solvent Detergent and water Anti rust Never Seize Lubricants Refer to Section 11 Other service items Compressed Air Source Engine Hoist Loctite 242 Blue Engine Ser...

Страница 28: ......

Страница 29: ...an and or replace filter smoothly Section 3D b Faulty engine component b See Engine Manufacturer s Service Manual 3 Engine dies down a Throttle adjustment a Adjust Section 3D under load b Binding in g...

Страница 30: ......

Страница 31: ...the engine manufacturer s instructions for engine service and repair The engine manual is available from your Jacobsen Dealer or Distributor NOTE Tests for alternators starters and regulator are inclu...

Страница 32: ......

Страница 33: ...Remove the baffle 3 and empty dust from the cover Wipe clean with a clean damp cloth NOTE It is not recommended to remove element to clean If element is to be removed replace with a new one 2 Remove...

Страница 34: ...ove radiator cap 2 and drain the coolant 4 Disconnect the inlet and outlet hoses by loosen ing hose clamps 3 5 Disconnect overflow tube at radiator cap 6 Remove attaching hardware 4 and 5 7 Inspect we...

Страница 35: ...CTION 1 Clean all sections of the exhaust system of dirt dust or other foreign material 2 Inspect exhaust system for cracks holes distor tion or deformation ENGINE SECTION 3D DIESEL ENGINE 3D 3 3D CAU...

Страница 36: ...clockwise two turns Use a suit able container to catch fuel which will flow from screw hole 3 Turn ignition switch ON to allow electric fuel pump to operate 4 When bubbles disappear from fuel coming o...

Страница 37: ...ure 3D 6 4 Disconnect the throttle cable at the fuel injection pump Figure 3D 7 5 Remove the exhaust pipe and radiator shroud de scribed in preceding paragraphs see Figure 3D 2 and 3D 3 6 Tag and remo...

Страница 38: ...lockwashers 5 and flat washers 6 that secure the engine to the frame 4 Install the radiator shroud and exhaust pipe as described in preceding paragraphs of this section 5 Tighten mounting bolts 4 afte...

Страница 39: ...1 Assembly 4D 2 4E Axle 4E 1 General 4E 1 Differential Lock Assembly 4E 2 Input Bevel Pinion 4E 2 General 4E 2 Disassembly 4E 3 Reassembly 4E 4 Break Away Torque Adjustment 4E 5 Reduction Gear and Dri...

Страница 40: ......

Страница 41: ...lent Lubricants Refer to Section 11 Special tools Bucher Guyer AG CH 8166 Niederweningen FAX 01 857 26 55 Adjusting tool 150 10511 0 Special circlip pliers 150 16789 0 Loctite Master Gasket Sealant or...

Страница 42: ......

Страница 43: ...erential lock d Repair Section 4E e Differential lock collar jammed e Repair Section 4E 3 Wheel scuffs turf a Differential lock engaged a Release on turns b Differential not disengaging b See 1 above...

Страница 44: ......

Страница 45: ...5 Repeat Steps 3 and 4 for the remaining bearings ASSEMBLY See Figure 4C 1 NOTE During reassembly be sure all the parts are clean and free of dirt 1 Start one bearing in yoke ear and position center...

Страница 46: ......

Страница 47: ...Figure 4D 1 1 Remove drive shaft assembly from tractor 2 Position the joint in a vise as shown 3 Remove the four snap rings 4 With a soft face hammer strike the top ear of the yoke This will drive th...

Страница 48: ...sing a socket or mandrel the same diameter as the bushing drive the bush ing slightly past the snap ring groove 4 Install the snap ring 5 Repeat Steps 3 and 4 for the other bushings 6 After assembly e...

Страница 49: ...GENERAL See Figure 4E 1 DRIVE TRAIN SECTION 4E AXLE 4E 1 4E Figure 4E 1 Axle Assembly...

Страница 50: ...parts To repair the sliding differential lock collar refer to Differential Disassembly for removal and Reassembly for installation INPUT BEVEL PINION GENERAL The input bevel pinion and ring gear are...

Страница 51: ...bevel pinion assembly from axle 3 If the original pinion shaft is to be used remove the shim pack tag and mark it for reassembly If the shims are damaged replace them with shims equal to the thicknes...

Страница 52: ...leeve and press bearing cone against sleeve 5 With the bearing inner race supported press out er bearing cone into housing until it just contacts the collapsible sleeve be careful not to collapse the...

Страница 53: ...housing 3 Install O ring and shims pack on pinion housing REDUCTION GEAR AND DRIVE AXLE GENERAL Bearings in the reduction gear case are press fitted The large gear is splined to the shaft The axle pin...

Страница 54: ...race of the bearing and press drive axle shaft into bearing Step 3 for right axle ONLY 3 Remove the differential lock assembly housing 4 Press drive axle with bearing into axle housing right axle ONL...

Страница 55: ...ts to 37 ft lbs 51 N m DIFFERENTIAL GENERAL Separate the axle housing only if bearings pinion gear ring gear differential lock collar and or differen tial are worn or damaged If the differential and o...

Страница 56: ...ring bore of gear case 3 Measure the distance between the special tool and end of pinion 4 Subtract this dimension from 0 689 17 5 mm 5 Build a shim pack equal to the final dimension ob tained in Step...

Страница 57: ...and input bevel pinion Apply Loctite 242 Blue to the pinion housing bolts and torque them to 37 ft lbs 51 N m 8 Measure the distance from the side of the differ ential bearing to the gear case flange...

Страница 58: ...Build a shim pack equal to 0 030 0 76 mm and install it in the bearing bore of the right axle 9 Assemble both axle halves together 10 Snug the bolts evenly do not tighten 11 Using a feeler gauge meas...

Страница 59: ...and Materials 5A 1 5B Failure Analysis 5B 1 5C Parking Brake 5C 1 Repair 5C 1 Adjustment 5C 1 5D Service Brake 5D 1 Repair 5D 1 Bleeding System 5D 1 5E Master Cylinder 5E 1 Repair 5E 1 Bleeding Syste...

Страница 60: ......

Страница 61: ...ND SERVICE TOOLS AND MATERIALS 5A 1 5A Tools required Standard automotive hand tools Metric tools Cleaning materials Stoddard solvent or equivalent Lubricants Refer to Section 11 Other service items B...

Страница 62: ......

Страница 63: ...ngs c Replace Section 5D 3 Service brake pedal a Worn brake pads a Replace Section 5D fades when pushed b Brake line leaks b Repair c Air in line c Bleed 4 Service brake does not a Binding pedal a Fre...

Страница 64: ......

Страница 65: ...n and turn knob in a clockwise direction apply and re lease brake lever every quarter turn until a defi nite snap over center action is achieved 2 Over adjustment causes hard lever action but does not...

Страница 66: ......

Страница 67: ...luid see Section 11 2 At the brake calipers open both bleed screws 3 Slowly push the brake pedal several times until all the air has been bled from the brake lines NOTE At the end of each pedal downwa...

Страница 68: ......

Страница 69: ...fluid see Section 11 2 At the brake calipers open both bleed screws 3 Slowly push the brake pedal several times until all the air has been bled from the brake lines NOTE At the end of each pedal down...

Страница 70: ......

Страница 71: ...Unit 6C 1 General 6C 1 Removal 6C 1 Disassembly 6C 2 Inspection 6C 4 Assembly 6C 5 Installation 6C 11 6D Steer Wheel Adjustments 6D 1 Toe In 6D 1 Turn Stop 6D 1 6E Steering Cylinder 6E 1 Removal 6E 1...

Страница 72: ......

Страница 73: ...aning materials Stoddard solvent or equivalent Other service items O ring and kin ring tool SJ 150 9000 11 Cardan shaft tool SJ 150 9000 3 Above tool can be purchased from Danfoss Inc 1696 Northrock C...

Страница 74: ......

Страница 75: ...Replace leaf springs Section 6C steering go to neutral position 4 Backlash a Splines of cardan shaft worn or a Cardan shaft to be replaced broken Section 6C b Leaf springs b Replace worn spring Secti...

Страница 76: ......

Страница 77: ...al steering REMOVAL See Figure 6C 1 1 Remove steering wheel cap 1 nut 2 flat wash er 3 and steering wheel 4 NOTE Insert 5 should come off with steering wheel 2 Remove steering unit cover 6 3 Label and...

Страница 78: ...ve end cover screws 1 and washers 2 NOTE There are seven screws one is a special screw note its position 3 Slide cover 3 sideways from gear wheel set 4 4 Lift gear wheel set 4 off housing 5 Remove car...

Страница 79: ...ing unit housing See Figure 6C 5 10 Remove O ring 22 kin ring 21 thrust bearing and washers 20 ring 19 and dust ring 23 11 Push cross pin 15 out of sleeve 16 12 Carefully push spool 17 from sleeve 16...

Страница 80: ...NOTE Steps 14 and 15 describe the removal of one of two shock valve assemblies Repeat Steps 14 and 15 for the other shock valve 16 Using a 8 mm hex socket wrench remove pres sure relief valve plug 30...

Страница 81: ...o flat neutral position springs 18 into slot of spool 17 4 Slide two curved springs 18 between the flat springs 5 Press springs together and push into slots of sleeve 16 6 Line up springs 18 and cente...

Страница 82: ...6 NOTE Ring 19 should rotate free of springs 18 8 Install cross pin 15 through sleeve and spool 9 Install thrust bearing and washers 20 being sure inside chamber of heavy washer goes on spool first ST...

Страница 83: ...ng 22 and kin ring 21 Place them on the guide tool as shown 12 Using the inner tool push and turn the guide through the outer tool sleeve until O ring 22 and kin ring 21 properly seat in the housing 1...

Страница 84: ...ert sleeve assembly 14 NOTE Sleeve to housing fit is very close Do not force together 16 Push sleeve 14 into housing pushing out the O ring and kin ring guide tool 17 Insert ball 11 into hole as shown...

Страница 85: ...24 Install gear wheel set 5 Engage the splines so the valley of the inner rotor is in line with the pin slot of the cardan shaft as shown 25 Install cover 3 flat washers 2 and screws 1 NOTE Be sure t...

Страница 86: ...tractor hydraulics and adjust as described in Section 8S 28 Install relief valve spool 34 spring 33 and us ing an 8 mm hex socket wrench plug 32 29 Install washer 31 and plugs 30 snug After adjusting...

Страница 87: ...3 Install insert 5 flat washer 3 steering wheel 4 and nut 1 Torque nuts to 25 30 ft lbs 34 41 N m 4 If steering unit was disassembled adjust shock valve and relief valve pressure settings as de scribe...

Страница 88: ......

Страница 89: ...ompletely to the right and left 3 In each direction the steering arms should con nect the stop bolts If they do not proceed with Step a a Remove the cylinder b Loosen the cylinder clamps on each end o...

Страница 90: ......

Страница 91: ...set the parking brake 2 Tag and remove hydraulic lines Cap the cylinder ports and plug the lines 3 Remove attaching hardware and remove cylinder STEERING SECTION 6E STEERING CYLINDER 6E 1 6E Figure 6E...

Страница 92: ...l the oil from the cylinder Disassemble following the steps as illustrated INSPECTION Inspect all parts for excessive wear cracks and broken parts Discard all O rings seals and backup rings STEERING S...

Страница 93: ...before assembly 4 Follow the steps as illustrated in Figure 6E 4 and reassembly INSTALLATION See Figure 6E 1 1 Install cylinder and secure with attaching hardware 2 Connect hydraulic hoses 3 Start tr...

Страница 94: ...STEERING SECTION 6E STEERING CYLINDER 6E 4 Figure 6E 4 Steering Cylinder Assembly...

Страница 95: ...7 7A Repair and Service Tools and Materials 7A 1 7B Failure Analysis 7B 1 7C Tire Service 7C 1 General 7C 1 Service 7C 1 SECTION 7 WHEELS AND TIRES...

Страница 96: ......

Страница 97: ...eaning materials Stoddard solvent or equivalent Other service items Commercially available tire sealant Non hardening Tire pressure gauge Compressed air with tire valve fitting WHEELS TIRES SECTION 7A...

Страница 98: ......

Страница 99: ...Under inflated tires a Inflate tires to 20 to 24 psi 1 4 to 1 6 bars front and 6 to 10 psi 41 to 68 bars rear b Steering malfunctioning b Steering test Refer to Sections 8M 8N c Wheel nuts loose c Tig...

Страница 100: ......

Страница 101: ...hen it is replaced This assures proper seating of the tire bead to the rim Then reduce the pressure to the desired level before using NOTE Never use grease or oil on the rim when mount ing a tire Bead...

Страница 102: ......

Страница 103: ...Face Seal Torque Recommendations 8C 3 8D Traction Pump 8D 1 General 8D 1 Removal 8D 1 Repair 8D 2 Inspection 8D 2 Installation 8D 3 8E Implement Pump 8E 1 General 8E 1 Removal 8E 1 Repair 8E 2 Disasse...

Страница 104: ...em 8Q 6 8R Instrument Test 8R 1 General 8R 1 Relief Valve Test 8R 2 Charge Relief Test 8R 2 Steering System Relief Test 8R 3 Adjustment 8R 3 Lift System Relief 8R 4 Adjustment 8R 4 Traction System Rel...

Страница 105: ...r Test 8R 17 Wing Mowers 8R 18 Pump Test 8R 18 Right Wing Motor Valve Test 8R 19 Right Wing Motor Tests 8R 19 Left Wing Motor Valve Test 8R 20 Left Wing Motor Tests 8R 20 Hydraulic Instrument Test Dat...

Страница 106: ......

Страница 107: ...ls Stoddard or equivalent solvent Detergent and water Loctite Locquic Primer T Lubricants Refer to Section 11 Grease Sunray DX671 or Gulf Supreme No 0 Other service items Seal and Repair Kits availabl...

Страница 108: ...HYDRAULICS SECTION 8A REPAIR AND SERVICE TOOLS AND MATERIALS 8A 2 Figure 8A 1 Wheel Restraint...

Страница 109: ...everse OK out of adjustment b Faulty traction loop relief b Test Section 8R valve s 4 No reverse or slow a Traction linkage damaged or a Repair adjust Section 2C forward OK out of adjustment b Faulty...

Страница 110: ...energize d Insufficient charge pressure to d Test Section 8R activate differential lock e Differential collar return spring e Repair Section 4E broken LIFT SYSTEM 1 Mowers will not lower a Engine RPM...

Страница 111: ...der leaking internally a Repair Section 8L themselves b Valve detent poppet not seating b Repair Section 8H or leaking c Detent spool not retracting c Repair Section 8H completely sticking 10 Mower s...

Страница 112: ...aulty pump section e Test Section 8R NO see a YES see c e OFF See a 5 Right wing mower doesn t a Faulty electrical circuit a See Section 10B run b Faulty motor control valve b Test Section 10I Check L...

Страница 113: ...mallet is recommended unless otherwise specified in the repair instruction Unless otherwise indicated apply a light coat of clean hydraulic fluid to parts as each is reassembled Ap ply clean grease to...

Страница 114: ...for O Ring Boss Fittings NOTE O rings should be lubricated with the fluid to be used in the system prior to assembly HYDRAULICS SECTION 8C GENERAL INSTRUCTIONS 8C 2 FIgure 8C 1 Reference Marking SAE...

Страница 115: ...e Size O D In Lbs 3 3 8 24 0 188 96 120 4 7 16 20 0 250 168 192 5 1 2 20 0 312 216 240 6 9 16 18 0 375 288 312 8 3 4 16 0 500 600 720 10 7 8 14 0 625 864 960 12 11 16 12 0 750 1500 1620 14 13 8 12 0 8...

Страница 116: ......

Страница 117: ...until a hydro pump test described in Section 8Q and or 8R is performed 1 Remove the seat and seat pan 2 Thoroughly clean area around entire pump with a suitable cleaning solvent Do not use material th...

Страница 118: ...gouged marks 2 Inspect piston shoes for excessive wear cracks or shoes that fall off pistons 3 Inspect shaft for excessive wear or damage 4 If any component condition is questionable replace hydrostat...

Страница 119: ...fasten the mounting plate 2 Connect all control linkage See Section 2 for prop er adjustments 3 Install the implement pump 4 Connect all hydraulic hoses and tubes 5 Install seat and seat pan 6 Start...

Страница 120: ......

Страница 121: ...p section 4 supplies oil for steering lift and lower charge oil for the traction pump differ ential lock and the 4 wheel drive valve REMOVAL See Figure 8E 1 1 Using a suitable solution clean the pump...

Страница 122: ...Recommended method of marking body sections is to use a fine point metal punch making one indentation in line on each section HYDRAULICS SECTION 8E IMPLEMENT PUMP 8E 2 CAUTION Never pry pump sections...

Страница 123: ...ng up from cover section 3 Use a new seal kit during assembly Use clean grease to keep seals in position 4 Remove alignment mark from gear sets after they have been installed with teeth in mesh 5 Rota...

Страница 124: ......

Страница 125: ...REPAIR Repairs are limited to replacing the 4 wheel drive pilot cartridge or changing O rings HYDRAULICS SECTION 8F 4 WHEEL DRIVE CONTROL VALVE 8F 1 8F Figure 8F 1 4 Wheel Drive Control Valve...

Страница 126: ......

Страница 127: ...ited to cleaning only Use a punch manu ally push poppet off its seat and flush with cleaning solvent If the problem still exists replace valve HYDRAULICS SECTION 8G ANTI SIPHON VALVE 8G 1 8G Figure 8G...

Страница 128: ......

Страница 129: ...r the three front cutting units REMOVAL 1 Drain and remove the fuel line 2 Tag and mark hydraulic lines on valve 3 Remove hydraulic lines 4 Disconnect lever linkage and remove 5 Remove valve DISASSEMB...

Страница 130: ...HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H 2 Figure 8H 3 Spool Assembly Removal Figure 8H 4 Relief Valve Removal...

Страница 131: ...rts as necessary 3 Inspect poppet seats for burrs or roughness 4 Discard old O rings and replace with new ones REASSEMBLY See Figures 8H 5 to 8H 7 HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H...

Страница 132: ...HYDRAULICS SECTION 8H LIFT AND LOWER CONTROL VALVE 8H 4 Figure 8H 7 Detent and Lockout Reassembly...

Страница 133: ...REPAIR HYDRAULICS SECTION 8I TRACTION MOTOR 8I 1 8I Figure 8I 1 Traction Motor Disassembly Figure 8I 2 Drive Shaft Disassembly...

Страница 134: ...nd shoes Pistons should be snug and shoes should be flat and have no signs of flaking NOTE Do not tap piston shoes 4 Inspect piston block Make sure the flat surface is free of score marks NOTE Do not...

Страница 135: ...HYDRAULICS SECTION 8I TRACTION MOTOR 8I 3 8I Figure 8I 4 Drive Shaft Reassembly Figure 8I 5 Traction Motor Reassembly...

Страница 136: ......

Страница 137: ...REPAIR HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 1 8J Figure 8J 1 Rear Traction Motor...

Страница 138: ...HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 2 Figure 8J 2 Seal Assembly...

Страница 139: ...HYDRAULICS SECTION 8J REAR TRACTION MOTOR 8J 3 8J Figure 8J 3 O Rings and Seals...

Страница 140: ......

Страница 141: ...REPAIR Repair of the control valve is limited to changing car tridges or renewing O ring on each cartridge HYDRAULICS SECTION 8K CONTROL VALVE 8K 1 8K Figure 8K 1 Control Valve...

Страница 142: ......

Страница 143: ...re the same FRONT CYLINDERS DISASSEMBLY See Figure 8L 1 1 Clean and air dry exterior of cylinder 2 Drain all the oil from the cylinder 3 Disassemble following the steps in Figure 8L 1 HYDRAULICS SECTI...

Страница 144: ...eals and seal ring REASSEMBLY 1 Lightly lubricate O rings seal ring and seals 2 Install seal kit as shown in Figure 8L 2 3 Lubricate all parts before assembly 4 Follow the steps as illustrated in Figu...

Страница 145: ...HYDRAULICS SECTION 8L LIFT CYLINDER 8L 3 8L Figure 8L 3 Lift Cylinder Assembly...

Страница 146: ...air dry exterior of cylinder 2 Drain all the oil from the cylinder 3 Disassemble following the steps in Figure 8L 4 4 Disassemble remainder of cylinder as shown in Fig ure 8L 4 HYDRAULICS SECTION 8L...

Страница 147: ...EMBLY 1 Lightly lubricate O rings backup rings and seals 2 Install seal kit as shown in Figure 8L 5 NOTE Do not install rod O ring at this time 3 Lubricate all parts before assembly 4 Follow the steps...

Страница 148: ...HYDRAULICS SECTION 8L LIFT CYLINDER 8L 6 Figure 8L 6 Wing Cylinder Assembly...

Страница 149: ...The following illustration shows one of the three valves REPAIR See Figure 8M 1 Repair of the valve consists of installing a new O ring kit for changing a coil 1 Follow the sequence as illustrated to...

Страница 150: ...sure it slides easily in the outer flux sleeve 5 Check for broken or cracked return spring INSTALLATION Install control valve to frame with attaching hardware SOLENOID COIL REPLACEMENT Refer to Secti...

Страница 151: ...erclockwise CCW rotating have the letter A stamped on the motor housing Prior to disassembly mark the position of the check valve in the cover to motor housing REPAIR See Figure 8N 2 Repair of the mot...

Страница 152: ...aning an indication of damage to motor or other hydraulic component 2 Inspect all parts for cracks nicks burrs and exces sive wear Replace entire motor if found damaged or worn REASSEMBLY See Figure 8...

Страница 153: ...s is located at the bottom left side of the hydraulic tank Repair is limited to cleaning only Disassemble and flush with a cleaning solvent HYDRAULICS SECTION 8O OIL COOLER COLD OIL BYPASS 8O 1 8O Fig...

Страница 154: ......

Страница 155: ...REPAIR Repair of the flotation control is renewing O ring or replacing the control cartridge HYDRAULICS SECTION 8P FLOTATION CONTROL 8P 1 8P Figure 8P 1 Back Pressure Control Valve...

Страница 156: ......

Страница 157: ...nce Always change the filter when changing the oil The filter should be changed after the initial 25 hours of operation Thereafter the filter should be changed approximately every 250 hours 2 Check al...

Страница 158: ...With the engine throttle wide open 2 wheel drive and cutting units lowered slowly step on the trac tion pedal If the engine labors or the tractor drive tires brake traction the traction motor is okay...

Страница 159: ...r steer ing the maximum right and or left the steering unit is okay If the steering wheel continues to turn proceed to Step 2 2 Remove both hydraulic lines from the steering cylin der plug the lines c...

Страница 160: ...HYDRAULICS SECTION 8Q HYDRAULIC FIELD TEST PROCEDURES 8Q 4...

Страница 161: ...Wing Remove hydraulic lines as shown in Figure 8Q 4 Plug line and cap port Left Wing Remove hydraulic lines as shown in Figure 8Q 4 Plug line and cap port 3 Pull lift control lever raising the mower...

Страница 162: ...plement mower switches ON engine not running and the reel directional switch in CUT check the plastic connector on the motor control valve the red LED should be on If the red LED is on proceed with St...

Страница 163: ...HYDRAULICS SECTION 8Q HYDRAULIC FIELD TEST PROCEDURES 8Q 7 Figure 8Q 5 Reel System 8Q...

Страница 164: ...motor If the case drain line feels warmer than the remaining motor it may have excessive internal leakage see Section 8N If only the right motor is affected check its case drain line If the case drai...

Страница 165: ...afe manner It is important to follow the instructions accurately and completely Make sure to plug lines and cap ports when so instructed Also read and follow the Preliminary Checks provided in Section...

Страница 166: ...advance throt tle to 2800 engine rpm Charge relief should read 190 250 psi NOTE The charge relief cartridge should not be adjusted If the charge relief pressure is higher or lower than 190 250 psi ad...

Страница 167: ...psi is obtained relief valve is okay If 1500 psi cannot be obtained proceed with relief valve adjustment Adjustment See Figure 8R 3 1 Shut the engine down before making the adjust ment 2 Remove the s...

Страница 168: ...be obtained proceed with re lief valve adjustment Adjustment See Figure 8R 4 1 Be sure engine is shut down 2 Remove relief valve cap from lift valve 3 Shims are used to adjust the pressure setting Ad...

Страница 169: ...5 1 Use a 0 5000 psi gauge with test adapter P N 551433 2 Plug gauge into port BD located on the top of the 4 wheel drive valve 3 Set the parking brake start the engine advance throttle to 2800 engine...

Страница 170: ...rt of the left motor Plug line cap motor port 4 Set the brake start the engine advance the throttle to 2800 engine rpm Engage the front motor circuit If 3000 psi is obtained relief valve is okay If 30...

Страница 171: ...er load valve start engine advance throt tle to 2800 engine rpm 5 Read record no load flow It should be 7 5 gpm 6 Slowly close tester load valve until 1500 psi is obtained and allow oil to heat up to...

Страница 172: ...t the engine slowly advance the throttle Flow should increase to approximately 4 5 5 0 gpm at approximately 1900 2000 engine rpm At this point flow should stop increasing as engine rpm continues to be...

Страница 173: ...he front mower NOTE DO NOT start engine If mower s come down and no oil leaks from disconnected tee the lift valve may be faulty repair valve see Section 8H NOTE A small amount of static oil may leak...

Страница 174: ...down and oil contin ues to leak from cylinder port cylinder is faulty repair cylinder see Section 8L RIGHT WING CYLINDER AND LIFT VALVE ISOLATION EST See Figure 8R 10 15 Raise right wing mower and lo...

Страница 175: ...charge pressure is not affected after changing the charge relief cartridge proceed with an in strument test implement pump section 4 11 Slowly close tester load valve until 3000 psi is obtained and al...

Страница 176: ...Open tester load valve start engine advance throt tle to 2800 engine rpm 19 Set parking brake apply and hold foot brake 20 Slowly close tester load valve until 3000 psi is obtained and allow oil to h...

Страница 177: ...Open tester load valve start engine advance throt tle to 2800 engine rpm 25 Engage 4 wheel drive switch 26 Set parking brake apply and hold foot brake 27 Slowly close tester load valve until 3000 psi...

Страница 178: ...or hose to L1 port 30 Install rear wheel restraints to the right and left rear wheels 31 Open tester load valve start engine advance throt tle to 2800 engine rpm 32 Engage 4 wheel drive switch 33 Set...

Страница 179: ...er load valve start engine advance throt tle to 2800 engine rpm 5 Read record no load flow It should be 10 0 gpm 6 Slowly close tester load valve until 2300 psi is ob tained and allow oil to heat up t...

Страница 180: ...ith Step 20 If flow drop is 1 2 1 gpm valve is marginal If flow drops more than 1 gpm valve has exces sive internal leakage Left Motor Test NOTE A pump and valve test must be performed be fore proceed...

Страница 181: ...wer reel switch into CUT and pull implement switch ON 35 Slowly close tester valve until 2500 psi is obtained 36 Read record gpm flow Subtract from flow obtained in CENTER MOTOR test If flow drops 1 2...

Страница 182: ...tester to the pump out let port and plug pump outlet line 3 Put the hose from the OUT port of tester into the hydraulic tank 4 Open tester load valve start engine advance throt tle to 2800 engine rpm...

Страница 183: ...ief valve adjustments reel system wing mowers adjustment Figure 8R 6 18 Slowly open tester load valve until 2500 psi is obtained 19 Read record gpm flow Subtract from flow obtained in PUMP test If low...

Страница 184: ...faulty Readjust see relief valve adjustments reel system wing mowers adjustment Figure 8R 6 18 Slowly open tester load valve until 2500 psi is obtained 19 Read record gpm flow Subtract flow obtained...

Страница 185: ...HYDRAULICS SECTION 8R INSTRUMENT TEST 8R 21 8R Figure 8R 19 Left Wing Motor Circuit Tests...

Страница 186: ...HYDRAULICS SECTION 8R INSTRUMENT TEST 8R 22 THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 187: ..._ Conclusion ________ gpm drop engine rpm drop ________ LIFT SYSTEM TESTS Front Mower and Lift Valve Isolation Test check correct Conclusion _____ No oil leakage mower does not come down _____ No oil...

Страница 188: ...gine rpm ________ 4 Wheel Drive Test ________ gpm 3000 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Right Motor NO LOAD ________ gpm engine rpm ________ L...

Страница 189: ...AD ________ gpm engine rpm ________ 2500 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Right Wing Motor Valve NO LOAD ________ gpm engine rpm ________ Pump...

Страница 190: ...pm engine rpm ________ Pump Test ________ gpm 2500 psi ________ gpm engine rpm ________ Conclusion ________ gpm drop engine rpm drop ________ Left Wing Inside Motor NO LOAD ________ gpm engine rpm ___...

Страница 191: ...HYDRAULICS 8S 1 8S Figure 8S 1 Flow Diagram...

Страница 192: ...HYDRAULICS 8S 3 Figure 8S 2 Schematic Early...

Страница 193: ...HYDRAULICS 8S 5 8S Figure 8S 3 Schematic Later...

Страница 194: ...3000 psi T p A B C 4 3 2 1 Inside Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge R...

Страница 195: ...e Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift...

Страница 196: ...e Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift...

Страница 197: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Страница 198: ...ide Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lif...

Страница 199: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Страница 200: ...Inside Outside Outside LH CTR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Va...

Страница 201: ...TR RH 50 psi Bypass 25 psi Bypass oil Cooler Suction Filter Diff Lock Weight Transfer Control Priority Valve Control Valve 17 Ltr Charge Relief Valve 250psi 1500 psi Lift Valve LH Center RH 4WD Valve...

Страница 202: ...HYDRAULICS 8S 7 Figure 8S 4 Traction System 1 of 4...

Страница 203: ...HYDRAULICS 8S 9 8S Figure 8S 5 Power Steering System 2 of 4...

Страница 204: ...HYDRAULICS 8S 11 Figure 8S 6 Lift System 3 of 4...

Страница 205: ...HYDRAULICS 8S 13 8S Figure 8S 7 Mower System 4 of 4...

Страница 206: ......

Страница 207: ...allation 9C 1 9D Hydraulic Tank 9D 1 General 9D 1 Removal and Installation 9D 1 9E Seat 9E 1 Removal and Installation 9E 1 9F Deck Lift Assembly 9F 1 Lift Assembly 9F 1 Wings Transport Lock Mechanism...

Страница 208: ......

Страница 209: ...en orange Paint Jacobsen black Anti rust Never Seize Lubricants Grease gun grease eg Sunray DX671 or Gulf Supreme No 0 Lithium based grease Other oil options Jacobsen Part No 502693 5 gal 19 liter Jac...

Страница 210: ......

Страница 211: ...ove 2000 a Increase engine rpm not occur when lever is b Lever linkage is worn b Repair or replace linkage actuated Section 2C c Mechanical binding c Lubricate repair d Hydraulics faulty d Test Sectio...

Страница 212: ......

Страница 213: ...D INSTALLATION See Figure 9C 1 1 Place a suitable container under tank and open tank drain valve 2 Remove fuel vent outlet and return lines from tank 3 Remove tank mounting hardware and tank 4 Remove...

Страница 214: ......

Страница 215: ...rance or air noted by a foamy appear ance or other contaminants a rancid odor indicating excessive heat or after a major component failure the hydraulic fluid should be changed NOTE The cap on the hyd...

Страница 216: ......

Страница 217: ...e from the slide mounting brackets 2 Lift the seat and slide mounts off seat pan To install the seat secure the seat assembly with at taching hardware Lubricate as described in Section 11 CHASSIS SECT...

Страница 218: ......

Страница 219: ...CHASSIS SECTION 9F DECK LIFT ASSEMBLY 1 9F Figure 9F 1 Lift Assembly LIFT ASSEMBLY See Figure 9F 1 1 Lower implement to ground...

Страница 220: ...e adjustments unless the arms have been disassembled Repair is limited to replacing damaged or worn parts NOTE When installing the center lock nut do not tight en against latch hook Latch hook must mo...

Страница 221: ...steering cylinder and hydraulic motors Cap or plug all fittings 4 Remove cotter pin and slotted nut 5 Remove capscrew 6 Making sure tractor and axle are well supported remove pivot shaft and thrust w...

Страница 222: ...5 Inspect steering assembly components for signs of wear and replace as necessary 6 Replace lower thrust bearing and thrust washers and spindle bushings as needed 7 Install thrust bearings and thrust...

Страница 223: ...oid 10F 1 Starter Motor 10F 2 10G Switches 10G 1 General 10G 1 Seat Switch Test 10G 1 Ignition Switch Test Early 10G 2 Ignition Switch Test Later 10G 4 Implement Mower Switch Test Early 10G 6 Wing Mow...

Страница 224: ...est Later 10G 23 10H Relay 10H 1 Engine Fuel Solenoid 10H 1 Horn 10H 1 Cruise Engage 10H 1 Cab 10H 1 Cruise Disengage Brake Relay 10H 2 Seat Delay Relay Test 10H 3 10I Solenoids 10I 1 Fuel Solenoid 10...

Страница 225: ...timeter Jumper wires 60 amp ammeter Cleaning materials Baking soda and water Other service items Electrical insulation compound P N 365422 ELECTRICAL SYSTEM SECTION 10A REPAIR AND SERVICE TOOLS AND MA...

Страница 226: ......

Страница 227: ...L c Faulty glow plug switch c Test Section 10G d 30 amp implement fuel circuit d Reset test Section 10J breaker tripped e Faulty fuel solenoid relay e Test replace Section 10H f Faulty fuel solenoid f...

Страница 228: ...C c Reverse sensing switch not c Adjust Section 2C adjusted d Faulty reverse sensing switch d Test Section 10G e Faulty 4 wheel drive switch e Test Section 10G f Faulty 4 wheel drive valve f See Secti...

Страница 229: ...Test replace Section 10H immediately when oper b Faulty wiring or bad electrical b Test Section 10C ator leaves seat Imple ground ment switch ON 6 Engine does not shut a Faulty time delay relay a Test...

Страница 230: ...e Faulty wiring or bad electrical e Test Section 10C ground 6 Hourmeter does not work a 10 amp gauge panel light circuit a Reset test Section 10J breaker tripped b Faulty hourmeter b Replace c Faulty...

Страница 231: ...i Test Section 10C ground 2 Cruise control drops off a Faulty holding relay a Test replace Section 10H after being set b Service brake switch not adjusted b Adjust Section 2C c Faulty cruise control...

Страница 232: ...10C ground 8 Cab heater and wipers do a Ignition switch OFF a Turn ON not work b Faulty cab relay b Test Section 10H c Faulty wiring or bad electrical c Test Section 10C ground 9 Heater fan does not...

Страница 233: ...y check as described below NOTE Before performing any component or wiring test check for corrosion and loose or missing con nections If a component switch relay etc is removed for test or replacement...

Страница 234: ...ings are above 0 5 the switch or wire is questionable ELECTRICAL SYSTEM SECTION 10C GENERAL INSTRUCTIONS 10C 2 Figure 10C 2 Resistance Test Ohms POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2...

Страница 235: ...performance or early failure due to loss of electrolyte 2 Keep terminals and top of battery clean Wash with baking soda and rinse with clear water Do not al low soda solution to enter cells as this w...

Страница 236: ...DC multimeter to battery terminals 2 Set voltmeter to 20 VDC 3 Crank the engine if battery voltage falls below 9 volts while cranking the battery is run down or faulty Charge and perform test again EL...

Страница 237: ...oltage should increase to a maximum 14V at 1500 engine rpm Current output should also increase to a maxi mum 35 amps at 2500 engine rpm NOTE Charge condition of battery will affect current amp output...

Страница 238: ...meter to 20 VDC and connect POS lead to terminal F and NEG to terminal E 3 Turn on the ignition switch The multimeter should read battery voltage If no voltage registers continue with voltage reg ulat...

Страница 239: ...inal 4 Set the multimeter to 200 VDC 5 Start and run engine at approximately 1500 rpm 6 Disconnect the battery NEG cable Voltage should be about 17 VDC Voltage should increase to 32 VDC as the en gine...

Страница 240: ...alternator 2 Set the multimeter to 200 ohms range 3 Connect the multimeter POS lead to terminal F and the NEG lead to terminal E The resistance should be approximately 6 5 10 ohms ELECTRICAL SYSTEM SE...

Страница 241: ...emove the NEG battery cable 5 Gradually accelerate the engine and watch the multimeter Voltage should rise as engine rpm increases Voltage should read 13 8 to 14 8 VDC If voltage does not increase wit...

Страница 242: ...EGULATOR TEST See Figure 10E 6 The regulator regulates the output voltage and current according to the electrical demand ELECTRICAL SYSTEM SECTION 10E CHARGING SYSTEM 10E 6 Figure 10E 6 Regulator Test...

Страница 243: ...switch is turned to the start position a click should be heard from the coil If no click is heard the coil or electrical supply may be defective Continue with the next step 4 Remove the PUR WHT soleno...

Страница 244: ...ct cable to POS terminal of battery 6 Touch the NEG cable to the NEG terminal on the battery The starter motor should turn If the starter does not turn or turns slow con nect a multimeter set at 20 VD...

Страница 245: ...EAT SWITCH TEST See Figure 10G 1 1 Disconnect seat switch connector 2 Set VOM to 200 ohms scale 3 Connect meter leads to connector terminals There should be no reading no continuity on VOM 4 Depress s...

Страница 246: ...ld be a reading of 0 0 5 ohms on the multimeter d Connect black NEG lead to terminal X and red POS lead to terminal Y There should be a reading of 0 0 5 ohms on the multimeter e Hold switch in START p...

Страница 247: ...tinuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms Contacts Closed Continuity 0 0 5 Ohms STEP 4C STEP 4E STEP 4F STEP 4A STEP 4D STEP 4B Position Continuity...

Страница 248: ...0 5 ohms in any of the following tests the switch is faulty and must be replaced b With key switch in RUN position connect black NEG test lead to terminal B and red POS lead to terminal I There should...

Страница 249: ...ELECTRICAL SYSTEM SECTION 10G SWITCHES 10G 5 10G Figure 10G 5 Ignition Switch Test Step 4...

Страница 250: ...om binations of terminals with switch in the OFF position There should be no reading on the multimeter 4 Place switch in ON position and test as follows a Check for continuity by connecting one multi...

Страница 251: ...position and test as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Connect one multim...

Страница 252: ...test as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Check for continuity across rem...

Страница 253: ...as follows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal C There should be 0 0 5 ohms on the mul timeter b Check for continuity across remaini...

Страница 254: ...lows a Check for continuity by connecting one multi meter test lead to terminal B and the other to terminal A There should be 0 0 5 ohms on the mul timeter b Check for continuity across remaining term...

Страница 255: ...ld switch in the ON position There should be a reading of 0 0 5 ohms on the multimeter Replace a switch that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL S...

Страница 256: ...est leads to switch terminals There should be a reading of 0 0 5 ohms on the multimeter 5 Lift and hold switch lever up in OFF position There should be no reading on the multimeter NOTE Switch must be...

Страница 257: ...button down There should be a reading of 0 0 5 ohms at multimeter Replace a switch that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL SYSTEM SECTION 10G SW...

Страница 258: ...ading on the multimeter no continuity 7 Depress switch lever There should be a reading on multimeter conti nuity Replace a switch that does not meet all the above test results or has resistance of 0 5...

Страница 259: ...om the switch 2 Set multimeter to 200 ohms scale 3 Connect leads to switch as shown There should be no continuity through the switch 4 Depress switch There should be a reading of 0 0 5 ohms at multime...

Страница 260: ...continuity through the switch 3 Actuate switch push switch in There should be a reading of 0 0 5 ohms at multimeter NOTE RED switch lead is not used Replace a switch that does not meet all the above...

Страница 261: ...t come on check circuit wiring and or bulb Hydraulic charge pressure light does not go off when engine is started At the switch disconnect the plug Light goes off proceed with switch test Step 1 Light...

Страница 262: ...s turned on and stays ON when engine is started Remove BLU wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circuit wiring for ground SWITCH TEST 1...

Страница 263: ...d on and stays ON when engine is started Remove TAN wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circuit wiring for ground SWITCH TEST 1 Set mul...

Страница 264: ...ring and or bulb Engine oil pressure light does not go off when engine is started Remove BLU wire from switch terminal Light goes off proceed with switch test Step 1 Light does not go off check circui...

Страница 265: ...water temperature light does not come on Check circuit wiring and or bulb SWITCH TEST 1 Using a suitable container fill it with engine or hydraulic oil 2 Heat the oil to 230 F 110 C 3 Set multimeter...

Страница 266: ...comes ON proceed with switch test Step 1 Air filter light does not come on check circuit wiring and or bulb SWITCH TEST 1 Set multimeter to 200 ohms scale 2 Connect test leads as shown There should b...

Страница 267: ...terminal 5 and the other to terminal 6 There should be 0 0 5 ohms on the mul timeter b Connect one multimeter test lead to terminal 2 and the other lead to terminal 3 c Check for continuity across al...

Страница 268: ......

Страница 269: ...nuity on both terminals 87 If there is continuity replace relay 4 Connect 12V across terminals 85 and 86 There should be an audible click 5 Connect black NEG lead from the multimeter to terminal 30 6...

Страница 270: ...inals 85 and 86 There should be an audible click 6 Connect black NEG lead from multimeter to terminal 30 7 Connect red POS lead from multimeter to ter minal 87a Open when coil is energized 8 Move red...

Страница 271: ...volts If not replace relay 5 Disconnect white wire from 12V Bat After a 1 to 2 second delay voltage reading on DMM should drop out if not replace relay ELECTRICAL SYSTEM SECTION 10H RELAY 10H 3 10H P...

Страница 272: ......

Страница 273: ...age is not present check wiring for an open or high resistance 5 Connect red POS lead of multimeter to termi nal of WHT wire No voltage should register proceed with Step 6 If battery voltage is presen...

Страница 274: ...RUN position 3 Adjust and connect rod at stop lever as necessary so that there is a gap between lever and stop with solenoid engaged 4 After adjustment turn ignition switch to OFF NOTE If not adjuste...

Страница 275: ...Hirshman connector from solenoid 4 Set multimeter to 20 VDC range 5 Connect black NEG multimeter lead to con nector as shown 6 Connect red POS lead of multimeter to con nector as shown Multimeter read...

Страница 276: ...ultimeter leads to coil as shown Coil ohms reading should be approximately 10 ohms if reading is correct Valve car tridge may be faulty Coil ohm reading not to specification change coil ELECTRICAL SYS...

Страница 277: ...ohms Replace a solenoid that does not meet all the above test results or has resistance of 0 5 ohms or more ELECTRICAL SYSTEM SECTION 10I SOLENOIDS 10I 5 10I POWER OFF ON 200m 2 20 200 1000 750 200 20...

Страница 278: ...hman connector from solenoid 4 Set multimeter to 20 VDC range 5 Connect black NEG multimeter lead to con nector as shown 6 Connect red POS lead of multimeter to con nector as shown Multimeter reads ba...

Страница 279: ...leads to coil as shown Coil ohms reading should be approximately 2 98 3 65 ohms if reading is correct Valve cartridge may be faulty Coil ohms reading is not to specification change coil ELECTRICAL SY...

Страница 280: ......

Страница 281: ...meter scale Replace a circuit breaker that does not meet these test results ELECTRICAL SYSTEM SECTION 10J CIRCUIT BREAKERS AND FUSE 10J 1 10J POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M...

Страница 282: ...AL SYSTEM SECTION 10J CIRCUIT BREAKERS AND FUSE 10J 2 POWER OFF ON 200m 2 20 200 1000 750200 20 2 200m 20M 2M 200M 20K 2K 200 200 DCV ACV ACA 200 2m 200m 2 2 200m 20m 10A 2m 200 DCA 20m 10A COM A 10A...

Страница 283: ...OTE See Section 10N for the location of all instru ments and gauges WATER TEMPERATURE GAUGE TEST See Figure 10K 1 Test the water temperature gauge as follows 1 Turn ignition switch to RUN ON 2 Disconn...

Страница 284: ......

Страница 285: ...be approximate ly 0 8 ohms cold If the reading is at infinity or 0 ohms the glow plug is defective and must be replaced ELECTRICAL SYSTEM SECTION 10L GLOW PLUGS 10L 1 10L POWER OFF ON 200m 2 20 200 1...

Страница 286: ......

Страница 287: ...diode is faulty If there is no continuity in either direction diode is also faulty ELECTRICAL SYSTEM SECTION 10M DIODE TEST 10M 1 10M POWER OFF ON 200m 2 20 200 1000 750 200 20 2 200m 20M 2M 200M 20K...

Страница 288: ......

Страница 289: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 1 10N Fogire 10N 1 Wiring Diagram 1 of 2...

Страница 290: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 3 Figure 10N 2 Wiring Diagram 1 of 2...

Страница 291: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 5 10N Figure 10N 3 Wiring Diagram for Figures 10N 1 and 10N 2 2 of 2...

Страница 292: ......

Страница 293: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Страница 294: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Страница 295: ...K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse Switch Rd Pu Wh B...

Страница 296: ...Accessory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse S...

Страница 297: ...ory Relay K2 Fuel Solenoid relay Light Switch Hour Meter Temp Gauge Rev Counter Fuel Gauge Horn Horn Relay Brake Pedal Switch Cruise Control Cruise Control Magnet Fuel Pump 4WD Switch Reverse Switch R...

Страница 298: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 7 Figure 10N 4 Component Location 1 of 3...

Страница 299: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 9 10N Figure 10N 5 Component Location 2 of 3...

Страница 300: ...ELECTRICAL SYSTEM SECTION 10N WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION 10N 11 Figure 10N 6 Component Location 3 of 3...

Страница 301: ...nd Charts 11B 1 General 11B 1 Lubrication Schedules 11B 1 Tractor Grease Chart 11B 1 Tractor Oil Chart 11B 1 Tractor Lubrication Chart 11B 1 Mower Lubrication Chart 11B 2 11C Maintenance Schedules 11C...

Страница 302: ......

Страница 303: ...pe of equip ment and the type of environment in which it operates While performing preventive maintenance tasks the individual should always be alert to conditions that may seem abnormal If an abnorma...

Страница 304: ...kit QTY KITS ORDERED __________ Kit consists of 10 ea 8476 TS Maintenance Summary Sheets 20 ea 8477 TS Service Order Sheets 5 ea 8478 TS Folders check color desired ____Orange Turf Tractors ____Gray...

Страница 305: ...footnotes on page 11C 3 letters a thru k give more detailed information PREVENTIVE MAINTENANCE SECTION 11B LUBRICATION SCHEDULES AND CHARTS 11B 1 11B Ref Qty Description Remarks 40 HOURS Every Week 1...

Страница 306: ...TION SCHEDULES AND CHARTS 11B 2 Ref Qty Description Remarks 40 HOURS Every Week 1 8 a Hydraulic lift cylinder ends 2 4 a Mower arm pivots 4 8 a Wing mower unit pivots 5 8 a Caster wheel pivots 6 10 a...

Страница 307: ...oil X Change every 500 hours 17 1 j Charge filter Change the first 25 hours Change every 250 hours thereafter 18 1 j Return filter 19 1 Tank strainer X 20 1 g Front drive wheel lube X X Change every...

Страница 308: ...re X Check clean f Radiator coolant X Check when cooled X Change Hood screen X Check clean Ensure trap door is closed X Close Ensure sealing foam on top of radiator and on trap door is in place X Inst...

Страница 309: ...9 quarts Use MIL L 214OC or API Classification CC CD CE Grade oil Recommended Oils Above 77 F use SAE 30 32 F to 77 F use SAE 20 Below 32 F Use SAE 10 or SAE 10W 30 e System capacity 8 oz heavy duty b...

Страница 310: ......

Страница 311: ...ration for Repair 12C 1 12D Mowers 12D 1 Pivot Housing and Push Arms 12D 1 Carrier Assembly 12D 2 Deck Fittings 12D 3 Blade Spindle Assembly 12D 4 General 12D 4 Disassembly 12D 6 Reassembly 12D 6 12E...

Страница 312: ......

Страница 313: ...ddard or equivalent solvent Detergent and water Lubricants Non metallic additive wheel bearing grease eg Sunray DX 692 or Enco Fibrox 280 Grease gun grease eg Sunray DX 671 or Gulf Supreme No 0 SAE 30...

Страница 314: ......

Страница 315: ...d Repair replace Sections 8L 8M 8N e Tractor hydraulic system e Test Sections 8M 8N malfunctioning 3 Uneven cutting a Deck not adjusted level a Adjust deck see Operator s Manual b Blades loose b Tight...

Страница 316: ......

Страница 317: ...s It may be necessary to use bearing pullers and or wooden blocks and hammer to free up some parts When such force is required to remove parts those parts should be replaced rather than reinstalled on...

Страница 318: ......

Страница 319: ...VOT HOUSING AND PUSH ARMS Removal and installation of the pivot housings and push arms are illustrated in Figure 12D 1 ATTACHMENTS SECTION 12D MOWERS 12D 1 12D Figure 12D 1 Pivot Housings and Push Arm...

Страница 320: ...CARRIER ASSEMBLY Repair of the carrier assemblies consist of replacing bushings and worn or damaged components see Fig ure 12D 2 ATTACHMENTS SECTION 12D MOWERS 12D 2 Figure 12D 2 Carrier Assembly...

Страница 321: ...DECK FITTINGS Removal and installation of deck fittings are illustrated in Figure 12D 3 ATTACHMENTS SECTION 12D MOWERS 12D 3 12D Figure 12D 3 Deck Fittings...

Страница 322: ...r see Figure 12D 5 In this section service of the motors consists only of the spindle assembly For service of the hydraulic mo tor see Section 8O In most cases the spindle housing and motor do not hav...

Страница 323: ...ATTACHMENTS SECTION 12D MOWERS 12D 5 12D Figure 12D 5 Motor Rotation By Code Letter...

Страница 324: ...bearing is to be changed 10 Remove motor assembly from spindle housing Do not disassemble motor 11 Remove spindle shaft bearing REASSEMBLY See Figure 12D 6 1 Install spindle bearing if removed 2 Inst...

Страница 325: ...ng the blades DO NOT follow the original angle of grind A Figure 12E 2 1 Grind new cutting edges on a diagonal as shown in B 2 Do not exceed 1 2 12 7 mm total metal removed at end of bar 3 Make sure t...

Страница 326: ...lling blades make sure blade is positioned correctly Torque center blade mounting screw to 75 ft lbs 102 N m and the two blade mounting adapter screws to 35 40 ft lbs 47 54 N m ATTACHMENTS SECTION 12E...

Страница 327: ...Repair of the caster wheels consist of replacing bush ings and worn or damaged components See Figure 12F 2 ATTACHMENTS SECTION 12F CASTER WHEELS 12F 1 12F Figure 12F 1 Caster Wheels...

Страница 328: ...ATTACHMENTS SECTION 12F CASTER WHEELS 12F 2 Figure 12F 2 Caster Wheel Repair...

Страница 329: ...13 THIS SECTION INTENTIONALLY LEFT BLANK SECTION 13 OPTIONS...

Страница 330: ......

Страница 331: ...Locations 14A 1 Tractor 14A 1 Mower 14A 3 14B Conversion Charts 14B 1 Millimeters to Decimals 14B 1 Decimals to Millimeters Fractions to Decimals to Millimeters 14B 2 U S to Metric Conversions 14B 3 S...

Страница 332: ......

Страница 333: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 1 14A TRACTOR Part No 964907 1 Part No 365339 2 Part No 365919 3...

Страница 334: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 2 Part No 361175 4 Part No 861883 9 Part No 339237 5 Part No 365956 6 Part No 339460 7 Part No 363134 8 Part No 366160 10 Part No 366527 11...

Страница 335: ...MISCELLANEOUS SECTION 14A PRECAUTION DECAL LOCATIONS 14A 3 14A MOWER Part No J T338141 1...

Страница 336: ......

Страница 337: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 1 14B MILLIMETERS TO DECIMALS...

Страница 338: ...MISCELLANEOUS SECTION 14B CONVERSION CHARTS 14B 2 DECIMALS TO MILLIMETERS FRACTIONS TO DECIMALS TO MILLIMETERS...

Страница 339: ...re Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp G...

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