Jacobsen HR5111 Service And Repair Instructions
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Jacobsen HR5111 Service And Repair Instructions

Jacobsen HR5111 Service And Repair Instructions

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Litho in U.S.A.
3/97
Suggested Retail Price
$60.00
SERVICE & REPAIR
WARNING: If incorrectly used this machine can cause severe injury. Those who
use and maintain 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.
INSTRUCTIONS
"All rights reserved, including the right to reproduce
HR5111
HR5111
Product No. 67760
with ROPS 69116
with CAB 69129
Includes Attachments
Copyright 1997 Jacobsen Div. of Textron Inc.
TM
TM

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  • Page 1 ROPS 69116 this illustration. with CAB 69129 Includes Attachments Copyright 1997 Jacobsen Div. of Textron Inc. “All rights reserved, including the right to reproduce Litho in U.S.A. 3/97 Suggested Retail Price WARNING: If incorrectly used this machine can cause severe injury. Those who $60.00...
  • Page 3 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS & TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS...

  • Page 5: Table Of Contents

    SECTION 1 INTRODUCTION 1A. General Information ............1A-1 Contents .
  • Page 7 5. Send your order to or visit your nearest AUTHO- testing procedures. If you, as user of this machine, do RIZED JACOBSEN TURF EQUIPMENT DISTRIB- not consider yourself or your repair facilities capable of UTOR.

  • Page 8: General Cleaning

    INTRODUCTION SECTION 1A. GENERAL INFORMATION GENERAL CLEANING Decals on the machine denote cautions, warnings, and dangers. These cautions, warnings, and danger decals Improper cleaning and lubrication of your machine re- must be on the machine at all times. If they become sults in many equipment failures.

  • Page 9: Torque Specifications

    INTRODUCTION SECTION 1A. GENERAL INFORMATION TORQUE SPECIFICATIONS STANDARD SAE GRADE #5 SCREWS Size Torque Values Size Torque Values 8-32 27-33 in-lbs. (3-4 N.m) ⁄ 67-83 ft-lbs. (90-113 N.m) 8-36 28-34 in-lbs. (3-4 N.m) ⁄ 81-99 ft-lbs.(110-134 N.m) 10-24 39-47 in-lbs. (4-5 N.m) ⁄...

  • Page 10: Fenders And Hood Removal And Installation

    AND INSTALLATION Using a suitable device, support the platform before Most service and repair of the HR5111 can be accom- removing any hardware. plished by opening the hood and/or seat pan. For bet- ter access, the hood, floor pan and engine compart- Figure 1A-2.
  • Page 11 SECTION 2 CONTROLS 2A. Repair and Service Tools and Materials ......... 2A-1 2B.

  • Page 13: Repair And Service Tools And Materials

    CONTROLS SECTION 2A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Refer to Section 11. 2A-1...

  • Page 15: Failure Analysis

    CONTROLS SECTION 2B. FAILURE ANALYSIS GENERAL The following table gives common problems, probable causes, and suggested remedies with page references to detailed description of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Engine does not turn a. Parking brake not set. a.
  • Page 16 CONTROLS SECTION 2B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 8. Instrument(s) do not a. Faulty wiring or bad electrical a. Test (Section 10C). work. ground. b. 10 amp gauge/panel light circuit b. Reset/test (Section 10J). breaker tripped. 9. No cruise control when a.
  • Page 17 CONTROLS SECTION 2B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 16. Engine shuts down when a. No operator in seat. a. Set in seat. implement switch is b. Faulty seat switch. b. Test (Section 10G). pulled to the ON position. c. Faulty timing delay relay. c.
  • Page 18 CONTROLS SECTION 2B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 21. Engine does not shut a. Faulty electrical circuit. a. See Section 10B. down when operator leaves seat (implement switch ON). 22. Panel lights do not come a. 10 amp gauge/panel light circuit a.

  • Page 19: Control Adjustments

    CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GENERAL THROTTLE (See Figure 2C-1) The repair of controls is limited to adjustment of link- Located to the right of the operator’s seat, the throttle ages, straightening of bent rods or replacement of de- control is used to regulate engine speed. Replace a fective parts and hardware.

  • Page 20: Traction Pedal

    CONTROLS SECTION 2C. CONTROL ADJUSTMENTS TRACTION PEDAL (See Figure 2C-2) The traction pedal controls travel direction and speed. depressed, it controls “forward” or “reverse”. Repair of The traction pedal is connected by linkage to the hy- the traction pedal and linkage is limited to replacement drostatic pump.

  • Page 21: Traction Pedal Neutral Adjustment

    CONTROLS SECTION 2C. CONTROL ADJUSTMENTS TRACTION PEDAL NEUTRAL ADJUSTMENT 1. Raise the tractor so all four wheels are off the ground. Put jack stands under frame to prevent If the tractor moves (“creeps”) in either direction while accidental lowering of tractor during adjustment. the engine is running, but traction pedal is not de- 2.

  • Page 22: Speed Limit Adjustment

    CONTROLS SECTION 2C. CONTROL ADJUSTMENTS REVERSE SENSING SWITCH WARNING (See Figure 2C-3) The tractor should shift into 4 wheel drive at approxi- mately 1.0 mph (switch closed). Use extreme caution during the following adjust- ment as the drive wheels will be off the ground 1.

  • Page 23: Parking Brake

    CONTROLS SECTION 2C. CONTROL ADJUSTMENTS PARKING BRAKE (See Figure 2C-4) CRUISE CONTROL SWITCH (See Figure 2C-6) The adjusting knob at the end of brake lever is used to compensate for brake lining and linkage wear, or to If the cruise control will not disengage when the pedal adjust to unusual holding demands.

  • Page 24: Gauges And Instruments

    CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS REPAIR 2. Disconnect battery ground (black) cable. 3. Label wires for proper identification and discon- NOTE nect wiring. Refer to Section 10G for test/repair of switches. 4. Remove attaching hardware and replace faulty Repair of instruments is limited to replacement of faulty instrument.
  • Page 25 SECTION 3 ENGINE 3A. Repair and Service Tools and Materials ........3A-1 3B.

  • Page 27: Repair And Service Tools And Materials

    Detergent and water. Anti-rust Never-Seize. Lubricants: Refer to Section 11. Other service items: Compressed Air Source, Engine Hoist. Loctite 242 (Blue). Engine Service Manual can be obtained from your Jacobsen Dealer or Distributor. Anti-freeze, 50-50 mix water and ethylene glycol. 3A-1...

  • Page 29: Failure Analysis

    GENERAL SECTION 3B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Engine cranks but a. Fuel tank empty. a. Check fuel level. does not start. b. Fuel petcock at filter closed. b. Open petcocks. c. Air in fuel line. c. Purge air (Section 3D). d.

  • Page 31: General Instructions

    CONTENTS NOTE Tests for alternators, starters, and regulator are The engine used in the HR5111 Tractor is a Kubota included in Section 10 of this manual. If these V-2203, 4 cylinder in-line, liquid cooled diesel engine. components are found faulty, refer to the engine This section covers repairs to the engine associated manufacturer’s manual for repair instructions.

  • Page 33: Air Cleaner

    GENERAL SECTION 3D. DIESEL ENGINE GENERAL 2. Remove the swing nut and gasket (4), and slide the element (5) out of assembly. A separate engine operator’s manual, prepared by the NOTE engine manufacturer is supplied with your tractor. Study the manual carefully until you are familiar with the main- If a new element is installed, use a new gasket tenance, operation and adjustment of your equipment.

  • Page 34: Radiator

    ENGINE SECTION 3D. DIESEL ENGINE RADIATOR (See Figure 3D-2) CLEANING RADIATOR CORE When dust enters between fins and tubes, blow out with air, then wash with tap water under pressure. CAUTION NOTE Never use a screwdriver or other pointed tool for Never open radiator cap (2) while engine is run- cleaning.

  • Page 35: Muffler Removal And Installation

    ENGINE SECTION 3D. DIESEL ENGINE MUFFLER REMOVAL AND INSTALLATION EXHAUST SYSTEM INSPECTION Remove and install the muffler and engine as shown 1. Clean all sections of the exhaust system of dirt, on Figure 3D-3. dust or other foreign material. 2. Inspect exhaust system for cracks, holes, distor- tion or deformation.

  • Page 36: Fuel Filter Service

    ENGINE SECTION 3D. DIESEL ENGINE FUEL FILTER SERVICE (See Figure 3D-4) The fuel filter is mounted on the left front of engine on the frame. Moisture and other foreign matter accumu- late in the fuel filter. Periodically clean and replace the filter element.

  • Page 37: Engine Removal

    ENGINE SECTION 3D. DIESEL ENGINE 8. One at a time, loosen the high pressure fuel injec- 5. Remove the exhaust pipe and radiator shroud de- tor line nuts at the injector while cranking the scribed in preceding paragraphs (see Figure 3D-2 engine.

  • Page 38: Engine Installation

    ENGINE SECTION 3D. DIESEL ENGINE ENGINE INSTALLATION 4. Install the radiator shroud and exhaust pipe as described in preceding paragraphs of this section. (See Figures 3D-6 to 3D-8) 5. Tighten mounting bolts (4) after all have been 1. Move the engine onto its approximate mounting installed.

  • Page 39: Drive Train

    SECTION 4 DRIVE TRAIN 4A. Repair and Service Tools and Materials ........4A-1 4B.

  • Page 41: Repair And Service Tools And Materials

    DRIVE TRAIN SECTION 4A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard Automotive hand tools. Metric tools. Cleaning materials: Stoddard solvent or equivalent. Loctite “chisel” gasket remover or equivalent. Lubricants: Refer to Section 11. Special tools: * Bucher-Guyer AG CH-8166 Niederweningen FAX: 01-857-26-55 * Adjusting tool 150-10511-0.

  • Page 43: Failure Analysis

    DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Differential lock does a. Torque on drive line. a. Stop tractor. not disengage. b. Differential lock collar jammed. b. Repair (Section 4E). c. Faulty differential lock piston. c. Repair (Section 4E). d.

  • Page 45: Hydrostat Drive U-Joint

    DRIVE TRAIN SECTION 4C. HYDROSTAT DRIVE U-JOINT GENERAL ASSEMBLY (See Figure 4C-1) NOTE The hydrostatic transmission is driven by a telescop- ing universal joint type drive shaft connected directly During reassembly be sure all the parts are clean between the hydro and engine flywheel plate. and free of dirt.

  • Page 47: Axle Drive U-Joint

    DRIVE TRAIN SECTION 4D. AXLE DRIVE U-JOINT GENERAL SERVICE The drive axle is driven by a telescoping universal DISASSEMBLY (See Figure 4D-1) joint type drive shaft connected directly between the 1. Remove drive shaft assembly from tractor. hydro motor and axle. 2.

  • Page 48: Assembly

    DRIVE TRAIN SECTION 4D. AXLE DRIVE U-JOINT ASSEMBLY (See Figure 4D-1) 3. Support the ear and using a socket or mandrel the same diameter as the bushing, drive the bush- NOTE ing slightly past the snap ring groove. During reassembly be sure all the parts are clean 4.
  • Page 49 DRIVE TRAIN SECTION 4E. AXLE GENERAL (See Figure 4E-1) Figure 4E-1. Axle Assembly 4E-1...

  • Page 50: General

    DRIVE TRAIN SECTION 4E. AXLE This section is divided into four subsections; Differ- INPUT BEVEL PINION ential Lock Assembly, Input Bevel Pinion, Reduction GENERAL Gear and Drive Axle and Differential. The input bevel pinion and ring gear are a matched For information on brake repair, refer to Sections 5D set and should be replaced as a set.

  • Page 51: Disassembly

    DRIVE TRAIN SECTION 4E. AXLE DISASSEMBLY (See Figure 4E-3) 2. Remove input bevel pinion assembly from axle. NOTE 3. If the original pinion shaft is to be used, remove the shim pack, tag and mark it for reassembly. If Before removing the input bevel pinion assembly the shims are damaged, replace them with shims from the axle, complete Step 1.

  • Page 52: Reassembly

    DRIVE TRAIN SECTION 4E. AXLE REASSEMBLY (See Figure 4E-4) 5. With the bearing inner race supported, press out- er bearing cone into housing until it just contacts 1. Support the inner race of the bearing cone. Press the collapsible sleeve, be careful not to collapse input shaft into bearing cone, taper toward the the sleeve.

  • Page 53: Break-Away Torque Adjustment

    DRIVE TRAIN SECTION 4E. AXLE BREAK-AWAY TORQUE ADJUSTMENT (See Figure 4E-5) NOTE The following adjustment is made with no seal installed in the pinion housing. 1. Tighten the elastic nut until a break-away torque of 4.5–6.3 in-lbs. (0.5–0.7 N.m) is obtained. NOTE Apply a slow steady increasing pressure on the torque wrench.

  • Page 54: Reassembly

    DRIVE TRAIN SECTION 4E. AXLE REASSEMBLY (See Figure 4E-7) (Step 3 for right axle ONLY) If the axle shaft(s) were not removed, proceed with 3. Remove the differential lock assembly housing. Step 5. 4. Press drive axle with bearing into axle housing, 1.

  • Page 55: Differential

    DRIVE TRAIN SECTION 4E. AXLE (Step 5 for right axle ONLY) DIFFERENTIAL 5. Install differential lock assembly cover. GENERAL 6. Press drive axle bearing and wheel axle outer bear- Separate the axle housing only if bearings, pinion ing into cover. gear, ring gear, differential lock collar, and/or differen- tial are worn or damaged.

  • Page 56: Input Bevel Pinion And Ring Gear Clearance

    DRIVE TRAIN SECTION 4E. AXLE Figure 4E9. Differential Reassembly INPUT BEVEL PINION AND RING GEAR CLEARANCE (See Figure 4E-10) NOTE Proceed with the following steps if a new matched input bevel pinion and ring gear are to be installed. 1. Install input bevel pinion assembly with no shims and torque it to 37 ft-lbs.

  • Page 57: Pinion And Ring Gear Backlash Adjustment

    DRIVE TRAIN SECTION 4E. AXLE PINION AND RING GEAR BACKLASH ADJUSTMENT General There are two methods described to adjust backlash. Method “A” and “B” should be reviewed prior to per- forming the adjustment to determine which will be used. Method “A” (See Figure 4E-11) 1.
  • Page 58 DRIVE TRAIN SECTION 4E. AXLE 4. Using a dial indicator against a pinion tooth, check 9. Assemble both axle halves together. the gear backlash. 10. Snug the bolts evenly, do not tighten. 5. Subtract backlash of 0.008" (0.2 mm) from the 11.
  • Page 59 SECTION 5 BRAKE SYSTEM 5A. Repair and Service Tools and Materials ........5A-1 5B.

  • Page 61: Brake System

    BRAKE SYSTEM SECTION 5A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Metric tools. Cleaning materials: Stoddard solvent or equivalent. Lubricants: Refer to Section 11. Other service items: Brake repair parts. Brake linings. 5A-1...

  • Page 63: Failure Analysis

    BRAKE SYSTEM SECTION 5B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Parking brake does not a. Brake is not adjusted. a. Adjust brake (Section 2C). hold tractor in position. b. Worn brake linings. b. Replace lining (Section 5C). c. Broken or worn cable. c.

  • Page 65: Repair

    BRAKE SYSTEM SECTION 5C. PARKING BRAKE REPAIR Repairs to the parking brake are limited to changing worn brake linings and renewing worn or damaged parts. Refer to Figure 5C-1. ADJUSTMENT (See Figure 5C-2) 1. Place brake lever in the disengaged position and turn knob in a clockwise direction, apply and re- lease brake lever every quarter turn until a defi- nite “snap over center”...

  • Page 67: Service Brake

    REPAIR Repair of the service brake calipers is shown in Fig- ure 5D-1. To service the calipers, a repair kit can be ordered from your local Jacobsen distributor. Refer to the parts catalog for the kit part number. BLEEDING SYSTEM (See Figure 5D-2) 1.

  • Page 69: Master Cylinder

    REPAIR Repair of the master cylinder is shown in Figure 5E-1. To service the master cylinders, a repair kit can be ordered from your local Jacobsen distributor. Refer to the parts catalog for the kit part number. BLEEDING SYSTEM (See Figure 5E-2) 1.

  • Page 71: Steering

    SECTION 6 STEERING 6A. Repair and Service Tools and Materials ........6A-1 6B.

  • Page 73: Repair And Service Tools And Materials

    STEERING SECTION 6A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. 6 mm hexagon socket wrench. 8 mm hexagon socket wrench. Cleaning 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.

  • Page 75: Failure Analysis

    STEERING SECTION 6B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. No turning of steering a. Insufficient oil supply. a. Check oil supply. wheel. b. Insufficient oil pressure or no b. Check (Section 8R). oil pressure. c. Steering relief valve sticking c.

  • Page 77: Steering Unit

    STEERING SECTION 6C. STEERING UNIT GENERAL NOTE Insert (5) should come off with steering wheel. The power steering unit is supplied with oil from the pump, Section 3. Power steering is provided as long 2. Remove steering unit cover (6). as the engine is running.

  • Page 78: Disassembly

    STEERING SECTION 6C. STEERING UNIT DISASSEMBLY (See Figures 6C-2 through 6C-6) NOTE Before disassembly, scribe a line from top to bot- tom of steering unit housing. This line can be used to determine proper orientation of sections for assembly (see Figure 6C-13). 1.
  • Page 79 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-4) (See Figure 6C-5) 9. Place steering unit on its side. Keeping cross pin 10. Remove O-ring (22), kin ring (21), thrust bearing horizontal, carefully push sleeve (14) from steer- and washers (20), ring (19) and dust ring (23). ing unit housing.

  • Page 80: Inspection

    STEERING SECTION 6C. STEERING UNIT (See Figure 6C-6) 16. Using a 8 mm hex socket wrench, remove pres- sure relief valve plug (30) and washer (31). NOTE 17. Remove plug (32), spring (33) and valve spool (34). If either shock valve plugs (26) in Step 15 and/or the relief valve plug (32) in Step 17 are removed, INSPECTION the relief setting will be destroyed.

  • Page 81: Assembly

    STEERING SECTION 6C. STEERING UNIT ASSEMBLY (See Figures 6C-7 3. Install two flat neutral position springs (18) into slot of spool (17). through 6C-12) 4. Slide two curved springs (18) between the flat 1. Coat all parts with oil. Make sure parts are clean. springs.
  • Page 82 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-8) 8. Install cross pin (15) through sleeve and spool. 7. Install ring (19) over sleeve (16). 9. Install thrust bearing and washers (20) being sure inside chamber of heavy washer goes on spool NOTE first.
  • Page 83 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-9) 12. Using the inner tool, push and turn the guide through the outer tool sleeve until O-ring (22) and kin ring 10. Place the steering unit on its side. Insert the outer (21) properly seat in the housing.
  • Page 84 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-10) 16. Push sleeve (14) into housing, pushing out the O-ring and kin ring guide tool. 14. Place the housing down on a flat surface. Hold sleeve assembly (14) so cross pin (15) is horizontal. 17.
  • Page 85 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-11) 25. Install cover (3), flat washers (2) and screws (1). 19. Install 3/16" suction valve balls (13) as shown. NOTE 20. Install suction valve pins (12) as shown. Be sure to place the special screw in the correct hole as shown.
  • Page 86 STEERING SECTION 6C. STEERING UNIT NOTE There are two shock valve assemblies. Instal- lation of both are the same, see Step 27. NOTE The pressure setting of this valve must be ad- justed. Use the tractor hydraulics and adjust as described in Section 8S.

  • Page 87: Installation

    STEERING SECTION 6C. STEERING UNIT INSTALLATION 4. If steering unit was disassembled, adjust shock valve and relief valve pressure settings as de- (See Figures 6C-1 and 6C-14) scribed in Section 8R. 1. Position and attach steering unit to tractor. 5. Install steering unit cover (6). 2.

  • Page 89: Steer Wheel Adjustments

    STEERING SECTION 6D. STEER WHEEL ADJUSTMENTS TOE-IN (See Figure 6D-1) 3. In each direction, the steering arms should con- nect the stop bolts. If they do not, proceed with 1. Turn steer wheels to straight ahead position. Step a. 2. Remove the cylinder rod end ball joint. a.

  • Page 91: Steering Cylinder

    STEERING SECTION 6E. STEERING CYLINDER REMOVAL (See Figure 6E-1) 1. Block the wheel and 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. Figure 6E-1. Steering Cylinder Removal and Installation 6E-1...

  • Page 92: Disassembly

    STEERING SECTION 6E. STEERING CYLINDER DISASSEMBLY (See Figure 6E-2) INSPECTION • Clean and air dry exterior of cylinder. Drain all the oil Inspect all parts for excessive wear, cracks and from the cylinder. Disassemble following the steps as broken parts. illustrated.

  • Page 93: Reassembly

    STEERING SECTION 6E. STEERING CYLINDER REASSEMBLY INSTALLATION (See Figure 6E-1) 1. Lightly lubricate O-rings, backup rings and seals. 1. Install cylinder and secure with attaching hardware. 2. Install seal kit as shown in Figure 6E-3. 2. Connect hydraulic hoses. 3. Lubricate all parts before assembly. 3.
  • Page 94 STEERING SECTION 6E. STEERING CYLINDER Figure 6E-4. Steering Cylinder Assembly 6E-4...
  • Page 95 SECTION 7 WHEELS AND TIRES 7A. Repair and Service Tools and Materials ........7A-1 7B.
  • Page 97 WHEELS & TIRES SECTION 7A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard solvent or equivalent. Other service items: Commercially available tire sealant. Non-hardening. Tire pressure gauge. Compressed air with tire valve fitting. 7A-1...
  • Page 99 WHEELS & TIRES SECTION 7B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Tractor rides hard. a. Over inflated tires. a. Reduce tire pressure 20 to 24 psi (1.4 to 1.6 bars) front and 6 to 10 psi (.41 to .68 bars) rear. 2.
  • Page 101 WHEELS & TIRES SECTION 7C. TIRE SERVICE GENERAL NOTE Never use grease or oil on the rim when mount- Tires are subject to damage from sharp objects. If large ing a tire. punctures or tears occur, it is advisable to take the tire (installed on the wheel) to a qualified tire repair shop.
  • Page 103 SECTION 8 HYDRAULICS 8A. Repair and Service Tools and Materials ......... 8A-1 8B.
  • Page 104 8M. Mower Motor Control Valve ........... . 8M-1 General .
  • Page 105 Mower System ..............8R-15 Front Mower .

  • Page 107: Repair And Service Tools And Materials

    Lubricants: Refer to Section 11. Grease: Sunray DX671 or Gulf Supreme No. 0. Other service items: Seal and Repair Kits (available from Jacobsen Distributors) Liquid Gasket, Loctite Superflex Ultra-BLUE™ (Blue) Petroleum Jelly Wheel Restraint (See Figure 8A-1) Straps, 3" wide, 12' long...
  • Page 108 HYDRAULICS SECTION 8A. REPAIR AND SERVICE TOOLS AND MATERIALS Figure 8A-1. Wheel Restraint 8A-2...

  • Page 109: Failure Analysis

    HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY TRACTION SYSTEM 1. Forward and reverse a. Dump valve not closed. a. Close valve. slow (2 WHD). b. Parking brake applied. b. Release. c. Traction linkage damaged or out c. Adjust/repair (Section 2C). of adjustment.
  • Page 110 HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 7. No differential lock. a. Faulty cartridge valve. a. Replace (Section 8K). Check LED in differential b. Faulty 4 wheel drive control valve b. Repair/replace (Section 8F). lock solenoid plug: spool. ON —...
  • Page 111 HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 5. Front mower will not a. Valve detent spool sticks. a. Repair (Section 8H). lower. b. Restriction in oil return line. b. Test (Section 8R). 6. Mower stops lowering a. Detent spool not locking in a.
  • Page 112 HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 3. Left wing runs slow. a. Reel-to-bedknife too tight. a. Adjust (Section 12E). b. Faulty reel or drive. b. Repair (Section 12D). c. Faulty reel motor. c. Test (Section 8R). d. Right wing motor excessive d.

  • Page 113: General Instructions

    Discard all seals and O-rings as they are removed. Install new seals and O-rings during reassembly. WARNING Most seals are available in component kit form from your Jacobsen Distributor. To avoid serious bodily injury, always lower mow- ers fully, place all controls in neutral and shut off CAUTION engine before inspecting hydraulic lines or hoses.

  • Page 114: 37° Flare Torque Recommendations

    On hoses with O-ring fittings, make sure O-rings are clean and hose fittings are properly seated before tightening. Always install new O-rings. See Figure 8C-2. Replacement O-rings for O-Ring Boss Fittings O-Ring Tubing O.D. Thread Jacobsen or Hose I.D. Size Part No. FIgure 8C-1. Reference Marking ⁄ ⁄...

  • Page 115: O-Ring Boss Torque Recommendations

    HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS O-Ring Boss Torque Recommendations Replacement O-Ring for ORS (Face Seal) Fittings ORS (Face Seal) ORS (Face Seal) Jacobsen Dash Thread Tube Torque Tube Size O-Ring Size Part No. Size Size O.D. In-Lbs. 339908 ⁄ 0.188...

  • Page 117: Traction Pump

    HYDRAULICS SECTION 8D. TRACTION PUMP GENERAL (See Figure 8D-1) 1. Remove the seat and seat pan. 2. Thoroughly clean area around entire pump with a The traction pump supplies oil to the traction system suitable cleaning solvent. Do not use material that of the tractor.

  • Page 118: Repair

    HYDRAULICS SECTION 8D. TRACTION PUMP REPAIR (See Figure 8D-2) CAUTION Refer to Figure 8D-2 for disassembly and reassembly of the traction pump. DO NOT lap valve plate bronze surface, piston INSPECTION block or piston shoes. 1. Inspect bronze surface of valve plate for scratch- es or gouged marks.
  • Page 119 HYDRAULICS SECTION 8D. TRACTION PUMP INSTALLATION (See Figure 8D-1) 1. Install the pump, rotating it back and forth to en- 4. Connect all hydraulic hoses and tubes. gage the splines, fasten the mounting plate. 5. Install seat and seat pan. 2.
  • Page 121 HYDRAULICS SECTION 8E. IMPLEMENT PUMP GENERAL REMOVAL (See Figure 8E-1) The implement pump has four positive displacement 1. Using a suitable solution, clean the pump and sur- gear pump sections. Pump sections are numbered rounding area. from the shaft end. Pump section 1 supplies oil to the 2.
  • Page 122 HYDRAULICS SECTION 8E. IMPLEMENT PUMP REPAIR CAUTION DISASSEMBLY (See Figure 8E-2) 1. Before disassembly mark pump sections, starting Never pry pump sections apart as damage to at drive shaft end, to ensure correct order of part sealing areas can result. Use of a soft face ham- reassembly.

  • Page 123: Installation

    HYDRAULICS SECTION 8E. IMPLEMENT PUMP 2. After removing tie bolts, disassemble pump one REASSEMBLY (See Figure 8E-2) section at a time. Before removing gear sets, 1. Apply a coat of clean hydraulic oil to all parts to mark a line across meshing teeth to ensure that ease assembly.
  • Page 125 HYDRAULICS SECTION 8F. 4 WHEEL DRIVE CONTROL VALVE REPAIR Repairs are limited to replacing the 4 wheel drive pilot cartridge or changing O-rings. Figure 8F-1. 4 Wheel Drive Control Valve 8F-1...
  • Page 127 HYDRAULICS SECTION 8G. ANTI-SIPHON VALVE REPAIR Repair is limited 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. Figure 8G-1. Anti-Siphon Valve 8G-1...

  • Page 129: General

    HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE GENERAL The lift and lower control valve is used to raise and lower the cutting units. Left control is for the left wing. Right control is for the right wing. Center control is for the three front cutting units.
  • Page 130 HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE Figure 8H-3. Spool Assembly Removal Figure 8H-4. Relief Valve Removal 8H-2...

  • Page 131: Inspection

    HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE INSPECTION CAUTION 1. Remove all nicks and burrs from parts. 2. Inspect parts for excessive wear or damage, re- place parts as necessary. Do not remove relief valve seat. 3. Inspect poppet seats for burrs or roughness. 4.
  • Page 132 HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE Figure 8H-7. Detent and Lockout Reassembly 8H-4...

  • Page 133: Repair

    HYDRAULICS SECTION 8I. TRACTION MOTOR REPAIR Figure 8I-1. Traction Motor Disassembly Figure 8I-2. Drive Shaft Disassembly 8I-1...
  • Page 134 HYDRAULICS SECTION 8I. TRACTION MOTOR INSPECTION 1. Inspect all parts for signs of wear or damage. 4. Inspect piston block. Make sure the flat surface is free of score marks. 2. Inspect needle bearing in housing and lock plate. Needles should be free of excess play and remain NOTE in the bearing cage.
  • Page 135 HYDRAULICS SECTION 8I. TRACTION MOTOR Figure 8I-4. Drive Shaft Reassembly Figure 8I-5. Traction Motor Reassembly 8I-3...

  • Page 137: Repair

    HYDRAULICS SECTION 8J. REAR TRACTION MOTOR REPAIR Figure 8J-1. Rear Traction Motor 8J-1...
  • Page 138 HYDRAULICS SECTION 8J. REAR TRACTION MOTOR Figure 8J-2. Seal Assembly 8J-2...
  • Page 139 HYDRAULICS SECTION 8J. REAR TRACTION MOTOR Figure 8J-3. O-Rings and Seals 8J-3...
  • Page 141 HYDRAULICS SECTION 8K. CONTROL VALVE REPAIR Repair of the control valve is limited to changing car- tridges or renewing O-ring on each cartridge. Figure 8K-1. Control Valve 8K-1...

  • Page 143: General

    HYDRAULICS SECTION 8L. LIFT CYLINDER GENERAL FRONT CYLINDERS The HR5111 tractor uses four hydraulic cylinders to DISASSEMBLY (See Figure 8L-1) raise and lower the cutting units. The two wing cylin- 1. Clean and air dry exterior of cylinder. ders are the same and are different from the two cylin- ders which are the same.
  • Page 144 HYDRAULICS SECTION 8L. LIFT CYLINDER INSPECTION REASSEMBLY 1. Inspect all parts for excessive wear, cracks and 1. Lightly lubricate O-rings, seal ring and seals. broken parts. 2. Install seal kit as shown in Figure 8L-2. 2. Discard all O-rings, seals and seal ring. 3.
  • Page 145 HYDRAULICS SECTION 8L. LIFT CYLINDER Figure 8L-3. Lift Cylinder Assembly 8L-3...
  • Page 146 HYDRAULICS SECTION 8L. LIFT CYLINDER WIRING CYLINDERS 2. Drain all the oil from the cylinder. 3. Disassemble following the steps in Figure 8L-4. DISASSEMBLY (See Figure 8L-4) 4. Disassemble remainder of cylinder as shown in Fig- 1. Clean and air dry exterior of cylinder. ure 8L-4.
  • Page 147 HYDRAULICS SECTION 8L. LIFT CYLINDER INSPECTION 2. Install seal kit as shown in Figure 8L-5.. 1. Inspect all parts for excessive wear, cracks and NOTE broken parts. Do not install rod O-ring at this time. 2. Discard all O-rings, seals and backup rings. 3.
  • Page 148 HYDRAULICS SECTION 8L. LIFT CYLINDER Figure 8L-6. Wing Cylinder Assembly 8L-6...

  • Page 149: General

    HYDRAULICS SECTION 8M. MOWER MOTOR CONTROL VALVE GENERAL REPAIR (See Figure 8M-1) The mower motor control valves control oil flow to the Repair of the valve consists of installing a new O-ring mower motors. It is a 2 position, 4 way open center kit for changing a coil.
  • Page 150 HYDRAULICS SECTION 8M. MOWER MOTOR CONTROL VALVE INSPECTION INSTALLATION 1. Inspect all parts for signs of excessive wear or Install control valve to frame with attaching hardware. damage. SOLENOID COIL REPLACEMENT 2. O-rings should be discarded and a new kit O-ring installed.
  • Page 151 HYDRAULICS SECTION 8N. MOWER MOTOR GENERAL (See Figure 8N-1) The motors used on the HR5111 are uni-directional and positioned according to their rotation. Viewed from the shaft end, clockwise (CW) rotating motors have the letter C stamped on the motor housing. Motors that are counterclockwise (CCW) rotating have the letter A stamped on the motor housing.

  • Page 152: Disassembly

    HYDRAULICS SECTION 8N. MOWER MOTOR DISASSEMBLY 1. Clean exterior of motor with suitable solvent be- fore removing the bolts. 2. Before disassembly mark motor sections, starting at drive shaft end, to ensure correct order and po- sition of parts when reassembling. Recommended method of marking body sections is to use a fine point metal punch, making one indentation for section #1, two indentations for section #2, etc.
  • Page 153 HYDRAULICS SECTION 8O. OIL COOLER COLD OIL BYPASS REPAIR The bypass is located at the bottom left side of the hydraulic tank. Repair is limited to cleaning only. Disassemble and flush with a cleaning solvent. Figure 8O-1. Bypass 8O-1...
  • Page 155 HYDRAULICS SECTION 8P. FLOTATION CONTROL REPAIR Repair of the flotation control is renewing O-ring or replacing the control cartridge. Figure 8P-1. Back Pressure Control Valve 8P-1...
  • Page 157 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES GENERAL FIELD TESTS When a hydraulic failure occurs, some simple, effec- The purpose of this section is to provide a guide for tive tests can be performed prior to using a test instru- field testing the hydraulic system.
  • Page 158 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES • • If the engine does not labor, a fault exists in the If the engine labors or the tractor drive tires traction pump. brake traction the traction motor is okay, pro- ceed with Step 8. 4.
  • Page 159 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES POWER STEERING SYSTEM • If the steering wheel continues to turn, proceed (See Figure 8Q-3) to Step 2. 2. Remove both hydraulic lines from the steering cylin- NOTE der, plug the lines, cap the cylinder ports. Before performing the following test, check the 3.
  • Page 160 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES 8Q-4...
  • Page 161 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES LIFT AND LOWER CONTROL Left Wing (See Figure 8Q-4) Remove hydraulic lines as shown in Figure 8Q-4. Plug line and cap port. NOTE 3. Pull lift control lever, raising the mower(s) and hold. Be sure engine is above 2000 rpm.
  • Page 162 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES MOWER SYSTEM (See Figure 8Q-5) DANGER The mower circuits can be divided into three separate circuits. Mower pump section 1 supplies oil to motor control valve. Then to right wing motors. KEEP CLEAR OF REELS. Mower pump section 2 supplies oil to a motor control valve.
  • Page 163 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES Figure 8Q-5. Reel System 8Q-7...
  • Page 164 HYDRAULICS SECTION 8Q. HYDRAULIC FIELD TEST PROCEDURES 4. Follow the procedure listed under the circuit hav- If only the right motor is affected, check its case ing the problem. drain line. If the case drain line feels warmer than the two remaining motors, it may have excessive Front Mowers internal leakage, see Section 8N.
  • Page 165 HYDRAULICS SECTION 8R. INSTRUMENT TEST GENERAL It is important to follow the instructions accurately and completely. Make sure to plug lines and cap ports when The tests in this section are provided as a means of so instructed. Also, read and follow the Preliminary isolating a problem in the hydraulic system.
  • Page 166 HYDRAULICS SECTION 8R. INSTRUMENT TEST RELIEF VALVE TEST • Charge relief should read 190–250 psi. CHARGE RELIEF TEST (See Figure 8R-2) NOTE 1. Use a 0–500 psi gauge with test adapter P/N The charge relief cartridge should not be adjusted. 551433.
  • Page 167 HYDRAULICS SECTION 8R. INSTRUMENT TEST STEERING SYSTEM RELIEF (See Figure 8R-3) 1. Use a 0–2000 psi gauge with test adapter P/N 551433. 2. Plug gauge into test port SD located on the con- trol valve block. 3. Set the brake, start the engine and advance throt- tle to 2800 engine rpm.
  • Page 168 HYDRAULICS SECTION 8R. INSTRUMENT TEST LIFT SYSTEM RELIEF (See Figure 8R-4) 1. Use a 0–2000 psi gauge with test adapter P/N 551433. 2. Plug gauge into test port LD located on the con- trol valve block. 3. Set the brake, start the engine and advance throt- tle to 2800 engine rpm.
  • Page 169 HYDRAULICS SECTION 8R. INSTRUMENT TEST TRACTION SYSTEM RELIEF Forward (See Figure 8R-5) 1. Use a 0–5000 psi gauge with test adapter P/N 551433. 2. Plug gauge into test port AD located on the top left of the 4 wheel drive valve. 3.
  • Page 170 HYDRAULICS SECTION 8R. INSTRUMENT TEST MOWER SYSTEM RELIEF There are three relief valves, one located under the coil on each motor control valve. The procedure below is the same for each circuit, front, right or left wings. Identify which circuit has the fault, then proceed as follows.
  • Page 171 HYDRAULICS SECTION 8R. INSTRUMENT TEST CHARGE PUMP TEST (See Figure 8R-7) 1. Remove outlet line from pump section 4 (pump section closest to the front axle). 2. Connect the IN port of the tester to the pump out- let port. 3.
  • Page 172 HYDRAULICS SECTION 8R. INSTRUMENT TEST PRIORITY VALVE TEST (See Figure 8R-8) NOTE A charge pump test must be performed before proceeding with this test. 9. At the top of the traction pump, remove the outlet line of the charge filter from the fitting. 10.
  • Page 173 HYDRAULICS SECTION 8R. INSTRUMENT TEST LIFT SYSTEM TEST (See Figure 8R-9) FRONT MOWER CYLINDERS AND LIFT VALVE ISOLATION TEST 15. Raise the front mower and block it in the up posi- tion. CAUTION Be certain the area beneath the mower is clear. 16.
  • Page 174 HYDRAULICS SECTION 8R. INSTRUMENT TEST LEFT WING CYLINDER AND LIFT VALVE RIGHT WING CYLINDER AND LIFT VALVE ISOLATION TEST (See Figure 8R-10) ISOLATION EST (See Figure 8R-10) 15. Raise left wing mower and lock in transport posi- 15. Raise right wing mower and lock in transport posi- tion.
  • Page 175 HYDRAULICS SECTION 8R. INSTRUMENT TEST TRACTION SYSTEM CAUTION TRACTION PUMP TEST (See Figure 8R-11) 1. Raise front wheels off the ground. DO NOT exceed 4000 psi during this test. 2. Remove 4 wheel drive hose from the left side of the traction pump, cap tee and plug line.
  • Page 176 HYDRAULICS SECTION 8R. INSTRUMENT TEST FRONT TRACTION MOTOR TEST 20. Slowly close tester load valve until 3000 psi is (See Figure 8R-12) obtained and allow oil to heat up to 150°F. NOTE 21. Read/record gpm flow. Subtract from flow obtained in TRACTION PUMP TEST.
  • Page 177 HYDRAULICS SECTION 8R. INSTRUMENT TEST 4 WHEEL DRIVE VALVE TEST 25. Engage 4 wheel drive switch. (See Figure 8R-13) 26. Set parking brake, apply and hold foot brake. NOTE 27. Slowly close tester load valve until 3000 psi is ob- A traction pump and front motor test must be tained and allow oil to heat up to 150°F.
  • Page 178 HYDRAULICS SECTION 8R. INSTRUMENT TEST REAR TRACTION MOTOR TEST 35. Read/record gpm flow. Subtract from flow obtained 40. Slowly close tester load valve until 3000 psi is ob- in 4 wheel drive valve test. Record engine rpm. Left Motor Test (See Figure 8R-14) tained and allow oil to heat up to 150°F.
  • Page 179 HYDRAULICS SECTION 8R. INSTRUMENT TEST MOWER SYSTEM 5. Read/record no load flow. It should be 10.0 gpm. 6. Slowly close tester load valve until 2300 psi is ob- FRONT MOWER tained and allow oil to heat up to 150°F. Pump Test (See Figure 8R-15) 7.
  • Page 180 HYDRAULICS SECTION 8R. INSTRUMENT TEST Motor Valve Test (See Figure 8R-16) Left Motor Test NOTE NOTE A pump test must be performed before proceed- A pump and valve test must be performed be- ing with this test. fore proceeding with this test. 8.
  • Page 181 Right Motor Test NOTE A pump, valve, center motor and left motor test must be performed before proceeding with this test. 32. Move wooden block to right motor blade. 33. Open tester load valve, start engine, advance throt- tle to 2800 engine rpm. 34.
  • Page 182 HYDRAULICS SECTION 8R. INSTRUMENT TEST WING MOWERS 4. Open tester load valve, start engine, advance throt- tle to 2800 engine rpm. Pump Test (See Figure 8R-17) 5. Read/record no load flow. It should be 10.0 gpm. Pump section 1 supplies oil to the right wing and pump 6.
  • Page 183 HYDRAULICS SECTION 8R. INSTRUMENT TEST Right Wing Motor Valve Test (See Figure 8R-18) Right Wing Motor Tests NOTE NOTE A pump section 1 test must be performed before A pump and right wing motor valve test must be proceeding with this test. performed before proceeding with this test.
  • Page 184 HYDRAULICS SECTION 8R. INSTRUMENT TEST Left Wing Motor Valve Test (See Figure 8R-19) 19. Read/record gpm flow. Subtract flow obtained in PUMP test. NOTE • If flow drops 1/2 gpm or less, motor valve is A pump section 2 test must be performed before okay, proceed with Step 20.
  • Page 185 HYDRAULICS SECTION 8R. INSTRUMENT TEST Figure 8R-19. Left Wing Motor Circuit Tests 8R-21...
  • Page 186 HYDRAULICS SECTION 8R. INSTRUMENT TEST THIS PAGE INTENTIONALLY LEFT BLANK 8R-22...
  • Page 187 HYDRAULICS SECTION 8R. INSTRUMENT TEST HYDRAULIC INSTRUMENT TEST DATA SHEET RELIEF VALVE TESTS Actual Settings Charge Relief _____ psi 190–250 psi Steering Relief _____ psi 1500 psi Lift System Relief _____ psi 1500 psi Traction System Relief Forward _____ psi 3500 psi Reverse _____ psi...
  • Page 188 HYDRAULICS SECTION 8R. INSTRUMENT TEST FLOW TESTS (Continued) TRACTION SYSTEM Traction Pump 2800 NO LOAD ________ gpm @ engine rpm ________ 2800 NO LOAD @ ________ gpm @ engine rpm ________ @ 3000 psi – ________ gpm @ engine rpm – ________ Conclusion = ________ gpm drop @ engine rpm drop = ________...
  • Page 189 HYDRAULICS SECTION 8R. INSTRUMENT TEST FLOW TESTS (Continued) MOWER SYSTEM TESTS (Continued) Front Mower Pump (Continued) Center Motor 2800 NO LOAD ________ gpm @ engine rpm ________ Center Motor Test ________ gpm @ 3000 psi – ________ gpm @ engine rpm – ________ Conclusion = ________ gpm drop @ engine rpm drop = ________...
  • Page 190 HYDRAULICS SECTION 8R. INSTRUMENT TEST FLOW TESTS (Continued) MOWER SYSTEM TESTS (Continued) Front Mower Pump (Continued) Right Wing Mower Pump (Section 1) 2800 NO LOAD ________ gpm @ engine rpm ________ @ 2500 psi – ________ gpm @ engine rpm – ________ Conclusion = ________ gpm drop @ engine rpm drop = ________...
  • Page 191 HYDRAULICS Figure 8S-1. Flow Diagram 8S-1...
  • Page 192 HYDRAULICS Figure 8S-2. Schematic (Early) 8S-3...
  • Page 193 HYDRAULICS Figure 8S-3. Schematic (Later) 8S-5...
  • Page 194 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 195 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 196 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 197 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 198 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 199 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...

  • Page 200: Deck Lift

    Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 201 Center 2300 psi 1500 psi Lift Valve 2300 psi Weight Transfer Control 1500 psi Charge Relief Valve 250psi 435 psi 3000 psi 4WD Valve Control Inside Valve Outside Priority Valve 17 Ltr 435 psi 3000 psi Diff Lock Hydrostatic 50 psi Pump 3500 psi Bypass...
  • Page 202 HYDRAULICS Figure 8S-4. Traction System (1 of 4) 8S-7...
  • Page 203 HYDRAULICS Figure 8S-5. Power Steering System (2 of 4) 8S-9...
  • Page 204 HYDRAULICS Figure 8S-6. Lift System (3 of 4) 8S-11...
  • Page 205 HYDRAULICS Figure 8S-7. Mower System (4 of 4) 8S-13...
  • Page 207 SECTION 9 CHASSIS 9A. Repair and Service Tools and Materials ........9A-1 9B.
  • Page 209 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). Jacobsen Part No. 502696, 2.5 gal. (9.5 liter). Sunoco H.P. Engine Oil SAE 10W-30. Mobil Delvac (Special) SAE 10W-30.
  • Page 211 CHASSIS SECTION 9B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Lift/lower functions do a. Engine rpm not above 2000. a. Increase engine rpm. not occur when lever is b. Lever linkage is worn. b. Repair or replace linkage actuated. (Section 2C). c.

  • Page 213: General

    CHASSIS SECTION 9C. FUEL TANK GENERAL REMOVAL AND INSTALLATION (See Figure 9C-1) The fuel tank is a single piece tank which should re- quire no servicing unless punctured or otherwise acci- 1. Place a suitable container under tank and open dentally damaged.

  • Page 215: General

    CHASSIS SECTION 9D. HYDRAULIC TANK GENERAL NOTE The cap on the hydraulic tank is a pressure cap. The hydraulic tank requires little or no service other than adding hydraulic oil when indicated by checking If water, air, or contamination is indicated, locate the the sight gauge and periodically cleaning the screen in source of the problem and take corrective action.

  • Page 217: Removal And Installation

    CHASSIS SECTION 9E. SEAT REMOVAL AND INSTALLATION 2. Lift the seat and slide mounts off seat pan. (See Figure 9E-1) To install the seat, secure the seat assembly with at- taching hardware. Lubricate as described in Section 11. 1. Remove the attaching hardware from the slide mounting brackets.

  • Page 219: Lift Assembly

    CHASSIS SECTION 9F. DECK LIFT ASSEMBLY LIFT ASSEMBLY (See Figure 9F-1) 1. Lower implement to ground. Figure 9F-1. Lift Assembly...
  • Page 220 CHASSIS SECTION 9F. DECK LIFT ASSEMBLY TRANSPORT LOCK MECHANISM NOTE (See Figure 9F-2) When installing the center lock nut, do not tight- en against latch hook. Latch hook must move The wing transport lock mechanism should not require freely. adjustments unless the arms have been disassembled. Repair is limited to replacing damaged or worn parts.

  • Page 221: General

    CHASSIS SECTION 9G. REAR AXLE GENERAL 5. Remove capscrew. 6. Making sure tractor and axle are well supported, Repair of the rear axle is limited to replacement of bro- remove pivot shaft and thrust washer to free axle ken parts and servicing bushings and bearings. (See from tractor frame.

  • Page 222: Spindle Removal And Installation

    CHASSIS SECTION 9G. REAR AXLE SPINDLE REMOVAL AND INSTALLATION 6. Replace lower thrust bearing and thrust washers and spindle bushings as needed. (See Figure 9G-1) 7. Install thrust bearings and thrust washers on spindle 1. Disconnect tie rod and head end of the steering assembly.
  • Page 223 SECTION 10 ELECTRICAL SYSTEM 10A. Repair and Service Tools and Materials ........10A-1 10B.
  • Page 224 Hydraulic Charge Filter Switch Test ......... . . 10G-18 Field Test .

  • Page 225: Repair And Service Tools And Materials

    ELECTRICAL SYSTEM SECTION 10A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Multimeter. Jumper wires. 60 amp ammeter. Cleaning materials: Baking soda and water. Other service items: Electrical insulation compound P/N 365422. 10A-1...

  • Page 227: Failure Analysis

    ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Engine will not turn over a. Battery dead. a. Charge or replace (Section 10D). when ignition switch is b. Parking brake not set. b. Set brake. engaged. c. Implement switch not in the OFF c.
  • Page 228 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY GLOW PLUG CIRCUIT 1. Glow plugs do not a. Parking brake not set. a. Set brake. come on. b. Implement switch not in the OFF b. Push into OFF position. position.
  • Page 229 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY IMPLEMENT CIRCUITS (Continued) 3. Only one wing does not a. Arm interlock switch not closing. a. Check switch/adjust (Section 2C). come on. b. Faulty arm interlock switch. b. Test switch (Section 10G). c.
  • Page 230 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY GAUGES AND PANEL LIGHTS (Continued) 3. Panel light does 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 position. b. Battery dead. b.
  • Page 231 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY GAUGES AND PANEL LIGHTS (Continued) 10. Horn does not sound a. 10 amp cruise/horn circuit a. Reset/test (Section 10J). when test switch is breaker tripped. pushed to the ON b. Faulty horn relay. b.
  • Page 232 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY CAB CIRCUITS (Continued) 4. Cab work lights do not a. Bulb burned out. a. Replace. work. b. Faulty wiring or bad electrical b. Test (Section 10C). ground. c. Faulty light switch. c.

  • Page 233: General Instructions

    ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS GENERAL NOTE Before performing any component or wiring test, Repair of the electrical system, for the most part, is check for corrosion and loose or missing con- limited to the replacement of faulty components or wir- nections.

  • Page 234: Resistance Test

    ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS RESISTANCE TEST 3. Read the Ω (ohms) on the multimeter. (See Figure 10C-2) • Contacts of a switch or a wire should have less than 0.5 Ω (ohms) reading. 1. Set the multimeter to an Ω (ohms) scale. •...

  • Page 235: Battery

    ELECTRICAL SYSTEM SECTION 10D. BATTERY GENERAL WARNING For normal service, use a battery rated 12V, 770 cold cranking amps at 0°F (–18°C) AABM Group #78NF. To avoid possible injury, stand away from battery when the charger is turned on. A damaged bat- WARNING tery or a battery with an internal short could explode.

  • Page 236: Testing

    ELECTRICAL SYSTEM SECTION 10D. BATTERY TESTING (See Figure 10D-1) 3. Crank the engine — if battery voltage falls below 9 volts while cranking, the battery is run-down or Test battery voltage as follows: faulty. Charge and perform test again. 1. Connect DC multimeter to battery terminals. 2.

  • Page 237: Charging System

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM GENERAL WARNING The 35 amp charging system consists of an alternator and separate regulator. See the Engine Manufacturer’s Service Manual for de- Use an ammeter rated at 40 or more amps. tailed repairs of the alternator. ALTERNATOR FIELD TEST 3.

  • Page 238: Alternator Input Voltage

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM ALTERNATOR INPUT VOLTAGE 3. Turn on the ignition switch. (See Figure 10E-2) • The multimeter should read battery voltage. 1. Remove the alternator plug. • If no voltage registers, continue with voltage reg- 2. Set the multimeter to 20 VDC and connect POS ulator test.

  • Page 239: No Load Test

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM NO LOAD TEST (See Figure 10E-3) 6. Disconnect the battery NEG (–) cable. • 1. Remove the electrical plug from the alternator. Voltage should be about 17 VDC. • 2. Using a jumper wire, connect the F terminal to the Voltage should increase to 32 VDC as the en- B terminal.

  • Page 240: Rotor Coil, Slip Ring And Brush Test

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM ROTOR COIL, SLIP RING AND BRUSH TEST 3. Connect the multimeter POS (+) lead to terminal (See Figure 10E-4) F and the NEG (–) lead to terminal E. • 1. Remove the plug from the alternator. The resistance should be approximately 6.5–10 Ω...

  • Page 241: No Load Regulating Voltage Test

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM NO LOAD REGULATING VOLTAGE TEST 5. Gradually accelerate the engine and watch the (See Figure 10E-5) multimeter. • 1. Set the multimeter to the 20 VDC range. Voltage should rise as engine rpm increases. Voltage should read 13.8 to 14.8 VDC.

  • Page 242: Regulator Test

    ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM REGULATOR TEST (See Figure 10E-6) The regulator regulates the output voltage and current according to the electrical demand. Figure 10E-6. Regulator Test 10E-6...

  • Page 243: Starter

    If no click is heard the coil or electrical supply ufacturer’s Service Manual which can be obtained may be defective. Continue with the next step. through your local Jacobsen Distributor. 4. Remove the PUR/WHT solenoid wire. 5. Set the multimeter to 20 VDC and connect the FIELD TEST POS (+) lead to the solenoid wire.

  • Page 244: Starter Motor

    ELECTRICAL SYSTEM SECTION 10F. STARTER STARTER MOTOR (See Figure 10F-2) 6. Touch the NEG (–) cable to the NEG (–) terminal on the battery. 1. Disconnect the NEG (–) battery cable. • The starter motor should turn. 2. Disconnect the PUR/WHT solenoid wire from the •...

  • Page 245: Switches

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES GENERAL This section provides instructions for testing the vari- 3. Connect meter leads to connector terminals. ous switches that are part of the electrical system. • There should be no reading (no continuity) on Repair is limited to replacement of components found VOM.

  • Page 246: Ignition Switch Test (Early)

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES IGNITION SWITCH TEST (EARLY) • There should be a reading of 0–0.5 Ω (ohms) on the multimeter. (See Figure 10G-2) c. Move red POS (+) lead to terminal A. 1. Disconnect ground (black) NEG (–) cable at bat- tery.
  • Page 247 ELECTRICAL SYSTEM SECTION 10G. SWITCHES Contacts Open Contacts Closed No Continuity Continuity 0–0.5 Ohms Position Continuity Position Continuity B+I+A None STEP 4A STEP 4B Contacts Closed Contacts Closed Continuity 0–0.5 Ohms Continuity 0–0.5 Ohms Position Continuity Position Continuity B+I+A B+I+A STEP 4C STEP 4D Contacts Closed...

  • Page 248: Ignition Switch Test (Later)

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES IGNITION SWITCH TEST (LATER) b. With key switch in RUN position, connect black NEG (–) test lead to terminal B and red POS (See Figure 10G-4) (+) lead to terminal I. 1. Disconnect ground (black) NEG (–) cable at battery. •...
  • Page 249 ELECTRICAL SYSTEM SECTION 10G. SWITCHES Figure 10G-5. Ignition Switch Test Step 4 10G-5...

  • Page 250: Implement (Mower) Switch Test (Early)

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES IMPLEMENT (MOWER) SWITCH TEST c. Check for continuity across all remaining com- binations of terminals (with switch in the OFF (EARLY) (See Figure 10G-6) position). NOTE • There should be no reading on the multimeter. See page 10G-23 for later switch.

  • Page 251: Wing Mower Control And Lighting Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES WING MOWER CONTROL AND LIGHTING c. Check for continuity across all remaining com- binations of terminals (with switch in the ON (1) SWITCH TEST (See Figure 10G-7) position). 1. Disconnect switch connectors. • There should be no reading on the multimeter. 2.

  • Page 252: Front Mower Control Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES FRONT MOWER CONTROL b. Check for continuity across remaining terminal (with switch in the ON (1) position). SWITCH TEST (See Figure 10G-8) • There should be no reading on the multimeter. 1. Disconnect switch connectors. 5.

  • Page 253: Wheel Drive Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES 4 WHEEL DRIVE SWITCH TEST b. Check for continuity across remaining terminal (with switch in the ON (fixed) position). (See Figure 10G-9) • There should be no reading on the multimeter. 1. Disconnect switch connectors. 5.

  • Page 254: Cruise Control Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES CRUISE CONTROL SWITCH TEST b. Check for continuity across remaining terminal (with switch in the ON (1) (momentary) position). (See Figure 10G-10) • There should be no reading on the multimeter. 1. Disconnect switch connectors. 5.

  • Page 255: Glow Plug Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES GLOW PLUG SWITCH TEST 3. Connect multimeter test leads to switch terminals with the switch in the OFF position. TEST SWITCH TEST (See Figure 10G-11) • There should be no reading on the multimeter. The glow plug switch is pushed by the operator to allow current flow to the glow plugs, prior to starting the 4.

  • Page 256: Front Mower Shut-Off Switch

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES FRONT MOWER SHUT-OFF SWITCH • There should be a reading of 0–0.5 Ω (ohms) on the multimeter. (See Figure 10G-12) 5. Lift and hold switch lever up in OFF position. The switch prevents operation of the mower when it is in the raised position.

  • Page 257: Brake Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES BRAKE SWITCH TEST 1. Remove the wires from the switch. WING MOWER SHUT-OFF SWITCH TEST 2. Set multimeter to 200 Ω (ohms) scale. PARKING BRAKE SWITCH TEST 3. Connect leads to switch as shown. REVERSE SENSING SWITCH TEST •...

  • Page 258: Neutral And Reverse Sensing Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES NEUTRAL AND REVERSE SENSING 5. Depress switch lever. SWITCH TEST (See Figure 10G-14) • There should be no reading at multimeter (no continuity). 1. Disconnect ground cable at battery. 6. Move test lead from NC to NO. 2.

  • Page 259: Horn Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES HORN SWITCH TEST (See Figure 10G-15) The horn switch sounds the tractor horn when the op- 4. Depress switch. erator pushes on the switch. It also can be used to test • There should be a reading of 0–0.5 Ω (ohms) at the lights on the monitor panel.

  • Page 260: Differential Lock Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES DIFFERENTIAL LOCK SWITCH TEST • There should be a reading of 0–0.5 Ω (ohms) at multimeter. (See Figure 10G-16) NOTE 1. Set multimeter to 200 Ω (ohms) scale. RED switch lead is not used. 2. Connect leads to switch plug as shown. •...

  • Page 261: Hydraulic Charge Pressure Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES HYDRAULIC CHARGE PRESSURE At the switch, disconnect the plug. • SWITCH TEST (See Figure 10G-17) Light goes off, proceed with switch test, Step 1. • The charge pressure switch is a normally CLOSED Light does not go off, check circuit wiring ground. (NC) switch.

  • Page 262: Hydraulic Charge Filter Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES HYDRAULIC CHARGE FILTER • Light goes off, proceed with switch test, Step 1. SWITCH TEST (See Figure 10G-18) • Light does not go off, check circuit wiring for ground. The charge filter switch is a normally OPEN (NO) switch. SWITCH TEST When the hydraulic oil pressure at the inlet of the charge oil filter increases above 20 psi the switch CLOSES and...

  • Page 263: Hydraulic Return Oil Filter Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES HYDRAULIC RETURN OIL FILTER • Light goes off, proceed with switch test, Step 1. SWITCH TEST (See Figure 10G-19) • Light does not go off, check circuit wiring for ground. The hydraulic return oil filter switch is a normally OPEN SWITCH TEST (NO) switch.

  • Page 264: Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES ENGINE OIL PRESSURE SWITCH TEST Remove BLU wire from switch terminal. • (See Figure 10G-20) Light goes off, proceed with switch test, Step 1. • The engine oil pressure switch is a normally CLOSED Light does not go off, check circuit wiring for ground. (NC) switch.

  • Page 265: Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES HYDRAULIC OIL TEMPERATURE SWITCH TEST ENGINE COOLING WATER TEMPERA- 1. Using a suitable container, fill it with engine or hydraulic oil. TURE SWITCH TEST (See Figure 10G-21) 2. Heat the oil to 230°F (110°C). The temperature switch is a normally OPEN (NO) switch. 3.

  • Page 266: Switch Test

    ELECTRICAL SYSTEM SECTION 10G. SWITCHES AIR CLEANER SERVICE INDICATOR SWITCH TEST SWITCH TEST (See Figure 10G-22) 1. Set multimeter to 200 Ω (ohms) scale. The air cleaner service indicator switch is a normally 2. Connect test leads as shown. OPEN (NO) switch. When the air filter becomes re- •...
  • Page 267 ELECTRICAL SYSTEM SECTION 10G. SWITCHES IMPLEMENT (MOWER) SWITCH TEST • There should be no reading on the multimeter. (See Figure 10G-23) 4. Place switch in ON position and test as follows: 1. Disconnect switch connectors. a. Check for continuity by connecting one multi- meter test lead to terminal 5 and the other to 2.

  • Page 269: Engine (Fuel) Solenoid

    ELECTRICAL SYSTEM SECTION 10H. RELAY ENGINE (FUEL) SOLENOID 4. Connect 12V across terminals 85 and 86. There should be an audible “click”. HORN 5. Connect black NEG (–) lead from the multimeter CRUISE ENGAGE to terminal 30. CAB (See Figure 10H-1) 6.

  • Page 270: Cruise Disengage (Brake Relay)

    ELECTRICAL SYSTEM SECTION 10H. RELAY CRUISE DISENGAGE (BRAKE RELAY) 5. Connect 12V across terminals 85 and 86. There should be an audible “click”. (See Figure 10H-2) 6. Connect black NEG (–) lead from multimeter to 1. Set multimeter to 200 Ω...

  • Page 271: Seat Delay Relay Test

    ELECTRICAL SYSTEM SECTION 10H. RELAY SEAT DELAY RELAY TEST 4. Connect red lead from DMM to yellow wire and black lead to ground NEG (–) terminal at battery. (See Figure 10H-3) • The DMM should read 12 volts. If not, replace 1.

  • Page 273: Fuel Solenoid

    ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS FUEL SOLENOID (See Figure 10I-1) • If multimeter reads battery voltage, tractor wir- ing is okay, proceed with Step 5. When the ignition switch is turned to the START posi- tion, the solenoid plunger retracts approximately 1" •...
  • Page 274 ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS ADJUSTMENT (See Figure 10I-2) 1. Disconnect solenoid rod at lever. 4. After adjustment, turn ignition switch to OFF. 2. Turn ignition switch to START momentarily with- NOTE out starting engine. This will seat solenoid plunger. If not adjusted properly, solenoid will not “hold Leave ignition switch in RUN position.

  • Page 275: Differential Lock

    ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS DIFFERENTIAL LOCK 4. Set multimeter to 20 VDC range. 4 WHEEL DRIVE (See Figure 10I-3) 5. Connect black NEG (–) multimeter lead to con- nector as shown. 1. Energize the solenoid. 6. Connect red POS (+) lead of multimeter to con- 2.
  • Page 276 ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS (See Figure 10I-4) • Coil Ω (ohms) reading should be approximately 10 Ω (ohms) if reading is correct. Valve car- 7. Set multimeter to 200 Ω (ohms) range. tridge may be faulty. 8. Connect multimeter leads to coil as shown. •...

  • Page 277: Glow Plug Solenoid Test

    ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS GLOW PLUG SOLENOID TEST 3. Connect multimeter test leads to terminals 3 and 4. (See Figure 10I-5) • Multimeter reading should be less than 0.5 Ω (ohms). 1. Connect a 12 VDC battery to terminals 1 and 2. Replace a solenoid that does not meet all the above •...

  • Page 278: Deck Motor Valve Solenoid

    ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS DECK MOTOR VALVE SOLENOID 4. Set multimeter to 20 VDC range. (See Figure 10I-6) 5. Connect black NEG (–) multimeter lead to con- nector as shown. 1. Energize the solenoid. 6. Connect red POS (+) lead of multimeter to con- 2.
  • Page 279 ELECTRICAL SYSTEM SECTION 10I. SOLENOIDS (See Figure 10I-7) • Coil Ω (ohms) reading should be approximately 2.98–3.65 Ω (ohms) if reading is correct. Valve 7. Set multimeter to 200 Ω (ohms) range. cartridge may be faulty. 8. Connect multimeter leads to coil as shown. •...

  • Page 281: Circuit Breakers And Fuse

    ELECTRICAL SYSTEM SECTION 10J. CIRCUIT BREAKERS AND FUSE CIRCUIT BREAKER TEST See Figure 10J-1 and test circuit breaker as follows: 3. Depress button (close). • 1. Set multimeter to 200 Ω (ohms) scale. There should be a reading (continuity) on meter scale.

  • Page 282: Fuse Test

    ELECTRICAL SYSTEM SECTION 10J. CIRCUIT BREAKERS AND FUSE FUSE TEST See Figure 10J-2 and test fuse as follows: 1. Set multimeter to 200 Ω (ohms) scale. 2. Connect meter leads to fuse as shown. • There should be a reading (continuity) on the meter scale.

  • Page 283: General

    ELECTRICAL SYSTEM SECTION 10K. GAUGES GENERAL WATER TEMPERATURE GAUGE TEST (See Figure 10K-1) Repair of gauges and sending units are limited to the replacement of faulty components or wiring. Before Test the water temperature gauge as follows: replacing a gauge that is not working make sure to 1.

  • Page 285: Glow Plugs

    ELECTRICAL SYSTEM SECTION 10L. GLOW PLUGS GLOW PLUG TEST 4. Connect one multimeter test lead to glow plug ter- minal and the other to housing. See Figure 10L-1 and test a suspected faulty glow plug • The multimeter reading should be approximate- as follows: ly 0.8 Ω...

  • Page 287: Diode Test

    ELECTRICAL SYSTEM SECTION 10M. DIODE TEST DIODE TEST 3. Reverse the POS (+) and NEG (–) test leads. • There should be no continuity. See Figure 10M-1 and test diode as follows: • 1. Set meter to scale. If continuity registers in both positions, the diode is faulty.
  • Page 289 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Fogire 10N-1. Wiring Diagram (1 of 2) 10N-1...
  • Page 290 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Figure 10N-2. Wiring Diagram (1 of 2) 10N-3...
  • Page 291 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Figure 10N-3. Wiring Diagram for Figures 10N-1 and 10N-2 (2 of 2) 10N-5...
  • Page 293 Og Bu Fuel Solenoid 30 amp Tn Rd Wh Bk Alternator Light Switch Wh Bk Glow Plugs Wh Rd Pk Bu Volt meter Glow Plug 10 amp Temp Gn Wh Switch 50 amp Gauge Hour Meter Wh Bk Pk Bu Pk Bu Bn Rd Fuel...
  • Page 294 Og Bu Fuel Solenoid 30 amp Tn Rd Wh Bk Alternator Light Switch Wh Bk Glow Plugs Wh Rd Pk Bu Volt meter Glow Plug 10 amp Gn Wh Switch Temp 50 amp Gauge Hour Meter Wh Bk Pk Bu Pk Bu Bn Rd Fuel...
  • Page 295 Og Bu Fuel Solenoid 30 amp Tn Rd Wh Bk Alternator Light Switch Wh Bk Glow Plugs Wh Rd Pk Bu Volt meter Glow Plug 10 amp Temp Gn Wh Switch 50 amp Gauge Hour Meter Wh Bk Pk Bu Pk Bu Bn Rd Fuel...
  • Page 296 Og Bu Fuel Solenoid 30 amp Tn Rd Wh Bk Alternator Light Switch Wh Bk Glow Plugs Wh Rd Pk Bu Volt meter Glow Plug 10 amp Gn Wh Switch Temp 50 amp Gauge Hour Meter Wh Bk Pk Bu Pk Bu Bn Rd Fuel...
  • Page 297 Og Bu Fuel Solenoid 30 amp Tn Rd Wh Bk Alternator Light Switch Wh Bk Glow Plugs Wh Rd Pk Bu Volt meter Glow Plug 10 amp Temp Gn Wh Switch 50 amp Gauge Hour Meter Wh Bk Pk Bu Pk Bu Bn Rd Fuel...
  • Page 298 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Figure 10N-4. Component Location (1 of 3) 10N-7...
  • Page 299 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Figure 10N-5. Component Location (2 of 3) 10N-9...
  • Page 300 ELECTRICAL SYSTEM SECTION 10N. WIRING DIAGRAMS AND COMPONENT LOCATION ILLUSTRATION Figure 10N-6. Component Location (3 of 3) 10N-11...
  • Page 301 SECTION 11 PREVENTIVE MAINTENANCE 11A. General ............... 11A-1 Preventive Maintenance .

  • Page 303: Preventive Maintenance

    Use the manufacturer’s recommendation of preventive The PMMRS kits and replacement forms (see Figure maintenance. These recommendations can then be 11A-1) are available directly from your local Jacobsen altered as experience is gained with the type of equip- Distributor. ment and the type of environment in which it operates.
  • Page 304 11A-2...

  • Page 305: Lubrication Schedules

    For easy reference a 25" x 19" wall chart can intervals. Intervals are based on a 40 hour week. These be obtained from your Jacobsen Distributor. are suggested intervals only. As experience is gained in operating this machine, the schedule can be tailored to Footnotes are found on Page 11C-4 and are shown in your operating time.

  • Page 306: Mower Lubrication Chart

    PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION SCHEDULES AND CHARTS MOWER LUBRICATION CHART Ref. Qty. Description Remarks 40 HOURS (Every Week) Hydraulic lift cylinder ends Mower arm pivots Wing mower unit pivots Caster wheel pivots Caster wheel axle 11B-2...

  • Page 307: Maintenance Schedule Chart

    PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES GENERAL The following charts summarize maintenance to be per- Reference numbers are keyed to the illustration on formed daily, weekly, every two weeks, monthly, every page 11C-3. Footnotes on page 11C-3 give additional three months, and annually. information.

  • Page 308: Engine

    PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE CHART Ref. Qty. Description ENGINE Fuel Check. Fuel oil #2 Cetane rating 45. Fuel filter Clean 100 hours. Replace 500 hours. Fuel lines and clamps Check 50 hours. Replace every 2 years. Engine oil Check.

  • Page 309: Footnotes

    Use pressure gun grease (NLGI Grade 0). Apply with grease gun. Use hand grease gun (NLGI Grade 0). System capacity: 20 gallons. Jacobsen hydraulic oil. Part No. 502696 carton containing two 2-1/2 gallons (9.5 liters) bottles or Part No. 502693, pail containing 5 gallons (19 liters).
  • Page 311 SECTION 12 ATTACHMENTS 12A. Repair and Service Tools and Materials ........12A-1 12B.
  • Page 313 ATTACHMENTS SECTION 12A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools, including driving tools, and seal spreaders; Blade Grinder. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Non-metallic additive wheel bearing grease (eg. Sunray DX 692 or Enco Fibrox 280).
  • Page 315 ATTACHMENTS SECTION 12B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Blades do not turn. a. Blades jammed. a. Clean underside of deck. b. Spindle bearing failure. b. Check bearings, repair (Section 12D). c. Drive assembly malfunctioning. c. Inspect, repair (Section 12D). d.

  • Page 317: Preparation For Repair

    ATTACHMENTS SECTION 12C. GENERAL INSTRUCTIONS PREPARATION FOR REPAIR WARNING Thoroughly clean decks prior to removal, disassembly and/or repair. Coat bare metal parts with light oil to prevent rust and corrosion. Before removing components or performing re- Decks are exposed to water, grass clippings, sand, pairs and adjustments, lower attachment, stop corrosive fertilizers, and foreign objects.

  • Page 319: Pivot Housing And Push Arms

    ATTACHMENTS SECTION 12D. MOWERS PIVOT HOUSING AND PUSH ARMS Removal and installation of the pivot housings and push arms are illustrated in Figure 12D-1. Figure 12D-1. Pivot Housings and Push Arms 12D-1...

  • Page 320: Carrier Assembly

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

  • Page 321: Deck Fittings

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

  • Page 322: Blade Spindle Assembly

    ATTACHMENTS SECTION 12D. MOWERS BLADE SPINDLE ASSEMBLY In this section service of the motors consists only of the spindle assembly. For service of the hydraulic mo- GENERAL tor see Section 8O. There are 7 motors, one for each blade on the HR111. In most cases the spindle housing and motor do not Motor rotation is identified in two ways, first: by their have to be removed to service the spindle assembly.
  • Page 323 ATTACHMENTS SECTION 12D. MOWERS Figure 12D-5. Motor Rotation By Code Letter 12D-5...
  • Page 324 ATTACHMENTS SECTION 12D. MOWERS DISASSEMBLY (See Figure 12D-6) 10. Remove motor assembly from spindle housing. Do not disassemble motor. 1. Remove blade and adapter. 11. Remove spindle shaft bearing. 2. Remove square drive key. REASSEMBLY (See Figure 12D-6) 3. Remove shaft protector. 1.

  • Page 325: General

    ATTACHMENTS SECTION 12E. BLADES GENERAL Every 50 hours examine the cutter bars to make sure they are in good operating condition. See Figure 12E-1. 1. The blades should follow along a straight line and should not be bent. Replace all bent blades. The damage may include a microscopic crack which could grow, allowing a piece of the bar to break off and be thrown out from under the mower, causing serious bodily injury.

  • Page 326: Blade Installation

    ATTACHMENTS SECTION 12E. BLADES BLADE INSTALLATION (See Figure 12E-4) When installing 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). Figure 12E-4.
  • Page 327 ATTACHMENTS SECTION 12F. CASTER WHEELS Repair of the caster wheels consist of replacing bush- ings and worn or damaged components. See Figure 12F-2. Figure 12F-1. Caster Wheels 12F-1...
  • Page 328 ATTACHMENTS SECTION 12F. CASTER WHEELS Figure 12F-2. Caster Wheel Repair 12F-2...
  • Page 329 SECTION 13 OPTIONS THIS SECTION INTENTIONALLY LEFT BLANK...
  • Page 331 SECTION 14 MISCELLANEOUS 14A. Precaution Decal Locations ........... . 14A-1 Tractor .
  • Page 333 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS TRACTOR Part No. 964907 Part No. 365339 Part No. 365919 14A-1...
  • Page 334 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS Part No. 361175 Part No. 861883 Part No. 339237 Part No. 365956 Part No. 339460 Part No. 366160 Part No. 366527 Part No. 363134 14A-2...
  • Page 335 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS MOWER Part No. J-T338141 14A-3...
  • Page 337 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS MILLIMETERS TO DECIMALS 14B-1...
  • Page 338 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS DECIMALS TO MILLIMETERS, FRACTIONS TO DECIMALS TO MILLIMETERS 14B-2...
  • Page 339 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS U.S. TO METRIC CONVERSIONS To Convert Into Divide By Linear Miles Kilometers 1.609 Measurement Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area Square Miles Square Kilometers 2.59 Square Feet...

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