Jacobsen HR-9016T 70541 Technical/Repair Manual
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Jacobsen HR-9016T 70541 Technical/Repair Manual

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HR-9016T
Rotary Mower
Technical/Repair Manual
70538, 70539, 70540, 70541

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Summary of Contents for Jacobsen HR-9016T 70541

  • Page 1 HR-9016T Rotary Mower Technical/Repair Manual 70538, 70539, 70540, 70541...
  • Page 3 ©2012 Jacobsen, A Textron Company. All rights reserved.
  • Page 5 Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen HR-9016T rotary mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user...
  • Page 6 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2012, Jacobsen, A Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4263110-Rev B...

  • Page 7: Table Of Contents

    Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous Repair 4263110-Rev B...
  • Page 9 Chapter 1 Safety Introduction ..............1-2 Prepare for the Job .

  • Page 10: Introduction

    SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
  • Page 11 SAFETY TN4080, TN4082 Figure 1-1 4263110-Rev B...
  • Page 12 SAFETY WARNING This structure's proctective capability may be impaired by structural damage, overturn, or alteration. If any of these conditions occur, the structure must be replaced. 557844 5002952 4181862 4181863 4263110-Rev B...
  • Page 13 SAFETY 41 8 1 8 64 4199140 4164281 4263110-Rev B...

  • Page 14: Inspect Safety Labels

    SAFETY Inspect Safety Labels Park Mower Safely Safety labels are critical to the safe operation of the See Figure 1-2. mower. Inspect the mower for any damaged, missing, or WARNING unreadable labels. Replace labels as necessary before placing the mower back in service. Before cleaning, adjusting, or repairing this equipment, disengage all drives, engage park Keep Work Area Clean...

  • Page 15: Use Lifting Equipment Safely

    SAFETY Use Lifting Equipment Safely Use Compressed Air and Air Tools Safely WARNING WARNING Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Always wear approved eye and ear protection Using underrated or worn lifting components can while using compressed air.

  • Page 16: Service Tires Safely

    SAFETY Service Tires Safely Handle Fuel Safely Handle fuel with care—it is highly flammable. WARNING WARNING An inflated tire contains explosive force. Use care when handling wheels and tires. • Never remove the fuel cap from the fuel tank, or add fuel, when the engine is running or while the engine is hot.

  • Page 17: Handle Chemical Products Safely

    SAFETY Handle Chemical Products Service Hydraulic System Safely Safely WARNING WARNING The hydraulic system is under pressure, and the oil may be hot! Exposure to chemical products could result in • Always allow the machine to cool completely serious injury. Handle chemical products with before performing service.

  • Page 18: Service Electrical Components Safely

    SAFETY Service Electrical Components Safely WARNING Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury. •...

  • Page 19: Specifications And

    Chapter 2 Specifications and General Information Machine Identification ............2-2 Machine Serial Number .

  • Page 20: Machine Identification

    SPECIFICATIONS AND GENERAL INFORMATION Machine Identification Models 70540 and 70541 Machine Serial Number See Figures 2-1 through 2-3. 11524 WILMAR BLVD, ® CHARLOTTE, NC 28273 A Textron Company 1 800 848 1636 (US) PRODUCT OF U.S.A. TN3994 Figure 2-3 A machine identification plate (1) listing the serial number TN4084 (4) and machine weight (3) is attached to the frame of the Figure 2-1...

  • Page 21: Component Location

    SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figure 2-5. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN4083 Seat Steering Assist Front Wheel (2) Instrument Panel Left Wing Deck Right Wing Deck Steering Wheel Front Deck Rear Wheel (2)

  • Page 22: Cutting Units

    SPECIFICATIONS AND GENERAL INFORMATION TN4080 Rear Wheel (2) Anti-Scalp Wheel (8) Battery (2) Hydraulic OIl Charge Filter Cutting Unit Motor (11) Rear Wheel Motor (2) Left Wing Deck Fuel Tank Steering Axle Assembly Caster Wheel Assembly (10) Figure 2-6: Component Location—Left Side 4263110-Rev B...

  • Page 23: Specifications

    SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Engine General Engine Specifications ® Manufacturer/Models Kubota V3800DICR-T-E3B Engine Type 4-Stroke, Diesel Fuel Requirement Low or Ultra Low Sulfur No. 2 Diesel Fuel (Cetane Rating 45) Number of Cylinders/Configuration 4/In-Line Displacement 230 (3.769) cu in.
  • Page 24 SPECIFICATIONS AND GENERAL INFORMATION Electrical Test Specifications Resistance Across Solenoid Coil— 7.1 ± 10% ohms Front Mow Solenoid 1 Coil at 68° F Resistance Across Solenoid Coil— 7.1 ± 10% ohms Front Mow Solenoid 2 Coil at 68° F Resistance Across Solenoid Coil— 7.1 ±...

  • Page 25: Hydrostatic Power Train

    SPECIFICATIONS AND GENERAL INFORMATION Hydrostatic Power Train Test Specifications Traction Pump Flow 32.8 (124) at 2700 rpm gpm (lpm) Forward System Relief Pressure 4387 ± 10% (302 ± 10%) at 2700 rpm psi (bar) Reverse System Relief Pressure 4387 ± 10% (302 ± 10%) at 2700 rpm psi (bar) Charge Pressure 313 ±...
  • Page 26 SPECIFICATIONS AND GENERAL INFORMATION Repair Specification Drive Shaft—Mounting Screw Torque 60–65 (81–88) lb-ft (N·m) Drive Shaft—Yoke Screw Torque 30–35 (41–47) lb-ft (N·m) Traction Pump—Port “CP” Fitting Torque 90 (122) lb-ft (N·m) Traction Pump—Port “T” Fitting Torque 110 (149) lb-ft (N·m) Traction Pump—Port “A”...

  • Page 27: Hydraulics

    SPECIFICATIONS AND GENERAL INFORMATION Hydraulics Test Specifications Cutting Unit Pumps Flow 13.3 (57) at 2400 rpm gpm (lpm) Lift/Steer Pump Flow 5.7 (22) at 2700 rpm gpm (lpm) Hydraulic Leakage Percentage Ranges 0–10% = Good 11–20% = Marginal 21% and Beyond = Bad Steer System Relief Valve Pressure Setting 1500 ±...
  • Page 28 SPECIFICATIONS AND GENERAL INFORMATION Steering Test and Adjustment Specifications Steering Axle Alignment Toe-In Measurement 0.062–0.25 (1.6–6.3) in. (mm) Steering Stop Bolt Gap 0.01–0.02 (0.25–0.5) in. (mm) Repair Specifications Steering Wheel Nut 25–30 (34–41) lb-ft (N·m) Steering Unit End Cover-to-Housing Screw Torque 20–24 (27–33) lb-ft (N·m) Steering Cylinder Fittings Torque...
  • Page 29 SPECIFICATIONS AND GENERAL INFORMATION Accessories and Miscellaneous Mounting Bolt Torque 200–240 (271–325) lb-ft (N·m) Heat Shield Mounting Screw Torque 40–50 (4.5–5.6) lb-in. (N·m) Traction Pedal Pedal Stop Height 1.50 ± 0.12 (38.1 ± 3.0) in. (mm) Fuel Tank Capacity 35 (132.5) gal (L) Front Tires Size...
  • Page 30 SPECIFICATIONS AND GENERAL INFORMATION Mower Speed Transport—2WD 0–20 (0–29) mph (km/h) Mowing 0–8.5 (0–13.6) mph (km/h) Reverse—2WD 0–5.5 (0–8.9) mph (km/h) Reverse—4WD 0–3 (0–4.8) mph (km/h) Weights and Dimensions Overall Weight 70538: 6392 (2899) lb (kg) 70539: 6607 (2996) 70540: 6392 (2899) 70541: 6607 (2996) Overall Cutting Width 16 (2.4)

  • Page 31: Specifications And General Information

    SPECIFICATIONS AND GENERAL INFORMATION Standard Torque Values NOTE NOTICE Jacobsen uses Grade 5 plated bolts as standard, unless All torque values included in these charts are otherwise noted. When tightening plated bolts, use the approximate and are for reference only. Use of value given for lubricated.

  • Page 32: Hydraulic Hose, Tube, And Fitting General Instructions

    Make sure hoses are assembled to proper “A” and “B” ports on components. TN4097 Hydraulic Hose and Tube Torque Values • SAE Boss O-Ring Kit Jacobsen PN 5002452 • O-Ring Face Seal (ORS) O-Ring Kit PN 5002454 Size lb-ft N·m •...
  • Page 33 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .

  • Page 34: Specifications

    ENGINE Specifications General Engine Specifications Engine ® Manufacturer/Models Kubota V3800DICR-T-E3B Engine Type 4-Stroke, Diesel Fuel Requirement Low or Ultra Low Sulfur No. 2 Diesel Fuel (Cetane Rating 45) Number of Cylinders/Configuration 4/In-Line Displacement 230 (3.769) cu in. (L) Bore x Stroke 3.94 x 4.72 (100 x 120) in.

  • Page 35: Component Location

    ENGINE Component Location ® Kubota V3800DICR-T-E3B See Figures 3-1 and 3-2. TN4228, TN4242, TN4098 Fan Belt Air Cleaner Assembly Alternator Coolant Temp Sensor Air Cleaner Indicator Starter Motor Engine Temperature Sensor Radiator Screen Engine Oil Pressure Switch Starter Relay Radiator Shield Sedimentor Filter Preheat Relay Engine Oil Cooler...
  • Page 36 ENGINE TN4186, TN4099 Electric Fuel Pump Thermostat Batteries Engine Coolant Temp Switch Muffler and Exhaust Assembly Remote Engine Oil Filter Assembly Coolant Recovery Tank Fuel Filter Radiator/Hydraulic Oil Cooler Figure 3-2: Component Location—Right Side 4263110-Rev B...

  • Page 37: Checks And Adjustments

    ENGINE Checks and Adjustments Purging the Fuel System Adjustment CAUTION Do not purge fuel system when engine is hot. NOTE Fuel system will need to be purged of air whenever fuel filter or fuel lines are removed, fuel tank is completely emptied, or engine has not been used for an extended time.

  • Page 38: Repair

    ENGINE Repair 5. Remove fan belt (4) from alternator (6), engine coolant pump (5), and crankshaft pulley (7). Fan Belt Installation Notes • Install fan belt by reversing the order of removal. Removal and Installation • Adjust belt tension by loosening alternator mounting See Figures 3-3 and 3-4.

  • Page 39: Air Cleaner Assembly

    ENGINE Air Cleaner Assembly Removal and Installation See Figures 3-5 through 3-7. CAUTION • Do not open the air cleaner assembly for inspection and cleaning until the air filter restriction gauge indicates an air filter restriction. Removing the air filter increases the possibility of dust, dirt, and contaminants entering the engine.

  • Page 40: Muffler And Exhaust Assembly

    ENGINE Muffler and Exhaust Assembly Removal and Installation See Figures 3-8 and 3-9. 9 10 11 CAUTION Do not attempt to service the exhaust system when the engine is hot. Serious personal injury 16 17 can occur. 13 14 15 16 1.

  • Page 41: Remote Engine Oil Filter Assembly

    ENGINE Remote Engine Oil Filter Assembly Coolant Recovery Tank Removal and Installation Removal and Installation See Figure 3-10. See Figure 3-11. 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Allow engine to cool completely. Do not attempt to service any part of the coolant system when the engine is hot.

  • Page 42: Radiator Screen And Shield

    ENGINE Radiator Screen and Shield Radiator/Hydraulic Oil Cooler Removal and Installation Removal and Installation See Figures 3-12 and 3-13. See Figures 3-14 through 3-18. 1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2. Allow engine to cool completely. Never remove the radiator cap when the coolant is hot.
  • Page 43 ENGINE 10. Remove radiator cap. 11. Loosen hose clamp (11), disconnect lower radiator hose (12), and drain coolant. 12. Remove four screws (2), lock washers (3), and nuts (4) and set coolant recovery tank and bracket (1) aside. NOTE Label all wires before disconnecting to ensure correct installation.
  • Page 44 Installation Notes • Install radiator/hydraulic oil cooler by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. • With lower radiator hose removed from radiator, flush inside of radiator with fresh water.

  • Page 45: Engine Oil Cooler

    ENGINE Engine Oil Cooler Thermostat Removal and Installation Removal and Installation See Figure 3-19. See Figures 3-20 and 3-21. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 46: Throttle Lever

    ENGINE Throttle Lever Removal and Installation See Figures 3-22 and 3-23. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove heat shield. (See “Heat Shield” on page 9-12.) 3. Disconnect battery negative (–) cables from batteries.

  • Page 47: Sedimentor Filter

    5. Thoroughly clean cup (2) and area surrounding Installation Notes sedimentor filter. • Install throttle lever by reversing the order of removal. 6. Remove cup (2) and filter element (3). • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. 4263110-Rev B 3-15...

  • Page 48: Fuel Filter

    ENGINE CAUTION Dispose of fuel properly. Contact the local environmental department for instructions on disposing of unwanted fuel products. Installation Notes • Clean the inside and outside of filter head (5). • Lightly lubricate O-ring with clean oil. • Install sedimentor filter by reversing the order of removal.

  • Page 49: Fuel Pump

    11. Remove fuel pump. Installation Notes • Install fuel pump by reversing the order of removal. TN4106 • Apply dielectric grease (Jacobsen PN 365422) to any Figure 3-27 wire connectors disconnected. 5. Turn fuel shutoff lever (1) to horizontal (off) position.

  • Page 50: Engine

    ENGINE Engine Removal and Installation See Figures 3-30 through 3-39. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Allow engine to cool completely. 3. Disconnect battery negative (–) cables from batteries. 4. Remove radiator/hydraulic oil cooler. (See “Radiator/Hydraulic Oil Cooler”...
  • Page 51 ENGINE 14 15 TN4217 Figure 3-36 16. Remove two screws (14), nuts (15), and clamp (16). TN4212 Figure 3-34 14. Remove two screws (10), lock washers (11), and clamps (12). TN4218 Figure 3-37 NOTE Label all hoses before disconnecting to ensure correct TN4106 installation.

  • Page 52: Engine Service

    • Install engine by reversing the order of removal. • If necessary, remove components from engine and install components on new engine. • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. • Use new exhaust gasket when installing exhaust system.

This manual is also suitable for:

Hr-9016t 70540Hr-9016t 70538Hr-9016t 70539

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