Page 1 GP400 Riding Greens Mower Technical/Repair Manual USAG004, USAD004...
Page 5 This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen GP400 riding greens mower 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 2011, Jacobsen, A Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4252490-Rev A...
Page 7 Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous Repair 4252490-Rev A...
Page 9: Table Of Contents
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 TN3769 Figure 1-1 4252490-Rev A...
Page 12 SAFETY 4252490-Rev A...
Page 13 SAFETY 4252490-Rev A...
Page 14: Inspect Safety Labels
SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figure 1-2. mower. Inspect the mower for any damaged, missing, or WARNING unreadable decals. Replace decals as needed 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 Chapter 2 Specifications and General Information Machine Identification ............2-2 Machine Serial Number .
Page 20: Machine Identification
SPECIFICATIONS AND GENERAL INFORMATION Machine Identification Engine Serial Number See Figure 2-3. Machine Serial Number See Figures 2-1 and 2-2. TN3811 Figure 2-3 The engine serial number plate (1) is attached to the top of the rocker arm cover. The plate also includes the engine model number and the engine code number.
Page 21: Component Location
SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figure 2-4. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN3653 Fuel Tank Park Brake Lever Steering Wheel Right Cutting Unit Hydraulic Tank Traction Pedal Center Cutting Unit Instrument Panel Seat...
Page 22: Specifications
SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Fuel System Capacity Fuel System Capacity 14.2 (54) gal (L) General Engine Specifications Diesel Models Manufacturer/Model Kubota/D722-E3B-RUNK-1 Engine Type Vertical 4-Cycle Diesel Fuel Requirement No. 2 Low or Ultra Low Sulfur Diesel (Minimum Cetane Rating 45) Number of Cylinders/Configuration 3/In-Line...
Page 23 SPECIFICATIONS AND GENERAL INFORMATION Electrical Test and Adjustment Specifications Resistance Across Solenoid Coil— 9 ± 10% ohms Mow Solenoid Coil Resistance Across Solenoid Coil— 5.6 ± 10% ohms Raise Solenoid Coil at 72° F (22° C) Resistance Across Solenoid Coil— 5.6 ±...
Page 24 SPECIFICATIONS AND GENERAL INFORMATION Hydrostatic Power Train Test Specifications Traction Pump Flow 13.5 (51) @ 3400 rpm gpm (lpm) Charge Pump Flow 5 (19) @ 3400 rpm gpm (lpm) Gear Pump Flow 5.8 (22) @ 3400 rpm gpm (lpm) Implement Relief Pressure 800 ±...
Page 25 SPECIFICATIONS AND GENERAL INFORMATION Hydraulics Test Specifications Charge Relief Valve Pressure Setting 150–210 (10–15) psi (bar) Implement Relief Valve Pressure Setting 800 ± 10% (55 ± 10%) psi (bar) Lift Relief Valve Pressure Setting 1250 ± 10% (86 ± 10%) psi (bar) Reel Relief Valve Pressure Setting 3020 ±...
Page 26 SPECIFICATIONS AND GENERAL INFORMATION Steering Repair Specifications Steering Wheel Nut Torque 28–30 (38–41) lb-ft (N·m) Steering Unit End Cover-to-Housing Screw Torque 20–24 (27–33) lb-ft (N·m) 4252490-Rev A...
Page 27 SPECIFICATIONS AND GENERAL INFORMATION Cutting Units Checks and Adjustments Bedknife Front Face Height 0.040 (1.0) in. (mm) Bedknife Front Face Angle degrees Bedknife Top Face Angle (Rear Relief) 8–10 degrees Reel Blade Relief Angle degrees Bedknife-to-Reel Gap 0.001–0.003 (0.025–0.076) in. (mm) Reel Bearing Pre-Load 0.040 (1.0) in.
Page 28 SPECIFICATIONS AND GENERAL INFORMATION Accessories and Miscellaneous Mounting Bolt Torque 37 (50) lb-ft (N·m) Bracket Screw Torque 52 (71) lb-ft (N·m) Fuel System Capacity 14.2 (54) gal (L) Front Tires Size 20 x 10-10 Type 2-Ply OTR Smooth Air Pressure 10 (0.70) psi (bar) Mounting Bolt Torque...
Page 29: Standard Torque Values
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 30: Hydraulic Hose, Tube, And Fitting General Instructions
SPECIFICATIONS AND GENERAL INFORMATION Hydraulic Hose, Tube, and Replacement O-Rings for O-Ring Boss Fittings Fitting General Instructions Tubing O.D. Thread Jacobsen Part O-Ring Installation or Hose I.D. Size Number • Always install new O-rings. 5/16-24 459290 • On hoses with O-ring fittings, make sure O-rings are 3/16 3/8-24 459291...
Page 31 Chapter 3 Engine Specifications ..............3-2 Fuel System Capacity .
Page 32: Specifications
ENGINE Specifications Fuel System Capacity Fuel System Capacity 14.2 (54) gal (L) General Engine Specifications Diesel Models Manufacturer/Model Kubota/D722-E3B-RUNK-1 Engine Type Vertical 4-Cycle Diesel Fuel Requirement No. 2 Low or Ultra Low Sulfur Diesel (Minimum Cetane Rating 45) Number of Cylinders/Configuration 3/In-Line Displacement 43.88 (719)
Page 33: Component Location
ENGINE Component Location Diesel Models See Figures 3-1 and 3-2. TN3769, TN3944, TN3943 Speed Control Plate Air Cleaner Assembly Starter Thermostat Fuel Shutoff Solenoid Coolant Recovery Bottle Engine Oil Pressure Switch Engine Temperature Sensor Radiator Drain Plug Alternator Engine Oil Filter Fan Belt Radiator Fill Cap Muffler...
Page 34 ENGINE TN3767, TN3948 Radiator Glow Plug Fuel Pump Fuel Filter Figure 3-2: Component Location—Right Side 4252490-Rev A...
Page 35: Gasoline Models
ENGINE Gasoline Models See Figure 3-33. TN3988 Air Filter Assembly Muffler Fuel Pump Throttle Cable Engine Oil Dipstick Fuel Filter Choke Engine Oil Fill Cap Engine Oil Cooler Figure 3-3: Component Location 4252490-Rev A...
Page 36: Checks And Adjustments-Diesel Models
ENGINE Checks and Adjustments— Diesel Models Purging the Fuel System (Diesel) See Figures 3-4 and 3-5. CAUTION Do not purge fuel system when engine is hot. NOTE TN3692 The fuel system will need to be purged of air whenever Figure 3-5 the fuel filter or fuel lines are removed, the fuel tank is completely emptied, or the engine has not been used for an extended time.
Page 37: Repair-Diesel Models
ENGINE Repair—Diesel Models Fan Belt (Diesel) Removal See Figures 3-6 and 3-7. CAUTION Use extreme care when working near the muffler. Do not attempt to service when the engine is hot. Serious personal injury can occur. NOTE Inspect and adjust the new engine belt after the first 50 TN1113 hours of operation.
Page 38: Air Filter Assembly (Diesel)
ENGINE Air Filter Assembly (Diesel) Removal and Installation See Figures 3-8 through 3-11. CAUTION • Do not open the air filter assembly for inspection or cleaning. Unnecessary removal of the air filter increases the risk of injecting dust and other impurities into the engine. •...
Page 39: Throttle Cable (Diesel)
ENGINE Throttle Cable (Diesel) Removal and Installation See Figure 3-12. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank” on page 9-4.) 3. Remove throttle lever. (See “Throttle Lever” on page 9-14.) 4 5 6 TN3977...
Page 40: Muffler (Diesel)
ENGINE Muffler (Diesel) Coolant Recovery Bottle (Diesel) Removal and Installation Removal and Installation See Figure 3-13. See Figure 3-14. CAUTION CAUTION Do not attempt to service the exhaust system Do not attempt to service any part of the coolant when the engine is hot. Serious personal injury system when the engine is hot.
Page 41: Thermostat (Diesel)
ENGINE Thermostat (Diesel) Removal and Installation See Figures 3-15 and 3-16. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank” on page 9-4.) 3. Allow the engine to cool completely. TN3855 Figure 3-16 7.
Page 42: Radiator (Diesel)
ENGINE Radiator (Diesel) Removal See Figures 3-17 through 3-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Allow the engine to cool completely. 3. Remove hydraulic oil cooler. (See “Hydraulic Oil Cooler (Diesel)” on page 6-60.) 4.
Page 43 ENGINE 18. Remove four screws (22), lock washers (23), and flat washers (24). 19. Remove four screws (26), four flat washers (27), and two radiator brackets (25). 19 20 21 TN3960 Figure 3-22 20. Remove two screws (29), two washers (33), two rubber bushings (34), two flat washers (32), four flat TN3954 washers (31), and two rubber bushings (30).
Page 44: Fuel Filter (Diesel)
ENGINE Fuel Filter (Diesel) CAUTION Removal and Installation Dispose of fuel properly. Contact the local See Figure 3-23. environmental department for instructions on disposing of unwanted fuel products. CAUTION Installation Notes Diesel fuel is highly flammable—handle with care. Use an approved container with a spout that will •...
Page 45: Fuel Pump (Diesel)
ENGINE Fuel Pump (Diesel) 8. Remove screw (1), lock washer (2), and flat washer (3). Removal and Installation 9. Remove screw (5), lock washer (6), and flat washer (7), and remove fuel pump (9). See Figure 3-24. Installation Notes CAUTION Diesel fuel is highly flammable—handle with care.
Page 46 ENGINE 4 5 6 TN3897 Figure 3-27 16. Loosen hose clamp (13) and disconnect fuel hose (14). TN3902 Figure 3-25 10. Loosen screw (1) and cable clamp (2). 11. Remove screw (4), nut (5), and clamp (6). 12. Disconnect throttle cable from engine. TN3961 Figure 3-28 TN3937...
Page 47: Engine Service (Diesel)
ENGINE Installation Notes • Inspect engine isolation mounts and replace if necessary. 17 18 19 • Install the engine by reversing the order of removal. • Tighten engine mounting screws (17 and 20) to 44 lb-ft (60 N·m). • If necessary, remove components from the engine and install the components on the new engine.
Page 48: Repair-Gasoline Models
ENGINE Repair—Gasoline Models Installation Notes • Wash air filter pre-cleaner in liquid detergent and water. Squeeze dry in a clean cloth. Saturate in clean Air Filter Assembly (Gasoline) engine oil and squeeze out excess oil in a clean, absorbent cloth. Replace air filter pre-cleaner if it Removal and Installation remains dirty or is damaged.
Page 49: Muffler Assembly (Gasoline)
ENGINE Muffler Assembly (Gasoline) 2. Raise the hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank” on page 9-4.) Removal and Installation 3. Allow the engine to cool completely. See Figure 3-33. CAUTION Do not attempt to service the exhaust system when the engine is hot.
Page 50: Throttle Cable (Gasoline)
ENGINE Throttle Cable (Gasoline) Choke Cable (Gasoline) Removal and Installation Removal and Installation See Figure 3-34. See Figures 3-35 and 3-36. 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 51: Fuel Filter (Gasoline)
ENGINE Fuel Filter (Gasoline) 6. Remove muffler assembly. (See “Muffler Assembly (Gasoline)” on page 3-19.) Removal and Installation 7. Remove traction pump. (See “Traction Pump and Control” on page 5-50.) See Figure 3-37. 8. Disconnect the throttle cable at the engine. (See 1.
Page 52: Engine Service (Gasoline)
ENGINE 12. Using the proper engine hoist, support the engine (1) and remove four nuts (3) and screws (5) securing the engine (1) to the engine mount plate (2). 13. Move wiring harnesses and fuel lines aside. 14. Check for any connected wires and components, and carefully remove the engine from the machine.
Page 53 Chapter 4 Electrical Specifications ..............4-3 Test and Adjustment Specifications .
Page 54 ELECTRICAL Component Tests and Adjustments ..........4-40 Electrical System and Component Testing .
Page 55: Specifications
ELECTRICAL Specifications Test and Adjustment Specifications Specification Resistance Across Solenoid Coil— 9 ± 10% ohms Mow Solenoid Coil Resistance Across Solenoid Coil— 5.6 ± 10% ohms Raise Solenoid Coil at 72° F (22° C) Resistance Across Solenoid Coil— 5.6 ± 10% ohms Lower Solenoid Coil at 72°...
Page 56: Theory And Diagnostic Information
ELECTRICAL Theory and Diagnostic Information Electrical Component Symbols The following symbols are used in the electrical schematics to represent various electrical components. Switches Single Pole, Single Throw Double Pole, Single Throw (SPST) (DPST) Single Pole, Double Throw Double Pole, Double Throw (SPDT) (DPDT) Proximity Switch...
Page 57 ELECTRICAL Motors and Generating Devices Electric Motors (may also Stator include “AC” or “DC”) Alternator Actuating Devices Solenoid Valve PTO Clutch Engine-Related Devices Ignition Coil Spark Plug Regulator Fuel Shutoff Solenoid Pull-In Hold-In Lights Single-Element Light Dual-Element Light 4252490-Rev A...
Page 58 ELECTRICAL Miscellaneous Symbols Enclosure Wires (crossing but not (cabinet, housing, etc.) connected) Ground (to earth) Wiring Connections Ground (to chassis) Coil Direct Current (DC) Battery (as shown on an oscilloscope) Alternating Current (AC) Diode (as shown on an oscilloscope) Resistor Pin and Socket Connector 4252490-Rev A...
Page 59: Electrical Schematic Component Identification
ELECTRICAL Electrical Schematic Component Identification Electrical components shown in the main schematic are identified with an alphanumeric callout. All electrical components shown in the electrical schematic are listed below. • A1—Control Module (See Figure 4-2.) • S6—Park Brake Switch (See Figure 4-3.) •...
Page 60: Electrical Schematic
ELECTRICAL Electrical Schematic See Figures 4-1 through 4-5. Splice 3 Splice 3 Splice 7 Splice 7 Lt Grn/ Lt Grn/ (10) Switch Engine Carb Stop Solenoid Relay Fuse Start Blk/ Voltage Regulator Stator AC Input Ignition Ignition Wht/Red AC Input Module Module DC Output...
Page 61 ELECTRICAL Electrical Schematic Continued Splice 3 Splice 3 Splice 3 Splice 7 Splice 7 Fuse Paddle Option Grn/ Connector Fuel Grn (1) Pump Yel/Blk (2) Grn/ Grn/ Grn/ BlK (3) J1-2 J2-11 J2-12 J1-8 Input Input Input Output Yel/Pnk Yel/Pnk Raise Switch Input J2-2 Yel/Blk Yel/Blk...
Page 62 ELECTRICAL Electrical Schematic Continued Splice 3 Splice 3 Splice 7 Splice 7 Splice 6 Raise/Lower Switch Raise Seat Lower Switch Yel/Pnk Yel/Pnk (6) Yel Horn Switch (1) Yel Yel/Blk Yel/Blk Yel/Brn Yel/Brn Pnk/Blk Horn Lt Grn/Pnk Lt Grn/Pnk Lt Grn/Pnk 3-Pin Park Connector...
Page 63 ELECTRICAL Electrical Schematic Continued Splice 3 Splice 3 Splice 7 Splice 7 Switch Mow/Transport Switch Yel/Blu Blu/Yel Engine Hydraulic N.O. Filter Pressure Pressure Light Light Red/Blk Blk/ Blu/ Engine Hydraulic Filter Pressure Pressure 25 PSI Switch Switch Yel/Blu Blu/Grn Blu/Grn Switched Power Circuit Ground Circuit TN3067...
Page 64 ELECTRICAL Electrical Schematic Continued Splice 3 Splice 3 Splice 7 (12) (11) Fuse Fuse Fuse Grn/ Grn/ Light Switch Grn/Org Blu/Red Blu/Red Blu/Red (1) Back Light Seat Connector Engine Temperature Blu/ Gauge (Diesel) Accessory Signal Socket Blu/ Blu/ Blu/ Work Work Light Light...
Page 65 ELECTRICAL Page Intentionally Blank 4252490-Rev A 4-13...
Page 66: Power Circuit-Theory Of Operation
ELECTRICAL Theory of Operation and • Engine oil pressure light • Hydraulic filter pressure light Sub-Circuit Schematics • Engine temperature gauge (diesel) The 10A fuse F5 provides voltage to the 12V accessory Power Circuit—Theory of Operation socket. Reference electrical schematic. See Figures 4-1 through The 15A fuse F6 provides voltage to the light switch.
Page 67: Diesel Engine Circuit-Theory Of Operation
ELECTRICAL Diesel Engine Circuit—Theory of The control module also flashes the alarm light at 1-second intervals while activating the glow plug circuit. Operation Start Circuit Power Circuit With the key switch held in the start position, the control When the key switch is turned to the run position, voltage module start relay output terminal J2-4 provides voltage is provided from key switch terminal B to control module to start relay terminal 86, energizing the relay.
Page 68: Diesel Engine Circuit Schematic
ELECTRICAL Diesel Engine Circuit Schematic See Figures 4-6 and 4-7. Splice 3 Splice 3 Splice 7 Splice 7 (10) Switch Fuel Fuse Pump Seat Start Switch Wht/Red Yel/Brn Wht/Red Wht/Red Lt Grn/Red Lt Grn/Red Fuel (2) Lt Grn/Brn Lt Grn/Brn Input Shutoff (4) Brn/Org...
Page 69 ELECTRICAL Diesel Engine Circuit Schematic Continued Splice 3 Splice 7 Fuse Grn/ Grn/ Grn/ Grn/ J1-8 J1-2 J2-11 J2-12 Output Input Input Input Park 3-Pin Yel/Brn Brake Connector J1-7 Seat Switch Input Switch Grn (1) Grn/Gry Grn/Gry Grn/Gry (2) Wht/Red Park Brake Input J1-11 J1-6 Start Input Blk (3)
Page 70 ELECTRICAL Page Intentionally Blank 4-18 4252490-Rev A...
Page 71: Gasoline Engine Circuit-Theory Of Operation
ELECTRICAL Gasoline Engine Circuit—Theory of The control module engine run output terminal J2-5 also provides voltage to engine stop relay terminal 86, which Operation energizes the relay. With the engine stop relay energized, the relay un-grounds the ignition modules, Power Circuit allowing the modules to produce spark when the engine When the key switch is turned to the run position, voltage is turning.
Page 72: Gasoline Engine Circuit Schematic
ELECTRICAL Gasoline Engine Circuit Schematic See Figures 4-8 and 4-9. Splice 3 Splice 3 Splice 7 Splice 7 (10) Fuse Switch Fuel Pump Seat Start Switch Wht/Red Yel/Brn Wht/Red Wht/Red Lt Grn/Red Lt Grn/Red Voltage Regulator Stator Lt Grn/Brn Lt Grn/Brn AC Input AC Input DC Output...
Page 73 ELECTRICAL Gasoline Engine Circuit Schematic Continued Splice 3 Splice 7 Fuse Grn/ Grn/ Grn/ Grn/ J1-8 J1-2 J2-11 J2-12 Output Input Input Input 3-Pin Park Yel/Brn Connector Brake J1-7 Seat Switch Input Switch Grn (1) Grn/Gry Grn/Gry Grn/Gry (2) Wht/Red Park Brake Input J1-11 J1-6 Start Input Blk (3)
Page 74 ELECTRICAL Page Intentionally Blank 4-22 4252490-Rev A...
Page 75: Raise/Lower Circuit-Theory Of Operation
ELECTRICAL Raise/Lower Circuit—Theory of Operation Power Circuit When the key switch is turned to the run position, voltage is provided from key switch terminal B to control module terminals J1-2, J2-11, and J2-12, powering up the control module. (See “Power Circuit—Theory of Operation” on page 4-14.) Raise Circuit When the raise/lower switch is placed in the raise...
Page 76 ELECTRICAL Raise Circuit Schematic See Figure 4-10. Splice 6 Switch Fuse Start Grn/ Grn/ Grn/ Grn/ Raise/Lower Switch J1-2 J2-11 J2-12 J1-8 Raise Input Input Input Output Lower Yel/Pnk Yel/Pnk (6) Yel Raise Switch Input J2-2 (1) Yel Yel/Blk Yel/Blk Lower Switch Input J1-12 Seat Switch...
Page 77 ELECTRICAL Lower Circuit Schematic See Figure 4-11. Splice 6 Switch Fuse Start Grn/ Grn/ Grn/ Grn/ Raise/Lower Switch J1-2 J2-11 J2-12 J1-8 Raise Input Input Input Output Lower Yel/Pnk Yel/Pnk (6) Yel Raise Switch Input J2-2 (1) Yel Yel/Blk Yel/Blk Lower Switch Input J1-12 Seat Switch...
Page 78: Mow Circuit-Theory Of Operation
ELECTRICAL Mow Circuit—Theory of Operation Power Circuit When the key switch is turned to the run position, voltage is provided from key switch terminal B to control module terminals J1-2, J2-11, and J2-12, powering up the control module. (See “Power Circuit—Theory of Operation” on page 4-14.) Interlock Circuit Before the system allows activation of the mow circuit,...
Page 79: Mow Circuit Schematic
ELECTRICAL Mow Circuit Schematic See Figure 4-12. Fuse Splice 3 Wht (10) (4) Grn Switch Splice 7 Start Fuse Switch Grn/ Grn/ Grn/ Grn/ Yel/Blu 3-Pin Blu/Yel J1-2 J2-11 J2-12 J1-8 Connector Input Input Input Output (1) Grn (2) Grn/Gry (3) BlK Yel/Blu Mow Switch Input J1-5...
Page 80: Backlap Circuit-Theory Of Operation
ELECTRICAL Backlap Circuit—Theory of Operation Power Circuit When the key switch is turned to the run position, voltage is provided from key switch terminal B to control module terminals J1-2, J2-11, and J2-12, powering up the control module. (See “Power Circuit—Theory of Operation” on page 4-14.) Interlock Circuit When backlapping, the following must occur:...
Page 81: Backlap Circuit Schematic
ELECTRICAL Backlap Circuit Schematic See Figure 4-13. Fuse Splice 3 Wht (10) (4) Grn Switch Splice 7 Start Switch Fuse Grn/ Yel/Blu Blu/Yel Grn/ Grn/ Grn/ 3-Pin J1-2 J2-11 J2-12 J1-8 Connector Input Input Input Output (1) Grn Yel/Blu (2) Grn/Gry Mow Switch Input J1-5 Mow/Transport (3) BlK...
Page 82: Work Light Circuit-Theory Of Operation
ELECTRICAL Work Light Circuit—Theory of Operation Power Circuit When the key switch is turned to the run position, voltage is provided from key switch terminal B to the light switch. (See “Power Circuit—Theory of Operation” on page 4-14.) Work Light Circuit When the light switch is placed in the on position, voltage is provided to the work lights, turning on the lights.
Page 83: Work Light Circuit Schematic
ELECTRICAL Work Light Circuit Schematic See Figure 4-14. Switch Start (12) Light Fuse Switch Blu/Red Blu/Red Blu/Red (1) Backlight Engine Temperature Gauge (Diesel) Splice 1 Signal Blu/ Fuse Block Terminals Blu/ Blu/ (Not Used) Work Work Light Light Unswitched Power Circuit Battery Switched Power Circuit Light Circuit...
Page 84 ELECTRICAL Page Intentionally Blank 4-32 4252490-Rev A...
Page 85: Instrumentation Circuit-Theory Of Operation
ELECTRICAL Instrumentation Circuit—Theory of Engine Coolant Temp Light (Diesel) Operation The engine temperature sensor resistance changes in relationship to the engine coolant temperature. As the engine temperature sensor is heated, the resistance of Power Circuit the sensor changes from a high resistance to a low When the key switch is turned to the run position, voltage resistance.
Page 86: Instrumentation Circuit Schematic
ELECTRICAL Instrumentation Circuit Schematic See Figures 4-15 and 4-16. Fuse Splice 3 Splice 7 Splice 7 Wht (10) (4) Grn Switch Start Horn Wht/Red Switch Fuse Grn/ Pnk/Blk Grn/ Grn/ Grn/ J1-2 J2-11 J2-12 J1-8 Input Input Input Output Wht/Red J1-6 Start Input Lt Grn/Pnk Lt Grn/Pnk...
Page 87 ELECTRICAL Instrumentation Circuit Schematic Continued Splice 7 Splice 7 Splice 7 (1) Backlight Engine Hydraulic Filter Pressure Pressure Engine Light Light Temperature Gauge Blk/ (Diesel) Blu/ Signal Engine Hydraulic Blu/ Filter Pressure Pressure Switch Switch Blu/Grn Engine Temperature Sensor (Diesel) Blu/Grn Blu/Grn Switched Power Circuit...
Page 88: Troubleshooting
ELECTRICAL Troubleshooting Power Circuit Symptom: Machine does not power up. Probable Cause Remedy Faulty wiring. Check wiring and connections at the battery posts. Check wiring and connections between the battery negative (–) cable and ground. Faulty battery. Replace battery with a known good battery. Insufficient circuit voltage.
Page 89: Charging Circuit
ELECTRICAL Charging Circuit Symptom: Battery not charging. Probable Cause Remedy Faulty battery. Replace battery with a known good battery. Insufficient circuit voltage. Turn the key switch to the run position; check for 12 volts at the alternator electrical connectors. If the voltage is not approximately 12 volts, diagnose the insufficient voltage issue.
Page 90: Work Light Circuit
ELECTRICAL Work Light Circuit Symptom: Work lights do not turn on. Probable Cause Remedy Faulty work light(s). Substitute the work light(s) with a known good work light(s). Faulty 15A fuse. Test the 15A light switch fuse. (See “Fuses Test” on page 4-41.) Faulty work light switch.
Page 91: Horn And Audible Alert Circuit
ELECTRICAL Symptom: Engine temperature gauge indicates a temperature when the engine is cold. Probable Cause Remedy Faulty engine temperature sensor. Substitute the engine temperature sensor with a known good engine temperature sensor. Faulty engine temperature sensor gauge. Substitute the engine temperature gauge with a known good engine temperature gauge. Symptom: Engine temperature gauge does not indicate a temperature.
Page 92: Component Tests And Adjustments
ELECTRICAL Component Tests and 5. Use a known good jumper wire of the correct gauge to bypass the wire in question. Adjustments 6. Test the function of the circuit. Does the circuit now operate properly? Electrical System and Component Replace the wire. Testing Continue testing other wires and components in the circuit.
Page 93: Fuses Test
ELECTRICAL Fuses Test Relays Test See Figure 4-17. See Figure 4-18. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter • Digital Multimeter or Ohmmeter • 12-Volt DC Power Source NOTE 1. Park the mower safely. (See “Park Mower Safely” on This procedure applies to the following fuses: page 1-6.) •...
Page 94: Engine Stop Relay (Gasoline)
ELECTRICAL Engine Stop Relay (Gasoline) Key Switch Test See Figure 4-19. See Figure 4-20. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 95: Rocker Switches Test
ELECTRICAL Rocker Switches Test 8. Measure the resistance between terminals (1 and 2). See Figure 4-21. Is the resistance value 0.02 ohm or less? The rocker switch is faulty; replace the Required Tools or Equipment rocker switch. Digital Multimeter or Ohmmeter Proceed to step 9.
Page 96: Backlap Switch Test
ELECTRICAL Backlap Switch Test Horn Switch Test See Figure 4-22. See Figure 4-23. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 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 97: Raise/Lower Switch Assembly Test
ELECTRICAL Raise/Lower Switch Assembly Test 6. Move and hold the raise/lower switch assembly in the lower position and measure the resistance between See Figure 4-24. terminals (2 and 3). Is the resistance value 0.02 ohm or less? Required Tools or Equipment Proceed to step 7.
Page 98: Seat Switch Test
ELECTRICAL Seat Switch Test Raise/Lower Solenoid Test See Figure 4-25. See Figure 4-26. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 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 99: Mow Solenoid Test
ELECTRICAL Mow Solenoid Test Fuel Shutoff Solenoid Test See Figure 4-27. See Figure 4-28. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 100: Fuel Shutoff Timer Test
ELECTRICAL Fuel Shutoff Timer Test 9. Measure the voltage between terminals (3 and 4). Is approximately 12 volts indicated? See Figure 4-29. Proceed to step 10. Required Tools or Equipment The fuel shutoff timer is faulty; replace the fuel shutoff timer. •...
Page 101: Mow/Transport Switch Adjustment
ELECTRICAL Mow/Transport Switch Adjustment See Figures 4-31 through 4-33. Required Tools or Equipment Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove instrument panel cover. (See “Instrument Panel Cover”...
Page 102: Repair
ELECTRICAL Repair Battery Cover Removal and Installation Control Module See Figure 4-35. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 4-34. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
Page 103: Battery
ELECTRICAL Battery NOTICE Removal and Installation Never place used batteries in the garbage. See Figure 4-36. Dispose of used batteries in accordance with all applicable regulations. WARNING 6. Remove battery (10). • Battery posts, terminals, and related accessories contain lead and lead Installation Note compounds.
Page 104: Starter Motor
ELECTRICAL Instrument Panel Installation Notes • Apply dielectric grease (Jacobsen PN 365422) to any Removal and Installation wire connectors disconnected. • Install alternator by reversing the order of removal. See Figure 4-39. • Adjust fan belt tension. (See “Fan Belt (Diesel)” on NOTE page 3-7.) If servicing individual components, it is not always...
Page 105: Rocker Switches
ELECTRICAL Rocker Switches Removal and Installation See Figures 4-40 and 4-41. NOTE This procedure applies to the following switches: • Mow switch (1) • Light switch (2) TN3887 Figure 4-41 4. Disconnect wire connector (4). 5. Depress taps (3) on each side of rocker switch and remove rocker switch from instrument panel.
Page 106: Horn Switch
ELECTRICAL Horn Switch Key Switch Removal and Installation Removal and Installation See Figure 4-42. See Figures 4-43 and 4-44. 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 107: Raise/Lower Switch Assembly
ELECTRICAL Raise/Lower Switch Assembly Removal and Installation See Figure 4-45. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove instrument panel cover. (See “Instrument Panel Cover” on page 9-13.) 4.
Page 108: Mow/Transport Switch
ELECTRICAL Mow/Transport Switch Installation Notes • Apply dielectric grease (Jacobsen PN 365422) to any Removal and Installation wire connectors disconnected. • Use new cable ties to secure wire connectors and See Figures 4-46 and 4-47. wire harness. 1. Park the mower safely. (See “Park Mower Safely” on •...
Page 109: Engine Oil Pressure Switch (Diesel)
ELECTRICAL Engine Oil Pressure Switch (Diesel) Installation Notes Removal and Installation Required Materials See Figure 4-49. ® Telfon Tape CAUTION • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. Engine components will become hot during operation. Allow engine components to cool •...
Page 110: Hydraulic Oil Charge Filter Pressure Switch
ELECTRICAL 4. Remove engine oil pressure switch. Installation Notes Required Materials ® Telfon Tape • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. • Apply Teflon tape to the threads of the oil pressure switch before installing. •...
Page 111: 12V Accessory Socket
ELECTRICAL 12V Accessory Socket Removal and Installation See Figures 4-52 through 4-55. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove instrument panel cover. (See “Instrument Panel Cover”...
Page 112: Fuses
ELECTRICAL Relays Installation Notes • Apply dielectric grease (Jacobsen PN 365422) to any Removal and Installation wire connectors disconnected. • Use new cable ties to secure wire connectors and See Figure 4-57. wire harness. • Install the 12V accessory socket by reversing the order of removal.
Page 113: Engine Temperature Sensor
ELECTRICAL Engine Temperature Sensor Installation Notes Removal and Installation Required Materials See Figure 4-58. ® Telfon Tape WARNING • Apply Teflon tape to the threads of the engine temperature sensor before installing. Engine coolant is hot and under pressure! Allow the cooling system to cool completely before •...
Page 114: Raise Solenoid
ELECTRICAL Installation Notes Installation Notes • Apply dielectric grease (Jacobsen PN 365422) to any • Apply dielectric grease (Jacobsen PN 365422) to any wire connectors disconnected. wire connectors disconnected. • Use new cable ties to secure wire connectors and • Use new cable ties to secure wire connectors and wire harness.
Page 115: Fuel Shutoff Solenoid
ELECTRICAL Fuel Shutoff Solenoid Warning Lights Removal and Installation Removal and Installation See Figure 4-62. See Figures 4-63 and 4-64. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) This procedure applies to the following warning lights: 2.
Page 116: Fuel Shutoff Timer
ELECTRICAL Fuel Shutoff Timer Removal and Installation See Figure 4-65. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove instrument panel cover. (See “Instrument Panel Cover” on page 9-13.) TN3905 Figure 4-64 NOTE...
Page 117: Hour Meter
ELECTRICAL Hour Meter Horn Removal and Installation Removal and Installation See Figure 4-66. See Figure 4-67. 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 118 ELECTRICAL 4-66 4252490-Rev A...
Page 119 Chapter 5 Hydrostatic Power Train Specifications ..............5-3 Test Specifications .
Page 120 HYDROSTATIC POWER TRAIN Instrument Test Procedures ........... . 5-35 Instrument Test Overview .
Page 121: Specifications
HYDROSTATIC POWER TRAIN Specifications Test Specifications Specification Traction Pump Flow 13.5 (51) @ 3400 rpm gpm (lpm) Charge Pump Flow 5 (19) @ 3400 rpm gpm (lpm) Gear Pump Flow 5.8 (22) @ 3400 rpm gpm (lpm) Implement Relief Pressure 800 ±...
Page 122: Hydraulic Hose, Tube, And Fitting General Instructions
HYDROSTATIC POWER TRAIN Hydraulic Hose, Tube, and Replacement O-Rings for O-Ring Boss Fittings Fitting General Instructions Tubing O.D. Thread Jacobsen Part O-Ring Installation or Hose I.D. Size Number • Always install new O-rings. 5/16-24 459290 • On hoses with O-ring fittings, make sure O-rings are 3/16 3/8-24 459291...
Page 123: Portable In-Line Filter
HYDROSTATIC POWER TRAIN Portable In-Line Filter See Figure 5-1. TN1376 Figure 5-1 When hydraulic components fail internally, debris from the failed component can spread throughout the hydraulic system and cause additional damage. This situation can be magnified when dealing with a closed-loop traction system, where oil is not filtered.
Page 124: Component Location
HYDROSTATIC POWER TRAIN Component Location See Figure 5-2. TN3767 Traction Pump Gear Pump Front Wheel Motor (2) Figure 5-2: Component Location 4252490-Rev A...
Page 125: Theory Of Operation And Sub-Circuit Schematics
HYDROSTATIC POWER TRAIN Theory of Operation and The charge oil is supplied to the closed-loop traction circuit via the check valves and exits the traction pump at Sub-Circuit Schematics ports “A” and “B.” Oil from port “A” is routed in parallel to the front wheel motors.
Page 126: Traction Circuit-Neutral Schematic (2Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Neutral Schematic (2WD Models) See Figures 5-3 and 5-4. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 127 HYDROSTATIC POWER TRAIN — Traction Circuit Neutral Schematic (2WD Models), Continued 0.052 in. Shuttle Valve 1.3 gpm Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Charge Pressure Oil TN3083 Charge Pressure Oil from Traction Pump (Port A) Return Oil from Steering Unit (Port T) Charge Pressure Oil from Traction Pump (Port B) Return Oil from Lift Valve (Port T) Return Oil to Oil Cooler...
Page 128 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-10 4252490-Rev A...
Page 129: Traction Circuit-Forward Schematic And Theory Of Operation (2Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic Shuttle Valve and Theory of Operation The shuttle valve located in the right front wheel motor is used to remove hot oil from the closed-loop traction drive (2WD Models) circuit when moving in the forward or reverse direction. Oil lost due to venting through the shuttle valve is System Conditions: replaced within the traction pump by cooler, filtered oil...
Page 130: Traction Circuit-Forward Schematic (2Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic (2WD Models) See Figures 5-5 and 5-6. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 131 HYDROSTATIC POWER TRAIN — Traction Circuit Forward Schematic (2WD Models), Continued 0.052 in. Shuttle Valve 1.3 gpm Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil TN3085 Operating Pressure Oil from Traction Pump (Port A) Return Oil from Steering Unit (Port T) Charge Pressure Oil from Traction Pump (Port B) Return Oil from Lift Valve (Port T)
Page 132 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-14 4252490-Rev A...
Page 133: Traction Circuit-Reverse Schematic And Theory Of Operation (2Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic Shuttle Valve and Theory of Operation The shuttle valve located in the right front wheel motor is used to remove hot oil from the closed-loop traction drive (2WD Models) circuit when moving in the forward or reverse direction. Oil lost due to venting through the shuttle valve is System Conditions: replaced within the traction pump by cooler, filtered oil...
Page 134: Traction Circuit-Reverse Schematic (2Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic (2WD Models) See Figures 5-7 and 5-8. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 135 HYDROSTATIC POWER TRAIN — Traction Circuit Reverse Schematic (2WD Models), Continued 0.052 in. Shuttle Valve 1.3 gpm Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil TN3087 Charge Pressure Oil from Traction Pump (Port A) Return Oil from Steering Unit (Port T) Operating Pressure Oil from Traction Pump (Port B) Return Oil from Lift Valve (Port T)
Page 136 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-18 4252490-Rev A...
Page 137: Traction Circuit-Neutral Schematic And Theory Of Operation (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Neutral Schematic Oil from the “RW2” port of the flushing valve flows against the flushing valve, through the check valve, and and Theory of Operation exits the “RW1” port of the flushing valve. It is then routed (3WD Models) in parallel to the front and rear wheel motors.
Page 138: Traction Circuit-Neutral Schematic (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Neutral Schematic (3WD Models) See Figures 5-9 and 5-10. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 139 HYDROSTATIC POWER TRAIN — Traction Circuit Neutral Schematic (3WD Models), Continued Shuttle Valve Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Rear Wheel Motor 20.75 Check Valve 0.040 in. Flushing Valve 1.3 gpm 0.020 in. Charge Pressure Oil TN3077 Charge Pressure Oil from Traction Pump (Port Charge Pressure Oil from Traction Pump (Port...
Page 140 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-22 4252490-Rev A...
Page 141: Traction Circuit-Forward Schematic And Theory Of Operation (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic Flushing Valve and Theory of Operation The flushing valve is used to remove hot oil from the closed-loop traction drive circuit when moving forward. (3WD Models) Oil lost due to venting through the flushing valve is replaced within the traction pump by cooler, filtered oil System Conditions: from the charge pump.
Page 142: Traction Circuit-Forward Schematic (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic (3WD Models) See Figures 5-11 and 5-12. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 143 HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic (3WD Models), Continued Shuttle Valve Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Rear Wheel Motor 20.75 Check Valve 0.040 in. Flushing Valve 1.3 gpm 0.020 in. Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil TN3079 Operating Pressure Oil from Traction Pump (Port A)
Page 144 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-26 4252490-Rev A...
Page 145: Traction Circuit-Reverse Schematic And Theory Of Operation (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic Oil from the “RW2” port of the flushing valve flows against the flushing valve, through the check valve, and and Theory of Operation exits the “RW1” port of the flushing valve. It is then routed (3WD Models) in parallel to the front and rear wheel motors.
Page 146: Traction Circuit-Reverse Schematic (3Wd Models)
HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic (3WD Models) See Figures 5-13 and 5-14. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Suction...
Page 147 HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic (3WD Models), Continued Shuttle Valve Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Rear Wheel Motor 20.75 Check Valve 0.040 in. Flushing Valve 1.3 gpm 0.020 in. Operating Pressure Oil Charge Pressure Oil Inlet or Drain Oil TN3081 Charge Pressure Oil from Traction Pump (Port A)
Page 148: Troubleshooting
HYDROSTATIC POWER TRAIN Troubleshooting Mower Will Not Move Forward or Reverse Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Parts and Maintenance Manual” for correct oil specifications.) Tow valve open. Close tow valve.
Page 149 HYDROSTATIC POWER TRAIN Hydrostatic System Operating Hot Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Parts and Maintenance Manual” for correct oil specifications.) Tow valve open. Close tow valve. (Refer to “Safety and Operation Manual.”) Oil cooler has dirt or debris in fins.
Page 150: Tests And Adjustments
HYDROSTATIC POWER TRAIN Tests and Adjustments WARNING Neutral Adjustment Prevent personal injury. Use properly rated lifting devices. Always be sure load is balanced before See Figures 5-15 through 5-18. lifting. Support the machine properly using jackstands. WARNING The hydraulic system is under pressure, and the oil will be hot.
Page 151 HYDROSTATIC POWER TRAIN 14. Rotate eccentric screw (6) until front wheels begin to rotate. Note position of screw. 15. Rotate eccentric screw (6) in the opposite direction until front wheels begin to rotate in the opposite direction. Note position of screw. 16.
Page 152: Field Test Procedures
HYDROSTATIC POWER TRAIN Field Test Procedures Traction System Test See Figure 5-19. When a hydraulic system failure occurs, some simple tests can be performed prior to using test instruments. NOTE The results of these tests can lead you to the suspected Be sure tow valve is closed before beginning traction component failure.
Page 153: Instrument Test Procedures
HYDROSTATIC POWER TRAIN Instrument Test Procedures Calculations: System Test Instrument Test Overview No Load Flow = 10 gpm The following tests are specifically designed to approach Loaded Flow = 6.9 gpm hydraulic testing on a system level. Each component 10 – 6.9 / 10 x 100 = Total System Leakage 31% within the system represents a portion of the total system leakage.
Page 154: Charge Pressure Test
HYDROSTATIC POWER TRAIN Charge Pressure Test See Figures 5-20 through 5-23. WARNING The hydraulic system is under pressure, and the oil will be hot. • Always relieve pressure in the hydraulic system before performing service. • Failure to follow appropriate safety precautions may result in death or serious injury.
Page 155: Traction System Test
HYDROSTATIC POWER TRAIN Traction System Test Retest charge pressure. Is charge pressure 150–210 psi (10–15 bar)? See Figures 5-24 through 5-31. Charge pressure relief valve is good. IMPORTANT Proceed to step 11. • Performing this test will isolate the traction pump For 3WD models, proceed to step 9.
Page 156 HYDROSTATIC POWER TRAIN TN3947 Figure 5-25 TN1761 6. Install flow lock tool (2) and secure to pump control Figure 5-24 arm. 7. Close tow valve completely by turning clockwise. 3. Install wheel restraints (1) to both front wheels. 8. For 3WD models, proceed to step 15. WARNING Prevent personal injury.
Page 157 HYDROSTATIC POWER TRAIN 9. Disconnect cap (9) from tee fitting (6). 10. Connect test hose (5) of flow meter inlet to tee fitting (6). 11. Disconnect cap (8) from tee fitting (7). 12. Connect test hose (3) of flow meter outlet to tee fitting (7).
Page 158 HYDROSTATIC POWER TRAIN 29. Stop engine, apply park brake, and return flow lock tool to the neutral position. 30. Calculate traction system leakage. (Step 27 – Step 28 / Step 27 x 100 = Leakage Percentage) Is traction system leakage 10% or less? The traction system is good.
Page 159: Traction Pump Tests
HYDROSTATIC POWER TRAIN Traction Pump Tests See Figures 5-32 through 5-37. IMPORTANT • Performing this test will isolate the traction pump from the rest of the hydrostatic system. • This test works together with the traction system test, wheel motors tests, and flushing valve check valve test to isolate a problem within the hydrostatic power train.
Page 160 HYDROSTATIC POWER TRAIN TN1357 Figure 5-34 8. Install blocking disks at locations (6 and 8). 9. Open flow meter valve (7) completely before starting engine. TN3104 Figure 5-36: Traction Pump Test—3WD Models— Blocking Disks Blocking Oil to Wheel Motors NOTE Verify engine rpm is within specification (3400 rpm ±...
Page 161: Wheel Motors Tests
HYDROSTATIC POWER TRAIN Wheel Motors Tests See Figures 5-38 through 5-45. IMPORTANT • Performing this test will isolate the wheel motors from the rest of the hydrostatic system. • This test works together with the traction system test, traction pump tests, and flushing valve check valve test to isolate a problem within the hydrostatic power train.
Page 162 HYDROSTATIC POWER TRAIN TN3941 Figure 5-38 6. Install blocking disk at location (1) to block oil to left front wheel motor inlet. 7. Open flow meter valve completely before starting engine. TN3968 Figure 5-39: Right Front Wheel Motor Test—2WD Models—Blocking Disk Blocking Oil to Left Front Wheel Motor, Front Wheels Restrained 5-44 4252490-Rev A...
Page 163 HYDROSTATIC POWER TRAIN TN3947 Figure 5-41 9. Adjust flow lock tool (2) to allow pump to produce 7 gpm (27 lpm) in the forward direction. 10. Use the flow meter to warm the hydraulic oil. Turn flow meter valve until a reading of 1000 psi (69 bar) is reached.
Page 164 HYDROSTATIC POWER TRAIN 16. Open flow meter valve completely before starting engine. TN3106 Figure 5-43: Left Front Wheel Motor Test—3WD Models—Front Wheels Restrained TN3969 Figure 5-42: Left Front Wheel Motor Test—2WD NOTE Models—Front Wheels Restrained Verify engine rpm is within specification (3400 rpm ± 50) to ensure accurate hydraulic test results.
Page 165 HYDROSTATIC POWER TRAIN 22. Stop engine, apply park brake, and return flow lock tool to the neutral position. 23. Calculate left front wheel motor leakage. (Step 12– Step 21 / Step 12 x 100 = Leak Percentage) Is left front wheel motor leakage 10% or less? The left front wheel motor is good.
Page 166: Flushing Valve Check Valve Test
HYDROSTATIC POWER TRAIN 38. Stop engine, apply park brake, and return flow lock tool to the neutral position. 39. Calculate rear wheel motor leakage. (Step 21 – Step 37 / Step 21 x 100 = Leak Percentage) Is rear wheel motor leakage 10% or less? The rear wheel motor is good.
Page 167 HYDROSTATIC POWER TRAIN 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Before performing this test, perform wheel motors tests leaving flow meter and rear wheel restraint connected as outlined. (See “Wheel Motors Tests” on page 5-43.) 3.
Page 168: Repair
HYDROSTATIC POWER TRAIN Repair Traction Pump and Control Removal and Installation See Figures 5-48 through 5-51. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure” on page 6-42.) 3.
Page 169 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-52 through 5-54. NOTE Service to the traction pump is limited to the following components: • Charge Pump • Implement Relief Valve • Charge Relief Valve • Trunnion and Shaft Seals Damage or excessive wear to traction pump components other than service components requires traction pump replacement.
Page 170 HYDROSTATIC POWER TRAIN 3. Remove (drive out) roll pin (3), and remove cam plate (4) from traction pump (1). 4. Remove three screws (2), and remove control weldment assembly (13) from traction pump (1). TN3970 Figure 5-53 NOTE Record the location of fittings before removing to ensure correct installation.
Page 171 HYDROSTATIC POWER TRAIN TN3913 Traction Pump Housing Shim (A/R) (Implement Relief) Seal Poppet (Charge Relief) Seal (2) Spring (Implement Relief) Bearing Spring (Charge Relief) Washer (2) Poppet (Implement Relief) Charge Pump (Gerotor) Shim (A/R) (Charge Relief) Retaining Ring (2) Charge Pump Housing O-Ring O-Ring (Charge Relief) Plug (Implement Relief)
Page 172 HYDROSTATIC POWER TRAIN Inspection Notes Inspection Notes • Keeping parts in assembly order, clean and air dry • Keeping parts in assembly order, clean and air dry each item for inspection. each item for inspection. • Inspect for worn or defective parts. •...
Page 173: Flushing Valve
HYDROSTATIC POWER TRAIN Flushing Valve Trunnion and Shaft Seals 1. Remove retaining rings (21) and washers (20). Removal and Installation NOTICE See Figure 5-55. 1. Park the mower safely. (See “Park Mower Safely” on When removing seals, use caution to prevent page 1-6.) damaging the housing bore or shaft surfaces.
Page 174 HYDROSTATIC POWER TRAIN 6. Disconnect hoses (4 and 5) from flushing valve NOTE assembly (6). Record the location of fittings before removing to ensure 7. Support flushing valve assembly (6). correct installation. 8. Remove three mounting screws (3). 2. Remove, inspect, and replace fittings (2) for ports 9.
Page 175: Wheel Motors
HYDROSTATIC POWER TRAIN Wheel Motors Removal and Installation Front Wheel Motor See Figures 5-57 through 5-60. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove front wheel. (See “Front Wheel” on page 9-19.) 3. Remove front wheel hub. (See “Front Wheel Hub” on page 9-22.) TN3881 Figure 5-58...
Page 176 HYDROSTATIC POWER TRAIN NOTE NOTES Record the location of fittings before removing to ensure • Label all hydraulic hoses and tubes before correct installation. disconnecting to ensure correct installation. 8. Remove, inspect, and replace fittings (7 and 8) from • Close all openings with caps or plugs to prevent left wheel motor (9) as necessary.
Page 177 HYDROSTATIC POWER TRAIN Installation Notes • Install rear wheel motor by reversing the order of removal. • Tighten rear wheel motor mounting screws (6) to 59– 66 lb-ft (80–90 N·m). • Tighten inlet and outlet port fittings (4 and 5) to 77 lb-ft (105 N·m).
Page 178 HYDROSTATIC POWER TRAIN Disassembly and Inspection—Left Front and Rear (3WD) Wheel Motors See Figures 5-63 through 5-66. TN3885 Seal Seal Drive Link Stator Half (2) Seal Ring, Commutator Bearing, Outer Thrust Bearing Thrust Washer (2) Vane (14) Commutator Ring Housing Bearing, Inner Rotor Set Rotor...
Page 179 HYDROSTATIC POWER TRAIN 9. Inspect commutator ring (22) for cracks or burrs. NOTE 10. Inspect commutator (20) for cracks, burrs, wear, The disassembly procedure for the left front and rear scoring, spalling, or brinelling. (3WD) wheel motors is the same. The motors differ in size, with the rear (3WD) motor being slightly larger.
Page 180 HYDROSTATIC POWER TRAIN TN3896 Figure 5-66 TN3893 Figure 5-65 NOTES • Minor shaft wear in the seal area (30) is allowed. If NOTE wear exceeds 0.020 in. (0.51 mm), replace the For motors with two-piece stator housings, check the coupling shaft. rotor clearance on each side of the rotor assembly.
Page 181 HYDROSTATIC POWER TRAIN CAUTION Remove the bearing only if replacement is required. The bearing must not be reused once removed. NOTE If inner bearing (8) requires replacement, measure and record the depth of the inner bearing in relation to the housing wear surface before removing the bearing.
Page 182 HYDROSTATIC POWER TRAIN Assembly—Left Front and Rear (3WD) Wheel Motors See Figures 5-67 through 5-69. TN3885 Seal Seal Drive Link Stator Half (2) Seal Ring, Commutator Bearing, Outer Thrust Bearing Thrust Washer (2) Vane (14) Commutator Ring Housing Bearing, Inner Rotor Set Rotor End Cover...
Page 183 HYDROSTATIC POWER TRAIN 5. Install a new thrust bearing (7) and two thrust NOTICE washers (12) into the housing. The thrust bearing must be positioned between the two thrust washers. It is important that all motor parts are absolutely 6. Install (press) inner bearing (8) into housing (3) to a clean, as contamination can result in serious depth of 0.105–0.125 in.
Page 184 HYDROSTATIC POWER TRAIN NOTE Two alignment studs, installed finger-tight into two of the screw holes, 180° apart, may be used to aid in assembly. These studs can be made by cutting the heads from 5/16-24 UNF 2A bolts that are 0.50 in. (12.7 mm) longer than the screws (24) used to hold the motor together.
Page 185 HYDROSTATIC POWER TRAIN Disassembly and Inspection—Right Front Wheel Motor See Figures 5-70 through 5-74. TN3886 Seal Bearing, Inner Wear Plate Commutator Ring Bearing, Outer Coupling Shaft Stator Half (2) End Cover Assembly Housing Thrust Bearing Vane (14) Plug, Shuttle Valve Backup Ring Drive Link Rotor...
Page 186 HYDROSTATIC POWER TRAIN TN3890 Figure 5-71 1. Place wheel motor (28) in a soft-jawed vice, with the coupling shaft pointed down and the vise jaws firmly TN3898 clamping each side of the housing mounting flange. Figure 5-72 2. Scribe or mark lines (29) across the side of wheel motor sections to mark the position and orientation of NOTICE motor segments before disassembly.
Page 187 HYDROSTATIC POWER TRAIN 15. Remove and discard seal rings (14) from each side 21. Place rotor set (13) and wear plate (15) on a flat of the manifold (19). surface, with the rotor (18) positioned in the stator so that two rotor lobes (180° apart) and the rotor vane 16.
Page 188 HYDROSTATIC POWER TRAIN 30. Inspect thrust bearing (7) for signs of wear, brinelling, WARNING corrosion, and for any damaged or missing rollers. Replace as needed. Use appropriate eye protection when using 31. Remove seal (6), backup ring (5), and backup compressed air for cleaning or drying purposes.
Page 189 HYDROSTATIC POWER TRAIN Assembly—Right Front Wheel Motor See Figures 5-75 through 5-78. TN3886 Seal Bearing, Inner Wear Plate Commutator Ring Bearing, Outer Coupling Shaft Stator Half (2) End Cover Assembly Housing Thrust Bearing Vane (14) Plug, Shuttle Valve Backup Ring Drive Link Rotor Screw (7)
Page 190 HYDROSTATIC POWER TRAIN 5. Install a new thrust bearing (7) and two thrust NOTICE washers (12) into the housing. The thrust bearing must be positioned between the two thrust washers. It is important that all motor parts are absolutely 6. Install (press) inner bearing (8) into housing (3) to a clean, as contamination can result in serious depth of 0.105–0.125 in.
Page 191 HYDROSTATIC POWER TRAIN NOTE Two alignment studs, installed finger-tight into two of the screw holes, 180° apart, may be used to aid in assembly. These studs can be made by cutting the heads from 5/16-24 UNF 2A bolts, that are 0.50 in. (12.7 mm) longer than the screws (25) used to hold the motor together.
Page 192 HYDROSTATIC POWER TRAIN 5-74 4252490-Rev A...
Page 193 Chapter 6 Hydraulics Specifications ..............6-3 Test Specifications .
Page 194 HYDRAULICS Repair ..............6-42 Hydraulic Oil Tank—Drain Procedure .
Page 195 HYDRAULICS Specifications Test Specifications Specifications Charge Relief Valve Pressure Setting 150–210 (10–15) psi (bar) Implement Relief Valve Pressure Setting 800 ± 10% (55 ± 10%) psi (bar) Lift Relief Valve Pressure Setting 1250 ± 10% (86 ± 10%) psi (bar) Reel Relief Valve Pressure Setting 3020 ±...
Page 196: Hydraulic Hose, Tube, And Fitting General Instructions
HYDRAULICS Hydraulic Hose, Tube, and Replacement O-Rings for O-Ring Boss Fittings Fitting General Instructions Tubing O.D. Thread Jacobsen Part O-Ring Installation or Hose I.D. Size Number • Always install new O-rings. 5/16-24 459290 • On hoses with O-ring fittings, make sure O-rings are 3/16 3/8-24 459291...
Page 197: Component Location
HYDRAULICS Component Location See Figures 6-1 and 6-2. TN3653, TN3765, TN3771 Center Lift Cylinder Lift Valve Right Front Lift Cylinder Reel Valve Unit Soft Drop Valve Hydraulic Oil Charge Filter Assembly Left Front Lift Cylinder Figure 6-1: Component Location—Front 4252490-Rev A...
Page 198 HYDRAULICS TN3767, TN3769 Hydraulic Oil Cooler Traction Pump Top Sequence Valve Gear Pump Bottom Sequence Valve Hydraulic Oil Tank Figure 6-2: Component Location—Rear 4252490-Rev A...
Page 199: Hydraulic Schematic (3Wd)
HYDRAULICS Hydraulic Schematic (3WD) See Figures 6-3 through 6-7. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Test Port Suction Strainer...
Page 200 HYDRAULICS Hydraulic Schematic (3WD), Continued Shuttle Valve Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 Rear Wheel Motor 20.75 Check Valve 0.040 in. Flushing Valve 1.3 gpm 0.020 in. TN3027 Figure 6-4 4252490-Rev A...
Page 201 HYDRAULICS Hydraulic Schematic (3WD), Continued Steering Cylinder Steering Unit 3.84 Steering Valve Check Valve TN3028 Figure 6-5 4252490-Rev A...
Page 202 HYDRAULICS Hydraulic Schematic (3WD), Continued Right Lift Cylinder Center Lift Cylinder Lift Lift Bottom Sequence Sequence Delay Valve Soft Drop Valve Check Lift Valve Lift Valve Solenoid Valve Left Lift Cylinder Relief Valve 1250 psi TN3029 Figure 6-6 6-10 4252490-Rev A...
Page 203 HYDRAULICS Hydraulic Schematic (3WD), Continued Reel Valve Unit Check Valve 0.020 in. Reel Speed Reel Control Valve Valve Relief Valve 3020 psi Backlap Enable Switch 145 Micron Filter Right Left Center Reel Reel Reel Motor Motor Motor 0.60 0.60 0.60 TN3030 Figure 6-7 4252490-Rev A...
Page 204: Hydraulic Schematic (2Wd)
HYDRAULICS Hydraulic Schematic (2WD) See Figures 6-8 through 6-12. Traction Pump Check Gear Valve Pump Charge Charge Pump Relief Valve Engine 150–210 psi 3400 rpm 0.92 ci 0.40 ci 0.33 ci Valve Implement Relief Valve 800 psi Check Valve Test Port Suction Strainer...
Page 205 HYDRAULICS Hydraulic Schematic (2WD), Continued 0.052 in. Shuttle Valve 1.3 gpm Right Front Wheel Motor 10.37 Left Front Wheel Motor 10.37 TN3032 Figure 6-9 4252490-Rev A 6-13...
Page 206 HYDRAULICS Hydraulic Schematic (2WD), Continued Steering Cylinder Steering Unit 3.84 Steering Valve Check Valve TN3028 Figure 6-10 6-14 4252490-Rev A...
Page 207 HYDRAULICS Hydraulic Schematic (2WD), Continued Right Lift Cylinder Center Lift Cylinder Lift Lift Bottom Sequence Sequence Delay Valve Soft Drop Valve Check Lift Valve Lift Valve Solenoid Valve Left Lift Cylinder Relief Valve 1250 psi TN3029 Figure 6-11 4252490-Rev A 6-15...
Page 208 HYDRAULICS Hydraulic Schematic (2WD), Continued Reel Valve Unit Check Valve 0.020 in. Reel Reel Valve Speed Control Valve Relief Valve 3020 psi Backlap Enable Switch 145 Micron Filter Right Left Center Reel Reel Reel Motor Motor Motor 0.60 0.60 0.60 TN3030 Figure 6-12 6-16...
Page 209 HYDRAULICS Page Intentionally Blank 4252490-Rev A 6-17...
Page 210: Theory Of Operation And Sub-Circuit Schematics
HYDRAULICS Theory of Operation and Sub-Circuit Schematics Steering Circuit Schematic and Theory of Operation System Conditions: • Engine running • Steering wheel turned to the right or left (left turn shown) Oil Supply to Steering Unit Hydraulic oil is drawn from the hydraulic oil tank by the charge pump.
Page 211: Steering Circuit Schematic
HYDRAULICS Steering Circuit Schematic See Figure 6-13. Steering Cylinder Steering Unit 3.84 Steering Valve Check Valve Operating Pressure Oil Metered Oil Return Oil TN3069 Operating Pressure Oil from Charge Pump (Traction Return Oil to Oil Cooler and Hydraulic Tank Pump Port V1) Figure 6-13 4252490-Rev A 6-19...
Page 212: Raise Circuit Schematic And Theory Of Operation
HYDRAULICS Raise Circuit Schematic and Theory Circuit Relief of Operation The lift system is protected by the 1250 psi (86 bar) relief valve in the lift valve. If the pressure on the pilot line of System Conditions: the relief valve reaches 1250 ± 10% psi (86 ± 10% bar), •...
Page 213: Raise Circuit Schematic
HYDRAULICS Raise Circuit Schematic See Figure 6-14. Right Lift Cylinder Center Lift Cylinder Bottom Sequence Sequence Delay Valve Soft Drop Valve Lift Valve Check Valve Solenoid Valve Left Lift Cylinder Relief Valve 1250 psi Operating Pressure Oil Return Oil TN3070 Return Oil to Oil Cooler and Hydraulic Tank Operating Pressure Oil from Reel Valve Unit (Port T) Figure 6-14...
Page 214: Lower Circuit Schematic And Theory Of Operation
HYDRAULICS Lower Circuit Schematic and Theory Circuit Relief of Operation The lift system is protected by the 1250 psi (86 bar) relief valve in the lift valve. If the pressure on the pilot line of System Conditions: the relief valve reaches 1250 ± 10% psi (86 ± 10% bar), •...
Page 215: Lower Circuit Schematic
HYDRAULICS Lower Circuit Schematic See Figure 6-15. Right Lift Cylinder Center Lift Cylinder Bottom Sequence Sequence Delay Valve Soft Drop Valve Lift Valve Check Valve Solenoid Valve Left Lift Cylinder Relief Valve 1250 psi Operating Pressure Oil Return Oil TN3071 Return Oil to Oil Cooler and Hydraulic Tank Operating Pressure Oil from Reel Valve Unit (Port T) Figure 6-15...
Page 216: Mow Circuit Schematic And Theory Of Operation
HYDRAULICS Mow Circuit Schematic and Theory of Circuit Relief Operation The mow circuit is protected by the 3020 psi (207 bar) relief valve. The relief valve will open if the oil pressure in System Conditions: the circuit reaches 3020 psi (207 bar), routing oil through •...
Page 217: Mow Circuit Schematic
HYDRAULICS Mow Circuit Schematic See Figure 6-16. Reel Valve Unit Check Valve 0.020 in. Reel Reel Speed Control Valve Valve Relief Valve 3020 psi Backlap Enable Switch 145 Micron Filter Right Left Center Reel Reel Reel Motor Motor Motor 0.60 0.60 0.60 Operating Pressure Oil...
Page 218: Backlap Circuit Schematic And Theory Of Operation
HYDRAULICS Backlap Circuit Schematic and Circuit Relief Theory of Operation The backlap circuit is protected by the 3020 psi (207 bar) relief valve. The relief valve will open if the oil pressure in System Conditions: the circuit reaches 3020 psi (207 bar), routing oil through •...
Page 219: Backlap Circuit Schematic
HYDRAULICS Backlap Circuit Schematic See Figure 6-17. Reel Valve Unit Check Valve 0.020 in. Reel Reel Valve Speed Control Valve Relief Valve 3020 psi Backlap Enable Switch 145 Micron Filter Right Left Center Reel Reel Reel Motor Motor Motor 0.60 0.60 0.60 Operating Pressure Oil...
Page 220: Field Test Procedures
HYDRAULICS Field Test Procedures When a hydraulic system failure occurs, some simple tests can be performed prior to using test instruments. The results of these tests can lead you to the suspected component failure. More extensive test procedures, using test instruments, are presented later in this section. (See “Instrument Test Procedures”...
Page 221: Steering Leakage Test
HYDRAULICS Steering Leakage Test IMPORTANT See Figure 6-21. Cutting units must be lowered to the ground. 1. Operate hydraulic system until oil temperature is 13. Disconnect tee fitting (4) from port “A” (3) of the lift 120–150° F (49–65° C). valve (5).
Page 222: Reel Motor Case Drain Test
HYDRAULICS Is steering cylinder leakage a nominal amount of 9. Stop engine and remove ignition key. oil or less? 10. Measure the amount of oil that flowed from the case Go to step 8. drain. The amount x 4 = amount per minute. Repair or replace steering cylinder.
Page 223: Instrument Test Procedures
HYDRAULICS Instrument Test Procedures Calculations: Cutting Units Circuit Test Instrument Test Overview No Load Flow = 10 gpm The following tests are specifically designed to approach Loaded Flow = 7.2 gpm hydraulic testing on a system level. Each component 10 – 7.2 / 10 x 100 = Total Circuit Leakage 28% within the system represents a portion of the total system leakage.
Page 224: Cutting Units Circuit Test
HYDRAULICS Cutting Units Circuit Test See Figures 6-22 through 6-24. IMPORTANT • Performing this test will isolate the gear pump, reel valve unit, and right reel motor from the rest of the cutting units circuit. • This test works together with the gear pump test, reel valve unit test, and reel motors test to isolate a problem with the cutting units circuit.
Page 225: Gear Pump Test
HYDRAULICS 16. Calculate cutting units circuit leakage. (Step 13 – Step 14 / Step 13 x 100 = Leak Percentage) Is cutting units circuit leakage 10% or less? The cutting units circuit is good. Proceed to “Reel Motors Test” on page 6-36. Proceed to next question.
Page 226 HYDRAULICS TN3796 Figure 6-25 TN3098 Figure 6-27: Gear Pump Test—Blocking Disk Between Pump and Reel Valve Unit 5. Block each side of rear wheels using suitable wheel blocks. 6. Bypass seat switch and release park brake. NOTE Verify engine rpm is within specification (3400 rpm ± 50) to ensure accurate hydraulic test results.
Page 227: Reel Valve Unit Test
HYDRAULICS 12. Calculate gear pump leakage. 2. Before performing this test, perform cutting units (Step 13 of previous test – Step 10 / Step 13 of circuit test, leaving flow meter connected as outlined. previous test x 100 = Leak Percentage) Is gear pump leakage 10% or less? The gear pump is good.
Page 228: Reel Motors Test
HYDRAULICS 12. Calculate reel valve unit leakage. (Step 10 of previous test – Step 10 / Step 10 of previous test x 100 = Leak Percentage) Is reel valve unit leakage 10% or less? The reel valve unit is good. Proceed to step 13.
Page 229 HYDRAULICS 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Verify engine rpm is within specification (3400 rpm ± 50) 2. Before performing this test, perform reel valve unit to ensure accurate hydraulic test results. test, leaving flow meter connected as outlined. 7.
Page 230 HYDRAULICS 21. Calculate left reel motor leakage. (Step 10 – Step 19 / Step 10 x 100 = Leak Percentage) Is left reel motor leakage 10% or less? The left reel motor is good. Proceed to step 22. Proceed to next question. Is left reel motor leakage 11–20%? The left reel motor is marginal.
Page 231: Implement Relief Valve Pressure Test
HYDRAULICS Implement Relief Valve Pressure Test NOTE See Figures 6-35 through 6-37. Verify engine rpm is within specification (3400 rpm ± 50) to ensure accurate hydraulic test results. NOTE 25. Start engine and run at full throttle (3400 rpm ± 50). Before performing this test, perform field test procedures.
Page 232 HYDRAULICS 8. Start engine and run at full throttle (3400 rpm ± 50). CAUTION Do not run implement relief valve over relief longer than 10 seconds or damage may occur to hydraulic system components. 9. Turn the steering wheel fully right against stop. 10.
Page 233: Lift Relief Valve Pressure Test
HYDRAULICS Lift Relief Valve Pressure Test See Figures 6-38 through 6-40. NOTE Before performing this test, perform field test procedures. (See “Field Test Procedures” on page 6-28.) WARNING The hydraulic system is under pressure, and the oil will be hot. •...
Page 234: Repair
HYDRAULICS Repair CAUTION Hydraulic Oil Tank—Drain Procedure Do not run mower lift system relief valve over relief longer than 10 seconds or damage may See Figure 6-41. occur to hydraulic system components. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 7.
Page 235: Gear Pump
HYDRAULICS Installation Notes • Ensure new O-ring is in place before installing hose on fitting. • Connect hose (2). • Replace hydraulic oil charge filter. (See “Hydraulic Oil Charge Filter Assembly” on page 6-59.) • Refill hydraulic tank. (Refer to “Parts and Maintenance Manual”...
Page 236 HYDRAULICS Disassembly, Inspection, and Assembly NOTE See Figures 6-44 through 6-46. Record the location of fittings before removing to ensure correct installation. 1. Remove, inspect, and replace dust cover (3) and tee fitting (4) as necessary. 2. Remove, inspect, and replace outlet port fitting (1) as necessary.
Page 237 HYDRAULICS Disassembly Notes 5. Inspect all parts for cracks, nicks, burrs, and excessive wear. Inspect for scoring, galling, and • Do not disassemble pump for repair unless test scratches on surfaces. Damage or excessive wear to procedures indicate internal leakage. gear pump components other than seal kit •...
Page 238: Lift Valve
HYDRAULICS Lift Valve Installation Notes • Install lift valve by reversing the order of removal. Removal and Installation • Ensure new O-rings are in place before installing hoses on fittings. See Figure 6-47. • Apply dielectric grease (Jacobsen PN 365422) to any 1.
Page 239 HYDRAULICS Assembly Notes NOTICE It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.
Page 240: Reel Valve Unit
HYDRAULICS Reel Valve Unit Removal and Installation See Figures 6-50 and 6-51. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure” on page 6-42.) NOTE The reel valve unit is located below the seat plate. 3.
Page 241 HYDRAULICS Disassembly, Inspection, and Assembly 15. Remove, inspect, and replace fitting (9) from port “B” as necessary. See Figures 6-52 and 6-53. WARNING Use appropriate eye protection when using compressed air for cleaning or drying purposes. Compressed air can cause serious personal injury.
Page 242: Soft Drop Valve
HYDRAULICS Soft Drop Valve Assembly Notes NOTICE Removal and Installation See Figures 6-54 through 6-56. It is important that all component parts are 1. Park the mower safely. (See “Park Mower Safely” on absolutely clean, as contamination can result in page 1-6.) serious damage and/or improper operation.
Page 243: Top And Bottom Sequence Valves
HYDRAULICS Top and Bottom Sequence Valves Removal and Installation See Figure 6-57. NOTE The top sequence valve is shown; the bottom sequence valve is similar. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery.
Page 244: Center Lift Cylinder
HYDRAULICS Installation Notes 6. Lower the cutting units. • Install sequence valve by reversing the order of removal. • Make sure new O-rings are in place before installing hoses on fittings. • Replace hydraulic oil charge filter. (See “Hydraulic Oil Charge Filter Assembly” on page 6-59.) •...
Page 245 HYDRAULICS NOTE Record the number of washers used and their locations to ensure correct installation. 8. Remove cotter pin (8) and washers (9). 9. Remove cotter pin (5) and washers (6), and remove pin (14) from lift cylinder (7) and lift arm (13). 10.
Page 246: Left And Right Front Lift Cylinders
HYDRAULICS Left and Right Front Lift Cylinders WARNING Removal and Installation Use appropriate eye protection when using See Figures 6-65 and 6-66. compressed air for cleaning or drying purposes. Compressed air can cause serious personal NOTE injury. Use safety reduction valves to reduce the air pressure to a safe level before use.
Page 247 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-67 through 6-70. TN3795 Figure 6-66 TN3816 5. Remove cotter pin (6) and washer (12), and remove Figure 6-67 pin (5) from lift cylinder (7) and lift arm (13). NOTE 6. Remove cotter pin (11) and washer (10), and remove lift cylinder (7) from frame (9).
Page 248 HYDRAULICS WARNING Use appropriate eye protection when using compressed air for cleaning or drying purposes. Compressed air can cause serious personal injury. Use safety reduction valves to reduce the air pressure to a safe level before use. NOTICE During repair of the cylinder, use extreme care not to damage the barrel, piston, rod, and sealing surfaces of the cylinder.
Page 249: Hydraulic Oil Tank (Diesel)
HYDRAULICS Hydraulic Oil Tank (Diesel) Removal and Installation See Figures 6-71 and 6-72. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery. 3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure”...
Page 250: Hydraulic Oil Tank (Gasoline)
HYDRAULICS Hydraulic Oil Tank (Gasoline) 7. Disconnect hoses (1, 5, and 6) from hydraulic oil tank. Removal and Installation 8. Support hydraulic oil/fuel tank (8) using a suitable lifting device. See Figures 6-73 and 6-74. 9. Remove three screws (2), lock washers (3), flat 1.
Page 251: Hydraulic Oil Charge Filter Assembly
HYDRAULICS CAUTION • When connecting fittings to the tank, be sure to hold the tank fitting with the proper wrench. If the proper wrench is not used, the fitting in the tank might break loose from the plastic and cause it to leak. •...
Page 252: Hydraulic Oil Cooler (Diesel)
HYDRAULICS Hydraulic Oil Cooler (Diesel) Removal and Installation See Figures 6-76 and 6-77. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery. 3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure”...
Page 253: Hydraulic Oil Cooler Assembly (Gasoline)
HYDRAULICS Hydraulic Oil Cooler Assembly (Gasoline) Removal and Installation See Figures 6-78 through 6-81. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery. 3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure”...
Page 254 HYDRAULICS Installation Notes 20 21 • Install oil cooler by reversing the order of removal. • Make sure new O-rings are in place before installing hoses and fittings. • Replace hydraulic oil charge filter. (See “Hydraulic Oil Charge Filter Assembly” on page 6-59.) •...
Page 255 Chapter 7 Steering Specifications ..............7-2 Component Location .
Page 256: Specifications
STEERING Specifications Repair Specifications Steering Wheel Nut Torque 28–30 (38–41) lb-ft (N·m) Steering Unit End Cover-to-Housing Screw Torque 20–24 (27–33) lb-ft (N·m) 4252490-Rev A...
Page 257: Component Location
STEERING Component Location See Figure 7-1. TN3653, TN3713 Control Arm Control Arm Lock Lever Steering Wheel Steering Cylinder Steering Unit Steering Yoke Figure 7-1: Component Location 4252490-Rev A...
Page 258: Repair
STEERING Repair Installation Notes • Install steering wheel by reversing the order of removal. Steering Wheel • Tighten the steering wheel nut (3) to 28–30 lb-ft (38–41 N·m). Removal and Installation See Figures 7-2 and 7-3. Steering Column Covers 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Removal and Installation See Figures 7-4 and 7-5.
Page 259: Control Arm
STEERING Control Arm Removal and Installation See Figures 7-6 and 7-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove steering unit. (See “Steering Unit” on page 7-6.) TN3691 Figure 7-5 TN3698 5. Inspect foam inserts (4 and 5) in the upper (2) and Figure 7-6 lower (3) steering column covers.
Page 260: Steering Unit
STEERING 10 11 TN3699 TN3693 Figure 7-7 7. Support the control arm (8). 8. Remove nut (9), screw (10), and two flat washers (11). 9. Pull the control arm (8) forward, while guiding the steering unit hoses (7) out of the control arm. 10.
Page 261 STEERING Installation Notes NOTES • Install steering unit by reversing the order of removal. • Label all hydraulic hoses before disconnecting to • Check hydraulic oil level. Add oil as needed. ensure correct installation. • Start the machine and check cylinder operation. •...
Page 262 STEERING TN3955 Figure 7-12 1. Scribe or mark a line (1) across the output shaft (3) and housing (2) before disassembly. TN3918 Figure 7-11 1. Place the steering unit service fixture (11) securely in a vise. 2. Place steering unit (10) into the service fixture (11), input shaft down.
Page 263 STEERING TN3922 Figure 7-15 NOTE The gearwheel to distributor plate is a tight fit. Tap the side of the gearwheel rim with a soft-faced hammer to loosen. 6. Remove the gearwheel rim (11), gearwheel (13), and two O-rings (12 and 14) as a unit, keeping the gearwheel and gearwheel rim in the same orientation TN3919 to each other.
Page 264 STEERING 7. Remove two sleeves (15). 8. Remove distributor plate (16). TN3929 Figure 7-19 NOTE The spring retaining ring may remain inside the housing when the spool and sleeve assembly is removed. 12. Remove spring retaining ring (22). 13. Remove spring set (21) from spool (20). 14.
Page 265 STEERING 17. Re-secure service fixture in vise with input shaft down. 18. Remove housing (2) from service fixture. 19. Remove seal (25) from housing (2). WARNING Use appropriate eye protection when using compressed air for cleaning or drying purposes. Compressed air can cause serious personal injury.
Page 266 STEERING TN3927 TN3955 TN3927 Figure 7-24 Figure 7-22 11. Align the lines (14) on the output shaft (15) and 4. Install seal (6) in housing (7). housing (7). 5. Lubricate the inside diameter of seal (6). 6. Place housing (7) into the service fixture, input shaft opening down.
Page 267 STEERING TN3923 Figure 7-26 14. Install two sleeves (18). 15. Install distributor plate (19). TN3919 Figure 7-28 19. Align end cover (24) to housing and install special screw (28) with nut (27) and washer (29) into the same location in the end cover as noted during removal.
Page 268: Steering Cylinder
STEERING Steering Cylinder Removal and Installation See Figures 7-29 through 7-31. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank” on page 9-4.) 3. Thoroughly clean the area surrounding the steering cylinder, especially the hydraulic hose fittings.
Page 269 STEERING 13. Remove ball joint (16) and jam nut (17) from steering cylinder (4). 14. Inspect ball joint. Replace as needed. Installation Notes • Install steering cylinder by reversing the order of removal. • Lubricate grease fitting with grease that meets or exceeds NLGI Grade 2 LB specifications.
Page 270 STEERING 6. Remove O-ring (9) from rod guide (6). NOTICE It is important that all components are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.
Page 271: Steering Yoke Assembly
STEERING Steering Yoke Assembly Removal and Installation See Figures 7-38 and 7-39. NOTE 2WD steering assembly is shown; 3WD steering assembly is similar. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank”...
Page 272 STEERING 7-18 4252490-Rev A...
Page 273 Chapter 8 Cutting Units Specifications ..............8-2 Component Location .
Page 274 CUTTING UNITS Specifications Checks and Adjustments Bedknife Front Face Height 0.040 (1.0) in. (mm) Bedknife Front Face Angle degrees Bedknife Top Face Angle (Rear Relief) 8–10 degrees Reel Blade Relief Angle degrees Bedknife-to-Reel Gap 0.001–0.003 (0.025–0.076) in. (mm) Reel Bearing Pre-Load 0.040 (1.0) in.
Page 275: Component Location
CUTTING UNITS Component Location See Figure 8-1. TN3653, TN3751, TN3752 Left Cutting Unit Reel Motor Grass Shield Cutting Unit Rear Roller Lift Lerveling Rods Counterweight Yoke Bedknife Backing Assembly Right Cutting Unit Reel Assembly Lift Arm Cutting Unit Frame Center Cutting Unit Cutting Unit Front Roller Adjusters Figure 8-1: Component Location...
Page 276: Troubleshooting
CUTTING UNITS Troubleshooting Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Even though the cutting units are properly sharpened and adjusted, some mowing practices and turf conditions can cause poor cutting results. These include: • Repetitious mowing patterns—tires running over the same path—may cause depressions and ruts.
Page 277 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. Ragged Cut Ragged cutting occurs when blades of grass are torn or damaged rather than cut. This is usually caused by incorrect height-of-cut adjustment, incorrect bedknife-to-reel adjustment, or dull blades.
Page 278 CUTTING UNITS Washboarding Washboarding is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is approximately 6–8 in. (15–20 cm). Color variation (light-to-dark) may also be noticed. This condition is usually caused by a rocking motion in the cutting unit(s).
Page 279 CUTTING UNITS Marcelling Marcelling is a wave-like cut appearance similar to washboarding but with a uniform cutting height and smaller wave tip-to-tip distance. In most cases, the wave tip-to-tip distance is 2 in. (5 cm) or less. Color variation (light-to-dark) may also be noticed. This condition is usually caused by an incorrect frequency-of-clip.
Page 280 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a cutting unit than on the other, or on one side of the mower than on the other. This is usually caused by mechanical wear or an incorrect roller or adjustment. TN0221 NOTE: Arrow indicates direction of travel.
Page 281 CUTTING UNITS Scalping Scalping is a condition in which areas of grass are cut noticeably shorter than the surrounding areas, resulting in a light green or even brown patch. This is usually caused by an excessively low height-of-cut setting and/or uneven turf.
Page 282 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Bedknife improperly adjusted. Adjust bedknife. (See “Bedknife-to-Reel Clearance Adjustment” on page 8-17.) Dull cutting edges. Sharpen reel and bedknife. (Refer to “Parts and Maintenance Manual.”) Mowing (ground) speed is too fast.
Page 283 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a damaged bedknife or reel blade. TN0224 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 8-33.) Damaged or unevenly worn reel.
Page 284 CUTTING UNITS Windrowing Windrowing is the deposit of clippings concentrated at one end of cutting unit(s) or between cutting units, forming line(s) in the direction of travel. TN0225 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall. Mow more often.
Page 285 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units cause a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to a different HOC (height-of-cut) adjustment from one cutting unit to another. TN1278 NOTE: Arrow indicates direction of travel. Probable Cause Remedy HOC inconsistent from one cutting unit to another.
Page 286 CUTTING UNITS Rifling or Tramlining Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife. TN0987 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Reel and/or bedknife unevenly worn.
Page 287 CUTTING UNITS Grass Graining Grass graining is a directional orientation of grass blades and/or stems usually due to mowing in one direction or constant traffic in one direction. TN2853 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Mowing in the same direction all the time. Mow against the grain or change the mowing pattern.
Page 288: Mechanical Troubleshooting
CUTTING UNITS Mechanical Troubleshooting Condition Probable Cause Remedy Reel drive does not engage. Traction lever and/or mow/transport switch Move traction lever and/or mow/transport not in the mow position. switch to the mow position. (Refer to “Safety and Operation Manual.”) Reel motor faulty. Repair or replace reel motor.
Page 289: Checks And Adjustments
CUTTING UNITS Checks and Adjustments Bedknife-to-Reel Clearance Adjustment See Figures 8-2 and 8-3. CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 1. Park the mower safely. (See “Park Mower Safely” on TN0893 page 1-6.) Figure 8-3...
Page 290: Height-Of-Cut (Hoc) Adjustment
CUTTING UNITS Height-of-Cut (HOC) Adjustment 9. Recheck each end with height-of-cut bar and readjust as necessary. See Figure 8-4. NOTES CAUTION • Check the position of each reel for desired To prevent personal injury and damage to the height-of-cut. cutting edges, handle the reel with extreme care. •...
Page 291: Reel Bearing Pre-Load Adjustment
CUTTING UNITS Reel Bearing Pre-Load Adjustment See Figures 8-6 through 8-10. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Back bedknife away from reel. (See “Bedknife-to-Reel Clearance Adjustment” on page 8-17.) TN2653 Figure 8-7 4. Remove screw (6), lock washer (7), washer (5), and spacer (4).
Page 292: Reel Leveling Rod Pre-Adjustment
CUTTING UNITS Reel Leveling Rod Pre-Adjustment See Figure 8-11. Required Materials ® Loctite 242 (Blue) 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove reel leveling rod. (See “Reel Leveling Rod” on page 8-23.) TN2653 Figure 8-9 6.
Page 293: Cutting Unit Leveling Adjustment
CUTTING UNITS Cutting Unit Leveling Adjustment See Figures 8-12 and 8-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Pre-adjust reel leveling rod, if necessary. (See “Reel Leveling Rod Pre-Adjustment” on page 8-20.) TN3759 Figure 8-12 TN3735 Figure 8-13 NOTE...
Page 294: Repair
CUTTING UNITS Repair Cutting Unit Removal and Installation See Figures 8-14 through 8-17. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove grass catcher (if equipped). NOTES • Perform steps 3 through 6 if removing the rear cutting unit.
Page 295: Lift Yoke
CUTTING UNITS Lift Yoke Removal and Installation See Figure 8-18. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the cutting unit. (See “Cutting Unit” on page 8-22.) TN3720 Figure 8-17 NOTE Perform step 9 if the cutting unit is to be disassembled. 12.
Page 296 CUTTING UNITS Right and Left Lift Arms Removal and Installation See Figures 8-21 through 8-23. NOTE The left lift arm is shown; the right lift arm is similar. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
Page 297 CUTTING UNITS Disassembly and Assembly NOTE See Figure 8-24. Record the locations of flat washers (7) to ensure correct installation. 4. Remove cotter pin (6), pin (5), and six flat washers (7) from lift cylinder (8) and lift arm (13). 5.
Page 298 CUTTING UNITS Center Lift Arm Removal and Installation See Figures 8-25 and 8-26. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove cutting unit. (See “Cutting Unit” on page 8-22.) TN3743 Figure 8-26 5. Remove cotter pin (9) and flat washer (10). 6.
Page 299: Swing Arm
CUTTING UNITS Swing Arm Disassembly and Assembly See Figure 8-27. TN3745 Screw (2) Ball Bearing (2) Thrust Washer Cotter Pin Carriage Bolt Spacer Bolt Washer (2) Bushing Flat Washer (2) Nyloc Nut Spring Pin Flat Washer Hose Clamp Pivot Shaft Link Arm Assembly Nyloc Nut (2) Tube Clamp Top Plate...
Page 300: Reel Motor
CUTTING UNITS Reel Motor Disassembly Notes • Before disassembly, clean the center lift arm and Removal and Installation swing arm—removing all dirt and debris. • Inspect link arm, center lift arm, swing arm, reel See Figure 8-28. steering pivot, and all bushings for damage or wear. NOTE Remove bushings only if replacement is required.
Page 301 CUTTING UNITS Installation Notes • Install the reel motor by reversing the order of removal. • Coat the reel motor shaft (4) and coupler (3) with grease that meets or exceeds NLGI Grade 2 LB specifications before installing reel motor (8). •...
Page 302 CUTTING UNITS TN3760 O-Ring (2) Retaining Screw (4) Driven Gear Shaft Seal Dowel Pin (2) Drive Shaft Thrust Plate Snap Ring Pump Housing Anti-Extrusion Ring Upper Seal Rear Cover Seal Anti-Extrusion Ring Washer (4) Thrust Plate Front Cover Figure 8-30 Disassembly Notes •...
Page 303 CUTTING UNITS Assembly Notes NOTICE It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.
Page 304: Grass Shield
CUTTING UNITS Grass Shield Bedknife Backing Assembly Removal and Installation Removal and Installation See Figure 8-32. See Figures 8-33 and 8-34. 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 305: Bedknife
CUTTING UNITS Bedknife 7. Remove bedknife backing assembly (4). Installation Notes Removal and Installation See Figure 8-35. Required Materials 1. Park the mower safely. (See “Park Mower Safely” on Anti-Seize Compound page 1-6.) 2. Remove bedknife backing assembly. (See “Bedknife Backing Assembly”...
Page 306: Reel Bearing Housing Assembly
CUTTING UNITS Reel Bearing Housing Assembly Installation Notes • Install reel bearing housing assembly by reversing Removal and Installation—Drive Side the order of removal. • Use bearing assembly tool (Jacobsen PN JAC5084) See Figure 8-36. to install reel bearing housing assembly onto reel shaft.
Page 307 CUTTING UNITS Assembly Notes • Install new grease seal (2). • Inspect bearing cup and cone (1) for wear or damage. Replace as needed. • Pack bearing (1) with grease that meets or exceeds NLGI Grade 2 LB specifications before assembly. •...
Page 308 CUTTING UNITS Disassembly and Assembly See Figure 8-40. TN3758 TN0940 Figure 8-41 Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting 1. Install reel bearing housing assembly (8) using Vent Fitting bearing assembly tool (Jacobsen PN JAC5084). Figure 8-40 2.
Page 309: Reel Assembly
CUTTING UNITS 8. Install counterweight (3), two lock washers (2), and CAUTION screws (1). 9. Lubricate grease fitting (11) with grease that meets To prevent personal injury and damage to the or exceeds NLGI Grade 2 LB specifications. Clean cutting edges, handle the reel with extreme care. grease fitting before lubricating and apply grease to the fitting with a hand grease gun only.
Page 310: Front Roller
CUTTING UNITS Front Roller Rear Roller Removal and Installation Removal and Installation See Figure 8-44. See Figure 8-45. 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 311: Roller Bearings
CUTTING UNITS Roller Bearings Removal See Figure 8-46. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove roller. (See “Front Roller” on page 8-38 or “Rear Roller” on page 8-38.) TN2651 Figure 8-46 3. Support one end of roller tube (4), and use a suitable hammer to drive the bearing (2) and outer seal (1) out of roller tube by tapping opposite end of shaft (3).
Page 312 CUTTING UNITS 8-40 4252490-Rev A...
Page 313 Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Component Location .
Page 314: Specifications
ACCESSORIES AND MISCELLANEOUS REPAIR Specifications Mounting Bolt Torque 37 (50) lb-ft (N·m) Bracket Screw Torque 52 (71) lb-ft (N·m) Fuel System Capacity 14.2 (54) gal (L) Front Tires Size 20 x 10-10 Type 2-Ply OTR Smooth Air Pressure 10 (0.70) psi (bar) Mounting Bolt Torque 55 (75)
Page 315: Component Location
ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 9-1. TN2096 OPS (Operator Protective Structure) Floorboard Assembly Instrument Panel Cover Seat and Seat Plate Splash Shield Fuel Tank Traction Pedal Front Wheel (2) Traction Lever Tool Box Throttle Lever Park Brake Lever Work Light (2) Rear Wheel Figure 9-1: Component Location...
Page 316: Checks And Adjustments
ACCESSORIES AND MISCELLANEOUS REPAIR Checks and Adjustments Raise Hydraulic Oil/Fuel Tank See Figures 9-3 and 9-4. Rotate Seat Forward NOTE See Figure 9-2. Diesel model is shown; gasoline model is similar. 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 317: Transport Speed Stop Adjustment
ACCESSORIES AND MISCELLANEOUS REPAIR Transport Speed Stop Adjustment See Figure 9-5. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN3793 TN3799 Figure 9-4 Figure 9-5 WARNING NOTE DO NOT remove the fuel tank cap while the Adjusting transport speed stop clockwise increases hydraulic oil/fuel tank is in the raised position.
Page 318: Mow Speed Stop Adjustment
ACCESSORIES AND MISCELLANEOUS REPAIR Mow Speed Stop Adjustment Park Brake Adjustment See Figure 9-6. See Figure 9-7. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Right park brake shown; left park brake is similar. To access left park brake, remove tool box.
Page 319: Repair
ACCESSORIES AND MISCELLANEOUS REPAIR Repair Removal and Installation See Figures 9-8 and 9-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hydraulic oil/fuel tank. (See “Raise Hydraulic Oil/Fuel Tank” on page 9-4.) TN3714 Figure 9-9 10.
Page 320 ACCESSORIES AND MISCELLANEOUS REPAIR TN3825 Figure 9-10 CAUTION TN3831 Contact with diesel fuel can damage your skin. Figure 9-11 Use gloves when working with diesel fuel. If you come in contact with diesel fuel, wash skin NOTE immediately. Label all wires before disconnecting to ensure correct installation.
Page 321: Fuel Tank (Gasoline)
ACCESSORIES AND MISCELLANEOUS REPAIR 2 3 4 TN3714 Figure 9-13 14. Lower fuel tank to operating position and disconnect TN3985 fuel tank breather hose (17). Figure 9-14 15. Remove four screws (18) and flat washers (19). 4. Support fuel tank (1) using a suitable lifting device. 16.
Page 322: Fuel Tank Support Pan
ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes Required Materials Anti-Seize Compound • Apply anti-seize compound to screws (2, 7, 9, 12, and 16) prior to installation. Do not overtighten these screws or tank may crack and cause a leak. • Install fuel tank by reversing the order of removal. Fuel Tank Support Pan Removal and Installation See Figures 9-17 and 9-18.
Page 323: Traction Pedal Assembly
ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Assembly Removal and Installation See Figures 9-19 through 9-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN3845 Figure 9-18 6. Remove two nuts (6), flat washers (7), flat washers (8) and nylon bearings (9), and remove fuel tank 9 10 support pan (10).
Page 324 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly Mow Speed Stop Bracket Assembly See Figure 9-23. TN3750 Figure 9-21 9. Remove screws (18) and nuts (19). 10. Remove six screws (17). 11. Remove upper floorboard (16). TN3755 Flat Washer (2) Mow Speed Bracket Bushing Lock Nut Spring-Disc...
Page 325: Instrument Panel Cover
ACCESSORIES AND MISCELLANEOUS REPAIR Instrument Panel Cover Traction Lever Assembly Removal and Installation Removal and Installation See Figure 9-24. See Figures 9-25 and 9-26. 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 326: Throttle Lever
ACCESSORIES AND MISCELLANEOUS REPAIR Park Brake Lever 6. Remove threaded traction lever knob (6). 7. Remove two nuts (8), flat washers (9), and screws Removal and Installation (10). 8. Remove traction lever assembly (7). See Figure 9-28. 1. Park the mower safely. (See “Park Mower Safely” on Installation Note page 1-6.) Install traction lever assembly by reversing the order of...
Page 327: Seat And Seat Plate
ACCESSORIES AND MISCELLANEOUS REPAIR Seat and Seat Plate 7. Using a lifting device, remove seat and seat plate. Installation Notes Removal and Installation • Install seat and seat plate by reversing the order of See Figures 9-29 and 9-30. removal. 1.
Page 328: Seat Switch
ACCESSORIES AND MISCELLANEOUS REPAIR Seat Switch Removal and Installation Standard Seat See Figure 9-34. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN3768 Figure 9-32 2. Remove four screws (6), flat washers (7), and nuts (8), and remove seat mount (4). 3.
Page 329: Tool Box
ACCESSORIES AND MISCELLANEOUS REPAIR Tool Box Floorboard Assembly Removal and Installation Removal and Installation See Figure 9-35. See Figures 9-36 through 9-39. 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 330: Splash Shield
ACCESSORIES AND MISCELLANEOUS REPAIR Splash Shield Removal and Installation See Figure 9-40. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN3776 Figure 9-38 11. Remove nuts (12), flat washers (13), screws (14), mow speed stop bracket (11), and traction pedal bracket (15).
Page 331: Work Light
ACCESSORIES AND MISCELLANEOUS REPAIR Work Light Front Wheel Removal and Installation Removal and Installation See Figure 9-41. See Figure 9-42. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Right work light is shown; left work light is similar. 2.
Page 332: Park Brake Caliper Assembly
ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes Disassembly and Assembly See Figure 9-44. • Inspect and clean any rust from hub or wheel mounting area. • Install wheel by reversing the order of removal. • Tighten mounting bolts to 55 lb-ft (75 N·m) using an alternating pattern.
Page 333 ACCESSORIES AND MISCELLANEOUS REPAIR TN3730 TN3877 Figure 9-45 Figure 9-47 5. Remove pin (2), clip (3), and cable (1). 7. Remove nut (8), flat washer (9), and clamp (7). NOTE • Note cable routing to ensure correct installation. • Note placement of cable ties to ensure correct installation.
Page 334: Front Wheel Hub
ACCESSORIES AND MISCELLANEOUS REPAIR Front Wheel Hub Rear Wheel and Steering Axle—2WD Units (Diesel) Removal and Installation Removal and Installation See Figure 9-49. 1. Park the mower safely. (See “Park Mower Safely” on See Figures 9-50 and 9-51. page 1-6.) 1.
Page 335: Steering Axle-2Wd Units (Diesel)
ACCESSORIES AND MISCELLANEOUS REPAIR Steering Axle—2WD Units (Diesel) Disassembly and Assembly See Figure 9-52. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove rear wheel and steering axle. (See “Rear Wheel and Steering Axle—2WD Units (Diesel)” on page 9-22.) TN3803 Figure 9-51...
Page 336: Rear Wheel And Steering Axle-2Wd Units (Gasoline)
ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheel and Steering Axle—2WD Units (Gasoline) Removal and Installation See Figures 9-53 and 9-54. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN3803 Figure 9-54 4. Loosen, but do not remove, axle nuts (4). 5.
Page 337: Steering Axle-2Wd Units (Gasoline)
ACCESSORIES AND MISCELLANEOUS REPAIR Steering Axle—2WD Units (Gasoline) Rear Wheel—3WD Units Disassembly and Assembly Removal and Installation See Figure 9-55. See Figure 9-56. 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 338: Rear Wheel Hub-3Wd Units
ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes Installation Notes • • Inspect and clean any rust from hub or wheel Required Materials mounting area. Anti-Seize Compound • Install wheel by reversing the order of removal. • Tighten lug nuts to 55–63 lb-ft (75–85 N·m) using an •...
Page 339 Index Index Battery Cover Removal and Installation ....4-50 Repair ......4-50 Numerics Bedknife...
Page 340 Index Chemical Products Safe Handling ......1-9 Definition of Terms Choke Cable (Gasoline) Grass Graining ..... . 8-15 Removal and Installation .
Page 341 Index Engine Oil Pressure Light Front Reel Valve Disassembly, Inspection, and Assembly . . 6-49 Removal and Installation ....4-63 Repair ......4-63 Removal and Installation .
Page 342 Index Hydraulic Oil Cooler (Gasoline) Removal and Installation ....6-61 Repair ......6-61 Gasoline Engine Circuit Schematic .
Page 343 Index Instrument Panel Lift Relief Valve Pressure Test Instrument Test Procedures ... . 6-41 Removal and Installation ....4-52 Repair .
Page 344 Index Mow Switch Preliminary Checks Field Test Procedures ... . . 5-34, 6-28 Test ....... 4-43 Mow/Transport Switch Prepare for the Job Adjustment .
Page 345 Index Rear Wheel and Steering Axle—2WD Units (Gasoline) Removal and Installation ....9-24 Repair ......9-24 Rear Wheel Hub—3WD Units Removal and Installation .
Page 346 Index Repair Hydraulic Oil Tank (Gasoline) ... 6-58 Hydraulics ......6-42 12V Accessory Socket .
Page 347 Index Throttle Cable (Diesel) ....3-9 Throttle Cable (Gasoline) ....3-20 Throttle Lever .
Page 348 Index Soft Drop Valve Steering Column Covers Removal and Installation ....7-4 Removal and Installation ....6-50 Repair .
Page 349 Index Throttle Cable (Gasoline) Removal and Installation ....3-20 Repair ......3-20 Test Backlap Switch .
Page 350 Index Traction System Test Field Test Procedures ....5-34 Instrument Test Procedures ... . . 5-37 Transport Speed Stop Adjustment Checks and Adjustments .
Page 352 A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. When Performance Matters. ™ Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

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Textron JACOBSEN GP400 Technical/Repair Manual

Chapter 1 Safety 1

Chapter 2 Specifications and General Information

Chapter 3 Engine

Chapter 4 Electrical

Chapter 5 Hydrostatic Power Train

Chapter 6 Hydraulics

Chapter 7 Steering

Chapter 8 Cutting Units

Chapter 9 Accessories and Miscellaneous Repair

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