Page 1 AR-3/TR-3 Trim Mowers Technical/Repair Manual AR30001, AR30002, TR30001, TR30002...
Page 4 ® WARNING Jacobsen AR-3 and TR-3™ trim mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user chemicals known to the State of California to...
Page 5 FOREWORD How to Use This Manual Warnings and Cautions Warning and Caution indicators are located throughout This manual is designed to provide multiple ways to the manual at specific points of interest. These notices locate and access repair information. are given to prevent personal injury, death and/or Read each section in entirety before beginning a equipment damage.
Page 6: Table Of Contents
Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Unit Accessories and Miscellaneous Repair...
Page 8 Chapter 1 Safety Introduction ..............1-3 Prepare for the Job .
Page 9 SAFETY Page Intentionally Blank 4181384 First Edition...
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 TN0991, TN0992 Figure 1-1: AR-3 shown, TR-3 is similar 4181384 First Edition...
Page 12 ( O r d e r 5 0 0 3 1 0 3 f o r 5 g a l . p a i l ) personas no capacitadas para ello usen la JACOBSEN TEXTRON - CHARLOTTE, NC maquina. Mantener los protectores en su lugar y sus U s e o f 1 0 W 3 0 i s a n a p p r o v e d tornillos debidamente fijados.
Page 13: Safety Labels Ec
SAFETY Safety Labels EC 4153197 1. Read Operator’s Manual 7. Do Not Remove Safety Shields While Engine is Running. 2. Keep a Safe Distance from the Machine 8. Danger of Explosion if the Battery Terminals are 3. Stay Clear of Hot Surfaces Short Circuited.
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 Safety 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 SAFETY 1-12 4181384 First Edition...
Page 20 AR-3 ........
Page 21 SPECIFICATIONS AND GENERAL INFORMATION Mower Identification Model Identification Number See Figure 2-1. AR-3 30001 and 30002 Trim and Fine-Cut Mower (72 in. [1.83 m] cutting width) with three rotary cutting units, 32.8 hp (24.5 kW), ® 3-cylinder, turbocharged diesel engine (Kubota ), and hydrostatic transmission.
Page 22 SPECIFICATIONS AND GENERAL INFORMATION Component Location If the machine requiring service is equipped with an accessory kit, see Section 9, “Accessories and Miscellaneous Repair” for removal, repair, and AR-3 installation procedures. See Figures 2-3 and 2-4. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures.
Page 23 SPECIFICATIONS AND GENERAL INFORMATION TN0992 Foot Support Left Front Wheel Motor Hood Front Wheel (2) Rear Wheel Motor Fuel Tank Rear (Center) Cutting Unit Figure 2-4: Component Location—Left Side 4181384 First Edition...
Page 24 SPECIFICATIONS AND GENERAL INFORMATION TR-3 See Figures 2-5 and 2-6. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0988 Canopy (Optional) Right Front Cutting Unit OPS (Optional) Right Front Wheel Motor Seat Front Wheel (2) Steering Wheel and Tower Hydraulic Oil Tank...
Page 25 SPECIFICATIONS AND GENERAL INFORMATION TN0989 Foot Support Left Front Wheel Motor Hood Front Wheel (2) Rear Wheel Motor Fuel Tank Rear (Center) Cutting Unit Figure 2-6: Component Location—Left Side 4181384 First Edition...
Page 26 SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Electrical Test Specifications Resistance Across Solenoid Coil— 10.43 ± 10% ohms 12-Volt Solenoid Coils @ 68°F Resistance Across Solenoid Coil— 41.74 ± 10% ohms 24-Volt Solenoid Coils @ 68°F Fuel Shutoff Solenoid Resistance 15.58 ohms between Terminal 1 and Ground...
Page 27 Rear Wheel Motor—End Cover Screw 55—59 (75—80) lb-ft (N·m) Torque Hydraulics Test and Adjustment Specifications Mow/Brake Relief Valve Pressure 3046 (210) psi (bar) Setting—30001 AR-3 Mow/Brake Relief Valve Pressure 3626 (250) psi (bar) Setting—30002 AR-3 Mow/Brake Relief Valve Pressure 3046 (210) psi (bar) Setting—TR-3 Lift/Steer Pump Flow Rate @ 3150 rpm 2.6 gpm (9.8 L/min) at 3150 rpm...
Page 28 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Tandem Pump—End Cap-to-Pump 32—36 (43—49) lb-ft (N·m) Body Screw Torque Lift Valve—Solenoid Coil Torque 3 (4) lb-ft (N·m) Lift Valve—Relief Valve Torque 37 (50) lb-ft (N·m) Lift Valve—Check Valve Torque 30 (40) lb-ft (N·m) Lift Valve—Orifice Plug Torque 2 (3) lb-ft (N·m)
Page 29 SPECIFICATIONS AND GENERAL INFORMATION Cutting Units Repair Specifications—AR-3 Deck Drive Motor Housing-to-Front 37 (50) lb-ft (N·m) Cover Screw Torque Cutter Blade Retaining Screw 70 (95) lb-ft (N·m) Torque Accessories and Miscellaneous Fuel Tank Capacity 6.6 (25) gal (L) M10 Mounting Hardware Torque 34 (46) lb-ft (N·m)
Page 30 SPECIFICATIONS AND GENERAL INFORMATION General Specifications Naturally-Aspirated Engine ® Manufacturer/Model Kubota /D1105-E Engine Type 4-stroke, overhead valve, diesel Fuel Requirement No. 2-D diesel fuel (ASTM D975) Number of Cylinders/Configuration 3, in-line Displacement 68.53 (1123) cu in. (cc) Bore x Stroke 3.07 x 3.09 (78 x 78.4) in.
Page 31 SPECIFICATIONS AND GENERAL INFORMATION Weights and Dimensions—AR-3 Overall Weight 2293 (1040) lb (kg) Width of Cut 72 (1.83) in. (m) Overall Width 79 (2.00) in. (m) Overall Height 52.7 (1.34) in. (m) Overall Length 123 (3.12) in. (m) Weights and Dimensions—TR-3...
Page 32 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 33 SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-14 4181384 First Edition...
Page 34 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .
Page 35: Specifications
ENGINE Specifications General Engine Specifications Naturally Aspirated Engine Manufacturer/Model Kubota/D1105-E Engine Type 4-Stroke, Overhead Valve, Diesel Fuel Requirement No. 2-D Diesel Fuel (ASTM D975) Number of Cylinders/Configuration 3, In-Line Displacement 68.53 (1123) cu in. (cc) Bore x Stroke 3.07 x 3.09 (78 x 78.4) in.
Page 36: Repair Specifications
ENGINE Repair Specifications Specifications Nylon Pump Coupler Flange, N·m 55 (75) lb-ft ( Socket-Head Screw Torque 4181384 First Edition...
Page 37: Component Location
ENGINE Component Location Kubota D1105-E See Figures 3-1 and 3-2. TN1034, TN1082 Radiator/Hydraulic Oil Cooler Muffler and Shield Thermostat Alternator Oil Filler Cap Fan Drive Belt Exhaust Manifold Oil Pressure Sending Unit Starter Motor Coolant Drain Valve Exhaust Down Pipe Figure 3-1: Component Location—Right Side 4181384 First Edition...
Page 38 ENGINE TN1033, TN1106 Fuel Filter Fan Drive Belt Air Cleaner Assembly Air Restriction Indicator Air Intake Hose Throttle Cable Coolant Overflow Tank In-Line Fuel Filter Coolant Filler/Pressure Cap Fuel Pump Radiator/Hydraulic Oil Cooler Engine Temperature Switch Figure 3-2: Component Location—Left Side 4181384 First Edition...
Page 39: Kubota D1105-T
ENGINE Kubota D1105-T See Figures 3-3 and 3-4. TN1036, TN1083 Radiator/Hydraulic Oil Cooler Exhaust Down Pipe Fan Drive Belt Exhaust Manifold Thermostat Muffler and Shield Oil Filler Cap Alternator Turbocharger Oil Pressure Sending Unit Starter Motor Coolant Drain Valve Figure 3-3: Component Location—Right Side 4181384 First Edition...
Page 40 ENGINE TN1035, TN1107 Fuel Filter Fan Drive Belt Air Cleaner Assembly Air Restriction Indicator Air Intake Hose Throttle Cable Coolant Overflow Tank Fuel Pump Coolant Filler/Pressure Cap In-Line Fuel Filter Radiator/Hydraulic Oil Cooler Engine Temperature Switch Figure 3-4: Component Location—Left Side 4181384 First Edition...
Page 41: Repair
ENGINE Repair Fan Belt Removal and Installation See Figures 3-5 and 3-6. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Disconnect the battery negative (–) cables at the battery. 3. Raise the hood. TN1113 Figure 3-6 5.
Page 42: Muffler
ENGINE Muffler Removal and Installation See Figures 3-9 through 3-13. CAUTION Engine components will become hot during operation. Allow engine components to cool before performing service. Failure to follow safety recommendations may result in injury. NOTE Turbocharged engine shown; naturally aspirated engine is similar.
Page 43 ENGINE TN1016 Figure 3-12 8. Remove gasket (17) from down pipe (16). 20 21 22 TN1013 Figure 3-10 4. Remove four lock nuts (6), lock washers (7), screws (8), and eight flat washers (9) from muffler (5) and down pipe (10). TN1014 TN1015 Figure 3-11...
Page 44: Exhaust Manifold-Naturally Aspirated Engine
ENGINE Exhaust Manifold—Naturally Aspirated Engine Removal and Installation 13 14 See Figures 3-14 through 3-16. CAUTION Engine components will become hot during operation. Allow engine components to cool before performing service. Failure to follow safety recommendations may result in injury. 1.
Page 45: Exhaust Manifold And Turbocharger
ENGINE Exhaust Manifold and Turbocharger Removal and Installation See Figures 3-17 through 3-20. CAUTION Engine components will become hot during operation. Allow engine components to cool before performing service. Failure to follow safety recommendations may result in injury. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2.
Page 46: Radiator/Hydraulic Oil Cooler
ENGINE 22 23 TN1167 Figure 3-20 10. Support the exhaust manifold/turbocharger assembly (21). TN1192 11. Remove six nuts (22) and lock washers (23), and Figure 3-21 remove exhaust manifold/turbocharger assembly (21) and gasket (24). NOTE Installation Notes Label all hoses before removing to ensure correct installation.
Page 47 ENGINE 9 10 11 9 10 11 TN1191 Figure 3-22 8. Loosen hose clamp (13), and disconnect overflow hose (12) from radiator/hydraulic oil cooler (14). 9. Loosen hose clamp (15), and disconnect hose (19) from radiator/hydraulic oil cooler (14). 10. Remove two screws (9), lock washers (10), and flat washers (11), and remove the overflow tank assembly (7) from radiator/hydraulic oil cooler (14).
Page 48 ENGINE TN1190 Figure 3-24 21. Remove RTV sealant from all seams and joints. Installation Notes 22. Remove three screws (39), lock washers (40), and Required Materials flat washers (41), and remove top flange (42) from radiator/hydraulic oil cooler (43). RTV Sealant 23.
Page 49: Thermostat
ENGINE Thermostat Removal and Installation See Figures 3-25 and 3-26. NOTE Naturally aspirated engine shown; turbocharged engine is similar. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Raise the hood. WARNING Engine coolant is hot and under pressure! Allow the cooling system to cool completely before performing service.
Page 50: Throttle Cable And Control Lever
ENGINE Throttle Cable and Control Lever NOTE Record the location of the spring washers before Removal and Installation removing to ensure correct installation. See Figures 3-27 through 3-31. 5. Remove screw (5), two spring washers (6), and NOTE throttle clamp (7) from throttle cable (4) and lever (3). 6.
Page 51: Fuel Pump-Naturally Aspirated Engine
ENGINE Fuel Pump—Naturally Aspirated 8. Press in on the tabs (12) on both sides of the throttle cable anchor block, and pull block out of throttle Engine control lever assembly (13). 9. Angle the throttle cable (5) up, and disconnect the Removal and Installation end of the cable from throttle control lever assembly See Figure 3-32.
Page 52: Fuel Pump-Turbocharged Engine
ENGINE Fuel Pump—Turbocharged Engine Engine Removal and Installation Removal and Installation See Figure 3-33. See Figures 3-34 through 3-42. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) page 1-7.) 2.
Page 53 ENGINE TN1203 TN1201 Figure 3-38 Figure 3-36 12. Remove flanged nut (17), and disconnect wire (16) 6. Remove starter motor (6). (See “Starter Motor” on from glow plug strip (18). page 4-75.) NOTE 7. Remove screw (7), lock washer (8), and flat washer (9), and remove ground strap (10) from engine block.
Page 54 ENGINE 15. Remove two screws (26), lock washers (27), flat washers (28), and washers or spacers (29). 16. Move fuse bracket (25) aside. 17. Remove radiator/hydraulic oil cooler. (See “Radiator/Hydraulic Oil Cooler” on page 3-13.) 18. Remove muffler and down pipe. (See “Muffler” on page 3-9.) WARNING The engine weighs approximately 214 lb (97 kg).
Page 55 ENGINE TN1205 Figure 3-41 22. Remove four screws (42) and lock washers (41), and remove fan (40) and spacer (39) from engine (38). 23. Remove two lock nuts (49), flat washers (36 and 48), and screws (35) from engine mounts (37 and 43). 24.
Page 56 ENGINE TN1206 Figure 3-42 31. Remove screw (54), lock washer (55), and flat NOTE washer (56). Perform steps 26 through 32 if the engine is to be 32. Remove screw (58), lock washer (59), and flat serviced or replaced. washer (60), and remove throttle cable bracket (57). 26.
Page 57: Engine Service
ENGINE Engine Service A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine related service. Proper attention to the engine manufacturer’s directions will ensure maximum service life of the engine. 3-24 4181384 First Edition...
Page 58 Chapter 4 Electrical Specifications ..............4-4 Test and Adjustment Specifications .
Page 59 ELECTRICAL Troubleshooting ............. . 4-50 Power Circuit .
Page 60 ELECTRICAL Repair ..............4-72 Battery and Battery Tray .
Page 61: Specifications
ELECTRICAL Specifications Test and Adjustment Specifications Specifications Resistance Across Solenoid Coil—12-Volt 10.43 ±10% ohms Solenoid Coils at 68°F Resistance Across Solenoid Coil—24-Volt 41.74 ±10% ohms Solenoid Coils at 68°F Fuel Shutoff Solenoid Resistance 15.58 ohms Between Terminal 1 and Ground Fuel Shutoff Solenoid Resistance 0.375 ohms...
Page 62: Fuse Identification
ELECTRICAL Fuse Identification See Figure 4-1. Fuse Box 2 Fuse Box 1 TN1149 Figure 4-1 • F1— 5A Fuse, Accessory Socket 2 • F2—15A Fuse, Accessory Socket 1 • F3—10A Fuse, Work Lights • F4—5A Fuse, Park Brake solenoid • F5—2A Fuse, Multi-Function Gauge •...
Page 63: 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) 1 The sample switch symbols shown are just a few of the many switch configurations.
Page 64 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 Lights Single-Element Light Dual-Element Light 4181384 First Edition...
Page 65 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 4181384 First Edition...
Page 66: Electrical Schematic Component Identification
ELECTRICAL Electrical Schematic Component Identification Electrical components shown in the main schematic are identified with an alpha-numeric callout. All electrical components shown in the electrical schematic are listed below. • A1—Control Module (See Figure 4-4.) • K2—Glow Plug Relay (See Figure 4-2.) •...
Page 67: Electrical Schematic
ELECTRICAL Electrical Schematic See Figures 4-2 through 4-7. Brn/Wht Brn/Wht Blk/Brn Blk/Brn Fuse Switch Heat Start Wht/ Fuse Wht/Red Wht/ Brn/Red Brn/Red Brn/Red Brn/Red Brn/Wht 7.5A Fuse Brn/ Brn/ Wht/ Blk/ Fuse Glow Plug Relay Start Relay Brn/ Brn/ Fuel Brn/ Pump Wht/...
Page 68 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Blk/Brn Blk/Brn Blk/Brn Grn/Blk Grn/Blk Lt Grn/Brn Lt Grn/Brn Fuse Grn/Org Brake Grn/Brn Backlap Release Yel/Blu Switch Safety (Model TR-3) Switch Lever Released Lever Backlap Engaged Lt Grn/Red Lt Grn/Brn Lt Grn/Brn Grn/Org Seat Lt Grn/Red Lt Grn/Red Switch Grn/Blk...
Page 69 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Blk/Brn Blk/Brn Grn/Blk Grn/Blk Grn/Blk Lt Grn/Brn Lt Grn/Brn Grn/Pnk Grn/Org Grn/Org Grn/Vio Grn/Brn Grn/Brn Yel/Blu Yel/Blu Grn/ Fuse Grn/Pnk Grn/ Grn/ Fuse Fuse Power Grn/ Grn/ Grn/ Yel/Vio Control Blk/Brn (12) 12V Start Relay Output Module Grn/Blk (2) 5 Volt Power Supply...
Page 70 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Grn/Blk Grn/Blk Grn/Pnk Grn/Pnk Grn/Pnk Grn/Vio Weight Transfer Switch Yel/Red Yel/Red Yel/Vio Yel/Vio Yel/Org Yel/Org Grn/Vio (10) Grn/Red Yel/ Yel/ Grn/Vio Raise/Lower Switch Weight Raise Transfer Solenoid Lower Red/Blk Red/Blk (2) (1) Grn/Blk Weight Transfer (4) Grn/Blk Org/Blk Org/Blk (5) Solenoid...
Page 71 ELECTRICAL Brn/Wht Brn/Wht Grn/Pnk Grn/Pnk Alternator Light Brn/ Setup Multi-Function Switch Gauge Grn/ Grn/ Brn/Wht (8) Battery Discharge Input Engine Hydraulic Grn (2) Switched Power Filter Brn/Yel (7) Pressure Hour Meter Enable Light Gry/Red Gry/Red (6) Light Setup Enable Wht/ Yel/ Blk/Wht (1) Fuel Level Input...
Page 72 ELECTRICAL Work Lights Switch Fuse Fuse Fuse Grn/ Grn/Wht Blu/Wht Blu/Wht Blu/ Accessory Accessory Socket 1 Socket 2 Blu/ Blu/Wht Blu/Wht Work Work Light Light TN1042 Figure 4-7 4181384 First Edition 4-15...
Page 73 ELECTRICAL Page Intentionally Blank 4-16 4181384 First Edition...
Page 74: Theory Of Operation And Sub Circuit Schematics
ELECTRICAL Theory of Operation and Sub 5-Volt Power Circuit Circuit Schematics With the control module powered up, the control module now provides 5 volts to the following components: • Seat switch Power Circuit—Theory of Operation • Mow switch Unswitched Power Circuit •...
Page 75: Power Circuit Schematic
ELECTRICAL Power Circuit Schematic See Figures 4-8 through 4-13. Brn/Wht Brn/Wht Blk/Brn Blk/Brn Fuse Switch Heat Start Wht/ Fuse Wht/Red Wht/ Brn/Red Brn/Red Brn/Red Brn/Red Brn/Wht 7.5A Fuse Brn/ Brn/ Wht/ Blk/ Fuse Glow Plug Relay Start Relay Brn/ Brn/ Fuel Brn/ Pump...
Page 76 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Blk/Brn Blk/Brn Blk/Brn Grn/Blk Grn/Blk Lt Grn/Brn Lt Grn/Brn Grn/Org Fuse Brake Grn/Brn Backlap Release Yel/Blu Switch Safety (Model TR-3) Switch Lever Released Lever Backlap Engaged Lt Grn/Red Lt Grn/Brn Lt Grn/Brn Grn/Org Seat Lt Grn/Red Lt Grn/Red Switch Grn/Blk...
Page 77 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Blk/Brn Blk/Brn Grn/Blk Grn/Blk Grn/Blk Lt Grn/Brn Lt Grn/Brn Grn/Pnk Grn/Vio Grn/Org Grn/Org Grn/Brn Grn/Brn Yel/Blu Yel/Blu Grn/ Fuse Grn/Pnk Grn/ Grn/ Fuse Fuse Power Grn/ Grn/ Grn/ Yel/Vio Control Blk/Brn (12) 12V Start Relay Output Module Grn/Blk (2) 5 Volt Power Supply...
Page 78 ELECTRICAL Brn/Wht Brn/Wht Brn/Wht Grn/Blk Grn/Blk Grn/Pnk Grn/Pnk Grn/Pnk Grn/Vio Weight Transfer Switch Yel/Red Yel/Red Yel/Vio Yel/Vio Yel/Org Yel/Org Grn/Vio (10) Grn/Red Yel/ Yel/ Grn/Vio Raise/Lower Switch Weight Raise Transfer Solenoid Lower Red/Blk Red/Blk (2) (1) Grn/Blk Weight (4) Grn/Blk Transfer Org/Blk Org/Blk (5)
Page 79 ELECTRICAL Brn/Wht Brn/Wht Grn/Pnk Grn/Pnk Alternator Light Setup Multi-Function Brn/ Switch Gauge Grn/ Grn/ Brn/Wht (8) Battery Discharge Input Engine Hydraulic Grn (2) Switched Power Filter Brn/Yel (7) Pressure Hour Meter Enable Light Gry/Red Gry/Red (6) Light Setup Enable Wht/ Yel/ Blk/Wht (1) Fuel Level Input...
Page 80 ELECTRICAL Work Lights Switch Fuse Fuse Fuse Grn/ Grn/Wht Blu/Wht Blu/Wht Accessory Accessory Blu/ Socket 1 Socket 2 Blu/ Blu/Wht Blu/Wht Work Work Light Light Ground Circuit Unswitched Power Circuit Switched Power Circuit TN1139 Figure 4-13 4181384 First Edition 4-23...
Page 81: Charging Circuit-Theory Of Operation
ELECTRICAL Charging Circuit—Theory of Operation With the engine running and the key switch in the run position, current flows from key switch terminal AC through 7.5-amp fuse F7 to the alternator field terminal, exciting the alternator. With the alternator field terminal excited, the alternator produces three-phase alternating current (AC).
Page 82: Charging Circuit Schematic
ELECTRICAL Charging Circuit Schematic See Figure 4-14. Brn/Wht Brn/Wht Fuse Switch Heat Fuse Start Multi-Function Gauge Alternator Brn/Wht (8) Light Battery Discharge input Grn (2) Switched Power Setup Enable Brn/ Fuel Level Input Brn/Yel (7) 7.5A Hour Meter Enable Fuse Brn/ Ground Brn/Yel...
Page 83: Glow Plug Circuit-Theory Of Operation
ELECTRICAL Glow Plug Circuit—Theory of Operation When the key switch is turned and held in the glow position, voltage is available from key switch terminal 19 to glow plug wait light H1. Current also flows from key switch terminal 19 to glow plug timer terminal 4, turning on the timer.
Page 84: Glow Plug Circuit Schematic
ELECTRICAL Glow Plug Circuit Schematic See Figure Page Intentionally Blank. Switch Heat Start Brn/Red Brn/Red Brn/Red Brn/Red Brn/Wht Brn/ Brn/ Fuse Glow Plug Relay Brn/ Brn/ Glow Brn/Red Plug Timer Brn/ Glow Plugs Glow Plug Wait Light Battery Brn/ Starter Motor Glow Plug Circuit Ground Circuit...
Page 85 ELECTRICAL Page Intentionally Blank 4-28 4181384 First Edition...
Page 86: Start Circuit-Theory Of Operation
ELECTRICAL Start Circuit—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30 and 40-amp fuse F12. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 87 ELECTRICAL Start Circuit With the start relay energized and when the key switch is turned to the start position, current flows from key switch terminal 50 to the starter motor solenoid, energizing the solenoid. To energize the starter solenoid, current flows from key switch terminal 50 to the following components: •...
Page 88: Start Circuit Schematic
ELECTRICAL Start Circuit Schematic See Figures 4-16 and 4-17. Switch Heat Start Wht/ Blk/Brn Blk/Brn Fuse Wht/Red Wht/ Brn/Red Brn/Red Brn/Red Brn/Red Brn/Wht Brn/ Brn/ Wht/ Blk/ Fuse Glow Plug Relay Start Relay Brn/ Brn/ Wht/ Glow Brn/Red Plug Wht/ Timer Wht Yel Wht Yel...
Page 89 ELECTRICAL Grn/Blk Grn/Blk Seat Switch Fuse Blk/Brn Grn/ Grn/ Grn/Blk (10) Grn/Blk Grn/ Fuse Power Grn/ Blk/Brn (12) Park 12V Start Relay Output Brake (2) Grn/Blk 5 Volt Power Supply Switch (17) Grn/Brn 5V Seat Sw Input Brake (16) Grn/Gry 5V Park Brake Sw Input Released Brake...
Page 90: Run Circuit-Theory Of Operation
ELECTRICAL Run Circuit—Theory of Operation Brake Release Safety Switch When the park brake release valve lever is placed in the Power Circuit released position, the brake release safety switch contacts open. With the switch contacts open, current is Unswitched power is available to key switch terminal 30. prevented from flowing to the hold-in side of the fuel When the key switch is turned to the run position, current shutoff solenoid, de-energizing the solenoid.
Page 91: Run Circuit Schematic-On Seat
ELECTRICAL Run Circuit Schematic—On Seat See Figure 4-18. Switch Grn/Blk Grn/Blk Grn/Blk Heat Start Grn/ Seat Switch Fuse (10) Grn/ Grn/ Grn/ Fuse Grn/ Power Grn/ (10) Park Brake 12V Fuel Shutoff Output Brake (2) Grn/Blk Release 5 Volt Power Supply Lt Grn/ Switch Safety...
Page 92: Run Circuit Schematic-Off Seat
ELECTRICAL Run Circuit Schematic—Off Seat See Figure 4-19. Switch Grn/Blk Grn/Blk Grn/Blk Heat Start Grn/ Seat Switch Fuse (10) Grn/ Grn/ Grn/ Fuse Grn/ Power Grn/ (10) Park Brake 12V Fuel Shutoff Output Brake (2) Grn/Blk Release 5 Volt Power Supply Lt Grn/ Switch Safety...
Page 93: Raise/Lower Circuit-Theory Of Operation
ELECTRICAL Raise/Lower Circuit—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 94: Raise/Lower Circuit Schematic
ELECTRICAL Raise/Lower Circuit Schematic See Figure 4-20. Weight Transfer Switch Heat Switch Start Yel/Red Yel/Vio Yel/Org Grn/Vio (10) Grn/Red Yel/ Yel/ Grn/Vio Fuse Weight Grn/ Transfer Solenoid Grn/ Grn/ Weight Transfer Solenoid Raise/Lower Power Switch Raise (13) Yel/Vio 12V Lower Sol Output Lower (14) Red/Blk...
Page 95: Mow Circuit-Theory Of Operation
ELECTRICAL Mow Circuit—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 96: Mow Circuit Schematic
ELECTRICAL Mow Circuit Schematic See Figure 4-21. Switch Heat Start Fuse Grn/ Grn/ Grn/ Fuse Power Grn/Blk (2) 5 Volt Power Supply Yel/Blu (4) 5V Mow Sw Input (5) Yel/Pnk 12V Mow Sol Output Control Module Switch Ground Yel/ Grn/Blk Yel/Blu Yel/ Gry/Yel...
Page 97: Park Brake Circuit-Theory Of Operation
ELECTRICAL Park Brake Circuit—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 98: Park Brake Circuit Schematic-Brake Released
ELECTRICAL Park Brake Circuit Schematic—Brake Released See Figure 4-22. Switch Grn/Blk Grn/Blk Heat Start Fuse Fuse Grn/ Grn/ Grn/ Fuse Power Grn/ (2) Grn/Blk 5 Volt Power Supply Brake Solenoid (16) Grn/Gry 5V Park Brake Sw Input Blu/ Park Brake Control Switch Module...
Page 99: Park Brake Circuit Schematic-Brake Locked
ELECTRICAL Park Brake Circuit Schematic—Brake Locked See Figure 4-23. Switch Grn/Blk Grn/Blk Heat Start Fuse Fuse Grn/ Grn/ Grn/ Fuse Power Grn/ (2) Grn/Blk 5 Volt Power Supply Brake Solenoid (16) Grn/Gry 5V Park Brake Sw Input Blu/ Park Brake Control Switch Module...
Page 100: Backlap Circuit Operation (Model Tr-3)-Theory Of Operation
ELECTRICAL Backlap Circuit Operation (Model TR-3)—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 101: Backlap Circuit Schematic (Model Tr-3)
ELECTRICAL Backlap Circuit Schematic (Model TR-3) See Figure 4-24. Switch Backlap Heat Switch Start Fuse Backlap Grn/ Grn/ Lt Grn/ Grn/ Grn/ Fuse Power Grn/Org (11) 12V Backlap Sw Input Lt Grn/Brn Lt Grn/Brn (10) 12V Fuel Shutoff Output Grn/Blk (2) 5 Volt Power Supply Yel/Blu (4) 5V Mow Sw Input...
Page 102: Weight Transfer Circuit-Theory Of Operation
ELECTRICAL Weight Transfer Circuit—Theory of Operation Power Circuit Unswitched power is available to key switch terminal 30. When the key switch is turned to the run position, current flows from the AC terminal of the key switch through 10-amp fuse F10 to control module terminals 3 and 8, powering up the module.
Page 103: Weight Transfer Circuit Schematic
ELECTRICAL Weight Transfer Circuit Schematic See Figure 4-25. Weight Transfer Switch Heat Switch Start Yel/Red Yel/Vio Yel/Org Grn/Vio (10) Grn/Red Yel/ Yel/ Grn/Vio Fuse Weight Transfer Grn/ Solenoid Grn/ Grn/ Weight Transfer Solenoid Raise/Lower Power Switch Raise (13) Yel/Vio 12V Lower Sol Output Lower (14) Red/Blk...
Page 104: Instrumentation Circuit-Theory Of Operation
ELECTRICAL Instrumentation Circuit—Theory of Multi-Function Gauge Operation Fuel Level Sender Input The float attached to the fuel level sender moves as the Power Circuit fuel level changes to various levels. The resistance of the Unswitched power is available to key switch terminal 30 fuel level sender changes in relationship to the position of and to multi-function gauge terminal (8) through 2-amp the float.
Page 105: Instrumentation Circuit Schematic
ELECTRICAL Instrumentation Circuit Schematic See Figure 4-26. Switch Setup Heat Fuse Start Switch Fuse Multi-Function Gauge Gry/Red Brn/Wht (8) Battery Discharge Input Fuse Grn/Pnk Grn (2) Switched Power Brn/Yel (7) To Alternator Hour Meter Enable Grn/ Grn/ Gry/Red (6) Setup Enable Blk/Wht (1) Fuel Level Input Engine...
Page 106: Work Lights Circuit-Theory Of Operation
ELECTRICAL Work Lights Circuit—Theory of Operation When the key switch is turned to the run position, voltage is available to work lights switch through 10-amp fuse F3. When the work lights switch is placed in the on, position current flows from the switch to the work lights, turning on the lights.
Page 107: Troubleshooting
ELECTRICAL Troubleshooting Power Circuit Symptom: No power to cab connector. Probable Cause Remedy Open fuse 40A fuse F11. Test fuse. (See “Fuse Test” on page 4-61.) Symptom: No power to accessory socket. Probable Cause Remedy Open fuse 15A fuse F2. Test fuse.
Page 108: Charging Circuit
ELECTRICAL Charging Circuit Symptom: Battery not charging. Probable Cause Remedy Faulty alternator output circuit. Make sure alternator output cable and battery positive (+) cable terminals are clean and tight. Check continuity between starter battery terminal and battery positive (+) terminal. Continuity must be indicated.
Page 109: Glow Plug Circuit
ELECTRICAL Glow Plug Circuit Symptom: Glow plugs do not get hot. Probable Cause Remedy Faulty power circuit. Measure voltage between 40A fuse F12 brn wire terminal and ground. Voltage must be approximately 12 VDC. Open 40A fuse F12. Test fuse. (See “Fuse Test” on page 4-61.) Faulty glow plug relay power circuit.
Page 110: Start Circuit
ELECTRICAL Start Circuit Symptom: Starter motor solenoid does not engage. Probable Cause Remedy Park brake switch in the released position. Place the park brake switch in the locked position. Neutral switch is in the pedal engaged Move drive pedals to the neutral position. position.
Page 111: Run Circuit
ELECTRICAL Run Circuit Symptom: Starter motor solenoid engages, but engine does not run. Probable Cause Remedy Brake release safety lever is in the Place the brake release lever in the engaged position. released position. Faulty brake release safety switch. Test switch. (See “Brake Safety Switch Test” on page 4-64.) Faulty 12V fuel solenoid output circuit.
Page 112: Raise/Lower Circuit
ELECTRICAL Raise/Lower Circuit Symptom: Lower solenoid does not energize. Probable Cause Remedy Faulty raise/lower switch. Test switch. (See “Joystick Test” on page 4-64.) Faulty weight transfer switch Test switch. (See “Rocker Switch Test” on page 4-66.) Faulty lower solenoid. Test solenoid. (See “Solenoid Test” on page 4-68.) Faulty raise/lower switch 5V power supply Measure voltage between raise/lower switch terminal 4 and ground.
Page 113: Mow Circuit
ELECTRICAL Mow Circuit Symptom: Mow solenoid does not energize. Probable Cause Remedy Raise/lower switch was not momentarily Momentarily place the raise/lower switch in the lower position to activate the cutting units. placed in the lower position. Faulty mow switch. Test switch. (See “Rocker Switch Test” on page 4-66.) Faulty mow solenoid.
Page 114: Weight Transfer Circuit
ELECTRICAL Weight Transfer Circuit Symptom: Weight transfer solenoids do not energize. Probable Cause Remedy Raise/lower switch was not momentarily Momentarily place the raise/lower switch in the lower position. placed in the lower position. Faulty weight transfer switch. Test switch. (See “Rocker Switch Test” on page 4-66.) Faulty weight transfer solenoids.
Page 115 ELECTRICAL Symptom: Hydraulic filter light is on with the key switch in the run position (engine off). Probable Cause Remedy Faulty hydraulic filter switch. Replace hydraulic filter switch. Symptom: Hydraulic filter light is on with the key switch in the run position (engine on). Probable Cause Remedy Blocked hydraulic filter.
Page 116: Work Lights Circuit
ELECTRICAL Symptom: Multi-function gauge does not display fuel level. Probable Cause Remedy Faulty fuel level sensor. Disconnect the multi-function gauge connector. With the fuel level sensor still installed in the machine, measure the resistance between the fuel level sensor terminals. If the resistance measured is not in the range of 4 to 80 ohms, bench test the sensor.
Page 117: General Information
ELECTRICAL Component Testing 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. General Information Resistance Test Repair of the electrical system, for the most part, is limited to the replacement of defective components or Required Tools or Equipment wiring.
Page 118: Fuse Test
ELECTRICAL Fuse Test Plug-In Fuses See Figure 4-28. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove fuse from fuse holder. (See “Plug-In Fuses” on page 4-77.) TN1109 Figure 4-29 4.
Page 119: Relay Tests
ELECTRICAL Relay Tests Glow Plug Relay See Figure 4-32. Start Relay See Figure 4-31. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Required Tools or Equipment 12-Volt DC Power Source and Leads Digital Multimeter, Ohmmeter, or Continuity Tester 12-Volt DC Power Source and Leads 1.
Page 120: Key Switch Test
ELECTRICAL Key Switch Test 9. Move the test lead to terminal (1). Is continuity indicated? See Figure 4-33. The switch is faulty; replace the switch. Required Tools or Equipment Proceed to step 10. 10. Move the test lead to terminal (2). Digital Multimeter, Ohmmeter, or Continuity Tester Is continuity indicated? 1.
Page 121: Brake Safety Switch Test
ELECTRICAL Brake Safety Switch Test See Figure 4-34. Lower Raise Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on Lower page 1-7.) Raise Switch 2. Remove the brake safety switch from the machine. Switch (See “Brake Safety Switch”...
Page 122: Traction Pedal Neutral Switch Test
ELECTRICAL 7. With the test leads connected as described in step 6, 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) move and hold the joystick in the raise position. 2. Remove the seat switch from the seat cushion. (See Is continuity indicated? “Seat and Mounting Plate”...
Page 123: Rocker Switch Test
ELECTRICAL Rocker Switch Test 3. Place the switch in the off position. See Figures 4-38 and 4-39. NOTE Use the alignment pin (8) as a reference point for correct orientation. 4. Connect one test lead to terminal (10). 5. Connect the other test lead to terminal (11) and check for continuity.
Page 124: Park Brake Switch Test
ELECTRICAL Park Brake Switch Test 9. Connect the other test lead to terminal (2) and check for continuity. See Figure 4-40. Is continuity indicated? Proceed to step 10. Required Tools or Equipment The switch is faulty; replace the switch. Digital Multimeter, Ohmmeter, or Continuity Tester 10.
Page 125: Solenoid Test
ELECTRICAL 5. Reverse the test leads, and record the reading. NOTE Does the meter read approximately 0.557 volts in On some meters it will be necessary to select a range for one direction, and an open circuit when the leads the component being tested.
Page 126: Fuel Shutoff Solenoid Test
ELECTRICAL Fuel Shutoff Solenoid Test Backlap Switch Test See Figure 4-43. See Figure 4-44. Required Tools Required Tools Digital Multimeter or Ohmmeter Digital Multimeter or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) page 1-7.) 2.
Page 127: Engine
ELECTRICAL Engine Oil Pressure Switch Test See Figure 4-45. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Check the engine oil level. Add oil as needed. (Refer to “Safety, Operation & Maintenance Manual” for oil specification.) TN1066 Figure 4-45...
Page 128: Fuel Level Sender Test
ELECTRICAL Fuel Level Sender Test See Figures 4-46 and 4-47. Required Tools or Equipment Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove the fuel level sender from the fuel tank. (See “Fuel Tank”...
Page 129: Repair
ELECTRICAL Repair Battery and Battery Tray Removal and Installation See Figures 4-48 through 4-50. WARNING • Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. • Always wear eye protection when servicing battery. 1.
Page 130 ELECTRICAL TN1059 Figure 4-50 8. Support the battery tray (21). 9. Remove one screw (20), lock washer (19), and flat washer (18) from the inside of the frame rail (17) and battery tray (21). 10. Remove two countersunk, socket-head screws (22) from the battery tray (21) and the outside of the frame rail (17).
Page 131: Alternator
ELECTRICAL Alternator 7 8 9 Removal and Installation See Figures 4-51 and 4-52. NOTE Turbocharged engine shown; naturally aspirated engine is similar. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Raise hood. 3. Disconnect the battery negative (–) cables at the battery.
Page 132: Starter Motor
ELECTRICAL Starter Motor Removal and Installation See Figures 4-53 through 4-55. 1. Park the mower safely. (See “Park Mower Safely” on 10 11 page 1-7.) 2. Raise hood. 3. Disconnect the battery negative (–) cables at the battery. TN1055 Figure 4-54 7.
Page 133: Instrument Panel
ELECTRICAL Instrument Panel Removal and Installation See Figures 4-56 through 4-58. NOTE If servicing individual components, it is not necessary to completely remove the instrument panel. In these cases the instrument panel can be moved aside for access to components. 1.
Page 134: Fuses
ELECTRICAL Fuses Strip Fuses Removal and Installation Plug-In Fuses See Figures 4-61 and 4-62. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on See Figures 4-59 and 4-60. page 1-7.) 1. Park the mower safely. (See “Park Mower Safely” on 2.
Page 135: Diode Module
ELECTRICAL Diode Module Start Relay Removal and Installation Removal and Installation See Figure 4-63. See Figure 4-64. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) page 1-7.) 2.
Page 136: Glow Plug Relay
ELECTRICAL Glow Plug Relay Removal and Installation See Figure 4-65. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Disconnect the battery negative (–) cables at the battery. 3. Raise the engine hood. TN1095 Figure 4-66 4.
Page 137: Rocker Switches
ELECTRICAL Rocker Switches See Figure 4-68. TN1066 TN1085 Figure 4-69 Figure 4-68 This procedure applies to the following switches: NOTE • Work Light Switch (Optional) (1) Label all wiring connectors before removing to ensure • Weight Transfer Switch (2) correct installation. •...
Page 138: Indicator Lamps
ELECTRICAL Indicator Lamps See Figure 4-71. TN1091 Figure 4-72 TN1066 Figure 4-71 NOTE This procedure applies to the following indicator lamps: Label all wiring connectors and record their locations • Control Module Warning/Engine Preheat Lamps (1) before removing to ensure correct installation. •...
Page 139: Brake Safety Switch
ELECTRICAL Brake Safety Switch Removal and Installation See Figure 4-74. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Disconnect the battery negative (–) cables at the battery. TN1093 Figure 4-75 NOTE Label all wiring connectors before removing to ensure correct installation.
Page 140: Control Module
ELECTRICAL Multi-Function Gauge NOTES • Record the orientation of the joystick before removing Removal and Installation to ensure correct installation. See Figures 4-78 and 4-79. • When removed, the joystick may come out as two NOTE separate pieces. If the joystick is to be tested after removal, connect the two pieces together using the Remove the multi-function gauge only if replacement is mounting hardware.
Page 141: Seat Switch
(1). Installation Notes • Install the neutral switch by reversing the order of removal. • Adjust the neutral switch. (See “TR-3 and Early Model 30001 AR-3 Traction Pedal Neutral Switch Adjustment” on page 5-20.) 4-84 4181384 First Edition...
Page 142: Solenoid Coils
ELECTRICAL Solenoid Coils Removal and Installation See Figure 4-83. See Figures 4-81 and 4-82. NOTE The mow solenoid is shown; all solenoids are removed and installed the same way. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2.
Page 143: Fuel Shutoff Solenoid
ELECTRICAL Fuel Shutoff Solenoid Backlap Switch Removal and Installation Removal and Installation See Figure 4-84. See Figure 4-85. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) page 1-7.) 2.
Page 144: Hydraulic Oil Filter Switch
ELECTRICAL Hydraulic Oil Filter Switch Installation Notes Removal and Installation Required Materials See Figure 4-86. ® Telfon Tape WARNING • Install the hydraulic filter switch by reversing the order of removal. The hydraulic system is under pressure, and the ® oil may be hot! •...
Page 145: Engine Temperature Switch
ELECTRICAL Installation Notes Required Materials ® Telfon Tape • Install the engine oil pressure switch by reversing the order of removal. ® • Apply Teflon tape to the threads of the oil pressure switch before installing. Engine Temperature Switch Removal and Installation See Figures 4-88 and 4-89.
Page 146: Fuel Level Sender
ELECTRICAL Fuel Level Sender Glow Plug Timer Removal and Installation Removal and Installation The fuel level sender removal and installation is included See Figure 4-91. in the fuel tank disassembly and assembly procedure. 1. Park the mower safely. (See “Park Mower Safely” on (See “Fuel Tank”...
Page 147 ELECTRICAL Page Intentionally Blank 4-90 4181384 First Edition...
Page 148: Hydrostatic Power Train
TR-3 and Early Model 30001 AR-3 Traction Pedal Neutral Switch Adjustment ..5-20 TR-3 and Late Model 30002 AR-3 Traction Pedal Neutral Switch Adjustment ..5-21 Repair .
Page 149: Specifications
When hydraulic components fail internally, debris from the failed component can spread throughout the hydraulic system causing additional damage. Contaminated hydraulic systems should be filtered using a portable in-line filter available through your Jacobsen Dealer. TN1367 Figure 5-1 4181384 First Edition...
Page 150: Component Location
HYDROSTATIC POWER TRAIN Component Location See Figure 5-2. TN0991, TN1240, TN1241 Rear Wheel Motor Hydrostatic Pump Left Front Wheel Motor Right Front Wheel Motor Figure 5-2: Power Train Component Location 4181384 First Edition...
Page 151: Theory Of Operation And Sub-Circuit Schematics
HYDROSTATIC POWER TRAIN Theory of Operation and Traction Pump Circuit Sub-Circuit Schematics The traction drive pump receives a supply of filtered, charge pressure oil from the charge pressure circuit. When the traction pedal is moved to the forward position, Traction Circuit Forward Schematic the engine-driven traction pump supplies operating and Theory of Operation pressure oil in parallel to the front wheel motors, and in...
Page 152 HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic See Figure 5-3. Solenoid Valve Mow and Brake Valve Relief Valve Load Control Valve Brake Solenoid Valve Hydraulic Oil Filter Check Valve Park Brake Release Valve Charge Pressure Relief Valve System Rear Relief Valves Valve Wheel Motor Front...
Page 153: Traction Circuit Reverse Schematic And Theory Of Operation
HYDROSTATIC POWER TRAIN Traction Circuit Reverse Schematic Traction Pump Circuit and Theory of Operation The traction drive pump receives a supply of filtered, charge pressure oil from the charge pressure circuit. See Figure 5-4. When the traction pedal is moved to the reverse position, System Conditions: the engine-driven traction pump supplies high-pressure oil to the rear wheel motor and the check valve in the...
Page 154 HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic See Figure 5-4. Solenoid Valve Mow and Brake Valve Relief Valve Load Control Valve Brake Solenoid Valve Hydraulic Oil Filter Check Valve Park Brake Release Valve Charge Pressure Relief Valve System Valve Relief Valves Rear Wheel Motor Front...
Page 155: Troubleshooting
HYDROSTATIC POWER TRAIN Troubleshooting Symptom: 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 “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Tow valve open.
Page 156 HYDROSTATIC POWER TRAIN Symptom: Hydraulic System Operating Hot Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Oil cooler has dirt or debris in fins. Clean oil cooler fins of dirt and debris.
Page 157: Field Test Procedures
HYDROSTATIC POWER TRAIN Field Test Procedures 2. Install wheel restraints (1) to both front wheels. 3. Lower the cutting units and move throttle lever to full When a hydraulic system failure occurs, some simple throttle. Slowly push the traction pedal forward. effective tests can be performed prior to performing an Does the engine labor or stall? test instrument.
Page 158: 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 159: Traction System Test
HYDROSTATIC POWER TRAIN 8. Check hydraulic oil level. Add oil as needed. (Refer to “Safety, Operation, and Maintenance Manual” for correct oil specifications.) Traction System Test See Figures 5-10 through 5-12. WARNING The hydraulic system is under pressure, and the oil will be hot.
Page 160 HYDROSTATIC POWER TRAIN TN1329 TN1293 Figure 5-9 Figure 5-11 4. Install wheel restraint to rear wheel. 8. Close tow valve (2) completely by turning clockwise. 5. Lift and support the machine so that the front wheels 9. Disconnect and plug hose (4). are off the ground.
Page 161: Traction Pump Tests
HYDROSTATIC POWER TRAIN Traction Pump Tests 17. Start engine and run at full throttle (3150 rpm ± 50). 18. Adjust flow lock tool (1) to allow pump to produce 10 See Figures 5-13 and 5-14. gpm (37.8 lpm) in the forward direction. 19.
Page 162 HYDROSTATIC POWER TRAIN CAUTION Do not exceed 3100 psi (214 bar) when testing system relief valves or equipment damage may occur. 13. Continue to close flow meter valve (2) until zero flow is obtained. Record forward system relief valve pressure. 14.
Page 163: Wheel Motors Test
HYDROSTATIC POWER TRAIN Wheel Motors Test See Figures 5-15 through 5-17. 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 164 HYDROSTATIC POWER TRAIN TN1358 Figure 5-15 TN1364 Figure 5-17 5. Install blocking disk at location (1) (backside of front axle housing) to block oil flow from right wheel motor. 10. Adjust flow lock tool (3) to allow pump to produce 10 gpm (37.8 lpm) in the forward direction.
Page 165: Transmission Neutral Adjustment
HYDROSTATIC POWER TRAIN NOTE NOTE Verify engine rpm is within specification (3150 rpm ± 50) Verify engine rpm is within specification (3150 rpm ± 50) to ensure accurate hydraulic test results. to ensure accurate hydraulic test results. 19. Start engine and run at full throttle (3150 rpm ± 50). 30.
Page 166 HYDROSTATIC POWER TRAIN WARNING Prevent personal injury. Use properly rated lifting devices. Always be sure load is balanced before lifting. Support the machine properly using jack stands. 3. Lift and support the machine so that the front and rear wheels are off the ground. TN1246 Figure 5-19 WARNING...
Page 167 Repeat the procedure if any wheel movement is noted. 15. Stop the engine. 16. Adjust the neutral switch. (See “TR-3 and Early Model 30001 AR-3 Traction Pedal Neutral Switch Adjustment” on page 5-20.). TR-3 and Early Model 30001 AR-3 Traction Pedal Neutral Switch...
Page 168 (See “Traction Pedal Neutral switch (2). (See “Traction Pedal Neutral Switch Test” Switch Test” on page 4-65.) on page 4-65.) TR-3 and Late Model 30002 AR-3 Traction Pedal Neutral Switch Adjustment See Figure 5-24. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.)
Page 169: Repair
HYDROSTATIC POWER TRAIN Repair Traction Pump Removal and Installation See Figure 5-25. 17 18 19 Figure 5-25 5-22 4181384 First Edition...
Page 170 HYDROSTATIC POWER TRAIN 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-7.) Note orientation of fittings on pump body to aid in 2. Remove the seat and mounting plate. (See Seat and assembly. Mounting Plate on page 9-16.) 22.
Page 171 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-26. TN1308 Screw (8) Retaining Ring Cylinder Block Spring O-Ring (2) Trunnion Cover Assembly Lip Seal Retaining Ring Hex Plug (2) O-Ring (2) O-Ring Valve Plate O-Ring (2) Lip Seal Internal Retaining Ring SCR Valve Shim (3) Seal Carrier...
Page 172: Front Wheel Motor
HYDROSTATIC POWER TRAIN 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 173 HYDROSTATIC POWER TRAIN TN1287 TN1287 Figure 5-29 Figure 5-30 8. Remove cotter pin (18). • Install the front wheel motor by reversing the order of removal. CAUTION • Apply anti-seize compound to the motor shaft threads. Be careful not to apply anti-seize compound The wheel hub may move unexpectedly when to the motor shaft (20).
Page 174 HYDROSTATIC POWER TRAIN Disassembly and Inspection See Figures 5-31 through 5-46. TN1311 Figure 5-33 NOTE TN1309 The spacer (9) may remain with the disk valve (6) when Figure 5-31 the valve housing is removed. 1. Scribe a line (1) along the side of hydraulic motor 3.
Page 175 HYDROSTATIC POWER TRAIN TN1314 TN1313 Figure 5-36 Figure 5-35 10. Remove the O-ring (17) from the mounting flange 7. Remove the O-ring (13) from the gear wheel set (15). assembly (19). 8. Remove the valve drive (14) from the gear wheel set 11.
Page 176 HYDROSTATIC POWER TRAIN TN1320 Figure 5-40 TN1316 15. Inspect the disks for any scratches on the mating Figure 5-38 surfaces (29) (front and rear). Replace the disks (28) if any damage is noted. NOTE Record the order of brake disks and stator rings to ensure correct assembly.
Page 177 HYDROSTATIC POWER TRAIN NOTE Record the orientation of the dust (41) and shaft (43) seals before removing to ensure correct installation. 20. Remove dust seal (41) and shaft seal (43) from the bearing housing (42). TN1317 Figure 5-42 17. Remove O-ring (37) from the bearing housing (38). 18.
Page 178 Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air only. Required Materials Seal Kit (Jacobsen P/N 4134020) NOTE Always install new seals and O-rings for assembly. Used TN1343 parts may leak.
Page 179 HYDROSTATIC POWER TRAIN 9. Install the brake piston (8) in the mounting flange (12) in the same orientation as recorded during removal. TN1317 Figure 5-48 5. Install the retaining ring (7) into the groove in the TN1322 bearing housing (6). Figure 5-50 6.
Page 180 HYDROSTATIC POWER TRAIN 11. Install the mounting flange assembly (19) on the IMPORTANT bearing housing assembly (18) using six socket-head screws (17). Tighten screws using an alternating The motor must be timed correctly. pattern to 27 lb-ft (37 N·m). TN1313 Figure 5-53 TN1314 14.
Page 181 HYDROSTATIC POWER TRAIN 17. Mark the bottom of a spline on both ends of the valve drive (26). 18. Line up mark on gear wheel set rotor (27) with marks on valve drive (26). TN1343 Figure 5-57 NOTE TN1313 Install the backing rings in the same locations as record Figure 5-55 during removal.
Page 182 HYDROSTATIC POWER TRAIN TN1310 TN1366 Figure 5-61 Figure 5-59: Correct Motor Timing 29. Install seven screws (46) in the end cover (47). Tighten screws using an alternating pattern to 52 lb-ft 26. Align mark on valve drive (43) with a hole in the outer (70 N·m).
Page 183: Rear Wheel Motor
HYDROSTATIC POWER TRAIN Rear Wheel Motor 5. Remove four motor mounting nuts (6), bolts (7), and eight washers (8). Removal and Installation 6. Remove hydraulic motor (4) from bracket (9). See Figures 5-62 through 5-65. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2.
Page 184 HYDROSTATIC POWER TRAIN Installation Notes Required Materials Anti-Seize Compound ® Loctite 242 (Blue) Thread Sealant • Install the rear wheel hydraulic motor by reversing the order of removal. TN1303 Figure 5-67 • Before tightening the hose connections (23, 24, and 25) position hoses to allow clearance between hoses and rear wheel (22).
Page 185 HYDROSTATIC POWER TRAIN Disassembly See Figures 5-68 through 5-75. TN1295 Figure 5-70 NOTE The spacer (8) may remain with the disk valve (5) when the valve housing is removed. 3. Remove the valve housing assembly (7) and spacer (8) from the channel plate (6). TN1290 4.
Page 186 HYDROSTATIC POWER TRAIN TN1297 Figure 5-72 NOTE Record the orientation of the valve drive before removing to ensure correct installation. 7. Remove the valve drive (17). NOTE Record the orientation of the channel plate before removing to ensure correct installation. 8.
Page 187 Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air only. Required Materials Seal Kit (Jacobsen P/N 002300620) NOTE TN1306 Always install new seals and O-rings for assembly. Used Figure 5-75 parts may leak.
Page 188 HYDROSTATIC POWER TRAIN TN1306 Figure 5-76 1. Install a new shaft seal (3) in bearing housing (2). 2. Install a new O-ring (1) in the bearing housing (2). 3. Install the shaft assembly (4) in the bearing housing (2). TN1296 Figure 5-78 6.
Page 189 HYDROSTATIC POWER TRAIN IMPORTANT The motor must be timed correctly. TN1367 Figure 5-79: Correct Motor Timing TN1297 11. Mark the gear wheel set rotor (18) at the point where Figure 5-80 the bottom of a spline tooth is opposite to the bottom of a tooth in the external rotor teeth.
Page 190 HYDROSTATIC POWER TRAIN 16. Install a new O-ring (24) on the channel plate (23). TN1305 Figure 5-84 19. Install alignment pin (29) in valve housing (if removed). TN1367 20. Install new O-rings (33 and 34) on the balance plate Figure 5-82: Correct Motor Timing (28).
Page 191 HYDROSTATIC POWER TRAIN TN1294 Figure 5-86 23. Install four screws (39) in the valve housing (40). Tighten screw using an alternating pattern to 55— 59 lb-ft (75—80 N·m). 5-44 4181384 First Edition...
Page 192: Hydraulics
Hydraulic Schematic—AR-3 Model AR30002 ........
Page 193 HYDRAULICS Repair ..............6-44 Tandem Pump .
Page 194 Specifications Hydrostatic Pump Flow 20 (76) at 3150 rpm gpm (lpm) Mow/Brake Relief Valve Pressure 3046 (210) psi (bar) Setting—AR-3 Model 30001 Mow/Brake Relief Valve Pressure 3626 (250) psi (bar) Setting—AR-3 Model 30002 Mow/Brake Relief Valve Pressure 3046 (210) psi (bar) Setting—TR-3...
Page 195 HYDRAULICS Repair Specifications Specifications Tandem Pump—End Cap-to-Pump 32—36 (43—49) lb-ft (N·m) Body Screw Torque Lift Valve—Solenoid Coil Torque 3 (4) lb-ft (N·m) Lift Valve—Relief Valve Torque 37 (50) lb-ft (N·m) Lift Valve—Check Valve Torque 30 (40) lb-ft (N·m) Lift Valve—Orifice Plug Torque 2 (3) lb-ft (N·m) Lift Valve—Hollow Hex Plug Torque...
Page 196 HYDRAULICS Component Location—AR-3 See Figures 6-1 and 6-2. TN0991, TN1242, TN1243 Hydraulic Oil Filter Left Front Lift Cylinder Mow and Brake Valve Left Front Cutting Unit Drive Motor Hydraulic Oil Manifold Right Front Cutting Unit Drive Motor Tandem Pump Assembly...
Page 197 HYDRAULICS TN0992 Flushing Valve Rear (Center) Cutting Unit Lift Radiator/Hydraulic Oil Cooler Cylinder Rear (Center) Cutting Unit Drive Hydraulic Oil Filter Motor Figure 6-2: Component Location—Left Side 4181384 First Edition...
Page 198: Component Location-Tr-3
HYDRAULICS Component Location—TR-3 See Figures 6-3 and 6-4. TN0988, TN1242, TN1243 Hydraulic Oil Filter Left Front Cutting Unit Drive Motor Mow and Brake Valve Right Front Cutting Unit Drive Motor Hydraulic Oil Manifold Right Front Lift Cylinder Tandem Pump Assembly Rear (Center) Cutting Unit Drive Lift Valve Motor...
Page 199 HYDRAULICS TN0989 Flushing Valve Hydraulic Oil Filter Backlap Valve (If Equipped) Left Front Lift Cylinder Radiator/Hydraulic Oil Cooler Rear (Center) Cutting Unit Lift Cylinder Figure 6-4: Component Location—Left Side 4181384 First Edition...
Page 200 HYDRAULICS Page Intentionally Blank 4181384 First Edition...
Page 201: Hydraulic Schematic-Ar-3 Model Ar30001
HYDRAULICS Hydraulic Schematic–AR-3 Model AR30001 See Figures 6-5 and 6-6. Lift Cylinders 0.04 in. Secondary Weight Transfer Solenoid Lift Valve 363 psi Left Front Right Front Center Rear 25 bar 0.052 in. Lower Raise Primary Weight Transfer Solenoid Cutting Unit Pump 9.6 GPM at 3150 RPM...
Page 202 HYDRAULICS Hydraulic Schematic–AR-3 Model AR30001 Cutting Unit Motors 14.52 cc/REV Right Front Left Front Center Rear Mow and Brake Valve Load Control Valve Relief Valve 3046 psi 210bar Brake Solenoid Valve Check Valve Park Brake Release Valve Hydraulic Oil Filter 0.04 in.
Page 203: Hydraulic Schematic-Ar-3 Model Ar30002
HYDRAULICS Hydraulic Schematic—AR-3 Model AR30002 See Figures 6-7 and 6-8. Lift Cylinders 0.04 in. Secondary Weight Transfer Solenoid Lift Valve 363 psi Center Rear Left Front Right Front 25 bar 0.052 in. Lower Raise Primary Weight Transfer Solenoid Cutting Unit Pump 9.6 GPM at 3150 RPM...
Page 204 HYDRAULICS Hydraulic Schematic–AR-3 Model AR30002 Cutting Unit Motors 14.52 cc/REV Left Front Right Front Center Rear Mow and Brake Valve Load Control Valve Relief Valve 3626 psi 250 bar Brake Solenoid Valve Check Valve Park Brake Release Valve Hydraulic Oil Filter 0.04 in.
Page 205: Hydraulic Schematic-Tr-3
HYDRAULICS Hydraulic Schematic–TR-3 See Figures 6-9 and 6-10. Lift Cylinders 0.028 in. Secondary Weight Transfer Solenoid Lift Valve 363 psi Right Front Center Rear Left Front 110 bar 0.052 in. Raise Lower Primary Weight Transfer Solenoid Cutting Unit Pump 9.6 GPM at 3150 RPM Steering Pump 2.6 GPM at 3150 RPM Hydraulic...
Page 206 HYDRAULICS Hydraulic Schematic—TR-3 CYLA CYLB Backlap Valve (Optional) Cutting Unit Motors 12.8 cc/Rev Backlap Speed Control Valve Right Front Left Front Center Rear (Optional) Mow and Brake Valve Load Control Valve Relief Valve 3046 psi 210bar Brake Solenoid Valve Check Valve Park Brake Release Valve Hydraulic Oil Filter...
Page 207: Theory Of Operation And Diagnostic Information
HYDRAULICS Theory of Operation and Diagnostic Information Steering Circuit and Theory of Operation See Figure 6-11. Hydraulic oil is drawn from the hydraulic oil tank by the steering pump. Operating pressure oil flows from the steering pump to the steering valve where there is a relief valve set to reach a maximum pressure of 1595 psi (110 bar).
Page 208: Steering Circuit Schematic
HYDRAULICS Steering Circuit Schematic See Figure 6-11. Cutting Unit Pump Steering Pump Hydraulic Oil Tank Steering Direction Valve Body Steering Lift and Cylinder Steering Relief Valve Steering Valve Oil Cooler Return Oil Inlet Oil Operating Pressure Oil TN1182 Operating Pressure Oil to Raise/Lower Return Oil from Traction Drive Circuit Circuit Return Oil from Raise/Lower Circuit...
Page 209: Raise Circuit Schematic And Theory Of Operation
HYDRAULICS Raise Circuit Schematic and Theory of Operation See Figure 6-12. System Conditions: • Engine running • Weight transfer switch in the off position • Raise/lower joystick in the raise position NOTE See “Raise/Lower Circuit—Theory of Operation” on page 4-36 for the electrical operation of this circuit. Operating pressure oil is supplied to the lift valve by the steering circuit, and oil flows to the primary weight transfer valve in the lift valve.
Page 210: Raise Circuit Schematic
HYDRAULICS Raise Circuit Schematic See Figure 6-12. Lift Cylinders 0.04 in. Center Rear Right Front Left Front Secondary Weight Transfer Solenoid Lift Valve Check Valve 0.052 in. Weight Transfer Raise Lower Relief Valve Oil Cooler Primary Weight Transfer Solenoid Hydraulic Oil Tank Operating Pressure Oil Return Oil TN1183...
Page 211: Lower Circuit Schematic And Theory Of Operation
HYDRAULICS Lower Circuit Schematic and Theory of Operation See Figure 6-13. System Conditions: • Engine running • Weight transfer switch in the off position • Raise/lower joystick in the lower position NOTE See “Raise/Lower Circuit—Theory of Operation” on page 4-36 for the electrical operation of this circuit. Operating pressure oil is supplied to the lift valve by the steering circuit, and oil flows to the primary weight transfer valve in the lift valve.
Page 212: Lower Circuit Schematic
HYDRAULICS Lower Circuit Schematic See Figure 6-13. Lift Cylinders 0.040 in. Right Front Center Rear Left Front Secondary Weight Transfer Solenoid Lift Valve Check Valve 363 psi 110 bar 0.052 in. Weight Transfer Relief Valve Lower Raise Oil Cooler Primary Weight Transfer Solenoid Hydraulic Oil Tank Metered Oil...
Page 213: Weight Transfer Circuit Schematic And Theory Of Operation
HYDRAULICS Weight Transfer Circuit Schematic and Theory of Operation See Figure 6-14. System Conditions: • Engine running • Weight transfer switch in the on position • Cutting units lowered NOTE See “Weight Transfer Circuit—Theory of Operation” on page 4-45 for the electrical operation of this circuit. The purpose of the weight transfer circuit is to allow the transfer of weight from the cutting units to the wheels to improve traction.
Page 214 HYDRAULICS Weight Transfer Circuit Schematic See Figure 6-14. Lift Cylinders 0.040 in. Center Rear Right Front Left Front Lift Valve Secondary Weight Transfer Solenoid 363 psi Check Valve 110 bar 0.052 in. Weight Transfer Lower Raise Relief Valve Oil Cooler Primary Weight Transfer Solenoid Hydraulic Oil Tank...
Page 215: Mow Circuit Schematic And Theory Of Operation
(center) motor before returning to the mow and brake valve at port M2. Each AR-3 cutting unit motor also has a check valve that is forced closed by the incoming oil from the mow and brake valve port M1. These valves will open, bypassing the cutting unit motors, when the cutting units are shut off to allow the blades to slow down before stopping.
Page 216: Mow Circuit Schematic
HYDRAULICS Mow Circuit Schematic See Figure 6-15. Cutting Unit Pump Steering Pump Hydraulic Oil Tank Mow and Brake Check Valve Valve Relief Valve Load Control Valve Brake Solenoid Valve Oil Cooler Cutting Unit Motors Right Center Left Rear Front Front Hydraulic Oil Tank Hydraulic Oil Tank Charge-Pressure Oil...
Page 217: Backlap Circuit Schematic And Theory Of Operation (Tr-3 Only)
HYDRAULICS Backlap Circuit Schematic and Theory of Operation (TR-3 Only) See Figure 6-16. System Conditions: • Engine running • Cutting units lowered • Mow switch in the on position • Park brake set • Backlap valve in backlap position • Backlap speed control valve adjusted for the desired backlapping speed NOTE See “Backlap Circuit Operation (Model TR-3)—Theory of...
Page 218: Backlap Circuit Schematic
HYDRAULICS Backlap Circuit Schematic See Figure 6-16. Cutting Unit Pump Steering Pump Hydraulic Oil Tank Mow and Brake Backlap Valve Valve Relief Valve Check Valve Load CYLA Control Valve CYLB Brake Solenoid Valve Backlap Speed Control Valve Oil Cooler Cutting Unit Motors Left Center Right...
Page 219: Field Test Procedures
HYDRAULICS Field Test Procedures 8. Remove support from cutting unit lift arm. After 15 minutes, does cutting unit drift down? Lift Cylinder Leakage Test Cylinder is bypassing oil. Replace lift cylinder. (See “Lift Cylinder” on page 6-54.) See Figures 6-17 and 6-18. Repeat the test for all of the lift cylinders.
Page 220: Cutting Unit Motor Test
HYDRAULICS 3. Remove both hydraulic hoses from the steering 10. Measure the amount of oil that flowed from the case cylinder, plug the hoses and cap the cylinder ports. drain. The amount x 4 = amount per minute. 4. Turn the steering wheel all the way to the right and Is the oil captured from the case drain within a then all the way left, only a little movement should be half pint per minute?
Page 221: Cutting Unit/Charge Pump System Test
HYDRAULICS The results from this test reveal leakage of 5% in the 6.8 – 6.5 / 6.8 x 100 = Center Rear Cutting Unit Motor traction pump, 5.3% in the mow/brake valve, 20% in the Leakage = 4.4% left cutting unit motor, 5.6% in the right cutting unit motor, and 4.4% in the center rear cutting unit motor.
Page 222: Cutting Unit/Charge Pump Test
HYDRAULICS 14. Read and record the cutting unit/charge pump no load flow. 15. Slowly close flow meter valve (4) until pressure reaches 2300 psi (159 bar). Read and record the cutting unit/charge pump system test loaded flow. 16. Open flow meter valve (4) and stop engine. 17.
Page 223 HYDRAULICS 2. Before performing this test, perform cutting unit NOTE system test leaving flow meter connected as outlined. Verify engine rpm is within specification (3150 rpm ± 50) to ensure accurate hydraulic test results. 5. Start engine and run at full throttle (3150 rpm ± 50). 6.
Page 224: Mow/Brake Valve Tests
HYDRAULICS Mow/Brake Valve Tests See Figures 6-25 and 6-26. 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 225: Adjust Mow/Brake Valve Relief Pressure
Pressure relief valve settings vary amongst models. injury. Determine which model is being tested and choose the correct question below. TR-3 and Early Model AR-3 30001. Is mow/brake Required Tools and Materials relief valve pressure 3046 psi (210 bar)? • Flow Meter Mow/brake pressure relief valve is good.
Page 226: Cutting Unit Motors Test
Cutting Unit Motors Test or serious injury. TR-3 and Early Model 30001 AR-3 6. Install suitable blocking device or tool in left front See Figures 6-28 and 6-29. cutting unit, preventing cutting unit from turning.
Page 227 HYDRAULICS 9. Use the flow meter to warm the hydraulic oil. Turn the 20. Slowly close flow meter valve (3) until pressure flow meter valve (3) until a reading of 1525 psi (105 reaches 2300 psi (159 bar). Read and record the bar) or one half of the relief valve rating is reached.
Page 228 “Safety, Operation, and Maintenance Manual” for or serious injury. correct oil specifications.) Late Model 30002 AR-3 6. Install suitable blocking device or tool in right front cutting unit, preventing cutting unit from turning. See Figures 6-30 and 6-31.
Page 229 HYDRAULICS 9. Use the flow meter to warm the hydraulic oil. Turn the 20. Slowly close flow meter valve (3) until pressure flow meter valve (3) until a reading of 1525 psi (105 reaches 2300 psi (159 bar). Read and record the left bar) or one half of the relief valve rating is reached.
Page 230: Lift/Steer System Relief Valve Pressure Test
HYDRAULICS 31. Calculate center rear cutting unit motor leakage. (Step 20 – Step 29 / Step 20 x 100 = Leak Percentage) Is center rear cutting unit motor leakage 10% or less? The center rear cutting unit motor is good. Proceed to step 32.
Page 231: Lift System Test
HYDRAULICS 9. Stop engine. Is lift/steer system relief pressure 1595 psi (110 bar)? Lift/steer system relief valve is good. Proceed to step 10. Test lift/steer pump. (See “Lift/Steer Pump Test” on page 6-41.) Test lift cylinder. (See “Lift Cylinder Leakage Test” on page 6-28.) Replace steering valve.
Page 232: Lift/Steer Pump Test
HYDRAULICS Lift/Steer Pump Test CAUTION See Figures 6-34 and 6-35. Do not exceed 1200 psi (83 bar) as this test does WARNING not utilize system relief. The hydraulic system is under pressure, and the 10. Use the flow meter to warm the hydraulic oil. Turn the oil will be hot.
Page 233: Lift Valve Leakage Test
HYDRAULICS 11. Calculate lift/steer pump leakage. (Step 6 – Step 7 / Step 6 x 100 = Leak Percentage) Is lift/steer pump leakage 10% or less? The lift/steer pump is good. Proceed to step Proceed to next question. Is lift/steer pump leakage 11% to 20%? The lift/steer pump is marginal.
Page 234 HYDRAULICS 11. Calculate lift valve leakage. (Step 7 of previous test – Step 9 / Step 7 of previous test x 100 = Leak Percentage) Is lift valve leakage 10% or less? The lift valve is good. Proceed to step 12. Proceed to next question.
Page 235: Repair
HYDRAULICS Repair Tandem Pump Removal and Installation See Figure 6-38. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove seat and mounting plate. (See “Seat and Mounting Plate” on page 9-16.) 3. Drain hydraulic oil. TN1124 Figure 6-38 NOTE...
Page 236 HYDRAULICS Disassembly and Assembly See Figure 6-39. 10 4 TN1232 Front Cover Backup Ring (4) O-Ring (2) Washer (4) Seal (4) Dowel Pin (2) Drive Gear Driven Gear Shaft Drive Shaft Twin Rear Cover Shaft Seal Thrust Plate (4) Body Screw (4) Ring Figure 6-39...
Page 237: Cutting Unit Motor
See Chapter 8—Cutting Units for cutting unit motor 3. Disconnect hydraulic hoses (3, 4, 7, and 8) from fittings. service information: • AR-3: See “Deck Drive Motor” on page 8-25. • TR-3: See “Reel Drive Motor” on page 8-33. 6-46 4181384 First Edition...
Page 238 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-42. TN1334 Figure 6-41 4. Support the lift valve (18). 5. Remove two nuts (15), flat washers (14), screws (11) and spacers (10), and remove lift valve (18) from mower. NOTE TN1335 Record the location and orientation of fittings on lift valve Solenoid Coil (4) Raise/Lower Solenoid Valve to ensure correct installation.
Page 239: Flushing Valve
Seal Kit, Primary Weight Transfer Solenoid Valve NOTES (Jacobsen P/N 4137266) • Label hydraulic hoses before disconnecting to ensure Seal Kit, Check Valve (Jacobsen P/N 4137267) correct installation. Seal Kit, Pilot Piston (Jacobsen P/N 4137268) Seal Kit, Relief Valve (Jacobsen P/N 4137269) •...
Page 240 Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air. Required Materials Seal Kit, Sequence Valve (Jacobsen P/N 4137262) Seal Kit, Check Valve (Jacobsen P/N 4137263) • Assemble flushing valve by reversing the order of removal.
Page 241: Mow/Brake Valve
HYDRAULICS Mow/Brake Valve Removal and Installation See Figures 6-45 and 6-46. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Drain hydraulic oil. TN1337 Figure 6-46 NOTE Record the location and orientation of fittings on lift valve to ensure correct installation.
Page 242 Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air. Required Materials Seal Kit, Load Control Valve (Jacobsen P/N 4137270) Seal Kit, Brake Solenoid Valve (Jacobsen P/N 4137265) Seal Kit, Mow Solenoid Valve...
Page 243: Brake Release Valve
HYDRAULICS Brake Release Valve Disassembly, Inspection, and Assembly NOTE Removal and Installation Mark location and orientation of fittings on brake release See Figure 6-48. valve. 1. Park the mower safely. (See “Park Mower Safely” on 1. Remove fittings from brake release valve. page 1-7.) 2.
Page 244: Hydraulic Filter
HYDRAULICS Hydraulic Filter Hydraulic Manifold Removal and Installation Removal and Installation See Figure 6-49. See Figure 6-50. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) page 1-7.) 2.
Page 245: Backlap Valve
HYDRAULICS Backlap Valve Installation Notes • Install backlap valve by reversing the order of Removal and Installation removal. • Ensure new O-rings are in place before installing See Figure 6-51. hoses on fittings. 1. Park the mower safely. (See “Park Mower Safely” on •...
Page 246 HYDRAULICS NOTES • Label all hydraulic hoses before disconnecting to ensure correct installation. • Close all openings with caps or plugs to prevent contamination. 6. Remove hydraulic hose fittings (9) from cylinder barrel (3). Installation Notes • Install lift cylinder by reversing the order of removal. •...
Page 247 3. Use a spanner wrench to remove rod guide assembly (8) from barrel. Required Materials NOTE Seal Kit (Jacobsen P/N 002301010) Note orientation of rod end to barrel to ease assembly. 4. Pull rod assembly out of barrel. • Lubricate all parts, O-rings, seals, and wiper with 5.
Page 248: Hydraulic Oil Cooler
HYDRAULICS Hydraulic Oil Cooler 4. Disconnect two hydraulic hoses (6 and 7) from hydraulic oil tank (5). Removal and Installation 5. Support the hydraulic oil tank (5). 6. Remove three screws (1), lock washers (2), and six NOTE flat washers (3 and 4), and remove hydraulic oil tank (5) from mower.
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Page 250: Steering
Chapter 7 Steering Specifications ..............7-3 Component Location .
Page 251 STEERING Page Intentionally Blank 4181384 First Edition...
Page 252: Specifications
STEERING Specifications Test Specifications Steering System Leakage Test— Zero—Nominal Amount pt (L) Cylinder Leakage Repair Specifications Steering Wheel Nut Torque 25 (34) lb-ft (N·m) Steering Cylinder-to-Rear Wheel 103 (140) lb-ft (N·m) Support Nut Torque 4181384 First Edition...
Page 253: Component Location
STEERING Component Location See Figure 7-1. TN0991, TN1228, TN1229, TN1230 Steering Unit Pump Steering Valve Rear Wheel Support Steering Tower Tilt Bracket Steering Cylinder Steering Column Steering Wheel Figure 7-1 4181384 First Edition...
Page 254: Tests And Adjustments
STEERING Tests and Adjustments WARNING Steering Leakage Test Do not turn steering wheel to the left. Failure to follow appropriate safety precautions See Figure 7-2. may result in death or serious injury. 1. Operate hydraulic system until oil temperature is at 120—150°F (49—65°C).
Page 255: Steer System Relief Valve Pressure Test
STEERING Steer System Relief Valve Pressure Test See Figures 7-3 and 7-4. 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 256: Repair
STEERING Repair Installation Notes Required Materials Steering Wheel ® Loctite 243 Medium-Strength, Oil-Resistant Thread Removal and Installation Locker See Figure 7-5. • Install the steering wheel by reversing the order of 1. Park the mower safely. (See “Park Mower Safely” on removal.
Page 257 STEERING TN1215, TN1215A TN1224 Figure 7-7 Figure 7-8 NOTES 11. Remove four socket-head screws (14) and lock washers (15), and remove the steering column (16) • Label all hydraulic hoses before disconnecting to from the steering valve (21). ensure correct installation. 12.
Page 258: Steering Tower
STEERING Steering Tower Removal and Installation See Figure 7-9. TN1212 M8 x 35 Hex Bolt M10 x 15.9 x 2.5 Lock Washer Tilt Cable M8 Flanged Lock Nut (4) Steering Unit Pivot Bracket M6 Speednut (6) M8 x 25 Carriage Bolt (4) Release Brackets Steering Unit Pivot Bolt (2) Steering Tower Weldment...
Page 259: Steering Cylinder
STEERING Removal Notes NOTE • Remove the steering valve. (See “Steering Valve” on Record the location of washers before removing to page 7-7.) ensure correct installation. • Disconnect the tilt cable (11) from the gas spring 4. Remove screw (2) and four flat washers (3) from the release brackets (17).
Page 260 STEERING TN1216 Figure 7-13 TN1218 • Install (tighten) screw (25) fully into the rear wheel Figure 7-12 support (28) before installing the nut (27). • Tighten nut (27) to 103 lb-ft (140 N·m). NOTE • Apply grease to lubrication fitting (26). (Refer to Record the location of the fittings before removal to “Safety, Operation, and Maintenance Manual”...
Page 261 STEERING TN1252 Figure 7-15 2. Remove the rod and piston assembly (3) from the cylinder body (4). TN1255 Figure 7-18 6. Remove wiper seal (12) and seal (13) from the end of the steering cylinder (14). Assembly Notes Required Materials Seal Kit TN1253 Figure 7-16...
Page 262: Rear Wheel Support
STEERING Rear Wheel Support Removal See Figures 7-20 and 7-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove the hood. (See “Hood” on page 9-6.) TN1216 Figure 7-20 3. Turn the wheel slightly to allow the screw (2) securing the rod end of the steering cylinder to align with the hole (1) in the wheel pivot weldment.
Page 263 STEERING Installation See Figures 7-22 and 7-23. TN1216 Figure 7-23 6. Connect the rod end (11) of steering cylinder to the rear wheel support (14) using screw (9) and four washers (10). Tighten screw fully. 7. Install nut (12) and lock washer (13) on screw (9). Tighten nut to 103 lb-ft (140 N·m).
Page 264 STEERING Page Intentionally Blank 4181384 First Edition 7-15...
Page 265 STEERING 7-16 4181384 First Edition...
Page 266 Mechanical Troubleshooting—AR-3 ........
Page 267: Specifications
CUTTING UNITS Specifications Rotary Cutting Units—AR-3 Repair Specification Deck Drive Motor Housing-to-Front 37 (50) lb-ft (N·m) Cover Screw Torque Cutter Blade Retaining Screw 70 (95) lb-ft (N·m) Torque 4181384 First Edition...
Page 268: Component Location
CUTTING UNITS Component Location AR-3 See Figure 8-1. TN0991, TN1262, TN1263 Rear (Center) Cutting Unit Drive Motor Deck Frame Left Front Cutting Unit Deck Roller Caster Wheels (2) Right Front Cutting Unit Yoke Figure 8-1 4181384 First Edition...
Page 269 CUTTING UNITS TR-3 See Figure 8-2. TN0988, TN1256, TN1257 Rear (Center) Cutting Unit Yoke Assembly Drive Motor Left Front Cutting Unit Front Roller Rear Roller Right Front Cutting Unit Cutting Reel Bedknife Shoe Assembly Figure 8-2 4181384 First Edition...
Page 270: Troubleshooting
CUTTING UNITS Troubleshooting Mechanical Troubleshooting—AR-3 Condition Probable Cause Remedy Rotary drive motors do not reach full Engine speed is insufficient, not set to Check/adjust engine speed. (Refer to speed. specification. “Safety, Operation, and Maintenance Manual.”) Rotary drive motors and/or hydraulic Check hydraulic system performance system performance is reduced.
Page 271: Quality Of Cut Troubleshooting-Ar-3
CUTTING UNITS Quality of Cut Troubleshooting—AR-3 Factors That Affect Cut Appearance In most cases, information provided by the user/customer will provide the basis for the repairs and adjustments that are required. However, it is recommended that a “test cut” be performed to evaluate the mower’s performance before beginning repairs.
Page 272 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. 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.
Page 273 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a cutting unit than the other or on one side of mower to the other. This is usually caused by mechanical wear or an incorrect roller or deck caster adjustment. TN0221 NOTE: Arrow indicates direction of travel.
Page 274 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 275 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Dull cutting blade(s). Sharpen blade(s). (Refer to “Safety, Operation, and Maintenance Manual.”) Mowing (ground) speed is too fast. Reduce mowing (ground) speed.
Page 276 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a damaged blade. TN0224 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Damaged blade(s). Replace blade(s). (See “Cutter Blade” on page 8-28.) Turning too aggressively. Cutting units don’t overlap during turns Turn less aggressively to allow cutting units to overlap.
Page 277 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 278 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units is a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to mismatched 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 279 CUTTING UNITS Mechanical Troubleshooting—TR-3 Condition Probable Cause Remedy Reel drive motors do not reach full speed. Engine speed is insufficient, not set to Check/adjust engine speed. (Refer to specification. “Safety, Operation, and Maintenance Manual.”) Reel drive motor(s) and/or hydraulic Check hydraulic system performance system performance is reduced.
Page 280 CUTTING UNITS Quality of Cut Troubleshooting—TR-3 Factors That Affect Cut Appearance In most cases, information provided by the user/customer will provide the basis for the repairs and adjustments that are required. However, it is recommended that a “test cut” be performed to evaluate the mower’s performance before beginning repairs.
Page 281 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. 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.
Page 282 CUTTING UNITS Marcelling Marcelling, like 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 2 in. (5 cm) or less. TN0220 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Mowing (ground) speed is too fast.
Page 283 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a reel than the other or one cutting unit to another. This is usually caused by mechanical wear or an incorrect roller or HOC (height-of-cut) adjustment. TN0221 NOTE: Arrow indicates direction of travel.
Page 284 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 (HOC) setting and/or uneven turf.
Page 285 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 reel-to-bedknife setting. (Refer to “Safety, Operation, and Maintenance Manual.”) Dull reel or bedknife cutting edges. Sharpen or replace reel blade and bedknife as necessary.
Page 286 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife. TN0224 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 8-37.) Damaged or unevenly worn reel.
Page 287 CUTTING UNITS Windrowing Windrowing is the deposit of clippings concentrated at one end of cutting unit(s) or between two cutting units, forming a line in the direction of travel. TN0225 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall. Mow more often.
Page 288 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 a reel and/or bedknife. TN0987 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Reel and/or bedknife unevenly worn.
Page 289 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units is a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to mismatched 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 290: Rotary Cutting Unit
CUTTING UNITS Repair—AR-3 5. Remove socket-head screw (9), lock washer (10), and flat washer (11), and remove collar (6) and washer (7) from lift arm pivot shaft (13). Rotary Cutting Unit 6. Roll cutting unit (12) forward and slide deck yoke (8) forward until it clears the lift arm pivot shaft (13).
Page 291 CUTTING UNITS TN1123 Figure 8-6 NOTES • Record the orientation of hydraulic hoses to motor and motor to deck to ensure correct installation. • Close all openings with caps or plugs to prevent contamination. 4. Remove hose (9) from elbow fitting (10). 5.
Page 292 CUTTING UNITS Disassembly and Assembly See Figure 8-7. TN1227 Support Shaft Shaft Seal Screw (4) Seal (2) Sleeve Bearing Sleeve Bearing Holder Pump Body Thrust Plate Retaining Ring Seal (2) Check Valve Body Dowel Pin (2) Shaft Seal Front Cover Ball Shaft Seal Steel Plug...
Page 293: Cutter Blade
Dry parts using compressed air. Required Materials Seal Kit (Jacobsen P/N 4157422) • Assemble the deck drive motor by reversing the order of disassembly. • Apply a coat of clean hydraulic oil to all parts to aid assembly.
Page 294: Front Deck Yoke
CUTTING UNITS Front Deck Yoke Removal and Installation See Figures 8-9 through 8-11. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) TN1196A Figure 8-11: Inner Side of Cutting Unit 6. Remove screws (19), flat washers (18), deck pivot (16), and bushing (15) from frame bracket (17) from inner side of the cutting unit frame (17).
Page 295: Deck Caster Wheels
CUTTING UNITS 2. Remove socket-head screw (5), lock washer (6), and flat washer (not shown), and remove collar (7) and washer (4) from lift arm pivot shaft (2). 3. Inspect lift arm shaft bushings (3). Remove only if replacement is required. 4.
Page 296: Mower Deck
CUTTING UNITS 4. Remove three snap ring lock pins (2) and spacers (4) from cutting height spindles (3) of cutting unit frame (5). 5. Lift mower deck (1) up and away from cutting unit frame (5). Installation Note Install the mower deck by reversing the order of removal. Disassembly and Assembly See Figure 8-18.
Page 297 CUTTING UNITS Installation Note Install the roller by reversing the order of removal. Disassembly, Inspection, and Assembly See Figure 8-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove deck roller from cutting unit. (See “Deck Roller”...
Page 298: Reel Drive Motor
CUTTING UNITS Repair—TR-3 Reel Drive Motor Removal and Installation See Figures 8-22 through 8-24. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) TN1258 Figure 8-24 NOTES • Label all hydraulic hoses before disconnecting to ensure correct installation. •...
Page 299 CUTTING UNITS Disassembly, Inspection, and Assembly See Figures 8-25 and 8-26. TN1323 Figure 8-25 1. Park the mower safely. (See “Park Mower Safely” on 4. Remove seal (9), backing seal (8), and thrust plate page 1-7.) (10) from the pump housing (3). 2.
Page 300 Dry parts using compressed air. Required Materials TN1333 Figure 8-26 Seal Kit (Jacobsen P/N 2702706) NOTE • Always install new seals and O-rings during Before removing the drive shaft and driven gear, mark assembly, used parts may leak.
Page 301: Cutting Unit
CUTTING UNITS Cutting Unit Removal and Installation See Figures 8-27 through 8-29. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) TN1163 Figure 8-29 4. Remove the socket-head screw (8), lock washer (9), and collar (7) from the yoke shaft. 5.
Page 302: Bedknife
CUTTING UNITS Bedknife Removal and Installation See Figure 8-33. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove the bedknife shoe assembly. (See “Bedknife Shoe” on page 8-36.) TN1260 Figure 8-31 TN1268 Figure 8-33 3. Remove 11 lock nuts (1) and screws (4), and remove the bedknife (3) from the bedknife shoe (2).
Page 303: Reel Bearing Housing Assemblies
CUTTING UNITS Reel Bearing Housing Assemblies Removal and Installation—Drive Side See Figure 8-34. TN1269 Figure 8-34 8-38 4181384 First Edition...
Page 304 CUTTING UNITS 1. Park the mower safely. (See “Park Mower Safely” on Installation Notes page 1-7.) • Install the bearing housing by reversing the order of 2. Remove the yoke assembly and mounting bracket. removal. (See “Yoke Assembly” on page 8-45.) •...
Page 305 CUTTING UNITS Removal and Installation—Non-Drive Side See Figure 8-35. TN1270 Figure 8-35 1. Park the mower safely. (See “Park Mower Safely” on 5. Remove bearing (25) from bearing housing (4). page 1-7.) 6. Remove socket-head screw (16) from shoulder bolt 2.
Page 306: Reel Blade
CUTTING UNITS CAUTION To prevent personal injury, use caution when working near the reel. 11. Rotate the bearing housing (4) up, so that the shoulder bolt (10) is at the top of the adjustment slot (11), and remove the shoulder bolt from the bearing housing (4) and cutting unit frame (6).
Page 307: Front Roller
CUTTING UNITS Front Roller Removal and Installation See Figures 8-37 through 8-40. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove the cutting unit. (See “Cutting Unit” on page 8-36.) 9 10 12 13 14 TN1282 Figure 8-39 NOTE...
Page 308 CUTTING UNITS Disassembly, Inspection, and Assembly See Figure 8-41. TN1272 Jam Nut (4) Rotary Lip Seal (2) Seal Ring (2) Grease Fitting (2) Shield (2) Spring (2) Taper Roller Bearing (2) Shaft Seal Journal (2) Washer (2) O-Ring (4) Plain Roller Bearing Housing (2) Ring Carrier (2) Circlip (2)
Page 309: Rear Roller
CUTTING UNITS 1. Remove two jam nuts (1) from both ends of roller shaft. 2. Remove roller shaft (14) from roller (15 or 16). 3. Remove components from both ends of roller and keep in order to ease assembly. 4. Inspect roller, shaft, bearing housings, bearings, journals, O-rings, springs, washers, seal rings, and seals for wear or damage.
Page 310: Yoke Assembly
CUTTING UNITS TN1265 TN1271 Figure 8-45 Roller Nut (2) Grease Fitting (2) Wear Sleeve (2) 3. Remove two (one each side) locknuts (3), screws (5), Oil Seal (2) Shaft flat washer (6), and spacer (4) from yoke assembly Bearing, Cup and Cone (2) (2) and cutting unit frame (1).
Page 311 CUTTING UNITS Page Intentionally Blank 8-46 4181384 First Edition...
Page 312: Accessories And Miscellaneous Repair
Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Repair Specifications .
Page 313 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications Repair Specifications Fuel Tank Capacity 6.6 (25) gal (l) M10 Mounting Hardware Torque 34 (46) lb-ft (N·m) M12 Mounting Hardware Torque 58 (79) lb-ft (N·m) Front Tires Size 20 x 12.00-10 Type Turf Trac, 4-Ply Air Pressure 14—20 (97—138) psi (kPa)
Page 314: Component Location
ACCESSORIES AND MISCELLANEOUS REPAIR Component Location TN0991 Canopy (Optional) Traction Pedal Damper Seat and Seat Platform Front Wheel (2) Fuel Tank Rear Wheel Traction Pedal Hood Work Lights (Optional) Figure 9-1: Component Location (AR-3 Shown) 4181384 First Edition...
Page 315: Repair
ACCESSORIES AND MISCELLANEOUS REPAIR Repair Removal and Installation Canopy See Figures 9-4 through 9-8. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) See Figures 9-2 and 9-3. 2. Raise and support the seat platform. 1.
Page 316 ACCESSORIES AND MISCELLANEOUS REPAIR TN1046 TN1048 Figure 9-5 Figure 9-7 TN1047 TN1049 Figure 9-6 Figure 9-8 5. Remove three M12 lock nuts (2), flat washers (3), 6. Remove two M10 lock nuts (5), screws (6), and four and screws (4) from the bottom of the bracket on flat washers (7) from the top of the bracket on each each side of the OPS assembly.
Page 317: Hood
ACCESSORIES AND MISCELLANEOUS REPAIR Hood Removal and Installation See Figures 9-9 and 9-10. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Raise and support the hood. TN1018 Figure 9-10 4. Remove the hood (4). Installation Note Install the hood by reversing the order of removal.
Page 318 ACCESSORIES AND MISCELLANEOUS REPAIR TN1019 Figure 9-11 9 10 4. Remove filler cap (1). TN1023 Figure 9-13 9. Support the fuel tank (7). NOTE One flat washer is placed between the mounting bracket and the fuel tank. 10. Remove screw (8), lock washer (9), and flat washers TN1020 (10 and 11) from the rear of the fuel tank (7).
Page 319 ACCESSORIES AND MISCELLANEOUS REPAIR NOTE Label all hoses before disconnecting to ensure correct installation. 12. Loosen hose clamp (19) and disconnect the return hose (18) from the fuel sender (15). 13. Loosen hose clamp (16) and disconnect the supply hose (17) from the fuel sender (15). 22 23 24 TN1024 Figure 9-16...
Page 320 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figure 9-17. TN1025 Filler Cap Lock Washer (5) Fuel Tank Flat Washer (5) O-Ring Collar, Fuel Sender Drain Plug Fuel Sender Pan-Head Screw (5) Gasket Figure 9-17 Disassembly Notes • Record the orientation of the fuel sender (9), gasket (10), and collar (8) before removing to ensure correct installation.
Page 321: Traction Pedal
ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Removal and Installation See Figures 9-18 through 9-21. 10 11 12 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) 2. Remove the traction pedal damper. (See “Traction Pedal Damper” on page 9-12.) TN1075 Figure 9-20 5.
Page 322 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly Pedal Assembly See Figure 9-23. Pedal Bracket Assembly See Figure 9-22. TN1077 Screw Pedal Cover Washer (3) Traction Pedal Mow Speed Stop Bracket Pedal Cover Lock Nut Figure 9-23 Assembly Note DO NOT overtighten lock nut (4), the mow speed stop bracket must be able to rotate after assembly.
Page 323: Traction Pedal Damper
ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Damper Removal and Installation See Figures 9-24 through 9-26. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) TN1069 Figure 9-25 5. Measure and record the distance (8) between the face of the damper and the end of the rod end. 6.
Page 324 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Inspection See Figures 9-27 through 9-31. TN1071 Figure 9-27 TN1114 1. Remove boot (1). Figure 9-29 NOTE The end cap is a tight fit. To aid in removal, place a length of metal tubing or a deep well socket over the piston rod and against the face of the end cap, and tap with a hammer to dislodge the end cap.
Page 325 ACCESSORIES AND MISCELLANEOUS REPAIR Assembly See Figures 9-32 through 9-39. TN1108 Figure 9-31 TN1108 NOTE Figure 9-32 Record the orientation of the reaction sleeves before removing to ensure correct installation. NOTE 7. Loosen the set screw (13) and remove the piston (12), reaction sleeve (14), inner (15) and outer (16) Install the reaction sleeves in the same orientation as springs, and reaction sleeve (11) from the piston rod...
Page 326 ACCESSORIES AND MISCELLANEOUS REPAIR TN1117 Figure 9-34 5. Hold the cylinder weldment (11) vertically, and fill to within 2.75—3.00 in. (70—75 mm) from the top edge TN1114 of the cylinder weldment with 80W-90 oil. Figure 9-36 6. Install the piston rod assembly (10) into the cylinder 9.
Page 327: Seat And Mounting Plate
ACCESSORIES AND MISCELLANEOUS REPAIR TN1026 Figure 9-40 TN1105 3. Disconnect the seat switch wiring harness (7) from Figure 9-38 the machine harness (6). ® 4. Support the seat (1). 12. Apply Teflon tape to the threads of screw (21), and install screw.
Page 328 ACCESSORIES AND MISCELLANEOUS REPAIR TN1028 TN1031 Figure 9-42 Figure 9-44 ® 10. Remove four Torx screws (16), and remove the seat 14. Disconnect the wiring harness (22) from the seat platform (15). switch (21). TN1032 Figure 9-45 15. Depress the tabs (23) on both sides of the seat switch, and remove the switch through the opening (24) in the bottom of the seat cushion.
Page 329: Work Light
ACCESSORIES AND MISCELLANEOUS REPAIR Work Light Rear Wheel Removal and Installation Removal and Installation See Figure 9-46. See Figure 9-48. 1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-7.) 2. Disconnect the battery negative (–) cables at the Prevent personal injury.
Page 330: Front Wheels
ACCESSORIES AND MISCELLANEOUS REPAIR Front Wheels Removal and Installation See Figure 9-49. WARNING Prevent personal injury. Use properly rated lifting devices. Always be sure load is balanced before lifting. 1. Park the mower safely. (See “Park Mower Safely” on page 1-7.) TN1065 Figure 9-49 NOTE...
Page 331 ACCESSORIES AND MISCELLANEOUS REPAIR Page Intentionally Blank 9-20 4181384 First Edition...
Page 332 Removal and Installation ....4-74 AR-3 .......
Page 333 Eye Protection ......1-7 Deck Drive Motor—AR-3 Disassembly and Assembly ... . . 8-27 Removal and Installation .
Page 334 Front Roller—TR-3 Hydraulic Component Location—AR-3 ... . . Disassembly, Inspection, and Assembly . . . 8-43 Removal and Installation ....8-42 Component Location—TR-3 .
Page 335 Removal and Installation ....6-50 Lift Cylinder Mower Deck—AR-3 Disassembly and Assembly ... . . 6-56 Disassembly and Assembly .
Page 336 Marcelling ......8-17 Cutting Units—AR-3 ....
Page 337 Electrical Main ..... . . 4-10 Removal and Installation ....4-78 Hydraulic Main—AR-3 Model AR30001 ..6-10 Hydraulic Main—AR-3 Model AR30002 ..6-12 Starter Motor Hydraulic Main—TR-3 .
Page 338 Electrical Sub-Circuits ....4-17 Mechanical—AR-3 ....
Page 339 INDEX Work Light Removal and Installation ....9-18 Work Light Circuit Schematic, Electrical ....4-49 Theory of Operation, Electrical .
Page 341 Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations. A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support.

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Tr-3 Ar30001 Ar30002 Tr30001 Tr30002

Jacobsen AR-3 Technical/Repair Manual

Table of Contents

Chapter 3 Engine

Chapter 4 Electrical

Chapter 5 Hydrostatic Power Train

Chapter 6 Hydraulics

Chapter 7 Steering

Chapter 8 Cutting Units

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