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Foreword General CALIFORNIA Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen® PGM 22™ walking greens 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 through the latest factory-approved troubleshooting and cause cancer and birth defects or other...
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Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2008 Textron Inc. “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4157082 First Edition...
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Table of Contents Safety Specifications and General Information Engine Electrical Power Train Handle and Controls Brakes Cutting Unit Miscellaneous Accessories 4157082 First Edition...
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.
SAFETY Safety Label Locations Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. TN0004 TN0003 Figure 1-1 Figure 1-2 4157082 First Edition...
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SAFETY ADVERTENCIA WARNING 1. Leer el manual del operador. No permitir 1. Read operators manual. Do not allow que personas no capacitadas para ello usen la maquina. untrained operators to use machine. 2. Mantener los protectores en su lugar y sus 2.
SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figures 1-3 through 1-6. mower. Inspect the mower for any damaged, missing, or WARNING unreadable decals. Replace decals as needed before placing the mower back in service. Before you clean, adjust, or repair this equipment, disengage all drives, engage parking Keep Work Area Clean...
SAFETY Use Lifting Equipment Safely WARNING Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Using underrated or worn lifting components can result in death or serious injury. • Always use a lifting device with a lifting capacity greater than the weight of the item being lifted.
SAFETY Use Compressed Air and Air Service Tires Safely Tools Safely WARNING WARNING An inflated tire contains explosive force. Use care when handling wheels and tires. Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious •...
SAFETY Handle Fuel Safely Handle Chemical Products Safely Handle fuel with care—it is highly flammable. WARNING WARNING • Never remove the fuel cap from the fuel tank, Exposure to chemical products could result in or add fuel, when the engine is running or serious injury.
SAFETY Dispose of Waste Materials Safely Routine service can produce waste products such as used oil, grease, and used batteries. If not handled properly, these materials can pose a threat to the environment. Collect fluids in well-marked, approved storage containers. Some waste fluids can react with certain types of plastics.
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Chapter 2 Specifications and General Information Mower Identification ............2-2 Model Identification Number .
Always provide the serial number of the unit when ordering replacement parts or requesting service information. Engine Serial Number ® A Textron Company CHARLOTTE, NC MADE IN U.S.A. YEAR OF 2006 PRODUCTION:...
SPECIFICATIONS AND GENERAL INFORMATION Component Location CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0004 Throttle Paddle Product Identification Plate Handle Kickstand OPC Bail Lever Traction Drum Fuel Shutoff and Choke Control Figure 2-4: Component Location—Rear TN0003 Park Brake Lever...
SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Brakes PGM 22 Park Brake Lever Actuating Force 10 (4.5) lb (kg) Park Brake Band—Anchor Pin 1.50 (38) in. (mm) Center-to-Center Distance (Park Brake Released) Cutting Unit PGM 22 Flat Surface Height at the Front of the 1/32 (0.8) in.
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SPECIFICATIONS AND GENERAL INFORMATION Mower PGM 22 Height-of-Cut Range 5/64—7/16 (2.0—11.1) in. (mm) High Profile Cut Yield 5/32 (4.0) in. (mm) Low Profile Cut Yield 7/64 (2.8) in. (mm) Tournament Cut Yield 5/64 (2.0) in. (mm) Super Tournament Cut Yield 1/16 (1.6) in.
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.
SPECIFICATIONS AND GENERAL INFORMATION Gasoline, Oils and Lubricant Refer to the engine manufacturer’s manual before using oxygenated (blended) fuel. Specifications Operational Checks Engine Oil Use only SAE 10W-30 engine oils with API classification WARNING SF or SG. Refer to the engine manufacturer’s manual for additional Never attempt to operate the machine unless you information.
SPECIFICATIONS AND GENERAL INFORMATION Engine Oil Check See Figures 2-5 through 2-7. CAUTION Maintain proper oil level! Operation of the mower with low oil level will result in engine damage. NOTE Allow the mower to cool before checking oil level. 1.
SPECIFICATIONS AND GENERAL INFORMATION Park Brake Check NOTE See Figure 2-10. The mower must be level before checking the oil level. 3. Push the mower forward so that the mower is resting on the traction roller. TN0021 Figure 2-8 4. Remove the inspection plug (1). When the chain case is properly filled the oil should be up to the level of the hole.
SPECIFICATIONS AND GENERAL INFORMATION 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0082 Figure 2-11 TN0031 Figure 2-13 2. Disengage the reel clutch lever (1). WARNING Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled. 3.
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SPECIFICATIONS AND GENERAL INFORMATION 4. Slide OPC bail (2) to the left and engage. Engine speed will increase, drive mechanism will engage, and wheels will begin to turn. Does the drive mechanism engage? Stop the engine immediately and repair the system.
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SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-12 4157082 First Edition...
ENGINE Specifications General Engine Specifications Engine PGM 22 Manufacturer/Model Honda/GX120 K1QJG2 Engine Type 4-Stroke, Overhead Valve, Single Cylinder Displacement 7.3 (118) cu in. (cc) Bore x Stroke 2.4 x 1.7 (60 x 42) in. (mm) Cooling System Forced Air Ignition System Transistorized Magneto PTO Shaft Rotation Counterclockwise...
ENGINE Troubleshooting This troubleshooting chart will cover basic engine troubleshooting information. A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for further engine troubleshooting information. Condition Probable Cause Remedy Engine does not start.
ENGINE Checks and Adjustments 8. Pull bail cable (4) until throttle lever (3) moves and engine speed starts to increase. Tighten cable clamp screw (5). Engine speed should be between 1500 Throttle and Clutch Control Cable and 1800 rpm. Verify that clutch is not engaged. Adjustment 9.
ENGINE TN0007 Figure 3-4 12. Slide cable guide (13) down until it touches throttle lever (12). Tighten cable guide set screw (11). TN0016 Figure 3-5 13. Move throttle paddle (14) to highest setting. Engage bail and verify that cable guide (13) does not touch 2.
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ENGINE TN0007 Figure 3-7 8. Remove jam nut (12) from throttle cable sheath (10). 9. Pull throttle cable sheath (10) down and remove it from handlebar top plate (9). 10. Disconnect end of throttle cable (13) from throttle paddle (8). 11.
ENGINE Engine and Clutch Removal See Figures 3-10 through 3-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove throttle cover. (See “Throttle Cover” on page 3-5.) 3. Remove air cleaner cover and air cleaner. (Refer to engine manual.) TN0005 Figure 3-10...
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ENGINE TN0009 TN0072 Figure 3-13 Figure 3-11 NOTE NOTE Use a strap wrench to prevent clutch from turning while removing screws. Label all wires before disconnecting to ensure correct installation. 11. Remove three socket-head screws (20) and lock washers (21). 7.
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ENGINE TN0079 Figure 3-17 TN0074 Figure 3-15 18. Remove four spacers (38) from frame. 14. Remove nut (30), lock washer (31), and screw (32). 15. Remove screw (27), lock washer (28), and bracket (29) from front of engine mounting plate (33). 16.
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ENGINE TN0076 Figure 3-19 20. Loosen two set screws (42) and remove clutch (43) from engine output shaft. 44 45 TN0045 Figure 3-21 23. Remove four nuts (53), lock washers (52), carriage bolts (51), and mounting plate (50) from engine (49). 44 45 TN0077 Figure 3-20...
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ENGINE Installation See Figures 3-22 through 3-33. Required Materials Anti-Seize Compound Loctite 242 (Blue) Thread Sealant TN0077 Figure 3-23 2. Install rear half of clutch cover (9) on engine using two screws (6) and washers (7). 3. Install key (10) in output shaft (8). 4.
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ENGINE TN0079 Figure 3-27 TN0076 8. Install four spacers (19) on frame and install Figure 3-25 engine/clutch assembly. 6. Tighten two set screws (15). TN0074 Figure 3-28 9. Secure engine mounting plate (28) to frame using a TN0075 screw (20) and lock washer (21). Do not tighten Figure 3-26 hardware at this time.
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ENGINE 39 40 39 40 29 30 39 40 39 40 TN0008 Figure 3-31 17. Install front half of clutch cover (41) using four screws TN0073 (39) and lock nuts (40). Figure 3-29 12. Install two screws (29) and lock washers (30) at rear of engine mounting plate (31).
ENGINE TN0005 Figure 3-33 21. Loosen throttle lever pivot nut (46) until throttle lever (48) returns to idle by itself. 22. Route throttle cable (57) and sheath (55) through cable clamp (53) and install cable guide (51). Do not tighten cable clamp screw (56) or cable guide set screw (58) at this time.
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Chapter 4 Electrical Component Location ............4-2 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. Single Pole, Single Throw Double Pole, Single Throw (SPST) (DPST) Single Pole, Double Throw Double Pole, Double Throw (SPDT) (DPDT) Temperature Switch...
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ELECTRICAL 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 4157082 First Edition...
ELECTRICAL Circuit Operation Ignition Circuit Operation See Figure 4-4. E-Stop Switch Engine On/Off Switch Splice 1 Ignition Coil Spark Plug Figure 4-4: Ignition Circuit—Run Position A magnet is mounted on the flywheel. When the flywheel turns, the magnet passes by the ignition coil (T1). The moving magnetic field provided by the magnet induces voltage in the primary windings in the ignition coil.
ELECTRICAL Troubleshooting Symptom: Engine does not run. Probable Cause Remedy Faulty E-stop switch. Test switch. (See “E-Stop Switch” on page 4-11.) Faulty engine on/off switch. Test switch. (See “Engine On/Off Switch” on page 4-11.) Faulty ignition coil. Test spark plug for spark. (Refer to engine manual for test procedure.) Symptom: Engine continues to run with E-stop switch in the OFF position.
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.
ELECTRICAL Engine On/Off Switch 5. Move engine on/off switch to the ON position and check for continuity. See Figures 4-5 and 4-6. Is continuity indicated? The switch is faulty; replace the switch. Required Tools or Equipment Proceed to Step 6. Digital Multimeter, Ohmmeter, or Continuity Tester 6.
ELECTRICAL 6. Move the engine on/off switch to the OFF position and check for continuity. Is continuity indicated? The switch is good. The switch is faulty; replace the switch. 7. Install E-stop switch. (See “Component Removal and Installation” on page 4-12.) 8.
POWER TRAIN Troubleshooting Condition Probable Cause Remedy Traction drive does not engage when OPC Park brake engaged. Release park brake. (Refer to Operator’s bail is engaged. Manual.) Clutch (OPC) cable not adjusted properly. Adjust clutch (OPC) cable. (See “Throttle and Clutch Control Cable Adjustment” on page 3-4.) Faulty traction/reel clutch.
POWER TRAIN Repair 7. Remove collar (3) and spring (4) from clutch control cable (7). 8. Loosen cable clamp screw (2) and remove the clutch Clutch Control Cable control cable (7) and sheath (8) from swivel nut (5) and cable guide (6). Removal See Figures 5-2 and 5-3.
POWER TRAIN Traction/Reel Drive Chain Case Cover Removal See Figures 5-6 through 5-9. 1. Park mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove left-side park brake band. (See “Park Brake Band” on page 7-6.) TN0044 Figure 5-6 3.
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POWER TRAIN 9 10 TN0031 Figure 5-8 NOTE TN0041 Record the location and number of shims used (if any) to Figure 5-9 ensure correct installation. 5. Remove the bedknife shoe mounting screw (8), NOTES shake-proof cone washer (9) and shim(s) (10) from •...
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POWER TRAIN Installation NOTE See Figures 5-11 through 5-16. ® Apply Loctite 242 (Blue) Thread Sealant to the threads of the socket-head screws (3 and 5) before installation. Required Materials 4. Install the cover (7) on the chain case using five ®...
POWER TRAIN Drive Chains NOTES • Apply anti-seize compound to the threads of the Removal bedknife shoe mounting screws before installing. See Figures 5-17 through 5-23. • Install shims (if any) in the same locations as 1. Park mower safely. (See “Park Mower Safely” on recorded during removal.
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POWER TRAIN 5. Remove washer (3) from reel shaft (5). TN0092 Figure 5-21 TN0090 8. Remove retaining ring (13) and washer (14) from the Figure 5-19 traction drum shaft (15). 6. Remove four screws (7) and lock nuts (8) and remove the front half of the clutch cover (9).
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POWER TRAIN TN0134 TN0096 Figure 5-26 Figure 5-23 3. Install the reel-to-traction chain (8) and sprocket 10. Remove key (18) from clutch/input shaft (19). assembly by sliding the drive pinion sprocket (9) onto the traction drum shaft (10) until the reel sprocket (6) Installation is started on the reel shaft (7).
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POWER TRAIN TN0092 Figure 5-28 6. Install washer (15) and retaining ring (14) on the traction drum shaft (16). TN0089 Figure 5-30 8. Install washer (20) on reel shaft (22). 9. Install two keys (21 and 23) on reel shaft (22). 18 19 TN0091 Figure 5-29...
POWER TRAIN 26 27 26 27 26 27 TN0094 26 27 Figure 5-33 TN0090 6. Remove clutch/input shaft (1). Figure 5-32 11. Install the front half of the clutch cover (28) using four screws (26) and lock nuts (27). 12. Install traction/reel chain case cover. (See “Traction/Reel Drive Chain Case Cover”...
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POWER TRAIN TN0099 Figure 5-35 TN0122 10. Remove oil fill plug (6). Figure 5-37 15. Remove bearing (12) from the traction drum shaft (13). TN0098 Figure 5-36 11. Rotate the planetary gear assembly (10) until the TN0143 outer set screw (8) aligns with oil filler hole (7). Figure 5-38 12.
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POWER TRAIN Disassembly and Assembly See Figure 5-39. TN0101 Bearing Grease Fitting Type 1 Groove Pin (3) Oil Seal Grease Seal Chain Case Housing (Press-Fit) Chain Guide Truss-Head Screw Filler Plug Bushing (2) (Press-Fit) Socket-Head Screw Lock Washer Handle Stud (Press-Fit) Oil Seal Lock Washer Washer...
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POWER TRAIN Installation See Figures 5-40 through 5-46. Required Materials ® Loctite Primer ® Loctite 518 Gasket Eliminator TN0095 Figure 5-42 9. Install bearing (13) on the reel shaft (16). 10. Install collar (15) on the reel shaft (16) and secure using a pin (14).
POWER TRAIN Right Frame Removal See Figures 5-47 through 5-55. 1. Park mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove engine. (See “Engine and Clutch” on page 3-7.) 3. Remove handle assembly. (See “Handle Assembly” on page 6-3.) 4.
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POWER TRAIN 8. Remove four flat socket-head screws (5) and right brake mounting bracket (4). TN0118 TN0116 Figure 5-51 Figure 5-49 11. Remove spacer (9) and bearing (10) from the traction 9. Remove the bearing housing assembly (6) and drum shaft. gasket (7).
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POWER TRAIN TN0112 Figure 5-53 13. Remove nut (17), washer (15), and spring (16) from the reel shaft. TN0119 Figure 5-54 14. Remove bearing (18) from the reel shaft. 19 20 19 20 TN0113 Figure 5-55 15. Remove nut (21) and lock washer (22). 16.
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POWER TRAIN Disassembly and Assembly See Figure 5-56. TN0120 Grease Fitting Oil Seal Oil Seal Handle Stud (Press-Fit) Grease Fitting Bearing Cup and Cone (2) Frame Bushing (Press-Fit) Figure 5-56 Assembly Note • Install new oil seals (3 and 5). •...
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POWER TRAIN Installation See Figures 5-57 through 5-64. TN0112 Figure 5-59 4. Install spring (8), washer (7), and nut (9) on the reel shaft. TN0113 Figure 5-57 1. Install the right side frame (5) to the front and rear crossbars using four screws (1) and lock washers (2). 2.
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POWER TRAIN TN0110 Figure 5-63 TN0117 8. Install the right brake mounting bracket (17) using Figure 5-61 four flat socket-head screws (18). 9. Install roll pin (16) in the transport drum shaft. 6. Install nut (12) on the traction drum shaft. TN0116 TN0109 Figure 5-62...
POWER TRAIN Traction Drive Drum Assembly Removal See Figures 5-65 through 5-68. 1. Park mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove drive chains. (See “Drive Chains” on page 5-9.) TN0122 Figure 5-67 8. Remove bearing (7) from the traction drum shaft (8). 9.
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POWER TRAIN Disassembly and Assembly See Figure 5-69. TN0135 Special Bolt (4 per Drum) Traction Drum (2) Differential Assembly Figure 5-69 Required Materials ® Loctite 242 (Blue) Thread Sealant Assembly Note ® Apply Loctite 242 (Blue) Thread Sealant to the threads of the special bolts (1) before installation.
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POWER TRAIN Installation See Figures 5-70 through 5-73. TN0102 Figure 5-72 4. Install inner set screw (8) into the planetary gear assembly (7), until the end is flush with the bottom of the threaded hole. TN0121, 0144 Figure 5-70 1. Install the traction drum assembly (1) into the frame assembly (2).
POWER TRAIN Traction Drum Disassembly and Assembly See Figure 5-74. TN0137 Grease Fitting Bushing Traction Drum Grease Seal Figure 5-74 Assembly Note Install a new grease seal (4). 5-26 4157082 First Edition...
HANDLE AND CONTROLS Adjustments Handle Height Adjustment See Figure 6-1. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0024 Figure 6-2 2. Remove four socket-head screws (2) and remove rear half of cover (1). TN0023 Figure 6-1 2.
HANDLE AND CONTROLS Handle Assembly Installation See Figures 6-4 and 6-5. Removal See Figures 6-6 through 6-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect throttle cable at engine throttle plate. (See “Throttle Cable” on page 3-5.) 3.
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HANDLE AND CONTROLS TN0036 TN0033 Figure 6-9 Figure 6-7 12. Remove handle assembly, by pressing in on handle NOTES tube (19) until end of tube clears stud (20). Slide other side off other stud. • Support handle assembly before removing mounting hardware.
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HANDLE AND CONTROLS TN0036 TN0033 Figure 6-11 Figure 6-13 2. Slide one handle tube (5) onto stud (6). Press other 6. Connect torsion spring (16) to handle stop (15). handle tube in until end of tube slips over end of stud. 3.
HANDLE AND CONTROLS 14. Adjust throttle and clutch cable. (See “Throttle and Clutch Control Cable Adjustment” on page 3-4.) 15. Check brake cable adjustment. Adjust as needed. (See “Park Brake Check and Adjustment” on page 7-4.) Handle and OPC Bail Removal TN0064 See Figures 6-15 through 6-17.
HANDLE AND CONTROLS Throttle Paddle Removal and Installation See Figure 6-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove handle cover. (See “Handle and OPC Bail” on page 6-6.) TN0060 Figure 6-19 Connect throttle cable (8) to handle (7) 10 11 TN0059 TN0063...
HANDLE AND CONTROLS Brake Control Lever Installation See Figures 6-24 and 6-25. Removal See Figures 6-22 and 6-23. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Release park brake. 3. Remove rear half of handle cover. (See “Handle Cover”...
BRAKES Specifications Brakes PGM 22 Park Brake Lever Actuating Force 10 (4.5) lb (kg) Park Brake Band—Anchor Pin 1.50 (38) in. (mm) Center-to-Center Distance (Park Brake Released) 4157082 First Edition...
BRAKES Troubleshooting Condition Probable Cause Remedy Park brake does not engage when the Park brake cables not adjusted properly. Adjust the park brake cables. (See “Park lever is engaged. Brake Check and Adjustment” on page 7-4.) Park brake cables damaged. Replace park brake cables.
BRAKES Checks and Adjustments 6. If the brakes do not meet specifications, proceed to “Adjustment Procedure.” Park Brake Check and Adjustment Adjustment Procedure See Figures 7-1 through 7-4. NOTE Check Procedure Minor adjustments are made at the handle. 1. Park the mower safely. (See “Park Mower Safely” on 1.
BRAKES Installation 5. Route the end of the brake cable (20) through the bracket (14), upper brake band pin (15), and the See Figures 7-8 and 7-9. lower brake band pin (19). 6. Position the brake band so the upper brake band pin (15) rests against the end of the cable sheath (13).
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BRAKES Installation See Figures 7-11 and 7-12. TN0012 Figure 7-11 1. Install park brake band (6) on bracket (3). 2. Install wheel hub (1). (See “Wheel Hubs and Bearings” on page 9-3.) 3. Install the lower brake band pin (8) into the brake band (6).
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CUTTING UNIT Specifications Adjustments PGM 22 Flat Surface Height at the Front of the 1/32 (0.8) in. (mm) Bedknife (Minimum) Reel-to-Bedknife Gap 0.001—0.003 (0.025—0.076) in. (mm) Reel Side-to-Side Clearance (Reel 0.040 (1.27) in. (mm) Bearing Pre-Load) 4157082 First Edition...
CUTTING UNIT Component Location Troubleshooting Cutting unit troubleshooting is broken down into two areas: Quality of Cut Appearance and Mechanical. Quality of Cut Appearance Troubleshooting, as the name states, evaluates the mower’s performance by the visual appearance of the cut delivered by the mower. Undesirable patterns and other conditions noted may be caused by various mechanical, environmental (variations in turf, grass conditions, weather, etc.), or operating...
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CUTTING UNIT 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 inches (15—20 cm).
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CUTTING UNIT 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 inches (5 cm) or less. TN0220 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
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CUTTING UNIT Step Cutting Step cutting is grass that is cut taller on one side of the reel than the other. This is usually caused by mechanical wear or an incorrect roller adjustment. TN0221 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
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CUTTING UNIT Scalping Scalping is areas of grass 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. TN0222 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
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CUTTING UNIT Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Bedknife improperly adjusted. Adjust bedknife. (See “Bedknife-to-Reel Adjustment” on page 8-13.) Dull cutting edges. Sharpen reel and bedknife.
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CUTTING UNIT Streaks A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife. TN0224 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 8-17.) Damaged or unevenly worn reel.
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CUTTING UNIT Windrowing Windrowing is the deposit of clippings concentrated at one end of the cutting unit, forming a line in the direction of travel. TN0225 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall.
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CUTTING UNIT Rifling or Tramlining Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife. TN0987 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
CUTTING UNIT Mechanical Troubleshooting Cutting Unit Condition Probable Cause Remedy Reel drive does not engage when Throttle/clutch cable is not adjusted Adjust throttle/clutch cable. (See “Throttle Operator Presence Control (OPC) bail is properly. and Clutch Control Cable Adjustment” engaged. on page 3-4.) Reel clutch is not engaged.
CUTTING UNIT Checks and Adjustments 7. Grass conditions will also affect the adjustment. a. Dry, sparse conditions will require a wider gap to prevent heat build-up and damage to the reel and Reel and Bedknife Inspection bedknife. See Figure 8-2. b.
CUTTING UNIT 5. Adjust the trailing edge of the reel in the same manner, then recheck the adjustment at the leading edge. 6. Tighten nut (2). Recheck adjustment. 7. When the reel and bedknife are properly adjusted, the reel will spin freely and will cut a piece of newspaper along the full length of the reel when the paper is held at 90°...
CUTTING UNIT Reel Bearing Pre-Load Adjustment See Figures 8-7 through 8-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0011 Figure 8-6 3. Loosen nuts (2) on both sides just enough to allow knob (1) to raise the front roller or turf groomer. Raise both sides an equal amount.
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CUTTING UNIT 9 10 9 10 TN0153 Figure 8-9 4. Install reel cover (7) and new gasket (8) using four socket-head screws (9) and lock washers (10). 8-16 4157082 First Edition...
CUTTING UNIT Repair Bedknife Removal and Installation Grass Shield See Figure 8-11. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 8-10. 2. Tip mower back on traction drum or tires. Do not 1.
CUTTING UNIT Bedknife Shoe Removal See Figures 8-12 through 8-15. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0030 Figure 8-14 4. Remove nut (6). 5. Tip mower back on traction drum or tires. Do not leave the mower tipped back for an extended length of time or oil may migrate into the combustion TN0030...
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CUTTING UNIT Disassembly and Assembly Installation See Figure 8-16. See Figures 8-17 through 8-19. Required Materials Anti-Seize Compound TN0156 Figure 8-17 1. Install the bedknife shoe assembly (2) with adjustment rod assemblies (1). TN0038 Nut (4) Bedknife Shoe Cups (4) Bedknife Adjuster Bolt (2) Spring (2) Figure 8-16...
CUTTING UNIT Reel Assembly Removal See Figures 8-20 and 8-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove drive chains. (See “Drive Chains” on page 5-9.) TN0037 Figure 8-19 NOTES • Apply anti-seize compound to the threads of the bedknife shoe mounting screws before installing.
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CUTTING UNIT CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 7. Remove the reel (6) from the frame (5). Installation See Figures 8-22 and 8-23. TN0095 Figure 8-23 3. Install the reel bearing (4) on the left (drive) side of the reel shaft (7).
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MISCELLANEOUS Specifications Transport Tires PGM 22 Transport Tire Air Pressure 6—8 (41—55) psi (kPa) Repair 3. To Install Wheels: Set the park brake, pull the retaining clip (2) back and hold. Place the wheel (1) on the hub and turn the wheel backwards until studs Transport Wheels (Optional) (4) on the rear of wheel line up with holes in the hub (3).
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MISCELLANEOUS Wheel Hubs and Bearings Disassembly See Figure 9-6. Removal See Figures 9-4 and 9-5. NOTE The hub assemblies are unique to each side and are marked “L” and “R.” Do not exchange them side-for-side. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
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MISCELLANEOUS TN0051 TN0056 Figure 9-10 Figure 9-8 2. Install bushing (5) and latching collar (6). NOTE Always use new seals. 3. Apply a thin film of lithium grease NLGI Grade 2 to the lips of the seals (8). 4. Using a seal driver, install seals (8) in the wheel hub (9).
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MISCELLANEOUS Disassembly and Assembly See Figure 9-14. TN0065 Figure 9-12 3. Remove two screws (1) and lock washers (2). 4. Remove kickstand assembly (3). TN0066 Support Bracket Groove Pin Support Rod and Foot Rest Spring Figure 9-14 TN0067 Figure 9-13 Installation Notes •...
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ACCESSORIES Troubleshooting Turf Groomer Condition Probable Cause Remedy Turf groomer does not engage when clutch Drive belt not properly tensioned. Adjust drive belt tension. (See “Turf is engaged. Groomer Drive Belt Tension Adjustment” on page 10-6.) Drive belt worn, stretched, or damaged. Replace drive belt.
ACCESSORIES Gear Drive Condition Probable Cause Remedy Vertical reel/soft touch brush does not Reel clutch not engaged. Engage reel clutch. See Operator’s engage when clutch is engaged. Manual. Traction/reel drive clutch faulty. Replace clutch. (See “Engine and Clutch” on page 3-7.) Shifter shaft roll pin loose or broken.
ACCESSORIES Checks and Adjustments Turf Groomer Drive Belt Tension Adjustment See Figures 10-2 through 10-4. NOTICE To prevent permanent damage to the belt, do not over-tighten, twist, fold, or bend the belt. Over-tightening the belt will cause premature belt failure and abrasive wear of the pulley and bearings.
The turf groomer is designed to Required Tools be a conditioner, not a vertical mower. Textron Turf Care and Specialty Products does Height-of-Cut Gauge Bar (Jacobsen P/N 158568) not recommend setting the groomer blades more than 1/16 in. (2 mm) below the reel cutting height.
ACCESSORIES 4. Adjust the brush assembly (3) to the desired depth below the ground line (bottom of rollers, 4 and 5), and tighten square head bolts (2) and jam nuts (1): a. For best results, position the brush 1/16 in. (1.58 mm) below the rollers.
ACCESSORIES Repair—Front Rollers Front Roller—Solid Tube and Segmented Removal See Figures 10-9 through 10-11. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels. 3.
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ACCESSORIES Disassembly—Solid Rollers See Figure 10-12. TN0314 Figure 10-13 1. Remove the shield (1) from one side of each new bearing (2). TN0312 Figure 10-12 1. Remove grease fittings (1 and 5) from the roller shaft (4). 2. Support one end of the roller (8), allowing enough free space for seal (6) and bearing (7) to exit the roller (8).
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ACCESSORIES TN0318 TN0316 Figure 10-17 Figure 10-15 4. Install the roller shaft (9) with bearing (6) into the NOTE roller (8) until the bearing is seated against the Always use new grease seals for installation. shoulder (7) in the roller. ®...
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ACCESSORIES Disassembly—Solid Tube and Grooved 4. Inspect the bearings (2 and 9). If replacement is required, use a blind hole bearing puller to remove Rollers the bearing cups (1 and 8) from both ends of the See Figure 10-18. roller (7). 5.
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ACCESSORIES Assembly—Solid Tube and Grooved Rollers NOTE See Figure 10-19. Bearings and bearing cups should always be replaced as a set. Required Tools and Materials 2. If removed, press new bearing cups (1 and 8) in the ® Permatex Anaerobic Sealer (or equivalent) roller (7).
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ACCESSORIES Disassembly—Grooved Disc Roller Assembly—Grooved Disc Roller See Figure 10-20. See Figure 10-21. TN0254 TN0254 TN0254 TN0254 Figure 10-20 Figure 10-21 1. Remove grease fittings (1 and 8) from the roller shaft 1. Install bearing (3) in the roller (5). (4).
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ACCESSORIES Disassembly—Grooved Segmented Roller See Figures 10-22 and 10-23. TN0252 TN0252 Figure 10-23 NOTE All three roller segment assemblies are disassembled in the same way. 5. Remove grease seals (11 and 15), ball bearings (12 and 16) and spacer (13) from the roller segment (14).
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ACCESSORIES 2. Apply lithium grease NLGI Grade 2 to the inside of Installation the spacer (3), and install the spacer (3) into the See Figures 10-26 through 10-28. roller segment (4). 1. Apply lithium grease NLGI Grade 2 to the height 3.
ACCESSORIES Repair—Turf Groomer Drive Belt Removal and Installation See Figures 10-29 and 10-30. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0068 Figure 10-28 7. Install carriage bolt (10) through adjuster bracket (13) and secure with flat washer (16), lock washer (15), and nut (14).
ACCESSORIES Drive Assembly 16 17 Removal 18 19 See Figures 10-31 through 10-34. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0334 Figure 10-33 8. Remove set screw (21) and drive pulley (20). 9. Loosen groomer shaft set screw (18) and roller shaft set screw (19).
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ACCESSORIES Disassembly and Assembly See Figure 10-35. TN0336 Figure 10-35 10-20 4157082 First Edition...
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ACCESSORIES 1/4” Lock Washer 5/16” Lock Nut 1/4-20 x 2” Hex Head Screw 14-20 x 3/4” Socket Head Screw 3/8-24 x 1/2” Hex Head Screw Right-Side Roller Bracket 3/8” Lock Washer Right-Side Mower Bracket 3/8” Flat Washer Special Washer Clutch Control Plate 3/8”...
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ACCESSORIES Installation 3. Tighten turf groomer shaft set screw (5) and roller shaft set screw (6). See Figures 10-36 through 10-39. 4. Place a straightedge (10) across the face of clutch pulley (9) and drive pulley (7). Make sure both pulleys are properly aligned.
ACCESSORIES Front Roller and Turf Groomer Installation See Figures 10-43 and 10-44. NOTE The front roller and turf groomer shaft must be removed and installed together. Removal and Installation See Figure 10-45. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
ACCESSORIES Front Roller Disassembly and Assembly See Figure 10-46. TN0328, 0337 Figure 10-46 1. Measure and record the distance between the face of Assembly Notes the locking collar and the bearing face (4). • Assemble roller (3) by reversing the order of 2.
ACCESSORIES Turf Groomer Shaft Assembly Disassembly See Figures 10-47 through 10-50. CAUTION To prevent personal injury and damage to cutting edges, handle the vertical mower shaft assembly with extreme care. TN0340 Figure 10-49 3. Remove the locking collar (6), two spacers (7), blades (8), and spacers (9) from shaft (10).
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ACCESSORIES Assembly See Figures 10-51 through 10-53. TN0341 Figure 10-51 1. Install locking collar (3) flush with the end of shaft (2). Tighten set screw (4). 2. Install two spacers (1) on shaft (2). TN0339, 0338 Figure 10-53 5. Install key (12) in bearing shaft assembly (11). Install shaft assembly (11) into the roller.
ACCESSORIES Repair—Vertical Reel and Soft-Touch Brush Vertical Reel—Disassembly See Figures 10-56 through 10-59. CAUTION To prevent personal injury and damage to cutting edges, handle the blade assembly with extreme care. TN0321 Figure 10-58 5. Remove two spacers (11) from blade roller shaft (14). 6.
ACCESSORIES Vertical Reel—Assembly NOTE See Figures 10-60 through 10-64. The blades must be installed so that the indexing holes are rotated 60° from the hole in the previous blade. Clockwise or counterclockwise rotation is acceptable, as long as the direction of rotation remains the same. 5.
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ACCESSORIES TN0319 Figure 10-64 10. Install key (19) and gear (18) on blade roller shaft (20). Secure the gear using screw (23), lock washer (22), and flat washer (21). 4157082 First Edition 10-33...
ACCESSORIES Soft-Touch Brush—Disassembly and Assembly See Figure 10-65. TN0327 Shaft Gear Bearing (2) (Press Fit) Washer Brush Assembly Lock Washer Screw Figure 10-65 Disassembly Note Assembly Note • Use a knife-edge puller to remove bearing (2) from • Bearing (2) is press fit. Use a press to install bearing shaft (1).
ACCESSORIES Repair—Miscellaneous Strip Brush Removal and Installation See Figure 10-66. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN0307 Figure 10-66 2. Loosen jam nut (3) on both sides of the mower. 3. Remove square head bolt (4), jam nut (3), and washers (2) from roller bracket (1) on both sides of the mower.
ACCESSORIES Scraper Blade Assembly Disassembly and Assembly See Figure 10-67. TN0344 Figure 10-67 1. Park the mower safely. (See “Park Mower Safely” on 8. Remove roller (11), scraper (4), and roller brackets (9 page 1-6.) and 14) from machine as an assembly. 2.
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INDEX Checks and Adjustments Accessories ......10-6 Backlapping Procedure ....8-14 Accessories Bedknife-to-Reel Adjustment .
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INDEX Drive Chains Front Roller and Turf Groomer Installation ......5-11 Removal and Installation ....10-25 Removal .
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