Textron JACOBSEN R-311 69166 Technical/Repair Manual
  1. Manuals
  2. Brands
  3. Textron Manuals
  4. Lawn Mower
  5. JACOBSEN R-311 69166
  6. Technical/repair manual

Textron JACOBSEN R-311 69166 Technical/Repair Manual

Hide thumbs
1
2
3
4
5
6
7
Table Of Contents
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
Table of Contents

Advertisement

Quick Links

Download this manual
R-311™
Rotary Mower
Technical/Repair Manual
69166

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the JACOBSEN R-311 69166 and is the answer not in the manual?

Questions and answers

Related Manuals for Textron JACOBSEN R-311 69166

Summary of Contents for Textron JACOBSEN R-311 69166

  • Page 1 R-311™ Rotary Mower Technical/Repair Manual 69166...
  • Page 2 ©2009 Jacobsen, A Textron Company. All rights reserved.
  • Page 4 Foreword General California Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen R-311 rotary 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...
  • Page 5 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2009, Jacobsen, a Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4203781 First Edition...
  • Page 6 Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous Repair 4203781 First Edition...

  • Page 8: Table Of Contents

    Chapter 1 Safety Introduction ..............1-2 Prepare for the Job .

  • Page 9: 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 10 SAFETY TN2166, TN2167 Figure 1-1 4203781 First Edition...
  • Page 11 SAFETY 4181865 4181863 NOTICE Do NOT fold this ROPS if a canopy is attached. Damage to the mower hood could result. 4203781 First Edition...
  • Page 12 SAFETY CAUTION Fill fuel tank to 2 inches below filler neck. DO NOT OVERFILL. 365919 4181861 4181862 4199140 4203781 First Edition...

  • Page 13: Inspect Safety Labels

    SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figures 1-2 and 1-3. 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 14: 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 15: 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 16: Handle Chemical Products Safely

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

  • Page 17: 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 18 Chapter 2 Specifications and General Information Mower Identification ............2-2 Serial Number .

  • Page 19: Mower Identification

    SPECIFICATIONS AND GENERAL INFORMATION Mower Identification Serial Number An identification plate (1) listing the serial number (3) is See Figures 2-1 through 2-5. attached to the frame of the mower and is located just ahead of the rear axle on the right side. Always provide the serial number of the unit when ordering replacement parts or requesting service information.

  • Page 20: Engine Serial Number

    SPECIFICATIONS AND GENERAL INFORMATION TN1858 Figure 2-4 TN1859 Figure 2-5 Engine Serial Number The engine serial number (5) is located on a plate attached to the top of the rocker arm cover which also includes the engine model number and the engine code number.

  • Page 21: Component Location

    SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figures 2-6 and 2-7. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN2166 Seat Left Cutting Unit Instrument Panel Center Cutting Unit Steering Wheel Right Cutting Unit Traction Pedal Fuel Tank Brake Pedal...
  • Page 22 SPECIFICATIONS AND GENERAL INFORMATION TN2167 4WD Valve Hydraulic Oil Tank Front Differential Rear Wheel Motor (2) Battery Figure 2-7: Component Location—Left Side 4203781 First Edition...

  • Page 23: Specifications

    SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Electrical Test and Adjustment Specifications Resistance Across Solenoid Coil—Front Mow 7.1 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Right Mow 7.1 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—...
  • Page 24 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Front Axle Motor—Backplate Assembly Screw Torque 15–18 (20–24) lb-ft (N·m) Front (Drive) Axle Assembly—U-Bolt Nut Torque 50 (67.8) lb-ft (N·m) Front Axle—Ring Gear Screw Torque 45–60 (61–81) lb-ft (N·m) Front Axle—Pinion Nut Torque 200–220 (271–298) lb-ft (N·m) Front Axle—Pinion Rotation Torque 20–40 (2.3–4.5)
  • Page 25 SPECIFICATIONS AND GENERAL INFORMATION Steering Test and Adjustment Specifications Steering System Leakage Test—Cylinder Leakage Zero–Nominal Amount pt (L) Rear Axle Alignment Toe-In Measurement 0.0625 (1.6) in. (mm) Rear Axle Spindle Arm-to-Axle Stop Measurement 0.030–0.060 (0.76–1.5) in. (mm) Repair Specifications Steering Wheel Nut 25–30 (34–41) lb-ft (N·m) Steering Column-to-Steering Unit Screw Torque...
  • Page 26 SPECIFICATIONS AND GENERAL INFORMATION Mower Speed Transport—2WD 0–14.9 (0–24) mph (km/h) Transport—4WD 0–7.8 (0–12.5) mph (km/h) Mowing 0–7.7 (0–12.4) mph (km/h) Reverse 0–6 (0–9.6) mph (km/h) Brakes Brake Pedal Adjusting Nut Torque 20 (27) lb-ft (N·m) Rotor Screw Torque 50 (5.65) lb-in.
  • Page 27 SPECIFICATIONS AND GENERAL INFORMATION Weights and Dimensions Overall Weight 3970 (1801) lb (kg) Width of Cut 134 (3404) in. (mm) Overall Width 139 (3531) in. (mm) Overall Height with OPS 84 (2134) in. (mm) Overall Height with OPS & Canopy 92 (2337) in.
  • Page 28 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 29 SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-12 4203781 First Edition...
  • Page 30 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .

  • Page 31: Specifications

    ENGINE Specifications General Engine Specifications Engine ® Manufacturer/Model Kubota Tier 3/V2203-M-E3B Engine Type 4-stroke, diesel Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45) Number of Cylinders/Configuration 4, in-line Displacement 134.1 (2198) cu in. (cc) Bore x Stroke 3.43 x 3.64 (87 x 92) in.

  • Page 32: Component Location

    ENGINE Component Location Kubota V2203-M-E3B See Figures 3-1 and 3-2. TN2123 Hydraulic Oil Cooler Coolant Overflow Reservoir Engine Coolant Temp Switch Engine Oil Cooler Hydraulic Oil Filter (2) Fan Drive Belt Radiator Oil Pressure Sending Unit Engine Temperature Sensor Thermostat Starter Motor Fuel Pump Air Cleaner Assembly...
  • Page 33 ENGINE TN2124 Hydraulic Tank Engine Oil Fill Cap Oil Filter Fuel Filter Air Cleaner Service Switch Radiator Cap Throttle Cable Figure 3-2: Component Location—Left Side 4203781 First Edition...

  • Page 34: Checks And Adjustments

    ENGINE Checks and Adjustments 7. Loosen nuts (11) and position throttle cable (12) in clamp (10) so that there is approximately 0.040 in. (1 mm) of clearance between the top of the throttle Throttle Cable cable slot (8) and the throttle handle stud (9). 8.

  • Page 35: Purging The Fuel System

    ENGINE Purging the Fuel System 7. Turn the ignition switch to the ON position to allow the fuel pump to operate. Adjustment 8. Close the air vent plug when bubbles disappear from the fuel flow and turn the ignition switch to the off See Figure 3-7.

  • Page 36: Repair

    ENGINE Repair Fan Belt Removal and Installation See Figures 3-8 and 3-9. NOTE Inspect and adjust the new engine belt after the first 50 hours of operation. Check and adjust annually thereafter. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 37: Air Cleaner Assembly

    ENGINE Air Cleaner Assembly Removal and Installation See Figures 3-10 and 3-11. CAUTION • Do not open the air cleaner assembly for inspection or cleaning. Unnecessary removal of the filter increases the risk of injecting dust and other impurities into the engine. •...

  • Page 38: Exhaust Manifold

    ENGINE Installation Notes • Install the muffler in the reverse order of removal. • Install new gaskets during installation. Exhaust Manifold Removal and Installation See Figure 3-14. CAUTION Do not attempt to service the exhaust system when the engine is hot. Serious personal injury can occur.

  • Page 39: Radiator/Oil Coolers

    ENGINE Radiator/Oil Coolers Removal and Installation See Figures 3-15 and 3-16. TN2154 Upper Radiator Hose Radiator Draincock Adapter Hose Clamp (4) Oil Cooler Mounting Tie (4) Screw (2) O-Ring Engine Temperature Sensor Flat Washer (4) Remote Oil Filter Bracket Engine Oil Filter Adapter Screw(5) Oil Cooler Spacer (4) Engine Oil Filter Head...
  • Page 40 ENGINE TN2155 TN2155 Shoulder Bolt (2) Oil Cooler Pivot Plate (2) Hydraulic Oil Cooler Remote Oil Cooler Bracket (2) Nut (2) Oil Cooler Spacer (4) Carriage Bolt (2) Screw (2) Lock Washer (10) Nut (8) Lock Nut (2) Screw (6) Flat Washer (4) Radiator Support Bracket (2) Flat Washer (2)
  • Page 41 ENGINE 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Lower mowing decks to ground. 3. Allow the engine to cool completely. 4. Raise the hood. Hydraulic Oil Cooler Removal See Figures 3-17 and 3-18. NOTE Label all hoses before removing to ensure correct installation.
  • Page 42 ENGINE WARNING Never remove the radiator cap when the coolant is hot. The engine must be shut down and cooled before the radiator cap is removed. Very hot coolant will be sprayed from the radiator if the cap is loosened before the engine has cooled. Serious personal injury can occur.

  • Page 43: Thermostat

    ENGINE Radiator Installation 1. Install the radiator by reversing the order of removal. 2. With the lower radiator hose removed from radiator, flush the inside of the radiator with fresh water. CAUTION Always use a mixture of antifreeze and fresh water in the engine cooling system.

  • Page 44: Throttle Cable And Control Lever

    ENGINE Throttle Cable and Control Lever Removal and Installation See Figures 3-24 through 3-27. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the instrument panel. (See “Instrument Panel” on page 4-87.) 1 2 3 TN2173 Figure 3-23 5.

  • Page 45: Fuel Filter

    ENGINE Installation Notes • Install the throttle cable and control lever by reversing the order of removal. • When replacing a worn or broken throttle cable, route the same as the old cable. • After replacing, follow the adjustment procedure. (See “Throttle Cable”...

  • Page 46: Fuel Pump

    ENGINE Fuel Pump Removal and Installation See Figure 3-30. CAUTION Diesel fuel is highly flammable. Handle with care. Use an approved container with a spout that will fit inside the fuel filler neck. Avoid using unapproved containers to transport fuel. Keep all fuel containers clean and closed when not in use.

  • Page 47: Engine

    ENGINE Engine 10. Disconnect and remove fuel hose (2) from outlet of fuel filter and from injection pump. Removal and Installation 11. Remove two nuts (7), two lock washers (6), four washers (5), and two screws (4) to remove fuel filter See Figures 3-31 through 3-35.
  • Page 48 ENGINE TN2098 Figure 3-34 17. Remove six screws (28) and lock washers (29) to disconnect the hydrostatic pump drive plate (30) from the engine. TN2110 Figure 3-33 14. Loosen clamps (17) and remove air intake hose (18) and hose (19). Cover the intake manifold opening. 15.
  • Page 49 ENGINE WARNING Prevent personal injury. Use a properly rated lifting device. Always be sure the load is balanced before lifting. TN2097 Figure 3-35 18. Using an engine hoist, support the engine (33) and 19. Check for any connected wires and components and remove the four engine mounting bolts (31) flat carefully remove the engine from the machine.

  • Page 50: Engine Service

    ENGINE Engine Service 20. Place the engine on a suitable stand or workbench that will support the full weight in a safe manner while A separate engine manual, prepared by the engine preventing damage to the engine. manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine-related NOTE service.
  • Page 51 ENGINE Page Intentionally Blank 3-22 4203781 First Edition...
  • Page 52 Chapter 4 Electrical Specifications ..............4-4 Test and Adjustment Specifications .
  • Page 53 ELECTRICAL Troubleshooting ............. . 4-63 Glow Plug Circuit .
  • Page 54 ELECTRICAL Repair ..............4-86 Battery .

  • Page 55: Specifications

    ELECTRICAL Specifications Test and Adjustment Specifications Specification Resistance Across Solenoid Coil—Front Mow 7.1 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Right Mow 7.1 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil— 7.1 ± 10% ohms Left Mow Solenoid Coil at 68°...

  • Page 56: Theory And Diagnostic Information

    ELECTRICAL Theory and Diagnostic Information Electrical Component Symbols The following symbols are used in the electrical schematics to represent various electrical components. Switches Single Pole, Single Throw Double Pole, Single Throw (SPST) (DPST) Single Pole, Double Throw Double Pole, Double Throw (SPDT) (DPDT) Proximity Switch...
  • Page 57 ELECTRICAL Motors and Generating Devices Electric Motors (may also Stator include “AC” or “DC.”) Alternator Actuating Devices Solenoid Valve PTO Clutch Engine-Related Devices Ignition Coil Spark Plug Regulator Fuel Shutoff Solenoid Pull-In Hold-In Lights Single-Element Light Dual-Element Light 4203781 First Edition...
  • Page 58 ELECTRICAL Miscellaneous Symbols Enclosure Wires (crossing but not (cabinet, housing, etc.) connected) Ground (to earth) Wiring Connections Ground (to chassis) Coil Direct Current (DC) Battery (as shown on an oscilloscope) Alternating Current (AC) Diode (as shown on an oscilloscope) Resistor Pin and Socket Connector 4203781 First Edition...

  • Page 59: 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. • B1—Engine Temperature Sensor (See Figure 4-4.) • K2—Accessory Relay (See Figure 4-1.) •...
  • Page 60 ELECTRICAL • Y4—Left Mow Solenoid (See Figure 4-3.) • Y5—4WD Solenoid (See Figure 4-3.) • Y6—4WD Rev Solenoid (See Figure 4-3.) • Y8—Cruise Control Magnet (See Figure 4-4.) 4203781 First Edition...

  • Page 61: Electrical Schematic

    ELECTRICAL Electrical Schematic See Figures 4-1 through 4-7. Brn/Red Brn/Red Circuit Start Breaker Pnk/ Wht/ Brn/Red Pnk/Blu Pur/wht Switch Glow Accessory Plug Relay Switch Pnk/Blu Red/ Fuel Grn/Wht Pull-In Relay Circuit Wht/ Breaker Grn/ Circuit Pull-In Hold-In Breaker Glow Fuel Plug Shutoff Alternator...
  • Page 62 ELECTRICAL Electrical Schematic Continued Brn/Red Park Brake Switch Switch Circuit Breaker Red/ Org/Brn Brn/Red Red/Wht Red/Wht Red/Lt Blu Red/Yel Seat Switch Wht/Brn Wht/Brn +12V Enable Right Time Wing 1 Sec. Delay Off Delay Proximity Relay Output Switch Wht/Blk Red/Blu Red/Yel N.O.
  • Page 63 ELECTRICAL Electrical Schematic Continued Circuit Reverse Breaker Front Kick Out Limit Switch Switch Reverse Forward Switch Red/Wht Brn/Red Mom. ON Solenoid Front Enable Switch 4WD Rev Solenoid Brn/Red Front Solenoid Fuel Pump Wing Enable Switch 66A Pnk Lt Grn 66A Pnk Lt Grn Right Left...
  • Page 64 ELECTRICAL Electrical Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay Wht/Grn +12V Lt Blu/Red Wht/Grn +12V Engine Lt Blu/Red Temperature Volt Gauge Meter Signal Brake Engine Pedal Temperature Switch Sensor Lt Blu/Red Cruise Control Switch Cruise Relay Disable Enable Wht/Red Wht/Grn Wht/Grn...
  • Page 65 ELECTRICAL Electrical Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn +12V +12V Fuel Hour Gauge Meter Signal Fuel Level Sensor Lt Blu Grn/Wht Lt Grn Glow Left Right Plug Turn Turn Light Indicator Indicator Lt Blu Grn/Wht Lt Grn TN2284 Figure 4-5 4-14 4203781 First Edition...
  • Page 66 ELECTRICAL Electrical Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Wht/ Return Charge Grn\ Filter Filter Filter Blu/ Service Gry/ Temp Service Service Light Grn\ Light Light Light Blu/ Gry/ Grn\ Return Charge Filter Filter Filter t˚ Pressure Pressure Pressure Switch Switch Temp Switch Switch...
  • Page 67 ELECTRICAL Electrical Schematic Continued Light Optional Switch Work Lights Road Circuit Breaker Work Org/ Tan/Red Tan/Red Org/Blu Tan/ Org/Blu Work Work Tail Light Light Light Org/Blu Org/Blu Cab/Canopy Lt Grn Option Lt Blu Connector Tan/Red Lt Blu Lt Blu Lt Grn Lt Grn TN1751 Figure 4-7...
  • Page 68 ELECTRICAL Page Intentionally Blank 4203781 First Edition 4-17...

  • Page 69: Theory Of Operation And Sub-Circuit Schematics

    ELECTRICAL Theory of Operation and • PTO switch terminal B • Seat switch Sub-Circuit Schematics • 10-amp circuit breaker (F4) • 10-amp circuit breaker (F6) Power Circuit—Theory of Operation Switched power is provided from 10-amp circuit breaker (F6) to the following: Unswitched Power Circuit •...

  • Page 70: Power Circuit Schematic

    ELECTRICAL Power Circuit Schematic See Figures 4-8 through 4-14. Brn/Red Brn/Red Unswitched Power Circuit Switched Power Circuit Interlock Circuit Ground Circuit Circuit Start Breaker Pnk/ Wht/ Brn/Red Pnk/Blu Pur/wht Switch Glow Accessory Plug Relay Switch Pnk/Blu Red/ Fuel Grn/Wht Pull-In Relay Circuit Wht/...
  • Page 71 ELECTRICAL Power Circuit Schematic Continued Brn/Red Park Brake Switch Switch Circuit Breaker Red/ Org/Brn Brn/Red Red/Wht Red/Wht Red/Lt Blu Red/Yel Seat Switch Wht/Brn Wht/Brn +12V Enable Right Time Wing 1 Sec. Delay Off Delay Proximity Relay Output Switch Wht/Blk Red/Blu Red/Yel N.O.
  • Page 72 ELECTRICAL Power Circuit Schematic Continued Circuit Reverse Breaker Front Kick-Out Limit Switch Switch Reverse Forward Switch Red/Wht Brn/Red Mom. ON Solenoid 4WD Rev Solenoid Brn/Red Front Solenoid Wing Fuel Pump Enable Switch 66A Pnk Lt Grn 66A Pnk Lt Grn Right Left Unswitched Power Circuit...
  • Page 73 ELECTRICAL Power Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay Wht/Grn +12V Lt Blu/Red Wht/Grn +12V Engine Lt Blu/Red Temperature Volt Gauge Meter Signal Brake Engine Pedal Temperature Switch Sensor Lt Blu/Red Cruise Control Switch Cruise Relay Disable Enable Wht/Red Wht/Grn...
  • Page 74 ELECTRICAL Power Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn +12V +12V Fuel Hour Gauge Meter Signal Fuel Level Sensor Lt Blu Grn/Wht Lt Grn Glow Left Right Plug Turn Turn Light Indicator Indicator Unswitched Power Circuit Switched Power Circuit Ground Circuit Lt Blu Grn/Wht Lt Grn...
  • Page 75 ELECTRICAL Power Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Wht/ Return Charge Grn\ Filter Filter Filter Blu/ Service Gry/ Temp Service Service Light Grn\ Light Light Light Blu/ Gry/ Grn\ Return Charge Filter Filter Filter t˚ Pressure Pressure Pressure Switch Switch Temp Switch...
  • Page 76 ELECTRICAL Power Circuit Schematic Continued Light Optional Switch Work Lights Road Circuit Breaker Work Org/ Tan/Red Tan/Red Org/Blu Tan/ Org/Blu Work Work Tail Light Light Light Org/Blu Org/Blu Cab/Canopy Lt Grn Option Lt Blu Connector Tan/Red Unswitched Power Circuit Switched Power Circuit Ground Circuit Lt Blu Lt Blu...

  • Page 77: Glow Plug Circuit-Theory Of Operation

    ELECTRICAL Glow Plug Circuit—Theory of Operation Unswitched Power Circuit Unswitched power is available from the battery positive terminal to the starter motor battery terminal and then from the starter motor battery terminal to 50-amp circuit breaker (F1) battery terminal. Unswitched power is available through the 50-amp circuit breaker (F1) to 10-amp circuit breaker (F5).

  • Page 78: Glow Plug Circuit Schematic

    ELECTRICAL Glow Plug Circuit Schematic See Figure 4-15. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/Red Glow Plug Switch Grn/Wht Grn/Wht Grn/ Glow Unswitched Power Circuit Plug Switched Power Circuit Light Glow Plug Circuit Interlock Circuit Grn/ Ground Circuit...

  • Page 79: Start Circuit-Theory Of Operation

    ELECTRICAL Start Circuit—Theory of Operation Key switch terminal S also provides voltage to fuel pull-in relay terminal 86, energizing the relay. With the relay energized, voltage is provided to the fuel shutoff solenoid Unswitched Power Circuit pull-in coil, energizing the coil. With the pull-in coil Unswitched power is available from the battery positive energized, the solenoid plunger retracts.

  • Page 80: Start Circuit Schematic

    ELECTRICAL Start Circuit Schematic See Figure 4-16. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/Red Pnk/Blu Pur/wht Accessory Switch Relay Circuit Breaker Pnk/Blu Mom. ON Pnk/Blu Fuel Pull-In Relay Red/ Wht/ Wht/ Circuit Breaker Pull-In Hold-In Fuel...

  • Page 81: Run Circuit-Theory Of Operation

    ELECTRICAL Run Circuit—Theory of Operation Run Circuit—Off Seat Before leaving the seat, the PTO switch must be in the off Unswitched Power Circuit position and the park brake switch in the on position. With the PTO switch in the off position and park brake switch Unswitched power is available from the battery positive in the on position, voltage is provided from the park brake terminal to the starter motor battery terminal and then...

  • Page 82: Run Circuit Schematic-On Seat

    ELECTRICAL Run Circuit Schematic—On Seat See Figure 4-17. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Switch Relay Circuit Breaker Pnk/Blu Mom. ON Pnk/Blu Seat Switch Wht/Brn Wht/Brn Circuit Breaker Fuel +12V Enable Time Pump...

  • Page 83: Run Circuit Schematic-Off Seat

    ELECTRICAL Run Circuit Schematic—Off Seat See Figure 4-18. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Switch Relay Circuit Breaker Pnk/Blu Mom. ON Pnk/Blu Seat Switch Wht/Brn Wht/Brn Circuit Breaker Fuel +12V Enable Pump Time...
  • Page 84 ELECTRICAL Page Intentionally Blank 4203781 First Edition 4-33...

  • Page 85: Charging Circuit-Theory Of Operation

    ELECTRICAL Charging Circuit—Theory of Operation Unswitched Power Circuit Unswitched power is available from the battery positive terminal to the starter motor battery terminal and then from the starter motor battery terminal to 50-amp circuit breaker (F1) battery terminal. Unswitched power is available through the 50-amp circuit breaker (F1) to 30-amp circuit breaker (F2) input terminal and from circuit breaker (F2) input terminal to 10-amp circuit...

  • Page 86: Charging Circuit Schematic

    ELECTRICAL Charging Circuit Schematic See Figure 4-19. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/Red Pnk/Blu Accessory Relay Pnk/Blu Pnk/Blu Wht/ Circuit Breaker Alternator Circuit Breaker Circuit Breaker Unswitched Power Circuit Switched Power Circuit Charging Circuit Starter Motor...
  • Page 87 ELECTRICAL Page Intentionally Blank 4-36 4203781 First Edition...

  • Page 88: Mow Circuit-Theory Of Operation

    ELECTRICAL Mow Circuit—Theory of Operation When the front deck is lowered, the front limit switch is turned to the on position. With the switch in the on position, voltage is provided to the front mow enable Unswitched Power Circuit switch. When the front mow enable switch is placed in the Unswitched power is available from the battery positive on position, voltage is provided to the front mow solenoid, terminal to the starter motor battery terminal and then...

  • Page 89: Mow Circuit Schematic

    ELECTRICAL Mow Circuit Schematic See Figures 4-20 and 4-21. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Red/Wht Red/Wht Brn/ Red/Lt Blu Red/Lt Blu Pnk/Blu Red/Yel Red/Yel Accessory Relay Seat Pnk/Blu Switch Wht/Brn Wht/Brn +12V Enable Circuit Time...
  • Page 90 ELECTRICAL Mow Circuit Schematic Continued Front Limit Switch Brn/Red Red/Wht Red/Wht Red/Wht Red/Lt Blu Red/Lt Blu Red/Yel Red/Yel Right Wing Proximity Switch Wht/Blk Red/Blu Red/Yel N.O. Red/Wht Front Enable Left Switch Wing Right Proximity Wing Switch Relay Wht/Blk Red/Blu Red/Lt Blu N.O.
  • Page 91 ELECTRICAL Page Intentionally Blank 4-40 4203781 First Edition...

  • Page 92: Four Wheel Drive Circuit-Theory Of Operation

    ELECTRICAL Four Wheel Drive Circuit—Theory of Four Wheel Drive Reverse Circuit Operation When the 4WD switch is held in the momentary on position, voltage is provided to the 4WD and 4WD rev solenoids, energizing the solenoids. Unswitched Power Circuit Unswitched power is available from the battery positive terminal to the starter motor battery terminal and then from the starter motor battery terminal to 50-amp circuit breaker (F1) battery terminal.

  • Page 93: Four Wheel Drive Circuit Schematic

    ELECTRICAL Four Wheel Drive Circuit Schematic See Figure 4-22. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Unswitched Power Circuit Switched Power Circuit 4WD Circuit Accessory Interlock Circuit Relay Ground Circuit Pnk/Blu Circuit Reverse Breaker Kick-Out...

  • Page 94: Four Wheel Drive Reverse Circuit Schematic

    ELECTRICAL Four Wheel Drive Reverse Circuit Schematic See Figure 4-23. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Unswitched Power Circuit Switched Power Circuit 4WD Circuit Accessory Reverse Circuit Relay Interlock Circuit Ground Circuit Pnk/Blu Circuit Reverse...
  • Page 95 ELECTRICAL Page Intentionally Blank 4-44 4203781 First Edition...

  • Page 96: Cruise Control-Theory Of Operation

    ELECTRICAL Cruise Control—Theory of Operation • Cruise control switch is momentarily placed in the disable position. Unswitched Power Circuit When the cruise control switch is placed in the disable position, voltage is provided to cruise cancel relay Unswitched power is available from the battery positive terminal 86, energizing the relay.

  • Page 97: Cruise Control Circuit Schematic

    ELECTRICAL Cruise Control Circuit Schematic See Figures 4-24 and 4-25. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Relay Pnk/Blu Horn Circuit Relay Breaker Seat Switch Lt Blu/Red Lt Blu/Red Wht/Brn Circuit Lt Blu/Red Breaker Wht/Brn...
  • Page 98 ELECTRICAL Cruise Control Circuit Schematic Continued Brake Pedal Switch Lt Blu/Red Cruise Control Switch Cruise Relay Disable Lt Blu/Red Enable Wht/Red Wht/Grn Wht/Grn Gry/ Gry/ Mom. Sw. Unswitched Power Circuit Cruise Cruise Cancel Switched Power Circuit Control Relay Gry/ Magnet Cruise Control Circuit Wht/Grn Gry/...

  • Page 99: Cruise Control Disable Circuit Schematic

    ELECTRICAL Cruise Control Disable Circuit Schematic See Figures 4-26 and 4-27. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Relay Pnk/Blu Horn Circuit Relay Breaker Seat Switch Lt Blu/Red Lt Blu/Red Wht/Brn Circuit Lt Blu/Red Breaker...
  • Page 100 ELECTRICAL Cruise Control Disable Circuit Schematic Continued Brake Pedal Switch Lt Blu/Red Cruise Control Switch Cruise Relay Disable Lt Blu/Red Enable Wht/Red Wht/Grn Wht/Grn Gry/ Gry/ Mom. Sw. Cruise Cruise Cancel Control Unswitched Power Circuit Relay Gry/ Magnet Switched Power Circuit Wht/Grn Gry/ Cruise Control Circuit...
  • Page 101 ELECTRICAL Page Intentionally Blank 4-50 4203781 First Edition...

  • Page 102: Work Lights Circuit-Theory Of Operation

    ELECTRICAL Work Lights Circuit—Theory of Operation Unswitched Power Circuit Light Circuit Unswitched power is available from the battery positive When the light switch is placed in the work position, terminal to the starter motor battery terminal and then voltage is provided to the work lights, turning on the from the starter motor battery terminal to 50-amp circuit lights.

  • Page 103: Work Lights Circuit Schematic

    ELECTRICAL Work Lights Circuit Schematic See Figures 4-28 and 4-29. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Circuit Breaker Accessory Relay Pnk/Blu Seat Switch Wht/Brn Circuit Breaker Wht/Brn +12V Enable Time 1 Sec. Delay Off Delay Relay...
  • Page 104 ELECTRICAL Work Lights Circuit Schematic Continued Light Optional Switch Work Lights Road Circuit Breaker Work Org/ Tan/Red Tan/Red Org/Blu Tan/ Org/Blu Work Work Tail Light Light Light Org/Blu Org/Blu Cab/Canopy Lt Grn Lt Grn Option Lt Blu Lt Blu Connector Tan/Red Glow Left...

  • Page 105: Instrumentation Circuit-Theory Of Operation

    ELECTRICAL Instrumentation Circuit—Theory of Engine Temperature Gauge Operation The engine temperature sensor resistance changes in relationship to the engine coolant temperature. As the engine temperature sensor is heated, the resistance of Unswitched Power Circuit the sensor changes from a high resistance to a low Unswitched power is available from the battery positive resistance.
  • Page 106 ELECTRICAL Low Charge Pressure Light When the low charge pressure switch is closed, a ground is provided to the low charge light, turning on the light. Ground is also provided from the low charge pressure switch through diode (V9) to horn relay terminal 85, energizing the relay.

  • Page 107: Instrumentation Circuit Schematic

    ELECTRICAL Instrumentation Circuit Schematic See Figures 4-30 through 4-32. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Circuit Relay Breaker Pnk/Blu Pnk/Blu Pnk/ Circuit Breaker Seat Switch Wht/Brn Circuit Breaker Wht/Brn +12V Enable Time 1 Sec.
  • Page 108 ELECTRICAL Instrumentation Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay Lt Blu/Red Wht/Grn Wht/Grn +12V +12V +12V +12V Engine Fuel Temperature Volt Hour Gauge Gauge Meter Meter Signal Signal Engine Fuel Temperature Level Sensor Sensor Switched Power Circuit Engine Temperature Circuit Fuel Level Circuit Ground Circuit...
  • Page 109 ELECTRICAL Instrumentation Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Wht/ Return Charge Grn\ Filter Filter Filter Blu/ Service Gry/ Temp Service Service Light Grn\ Light Light Light Blu/ Gry/ Grn\ Return Charge Filter Filter Filter t˚ Pressure Pressure Pressure Switch Switch Temp Switch...

  • Page 110: Horn/Test Circuit-Theory Of Operation

    ELECTRICAL Horn/Test Circuit—Theory of When the horn/test switch is in the on position, a ground is provided through diode (V3) to the air filter service Operation light, turning on the light. Ground is also provided through diode (V4) to the return filter service light, turning on the Unswitched Power Circuit light.

  • Page 111: Horn/Test Circuit Schematic

    ELECTRICAL Horn/Test Circuit Schematic See Figures 4-33 through 4-35. Brn/Red Brn/Red Park Brake Circuit Switch Switch Breaker Red/ Switch Org/Brn Brn/Red Start Brn/ Pnk/Blu Accessory Circuit Relay Breaker Pnk/Blu Pnk/Blu Pnk/ Circuit Breaker Seat Switch Wht/Brn Circuit Breaker Wht/Brn +12V Enable Time 1 Sec.
  • Page 112 ELECTRICAL Horn/Test Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay Lt Blu/Red Wht/Grn Wht/Grn +12V +12V +12V +12V Engine Fuel Temperature Volt Hour Gauge Gauge Meter Meter Signal Signal Engine Fuel Temperature Level Sensor Sensor Switched Power Circuit Horn Circuit Ground Circuit Test Circuit...
  • Page 113 ELECTRICAL Horn/Test Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Wht/ Return Charge Grn\ Filter Filter Filter Blu/ Service Gry/ Temp Service Service Light Grn\ Light Light Light Blu/ Gry/ Grn\ Return Charge Filter Filter Filter t˚ Pressure Pressure Pressure Switch Switch Temp Switch...

  • Page 114: Troubleshooting

    ELECTRICAL Troubleshooting Glow Plug Circuit Symptom: Glow plugs do not get hot. Probable Cause Remedy Faulty circuit breaker. Test 50A circuit breaker F3. (See “Thermal Circuit Breakers Test” on page 4-74.) Faulty power circuit. Check continuity between 50A circuit breaker F3 and glow plug solenoid terminal. Continuity must be indicated.

  • Page 115: Run Circuit

    ELECTRICAL Run Circuit Symptom: Engine stops running when the park brake is released. Probable Cause Remedy Faulty seat switch. Test seat switch. (See “Seat Switch Test” on page 4-77.) Faulty time delay relay. Test time delay relay. (See “Time Delay Relay Test” on page 4-75.) Charging Circuit Symptom: Battery not charging.
  • Page 116 ELECTRICAL Symptom: Right mow solenoid does not energize. Probable Cause Remedy Faulty right wing proximity switch. With the right wing in the lowered position, check the proximity switch LED indicator. If the LED does not turn on, substitute the proximity switch with a known good switch. Faulty right wing relay.

  • Page 117: Four Wheel Drive Circuit

    ELECTRICAL Four Wheel Drive Circuit Symptom: Four wheel drive solenoid does not energize. Probable Cause Remedy Tripped 10-amp circuit breaker (F6). Reset circuit breaker. Faulty 4WD switch. Test 4WD switch. (See “4WD Switch Test” on page 4-81.) Faulty reverse kick-out switch. Test reverse kick-out switch.

  • Page 118: Cruise Control Circuit

    ELECTRICAL Cruise Control Circuit Symptom: Cruise control magnet does not energize. Probable Cause Remedy Tripped 10-amp circuit breaker (F6). Reset circuit breaker. Faulty brake pedal switch. Test brake pedal switch. (See “Micro Switches Test” on page 4-82.) Faulty cruise control switch. Test cruise control switch.

  • Page 119: Instrumentation Circuit

    ELECTRICAL Instrumentation Circuit Horn/Test Circuit When the horn/test switch is pressed, the horn sounds and the following indicator lights turn on: • Air filter service light • Return filter service light • Hyd oil temp light • Charge filter service light •...
  • Page 120 ELECTRICAL Symptom: Charge filter pressure light is on with the key switch in the run position (engine off). Probable Cause Remedy Faulty charge filter pressure switch. Replace charge filter pressure switch. Symptom: Charge filter pressure light is on with the key switch in the run position (engine on).
  • Page 121 ELECTRICAL Symptom: Air filter service light does not turn on. Probable Cause Remedy Faulty ground circuit. Check continuity between air filter pressure switch blk wire terminal and ground. Continuity must be indicated. Faulty air filter pressure switch. With a jumper wire, connect the air filter pressure switch blu/wht wire terminal to ground. With the key switch in the run position, check the air filter service light.
  • Page 122 ELECTRICAL Symptom: Fuel gauge does not indicate fuel level. Probable Cause Remedy Faulty fuel level sensor. With a jumper wire, connect the fuel level sensor brn wire terminal to ground. With the key switch in the run position, check the gauge. If the gauge is indicating full scale, replace the fuel level sensor.

  • Page 123: Horn And Audible Alert Circuit

    ELECTRICAL Horn and Audible Alert Circuit Symptom: Horn does not sound when horn switch is pressed. Probable Cause Remedy Faulty horn switch. With the key switch in the run position, press the horn switch. If the horn does not sound, test horn switch.

  • Page 124: Component Testing

    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 125: Circuit Breakers Test

    ELECTRICAL Circuit Breakers Test Thermal Circuit Breakers Test See Figure 4-36. See Figure 4-37. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 126: Relays Test

    ELECTRICAL Relays Test Time Delay Relay Test See Figure 4-38. See Figure 4-39. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 127: Key Switch Test

    ELECTRICAL Key Switch Test Horn/Test Switch Test See Figure 4-40. See Figure 4-41. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 128: Seat Switch Test

    ELECTRICAL Seat Switch Test Glow Plug Switch Test See Figure 4-42. See Figure 4-43. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 129: Front Limit Switch Test

    ELECTRICAL Front Limit Switch Test PTO Switch Test See Figure 4-44. See Figure 4-45. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 130: Front Mow Enable Switch Test

    ELECTRICAL 11. Check for continuity. 5. Check for continuity. Is continuity indicated? Is continuity indicated? Proceed to step 12. The switch is faulty; replace the switch. The switch is faulty; replace the switch. Proceed to step 6. 12. Connect test leads to the switch terminals (4 and 5). 6.
  • Page 131 ELECTRICAL 2. Remove switch. (See “Rocker Switches” on 15. Check for continuity. page 4-97.) Is continuity indicated? The switch is faulty; replace the switch. Proceed to step 16. 16. Connect test leads to the switch terminals (6 and 7). 17. Check for continuity. Is continuity indicated? The switch is faulty;...

  • Page 132: Cruise Control Switch Test

    ELECTRICAL Cruise Control Switch Test 12. Check for continuity. Proceed to step 13. See Figure 4-48. The switch is faulty; replace the switch. 13. Place the switch in the OFF (middle) position. Required Tools or Equipment 14. Check for continuity. Digital Multimeter, Ohmmeter, or Continuity Tester Is continuity indicated? The switch is faulty;...

  • Page 133: Micro Switches Test

    ELECTRICAL Micro Switches Test 6. Place the switch in the (4) position. 7. Check for continuity. See Figure 4-50. Is continuity indicated? Required Tools or Equipment The switch is faulty; replace the switch. Proceed to step 8. Digital Multimeter, Ohmmeter, or Continuity Tester 8.

  • Page 134: Fuel Level Sensor Test

    ELECTRICAL Fuel Level Sensor Test 6. Move the float (2) to the empty position and read the resistance value. See Figure 4-51. Is the resistance value approximately 256 ohms? The sensor is good. Required Tools or Equipment The sensor is faulty; replace fuel level Digital Multimeter, Ohmmeter, or Continuity Tester sensor.

  • Page 135: Fuel Shutoff Solenoid Test

    ELECTRICAL 3. Using a multimeter or ohmmeter, measure the resistance between terminals (1 and 2). Refer to the specifications listed for the specific solenoid resistance. • Front Mow Solenoid Coil–7.1 ohms ± 10% at 68° F • Right Mow Solenoid Coil–7.1 ohms ± 10% at 68° F •...

  • Page 136: Diodes Test

    ELECTRICAL Diodes Test Fuel Pump Test See Figure 4-55. See Figure 4-56. Required Tools or Equipment Required Tools or Equipment Digital Multimeter Jumper Wire 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 137: Repair

    ELECTRICAL Repair NOTICE Battery Never place used batteries in the garbage. Dispose of used batteries in accordance with all applicable regulations. Removal and Installation See Figure 4-57. NOTES WARNING • Install the battery by reversing the order of removal. • Battery posts, terminals, and related •...

  • Page 138: Starter Motor

    ELECTRICAL Instrument Panel 10. Remove alternator (3). Installation Notes Removal and Installation • Install the alternator by reversing the order of See Figure 4-60. removal. NOTE • Adjust fan belt tension. (Refer to “Safety, Operation, and Maintenance Manual.”) If servicing individual components, it is not necessary to completely remove the instrument panel.

  • Page 139: Circuit Breakers

    ELECTRICAL Installation Notes NOTE • Anti-seize must be applied to screw threads when Label all wires before disconnecting to ensure correct installing instrument panel. installation. • Install the instrument panel by reversing the order of 5. Disconnect wire connectors (2 and 4). removal.

  • Page 140: Relays

    ELECTRICAL Main 50-Amp Thermal Circuit Breaker • Cruise Cancel Relay (3) • Cruise Relay (4) • Fuel Pull-In Relay (5) • Horn Relay (6) • Accessory Relay (7) NOTE For time delay relay, see “Time Delay Relay” on page 4-90. Removal and Installation See Figures 4-66 and 4-67.

  • Page 141: Time Delay Relay

    ELECTRICAL Time Delay Relay Key Switch Removal and Installation Removal and Installation See Figure 4-67. See Figures 4-68 through 4-70. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 142: Park Brake Switch

    ELECTRICAL Park Brake Switch Removal and Installation See Figure 4-71. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN2222 Figure 4-70 1 2 3 NOTE Label all wires before disconnecting to ensure correct installation.

  • Page 143: Brake Pedal Switch

    ELECTRICAL Brake Pedal Switch Horn/Test Switch Removal and Installation Removal and Installation See Figure 4-72. See Figure 4-73. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 144: Seat Switch

    ELECTRICAL Seat Switch Removal and Installation See Figures 4-74 through 4-78. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN2270 Figure 4-75 6. Disengage bellows (5) from hooks (4). 7.

  • Page 145: Glow Plug Switch

    ELECTRICAL Glow Plug Switch Removal and Installation See Figures 4-79 and 4-80. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove instrument panel. (See “Instrument Panel” on page 4-87.) TN2272 Figure 4-77...

  • Page 146: Pto Switch

    ELECTRICAL PTO Switch Removal and Installation See Figures 4-81 through 4-83. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the battery negative (–) cable at the battery. 3. Remove instrument panel. (See “Instrument Panel” on page 4-87.) TN1969 Figure 4-83...

  • Page 147: Right And Left Wing Proximity Switches

    ELECTRICAL Right and Left Wing Proximity Front Limit Switch Switches Removal and Installation Removal and Installation See Figures 4-85 and 4-86. 1. Park the mower safely. (See “Park Mower Safely” on See Figure 4-84. page 1-6.) 1. Park the mower safely. (See “Park Mower Safely” on 2.

  • Page 148: Rocker Switches

    ELECTRICAL 7. Remove nut (4), wire harness (5), and switch (11). Installation Notes • Install the front limit switch by reversing the order of removal. • Adjust actuator arm (9) so that switch is engaged when front lift arms are raised. Rocker Switches See Figure 4-87.

  • Page 149: Reverse Kick-Out Switch

    ELECTRICAL Reverse Kick-Out Switch Removal and Installation See Figure 4-92. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. 1 2 3 4 TN1966 Figure 4-90 • Make sure wing mow enable switch and light switch are installed as shown in Figure 4-90 (arrow indicates rear of mower).

  • Page 150: Air Filter Pressure Switch

    ELECTRICAL Air Filter Pressure Switch Return Filter Pressure Switch Removal and Installation Removal and Installation See Figure 4-93. See Figure 4-94. 1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2. Raise the hood. The hydraulic system is under pressure, and the oil may be hot! 3.

  • Page 151: Hyd Oil Temp Switch

    ELECTRICAL 4. Disconnect connectors (2) from the return filter pressure switch (1). 5. Remove return filter pressure switch (1). Installation Notes Required Materials ® Telfon Tape • Install the return filter pressure switch by reversing the order of removal. • Apply Teflon tape to the threads of the return filter pressure switch before installing.

  • Page 152: Charge Filter Pressure Switch

    ELECTRICAL Charge Filter Pressure Switch Installation Notes Removal and Installation Required Materials See Figure 4-96. ® Telfon Tape WARNING • Install the charge filter pressure switch by reversing the order of removal. The hydraulic system is under pressure, and the oil may be hot! •...

  • Page 153: Engine Temperature Sensor

    ELECTRICAL Installation Notes 4. Remove nut (2) and disconnect wire (3) from the engine temperature sensor (1). Required Materials 5. Remove engine temperature sensor (1). ® Telfon Tape Installation Notes • Install the engine oil pressure switch by reversing the Required Materials order of removal.

  • Page 154: Low Charge Pressure Switch

    ELECTRICAL NOTE Label all wires before disconnecting to ensure correct installation. 4. Remove nut (3) and disconnect wire (2) from the engine coolant temp switch (1). 5. Remove engine coolant temp switch (1). Installation Notes Required Materials ® Telfon Tape •...

  • Page 155: Mow Solenoids

    ELECTRICAL Mow Solenoids See Figures 4-101 through 4-103. TN2269 TN2268 Figure 4-103: Front Mow Solenoid Figure 4-101: Left Mow Solenoid This procedure applies to the following solenoids: • Left Mow Solenoid (1) • Right Mow Solenoid (2) • Front Mow Solenoid (3) The left mow solenoid is located on the left deck valve.

  • Page 156: 4Wd Solenoids

    ELECTRICAL 4WD Solenoids See Figures 4-105 and 4-106. TN2269 Figure 4-104 NOTE Label connectors before disconnecting to ensure correct installation. TN2334 Figure 4-105: 4WD Solenoid 4. Disconnect connector (4) from solenoid (6). 5. Remove nut (7) and solenoid (6) from the valve (5). Installation Notes •...

  • Page 157: Glow Plug Solenoid

    ELECTRICAL Glow Plug Solenoid 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Removal and Installation 2. Disconnect the negative (–) battery cable at the battery. See Figure 4-108. 3. Locate correct valve. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 158: Fuel Shutoff Solenoid

    ELECTRICAL Fuel Shutoff Solenoid Removal and Installation See Figure 4-109. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood. 3. Disconnect the negative (–) battery cable at the battery. TN2267 Figure 4-110 NOTE Label all wires before disconnecting to ensure correct installation.

  • Page 159: Indicator Lights

    ELECTRICAL • Engine Coolant Temp Light (7) • Engine Oil Pressure Light (5) • Left Turn Indicator (6) Removal and Installation See Figure 4-114. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery.

  • Page 160: Diodes

    ELECTRICAL Diodes 8. Remove diode (6) from diode holder (7). Installation Note Removal and Installation Install the diode by reversing the order of removal. See Figures 4-115 and 4-116. 1. Park the mower safely. (See “Park Mower Safely” on Engine Temperature Gauge page 1-6.) 2.

  • Page 161: Volt Meter And Fuel Gauge

    ELECTRICAL Volt Meter and Fuel Gauge NOTE See Figure 4-118. Label all wires before disconnecting to ensure correct installation. 5. Disconnect wire terminals (4). 6. Remove gauge (1). Installation Note Install the gauge by reversing the order of removal. Hour Meter Removal and Installation See Figure 4-120.

  • Page 162: Horn

    ELECTRICAL Horn 3. Drain fuel until level is below fuel level sensor mount opening. Removal and Installation See Figure 4-121. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the battery negative (–) cable at the battery.
  • Page 163 ELECTRICAL Page Intentionally Blank 4-112 4203781 First Edition...
  • Page 164 Chapter 5 Hydrostatic Power Train Specifications ..............5-3 Test and Adjustment Specifications .
  • Page 165 HYDROSTATIC POWER TRAIN Repair ..............5-46 Front Axle U-Joint .

  • Page 166: Specifications

    HYDROSTATIC POWER TRAIN Specifications Test and Adjustment Specifications Specification Traction Pump Flow 30.1 (114) at 2800 rpm gpm (lpm) Charge Pump Flow 9.3 (35) at 2800 rpm gpm (lpm) Forward System Relief Pressure 3500 (241) at 2800 rpm psi (bar) Reverse System Relief Pressure 3500 (241) at 2800 rpm psi (bar)

  • Page 167: Portable In-Line Filter

    HYDROSTATIC POWER TRAIN Portable In-Line Filter See Figure 5-1. TN1367 Figure 5-1 When hydraulic components fail internally, debris from the failed component can spread throughout the hydraulic system, causing additional damage. This situation can be magnified when dealing with a closed loop traction system where oil is not filtered.

  • Page 168: Component Location

    HYDROSTATIC POWER TRAIN Component Location See Figures 5-2 and 5-3. TN2312, TN2313, TN2096 Hydrostatic Pump Gear Pump Front Axle Motor 4WD Valve Front Axle U-Joint Front Axle Figure 5-2: Component Location—Left Side 4203781 First Edition...
  • Page 169 HYDROSTATIC POWER TRAIN TN2263, TN2168 Control Valve Right Rear Wheel Motor Left Rear Wheel Motor Figure 5-3: Component Location—Right Side 4203781 First Edition...

  • Page 170: Theory Of Operation And Sub-Circuit Schematics

    HYDROSTATIC POWER TRAIN Theory of Operation and Sub-Circuit Schematics Traction Circuit—Neutral Schematic and Theory of Operation System Conditions: • Engine running • Park brake released • Traction pedal in the NEUTRAL position Charge Pressure Circuit The traction pump and gear pump are both driven by the engine.
  • Page 171 HYDROSTATIC POWER TRAIN Traction Circuit—Neutral Schematic See Figures 5-4 and 5-5. 3500 psi Check Valve Gear Pump 2.48 ci 0.77 ci 1.04 ci 1.04 ci 1.04 ci 2800 ±50 RPM Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch 25 psi...
  • Page 172 HYDROSTATIC POWER TRAIN — Traction Circuit Neutral Schematic, Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 5.04 ci Motor 4WD Reverse Solenoid Right Wheel Motor 11.9 11.9 Charge Pressure Light Switch Left 125 psi N.C. Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm...
  • Page 173 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-10 4203781 First Edition...

  • Page 174: Traction Circuit-Forward 2Wd Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 2WD Charge pressure oil is also supplied to port “C” of the 4WD valve. With the 2WD/4WD switch in the 2WD Schematic and Theory of Operation position, oil flows through the 4WD reverse solenoid and secondary 4WD shuttle valves, applying equal pressure System Conditions: to both sides of the right and left rear wheel motors.

  • Page 175: Traction Circuit-Forward 2Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 2WD Schematic See Figures 5-6 and 5-7. 3500 psi Check Valve Gear Pump 2.48 ci 2800 ±50 RPM 0.77 ci 1.04 ci 1.04 ci 1.04 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch...
  • Page 176 HYDROSTATIC POWER TRAIN — Traction Circuit Forward 2WD Schematic, Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 5.04 ci Motor 4WD Reverse Solenoid Right Wheel Motor 11.9 11.9 Charge Pressure Light Switch Left 125 psi N.C. Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm...
  • Page 177 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-14 4203781 First Edition...

  • Page 178: Traction Circuit-Reverse 2Wd Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 2WD Operating pressure oil is also supplied to port “B” of the 4WD valve. With the 2WD/4WD switch in the 2WD Schematic and Theory of Operation position, oil flows through the 4WD reverse solenoid and secondary 4WD shuttle valves, applying equal pressure System Conditions: to both sides of the right and left rear wheel motors.

  • Page 179: Traction Circuit-Reverse 2Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 2WD Schematic See Figures 5-8 and 5-9. 3500 psi Check Valve 1.04 ci 1.04 ci 2.48 ci Gear Pump 0.77 ci 1.04 ci 2800 ±50 RPM Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch...
  • Page 180 HYDROSTATIC POWER TRAIN — Traction Circuit Reverse 2WD Schematic, Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 5.04 ci Motor Reverse Solenoid Right Wheel Motor 11.9 11.9 Charge Pressure Light Switch Left 125 psi N.C. Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm...
  • Page 181 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-18 4203781 First Edition...

  • Page 182: Traction Circuit-Forward 4Wd Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 4WD When the 2WD/4WD switch is placed in the 4WD position, the primary 4WD solenoid in the control valve Schematic and Theory of Operation shifts, allowing oil to flow through the valve. Oil is then routed to the pilot line of the secondary 4WD shuttle System Conditions: valve in the 4WD valve, causing the valve to shift.

  • Page 183: Traction Circuit-Forward 4Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 4WD Schematic See Figures 5-10 and 5-12. 3500 psi Check Valve Gear Pump 2.48 ci 2800 ±50 RPM 0.77 ci 1.04 ci 1.04 ci 1.04 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch...
  • Page 184 HYDROSTATIC POWER TRAIN Traction Circuit—Forward 4WD Schematic, Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 5.04 ci Motor Reverse Solenoid Right Wheel Motor 11.9 11.9 Charge Pressure Light Switch Left 125 psi N.C. Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm Primary 4WD...
  • Page 185 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-22 4203781 First Edition...

  • Page 186: Traction Circuit-Reverse 4Wd Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD The primary 4WD solenoid in the control valve also shifts, allowing oil to flow to the pilot line of the secondary 4WD Schematic and Theory of Operation shuttle valve, causing the valve to shift. System Conditions: With the secondary 4WD shuttle valve shifted, oil exiting the rear wheel motors enters the 4WD valve at ports “R1”...

  • Page 187: Traction Circuit-Reverse 4Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD Schematic See Figures 5-12 and 5-13. 3500 psi Check Valve 1.04 ci 1.04 ci 2.48 ci Gear Pump 0.77 ci 1.04 ci 2800 ±50 RPM Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch...
  • Page 188 HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD Schematic, Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 5.04 ci Motor Reverse Solenoid Right Wheel Motor 11.9 11.9 Charge Pressure Light Switch Left 125 psi N.C. Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm Primary 4WD...

  • Page 189: Troubleshooting

    HYDROSTATIC POWER TRAIN Troubleshooting Mower Will Not Move Forward or Reverse Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Tow valve open. Close tow valve.
  • Page 190 HYDROSTATIC POWER TRAIN Hydrostatic System Operating Hot Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Tow valve open. Close tow valve. (Refer to “Safety, Operation, and Maintenance Manual.”) Oil cooler has dirt or debris in fins.

  • Page 191: Tests And Adjustments

    HYDROSTATIC POWER TRAIN Tests and Adjustments Traction Linkage Adjustments See Figures 5-14 through 5-17. Traction Pedal Neutral Adjustment TN2342 TN2342 Figure 5-14 3. Disengage the park brake. NOTE 4. Bypass the seat switch. If the mower creeps in either direction while the engine is 5.
  • Page 192 HYDROSTATIC POWER TRAIN 9. Stop the engine. 5. Position reverse kick-out switch (6) to achieve continuity when the traction pedal is in the neutral 10. Hold the adjustment nut (2) and tighten the jam nuts position and the 4WD switch is in the ON position, (1).
  • Page 193 HYDROSTATIC POWER TRAIN TN2342 TN2342 Figure 5-16 1. Loosen lock nuts (12). 14. When the desired reverse speed adjustment is obtained, proceed to “Forward” adjustment. 2. Remove nut (15), lock washer (16), two flat washers (17), and screw (18) from ball joint (14), and Forward disconnect the ball joint from the throttle pedal lever The forward limit is adjusted by changing the height of...

  • Page 194: Weight Transfer Adjustment

    HYDROSTATIC POWER TRAIN 1. Rotate the mow speed stop (20) fully clockwise so it 1. Loosen adjustment lock (1). is positioned over the front stop stud (21). 2. Rotate adjustment knob (2) counterclockwise to 2. Move the traction pedal (19) to the maximum forward decrease upward force on the cutting unit lift position.

  • Page 195: Field Test Procedures

    HYDROSTATIC POWER TRAIN Field Test Procedures 3. Install wheel restraints (1) to all four wheels. 4. 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 using a test Does the engine labor or stall? instrument.

  • Page 196: Instrument Test Procedures

    HYDROSTATIC POWER TRAIN Instrument Test Procedures Calculations: System Test Instrument Test Overview No Load Flow = 15 gpm The following tests are specifically designed to approach Loaded Flow = 9.4 gpm hydraulic testing on a system level. Each component 15 – 9.4 / 15 x 100 = Total System Leakage 37% within the system represents a portion of the total system leakage.

  • Page 197: Charge Pump Test

    HYDROSTATIC POWER TRAIN 9. Disconnect and remove test equipment. Install all hoses and fittings as noted prior to removal. 10. Install and connect all components as noted prior to test. 11. Check hydraulic oil level. Add oil as needed. (Refer to “Safety, Operation, and Maintenance Manual”...
  • Page 198 HYDROSTATIC POWER TRAIN CAUTION Do not exceed 1500 psi (103 bar) as this test does not utilize system relief. 9. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (4) until a reading of 750 psi (52 bar) or one half of the relief valve rating is reached.

  • Page 199: Traction System Test

    HYDROSTATIC POWER TRAIN Traction System Test See Figures 5-25 through 5-30. IMPORTANT • This test works together with the wheel motors test to isolate a problem within the hydrostatic power train. • Performing this test will isolate the traction pump and front axle motor from the rest of the hydrostatic system.
  • Page 200 HYDROSTATIC POWER TRAIN 17. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (7) until a reading of 1750 psi (121 bar) or one half of the relief valve rating is reached. Warm oil to 120–150° F (49–65° C); open valve fully after operating temperature is reached.
  • Page 201 HYDROSTATIC POWER TRAIN 32. Open flow meter valve (7), stop engine, and set park brake. Return flow lock tool back to neutral position. 33. Calculate traction system leakage. (Step 30 – Step 31 / Step 30 x 100 = Leakage Percentage) Is 2WD traction system leakage 10% or less? The pump and front axle motor are good.

  • Page 202: Traction Pump Tests

    HYDROSTATIC POWER TRAIN Traction Pump Tests See Figures 5-31 through 5-33. 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 203 HYDROSTATIC POWER TRAIN 8. Adjust flow lock tool (6) to allow pump to produce 15 18. Use the flow meter to warm the hydraulic oil. Turn the gpm (57 lpm) in the forward direction. flow meter valve (2) until a reading of 1750 psi (121 bar) or one half of the relief valve rating is reached.

  • Page 204: Front Axle Motor Test

    HYDROSTATIC POWER TRAIN Front Axle Motor Test IMPORTANT See Figures 5-34 through 5-41. • If performing this test after performing the traction system test, and the test results have IMPORTANT proven the pump and front axle motor to be • This test works together with the 2WD traction good, proceed to step 16.
  • Page 205 HYDROSTATIC POWER TRAIN 9. Adjust flow lock tool (7) to allow pump to produce 15 gpm (57 lpm) in the forward direction. 10. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve until a reading of 1750 psi (121 bar) or one half of the relief valve rating is reached.
  • Page 206 HYDROSTATIC POWER TRAIN 17. Open flow meter valve completely before starting 23. Engage 4WD switch in the forward position. engine. 24. Slowly close flow meter valve until pressure reaches 18. Set park brake. 2625 psi (181 bar). Read and record loaded flow. 25.
  • Page 207 HYDROSTATIC POWER TRAIN Left Rear Wheel Motor Test 33. Engage 4WD switch in the forward position. 28. Open flow meter valve completely before starting 34. Slowly close flow meter valve until pressure reaches engine. 2625 psi (181 bar). Read and record loaded flow. 35.
  • Page 208 HYDROSTATIC POWER TRAIN Right Rear Wheel Motor Test 44. Slowly close flow meter valve until pressure reaches 2625 psi (181 bar). Read and record loaded flow. 38. Open flow meter valve completely before starting engine. 45. Open flow meter valve, stop engine, and set park brake.

  • Page 209: Repair

    HYDROSTATIC POWER TRAIN Repair Front Axle U-Joint Removal and Installation See Figure 5-42. TN2322 Figure 5-42 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the front axle motor (3). (See “Front Axle Motor” on page 5-58.) 3.

  • Page 210: Traction Pump U-Joint

    HYDROSTATIC POWER TRAIN Traction Pump U-Joint Removal and Installation See Figure 5-43. TN2099 Figure 5-43 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) It may be necessary to rotate the flywheel to access all of 2.

  • Page 211: Traction Pump

    HYDROSTATIC POWER TRAIN Traction Pump 3. Remove six screws (10) and lock washers (11) from pump drive flange (12) and flywheel (3). Removal and Installation WARNING See Figures 5-44 and 5-45. 1. Park the mower safely. (See “Park Mower Safely” on Prevent personal injury.
  • Page 212 HYDROSTATIC POWER TRAIN Installation Notes • Install the hydrostatic pump by reversing the order of removal. • Lubricate all O-rings prior to assembly. • Make sure new O-rings are in place before installing hoses on fittings. • Pressure filter the hydraulic system. (See “Portable In-Line Filter”...
  • Page 213 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-46. TN2328 Plug (2) Cam Plate Insert O-Ring (2) Thrust Race (2) Spring (2) Rotating Kit Bearing Cone (2) Plug Relief Valve (2) Trunnion Key Bearing Cover Plate Tow Valve Cam Plate Drive Shaft Housing Top Screw (2)

  • Page 214: 4Wd Valve

    HYDROSTATIC POWER TRAIN 4WD Valve NOTICE Removal and Installation • It is important that pump parts are marked See Figure 5-47. and placed in assembly order to aid in assembly. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) •...
  • Page 215 HYDROSTATIC POWER TRAIN Installation Notes 6. Remove straight adapter (8) from port “L2.” • Install the 4WD valve by reversing the order of 7. Remove straight adapter (9) from port “L1.” removal. 8. Remove 90° adapter (10) from port “C.” •...

  • Page 216: Control Valve

    HYDROSTATIC POWER TRAIN Control Valve 14. Remove O-rings (19 and 20) and backup ring (18) from check valve (21). Removal and Installation 15. Remove secondary 4WD shuttle valve (23) from valve block (26). See Figure 5-50. 16. Remove O-rings (22 and 24) and backup rings (25) 1.
  • Page 217 HYDROSTATIC POWER TRAIN 8. Support the control valve (14). 1. Remove dust cover (1), diagnostic port adapter (2), and 90° adapter (3) from port “LD.” 9. Remove mounting screws (4), washers (5), lock washers (6), and nuts (7). 2. Remove straight adapter (4) from port “ST.” 10.
  • Page 218 HYDROSTATIC POWER TRAIN TN2337 TN2337 Figure 5-52 NOTE NOTICE Record the location of the all cartridges before removing • It is important that all component parts are to ensure correct installation. absolutely clean, as contamination can result 11. Remove plug (18) and charge pressure relief valve in serious damage and/or improper operation.
  • Page 219 HYDROSTATIC POWER TRAIN NOTICE • It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. • Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.

  • Page 220: Front Axle Motor

    HYDROSTATIC POWER TRAIN Front Axle Motor Removal and Installation See Figure 5-53. TN2323 Figure 5-53 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Record the location and orientation of all fittings before NOTES removing to ensure correct installation. •...
  • Page 221 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-54. TN2357 Retaining Ring (if equipped) Spacer Piston Assemblies (9) Retaining Ring Shaft Seal Pistons (9) Spider Housing Assembly Rotating Kit Assembly Pilot Drive Shaft Bearing Race (2) Thrust Race (if equipped) Spring O-Ring Thrust Bearing...

  • Page 222: Front (Drive) Axle Assembly

    HYDROSTATIC POWER TRAIN Assembly Notes NOTICE NOTICE • It is important that motor parts are marked and placed in assembly order to aid in • It is important that all motor parts are assembly. absolutely clean, as contamination can result •...
  • Page 223 HYDROSTATIC POWER TRAIN 3. Remove front deck. (See “Front Deck” on page 8-19.) 4. Remove front lift cylinders. (See “Front Lift Cylinders” on page 6-68.) 5. Remove front lift arms. (See “Front Lift Arms” on page 8-21.) WARNING • Support the machine using properly rated jackstands.
  • Page 224 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-57. 17 18 TN2352 Nut (4) End Yoke Machined Screw (4) Roller Bearing Cone Plate Retainer Flat Washer Left Side Axle Tube Gear and Pinion Assembly Steel Spacer Pinion Nut Carrier Sub-Assembly Adjustment Shim Outer Shaft Seal Pinion Oil Seal Slinger...
  • Page 225 HYDROSTATIC POWER TRAIN 1. Remove oil level/fill plug and drain lubricant. Assembly Notes 2. Disassemble front axle as shown. NOTICE 3. Place parts in assembly order on a clean work area as they are removed. • It is important that all component parts are absolutely clean, as contamination can result NOTICE in serious damage and/or improper operation.

  • Page 226: Rear Wheel Motor

    HYDROSTATIC POWER TRAIN Rear Wheel Motor Removal and Installation See Figures 5-58 through 5-61. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove rear wheel. (See “Rear Wheels” on page 9-18.) TN1963 Figure 5-60 7. Remove cotter pin (10). TN1970 CAUTION Figure 5-58...
  • Page 227 HYDROSTATIC POWER TRAIN TN1964 Figure 5-61 12. Remove four screws (17) and lock washers (16). 13. Remove guard (18) and wheel motor (15) from motor mount (19). Installation Notes Required Materials Anti-Seize Compound • Install the rear wheel motor by reversing the order of removal.
  • Page 228 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-62 and 5-63. TN1779 Seal, Exclusion Shaft and Bearing Kit Valve Drive Pin (2) Bearing Housing Seal Valve Plate Spring (2) O-Ring (4) Wear Plate Valve Port Manifold Cover Back-Up Ring Drive Balance Ring Screw (4)
  • Page 229 HYDROSTATIC POWER TRAIN Rear Wheel Motor Timing NOTICE • It is important that motor parts are marked and placed in assembly order to aid in assembly. • It is important that all motor parts are absolutely clean, as contamination can result in serious damage and/or improper operation.

  • Page 230: Traction Linkage

    HYDROSTATIC POWER TRAIN Traction Linkage Disassembly and Assembly See Figure 5-64. TN2340 TN2340 Lock Nut (2) Magnet Support Pin (2) Top Block (2) Jam Nut (5) Flat Washer (8) Spring (2) Traction Arm Rubber Mount Traction Arm Heavy Lock Washer (7) Cruise Control Magnet Bracket Washer (2) Bushing (2)
  • Page 231 HYDROSTATIC POWER TRAIN 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove seat and seat platform. (See “Seat and Seat Platform” on page 9-10.) 3. Disassemble traction linkage as shown in Figure 5-64 on page 5-68. NOTES When removing rod ends (25 and 30) from traction pump adjusting rod (28), record the number of turns needed to...
  • Page 232 Chapter 6 Hydraulics Specifications ..............6-3 Test and Adjustment Specifications .
  • Page 233 HYDRAULICS Instrument Test Procedure ........... . . 6-27 Instrument Test Overview .
  • Page 234 HYDRAULICS Specifications Test and Adjustment Specifications Specifications Front Cutting Unit Pump Flow 12.2 (46.2) at 2800 rpm gpm (lpm) Left Wing Cutting Unit Pump Flow 12.2 (46.2) at 2800 rpm gpm (lpm) Right Wing Cutting Unit Pump Flow 12.2 (46.2) at 2800 rpm gpm (lpm) Lift/Steer Pump Flow 9.1 (34.5) at 2800 rpm...

  • Page 235: Component Location

    HYDRAULICS Component Location See Figures 6-1 and 6-2. TN2096, TN2123, TN2196 Right Deck Valve Gear Pump Left Wing Lift Cylinder Hydraulic Oil Cooler Left Deck Valve Left Wing Cutting Unit Motor (2) Hydraulic Oil Tank Front Lift Cylinder (2) Charge Pressure Filter Front Cutting Unit Motor (3) Hydraulic Oil Return Filter Front Deck Valve...
  • Page 236 HYDRAULICS TN1769 Lift Valve Right Wing Cutting Unit Motor (2) Right Wing Lift Cylinder Figure 6-2: Component Location—Right Side 4203781 First Edition...

  • Page 237: Hydraulic Schematic

    HYDRAULICS Hydraulic Schematic See Figures 6-3 through 6-7. Check 3500 psi Valve Gear Pump 0.77 ci 1.04 ci 1.04 ci 1.04 ci 2.48 ci 2800 ±50 rpm Check 3500 psi Valve Hydrostatic Traction Pump 10 Micron Filter 25 psi Switch 25 psi Crack Suction...
  • Page 238 HYDRAULICS Hydraulic Schematic Continued Front Axle 5.04 ci 4WD Valve Secondary 4WD Motor Shuttle Valve Reverse Solenoid Right Wheel Motor Charge Pressure Light Switch 11.9 125 psi N.C. 11.9 Control Valve Left Wheel Motor Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm Primary 4WD...
  • Page 239 HYDRAULICS Hydraulic Schematic Continued Steering Unit Steering Valve Check Valve Relief Valve 1500 psi Steering 6.1 ci Cylinder TN2066 Figure 6-5 4203781 First Edition...
  • Page 240 HYDRAULICS Hydraulic Schematic Continued Lift Valve Relief Valve 1500 psi Left Lift Valve Front Lift Valve Right Lift Valve 50 psi Weight Transfer Valve 300 psi 300 psi 300 psi Detent Valve Detent Valve Detent Valve 0.060" Orifice 0.060" Orifice 0.060"...
  • Page 241 HYDRAULICS Hydraulic Schematic Continued CW Outside Check 1.04 ci Right Wing Valve 100 psi Motor 0.067 Right Deck Valve Solenoid Valve CCW Inside Relief Valve Right Wing 1.04 ci 3000 psi Motor 0.067 Blade Brake Relief 630 psi CW Inside Check Left Wing Valve...
  • Page 242 HYDRAULICS Page Intentionally Blank 4203781 First Edition 6-11...

  • Page 243: Theory Of Operation And Diagnostic Information

    HYDRAULICS Theory of Operation and Diagnostic Information Steering Circuit Schematic and Theory of Operation System Conditions: • Engine running • Steering wheel turned to the right or left (right turn shown) Oil Supply to Steering Valve Hydraulic oil is drawn from the hydraulic oil tank by section 1 of the gear pump assembly.

  • Page 244: Steering Circuit Schematic

    HYDRAULICS Steering Circuit Schematic See Figure 6-8. Steering Valve Steering Cylinder Check Valve Relief Valve 1500 psi 6.1 ci Steering Unit Operating Pressure Oil Charge Pressure Oil Metered Oil Return Oil TN2186 Operating Pressure Oil from Control Valve (Port ST) Charge Pressure Oil to Charge Filter Figure 6-8 4203781 First Edition...

  • Page 245: Raise Circuit Schematic And Theory Of Operation

    HYDRAULICS Raise Circuit Schematic and Theory of Operation System Conditions: • Engine running at fast idle • Right, left, and/or front lift/lower lever(s) in the RAISE position NOTE The cutting unit motors will automatically shut off as the cutting units are raised. (See “Mow Circuit (OFF) Theory of Operation”...

  • Page 246: Raise Circuit Schematic

    HYDRAULICS Raise Circuit Schematic See Figure 6-9. Charge Pressure Light Switch 125 psi N.C. Control Valve Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm Primary 4WD Solenoid Lift Valve Relief Valve 1500 psi Left Lift Valve Right Lift Valve Front Lift Valve 50 psi Weight...

  • Page 247: Lower Circuit Schematic And Theory Of Operation

    HYDRAULICS Lower Circuit Schematic and Theory of Operation System Conditions: • Engine running • Right, left, and/or front lift/lower lever(s) in the LOWER position Oil Supply to Lift Valves Hydraulic oil is drawn from the hydraulic oil tank by section 1 of the gear pump assembly. Before entering the gear pump assembly, the inlet oil is filtered by a 100-mesh screen to remove any debris.

  • Page 248: Lower Circuit Schematic

    HYDRAULICS Lower Circuit Schematic See Figure 6-10. Charge Pressure Light Switch 125 psi N.C. Control Valve Charge Pressure Relief Valve 160 psi Priority Valve 4.5 gpm Primary 4WD Solenoid Lift Valve Relief Valve 1500 psi Left lift Valve Front Lift Valve Right Lift Valve 50 psi Weight...

  • Page 249: Mower Deck Float Circuit Schematic And Theory Of Operation

    HYDRAULICS Mower Deck Float Circuit Schematic and Theory of Operation System Conditions: • Engine running • Right, left, and/or front cutting units lowered to the ground • Right, left, and/or front cutting units lift/lower lever(s) in the NEUTRAL position Oil Supply to Lift Valves Hydraulic oil is drawn from the hydraulic oil tank by section 1 of the gear pump assembly.
  • Page 250 HYDRAULICS Mower Deck Float Circuit Schematic See Figure 6-11. Charge Pressure Light Switch 125 psi N.C. Control Valve Charge Pressure Relief Valve 250 psi Priority Valve 4.5 gpm Primary 4WD Solenoid Lift Valve Relief Valve 1500 psi 50 psi Front Lift Valve Left Lift Valve Right Lift Valve Weight...

  • Page 251: Mow Circuit (On) Schematic And Theory Of Operation

    HYDRAULICS Mow Circuit (ON) Schematic and Oil Return Theory of Operation Oil returning from the motors enters the valve body at port “B,” and flows through the pilot-operated brake valve, System Conditions: exiting the valve body at port “T” and is returned to the •...

  • Page 252: Mow Circuit (On) Schematic

    HYDRAULICS Mow Circuit (ON) Schematic See Figure 6-12. CW Outside Check Valve Right Wing 1.04 ci 100 psi Motor 0.067 Right Deck Valve Solenoid CCW Inside Valve Relief Valve Right Wing 3000 psi 1.04 ci Motor 0.067 Blade Brake Relief 630 psi CW Inside Check...

  • Page 253: Mow Circuit (Off) Schematic And Theory Of Operation

    HYDRAULICS Mow Circuit (OFF) Schematic and Theory of Operation System Conditions: • Engine running • Cutting units lowered • Mow switches in the OFF position • Park brake released NOTE See “Mow Circuit—Theory of Operation” on page 4-37 for the electrical operation of this circuit. Oil Supply to Deck Valves Oil is drawn from the hydraulic tank through a 100-mesh screen, and enters the gear pump, supplying oil to all four...

  • Page 254: Mow Circuit (Off) Schematic

    HYDRAULICS Mow Circuit (OFF) Schematic See Figure 6-13. Check CW Outside Valve Right Wing 1.04 ci 100 psi Motor 0.067 Right Deck Valve Solenoid CCW Inside Valve Relief Valve Right Wing 3000 psi 1.04 ci Motor 0.067 Blade Brake Relief 630 psi CW Inside Check...

  • Page 255: Field Test Procedures

    HYDRAULICS Field Test Procedures 8. Remove support from front cutting unit. After 15 minutes, does cutting unit drift down? Front Lift Cylinders Leakage Test Cylinder is bypassing oil. Replace lift cylinder. (See “Front Lift Cylinders” on See Figure 6-14. page 6-68.) Repeat the test for all of the lift cylinders.

  • Page 256: Power Steering Circuit Test

    HYDRAULICS 4. Start the engine and turn the steering wheel all the NOTE way to the right and then all the way to the left. Only a little movement should be evident. Figure 6-15 shows left wing lift cylinder. Procedure is similar for right wing lift cylinder.
  • Page 257 HYDRAULICS WARNING Safely block cutting unit from rotating using a suitable device or tool. Failure to follow appropriate safety precaution may result in death or serious injury. 7. Install suitable blocking device or tool in cutting unit, preventing cutting unit from turning. 8.

  • Page 258: Instrument Test Procedure

    HYDRAULICS Instrument Test Procedure Circuit and Rear Cutting Unit Pump No Load Flow – Loaded Flow / No Load Flow x 100 = Leak Percentage Instrument Test Overview Calculations: The following tests are specifically designed to approach hydraulic testing on a system level. Each component Circuit Test within the system represents a portion of the total system No Load Flow = 10 gpm...

  • Page 259: Front Cutting Unit Circuit Test

    HYDRAULICS Front Cutting Unit Circuit Test See Figures 6-16 through 6-18. IMPORTANT • This test works together with the front cutting units motors test to isolate a problem with the front cutting unit circuit. • Performing this test will isolate the front cutting unit pump, deck valve, and right front cutting unit motor from the rest of the front cutting unit circuit.

  • Page 260: Front Cutting Unit Pump Test

    HYDRAULICS 15. Calculate front cutting units circuit leakage. (Step 12 – Step 13 / Step 12 x 100 = Leak Percentage) Is front cutting units circuit leakage 10% or less? The front cutting units circuit is good. Proceed to “Front Cutting Unit Motors Test” on page 6-33.
  • Page 261 HYDRAULICS TN2239 Figure 6-19 TN2244 Figure 6-21: Front Cutting Unit Pump Test—Blocking TN1363 Disk Between Pump and Deck Valve Figure 6-20 5. Bypass seat switch and set park brake. 3. Install blocking disk between hydraulic hose (1) and tee fitting (3). NOTE 4.

  • Page 262: Front Cutting Unit Deck Valve Test

    HYDRAULICS 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Before performing this test, perform front cutting unit Do not exceed 3350 psi (231 bar) when testing circuit test, leaving flow meter connected as outlined. pump or equipment damage may occur.
  • Page 263 HYDRAULICS 11. Calculate front cutting unit deck valve leakage. (Step 9 of previous test – Step 9 / Step 9 of previous test x 100 = Leak Percentage) Is front cutting unit deck valve leakage 10% or less? The front cutting unit deck valve is good. Proceed to step 12.

  • Page 264: Adjust Front Cutting Unit Deck Valve System Relief Valve Pressure

    HYDRAULICS Adjust Front Cutting Unit Deck Valve 4. Rotate screw (2) to adjust the relief valve pressure setting. System Relief Valve Pressure To increase the pressure setting: Turn the screw See Figure 6-25. in (clockwise). To decrease the pressure setting: Turn the screw WARNING out (counterclockwise).
  • Page 265 HYDRAULICS WARNING Safely block cutting unit from rotating using a suitable device or tool. Failure to follow appropriate safety precaution may result in death or serious injury. 4. Install suitable blocking device or tool in left front cutting unit motor, preventing left front cutting unit motor from turning.
  • Page 266 HYDRAULICS 11. Calculate front cutting unit right motor leakage. (Step 9 of front cutting unit deck valve tests – Step 9 / Step 9 of front cutting unit deck valve tests x 100 = Leak Percentage) Is front cutting unit left motor leakage 10% or less? The front cutting unit left motor is good.
  • Page 267 HYDRAULICS 21. Calculate front cutting unit center motor leakage. (Step 9 – Step 19 / Step 9 x 100 = Leak Percentage) Is front cutting unit center motor leakage 10% or less? The front cutting unit center motor is good. Proceed to step 22.

  • Page 268: Right Wing Cutting Unit Circuit Test

    HYDRAULICS Right Wing Cutting Unit Circuit Test 31. Calculate front cutting unit right motor leakage. (Step 19 – Step 29 / Step 19 x 100 = Leak See Figures 6-30 through 6-32. Percentage) IMPORTANT Is front cutting unit right motor leakage 10% or less? •...
  • Page 269 HYDRAULICS TN1363 Figure 6-31 4. Install tee fitting (5) to fitting (1). 5. Connect test hose (6) of flow meter inlet and hose (2) to tee fitting (5). NOTE Make sure hose end is under oil level in hydraulic tank to prevent aeration of oil.

  • Page 270: Right Wing Cutting Unit Pump Test

    HYDRAULICS 16. Calculate right wing cutting unit circuit leakage. (Step 13 – Step 14 / Step 13 x 100 = Leak Percentage) Is right wing cutting unit circuit leakage 10% or less? The right wing cutting unit circuit is good. Proceed to “Right Wing Cutting Unit Motors Test”...

  • Page 271: Right Wing Cutting Unit Deck Valve Test

    HYDRAULICS 9. Slowly close flow meter valve (2) until pressure reaches 2250 psi (155 bar). Read and record the right wing cutting unit pump loaded flow. 10. Open flow meter valve (2), disengage switches, and stop engine. 11. Calculate right wing cutting unit pump leakage. (Step 13 of previous test –...
  • Page 272 HYDRAULICS 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Before performing this test, perform right wing cutting unit pump test, leaving flow meter connected as outlined. TN2062 Figure 6-36 3. Install blocking disk at fitting (1) on right wing cutting unit outside motor, blocking oil flow from entering right wing cutting unit outside motor.

  • Page 273: Adjust Right Wing Cutting Unit Deck Valve System Relief Valve Pressure

    HYDRAULICS Adjust Right Wing Cutting Unit Deck 11. Calculate right wing cutting unit deck valve leakage. (Step 9 of previous test – Step 9 / Step 9 of previous Valve System Relief Valve Pressure test x 100 = Leak Percentage) See Figure 6-39.

  • Page 274: Right Wing Cutting Unit Motors Test

    HYDRAULICS 4. Rotate screw (2) to adjust the relief valve pressure 2. Before performing this test, perform right wing cutting setting. unit deck valve test, leaving flow meter connected as outlined. To increase the pressure setting: Turn the screw in (clockwise). 3.
  • Page 275 HYDRAULICS test x 100 = Leak Percentage) Is right wing cutting unit outside motor leakage 10% or less? The right wing cutting unit outside motor is good. Proceed to step 12. Proceed to next question. Is right wing cutting unit outside motor leakage 11% to 20%? The right wing cutting unit outside motor is marginal.
  • Page 276 HYDRAULICS 21. Calculate right wing cutting unit inside motor leakage. (Step 9 – Step 19 / Step 9 x 100 = Leak Percentage) Is right wing cutting unit inside motor leakage 10% or less? The right wing cutting unit inside motor is good.

  • Page 277: Left Wing Cutting Unit Circuit Test

    HYDRAULICS Left Wing Cutting Unit Circuit Test See Figures 6-43 through 6-45. IMPORTANT • This test works together with the left cutting unit motors test to isolate a problem with the left cutting unit circuit. • Performing this test will isolate the left wing cutting unit pump, deck valve, and left wing cutting unit inside motor from the rest of the left wing cutting unit circuit.

  • Page 278: Left Wing Cutting Unit Pump Test

    HYDRAULICS 16. Calculate left wing cutting unit circuit leakage. (Step 13 – Step 14 / Step 13 x 100 = Leak Percentage) Is left wing cutting unit circuit leakage 10% or less? The left wing cutting unit circuit is good. Proceed to “Left Wing Cutting Unit Motors Test”...
  • Page 279 HYDRAULICS TN2258 Figure 6-46 TN1363 TN2251 Figure 6-47 Figure 6-48: Left Wing Cutting Unit Pump Test— 3. Install blocking disk between hose (1) and tee fitting Blocking Disk Between Pump and Deck Valve (3). 5. Bypass seat switch and set park brake. 4.

  • Page 280: Left Wing Cutting Unit Deck Valve Test

    HYDRAULICS Left Wing Cutting Unit Deck Valve CAUTION Test Do not exceed 3350 psi (231 bar) when testing See Figures 6-49 through 6-51. pump or equipment damage may occur. WARNING 9. Slowly close flow meter valve (2) until pressure The hydraulic system is under pressure, and the reaches 2250 psi (155 bar).
  • Page 281 HYDRAULICS NOTE Verify engine rpm is within specification (2800 rpm ± 50) to ensure accurate hydraulic test results. 6. Start engine and run at full throttle (2800 rpm ± 50). 7. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (2) until a reading of 1500 psi (103 bar) or one half of the relief valve rating is reached.

  • Page 282: Adjust Left Wing Cutting Unit Deck Valve System Relief Valve Pressure

    HYDRAULICS 15. Open flow meter valve (2), disengage switches, and stop engine. Is left wing cutting unit deck valve system relief valve pressure 2700 psi (186 bar) to 3300 psi (228 bar)? Left wing cutting unit deck valve system relief valve is good.

  • Page 283: Left Wing Cutting Unit Motors Test

    HYDRAULICS Left Wing Cutting Unit Motors Test See Figures 6-53 through 6-55. IMPORTANT • This test works together with the left wing cutting unit circuit test to isolate a problem with the left wing cutting unit motors. • Performing this test will isolate the left wing cutting unit motors from the rest of the left wing cutting units circuit.
  • Page 284 HYDRAULICS NOTE Verify engine rpm is within specification (2800 rpm ± 50) to ensure accurate hydraulic test results. 6. Start engine and run at full throttle (2800 rpm ± 50). 7. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (1) until a reading of 1500 psi (103 bar) or one half of the relief valve rating is reached.

  • Page 285: Lift/Steer Relief Valve Pressure Test

    HYDRAULICS Lift/Steer Relief Valve Pressure Test 21. Calculate left outside cutting unit motor leakage. (Step 9 – Step 19 / Step 9 x 100 = Leak Percentage) See Figures 6-56 and 6-57. Is left outside cutting unit motor leakage 10% or NOTE less? The left outside cutting unit motor is good.

  • Page 286: Lift/Steer Pump Test

    HYDRAULICS CAUTION Do not run mower steer relief valve over relief longer than 10 seconds or damage may occur to hydraulic system. 12. Turn the steering wheel fully right against stop. 13. Record pressure reading. 14. Stop engine. Is steer relief pressure 1500 psi (103 bar)? Steer relief valve is good.
  • Page 287 HYDRAULICS 2. Raise the seat and seat platform. TN2237 Figure 6-58 3. Disconnect hose (1) from fitting (2). TN2255 TN2255 Figure 6-60: Lift Steer Pump Test 7. Set park brake. NOTE Verify engine rpm is within specification (2800 rpm ± 50) to ensure accurate hydraulic test results.
  • Page 288 HYDRAULICS 13. Calculate lift/steer pump leakage. (Step 10 – Step 11 / Step 10 x 100 = Leak Percentage) Is lift/steer pump leakage 10% or less? The lift/steer pump is good. Proceed to step 14. Proceed to next question. Is lift/steer pump leakage 11% to 20%? The lift/steer pump is marginal.

  • Page 289: Repair

    HYDRAULICS Repair Installation Notes • Ensure new O-ring is in place before installing hose on fitting. Hydraulic Oil Tank—Drain Procedure • Connect hose (1). See Figure 6-61. • Replace hydraulic oil return filter. (See “Hydraulic Oil 1. Park the mower safely. (See “Park Mower Safely” on Return Filter”...
  • Page 290 HYDRAULICS TN2278 Figure 6-63 7. Remove gear pump strap (8). 8. Remove two screws (13) and lock washers (12). 9. Remove gear pump (7). 10. Remove gasket (11), pump adapter (10), and O-ring (9). Installation Notes • Install gear pump by reversing the order of removal. •...
  • Page 291 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-64 and 6-65. 13 8 TN2350 Shaft Seal Wear Plate (8) Gear Plate (4) Gear Set (3) Front Cover/Flange Seal Ring (8) Body (3) Screw (8) Pre-Load Seal (4) Gear Set (Drive Shaft) Rear Cover Assembly Load Seal (4) Dowel Pin (8)
  • Page 292 HYDRAULICS Disassembly Notes Assembly Notes • Do not disassemble pump for repair unless test NOTICE procedures indicate internal leakage. • Never pry components apart. Use a soft face It is important that all component parts are hammer, and gently tap housing and shaft to absolutely clean, as contamination can result in separate pump bodies.

  • Page 293: Deck Motors

    HYDRAULICS Deck Motors 10. Support lift valve (9). 11. Remove nuts, lock washers, and mounting screws Removal and Installation (1). 12. Remove lift valve (9). NOTE Installation Notes See Chapter 8—Cutting Units for deck motor service • Install the lift valve by reversing the order of removal. information.
  • Page 294 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-67. 14 13 TN1834 Plug (3) Plug (3) Cap (3) Spool (3) O-Ring (3) Plug (3) Retaining Ring (3) Detent Plunger (3) Spring (3) Plug Spacer (3) Detent Spring (3) Poppet (3) Shim (3) Spring (3) O-Ring (3) Seat (3)

  • Page 295: Right Deck Valve

    HYDRAULICS 1. Remove all fittings from the lift valve. 2. Remove, inspect, and replace lift valve components as needed. 3. Clean all parts using clean solvent, and dry using compressed air. 4. Inspect all parts for wear or damage. Replace parts as needed.

  • Page 296: Left Deck Valve

    HYDRAULICS Left Deck Valve Installation Notes • Install the deck valve by reversing the order of Removal and Installation removal. • Make sure new O-rings are in place before installing See Figure 6-69. hoses on fittings. 1. Park the mower safely. (See “Park Mower Safely” on •...
  • Page 297 HYDRAULICS NOTES • Label all hydraulic hoses and tubes before disconnecting to aid in installation. • Close all openings with caps or plugs to prevent contamination. 5. Disconnect hydraulic hoses (3 through 6). 6. Support the deck valve (1). 7. Remove the mounting screws (7) and washers (8). 8.

  • Page 298: Hydraulic Oil Return Filter

    HYDRAULICS Assembly Notes NOTICE 2 3 4 It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.

  • Page 299: Front Lift Cylinders

    HYDRAULICS 2. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2292 Figure 6-73 4. Disconnect electrical connector (6). TN2300 Figure 6-74 NOTES • Label all hydraulic hoses to aid in installation. NOTES • Close all openings with caps or plugs to prevent •...
  • Page 300 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-75 and 6-76. NOTE The machine was built with two types of cylinders, either a threaded gland or a snap ring gland. Determine which type of cylinder was used and disassemble as needed. TN1839, TN1841 Grease Fitting (2) Seal...
  • Page 301 HYDRAULICS TN1840 TN1840, TN1842 Grease Fitting (2) Piston Rod Seal Barrel O-Ring (2) Lock Ring Rod Guide Backup Washer Lock Ring O-Ring Seal Ring Spacer Wiper O-Ring Figure 6-76: Snap Ring Gland 6-70 4203781 First Edition...
  • Page 302 HYDRAULICS Disassembly Notes Assembly Notes NOTICE NOTICE During repair of the cylinder, use extreme care It is important that all component parts are not to damage the barrel, piston, rod, and sealing absolutely clean, as contamination can result in surfaces of the cylinder. serious damage and/or improper operation.

  • Page 303: Wing Lift Cylinders

    HYDRAULICS Wing Lift Cylinders Installation Notes • Install lift cylinder by reversing the order of removal. Removal and Installation • Make sure new O-rings are in place before installing hoses on fittings. See Figure 6-77. • Replace hydraulic oil return filter. (See “Hydraulic Oil CAUTION Return Filter”...
  • Page 304 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-78 and 6-79. NOTE The machine was built with two types of cylinders, either a threaded gland or a snap ring gland. Determine which type of cylinder was used and disassemble as needed. TN1839, TN1841 Grease Fitting (2) Seal...
  • Page 305 HYDRAULICS TN1840 TN1840, TN1842 Grease Fitting (2) Piston Rod Seal Barrel O-Ring (2) Lock Ring Rod Guide Backup Washer Lock Ring O-Ring Seal Ring Spacer Wiper O-Ring Figure 6-79: Snap Ring Gland 6-74 4203781 First Edition...

  • Page 306: Hydraulic Oil Cooler

    HYDRAULICS Disassembly Notes Assembly Notes NOTICE NOTICE During repair of the cylinder, use extreme care It is important that all component parts are not to damage the barrel, piston, rod, and sealing absolutely clean, as contamination can result in surfaces of the cylinder. serious damage and/or improper operation.

  • Page 307: Hydraulic Oil Tank

    HYDRAULICS Hydraulic Oil Tank Removal and Installation See Figures 6-80 through 6-82. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery. 3. Raise the seat and seat platform. 4.
  • Page 308 HYDRAULICS TN2302 Figure 6-82 15. Disconnect glow plug solenoid (15) and fuel pump (16) from hydraulic oil tank back supports (14). 16. Remove tank straps (18). 17. Support the hydraulic oil tank (17). 18. Remove hydraulic oil tank back supports (14). 19.
  • Page 309 HYDRAULICS Installation Notes • Install hydraulic oil tank by reversing the order of removal. CAUTION When connecting fittings to the tank, be sure to hold the tank fitting with the proper wrench. If the proper wrench is not used, the fitting in the tank might break loose from the tank and cause it to leak.
  • Page 310 Chapter 7 Steering Specifications ..............7-2 Component Location .
  • Page 311 STEERING Specifications Test and Adjustment Specifications Steering System Leakage Test—Cylinder Leakage Zero–Nominal Amount pt (L) Rear Axle Alignment Toe-In Measurement 0.0625 (1.6) in. (mm) Rear Axle Spindle Arm-to-Axle Stop Measurement 0.030–0.060 (0.76–1.5) in. (mm) Repair Specifications Steering Wheel Nut 25–30 (34–41) lb-ft (N·m) Steering Column-to-Steering Unit Screw Torque 7.5–10 (10–13)

  • Page 312: Component Location

    STEERING Component Location See Figure 7-1. TN2166, TN2122, TN2126 Tie Rod Tilt Lever Steering Unit Steering Axle Steering Wheel Steering Column Steering Cylinder Steering Tower Cover Figure 7-1 4203781 First Edition...

  • Page 313: Tests And Adjustments

    STEERING Tests and Adjustments Turning Radius (Equal Angle) Adjustment IMPORTANT Steering Linkage Adjustments The steering linkage must be adjusted in proper See Figures 7-2 through 7-7. sequence. Do not perform this procedure until the tie rod adjustment has been performed. (See “Tie Rod IMPORTANT Adjustment”...
  • Page 314 STEERING 6. Remove cotter pins (4 and 5) and castle nuts (3 and 6), and lift steering cylinder (1) from frame bracket (2) and steering arm (7). TN1877 Figure 7-6: Steering Stop Bolt—Right Side TN1828 Figure 7-5 7. Loosen clamp bolts/nuts (8 and 9) on both sides of steering cylinder (11).

  • Page 315: Steering Relief Valve Pressure Test

    STEERING Steering Relief Valve Pressure Test See Figures 7-8 and 7-9. 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 316: Steering Leakage Test

    STEERING Steering Leakage Test 7. Check for oil leakage in the drain pan. Is steering cylinder leakage a nominal amount of See Figure 7-10. oil or less? 1. Operate hydraulic system until oil temperature is at Go to step 10. 120–150°...

  • Page 317: Repair

    STEERING Repair Steering Tower Cover Removal and Installation See Figure 7-11. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2127 Figure 7-12 2. Remove (unsnap) the cap (1) from the steering wheel (4). 3. Remove nut (2) and internal-tooth lock washer (3). 4.

  • Page 318: Steering Unit

    STEERING Steering Unit Removal and Installation See Figures 7-13 and 7-14. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the steering tower cover. (See “Steering Tower Cover” on page 7-8.) NOTE 13 14 If available, use a portable hydraulic filtering unit to remove the hydraulic oil from the hydraulic tank.
  • Page 319 STEERING Steering Unit Service Fixture See Figures 7-15 and 7-16. Required Tools or Equipment Steering Unit Service Fixture TN2142 0.165 in. (4.2 mm) 2.0 in. (50.8 mm) 0.250 in. (6.35 mm) Ø Hole (4) 4.0 in. (101.5 mm) 2.280 in. (58.0 mm) Ø 1.5 in.
  • Page 320 STEERING Disassembly See Figure 7-17. TN2141 Emergency Steering Ball Cross Pin End Cover Spacer Ball Stop Sleeve O-Ring (2) Cardan Shaft Thin Bearing Race Spring Set Gearwheel Rim Housing Bearing Check Valve Ball Gearwheel Name Plate Thick Bearing Race Special Screw (4) Distributor Plate Steering Relief Valve Spool...
  • Page 321 STEERING CAUTION Wear eye protection when assembling and disassembling the steering unit. Springs and other objects may be propelled into the air, causing eye injury. NOTES • Before attempting repairs or disassembly of any hydraulic components, thoroughly clean the components and work area. A clean work area is essential to satisfactory operation of repaired hydraulic components.
  • Page 322 STEERING Assembly See Figures 7-18 through 7-21. TN2141 Emergency Steering Ball Cross Pin End Cover Spacer Ball Stop Sleeve O-Ring (2) Cardan Shaft Thin Bearing Race Spring Set Gearwheel Rim Housing Bearing Check Valve Ball Gearwheel Name Plate Thick Bearing Race Special Screw (4) Distributor Plate Steering Relief Valve...
  • Page 323 STEERING 5. While holding the cross pin in place, guide the spool CAUTION and sleeve assembly into housing (23). 6. Place emergency steering ball (1) in port “P.” Wear eye protection when assembling and 7. Place ball stop (2) in port “P.” disassembling the steering unit.

  • Page 324: Steering Column

    STEERING Steering Column Removal and Installation See Figure 7-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the steering wheel (See “Steering Wheel” on page 7-8.) TN2148 Figure 7-21 10 11 16. Align end cover (15) to housing (23) and install special screws (12) into ports “T,”...

  • Page 325: Steering Tower

    STEERING Steering Tower 2. Remove the steering tower cover. (See “Steering Tower Cover” on page 7-8.) Removal and Installation 3. Remove the steering column. (See “Steering Column” on page 7-15.) See See Figure 7-23. 4. Remove the horn/test switch. (See “Horn/Test 1.

  • Page 326: Steering Cylinder

    STEERING Steering Cylinder Removal and Installation See Figures 7-24 through 7-26. Required Tools or Equipment Ball Joint Removal Tool 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Thoroughly clean the area surrounding the steering cylinder, especially the hydraulic hose fittings. TN1799 Figure 7-25 6.
  • Page 327 STEERING 9. Remove ball joints (10 and 13) and clamps (14 and 16) from steering cylinder (15). 10. Inspect ball joints. Replace as needed. Installation Notes • Install the steering cylinder by reversing the order of removal. • Using information recorded during disassembly, install ball joints into tie rod with the correct number of turns.
  • Page 328 STEERING Disassembly, Inspection, and Assembly See Figure 7-27. TN1790 Barrel Backup Ring (2) Rod Seal Snap Ring (Small) O-Ring Rod Wiper O-Ring Seal Ring O-Ring Snap Ring (Large) Piston Rod Guide Rod Guide Figure 7-27 1. Remove the small snap ring (13) and rod guide (12). WARNING 2.

  • Page 329: Tie Rod Assembly

    STEERING 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. 8.
  • Page 330 STEERING Disassembly, Inspection, and Assembly See Figure 7-30. TN1819 Castle Nut Tie Rod Grease Fitting (2) Hex-Head Bolt Lock Washer Lock Washer Threaded Ball Joint, Left Threaded Ball Joint, Right Tie Rod Clamp Tie Rod Clamp Castle Nut Hex-Head Bolt Figure 7-30 Disassembly Note Assembly Notes...

  • Page 331: Rear Axle

    STEERING Rear Axle Removal and Installation See Figure 7-31. TN1829 Cotter Pin Hose, Left Lock Washer Steering Axle Assembly Castle Nut Hex-Head Bolt Hose, Right Thrust Washer (3) Frame Bracket (Rear) Pivot, Steering Axle Steering Cylinder Frame Bracket (Front) Flat Washer Grease Fitting Figure 7-31 7-22...
  • Page 332 STEERING 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the rear wheel motors. (See “Rear Wheel Motor” on page 5-63.) NOTES • Label all hydraulic hoses and record their locations to ensure correct installation. •...
  • Page 333 STEERING Disassembly, Inspection, and Assembly See Figure 7-32. TN1777 Tie Rod Assembly Thrust Washer (6) Castle Nut (2) Hex Bolt (6) Roll Pin (2) Bushing, Mount Pivot (4) Cotter Pin (4) Axle Socket-Head Screw (2) Grease Fitting (2) Motor Mount (2) Castle Nut (2) Hex Nut (2) Thrust Bearing (2)
  • Page 334 STEERING Disassembly Notes • Before disassembly, clean and remove all dirt and grass from rear axle assembly. • Inspect all bushings, thrust washers, and bearings for damage or wear. • Inspect steering cylinder for leaks or dents to the barrel and rod. •...
  • Page 335 STEERING Page Intentionally Blank 7-26 4203781 First Edition...
  • Page 336 Chapter 8 Cutting Units Specifications ..............8-2 Repair Specifications .

  • Page 337: Specifications

    CUTTING UNITS Specifications Repair Specifications Specifications Blade Retaining Screw lb-ft N·m 75 (100) Adapter Screws lb-ft N·m 35–40 (47–54) 4203781 First Edition...

  • Page 338: Component Location

    CUTTING UNITS Component Location See Figure 8-1. TN2096 Swivel Caster Wheel Assembly (6) Wing Lift Arm (2) Anti-Scalp Wheel (4) Deck Motor (7) Outer Wing Caster Arm (2) Front Deck Assembly Right Wing Deck Assembly Left Wing Deck Assembly Front Caster Arm (2) Front Deck Lift/Push Arms Height-of-Cut Spacers Anti-Scalp Wheel...

  • Page 339: Tests And Adjustments

    CUTTING UNITS Tests and Adjustments Deck Rake Adjustment Front Deck Deck Leveling Adjustment See Figures 8-3 and 8-4. See Figure 8-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Set all tire pressures for machine and caster wheels. Set front machine tires at 16–20 psi (110–138 kPa), rear machine tires at 10–12 psi (69–83 kPa), and caster tires at 20–25 psi (138–172 kPa).
  • Page 340 CUTTING UNITS Wing Decks See Figure 8-5. TN1880 Figure 8-4 4. Lift the rear of front deck until level, and then lift an additional 1/8 inch to 1/4 inch. 5. Insert shims (3) on lift arms and secure in place. 6.

  • Page 341: Final Adjustments

    CUTTING UNITS Final Adjustments 1. Make a sample cut with front deck and wing decks. If front deck is cutting at the same height as wing decks, unit is ready. 2. If front deck is cutting lower, add 1/8 inch flat washer to front caster height-of-cut spacer.

  • Page 342: Troubleshooting

    CUTTING UNITS Troubleshooting Mechanical Troubleshooting Condition Probable Cause Remedy Drive motors do not reach full speed. Engine speed is insufficient, not set to Check engine speed. (Refer to “Safety, specification. Operation, and Maintenance Manual.”) Rotary drive motors and/or hydraulic Check hydraulic system performance. system performance is reduced.

  • Page 343: Quality Of Cut Troubleshooting

    CUTTING UNITS Quality of Cut Troubleshooting 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 344 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 345 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a cutting unit than on the other, or on one side of the mower than on the other. This is usually caused by mechanical wear or an incorrect roller or deck caster adjustment.
  • Page 346 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 347 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). Replace or sharpen blade(s). (Refer to “Safety, Operation, and Maintenance Manual.”) Mowing (ground) speed is too fast. Reduce mowing (ground) speed.
  • Page 348 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 “Blade” on page 8-18.) Turning too aggressively. Cutting units don’t overlap during turns Turn less aggressively to allow cutting units to overlap.
  • Page 349 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 350 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units cause a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to a different HOC (height-of-cut) adjustment from one cutting unit to another. TN1278 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Improper tire pressure.

  • Page 351: Repair

    CUTTING UNITS Repair Installation Notes • Install the deck motor by reversing the order of removal. Deck Motor • Install the motor on the deck, making sure that it is in proper orientation with the marks made on removal. Removal and Installation •...
  • Page 352 CUTTING UNITS Disassembly and Assembly See Figure 8-7. TN1821 Cover Motor Body Shaft Key Small Snap Ring Backing Seal (2) Spindle Bearing Washer Bushing Seal (2) Flanged Bushing (2) O-Ring Large Snap Ring O-Ring (2) Spindle Shaft Seal Motor Shaft Guard Figure 8-7 1.

  • Page 353: Blade

    CUTTING UNITS Blade NOTICE Removal and Installation It is important that all motor parts are absolutely See Figure 8-8. clean, as contamination can result in serious damage and/or improper operation. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Never use shop towels or rags to dry parts after cleaning, as lint may clog passages.

  • Page 354: Front Deck

    CUTTING UNITS Front Deck Removal and Installation See Figure 8-9. 1. Lower front deck to the ground, and park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove deck motors. (See “Deck Motor” on page 8-16.) TN2132 Figure 8-9 3.
  • Page 355 CUTTING UNITS Disassembly and Assembly See Figure 8-10. 27 26 TN2133 Bushing (2) Lock Washer (5) Flat Washer Screw (3) Anti-Scalp Wheel Screw Nut (5) Screw Screw Shaft Flat Washer (2) Motor (3) Lock Nut Plate Lock Washer Caster Arm Decal (5) Key (3) Carriage Bolt...

  • Page 356: Front Lift Arms

    CUTTING UNITS Assembly Notes Installation Notes • Assemble front deck in reverse order of disassembly. • Install front lift arms by reversing the order of removal. • Lubricate grease fittings with grease that meets or exceeds NLGI Grade 2 LB specifications. Apply •...
  • Page 357 CUTTING UNITS Disassembly and Assembly See Figure 8-12. 21 22 21 22 TN2134 Flat Washer (4) Lock Washer (3) Washer (2) Front Arm Lift Cylinder (2) Shim (as required) Screw (2) Retaining Pin (4) Spacer (2) Left Front Lift Arm Lift Arm Bumper (2) Bracket Screw...

  • Page 358: Wing Decks

    CUTTING UNITS Assembly Notes • Assemble front lift arms in reverse order of disassembly. • Always use new cotter pins. • Lubricate grease fittings with grease that meets or exceeds NLGI Grade 2 LB specifications. Apply grease with a manual grease gun and fill slowly until grease begins to seep out.
  • Page 359 CUTTING UNITS Disassembly and Assembly See Figure 8-15. NOTE Right wing deck shown; left is similar. TN2136 Bushing (3) Screw Lock Nut Blade (2) Spacer Caster Arm (2) Flat Washer Bumper Screw (2) Flat Washer Screw (2) Reflector Carriage Bolt Screw (2) Screw Flat Washer (4)

  • Page 360: Wing Deck Lift Arms

    CUTTING UNITS Disassembly Note Inspect all moving parts for wear or damage. Replace as necessary. 12 13 Assembly Notes • Assemble wing deck in reverse order of disassembly. 9 10 • Tighten adapter screws (23) to 35–40 lb-ft (47–54 N·m). •...
  • Page 361 CUTTING UNITS Disassembly and Assembly See Figure 8-18. NOTE Right wing deck lift arm shown; left is similar. TN1843 Spacer (2) Washer (4) Block Washer Lock Nut (3) Flat Washer (2) Lock Washer Washer Shim Screw Screw Wing Deck Lift Arm Magnet Shaft Rubber Stop (2)

  • Page 362: Swivel Caster Wheels

    CUTTING UNITS Disassembly Note Installation Notes Inspect all moving parts for wear or damage. Replace as • Install the swivel caster wheels by reversing the order necessary. of removal. • Lubricate grease fittings with grease that meets or Assembly Notes exceeds NLGI Grade 2 LB specifications.

  • Page 363: Fixed Caster Wheels

    CUTTING UNITS Disassembly and Assembly Disassembly Notes • Note position and order of flat washers and See Figure 8-20. height-of-cut spacers for proper assembly. • Inspect all moving parts for wear or damage. Replace as necessary. Assembly Notes • Assemble caster wheel in reverse order of disassembly.

  • Page 364: Anti-Scalp Wheels

    CUTTING UNITS Anti-Scalp Wheels Disassembly and Assembly See Figure 8-22. Removal and Installation See Figure 8-23. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise and support cutting deck using jackstands. TN2139 Figure 8-23 3. Remove screw (1), lock washer (2), and nut (3). 4.
  • Page 365 CUTTING UNITS Disassembly and Assembly See Figure 8-24. TN1864 Anti-Scalp Wheel (2) Cotter Pin Spacer (2) Bushings Flat Washer (2) Anti-Scalp Wheel Screw (2) Shaft Lock Nut (2) Screw Lock Washer Figure 8-24 Disassembly Note Inspect all parts for wear or damage. Replace as necessary.
  • Page 366 Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Component Location .
  • Page 367 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications OPS Mounting Hardware Mounting Hardware Torque 135–165 (183–224) lb-ft (N·m) Fuel Tank Capacity 20 (75.7) gal (L) Front Tires Size 26 x 12.00-12 Type 6-Ply Air Pressure 16–20 (0.55–0.69) psi (bar) Mounting Bolt Torque 85–95 (115–129) lb-ft (N·m) Rear Tires Size...
  • Page 368 ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 9-1. TN2096 OPS (Operator Protective Structure) Hood Right Side Fender Seat and Seat Platform Left Side Fender Traction Pedal Front Cowling Rear Wheel (2) Fuel Tank Utility Box Front Wheel (2) Brake Pedal Figure 9-1 4203781 First Edition...

  • Page 369: Checks And Adjustments

    ACCESSORIES AND MISCELLANEOUS REPAIR Checks and Adjustments 10. Repeat steps 2 through 9 for each cable as required. IMPORTANT Brake Pedal Adjustment Check adjustment of park brake switch (5) whenever See Figure 9-2. interlock system is not operating correctly. (See “Park Brake Switch”...

  • Page 370: Front Cowling

    ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes • Center the canopy before tightening the mounting hardware. • Install the canopy by reversing the order of removal. Front Cowling Removal and Installation See Figures 9-5 through 9-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2204 Figure 9-6...

  • Page 371: Ops

    ACCESSORIES AND MISCELLANEOUS REPAIR Hood Removal and Installation Removal and Installation See Figure 9-8. See Figure 9-9. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 372: Fuel Tank

    ACCESSORIES AND MISCELLANEOUS REPAIR Fuel Tank Removal and Installation See Figures 9-10 through 9-13. CAUTION Diesel fuel is highly flammable. Do not drain fuel indoors. Heaters can ignite fuel vapors. Use extreme caution when draining fuel. 1. Park the mower safely. (See “Park Mower Safely” on TN2223 page 1-6.) Figure 9-11...
  • Page 373 ACCESSORIES AND MISCELLANEOUS REPAIR TN2114 Figure 9-13 11. Support the fuel tank (9) and remove the two mounting screws (12), lock washers (11), and flat washers (10). 12. Remove the fuel tank from the machine. Installation Notes Required Materials Anti-Seize Compound •...
  • Page 374 ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Disassembly and Assembly See Figure 9-14. TN2119 Forward Pedal Grip Pedal Support Bracket Lock Washer (2) Lock Nut Screw (2) Flange Nut (2) Switch Shim (As Required) Mow Speed Stop Traction Pedal Nylon Bearing (2) Reverse Kick-Out Switch Flat Washer Reverse Pedal Grip...

  • Page 375: Seat And Seat Platform

    ACCESSORIES AND MISCELLANEOUS REPAIR 1. Park the mower safely. (See “Park Mower Safely” on 3. Remove utility box. (See “Utility Box” on page 9-15.) page 1-6.) 2. Remove two screws (2) from pedal arm (20). 3. Lift traction pedal (3) out and away from machine. 4.
  • Page 376 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figures 9-17 and 9-18. TN2120 Seat Screw (4) Rear Seat Stop (2) Screw (4) Nut (4) Seat Rail Seat Riser (4) Rubber Stop Spacer (3) Nut (4) Screw (4) Screw (4) Warning Decal Seat Rail with Handle Seat Base Figure 9-17...
  • Page 377 ACCESSORIES AND MISCELLANEOUS REPAIR TN2277 Backrest Cushion Left Side Adjustable Arm Rest Kit Air Spring Kit Seat Belt Right Side Adjustable Arm Rest Kit Left Side Cover Shock Absorber Kit OPS Switch Kit Document Net Kit Backrest Adjustment Kit 12V Compressor Right Side Cover Lumbar Handle Kit Bellows...

  • Page 378: Footrest Floor

    ACCESSORIES AND MISCELLANEOUS REPAIR Footrest Floor Removal and Installation See Figures 9-19 through 9-22. 1. Park the mower safely. (See “Park Mower Safely” on 9 10 page 1-6.) 2. Remove steering tower. (See “Steering Tower” on page 7-16.) 3. Remove work light kit (if equipped). (See “Work Light Kit”...

  • Page 379: Floorboard

    ACCESSORIES AND MISCELLANEOUS REPAIR TN2200 Figure 9-22 14. Remove two carriage bolts (29) and flange nuts (30). 15. Remove two nuts (26), lock washers (27), and carriage bolts (28). TN2021 16. Using a suitable lifting device, raise and remove Figure 9-23 footrest floor from machine.

  • Page 380: Utility Box

    ACCESSORIES AND MISCELLANEOUS REPAIR 10. Lift rear of footrest floor (11) and slide floorboard to the rear until the floorboard clears the footrest floor. 11. Remove floorboard from the machine. 9 10 Installation Note Install the floorboard by reversing the order of removal. Utility Box Removal and Installation See Figures 9-28and 9-29.

  • Page 381: Left Fender

    ACCESSORIES AND MISCELLANEOUS REPAIR Left Fender Removal and Installation See Figures 9-30 and 9-31. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove utility box. (See “Utility Box” on page 9-15.) 5 6 7 TN2207 Figure 9-30 3.

  • Page 382: Right Fender

    ACCESSORIES AND MISCELLANEOUS REPAIR Right Fender Work Light Kit Removal and Installation Removal and Installation See Figure 9-32. See Figure 9-33. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 383: Rear Wheels

    ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheels Front Wheels Removal and Installation Removal and Installation See Figure 9-34. See Figure 9-35. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.
  • Page 384 ACCESSORIES AND MISCELLANEOUS REPAIR Brake Pedal Disassembly and Assembly See Figure 9-36. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2113 Carriage Bolt (2) Flat Washer Lock Washer (4) Grease Fitting Lock Nut Screw Nut (4) Lock Washer (4) Park Brake Lever Pedal Grip...

  • Page 385: Brake Caliper Assembly

    ACCESSORIES AND MISCELLANEOUS REPAIR Assembly Notes • Required Materials ® Loctite 242 (Blue) • Adjust brake pedal switch so contacts are closed with the brake engaged and open as soon as the brake pedal is pressed. • Clean grease fitting (22) before and after lubricating. •...

  • Page 386: Front Wheel Hubs And Rotors

    ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes 7. Loosen the wheel hub (3) from the axle shaft (6) using a puller. • Install the brake caliper assembly by reversing the order of removal. 8. Remove castle nut (4) and wheel hub (3) from axle shaft (6).
  • Page 387 ACCESSORIES AND MISCELLANEOUS REPAIR Page Intentionally Blank 9-22 4203781 First Edition...
  • Page 388 INDEX INDEX Battery Removal and Installation ....4-85 Numerics Repair ......4-85 4WD Rev Solenoid Blade...
  • Page 389 INDEX Component Identification Electrical Schematic ....4-8 Deck Leveling Adjustment Component Location Tests and Adjustments ....8-4 Cutting Units .
  • Page 390 INDEX Electrical Schematic Fixed Caster Wheels Component Identification ....4-8 Disassembly and Assembly ... . 8-29 Removal and Installation .
  • Page 391 INDEX Front Mow Enable Switch Glow Plug Solenoid Removal and Installation ....4-96 Removal and Installation ....4-105 Repair .
  • Page 392 INDEX Hydraulics Instrument Test Procedures Component Location ....6-4 Adjust Front Cutting Unit Deck Valve System Relief Field Test Procedures ....6-24 Valve Pressure .
  • Page 393 INDEX Left Wing Proximity Switch Removal and Installation ....4-95 Repair ......4-95 Park Brake Switch Removal and Installation .
  • Page 394 INDEX Rear Wheel Motor Disassembly, Inspection, and Assembly . . . 5-65 Rear Wheel Motor Timing, Assembly ..5-66 Removal and Installation ....5-63 Repair .
  • Page 395 INDEX Repair Fuel Tank ......9-7 4WD Rev Solenoid ....4-104 Gear Pump .
  • Page 396 INDEX Traction Pedal ......9-9 Traction Pump ..... . . 5-48 Traction Pump U-Joint .
  • Page 397 INDEX Schematic, Hydraulic Steering Leakage Test Traction Circuit—Forward 2WD ..5-12 Test and Adjustments ....7-7 Traction Circuit—Forward 4WD .
  • Page 398 INDEX Theory of Operation Charging Circuit ..... 4-34 Cruise Control ..... . . 4-44 Test Four Wheel Drive Circuit .
  • Page 399 INDEX Traction Circuit—Reverse 2WD Volt Meter Hydraulic Schematic ....5-16 Removal and Installation ....4-109 Theory of Operation .
  • Page 401 A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. When Performance Matters. ™ Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

Table of Contents