Textron Jacobsen HR-5111 Technical/Repair Manual
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Textron Jacobsen HR-5111 Technical/Repair Manual

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HR-5111™
Rotary Mower
Technical/Repair Manual
69116

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Summary of Contents for Textron Jacobsen HR-5111

  • Page 1 HR-5111™ Rotary Mower Technical/Repair Manual 69116...
  • Page 3 ©2009 Jacobsen, A Textron Company. All rights reserved.
  • Page 5 Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen HR-5111 rotary mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user...
  • Page 6 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2009, Jacobsen, a Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4203780 First Edition...
  • Page 7 Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous Repair 4203780 First Edition...

  • Page 9: Table Of Contents

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

  • Page 10: Introduction

    SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
  • Page 11 SAFETY TN1767, TN1770 Figure 1-1 4203780 First Edition...
  • Page 12 SAFETY 4203780 First Edition...
  • Page 13 SAFETY 4203780 First Edition...

  • Page 14: Inspect Safety Labels

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

  • Page 15: Use Lifting Equipment Safely

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

  • Page 16: Service Tires Safely

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

  • Page 17: Handle Chemical Products Safely

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

  • Page 18: Service Electrical Components Safely

    SAFETY Service Electrical Components Safely WARNING Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury. •...
  • Page 19 Chapter 2 Specifications and General Information Mower Identification ............2-2 Serial Number .

  • Page 20: 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 tractor 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 21: Engine Serial Number

    SPECIFICATIONS AND GENERAL INFORMATION Engine Serial Number Optional Machine Accessories The engine serial number (6) is located on a plate This manual is structured to cover all basic machine attached to the top of the rocker arm cover which also components and repair.
  • Page 22 SPECIFICATIONS AND GENERAL INFORMATION TN1770 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—Shaft Seal Installation Depth 7/32 (5.5) in. (mm) Front Axle Motor—Backplate Assembly Screw Torque 15—18 (20—24) lb-ft (N·m) Differential Lock Assembly—Fork Screw Torque 19 (26) lb-ft (N·m) Differential Lock Assembly—Housing Screw Torque 37 (51) lb-ft (N·m) Input Bevel Pinion Assembly—Housing Screw Torque...
  • Page 25 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Gear Pump—Rear Cover-to-Pump Body Bolt Torque 20 (27) lb-ft (N·m) Mow Solenoid Valve Torque 24—26 (32.5—35.3) lb-ft (N·m) Mow Solenoid Valve Nut Torque 5—7 (6.8—9.5) lb-ft (N·m) Blade Brake Relief Valve Torque 33—37 (44.7—50.2) lb-ft (N·m) Deck Valve System Relief Valve Torque 24—26 (32.5—35.3)
  • Page 26 SPECIFICATIONS AND GENERAL INFORMATION Rear Tires Size 23 x 10.50-12 Type 4-Ply Air Pressure 8—10 (55—69) psi (bar) Mounting Bolt Torque 40—50 (54—68) lb-ft (N·m) Mower Speed Transport—2WD 0—15 (0—24) mph (km/h) Transport—4WD 0—8.4 (0—13.5) mph (km/h) Mowing 0—7.5 (0—12) mph (km/h) Reverse 0—6 (0—9.7)
  • Page 27 SPECIFICATIONS AND GENERAL INFORMATION Weights and Dimensions Overall Weight 3780 (1718) lb (kg) Width of Cut 134 (3404) in. (mm) Overall Width 139 (3531) in. (mm) Overall Height with OPS 81 (2057) in. (mm) Overall Height with OPS & Canopy 89 (2260) 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 4203781 First Edition 2-11...
  • Page 30 SPECIFICATIONS AND GENERAL INFORMATION 2-12 4203781 First Edition...
  • Page 31 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .

  • Page 32: Specifications

    ENGINE Specifications General Engine Specifications Engine ® Manufacturer/Model Kubota Tier 2/V2203-DI-B Engine Type 4-stroke, diesel Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45) Number of Cylinders/Configuration 4, in-line Displacement 131.1 (2148) cu in. (cc) Bore x Stroke 3.43 x 3.64 (87 x 92.4) in.

  • Page 33: Component Location

    ENGINE Component Location Kubota V2203-DI-B See Figures 3-1 and 3-2. TN2003, TN2036 Hydraulic Oil Cooler Oil Pressure Sending Unit Radiator Starter Motor Thermostat Alternator Air Cleaner Assembly Fan Drive Belt Coolant Overflow Reservoir Engine Temperature Sensor Hydraulic Oil Filters Fuel Pump Figure 3-1: Component Location—Right Side 4203780 First Edition...
  • Page 34 ENGINE TN2004, TN2005 Hydraulic Tank Oil Filler Cap Air Cleaner Service Switch Oil Filter Radiator Cap Fuel Filter Throttle Cable Fuel Shutoff Solenoid Figure 3-2: Component Location—Left Side 4203780 First Edition...

  • Page 35: Checks And Adjustments

    ENGINE Checks and Adjustments 6. Move throttle lever to slow idle position. Throttle Cable Adjustment See Figures 3-3 through 3-5. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2011 Figure 3-5 7. Loosen clamp nuts (18) and position cable in clamp so that governor throttle lever (15) contacts the idle screw (14).

  • Page 36: Fuel Solenoid Rod

    ENGINE Fuel Solenoid Rod Purging the Fuel System Adjustment Adjustment See Figure 3-6. See Figure 3-7. 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Raise the hood. Do not purge fuel system when engine is hot. NOTE Whenever the fuel filter or fuel lines are removed, the fuel tank is completely emptied, or the engine has not been...

  • Page 37: Repair

    ENGINE Repair 7. Turn the ignition switch to the on position to allow the fuel pump to operate. 8. Close the air vent plug when bubbles disappear from Fan Belt the fuel flow and turn the ignition switch to the off position.

  • Page 38: 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 39: Muffler

    ENGINE TN1996 Figure 3-12 4. Remove the muffler clamp and hardware (2) from the TN2001 exhaust pipe (1). Figure 3-11 5. Remove four nuts (4), isolation mounts (5), screws (7), and eight flat washers (3). Remove the muffler 4. Remove the wing nut and gasket (4), and slide the (8) from the two muffler brackets (6) and exhaust element (5) out of the assembly.

  • Page 40: 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 41: Radiator/Hydraulic Oil Cooler

    ENGINE Radiator/Hydraulic Oil Cooler Removal and Installation See Figure 3-15. TN1998 Screw (4) Radiator Wing Nut (2) Lock Washer (4) Nut (8) Shoulder Bolt (2) Flat Washer (4) Lock Washer (10) Hydraulic Oil Cooler Pivot Plate Radiator Shroud Radiator Support Bracket (2) Petcock Seal (2) Hydraulic Oil Cooler...
  • Page 42 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 3-16 and 3-17. NOTE 10 11 Label all hoses before removing to ensure correct installation.
  • Page 43 ENGINE 7. Disconnect engine temperature sensor lead from NOTE engine temperature sensor (11). Label all hoses before removing to ensure correct 8. Loosen two clamps (13) and remove lower radiator installation. hose (12). 18 19 TN2016 Figure 3-20 TN2009 9. Remove the two shoulder bolts (14), lock washers Figure 3-18 (15), and nuts (16).

  • Page 44: Thermostat

    ENGINE Installation Notes CAUTION • Install the thermostat by reversing the order of removal. Allow the engine coolant to completely cool • Clean gasket surface. before removing the radiator cap. Hot coolant sprayed from the cap can cause serious personal •...

  • Page 45: Fuel Filter

    ENGINE 4. Disconnect and remove ball joint (10) from throttle Installation Notes lever control (7) and throttle cable (9). • Install the throttle cable and control lever by reversing 5. Remove nut (8) and slide throttle cable through the order of removal. frame.

  • Page 46: Fuel Pump

    ENGINE Fuel Pump Removal and Installation See Figure 3-28. 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 11. Remove two nuts (7), two lock washers (6), four washers (5), and two screws (4) to remove fuel filter assembly. Removal and Installation See Figures 3-29 through 3-34. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
  • Page 48 ENGINE TN1997 Figure 3-33 22. Remove six screws (40) and lock washers (39) to disconnect the hydrostatic pump drive plate (38) from the engine. TN2026 Figure 3-32 19. Loosen clamps (27) and remove air intake hose (28) and hose (29). Cover intake manifold opening. 20.
  • Page 49 ENGINE WARNING Prevent personal injury. Use a properly rated lifting device. Always be sure the load is balanced before lifting. TN1995 Figure 3-34 23. Using an engine hoist, support the engine (43) and 25. Place the engine on a suitable stand or workbench remove the four engine mounting bolts (41) and flat that will support the full weight in a safe manner while washers (42).

  • Page 50: Engine Service

    ENGINE Engine Service NOTE A separate engine manual, prepared by the engine If the engine is being replaced, some components must manufacturer, is supplied with this machine. Refer to the be removed and installed on the new engine. See the engine manufacturer’s manual for all engine-related “Parts &...
  • Page 51 Chapter 4 Electrical Specifications ..............4-4 Test and Adjustment Specifications .
  • Page 52 ELECTRICAL Troubleshooting ............. . 4-62 Glow Plug Circuit .
  • Page 53 ELECTRICAL Repair ..............4-86 Battery and Battery Tray .

  • Page 54: Specifications

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

  • Page 55: 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 56 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 4203780 First Edition...
  • Page 57 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 4203780 First Edition...

  • Page 58: 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.) • K4—Time Delay Relay (See Figure 4-2.) •...
  • Page 59 ELECTRICAL • Y6—4WD Rev Solenoid (See Figure 4-3.) • Y7—Diff Lock Solenoid (See Figure 4-3.) • Y8—Cruise Control Magnet (See Figure 4-4.) 4203780 First Edition...

  • Page 60: Electrical Schematic

    ELECTRICAL Electrical Schematic See Figures 4-1 through 4-7. Brn/Red Brn/Red Start Brn/Red Pnk/Blu Circuit Breaker Pur/wht Switch Wht/ Accessory Relay Pnk/Blu Pnk/Blu Glow Plug Switch Fuel Pull-In Relay Wht/ Red/ Grn/Wht Grn/Wht Circuit Breaker Alternator Grn/ Pull-In Hold-In Fuel Shutoff Glow Solenoid Plug...
  • Page 61 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 62 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 Diff Lock 4WD Rev Switch Solenoid Brn/Red Front Solenoid Diff Lock Wing Solenoid Enable Fuel Switch Pump 66A Pnk Lt Grn...
  • Page 63 ELECTRICAL Electrical Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay +12V Lt Blu/Red Wht/Grn +12V Engine Lt Blu/Red Wht/Grn 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 64 ELECTRICAL Electrical Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn +12V +12V +12V Tachometer Fuel Hour Gauge Meter Signal Signal Fuel Engine Level Speed Sensor Sensor Lt Blu Grn/Wht Lt Grn Glow Left Right Plug Turn Turn Light Indicator Indicator Lt Blu Grn/Wht Lt Grn TN1749...
  • Page 65 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 66 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 67 ELECTRICAL Page Intentionally Blank 4203780 First Edition 4-17...

  • Page 68: Theory Of Operation And Sub-Circuit Schematics

    ELECTRICAL Theory of Operation and Switched power is provided from 10-amp circuit breaker (F6) to the following: Sub-Circuit Schematics • 4WD switch • Diff lock switch Power Circuit—Theory of Operation • Fuel pump • Horn relay terminals 30 and 86 Unswitched Power Circuit •...

  • Page 69: 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 Start Brn/Red Pnk/Blu Circuit Breaker Pur/wht Switch Wht/ Accessory Relay Pnk/Blu Pnk/Blu Glow Plug Switch Fuel Pull-In Relay Wht/ Red/ Grn/Wht Grn/Wht...
  • Page 70 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 71 ELECTRICAL Power Circuit Schematic Continued Circuit Reverse Breaker Front Kick-Out Limit Switch Switch Reverse Forward Switch Red/Wht Brn/Red Mom. ON Solenoid Diff Lock 4WD Rev Switch Solenoid Brn/Red Front Solenoid Diff Lock Wing Solenoid Enable Fuel Switch Pump 66A Pnk Lt Grn 66A Pnk Lt Grn...
  • Page 72 ELECTRICAL Power Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn Horn Horn Relay +12V Lt Blu/Red Wht/Grn +12V Engine Lt Blu/Red Wht/Grn 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 73 ELECTRICAL Power Circuit Schematic Continued Wht/Grn Wht/Grn Wht/Grn Wht/Grn +12V +12V +12V Tachometer Fuel Hour Gauge Meter Signal Signal Fuel Engine Level Speed Sensor 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...
  • Page 74 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 75 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 76: 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 77: 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 78: 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 79: 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/ Diff Lock Wht/ Switch Circuit Breaker...

  • Page 80: 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 81: 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 Diff Lock Switch Wht/Brn Circuit Breaker +12V Enable...

  • Page 82: 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 Diff Lock Switch Wht/Brn Circuit Breaker +12V Enable...
  • Page 83 ELECTRICAL Page Intentionally Blank 4203780 First Edition 4-33...

  • Page 84: 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 85: 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 86: Mow Circuit-Theory Of Operation

    ELECTRICAL Mow Circuit—Theory of Operation NOTE The proximity switch is a solid state switch and will have Unswitched Power Circuit approximately a 2 to 3 volt drop across the switch when Unswitched power is available from the battery positive activated. terminal to the starter motor battery terminal and then When the front deck is lowered, the front limit switch is from the starter motor battery terminal to 50-amp circuit...

  • Page 87: 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 88 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 89 ELECTRICAL Page Intentionally Blank 4203780 First Edition 4-39...

  • Page 90: 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 91: 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 Diff Lock Circuit Relay Interlock Circuit Ground Circuit Pnk/Blu Circuit Reverse...

  • Page 92: 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...
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  • Page 94: 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 95: 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 96 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 97: 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 98 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 99 ELECTRICAL Page Intentionally Blank 4203780 First Edition 4-49...

  • Page 100: 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 101: 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 102 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 103: 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 104 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. Engine Coolant Temp Light When the engine coolant temp switch is closed, a ground is provided to the engine coolant temp light, turning on the light.

  • Page 105: 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 106 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 +12V Engine Tachometer Fuel Temperature Volt Hour Gauge Gauge Meter Meter Signal Signal Signal Engine Fuel Engine Temperature Level Speed Sensor Sensor Sensor...
  • Page 107 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 108: 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 109: 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 110 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 +12V Engine Tachometer Fuel Temperature Volt Hour Gauge Gauge Meter Meter Signal Signal Signal Engine Fuel Engine Temperature Level Speed Sensor Sensor Sensor...
  • Page 111 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 112: 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 4-73.) Faulty power circuit. Check continuity between 50A circuit breaker F3 and glow plug solenoid terminal. Continuity must be indicated.

  • Page 113: 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 4-76.) Faulty time delay relay. Test time delay relay. (See “Time Delay Relay Test” on page 4-74.) Charging Circuit Symptom: Battery not charging.
  • Page 114 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 115: 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 116: 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 117: 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 118 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 119 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 120 ELECTRICAL Symptom: Tachometer does not indicate engine speed. Probable Cause Remedy Faulty engine speed sensor. Substitute the engine speed sensor with a known good sensor. Faulty switched power circuit. With the key switch in the ON position, measure voltage between tachometer org terminal and ground.

  • Page 121: 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 122: 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 123: 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 124: 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 125: 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 126: 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 127: 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 128: 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 129: Wing Mow Enable And Light Switches Test

    ELECTRICAL Wing Mow Enable and Light Switches 9. Check for continuity. Test Is continuity indicated? The switch is faulty; replace the switch. See Figure 4-47. Proceed to step 10. Required Tools or Equipment 10. Connect test leads to the switch terminals (2 and 3). 11.

  • Page 130: Cruise Control Switch Test

    ELECTRICAL 25. Check for continuity. 7. Check for continuity. Is continuity indicated? Is continuity indicated? Proceed to step 26. Proceed to step 8. The switch is faulty; replace the switch. The switch is faulty; replace the switch. 26. Place the switch in the (4) position. 8.

  • Page 131: 4Wd Switch Test

    ELECTRICAL 4WD Switch Test 12. Check for continuity. Is continuity indicated? See Figure 4-49. Proceed to step 13. Required Tools or Equipment The switch is faulty; replace the switch. 13. Place the switch in the OFF (middle) position. Digital Multimeter, Ohmmeter, or Continuity Tester 14.

  • Page 132: Micro Switches Test

    ELECTRICAL Micro Switches Test Diff Lock Switch Test See Figure 4-50. See Figure 4-51. 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 133: Fuel Level Sensor Test

    ELECTRICAL 10. Release the plunger to the extended position. 5. Move the float (2) to the full position and read the resistance value. 11. Check for continuity. Is the resistance value approximately 32 ohms? Is continuity indicated? Proceed to step 6. The diff lock switch is good.

  • Page 134: Fuel Shutoff Solenoid Test

    ELECTRICAL Fuel Shutoff Solenoid Test NOTE See Figure 4-54. On some meters it will be necessary to select a range for the solenoid being tested. Required Tools or Equipment 3. Using a multimeter or ohmmeter, measure the resistance between terminals (1 and 2). Refer to the Digital Multimeter, Ohmmeter, or Continuity Tester specifications listed for the specific solenoid resistance.

  • Page 135: 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. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 136: Repair

    ELECTRICAL Repair 7. Lower battery (14) and battery tray (13) with floor jack. 8. Remove nut (9), lock washer (10), flat washer (11), Battery and Battery Tray and screw (12). Remove battery and battery tray. Removal and Installation NOTICE See Figures 4-57. Never place used batteries in the garbage.

  • Page 137: Starter Motor

    ELECTRICAL Circuit Breakers 6. Remove fan drive belt (9) from alternator pulley. 7. Support the alternator (3). Removal and Installation 8. Remove screw (8), lock washer (7), and flat washer (6). See Figures 4-60 and 4-61. 9. Remove screw (5) and nut (4). 1.

  • Page 138: Thermal Circuit Breakers

    ELECTRICAL Thermal Circuit Breakers Main 50-Amp Thermal Circuit Breaker Removal and Installation See Figures 4-62 and 4-63. 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.

  • Page 139: Time Delay Relay

    ELECTRICAL Time Delay Relay • Horn Relay (6) • Accessory Relay (7) Removal and Installation NOTE See Figure 4-66. For time delay relay, (See “Time Delay Relay” on 1. Park the mower safely. (See “Park Mower Safely” on page 4-89.) page 1-6.) 2.

  • Page 140: Key Switch

    ELECTRICAL Key Switch Removal and Installation See Figures 4-67 through 4-70. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN1905 Figure 4-69 5. Remove key switch cover (4). TN1903 Figure 4-67 3.

  • Page 141: Park Brake Switch

    ELECTRICAL Park Brake Switch Brake Pedal Switch Removal and Installation Removal and Installation See Figure 4-71. See Figure 4-72. 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: Horn/Test Switch

    ELECTRICAL Horn/Test Switch Installation Notes • Adjust jam nut (4) for proper switch height if Removal and Installation necessary. • Install horn switch by reversing the order of removal. See Figures 4-73 and 4-74. 1. Park the mower safely. (See “Park Mower Safely” on Seat Switch page 1-6.) 2.

  • Page 143: Glow Plug Switch

    ELECTRICAL Glow Plug Switch Removal and Installation See Figures 4-78 through 4-81. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN1988 Figure 4-76 10. Cut cable ties (8). TN1903 Figure 4-78 3.

  • Page 144: Engine Temperature Gauge

    ELECTRICAL Engine Temperature Gauge Removal and Installation See Figures 4-82 through 4-84. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN1917 Figure 4-80 5. Remove boot with retaining nut (4). TN1903 Figure 4-82 3.

  • Page 145: Indicator Lights

    ELECTRICAL • Charge Filter Service Light (8) • Low Charge Pressure Light (4) • Engine Coolant Temp Light (7) • Engine Oil Pressure Light (5) • Left Turn Indicator (6) Removal and Installation See Figures 4-86 through 4-88. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 146: Pto Switch

    ELECTRICAL TN2034 TN1937 Figure 4-88 Figure 4-90 5. Rotate indicator light holder (15) 1/8 turn counterclockwise to disengage from socket (14). NOTE 6. Pull indicator light from indicator light holder. Label all wires before disconnecting to ensure correct installation. Installation Note 4.

  • Page 147: Right And Left Wing Proximity Switches

    ELECTRICAL Right and Left Wing Proximity 2. Disconnect the negative (–) battery cable at the battery. Switches 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.

  • Page 148: Rocker Switches

    ELECTRICAL Rocker Switches See Figure 4-95. TN1937 Figure 4-96 NOTE Label all wires before disconnecting to ensure correct TN1936 installation. Figure 4-95 4. Disconnect wire connector (8). This procedure applies to the following switches: 5. Spread panel plug tab (6) on each side of rocker switch (7) and pull rocker switch to remove.

  • Page 149: Reverse Kick-Out Switch

    ELECTRICAL Reverse Kick-Out Switch Removal and Installation See Figure 4-100. 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 4-98 • Arrow indicates rear of mower. •...

  • Page 150: Diff Lock Switch

    ELECTRICAL Diff Lock Switch Air Filter Pressure Switch Removal and Installation Removal and Installation See Figure 4-101. See Figure 4-102. 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 151: Return Filter Pressure Switch

    ELECTRICAL Return Filter Pressure Switch 4. Disconnect connectors (2) from the return filter pressure switch (1). Removal and Installation 5. Remove return filter pressure switch (1). See Figure 4-103. Installation Notes WARNING Required Materials The hydraulic system is under pressure, and the ®...

  • Page 152: Charge Filter Pressure Switch

    ELECTRICAL Charge Filter Pressure Switch Removal and Installation See Figure 4-105. WARNING The hydraulic system is under pressure, and the oil may be hot! • Always allow the machine to cool completely before performing service. • Always relieve pressure in the hydraulic system before performing service.

  • Page 153: Engine Oil Pressure Switch

    ELECTRICAL Installation Notes Installation Notes Required Materials Required Materials ® ® Telfon Tape Telfon Tape • Install the charge filter pressure switch by reversing • Install the engine oil pressure switch by reversing the the order of removal. order of removal. •...

  • Page 154: Engine Coolant Temp Switch

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

  • Page 155: Mow Solenoids

    ELECTRICAL TN1868 TN1921 Figure 4-111: Right Mow Solenoid Figure 4-109 NOTES • The low charge pressure switch is installed on the control valve. • Label all wires before disconnecting to ensure correct installation. 3. Remove cover (1). 4. Disconnect wire connector (3). 5.

  • Page 156: 4Wd Solenoids

    ELECTRICAL 4WD Solenoids Removal and Installation See Figure 4-113. See Figures 4-114 and 4-115. NOTE The left mow solenoid is shown; all solenoids are removed and installed the same way. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 157: Glow Plug Solenoid

    ELECTRICAL Glow Plug Solenoid Removal and Installation See Figure 4-116. Removal and Installation NOTE See Figure 4-117. The diff lock solenoid is shown; all solenoids are removed 1. Park the mower safely. (See “Park Mower Safely” on and installed the same way. page 1-6.) 1.

  • Page 158: Fuel Shutoff Solenoid

    ELECTRICAL Fuel Shutoff Solenoid Removal and Installation See Figure 4-118. 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. TN2038 Figure 4-119 NOTE Label all wires before disconnecting to ensure correct installation.

  • Page 159: Diodes

    ELECTRICAL 5. Remove screws (2), lock washers (3), flat washers (4), and trim (8). 6. Remove screws (5), lock washers (6), and flat washers (7). TN2042 Figure 4-121 6. Remove cruise control magnet (3) from bracket (4). TN2023 Installation Note Figure 4-123 Install the cruise control magnet by reversing the order of 7.

  • Page 160: Instrument Panel

    ELECTRICAL Instrument Panel 10. Lift and move the instrument panel aside or service components as needed. Removal and Installation Installation Notes See Figure 4-124. • Anti-seize must be applied to screw threads when NOTE installing instrument panel. • Install the instrument panel by reversing the order of If servicing individual components, it is not necessary to removal.

  • Page 161: Volt Meter, Hour Meter, And Fuel Gauge

    ELECTRICAL Volt Meter, Hour Meter, and Fuel Gauge See Figure 4-126. TN2030 Figure 4-127 4. Remove nuts (5), lock washers (6), and bracket (4). NOTE TN2030 Label all wires before disconnecting to ensure correct Figure 4-126 installation. This procedure applies to the following gauges: 5.

  • Page 162: Tachometer

    ELECTRICAL Tachometer Installation Note Install the tachometer by reversing the order of removal. Removal and Installation Horn See Figures 4-128 and 4-129. 1. Park the mower safely. (See “Park Mower Safely” on Removal and Installation page 1-6.) See Figure 4-130. 2.

  • Page 163: Fuel Level Sensor

    ELECTRICAL Fuel Level Sensor Installation Note Install the fuel level sensor by reversing the order of Removal and Installation removal. See Figures 4-131 and 4-132. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery.
  • Page 164 ELECTRICAL 4-114 4203780 First Edition...
  • Page 165 Chapter 5 Hydrostatic Power Train Specifications ..............5-3 Test and Adjustment Specifications .
  • Page 166 HYDROSTATIC POWER TRAIN Repair ..............5-47 Front Axle U-Joint .

  • Page 167: Specifications

    HYDROSTATIC POWER TRAIN Specifications Test and Adjustment Specifications Specification Traction Pump Flow 35 (132) at 2850 rpm gpm (Lpm) Charge Pump Flow 10.5 (40) at 2850 rpm gpm (Lpm) Forward System Relief Pressure 3625 (250) at 2850 rpm psi (bar) Reverse System Relief Pressure 3625 (250) at 2850 rpm psi (bar)

  • Page 168: 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 169: Component Location

    HYDROSTATIC POWER TRAIN Component Location See Figures 5-2 and 5-3. TN1768, TN1970, TN1893 Hydrostatic Pump Front Axle Motor 4WD Valve Gear Pump Front Axle U-Joint Front Axle Figure 5-2: Component Location—Left Side 4203780 First Edition...
  • Page 170 HYDROSTATIC POWER TRAIN TN1769, TN1921 Control Valve Right Rear Wheel Motor Left Rear Wheel Motor Figure 5-3: Component Location—Right Side 4203780 First Edition...

  • Page 171: 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 NEUTRAL position Charge Pressure Circuit The traction pump and gear pump are both driven by the engine.
  • Page 172 HYDROSTATIC POWER TRAIN Traction Circuit—Neutral Schematic See Figures 5-4 and 5-5. 3500 psi Check Valve Gear Pump 2.48 ci 2800 ±50 RPM 0.65 ci 1.08 ci 1.08 ci 1.08 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch 25 psi Crack...
  • Page 173 HYDROSTATIC POWER TRAIN — Traction Circuit Neutral Schematic Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 2.48 ci Motor 4WD Reverse Solenoid Right Wheel Motor 11.9 Differential Lock 11.9 Charge Pressure Left Light Switch Wheel 125 psi N.C. Motor Charge Pressure Relief Valve 250 psi Priority Valve...
  • Page 174 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-10 4203780 First Edition...

  • Page 175: 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 176: Traction Circuit-Forward 2Wd, Differential Locked Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 2WD, Differential Locked Schematic See Figures 5-6 and 5-7. 3500 psi Check Valve Gear Pump 2.48 ci 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2800 ±50 RPM Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch...
  • Page 177 HYDROSTATIC POWER TRAIN — Traction Circuit Forward 2WD Differential Locked Schematic Continued 4WD Valve Secondary 4WD Shuttle Valve Front 2.48 ci Axle Motor 4WD Reverse Solenoid Right Wheel Motor 11.9 Differential Lock 11.9 Charge Pressure Left Light Switch Wheel 125 psi N.C. Motor Charge Pressure Relief Valve 250 psi...
  • Page 178 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-14 4203780 First Edition...

  • Page 179: 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 180: Traction Circuit-Reverse 2Wd, Differential Unlocked Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 2WD, Differential Unlocked Schematic See Figures 5-8 and 5-9. 3500 psi Check Valve 1.08 ci 1.08 ci 2.48 ci Gear Pump 0.65 ci 1.08 ci 2800 ±50 RPM Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch...
  • Page 181 HYDROSTATIC POWER TRAIN — Traction Circuit Reverse 2WD, Differential Unlocked Schematic Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 2.48 ci Motor Reverse Solenoid Right Wheel Motor 11.9 Differential Lock 11.9 Charge Pressure Left Light Switch Wheel Motor 125 psi N.C. Charge Pressure Relief Valve 250 psi Priority Valve...
  • Page 182 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-18 4203780 First Edition...

  • Page 183: 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 4WD solenoid in the control valve shifts, Schematic and Theory of Operation allowing oil to flow through the valve. Oil is then routed to the pilot line of the secondary 4WD shuttle valve in the System Conditions: 4WD valve, causing the valve to shift.

  • Page 184: Traction Circuit-Forward 4Wd, Differential Locked Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 4WD, Differential Locked Schematic See Figures 5-10 and 5-11. 3500 psi Check Valve Gear Pump 2.48 ci 2800 ±50 RPM 0.65 ci 1.08 ci 1.08 ci 1.08 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch...
  • Page 185 HYDROSTATIC POWER TRAIN Traction Circuit—Forward 4WD, Differential Locked Schematic Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 2.48 ci Motor 4WD Reverse Solenoid Right Wheel Motor 11.9 Differential Lock 11.9 Charge Pressure Left Light Switch Wheel 125 psi N.C. Motor Charge Pressure Relief Valve 250 psi...
  • Page 186 HYDROSTATIC POWER TRAIN Page Intentionally Blank 5-22 4203780 First Edition...

  • Page 187: Traction Circuit-Reverse 4Wd Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD When the 2WD/4WD switch is held in the momentary 4WD reverse position, the 4WD reverse solenoid shifts, Schematic and Theory of Operation allowing operating-pressure oil to flow through the valve to ports “R2” (right motor) and “L2” (left motor) driving the System Conditions: rear wheels.

  • Page 188: Traction Circuit-Reverse 4Wd, Differential Unlocked Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD, Differential Unlocked Schematic See Figures 5-12 and 5-13. 3500 psi Check Valve Gear Pump 2800 ±50 RPM 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch...
  • Page 189 HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 4WD, Differential Unlocked Schematic Continued 4WD Valve Secondary 4WD Shuttle Valve Front Axle 2.48 ci Motor Reverse Solenoid Right Wheel Motor 11.9 Differential Lock 11.9 Charge Pressure Left Light Switch Wheel Motor 125 psi N.C. Charge Pressure Relief Valve 250 psi Priority Valve...

  • Page 190: 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 191 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 192 HYDROSTATIC POWER TRAIN 4WD Will Not Engage Probable Cause Remedy 4WD solenoid in control valve does not engage when 4WD switch Problem in electrical circuit. (See Electrical section, is placed in ON position. Troubleshooting—“Four Wheel Drive Circuit Schematic” on page 4-41.) 4WD valve in control valve assembly sticking.

  • Page 193: Tests And Adjustments

    HYDROSTATIC POWER TRAIN Tests and Adjustments Traction Linkage Adjustments See Figures 5-14 through 5-19. Traction Pedal Neutral Adjustment TN1985 Figure 5-14 NOTE WARNING If the mower creeps in either direction while the engine is Use extreme caution while performing the running and the traction pedal is in the NEUTRAL following adjustment, as the drive wheels will be position, the hydro linkage may need adjustment.
  • Page 194 HYDROSTATIC POWER TRAIN Reverse Kick-Out Switch Initial Adjustment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. TN2140 Figure 5-16 4.
  • Page 195 HYDROSTATIC POWER TRAIN Reverse Kick-Out Switch Adjustment IMPORTANT The traction linkage must be adjusted in proper sequence. Do not perform this procedure until the traction pedal neutral adjustment has been performed. (See “Traction Pedal Neutral Adjustment” on page 5-29.) 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 196: Weight Transfer Adjustment

    HYDROSTATIC POWER TRAIN 1. Move the traction pedal (14) to the maximum forward position. If the pedal touches the stop stud (13) before reaching the maximum forward position, adjust the stop stud position. 2. Loosen jam nut (16) and lock nut (15). 3.

  • Page 197: Field Test Procedures

    HYDROSTATIC POWER TRAIN NOTE Adjusting weight transfer knob completely clockwise may cause decks not to lower. 3. Rotate adjustment knob (1) clockwise to increase upward force on cutting unit lift cylinders. This will improve machine traction and reduce wheel spin. 4.

  • Page 198: 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 199: Charge Pump Test

    HYDROSTATIC POWER TRAIN Charge Pump Test See Figures 5-24 through 5-26. WARNING The hydraulic system is under pressure, and the oil will be hot. • Always relieve pressure in the hydraulic system before performing service. • Failure to follow appropriate safety precautions may result in death or serious TN1921 injury.
  • Page 200 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 201: Traction System Test

    HYDROSTATIC POWER TRAIN Traction System Test See Figures 5-27 through 5-32. 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 202 HYDROSTATIC POWER TRAIN 16. Adjust flow lock tool (2) to allow pump to produce 15 gpm (57 Lpm) in the forward direction. 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.
  • Page 203 HYDROSTATIC POWER TRAIN 25. Disengage 4WD switch. 31. Slowly close flow meter valve (7) until pressure reaches 2625 psi (181 bar). Read and record loaded flow. 32. Open flow meter valve (7), stop engine, and set park brake. Return flow lock tool back to neutral position. 33.

  • Page 204: Traction Pump Tests

    HYDROSTATIC POWER TRAIN Traction Pump Tests See Figures 5-33 through 5-35. 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 205 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 206: Front Axle Motor Test

    HYDROSTATIC POWER TRAIN Front Axle Motor Test IMPORTANT See Figures 5-36 through 5-43. • 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 15.
  • Page 207 HYDROSTATIC POWER TRAIN TN1364 Figure 5-38 TN2069 8. Adjust flow lock tool (5) to allow pump to produce 15 Figure 5-39 gpm (57 Lpm) in the forward direction. 14. Remove blocking disks from locations (6 and 7). 9. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve until a reading of 1750 psi (121 bar) Secondary 4WD Shuttle Valve Test or one half of the relief valve rating is reached.
  • Page 208 HYDROSTATIC POWER TRAIN 25. Calculate secondary 4WD shuttle valve leakage. (Step 11 – Step 23 / Step 11 x 100 = Leak Percentage) Is secondary 4WD shuttle valve leakage 10% or less? The secondary 4WD shuttle valve is good. Proceed to step 26. Proceed to next question.
  • Page 209 HYDROSTATIC POWER TRAIN Left Rear Wheel Motor Test 32. Engage 4WD switch in the forward position. 27. Open flow meter valve completely before starting 33. Slowly close flow meter valve until pressure reaches engine. 2625 psi (181 bar). Read and record loaded flow. 34.
  • Page 210 HYDROSTATIC POWER TRAIN Right Rear Wheel Motor Test 42. Engage 4WD switch in the forward position. 37. Open flow meter valve completely before starting 43. Slowly close flow meter valve until pressure reaches engine. 2625 psi (181 bar). Read and record loaded flow. 44.

  • Page 211: Repair

    HYDROSTATIC POWER TRAIN Repair Front Axle U-Joint Removal and Installation See Figure 5-44. TN1984 Figure 5-44 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove park brake. (See “Park Brake” on page 9-11.) 3. Remove front axle motor (2). (See “Front Axle Motor” on page 5-58.) 4.

  • Page 212: Traction Pump U-Joint

    HYDROSTATIC POWER TRAIN Traction Pump U-Joint Removal and Installation See Figure 5-45. TN2032 Figure 5-45 5-48 4203780 First Edition...
  • Page 213 HYDROSTATIC POWER TRAIN 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the 4WD valve. (See “4WD Valve” on page 5-53.) NOTE It may be necessary to rotate the flywheel to access all of the pump drive flange screws. 3.

  • Page 214: Traction Pump

    HYDROSTATIC POWER TRAIN Traction Pump Removal and Installation See Figures 5-46 and 5-47. 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 9-13.) 3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure”...
  • Page 215 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-48. TN1895 Screw (4) Rotating Assembly O-Ring Housing Trunnion Cover Valve Plate Coupler Drive Shaft Inner Race Gasket Screw, Bottom (2) Retaining Ring (2) O-Ring Plug (2) Backplate Thrust Race (2) Washer (2) Spring (2) Dowel Pin (2)
  • Page 216 HYDROSTATIC POWER TRAIN NOTICE • It is important that motor parts are marked and placed in assembly order to aid in assembly. • It is important that all pump parts are absolutely clean, as contamination can result in serious damage and/or improper operation. •...

  • Page 217: 4Wd Valve

    HYDROSTATIC POWER TRAIN 4WD Valve Installation Notes • Install the 4WD valve by reversing the order of Removal and Installation removal. • Lubricate all O-rings prior to assembly. See Figure 5-49. • Make sure new O-rings are in place before installing 1.
  • Page 218 HYDROSTATIC POWER TRAIN 6. Remove straight adapter (8) from port “L2.” 14. Remove O-rings (19 and 20) and backup ring (18) from check valve (21). 7. Remove straight adapter (9) from port “L1.” 15. Remove secondary 4WD shuttle valve (23) from 8.

  • Page 219: Control Valve

    HYDROSTATIC POWER TRAIN Control Valve Installation Notes • Install the control valve by reversing the order of Removal and Installation removal. • Lubricate all O-rings prior to assembly. See Figure 5-52. • Make sure new O-rings are in place before installing 1.
  • Page 220 HYDROSTATIC POWER TRAIN PT1975 TN1975 Figure 5-54 5. Remove dust cover (7), diagnostic port adapter (8), 18. Remove O-rings (31 and 32) and backup rings (36) and 90° adapter (9) from port “CD.” from 4WD valve (33). 6. Remove 45° adapter (10) from port “F.” 19.
  • Page 221 HYDROSTATIC POWER TRAIN Assembly Notes NOTICE • It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. • Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.

  • Page 222: Front Axle Motor

    HYDROSTATIC POWER TRAIN Front Axle Motor Removal and Installation See Figure 5-55. TN1983 Figure 5-55 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 223 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figure 5-56. TN1902 TN1902 Retaining Ring Thrust Bearing Cam Plate Insert Screw (6) Shaft Seal Rotating Assembly Thrust Race (2) Washer Drive Shaft O-Ring Retaining Ring (2) Housing Backplate Assembly Figure 5-56 NOTES NOTICE •...

  • Page 224: Front (Drive) Axle Assembly

    HYDROSTATIC POWER TRAIN Front (Drive) Axle Assembly Inspection Notes • Keeping parts in assembly order, clean and air dry Removal and Installation each item for inspection. • Inspect for worn or defective parts. See Figures 5-57 through 5-67. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Do not lap the piston shoes, piston block, or backplate...
  • Page 225 HYDROSTATIC POWER TRAIN 15 16 17 TN2044 Figure 5-58 TN2050 5. Remove two screws (4) and lock washers (5), and Figure 5-60 remove front limit switch (6) and spacer (3). 10. Remove two nuts (15), lock washers (16), and screws (17), and four flat washers (18) from console support (14) and right side front lift arm support (19).
  • Page 226 HYDROSTATIC POWER TRAIN 38 39 24 25 TN2051 TN2047 Figure 5-64 Figure 5-62 NOTES • Label all hydraulic hoses before disconnecting to ensure correct installation. • Plug hydraulic hoses after disconnecting to prevent the loss of hydraulic oil. 12. Disconnect hydraulic line (22) from gear pump. 13.
  • Page 227 HYDROSTATIC POWER TRAIN TN2056 Figure 5-67 30. Remove four screws (67) and lock washers (66), and remove front axle assembly (68) from the frame. Installation Notes • Install the front axle by reversing the order of TN2054 removal. Figure 5-66 •...

  • Page 228: Differential Lock Assembly

    HYDROSTATIC POWER TRAIN Differential Lock Assembly Assembly Notes NOTICE Disassembly, Inspection, and Assembly See Figure 5-68. • It is important that all 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.

  • Page 229: Input Bevel Pinion Assembly

    HYDROSTATIC POWER TRAIN Input Bevel Pinion Assembly Disassembly and Inspection See Figure 5-69. TN1911 Screw (4) Nut, Elastic Stop Collapsible Spacer O-Ring Bearing Cup, Outer Seal, Outer Bearing Cup, Inner Shim (As Required) Bearing Cone, Outer O-Ring Bearing Cone, Inner Axle Assembly Spacer Pinion Housing...
  • Page 230 HYDROSTATIC POWER TRAIN NOTES • Do not remove the input bevel pinion assembly from the axle assembly before removing the elastic stop nut (5). • Once the elastic stop nut (5) has been loosened, a new collapsible spacer (9) must be installed. 1.
  • Page 231 HYDROSTATIC POWER TRAIN Assembly See Figures 5-70 and 5-71. TN1911 Screw (4) Nut, Elastic Stop Collapsible Spacer O-Ring Bearing Cup, Outer Seal, Outer Bearing Cup, Inner Shim (As Required) Bearing Cone, Outer O-Ring Bearing Cone, Inner Axle Assembly Spacer Pinion Housing Pinion Shaft Figure 5-70 4203780 First Edition...
  • Page 232 HYDROSTATIC POWER TRAIN Required Materials NOTE Lubricate all O-rings prior to assembly. ® Loctite 242 (Blue) 10. Install O-ring (13) on pinion housing (8). IMPORTANT NOTE • If the original pinion shaft was reused, proceed to Always replace the bearing cones and cups as a set. step 11.

  • Page 233: Drive Axle Reducer Assembly

    HYDROSTATIC POWER TRAIN Drive Axle Reducer Assembly 5. Remove two dowel sleeves (3) from the differential housing (10). Removal NOTE See Figure 5-72. The bearings are press-fit in the differential housing. Remove the bearings only if replacement is required. 6. Remove the drive axle (1) and wheel axle (9) bearings from the differential housing (10).
  • Page 234 HYDROSTATIC POWER TRAIN Disassembly and Inspection See Figure 5-73. TN1786 Ball Bearing (2 per side) Retaining Ring Wheel Bolt (5 per side) Washer Reducer Shaft Seal Flat Head Screw (5 per side) Gear, Reducer Housing, Reducer Brake Disk Spacer, Tube Ball Bearing Drive Axle Retaining Ring...
  • Page 235 HYDROSTATIC POWER TRAIN Installation See Figures 5-74 through 5-79. Required Materials ® Loctite Ultra-Blue Gasket Material TN1923 Figure 5-75 7. Press ball bearings (5 and 7) into the reducer housing (6). TN1924 8. Install retaining ring (8) and seal (9) into the reducer Figure 5-74 housing (6).
  • Page 236 HYDROSTATIC POWER TRAIN TN1926 Figure 5-77 10. Press the drive axle/brake disk assembly (14) into the reducer housing (13). TN1928 Figure 5-79 12. Clean the mating surfaces (20 and 21) of the differential housing (28) and reducer housing (23). Make sure the surfaces are dry. Apply Loctite Ultra Blue gasket material in a continuous bead around the mating surface, making sure to go around each hole.

  • Page 237: Differential Assembly

    HYDROSTATIC POWER TRAIN Differential Assembly Disassembly and Inspection See Figure 5-80. TN1787 Differential Housing, Right Differential Lock Collar Ball Bearing (2) Differential Screw (8) Shim (As Required) Plug (2) Differential Housing, Left Breather Shim (As Required) Hex Head Bolt (8) Seal Dowel Sleeve (2) Shim (As Required)
  • Page 238 HYDROSTATIC POWER TRAIN 1. Remove both drive axle reducer assemblies. (See “Drive Axle Reducer Assembly” on page 5-69.) 2. Remove the input bevel pinon assembly. (See “Input Bevel Pinion Assembly” on page 5-65.) NOTES Remove the breather (3), plugs (10), drain plug (16), and seal (15) only if replacement is required.
  • Page 239 HYDROSTATIC POWER TRAIN 7. Remove the input bevel pinion assembly (8) and 15. Apply Loctite 242 to eight screws (11) before differential assembly (6). assembly. Install screws and tighten to 37 lb-ft (51 N·m). 8. Place the shim pack in the bearing bore of the left differential housing (9).
  • Page 240 HYDROSTATIC POWER TRAIN Determine Shim Thickness Method “B” See Figure 5-87. There are two possible methods for determining the thickness of shims needed for the right differential housing. Review each procedure to determine which method best fits your application. Method “A” See Figures 5-85 and 5-86.

  • Page 241: Rear Wheel Motor

    HYDROSTATIC POWER TRAIN Rear Wheel Motor Removal and Installation See Figures 5-88 through 5-91. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove rear wheel. (See “Rear Wheels” on page 9-17.) TN1963 Figure 5-90 7. Remove cotter pin (10). TN1970 CAUTION Figure 5-88...
  • Page 242 HYDROSTATIC POWER TRAIN TN1964 Figure 5-91 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 243 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-92 and 5-93. 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 244 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 245: Traction Linkage

    HYDROSTATIC POWER TRAIN Traction Linkage Disassembly and Assembly See Figure 5-94. TN1980 Lock Nut (2) Pin, Magnet Support (2) Block, Top (2) Screw Flat Washer (8) Spring (2) Rubber Mount, Traction Arm Traction Arm Lock Washer, Heavy (7) Bracket, Cruise Control Magnet Washer (2) Bushing (2) Nut (3)
  • Page 246 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 9-13.) 3. Disassemble traction linkage as shown in Figure 5-94 on page 5-81. NOTES When removing rod ends (24 and 29) from traction pump adjusting rod (27), record the number of turns needed to...
  • Page 247 Chapter 6 Hydraulics Specifications ..............6-3 Test and Adjustment Specifications .
  • Page 248 HYDRAULICS Instrument Test Procedure ........... . . 6-27 Instrument Test Overview .
  • Page 249 HYDRAULICS Specifications Test and Adjustment Specifications Specifications Front Cutting Unit Pump Flow 13 (49.2) at 2800 rpm gpm (Lpm) Left Wing Cutting Unit Pump Flow 13 (49.2) at 2800 rpm gpm (Lpm) Right Wing Cutting Unit Pump Flow 13 (49.2) at 2800 rpm gpm (Lpm) Lift/Steer Pump Flow 7.9 (30) at 2800 rpm...

  • Page 250: Component Location

    HYDRAULICS Component Location See Figures 6-1 and 6-2. TN1768, TN1780, TN1893 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 251 HYDRAULICS TN1769 Lift Valve Right Wing Cutting Unit Motor (2) Right Wing Lift Cylinder Figure 6-2: Component Location—Right Side 4203780 First Edition...

  • Page 252: Hydraulic Schematic

    HYDRAULICS Hydraulic Schematic See Figures 6-3 through 6-7. Check 3500 psi Valve Gear Pump 2800 ±50 rpm 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci Check Valve 3500 psi Hydrostatic Traction Pump 10 Micron 25 psi Switch Charge Filter 25 psi Crack...
  • Page 253 HYDRAULICS Hydraulic Schematic Continued Front Axle 2.48 ci 4WD Valve Motor Secondary 4WD Shuttle Valve Reverse Solenoid Right Wheel Differential Lock Motor Charge Pressure Light Switch 11.9 125 psi N.C. 11.9 Left Wheel Charge Pressure Motor Relief Valve 250 psi Priority Valve 4.5 gpm Differential...
  • Page 254 HYDRAULICS Hydraulic Schematic Continued Steering Valve Check Valve 6.6 ci Relief Valve 1450 psi Steering Cylinder Steering Unit TN1734 Figure 6-5 4203780 First Edition...
  • Page 255 HYDRAULICS Hydraulic Schematic Continued Lift Valve Relief Valve 1500 psi Front Lift Valve Right Lift Valve Left 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 256 HYDRAULICS Hydraulic Schematic Continued CW Outside Right Wing 1.04 ci Motor 0.67" Right Deck Valve Solenoid CCW Inside Valve Relief Valve Right Wing 3000 psi 1.04 ci Motor 0.67" Blade Brake Relief 630 psi CW Inside Left Wing 1.04 ci Motor 0.67"...
  • Page 257 HYDRAULICS Page Intentionally Blank 4203780 First Edition 6-11...

  • Page 258: 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 259: Steering Circuit Schematic

    HYDRAULICS Steering Circuit Schematic See Figure 6-8. Steering Valve Check Valve 6.6 ci Relief Valve 1450 psi Steering Cylinder Steering Unit Hydraulic Oil Cooler Charge Pressure Oil Operating Pressure Oil TN1716 Operating Pressure Oil from Control Valve (Port ST) Charge Pressure Oil to Charge Filter Figure 6-8 4203780 First Edition 6-13...

  • Page 260: 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 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 261: Raise Circuit Schematic

    HYDRAULICS Raise Circuit Schematic See Figure 6-9. Differential Lock Charge Pressure Light Switch 165 psi N.C. Charge Pressure Relief Valve 250 psi Priority Valve 4.5 gpm Differential Lock Solenoid 4WD Solenoid Control Valve Lift Valve Relief Valve 1500 psi Left Lift Valve Right Lift Valve Front Lift Valve 50 psi...

  • Page 262: 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 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 263: Lower Circuit Schematic

    HYDRAULICS Lower Circuit Schematic See Figure 6-10. Differential Lock Charge Pressure Light Switch 165 psi N.C. Charge Pressure Relief Valve 250 psi Priority Valve 4.5 gpm Differential Lock Solenoid 4WD Solenoid Control Valve Lift Valve Relief Valve 1500 psi Left Spool Valve Front Spool Valve Right Spool Valve 50 psi...

  • Page 264: 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 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 265 HYDRAULICS Mower Deck Float Circuit Schematic See Figure 6-11. Differential Lock Charge Pressure Light Switch 165 psi N.C. Charge Pressure Relief Valve 250 psi Priority Valve 4.5 gpm Differential Lock Solenoid 4WD Solenoid Control Valve Lift Valve Relief Valve 1500 psi Left Spool Valve 50 psi Right Spool Valve...

  • Page 266: 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 267: Mow Circuit (On) Schematic

    HYDRAULICS Mow Circuit (ON) Schematic See Figure 6-12. CW Outside Right Wing 1.04 ci Motor 0.67" Right Deck Valve Solenoid CCW Inside Valve Relief Valve Right Wing 3000 psi 1.04 ci Motor 0.67" Blade Brake Relief 630 psi CW Inside Left Wing 1.04 ci Motor...

  • Page 268: Mow Circuit (Off) Theory Of Operation

    HYDRAULICS Mow Circuit (OFF) Theory of Operation System Conditions: • Engine running • Cutting units lowered • Mow switches in OFF position • Park brake released NOTE See “Mow Circuit—Theory of Operation” on page 4-36 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 269: Mow Circuit (Off) Schematic

    HYDRAULICS Mow Circuit (OFF) Schematic See Figure 6-13. CW Outside Right Wing 1.04 ci Motor 0.67" Right Deck Valve Solenoid CCW Inside Valve Relief Valve Right Wing 3000 psi 1.04 ci Motor 0.67" Blade Brake Relief 630 psi CW Inside Left Wing 1.04 ci Motor...

  • Page 270: 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 6-69.) Repeat the test for all of the lift cylinders.

  • Page 271: Wing Lift Cylinders Leakage Test

    HYDRAULICS Wing Lift Cylinders Leakage Test 8. Remove support from wing cutting unit. After 15 minutes, does cutting unit drift down? See Figure 6-15. Cylinder is bypassing oil. Replace lift WARNING cylinder. (See “Wing Lift Cylinders” on page 6-73.) The hydraulic system is under pressure, and the Repeat the test for all of the lift cylinders.

  • Page 272: Power Steering Circuit Test

    HYDRAULICS Power Steering Circuit Test NOTES The purpose of this test is to determine if the steering • Perform test on only one cutting unit motor at a time. cylinder and the steering valve are operating properly. • The case drain on a hydraulic motor is used to return NOTE lubrication or bypassed hydraulic oil back to the hydraulic tank.

  • Page 273: 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 274: 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 275: Front Cutting Unit Pump Test

    HYDRAULICS 16. Calculate front cutting units circuit leakage. (Step 13 – Step 14 / Step 13 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 6-34.
  • Page 276 HYDRAULICS TN2047 Figure 6-19 TN2072 Figure 6-21: Front Cutting Unit Pump Test—Blocking TN1363 Disk Between Pump and Deck Valve Figure 6-20 5. Set park brake. 3. Install blocking disk between hydraulic line (1) and 6. Bypass seat switch. tee fitting (3). 4.

  • Page 277: 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 278 HYDRAULICS 11. Calculate front cutting unit deck valve leakage. (Step 10 of previous test – Step 9 / Step 10 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 279: 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 280: Front Cutting Unit Motors Test

    HYDRAULICS Front Cutting Unit Motors Test See Figures 6-26 through 6-29. IMPORTANT • This test works together with the front cutting units circuit test to isolate a problem with the front cutting units circuit. • Performing this test will isolate the front cutting unit motors from the rest of the front cutting unit circuit.
  • Page 281 HYDRAULICS 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. Warm oil to 120—150°...
  • Page 282 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 283: 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 284 HYDRAULICS TN1363 Figure 6-31 4. Install tee fitting (5) to fitting (2). 5. Connect test hose (6) of flow meter inlet and hose (1) to tee fitting (5). NOTE Make sure hose end is under oil level in hydraulic tank to prevent aeration of oil.

  • Page 285: 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 286: 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 287 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 288: 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 289: 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 290 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 291 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 292: 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 293: 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 294 HYDRAULICS TN2047 Figure 6-46 TN2078 Figure 6-48: Left Wing Cutting Unit Pump Test— Blocking Disk Between Pump and Deck Valve 5. Bypass seat switch and set park brake. TN1363 Figure 6-47 NOTE 3. Install blocking disk between hose (1) and tee fitting Verify engine rpm is within specification (2800 rpm ±...

  • Page 295: 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 296 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 297: 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 298: 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 299 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 300: Lift/Steer System Relief Valve Pressure Test

    HYDRAULICS Lift/Steer System Relief Valve 21. Calculate left outside cutting unit motor leakage. (Step 9 – Step 19 / Step 9 x 100 = Leak Percentage) Pressure Test Is left outside cutting unit motor leakage 10% or See Figures 6-56 and 6-57. less? The left outside cutting unit motor is good.
  • Page 301 HYDRAULICS CAUTION Do not run mower steer system 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 system relief pressure 1450 psi (100 bar)? Steer system relief valve is good.

  • Page 302: Lift/Steer Pump Test

    HYDRAULICS Lift/Steer Pump Test See Figures 6-58 and 6-59. NOTE Before performing this test perform field test procedures. (See “Field Test Procedures” on page 6-24.) WARNING The hydraulic system is under pressure, and the oil will be hot. • Always relieve pressure in the hydraulic TN1359 system before performing service.
  • Page 303 HYDRAULICS 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 304: 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 305 HYDRAULICS TN1865 Figure 6-63 8. Remove gear pump strap (8). 9. Remove two screws (13) and lock washers (12). 10. Remove gear pump (7). 11. Remove gasket (11), flange adapter (10), and O-ring (9). Installation Notes • Install gear pump by reversing the order of removal. •...
  • Page 306 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-64 and 6-65. TN1816 Seal Ring (8) Coupling (3) Screw (8) Front Cover/Flange Pre-Load Seal (4) Gear Set (3) Dowel Pin (8) Shaft Seal Load Seal (4) Gear Plate (4) Body (3) Wear Plate (8) Rear Cover Assembly Gear Set (Drive Shaft) Figure 6-64...

  • Page 307: Deck Motors

    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 308: Lift Valve

    HYDRAULICS Lift Valve Installation Notes • Install the lift valve by reversing the order of removal. Removal and Installation • Make sure new O-rings are in place before installing hoses on fittings. See Figure 6-66. • Replace hydraulic oil return filter. (See “Hydraulic Oil 1.
  • Page 309 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 310: 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. 7 8 9 4. Inspect all parts for wear or damage. Replace parts as needed.

  • Page 311: 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 312: Front Deck Valve

    HYDRAULICS Front 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 6-70. hoses on fittings. 1. Park the mower safely. (See “Park Mower Safely” on •...

  • Page 313: Hydraulic Oil Return Filter

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

  • Page 314: Charge Pressure Filter

    HYDRAULICS 2 3 4 2 3 4 TN1765 Figure 6-72 TN1764 4. Disconnect electrical connectors (1). Figure 6-73 4. Disconnect electrical connector (7). NOTES • Label all hydraulic hoses and tubes to aid in NOTES installation. • Label all hydraulic hoses and tubes to aid in •...

  • Page 315: Front Lift Cylinders

    HYDRAULICS Front 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 6-74. • Replace hydraulic oil return filter. (See “Hydraulic Oil CAUTION Return Filter”...
  • Page 316 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 snap ring gland. Determine which type of cylinder was used and disassemble as needed. TN1839, TN1841 Grease Fitting (2) Seal O-Ring...
  • Page 317 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 4203780 First Edition 6-71...
  • Page 318 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 319: 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 320 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 snap ring gland. Determine which type of cylinder was used and disassemble as needed. TN1839, TN1841 Grease Fitting (2) Seal O-Ring...
  • Page 321 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 4203780 First Edition 6-75...
  • Page 322 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 323: Hydraulic Oil Cooler

    HYDRAULICS Hydraulic Oil Cooler 7. Disconnect hoses (7 and 8) from hydraulic oil tank. Removal and Installation NOTE The hydraulic oil cooler is in close proximity to the radiator and uses the engine cooling fan to cool the hydraulic oil. Removal and installation of the radiator/hydraulic oil cooler is described in Chapter 3—...
  • Page 324 HYDRAULICS TN1885 Figure 6-82 13. Remove charge pressure filter bracket (14). 14. Remove tank straps (17). 15. Support the hydraulic oil tank (16). 16. Remove hydraulic oil tank back supports (15). 17. Remove the hydraulic oil tank (16). 6-78 4203780 First Edition...
  • Page 325 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 326 HYDRAULICS Page Intentionally Blank 6-80 4203780 First Edition...
  • Page 327 Chapter 7 Steering Specifications ..............7-2 Component Location .

  • Page 328: Specifications

    STEERING Specifications Test and Adjustment Specifications Steering System Leakage Test— Zero—Nominal Amount pt (L) Cylinder Leakage Rear Axle Alignment Toe-In 0.0625 (1.6) in. (mm) Measurement Rear Axle Spindle Arm-to-Axle Stop 0.030—0.060 (0.76—1.5) in. (mm) Measurement Repair Specifications Steering Wheel Nut 28—30 (38—41) lb-ft (N·m) Steering Valve Rotor-to-Stator...

  • Page 329: Component Location

    STEERING Component Location See Figure 7-1. TN1767, 1856 Tie Rod Steering Cylinder Steering Wheel Steering Axle Tilt Lever Steering Valve Steering Console Figure 7-1 4203780 First Edition...

  • Page 330: 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 331 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 332: 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 333: Steering Leakage Test

    STEERING Steering Leakage Test WARNING See Figure 7-10. Do not turn steering wheel to the right. 1. Operate hydraulic system until oil temperature is at 120—150° F (49—65° C). Failure to follow appropriate safety precautions may result in death or serious injury. 2.

  • Page 334: Repair

    STEERING Repair Steering Valve Removal and Installation Steering Wheel See Figures 7-12 through 7-17. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 7-11. 2. Remove the steering wheel. (See “Steering Wheel” 1.
  • Page 335 STEERING TN1742 Figure 7-13 TN1740 7. Remove two screws (5) from console cover (6). Figure 7-15 NOTES • Label all hydraulic hoses and record their locations to ensure correct installation. • Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil. 9.
  • Page 336 STEERING Installation Notes • Install the steering valve by reversing the order of removal. • When installing the tilt lever (19), screw the lever in until tight, and then back the lever off to the position shown. Hold the lever and tighten the jam nuts (20). •...
  • Page 337 STEERING Steering Valve Service Fixture IMPORTANT See Figures 7-18 and 7-19. Scribe a line from the top to the bottom of the steering valve assembly, not including the steering Required Tools or Equipment tube. Use the scribed line for reference when assembling the valve sections.
  • Page 338 STEERING Disassembly See Figure 7-20. TN1796 Adapter, Straight (2) Commutator Upper Cover Plate Port Cover Isolation Manifold Alignment Pin (5) Gasket Adapter, Straight (2) Drive Link Drive Link Spacer Retaining Ring Relief Valve Assembly Alignment Pin (4) Rotor Retaining Plate O-Ring Spring (3) Stator...
  • Page 339 STEERING 12. Remove drive link spacer (25), rotor (26), and stator CAUTION (27) from drive plate (28). 13. Remove face seal (32) and seal spacer (33). Wear eye protection when assembling and 14. Remove thrust bearing (30) and spacer (29). disassembling the steering valve.
  • Page 340 STEERING Inspection See Figures 7-21 and 7-22. TN1796 Adapter, Straight (2) Commutator Upper Cover Plate Port Cover Isolation Manifold Alignment Pin (5) Gasket Adapter, Straight (2) Drive Link Drive Link Spacer Retaining Ring Relief Valve Assembly Alignment Pin (4) Rotor Retaining Plate O-Ring Spring (3)
  • Page 341 STEERING Assembly IMPORTANT See Figures 7-23 through 7-26. Always replace springs as a set. 1. Inspect the springs (16 and 17) for bent, broken, or Service Part Kits distorted coils. Seal Kit (Jacobsen PN 557738) 2. Inspect the finished ground surfaces of all the Metering Assembly Kit (Jacobsen PN 1004867-01) components.
  • Page 342 STEERING TN1796 Adapter, Straight (2) Commutator Upper Cover Plate Port Cover Isolation Manifold Alignment Pin (5) Gasket Adapter, Straight (2) Drive Link Drive Link Spacer Retaining Ring Relief Valve Assembly Alignment Pin (4) Rotor Retaining Plate O-Ring Spring (3) Stator Input Shaft Ball, 9/32 inch Spring (3)
  • Page 343 STEERING NOTE NOTE In the following assembly steps, it is important to align the Make sure the alignment pins (49) are pressed below the components for proper operation of the steering valve. surface of the commutator (48). Use the scribed line for reference when assembling the 11.

  • Page 344: Steering Console

    STEERING Steering Console 19. Lubricate and install the thrust bearing spacer (29) and thrust bearing (30) into the metering ring (19). Removal and Installation 20. Place the metering package (20—28) into the metering ring (19), engaging the drive slot with the See See Figures 7-27 through 7-34.
  • Page 345 STEERING 5. Loosen jam nuts (9). 6. Tilt the steering console (8) forward. 7. Remove (unscrew) the tilt lever (7) from console (8). TN1888 Figure 7-31 NOTE Label all wiring connectors and record their locations to ensure correct installation. 10. Disconnect console harness connector (18) from wiring harness.
  • Page 346 STEERING TN1890 Figure 7-32 15. Remove two nuts (22), lock washers (21), and screws (20). Remove indictor light module (23) from console (19). TN1891 Figure 7-33 16. Support the console (25). 17. Remove nut (27), lock washer (26), and bolt (24). Remove the console (25) from the support (29).

  • Page 347: Steering Cylinder

    STEERING Steering Cylinder Removal and Installation See Figures 7-35 through 7-37. 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. TN1743 Figure 7-34 •...
  • Page 348 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 349 STEERING Disassembly, Inspection, and Assembly See Figure 7-38. 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 7-38 1. Remove the small snap ring (13) and rod guide (12). WARNING 2.

  • Page 350: 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 351 STEERING Disassembly, Inspection, and Assembly See Figure 7-41. 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 7-41 Disassembly Note Record the number of turns required to remove ball joints...

  • Page 352: Rear Axle

    STEERING Rear Axle Removal and Installation See Figure 7-42. 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 7-42 7-26...
  • Page 353 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 5-77.) NOTES • Label all hydraulic hoses and record their locations to ensure correct installation. •...
  • Page 354 STEERING Disassembly, Inspection, and Assembly See Figure 7-43. 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 355 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 356 STEERING Page Intentionally Blank 7-30 4203780 First Edition...
  • Page 357 Chapter 8 Cutting Units Specifications ..............8-2 Repair Specifications .

  • Page 358: 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) 4203780 First Edition...

  • Page 359: Component Location

    CUTTING UNITS Component Location See Figure 8-1. TN1768 Swivel Caster Wheel Assembly (6) Inner Wing Caster Arm (2) Fixed Caster Wheel Assembly (2) Deck Motor (7) Wing Lift Arm (2) Anti-Scalp Wheel (4) Right Wing Deck Assembly Outer Wing Caster Arm (2) Front Deck Assembly Front Deck Lift/Push Arms Left Wing Deck Assembly...

  • Page 360: 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 20 psi, rear machine tires at 10 psi, and casters at 23 psi.
  • Page 361 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 362: 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 363: 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 364: 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 365 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 366 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 367 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 368 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 369 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 370 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 371 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 372: 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 373 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 374: 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 375: 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.) TN1838 Figure 8-9 2. Remove deck motors. (See “Deck Motor” on page 8-16.) 3.
  • Page 376 CUTTING UNITS Disassembly and Assembly See Figure 8-10. 27 26 TN1899 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 377: 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 378 CUTTING UNITS Disassembly and Assembly See Figure 8-12. TN1897 Screw (2) Nut (2) Bushing (4) Shim Lock Washer Lock Washer (3) Lock Washer (2) Flat Washer (2) Bumper Screw Pin (2) Washer Lift Cylinder Screw Shaft Screw Bracket Grease Fitting Actuator Arm Bracket Flat Washer (2)

  • Page 379: 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 380 CUTTING UNITS Disassembly and Assembly See Figure 8-15. NOTE Right wing deck shown; left is similar. TN1900 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 381: 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 382 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 383: Swivel Caster Wheels

    CUTTING UNITS Disassembly Note 7. Inspect yoke (1) along with the flat washers (3), caster wheel spacers (4), and height-of-cut spacers Inspect all moving parts for wear or damage. Replace (5) for wear or damage. Replace as necessary. parts as necessary. 8.

  • Page 384: 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 385: 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. TN1863 Figure 8-23 3. Remove screw (1), lock washer (2), and nut (3). 4.
  • Page 386 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 387 Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Component Location .
  • Page 388 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 100—120 (135—162) lb-ft (N·m) Rear Tires Size...

  • Page 389: Component Location

    ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 9-1. TN1768, TN1849 OPS (Operator Protective Structure) Front Wheel (2) Seat and Seat Platform Differential Lock Switch Hood Brake Pedal Park Brake Traction Pedal Rear Wheel (2) Fuel Tank Figure 9-1 4203780 First Edition...

  • Page 390: Checks And Adjustments

    ACCESSORIES AND MISCELLANEOUS REPAIR Checks and Adjustments Brake Pedal Adjustment See Figure 9-3. Park Brake Adjustment 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 9-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 391: Bleed Brake System

    ACCESSORIES AND MISCELLANEOUS REPAIR Bleed Brake System Repair See Figure 9-4. Canopy 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Removal and Installation 2. Fill master cylinder with approved brake fluid. See operator’s manual for brake fluid recommendations. See Figures 9-5 and 9-6.

  • Page 392: Ops

    ACCESSORIES AND MISCELLANEOUS REPAIR 6. Repeat steps 4 and 5 for other side of mower. 7. Lift OPS (6) and slide toward rear of mower until OPS Removal and Installation clears the end of the mower. See Figures 9-7 and 9-8. Installation Notes 1.

  • Page 393: 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 page 1-6.) 2.
  • Page 394 ACCESSORIES AND MISCELLANEOUS REPAIR Figure 9-13 11. Support the fuel tank (9) and remove the two mounting screws (11) and washers (10). 12. Remove the fuel tank from the mower. Required Materials Anti-Seize Compound Installation Notes • Apply anti-seize to the fuel tank screws (11). •...
  • Page 395 ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Disassembly and Assembly See Figure 9-14. Bushing (2) Flat Washer (2) Nut (2) Traction Pedal Lock Washer (2) Lock Washer (2) Nut (2) Nut (2) Switch Bracket Lock Washer (2) Cotter Pin Lock Washer (2) Flat Washer (2) Flat Washer (2) Nut (2)
  • Page 396 ACCESSORIES AND MISCELLANEOUS REPAIR 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove nut (14), lock washer (13), and flat washer (12) from ball joint (28). 3. Remove two nuts (3), lock washers (4), flat washers (5), and two screws (31) from traction pedal mounting bracket (6).
  • Page 397 ACCESSORIES AND MISCELLANEOUS REPAIR Park Brake Disassembly and Assembly See Figures 9-15 and 9-16. Screw (2) Right Side Brake Switch Bracket Screw (2) Flat Washer (2) Flat Washer (2) Park Brake Pin Nut (2) Park Brake Cable Pulley (2) Release Spring Bracket Lock nut Lock Washer (2) Spacer (2)
  • Page 398 ACCESSORIES AND MISCELLANEOUS REPAIR 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Place wheel chocks in front of and behind front wheels. 3. Remove the battery. (See “Battery and Battery Tray” on page 4-86.) 4. Place brake lever in the disengaged position. 5.

  • Page 399: Seat And Seat Platform

    ACCESSORIES AND MISCELLANEOUS REPAIR Seat and Seat Platform Installation Notes • Install the seat and seat platform by reversing the Removal and Installation order of removal. • Carefully route and secure seat switch wire harness See Figures 9-17 and 9-18. to avoid damage from pinched wires.
  • Page 400 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figures 9-19 and 9-20. Seat Trim Seal Foam, Front Screw Lock Washer Armrest, Left-Hand Flat Washer Roll Pin Lock Washer Armrest, Right-Hand Seat Suspension, Mini Knob Flat Washer Seat Switch Spacer Seat Pan Trim Seal Lock Washer Flat Washer...
  • Page 401 ACCESSORIES AND MISCELLANEOUS REPAIR Push Nut (4) Spring Hanger Pivot Shaft (2) Lock nut Spring Kit Knob Spring (2) Screw Flat Washer Bearing (4) Bumper (2) Lock Washer Figure 9-20: Mini Seat Suspension 4203780 First Edition 9-15...

  • Page 402: Floorboard

    ACCESSORIES AND MISCELLANEOUS REPAIR Floorboard Removal and Installation See Figures 9-21 through 9-23. 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 9-13.) 3. Remove instrument panel. (See “Instrument Panel” on page 4-110.) 4.

  • Page 403: Work Light Kit

    ACCESSORIES AND MISCELLANEOUS REPAIR Work Light Kit Rear Wheels Removal and Installation Removal and Installation See Figure 9-24. See Figure 9-25. 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 404: Front Wheels

    ACCESSORIES AND MISCELLANEOUS REPAIR Front Wheels Removal and Installation See Figure 9-26. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Block both sides of rear wheels using suitable wheel blocks. Figure 9-26 3. Loosen, but do not remove, lug nuts (3). 4.

  • Page 405: Brake Pedal

    ACCESSORIES AND MISCELLANEOUS REPAIR Brake Pedal Disassembly and Assembly See Figure 9-27. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Screw External Tooth Washer Brake Pedal Lock Washer Woodruff Key Brake Switch Activator Plate Lock Washer Brake Hub Set Screw Carriage Bolt...

  • Page 406: Brake Master Cylinder

    ACCESSORIES AND MISCELLANEOUS REPAIR Brake Master Cylinder Brake Caliper Removal and Installation Removal and Installation See Figures 9-28 and 9-29. See Figure 9-30. 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 407 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figure 9-31. Brake Caliper Brake Pad Set Caliper Seal Repair Kit Caliper Bleed Screw Pad Retaining Pin and Spring Kit Bleed Screw Cap Figure 9-31 NOTE Inspect and clean any rust from pad retaining pins (3). Apply anti-seize compound to pad retaining pins and ensure pad retaining pins slide freely.
  • Page 408 ACCESSORIES AND MISCELLANEOUS REPAIR Page Intentionally Blank 9-22 4203780 First Edition...
  • Page 409 INDEX Numerics 4WD Rev Solenoid Battery Removal and Installation ....4-107 Removal and Installation ....4-85 Repair .
  • Page 410 INDEX Circuit Breakers Cruise Control Switch Removal and Installation ....4-87 Removal and Installation ....4-98 Repair .
  • Page 411 INDEX Differential Lock Assembly Engine Temperature Gauge Disassembly, Inspection, and Assembly . . . 5-64 Removal and Installation ....4-94 Repair ......5-64 Repair .
  • Page 412 INDEX Front Axle U-Joint Fuel Shutoff Solenoid Removal and Installation ....5-47 Removal and Installation ....4-108 Repair .
  • Page 413 INDEX Hour Meter Removal and Installation ....4-111 Repair ......4-111 Indicator Lights Removal and Installation .
  • Page 414 INDEX Muffler Removal, Inspection, and Installation ..3-9 Repair ......3-9 Left Deck Valve Removal and Installation .
  • Page 415 INDEX Radiator Removal and Installation ....3-12 Radiator/Hydraulic Oil Cooler Removal and Installation ....3-11 Repair .
  • Page 416 INDEX Repair Fuel Pump ......3-16 4WD Rev Solenoid ....4-106 Fuel Shutoff Solenoid .
  • Page 417 INDEX Time Delay Relay ..... 4-89 Traction Linkage ..... 5-81 Traction Pedal .
  • Page 418 INDEX Schematic, Hydraulic Steering Cylinder Traction Circuit—Forward 2WD ..5-12 Disassembly, Inspection, and Assembly . . . 2-23 Traction Circuit—Forward 4WD ..5-20 Removal and Installation .
  • Page 419 INDEX Test Theory of Operation 4WD Rev Solenoid ....4-83 Charging Circuit ..... 4-34 4WD Solenoid .
  • Page 420 INDEX Traction Circuit—Reverse 2WD Weight Transfer Hydraulic Schematic ....5-16 Tests and Adjustments....5-32 Theory of Operation .
  • Page 422 A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. When Performance Matters. ™ Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

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