Textron Jacobsen SLF530 Repair Manual
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Textron Jacobsen SLF530 Repair Manual

Super lightweight fairway mower
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SLF530™
Super Lightweight
Fairway Mower
Repair Manual
WARNING: If incorrectly used this machine can cause severe injury. Those
who use and maintain this machine should be trained in its proper use,
warned of its dangers and should read the entire manual before attempting to
set up, operate, adjust or service the machine.
© 2018 Textron Specialty Vehicles (TSV)
This manual may not re reproduced in whole or in part without the
express permission of TSV (Augusta) Technical Communications
Department.

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Summary of Contents for Textron Jacobsen SLF530

  • Page 1 © 2018 Textron Specialty Vehicles (TSV) This manual may not re reproduced in whole or in part without the express permission of TSV (Augusta) Technical Communications Department.
  • Page 3 This manual provides detailed information and procedures to safely repair and maintain the following:  WARNING Jacobsen SLF530 Super Lightweight Fairway mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user...
  • Page 4 FOREWORD How to Use This Manual Quick Reference Specifications A list of all machine specifications can be found in This manual is designed to provide multiple ways to Chapter 2 Specifications and General Information. This is locate and access repair information. a list of all specifications from each chapter, combined Read each section in entirety before beginning a and listed in one place for easy reference.
  • Page 5 Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Units Accessories and Miscellaneous Repair 673831-Rev A...

  • Page 7: Table Of Contents

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

  • Page 8: 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 9 SAFETY MAR0230 Figure 1-1 673831-Rev A...
  • Page 10 SAFETY 4181865 REV B 20°+ 4262591 009034880 S ≤ 15 mg/kg 4324674 4397486 673831-Rev A...
  • Page 11 SAFETY 1.37 - 1.72 bar 20 - 25 psi 3008682 673831-Rev A...

  • Page 12: Inspect Safety Labels

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

  • Page 13: 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 14: 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 15: 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.

  • Page 16: 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 17 Chapter 2 Specifications and General Information Mower Identification ............2-2 Serial Number .
  • Page 18 SPECIFICATIONS AND GENERAL INFORMATION Mower Identification The first digit is the mower identification. • F: 3WD Option SLF530 Mower See Figures 2-1 through 2-3. • G: 4WD Option SLF530 Mower The second digit is the cutting unit configuration. • 5: Five 18 inch (457 mm) cutting units, three front and two rear.
  • Page 19 SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figure 2-4.  CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. MAR0232 Seat Left Front Reel Right Rear Reel Hydraulic Tank Instrument Panel Center Reel Fuel Tank Battery Steering Wheel...
  • Page 20 SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Electrical Test and Adjustment Specifications Resistance Across Solenoid Coil—Front Mow 5.3 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Rear Mow 5.3 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Front Backlap 5.3 ±...
  • Page 21 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Traction Pump Charge Relief Valve Plug 60-150 (81-203) lb-ft (N·m) End Cap Screws 40 (54) lb-ft (N·m) Loop Flushing Valve Plug 33 (45) lb-ft (N·m) Neutral Return Seal Nut 16 (22) lb-ft (N·m) Bypass Valve 15 (20) lb-ft (N·m) High Pressure Relief Valves...
  • Page 22 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Gear Pump—Rear Cover-to-Pump Body Bolt Torque 33 (45) lb-ft (N·m) Lift Valve—Coil Nut Torque 10 (13.5) lb-ft (N·m) Lift Valve—Relief Valve Torque 24–26 (32.5–35.3) lb-ft (N·m) Lift Valve—Check Valve Torque 19–21 (25.8–28.5) lb-ft (N·m) Lift Valve—Rear Side Port “T”...
  • Page 23 SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications Reel Drive Motor—Rear Cover-to-Body Retaining 18.5 (25) lb-ft (N·m) Screw Torque Reel Drive Motor with -4 ORFS Case Drain—Case 11 (14.9) lb-ft (N·m) Drain Fitting Torque Reel Drive Motor—IN/OUT Port Fittings 60 (81.3) lb-ft (N·m) Bedknife Adjustment Assembly—Inside of Belleville 1.500 ±...
  • Page 24 SPECIFICATIONS AND GENERAL INFORMATION 4WD Option Rear Tires Size 20 x 10-10 Type 2-Ply Smooth Air Pressure 16 (1.1) psi (bar) Mounting Nut Torque 85–90 (115–120) lb-ft (N·m) Mower Speed Transport 0–10.5 (0–16.9) mph (km/h) Mowing 0–6 (0–9.6) mph (km/h) Reverse 0–4 (0–6.4) mph (km/h)
  • Page 25 SPECIFICATIONS AND GENERAL INFORMATION Weights and Dimensions Width Of Cut 82 (2083) in. (mm) Overall Width 96.7 (2456) in. (mm) Maximum Width Transport With Cutting Units Raised 91.8 (2332) in. (mm) Maximum Height With ROPS 83.2 (2113) in. (mm) Total Length (3WD Option) 104.9 (2664) in.
  • Page 26 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 27 Chapter 3 Engine Specifications ..............3-2 Component Location .
  • Page 28 ENGINE Specifications General Engine Specifications ® Manufacturer/Model Kubota Tier 4 D1105-E4B Engine Type 4-Stroke, Diesel Fuel Requirement No. 2 Ultra-Low Sulfur Diesel Fuel (Cetane Rating 45) Fuel System Capacity 7.6 (28.7) gal (L) Number of Cylinders/Configuration 3, In-Line Displacement 68.5 (1123) cu in.

  • Page 29: Component Location

    ENGINE Component Location Kubota D1105-E4B See Figures 3-1 and 3-2. MAR0240 Muffler Alternator Fuel Pump Exhaust Manifold Fan Belt Fuel Filter Starter Motor Thermostat Engine Remote Oil Filter Engine Oil Pressure Switch Fuel Pre-Filter Figure 3-1: Component Location—Engine Front 673831-Rev A...
  • Page 30 ENGINE MAR0241 Fuel Shutoff Solenoid Engine Temperature Sensor Throttle Cable Engine Oil Drain Plug (2) Air Vent Screw Engine Oil Fill Cap Figure 3-2: Component Location—Engine Rear Side 673831-Rev A...

  • Page 31: Checks And Adjustments

    ENGINE Checks and Adjustments 6. Loosen the air vent screw (2) on the injection pump by turning it counterclockwise two turns.  Purging the Fuel System WARNING Adjustment The engine may start during this process. Be careful of injury due to moving components. If See Figure 3-3.

  • Page 32: Repair

    ENGINE Repair Air Cleaner Assembly Removal and Installation Fan Belt See Figure 3-5. Removal and Installation  CAUTION See Figure 3-4. • Do not open the air cleaner assembly for 1. Park the mower safely. (See “Park Mower Safely” on inspection and cleaning until the air filter page 1-6.) restriction gauge indicates an air filter...

  • Page 33: Muffler And Exhaust Assembly

    ENGINE 5. Pull air filter element from filter housing (8). Using 6. Disengage and remove tailpipe (7). damp, lint-free cloths, clean inside of filter housing. 7. Support muffler (12) and remove four screws (8), lock 6. Inspect hose (7) for wear or damage, and replace as washers (9), flat washers (10) and nuts (11).

  • Page 34: Radiator/Hydraulic Oil Cooler Assembly

    ENGINE Radiator/Hydraulic Oil Cooler Assembly Removal See Figures 3-7 through 3-10.  WARNING Never remove the expansion tank cap when the coolant is hot. The engine must be shut down and cooled before the expansion tank cap is removed. Very hot coolant will be sprayed from the expansion if the cap is loosened before the engine has cooled.
  • Page 35 ENGINE 8. Disconnect pump drain hose (14) and front reel valve return hose (15) from tee fitting (16). 9. Remove tee fitting (16), adapter fitting (17) and union fitting (18). 10. Disconnect cooler return hose (19). 11. Loosen hose clamps (36 and 37), and remove the upper radiator hose (38) and lower radiator hose (39) from the radiator/hydraulic oil cooler assembly.
  • Page 36 ENGINE 8. Fill radiator through expansion tank with clean water and ethylene glycol based antifreeze mixed for coldest ambient temperature. 9. Install expansion tank cap and start engine following instructions in “Safety and Operation Manual.”  CAUTION Allow the engine coolant to completely cool before removing the expansion tank cap.

  • Page 37: Thermostat

    ENGINE Thermostat Fuel Filters Removal and Installation Removal and Installation See Figure 3-11. See Figure 3-12.  1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Allow engine to cool completely. Diesel fuel is combustible—handle with care. Use an approved container with a spout that will fit 3.

  • Page 38: Fuel Pump

    ENGINE 6. Loosen hose clamps (1) and disconnect hoses (2  CAUTION and 3) from fuel pump (7). 7. Remove two screws (4), lock washers (5) and flat Dispose of fuel properly. Contact the local washers (6). environmental department for instructions on 8.

  • Page 39: Engine

    ENGINE Engine Removal and Installation See Figures 3-15 through 3-21. NOTE 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Allow engine to cool completely. 3. Disconnect battery negative (–) cable at battery. 4. Drain engine oil. 5.
  • Page 40 ENGINE NOTE • Label all wires before disconnecting to ensure correct installation. • Label all hoses before disconnecting to ensure correct installation. 24. Remove nut and disconnect wire (16) from glow plug connector bar. 25. Remove nut and disconnect wire (17) from coolant temperature sending unit.
  • Page 41 ENGINE 35. Remove two screws (36), lock washers (37), flat  WARNING washers (38), and nuts (39). Remove two engine mounts (40). Prevent personal injury. Use a properly rated 36. Place engine on a suitable stand or workbench that lifting device. Always be sure the load is will support full weight in a safe manner while balanced before lifting.
  • Page 42 ENGINE Disassembly, Inspection, and Assembly See Figure 3-22. 42 43 1 2 3 MAR0260 Engine Mount Screws (10) Clamp Screw Flat Washer (2) Flat Washer (2) Lock Washer (10) Flat Washer Nut (2) M8 x 40 mm Screw Flat Washer(10) Remote Filter Hose Clamp Filter Bracket Flat Washer (2)

  • Page 43: Engine Service

    ENGINE 1. Remove ten screws (1), lock washers (2) and flat Assembly Notes washers (3). Remove front engine mount (4), rear • Assemble the engine by reversing the order of engine mount (5) and exhaust mount (6). disassembly. 2. Remove engine ground cable (7). •...
  • Page 44 ENGINE Page Intentionally Blank 3-18 673831-Rev A...
  • Page 45 Chapter 4 Electrical Specifications ..............4-3 Test and Adjustment Specifications .
  • Page 46 ELECTRICAL Component Testing ............4-52 Electrical System and Component Testing .

  • Page 47: Specifications

    ELECTRICAL Specifications Test and Adjustment Specifications Specification Resistance Across Solenoid Coil—Front Mow 5.3 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Rear Mow 5.3 ± 10% ohms Solenoid Coil at 68° F Resistance Across Solenoid Coil—Front Backlap 5.3 ±...

  • Page 48: 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 49 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 673831-Rev A...
  • Page 50 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 673831-Rev A...

  • Page 51: Connector Terminal Identification

    ELECTRICAL Connector Terminal Identification Main Harness 4340549 Front Mow Solenoid (SOL1) CAN Resistor (R3) Starter F (M1) Fuel Solenoid (K15) Rear Mow Solenoid (SOL2) Front Backlap Solenoid (SOL3) Rear Backlap Solenoid (SOL4) Lower Solenoid (SOL5) Male Terminal Lift Solenoid (SOL6) 4WD Solenoid (SOL7) Neutral Proximity Switch (SW7) Starter S (M1)
  • Page 52 ELECTRICAL Armrest Harness 4340548 Mow Switch (SW2) (Red) Ignition Switch (SW1) Parking Brake Switch (SW5) (Orange) CAN Resistor (R4) Joystick (SW3) Light Switch (SW6) (Black) Side Shift Switch (SW9) (White)* * Not used on this mower Display (U2) Main Harness (J1) Terminal Identification is from open (Not Wire) end of connector Figure 4-2 673831-Rev A...

  • Page 53: 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—Battery (See Figure 4-3.) • SOL12—Fuel Solenoid (See Figure 4-3.) •...

  • Page 54: Electrical Schematic

    ELECTRICAL Electrical Schematic See Figures 4-3 and 4-4. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye J4-A MCU 1-09 CAN H 914 - Gn 914 - Gn MCU 1-08 CAN L J4-B 20 - Bk MCU 1-07 Ground...
  • Page 55 ELECTRICAL Electrical Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 110 - DBu/Wh 20 - Bk MCU 5-02 114 - Gn 114 - Gn J5-B SOL1 115 - Ye 115 - Ye 110 - DBu/Wh...

  • Page 56: Theory Of Operation And Sub-Circuit Schematics

    ELECTRICAL Theory of Operation and Unswitched power is available from 35-amp fuse (F19) output terminal to the starter relay (K14) terminal 30. Sub-Circuit Schematics Unswitched power is available from 10-amp fuse (F19) output terminal to the differential lock driver (U9) terminal Power Circuit—Theory of Operation Switched Power Circuit (Green) Unswitched Power Circuit (Red)
  • Page 57 ELECTRICAL • Parking brake switch (SW5) in the on position, switched power detected at MCU (U1) terminal 4-08 • Traction pedal is in the Neutral position, neutral switch is closed and switched power is detected at MCU (U1) terminal 4-10 With the mow switch in the off position, the parking brake switch in the on position and traction pedal in the Neutral position, power is sent from MCU terminal 2-06 to the...

  • Page 58: Power Circuit Schematic

    ELECTRICAL Power Circuit Schematic See Figures 4-5 and 4-6. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground 20 - Bk...
  • Page 59 ELECTRICAL Power Circuit Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 110 - DBu/Wh 20 - Bk MCU 5-02 114 - Gn 114 - Gn J5-B SOL1 115 - Ye 115 - Ye...
  • Page 60 ELECTRICAL Page Intentionally Blank 4-16 673831-Rev A...

  • Page 61: Start Circuit-Theory Of Operation

    ELECTRICAL Start Circuit—Theory of Operation Glow Plug Circuit When the key switch is turned to the run position, voltage Unswitched Power Circuit (Red) is sent from key switch terminal 2 to MCU (U1) terminal 4-07. Unswitched power is available from the battery positive terminal to the 3-way distribution block.

  • Page 62: Start Circuit Schematic

    ELECTRICAL Start Circuit Schematic See Figures 4-7 and 4-8 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground 20 - Bk...
  • Page 63 ELECTRICAL Start Circuit Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 MCU 5-02 114 - Gn 114 - Gn J5-B 115 - Ye 115 - Ye J5-A Mow 2 MCU 5-04...
  • Page 64 ELECTRICAL Page Intentionally Blank 4-20 673831-Rev A...

  • Page 65: Run Circuit-Theory Of Operation

    ELECTRICAL Run Circuit—Theory of Operation When the operator is on the seat, the seat switch contacts close. With the seat switch contacts closed, voltage is provided to MCU (U1) terminal 4-01. Unswitched Power Circuit With voltage provided to MCU terminal 4-01. The MCU Unswitched power is available from the battery positive continues to provide voltage to the fuel shutoff hold-in terminal to the 3-way distribution block.

  • Page 66: Run Circuit Schematic-On Seat

    ELECTRICAL Run Circuit Schematic—On Seat See Figures 4-9 and 4-10 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground...
  • Page 67 ELECTRICAL Run Circuit Schematic—On Seat Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 MCU 5-02 114 - Gn 114 - Gn J5-B 115 - Ye 115 - Ye J5-A Mow 2 MCU 5-04...

  • Page 68: Run Circuit Schematic-Off Seat

    ELECTRICAL Run Circuit Schematic—Off Seat See Figure 4-11. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye J4-A MCU 1-09 CAN H 914 - Gn 914 - Gn MCU 1-08 CAN L J4-B 20 - Bk MCU 1-07 Ground...
  • Page 69 ELECTRICAL un Circuit Schematic—Off Seat Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 MCU 5-02 114 - Gn 114 - Gn J5-B 115 - Ye 115 - Ye J5-A Mow 2 MCU 5-04...

  • Page 70: 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 3-way distribution block. Unswitched power is available from the 3-way distribution block to the following: • Alternator battery terminal • 30-amp fuse (F3) •...

  • Page 71: Charging Circuit Schematic

    ELECTRICAL Charging Circuit Schematic See Figure 4-13. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye J4-B MCU 1-09 CAN H 914 - Gn 914 - Gn MCU 1-08 CAN L J4-A 20 - Bk 8 - Og...
  • Page 72 ELECTRICAL Page Intentionally Blank 4-28 673831-Rev A...

  • Page 73: Mow/Backlap Circuit-Theory Of Operation

    ELECTRICAL Mow/Backlap Circuit—Theory of When the mow speed lever is placed in the MOW position, the mow speed proximity switch (SW12) is Operation activated. With the switch activated, voltage is provided to MCU terminal 4-09. Unswitched Power Circuit When the reels are lowered, the center lift arm is brought Unswitched power is available from the battery positive near the magnetic target zone of the lift proximity switch terminal to the 3-way distribution block.

  • Page 74: Mow/Backlap Circuit Schematic

    ELECTRICAL Mow/Backlap Circuit Schematic See Figures 4-14 and 4-15. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground 20 - Bk...
  • Page 75 ELECTRICAL Mow/Backlap Circuit Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 110 - DBu/Wh 20 - Bk MCU 5-02 114 - Gn 114 - Gn J5-B SOL1 115 - Ye 115 - Ye...
  • Page 76 ELECTRICAL Page Intentionally Blank 4-32 673831-Rev A...

  • Page 77: Lift/Lower Circuit-Theory Of Operation

    ELECTRICAL Lift/Lower Circuit—Theory of Lift Circuit Operation Pull back on the joystick (SW3) to lift the cutting units. With the joystick pulled, power is supplied from joystick terminal 2 to the MCU terminal 5-11. Unswitched Power Circuit (Red) When the signal is detected at MCU (U1) terminal 5-11, Unswitched power is available from the battery positive power is supplied from terminal 2-01 to the lift solenoid terminal to the 3-way distribution block.

  • Page 78: Lift/Lower Circuit Schematic

    ELECTRICAL Lift/Lower Circuit Schematic See Figures 4-16 and 4-17. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground 20 - Bk...
  • Page 79 ELECTRICAL Lift/Lower Circuit Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 MCU 5-02 114 - Gn 114 - Gn J5-B 115 - Ye 115 - Ye J5-A Mow 2 MCU 5-04...
  • Page 80 ELECTRICAL Page Intentionally Blank 4-36 673831-Rev A...

  • Page 81: Optional Work Lights Circuit-Theory Of Operation

    ELECTRICAL Optional Work Lights Circuit—Theory of Operation Unswitched Power Circuit Unswitched power is available from the battery positive terminal to the 3-way distribution block. Unswitched power is available from the 3-way distribution block to the following: • 30-amp fuse (F3) •...

  • Page 82: Optional Work Lights Circuit Schematic

    ELECTRICAL Optional Work Lights Circuit Schematic See Figures 4-18 and 4-19. – 1 - Rd 1 - Rd 106-Og 3 - Rd 1 - Rd 20 - Bk 105 - Rd/Og Unswitched power circuit Switched power circuit Work light circuit CAN Circuit Grounds 1 - Rd...
  • Page 83 ELECTRICAL Optional Work Lights Circuit Schematic Continued Bu/Ye 6 - Og 20 - Bk Bu/Ye Bu/Ye 158 - Og 157 - Bu/Gn J2-2 J2-1 J1-14 Bu/Ye Unswitched power circuit Switched power circuit Work light circuit CAN Circuit Grounds 5 - Og 4 - Rd/Ye 1 - Rd 1 - Rd...
  • Page 84 ELECTRICAL Page Intentionally Blank 4-40 673831-Rev A...

  • Page 85: Instrumentation Circuit-Theory Of Operation

    ELECTRICAL Instrumentation Circuit—Theory of Fan circuit Operation Power flows through the 2.5 k engine temperature resistor (R2) to the engine temperature sensor (R5) and the MCU (U1) terminal 3-02. Unswitched Power Circuit The engine temperature sensor (R5) resistance changes Unswitched power is available from the battery positive in relationship to the engine coolant temperature.

  • Page 86: Instrumentation Circuit Schematic

    ELECTRICAL Instrumentation Circuit Schematic See Figures 4-20 and 4-21. 915 - Ye 915 - Ye 914 - Gn 914 - Gn 915 - Ye 915 - Ye MCU 1-09 CAN H J4-A 914 - Gn 914 - Gn J4-B MCU 1-08 CAN L 20 - Bk MCU 1-07 Ground 20 - Bk...
  • Page 87 ELECTRICAL Instrumentation Circuit Schematic Continued 915 - Ye 915 - Ye 115 - Ye J1-5 914 - Gn 914 - Gn 114 - Gn J1-6 MCU 5-02 114 - Gn 114 - Gn J5-B 115 - Ye 115 - Ye J5-A Mow 2 MCU 5-04...

  • Page 88: Unused Circuits

    ELECTRICAL Unused Circuits The harness contains wiring for additional circuits that are not used on this mower. The associated input and output circuits are disabled in the MCU. The unused circuits are: • Weight Transfer Solenoid (SOL9) - MCU 2-12 •...

  • Page 89: Unused Circuits Schematic

    ELECTRICAL Unused Circuits Schematic See Figure 4-22. MCU 5-02 Mow 2 MCU 5-04 Backlap MCU 6-03 Backlap 2 MCU 6-05 20 - Bk 157 - Bu/Wh Lower Solenoid MCU 2-01 SOL5 157 - Bu/Wh 20 - Bk SOL13 108 - Ye 20 - Bk Lift Solenoid MCU 2-03...

  • Page 90: Troubleshooting

    ELECTRICAL Troubleshooting Glow Plug Circuit Symptom: Glow plugs do not get hot. Probable Cause Remedy Faulty 40-amp fuse (F2). Test 40-amp fuse (F2). (See “Fuse Test” on page 4-53.) Faulty power circuit. Check continuity between 40-amp fuse (F2) and glow plug relay (K2) terminal 30. Continuity must be indicated.

  • Page 91: Run Circuit

    ELECTRICAL Symptom: Engine does not run. Probable Cause Remedy Faulty fuel shutoff solenoid. Test fuel shutoff solenoid (SOL12). (See “Fuel Solenoid Test” on page 4-59.) Faulty fuel solenoid pull-in circuit. Check continuity between starter (M1) terminal F and fuel solenoid (SOL12) terminal A. Faulty fuel solenoid hold-in circuit Check continuity between MCU (U1) terminal 2-06 and fuel solenoid (SOL12) terminal B.

  • Page 92: Mow/Backlap Circuits

    ELECTRICAL Mow/Backlap Circuits Symptom: Mow solenoids do not energize. Probable Cause Remedy Engine in overheat condition. Mow solenoids (SOL1 and SOL2) will not energize if engine temperature is above 230° F (110° C). Allow the engine to cool and check the engine cooling system. Faulty mow switch.

  • Page 93: Lift/Lower Circuit

    ELECTRICAL Lift/Lower Circuit Symptom: Cutting units do not lower. Probable Cause Remedy Engine in overheat condition. Lower solenoid (SOL5) will not energize if the engine temperature is above 230° F (110° C). Allow the engine to cool and check the engine cooling system. Faulty lift/lower joystick.

  • Page 94: Instrumentation Circuit

    ELECTRICAL Instrumentation Circuit Symptom: Fan does not turn on. Probable Cause Remedy Engine temperature is below 150° F (66° The fan motor (M4) does not turn on until the engine temperature reaches 150° F (66° C) Faulty 30-amp fuse (F5) Test 30-amp fuse (F5).
  • Page 95 ELECTRICAL Symptom: LDU does not indicate a temperature. Probable Cause Remedy Faulty engine temperature sensor. Test the temperature sender (R5). (See “Engine Temperature Sender Test” on page 4-62.) Faulty engine temperature circuit. Check continuity between MCU (U1) terminal 3-02 and the engine temperature sensor (R5) terminal.

  • Page 96: 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 97: Fuse Test

    ELECTRICAL Fuse Test Relays Test See Figure 4-23. See Figure 4-24. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester • Digital Multimeter, Ohmmeter, or Continuity Tester • 12-volt DC Power Source 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 1.

  • Page 98: Key Switch Test

    ELECTRICAL Key Switch Test Seat Switch Test See Figure 4-25. See Figure 4-26. 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 99: Mow Switch Test

    ELECTRICAL Mow Switch Test 12. Check for continuity. Is continuity indicated? See Figure 4-27. Proceed to step 13. Required Tools or Equipment The switch is faulty; replace the switch. 13. Connect test leads to the switch terminals (4 and 5). •...

  • Page 100: Parking Brake Switch Test

    ELECTRICAL Parking Brake Switch Test 12. Check for continuity. Is continuity indicated? See Figure 4-28. Proceed to step 13. Required Tools or Equipment The switch is faulty; replace the switch. 13. Connect test leads to the switch terminals (4 and 5). Digital Multimeter, Ohmmeter, or Continuity Tester 14.

  • Page 101: Light Switch Test

    ELECTRICAL Light Switch Test 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 4-29. NOTES Required Tools or Equipment This procedure applies to the following micro switches: Digital Multimeter, Ohmmeter, or Continuity Tester • Neutral Switch •...

  • Page 102: Lift/Lower Joystick Test

    ELECTRICAL Lift/Lower Joystick Test 7. Check for continuity. Is continuity indicated? See Figure 4-31. Proceed to step 8. Required Tools or Equipment The joystick is faulty; replace the joystick. 8. Place the joystick in the center position. Digital Multimeter, Ohmmeter, or Continuity Tester 9.

  • Page 103: Solenoids Test

    ELECTRICAL Solenoids Test • Backlap Solenoid Coils–7.1 ohms ± 10% at 68° F • Lift/Lower Solenoid Coils–7.1 ohms ± 10% at 68° F See Figure 4-32. • Brake Solenoid Coil–10.3 ohms ± 10% at 68° F • 4WD Solenoid Coil–3.4 ohms ± 10% at 68° F Required Tools or Equipment Does the resistance through the component Digital Multimeter or Ohmmeter...

  • Page 104: Resistor Test

    ELECTRICAL Resistor Test Diode Test See Figure 4-34. See Figure 4-35. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter 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 105: Fuel Pump Test

    ELECTRICAL Fuel Pump Test Fan Motor Test See Figure 4-36. See Figure 4-37. Required Tools or Equipment Required Tools or Equipment 12-volt DC Power Source 12-volt DC Power Source 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 106: Engine Temperature Sender Test

    ELECTRICAL Engine Temperature Sender Test  WARNING See Figure 4-38. To prevent burns, be careful when working with hot oil. Do not hold the temperature sender with Required Tools or Equipment your bare hands, always wear gloves or other Digital Multimeter or Ohmmeter means to hold the sender in the oil.

  • Page 107: Repair

    ELECTRICAL Repair 5. Remove two screws (3), flat washers (4), rear battery clamp (5) and nuts (6). 6. Remove two screws (7), flat washers (8) and front Battery battery clamp (9). 7. Lift and remove the battery (12). Removal and Installation See Figure 4-39.

  • Page 108: Instrument Panel

    ELECTRICAL Instrument Panel Rocker Switches This procedure applies to the following rocker switches: Removal and Installation • Mow Switch (1) See Figure 4-40. • Parking Brake Switch (2) NOTE • Optional Light Switch (3) If servicing individual components, it is not necessary to Removal and Installation completely remove the instrument panel.

  • Page 109: Lift/Lower Joystick

    ELECTRICAL Relays 5. Press the wings (6) on the front and back of the switch. Remove the switch from the panel. See Figure 4-44. Installation Note NOTE Install the rocker switches by reversing the order of This procedure applies to the following relays: removal.

  • Page 110: Fuses

    ELECTRICAL Fuses  CAUTION NOTE To prevent injury to the operator or damage to the mower, never replace a fuse with a higher This procedure applies to the following relays: amperage rating fuse. • 10-amp accessory outlet fuse F1 (1) Never bypass fuses.

  • Page 111: Key Switch

    ELECTRICAL Key Switch LDU Buzzer Removal and Installation Removal and Installation See Figure 4-47. See Figure 4-48. 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 112: Seat Switch

    ELECTRICAL Seat Switch Neutral Proximity Switch Removal and Installation Removal and Installation See Figure 4-49. See Figure 4-50. 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 113: Lift Proximity Switch

    ELECTRICAL Lift Proximity Switch Forward Proximity Switch Removal and Installation Removal and Installation See Figure 4-51. See Figure 4-52. 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 114: Fan Motor

    ELECTRICAL Fan Motor Engine Oil Pressure Switch Removal and Installation Removal and Installation See Figure 4-53. See Figure 4-54.  1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Disconnect the negative (–) battery cable at the Engine components will become hot during battery.

  • Page 115: Engine Temperature Sensor

    ELECTRICAL Engine Temperature Sensor Fuel Solenoid Removal and Installation Removal and Installation See Figure 4-55. See Figure 4-56.  1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2. Raise the hood. Engine coolant is hot and under pressure! Allow the cooling system to cool completely before 3.

  • Page 116: Fuel Pump

    ELECTRICAL Fuel Pump Mow and Backlap Solenoid Coils This procedure applies to the following solenoids: Removal and Installation • Front Mow Solenoid (1) See Figure 4-57. • Rear Mow Solenoid (2) 1. Park the mower safely. (See “Park Mower Safely” on •...

  • Page 117: Lift And Lower Solenoid Coils

    ELECTRICAL Lift and Lower Solenoid Coils 4WD Solenoid Coil This procedure applies to the following solenoids: Removal and Installation • Lift Solenoid (1) See Figure 4-60. • Lower Solenoid (2) 1. Park the mower safely. (See “Park Mower Safely” on The lift and lower solenoid coils are located on the lift page 1-6.) valve (3) under the operator platform.

  • Page 118: Parking Brake Solenoid Coil

    ELECTRICAL Parking Brake Solenoid Coil Removal and Installation Removal and Installation See Figure 4-61. See Figure 4-62. 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 119: Alternator

    ELECTRICAL Alternator Removal and Installation See Figure 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. MAR0039 Figure 4-63 NOTE Label all wires before disconnecting to ensure correct installation.
  • Page 120 ELECTRICAL Alternator Disassembly and Assembly MAR0067 Figure 4-64: Alternator Disassembly 8. Remove two screws (15) and two nuts (16). NOTE 9. Press on pulley end of rotor (20) to separate the If the alternator screws or nuts have rust or other alternator frame.
  • Page 121 ELECTRICAL Alternator Rotor Inspection NOTES Do not remove the stator from the drive end frame (25). 16. Check the bearings for smooth rotation. Replace if required. Assembly Notes • Assemble the alternator by reversing the order of removal. • Torque the alternator pulley nut (1) to 50 ft-lb (68 Nm). Alternator Stator Coil Inspection MAR0069 Figure 4-66: Rotor Inspection...

  • Page 122: Starter Motor

    ELECTRICAL 1. Measure the brush length (1) with a vernier caliper. Alternator Voltage Regulator Inspection Is the brush length less than 0.33 in. (8.4 mm)? Replace the brush. Continue with step 2. 2. Make sure that the brushes (2) moves smoothly. 3.
  • Page 123 ELECTRICAL NOTE Label all wires before disconnecting to ensure correct installation. 4. Disconnect starter cable (3) from the starter motor (1). 5. Disconnect wire connectors (4 and 5) from the starter motor (1). 6. Support the starter motor (1). 7. Remove screws (2). 8.
  • Page 124 ELECTRICAL 1. Remove nut (1) securing motor lead (2) to the 3. Check for continuity between the brush brackets (4) and the metal support plate (5). solenoid. 2. Remove two long screws (3) and remove the motor Is continuity indicated? assembly from the solenoid (19).
  • Page 125 ELECTRICAL Starter Armature Inspection 4. Check for continuity across the commutator segments (4) and the armature coil core (5). Is continuity indicated? The armature is bad. Replace the armature. Continue with step 5. 5. Check for continuity across the segments of the commutator (4).
  • Page 126 ELECTRICAL Page Intentionally Blank 4-82 673831-Rev A...
  • Page 127 Chapter 5 Hydrostatic Power Train Specifications ..............5-3 Test and Adjustment Specifications .
  • Page 128 HYDROSTATIC POWER TRAIN Instrument Test Procedures ........... . 5-25 Instrument Test Overview .

  • Page 129: Specifications

    HYDROSTATIC POWER TRAIN Specifications Test and Adjustment Specifications Specification Traction Pump Flow 27.7 (105) at 3000 rpm gpm (lpm) Charge Pump Flow 5.2 (19.8) at 3000 rpm gpm (lpm) Forward System Relief Pressure 4060 (280) psi (bar) Reverse System Relief Pressure 4060 (280) psi (bar) Charge Pressure...

  • Page 130: Hydraulic Hose, Tube, And Fitting General Instructions

    HYDROSTATIC POWER TRAIN Hydraulic Hose, Tube, and Fitting Replacement O-Rings for O-Ring Boss Fittings General Instructions Tubing O.D. Thread Jacobsen Part O-Ring Installation or Hose I.D. Size Number • Always install new O-rings. 5/16-24 459290 • On hoses with O-ring fittings, make sure O-rings are 3/16 3/8-24 459291...

  • Page 131: Hydraulic Service Tools

    HYDROSTATIC POWER TRAIN Hydraulic Service Tools Digital Hydraulic Tester Part Number AT40031 NOTE The hydraulic service tools listed here can be obtained from K-Line Industries at http://klineind.com. Portable In-Line Filter Part Number JAC5097 TN4288 Features • Flow up to 100 gpm (379 lpm) •...
  • Page 132 HYDROSTATIC POWER TRAIN Digital Pressure Gauge Kit Hydraulic Test Fitting Kit Part Number JAC5106 Part Number JAC5001A NOTE For detailed component descriptions and sizes, please see the K-Line Industries website at http://klineind.com. Contents • Twenty ORFS tee fittings in five sizes •...

  • Page 133: Component Location

    HYDROSTATIC POWER TRAIN Component Location See Figure 5-1. MAR0144 Hydrostatic Pump Right Front Wheel Motor Rear Wheel Motor (3WD Option) 4WD Valve (4WD Option Only) Left Rear Wheel Motor (4WD Option) Left Front Wheel Motor Right Rear Wheel Motor (4WD Option) Figure 5-1: Component Location 673831-Rev A...

  • Page 134: 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 • Parking brake switch ON • Traction pedal in the NEUTRAL position Charge Pressure Circuit The traction pump and gear pump are both driven by the engine.

  • Page 135: Traction Circuit-3Wd Neutral Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—3WD Neutral Schematic See Figure 5-2. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 28.7 ci Rear Wheel 200 psi Motor 13 ci Charge Left Front...

  • Page 136: Traction Circuit-2Wd/4Wd Neutral Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—2WD/4WD Neutral Schematic See Figures 5-3 and 5-4. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi 13 ci Charge Left Front Filter Wheel Motor...
  • Page 137 HYDROSTATIC POWER TRAIN —2WD/ Traction Circuit 4WD Neutral Schematic Continued Right Rear Wheel Motor 14.3 ci Valve Left Rear Wheel Motor 14.3 ci Charge Pressure Oil Charge pressure oil from upper front motor Charge pressure oil to lower front motor tube tube Figure 5-4...

  • Page 138: Traction Circuit-Forward Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic The 3WD check valve blocks the flow to the pump and forces the flow to the rear wheel motor Port A, driving the and Theory of Operation rear wheel in the forward direction. Oil exiting the rear wheel motor Port B is returned to the traction pump Port System Conditions: A to replenish the intake side of the pump.

  • Page 139: Traction Circuit-Forward 3Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 3WD Schematic See Figure 5-5. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 28.7 ci Rear Wheel 200 psi Motor 13 ci Charge Left Front...

  • Page 140: Traction Circuit-Forward 2Wd/4Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Forward 2WD/4WD Schematic See Figures 5-6 and 5-7. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi 13 ci Charge Left Front Filter Wheel Motor...
  • Page 141 HYDROSTATIC POWER TRAIN — Traction Circuit Forward 2WD/4WD Schematic, Continued 2WD Forward Operation Right Rear Wheel Motor 14.3 ci Valve Left Rear Wheel Motor 14.3 ci Operating Pressure Oil Charge Pressure Oil 4WD Forward Operation Right Rear Wheel Motor 14.3 ci Valve Left Rear Wheel Motor...

  • Page 142: Traction Circuit-Reverse Schematic And Theory Of Operation

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic The reverse operating pressure oil flows through the 3WD check valve and is not forced through the rear and Theory of Operation wheel motor. The hose connections on both sides of the check valve provides no driving force to the rear wheel System Conditions: motor, but allows the motor to rotate freely as the mower •...

  • Page 143: Traction Circuit-Reverse 3Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 3WD Schematic See Figure 5-8. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 28.7 ci Rear Wheel 200 psi Motor 13 ci Charge Left Front...

  • Page 144: Traction Circuit-Reverse 2Wd/4Wd Schematic

    HYDROSTATIC POWER TRAIN Traction Circuit—Reverse 2WD/4WD Schematic See Figures 5-9 and 5-10. Mesh Right Front Screen Wheel Motor 13 ci 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi 13 ci Charge Left Front Filter Wheel Motor...
  • Page 145 HYDROSTATIC POWER TRAIN — Traction Circuit Reverse 2WD/4WD Schematic, Continued 2WD/4WD Reverse Operation Right Rear Wheel Motor 14.3 ci Valve Left Rear Wheel Motor 14.3 ci Operating Pressure Oil Charge Pressure Oil MAR0077 Charge pressure oil from upper front motor Charge pressure oil to lower front motor tube tube Figure 5-10...

  • Page 146: 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.) Bypass valve open. Close bypass valve.
  • Page 147 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.) Bypass valve open. Close bypass valve. (Refer to “Safety, Operation, and Maintenance Manual.”) Loop flushing valve worn or damaged.

  • Page 148: Tests And Adjustments

    HYDROSTATIC POWER TRAIN Tests and Adjustments Speed Stop Adjustments See Figure 5-12. Neutral Switch Adjustment 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 5-11. 2. Disconnect the negative (–) battery cable at the 1. Park the mower safely. (See “Park Mower Safely” on battery.

  • Page 149: Forward Switch Adjustment

    HYDROSTATIC POWER TRAIN Forward Switch Adjustment See Figure 5-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable at the battery. MAR0143 Figure 5-13 The mower has a proximity switch (1) located on the traction pedal, which signals the controller when the traction pedal is moved in the forward position.

  • Page 150: Field Test Procedures

    HYDROSTATIC POWER TRAIN Field Test Procedures When a hydraulic system failure occurs, some simple effective tests can be performed prior to using a test instrument. The results of these tests can lead you to the suspected component failure. More extensive test procedures, using test instruments, are presented later in this section.

  • Page 151: Instrument Test Procedures

    HYDROSTATIC POWER TRAIN Instrument Test Procedures Charge Pressure Test See Figure 5-15. Instrument Test Overview  WARNING The following tests are specifically designed to approach hydraulic testing on a system level. Each component The hydraulic system is under pressure, and the within the system represents a portion of the total system oil will be hot.

  • Page 152: Charge Pump Test

    HYDROSTATIC POWER TRAIN 8. Stop the engine. Is charge pressure approximately 200 psi (13.8 bar)? Charge pressure relief valve is good. Proceed to step 9. Charge pump or charge pressure relief valve is at fault. Inspect, repair, or replace charge pressure relief valve.

  • Page 153: Flow Lock Tool

    HYDROSTATIC POWER TRAIN Flow Lock Tool NOTE See Figures 5-19 and 5-20. Verify engine rpm is within specification (3000 rpm ± 50) to ensure accurate hydraulic test results. IMPORTANT 8. Start engine and run at full throttle (3000 rpm ± 50). •...

  • Page 154: Traction System Test

    HYDROSTATIC POWER TRAIN Traction System Test See Figures 5-21 through 5-23. IMPORTANT • This test determines if there is a problem within the hydrostatic power train.  WARNING The hydraulic system is under pressure, and the oil will be hot. •...

  • Page 155: Traction Pump Tests

    HYDROSTATIC POWER TRAIN Traction Pump Tests 15. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (10) until a reading of 2030 psi (140 See Figure 5-24. bar) or one half of the relief valve rating is reached. ...
  • Page 156 HYDROSTATIC POWER TRAIN 7. Start engine, move parking brake switch to the OFF 18. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (10) until a reading of 2030 psi (140 position, and run at full throttle (3000 rpm ± 50). bar) or one half of the relief valve rating is reached.

  • Page 157: 3Wd System Test

    HYDROSTATIC POWER TRAIN 3WD System Test 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figures 5-25 through 5-27. 2. Before performing this test, perform traction system  test and pump tests. WARNING The hydraulic system is under pressure, and the oil will be hot.
  • Page 158 HYDROSTATIC POWER TRAIN 3. Connect test hose (2) of flow meter inlet to fitting (3). Right Front Wheel Motor Test 4. Connect test hose (4) of flow meter inlet to hose (5). 19. Remove blocking disks from locations (13 and 14). 5.
  • Page 159 HYDROSTATIC POWER TRAIN Rear Wheel Motor Test 28. Remove test hose from fittings (17 and 18) 29. Assemble hose (15) to fitting (17). 30. Assemble hose (16) to fitting (18). 31. Open flow meter valve completely before starting engine. 32. Start engine, move parking brake switch to the OFF position, and run at full throttle (3000 rpm ±...
  • Page 160 HYDROSTATIC POWER TRAIN 3WD Hydrostatic Powertrain Instrument Test Data Sheet Relief Valve Tests Actual Valve Setting Charge Relief Valve 200 psi (13.8 BAR) Forward Traction Relief Valve 4060 psi (280 BAR) Reverse Traction Relief Valve 4060 psi (280 BAR) Traction Pump Flow Tests (15 gpm –...

  • Page 161: 4Wd System Test

    HYDROSTATIC POWER TRAIN 4WD System Test 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figures 5-28 through 5-30. 2. Before performing this test, perform traction system  test and pump tests. WARNING The hydraulic system is under pressure, and the oil will be hot.
  • Page 162 HYDROSTATIC POWER TRAIN 3. Connect test hose (2) of flow meter inlet to fitting (3). Left Front Wheel Motor Test 4. Connect test hose (4) of flow meter inlet to hose (5). 20. Remove blocking disk from locations (13 and 14). 5.
  • Page 163 HYDROSTATIC POWER TRAIN Right Front Wheel Motor Test Left Rear Wheel Motor Test 32. Remove blocking disks from locations (15 and 16). 42. Remove blocking disks from locations (17 and 18). 33. Open flow meter valve completely before starting 43. Open flow meter valve completely before starting engine.
  • Page 164 HYDROSTATIC POWER TRAIN Right Rear Wheel Motor Test 52. Remove blocking disks from locations (19 and 20). 53. Open flow meter valve completely before starting engine. 54. Start engine, move parking brake switch to the OFF position, and run at full throttle (3000 rpm ± 50). 55.
  • Page 165 HYDROSTATIC POWER TRAIN 4WD Hydrostatic Powertrain Instrument Test Data Sheet Relief Valve Tests Actual Valve Setting Charge Relief Valve 200 psi (13.8 BAR) Forward Traction Relief Valve 4060 psi (280 BAR) Reverse Traction Relief Valve 4060 psi (280 BAR) Traction Pump Flow Tests (15 gpm –...

  • Page 166: Repair

    HYDROSTATIC POWER TRAIN Repair Traction Pump Removal and Installation See Figures 5-31 and 5-32. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood 3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Drain Procedure” on page 6-49.) 4.
  • Page 167 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-33 through 5-40. 38 39 MAR0093 O-Ring (2)  O-Ring  Internal Retaining Ring (2) Screw (4) Seal Support Washer Trunnion Cover Loop Flushing Plug (2) 4060 psi Relief Valve (2) Shaft Seal ...
  • Page 168 HYDROSTATIC POWER TRAIN 8. Press bearing (5) off the input shaft (6) using the NOTICE inner race. 9. Remove the remaining external retaining ring (4). • It is important that pump parts are marked and placed in assembly order to aid in Trunnion Covers assembly.
  • Page 169 HYDROSTATIC POWER TRAIN Relief Valves Bypass Valve 42 43 MAR0135 MAR0137 Figure 5-36 Figure 5-38 1. Remove the charge pressure relief valve plug (19). 1. Remove the bypass valve (38). Remove and discard O-ring (20). 2. Remove back up ring (39) and O-ring (40). 2.
  • Page 170 HYDROSTATIC POWER TRAIN 5. Lift valve plate (17) off rotating kit (9). If dowel pin Inspection Notes (18) did not stay in end cap (24), remove dowel pin. • Keeping parts in assembly order, clean and air dry each item for inspection. Pump Housing •...

  • Page 171: 4Wd Valve

    HYDROSTATIC POWER TRAIN 4WD Valve 9. Remove two mounting screws (13), lock washers (14) and flat washers (15). Removal and Installation 10. Remove the 4WD valve (12). Installation Notes See Figure 5-41. • Install the 4WD valve by reversing the order of 1.
  • Page 172 HYDROSTATIC POWER TRAIN 13. Remove O-rings and backup rings from 4WD solenoid valve (18). 14. Remove two check valves (21) from valve block (17). 15. Remove O-rings and backup ring from check valves (21). 16. Remove gauge port plugs (23) and hollow plug (22) from valve block (17).

  • Page 173: Front Wheel Motor

    HYDROSTATIC POWER TRAIN Front Wheel Motor Installation Notes • Install front wheel motor by reversing the order of Removal and Installation removal. • Tighten front wheel motor mounting screws (9) to See Figure 5-43. 90 lb-ft (122 N·m). 1. Park the mower safely. (See “Park Mower Safely” on •...
  • Page 174 HYDROSTATIC POWER TRAIN Spring Washer Compression Tools Outer Roller Bearing— Inner Race Installation Tool See Figure 5-44. See Figure 5-45. Required Tools or Equipment Required Tools or Equipment • Spring Washer Compression Tool Bolt and Nut Outer Roller Bearing— • Spring Washer Compression Tool Inner Race Installation Tool MAR0097 4.33 in.
  • Page 175 HYDROSTATIC POWER TRAIN Inner Roller Bearing— Inner Roller Bearing— Inner Race Installation Tool Outer Race Installation Tool See Figure 5-47. See Figure 5-48. Required Tools or Equipment Required Tools or Equipment Inner Roller Bearing— Inner Roller Bearing— Inner Race Installation Tool Outer Race Installation Tool MAR0100 1.97 in.
  • Page 176 HYDROSTATIC POWER TRAIN Shaft Seal Installation Tool See Figure 5-49. Required Tools or Equipment Shaft Seal Installation Tool MAR0101 Knurl 0.39 in. (10 mm) 1.38 in. (35 mm) Ø 1.18 in. (30 mm) 0.39 in. (10 mm) 1.89 in. (48 mm) Ø 3.94 in.
  • Page 177 HYDROSTATIC POWER TRAIN Front Wheel Motor Disassembly See Figures 5-50 through 5-58. 21 22 MAR0102 Motor Shaft Stud (5) Backup Ring Snap Ring Environmental Seal Valving Brake Shaft Spring Washer Outer Roller Bearing Seal Ring External Brake Disc (21) Screw (10) Bearing Support Seal Ring Internal Brake Disc (20)
  • Page 178 HYDROSTATIC POWER TRAIN Brake Disassembly First Method with a Mandrel and Bolt MAR0104 Figure 5-52 a. Install the spring washer compression tool onto MAR0103 spring washer (36). Figure 5-51 b. Lubricate the spring compression tool bolt threads and nut faces, and tighten the spring compression IMPORTANT tool bolt into brake piston (32) down to the thread root.
  • Page 179 HYDROSTATIC POWER TRAIN NOTE Mark the mounting direction of snap ring (35) prior to removal. 5. Remove snap ring (35), spring washer (36), and brake piston (32). 6. Remove and discard O-ring (31). 7. Remove ten screws (37) and remove brake housing (38).
  • Page 180 HYDROSTATIC POWER TRAIN 23. Remove snap ring (8). 24. Release press force and remove inner roller bearing—inner race installation tool. NOTE When removing shim spacer (7), measure and note the thickness of the shim spacer. 25. Remove shim spacer (7). MAR0109 Figure 5-57 26.
  • Page 181 HYDROSTATIC POWER TRAIN Front Wheel Motor Assembly See Figures 5-59 through 5-65. 21 22 MAR0102 Motor Shaft Stud (5) Backup Ring Snap Ring Environmental Seal Valving Brake Shaft Spring Washer Outer Roller Bearing Seal Ring External Brake Disc (21) Screw (10) Bearing Support Seal Ring Internal Brake Disc (20)
  • Page 182 HYDROSTATIC POWER TRAIN Motor Assembly 10. Using the outer roller bearing—inner race installation tool and a soft-faced hammer, install outer roller NOTICE bearing (3) and inner race in outer roller bearing outer race. • It is important that all component parts are 11.
  • Page 183 HYDROSTATIC POWER TRAIN Using the press and inner roller bearing—inner IMPORTANT race installation tool, apply 12,364 lb (55,000 N) force (F) to bearing (6) for five seconds, then Make sure locating pin in valving (14) aligns with timing reduce force to 618 lb (2750 N). notch in valving cover (18) when installing valving in valving cover.
  • Page 184 HYDROSTATIC POWER TRAIN ® 32. Apply Loctite 638 retaining compound to the external diameter of bushing (22), and position bushing on valving cover (18) with the chamfer of the bushing facing toward the valving cover. 33. Using the large diameter end of brake shaft (25) and a soft-faced hammer, install bushing (22) into valving cover flush to 0.004 in.
  • Page 185 HYDROSTATIC POWER TRAIN 49. Install brake piston in brake housing. 50. Lubricate spring washer (36) with Mobilux EP2 grease, or equivalent NLGI Grade EP2 grease, and install spring washer on brake piston (32). 51. Compress spring washer (36) by one of the two methods described in “Front Wheel Motor Disassembly”...

  • Page 186: Rear Wheel Motor

    HYDROSTATIC POWER TRAIN Rear Wheel Motor 9. Remove four screws (10), lock washers (11) and nuts (12). 3WD Rear Motor Removal and Installation 10. Remove wheel motor (3) from steering yoke (13). See Figure 5-66. Installation Notes 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Required Materials 2.
  • Page 187 HYDROSTATIC POWER TRAIN Shell Bearing Removal Tool  CAUTION See Figure 5-68. The wheel hub may move unexpectedly when Required Tools or Equipment using a puller. To prevent injury and/or property damage, do not remove the castle nut until the Shell Bearing—...
  • Page 188 HYDROSTATIC POWER TRAIN Disassembly and Inspection See Figures 5-69 through 5-71. NOTE Disassembly is the same for both the 3WD and 4WD motors. The difference between the motors is the width of gerolor assembly (22) and length of the screws (24). MAR0118 Back-up washer Back-up Ring (2)
  • Page 189 HYDROSTATIC POWER TRAIN 14. Remove two bearing races (9) and thrust bearing NOTICE (10). 15. Remove grease seal (3) by wedging it out with a • It is important that motor parts are marked screwdriver. and placed in assembly order to aid in assembly.
  • Page 190 HYDROSTATIC POWER TRAIN Assembly See Figures 5-72 through 5-81. MAR0118 Back-up washer Back-up Ring (2) Bearing Shaft Seal O-Ring Thrust Bearing Grease Seal Bearing Race (2) Valve Spring Valve Plate Bearing Shell Thrust Bearing Dowel Pin (4) Geroler Assembly Housing Output Shaft Balance Ring End Cap...
  • Page 191 HYDROSTATIC POWER TRAIN MAR0122 Figure 5-73 MAR0124 1. Position the housing (5) in the vertical position on a Figure 5-75 clean smooth surface. Use Delta motor shell bearing tool (25) to press new shell bearing (4) into the 3. Flip the housing (5). Install back-up washer (7) into housing.
  • Page 192 HYDROSTATIC POWER TRAIN MAR0126 Figure 5-77 MAR0128 Figure 5-79 6. Install four dowel pins (16) into the blind holes on the balancing ring (17) using sufficient Loctite 277 9. Insert button end of drive (12) into end of output shaft adhesive to hold the pins.
  • Page 193 HYDROSTATIC POWER TRAIN MAR0130 Figure 5-81 16. Grease two O-rings (6) and assemble to geroler assembly (22). 17. Assemble the geroler assembly (22) to the valve plate (21) with the splined end away from the housing. For proper timing, the marked spline (Y) of the drive (12) must be aligned with a geroler star tip (W).

  • Page 194: Traction Linkage

    HYDROSTATIC POWER TRAIN Traction Linkage Assembly Notes • Assemble the traction linkage by reversing the order Disassembly and Assembly of disassembly. See Figure 5-82. • Torque trunnion cover screws (13) to 24 lb-ft (33 N·m). • Adjust neutral switch. (See “Neutral Switch Adjustment”...
  • Page 195 Chapter 6 Hydraulics Specifications ..............6-3 Test and Adjustment Specifications .
  • Page 196 HYDRAULICS Instrument Test Procedures ........... . 6-27 Instrument Test Overview .
  • Page 197 HYDRAULICS Specifications Test and Adjustment Specifications Specifications Front Reel Valve Pump Flow 5.2 (19.8) at 3000 rpm gpm (lpm) Rear Reel Valve Pump Flow 5.2 (19.8) at 3000 rpm gpm (lpm) Lift/Steer Pump Flow 5.2 (19.8) at 3000 rpm gpm (lpm) Hydraulic Leakage Percentage Ranges 0–10% = Good 11–20% = Marginal...

  • Page 198: Hydraulic Hose, Tube, And Fitting General Instructions

    HYDRAULICS Hydraulic Hose, Tube, and Fitting Replacement O-Rings for O-Ring Boss Fittings General Instructions Tubing O.D. Thread Jacobsen Part O-Ring Installation or Hose I.D. Size Number • Always install new O-rings. 5/16-24 459290 • On hoses with O-ring fittings, make sure O-rings are 3/16 3/8-24 459291...

  • Page 199: Hydraulic Service Tools

    HYDRAULICS Hydraulic Service Tools Digital Hydraulic Tester Part Number AT40031 NOTE The hydraulic service tools listed here can be obtained from K-Line Industries at http://klineind.com. Portable In-Line Filter Part Number JAC5097 TN4288 Features • Flow up to 100 gpm (379 lpm) •...

  • Page 200: Digital Pressure Gauge Kit

    HYDRAULICS Digital Pressure Gauge Kit Hydraulic Test Fitting Kit Part Number JAC5106 Part Number JAC5001A NOTE For detailed component descriptions and sizes, please see the K-Line Industries website at http://klineind.com. Contents • Twenty ORFS tee fittings in five sizes • Eight ORFS 90° elbow fittings in four sizes •...

  • Page 201: Component Location

    HYDRAULICS Component Location See Figure 6-1. MAR0196 Hydraulic Tank Steering Valve Rear Lift Cylinder (2) Gear Pump Steering Cylinder (3WD Option) Reel Motor (2) Front Reel Valve Steering Cylinder (4WD Option) Charge Filter Rear Reel Valve Front Reel Motor (3) Lift Valve Front Lift Cylinder (3) Figure 6-1: Component Location...

  • Page 202: Hydraulic Schematic

    HYDRAULICS Hydraulic Schematic See Figures 6-2 and 6-3. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center Reel...
  • Page 203 HYDRAULICS Hydraulic Schematic Continued 3WD Option Steering Cylinder 4WD Option Steering Cylinder Steering Valve Left Front Center Right Front Cylinder Cylinder Cylinder .032 One Way Orifice .032 One Way Orifice .032 One Way Orifice .026 One Way Orifice .026 .026 One Way One Way Lift...

  • Page 204: 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 205: Steering Circuit Hydraulic Schematic

    HYDRAULICS Steering Circuit Hydraulic Schematic See Figures 6-4 and 6-5. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center...
  • Page 206 HYDRAULICS Steering Circuit Hydraulic Schematic Continued 3WD Option Steering Cylinder 4WD Option Steering Cylinder Steering Valve Left Front Center Right Front Cylinder Cylinder Cylinder .032 One Way Orifice .032 One Way Orifice .032 One Way Orifice .026 One Way Orifice .026 .026 SOL4...

  • Page 207: Lift Circuit Schematic And Theory Of Operation

    HYDRAULICS Lift Circuit Schematic and Theory of Operation System Conditions: • Engine running at fast idle • Lift/lower joystick in the lift position NOTE The cutting unit motors will automatically shut off as the cutting units are lifted. Oil Supply to the Lift Valve Hydraulic oil is drawn from the hydraulic oil tank by section 1 of the gear pump assembly.

  • Page 208: Lift Circuit Hydraulic Schematic

    HYDRAULICS Lift Circuit Hydraulic Schematic See Figures 6-6 and 6-7. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center...
  • Page 209 HYDRAULICS Lift Circuit Hydraulic Schematic Continued 3WD Option Steering Cylinder 4WD Option Steering Cylinder Steering Valve Left Front Center Right Front Cylinder Cylinder Cylinder .032 One Way Orifice .032 One Way Orifice .032 One Way Orifice .026 One Way Orifice .026 .026 SOL4...

  • Page 210: Lower Circuit Schematic And Theory Of Operation

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

  • Page 211: Lower Circuit Hydraulic Schematic

    HYDRAULICS Lower Circuit Hydraulic Schematic See Figures 6-8 and 6-9. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center...
  • Page 212 HYDRAULICS Lower Circuit Hydraulic Schematic Continued 3WD Option Steering Cylinder 4WD Option Steering Cylinder Steering Valve Left Front Center Right Front Cylinder Cylinder Cylinder .032 One Way Orifice .032 One Way Orifice .032 One Way Orifice .026 One Way Orifice .026 .026 SOL4...

  • Page 213: 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 reel valves at port “B” and flows through the solenoid valves, exiting the System Conditions: valves at port “T.” • Engine running at fast idle Front Reels: The oil from the front reel motors is routed •...

  • Page 214: Mow Circuit Hydraulic Schematic

    HYDRAULICS Mow Circuit Hydraulic Schematic See Figure 6-10. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center Reel...

  • Page 215: Backlap Circuit Schematic And Theory Of Operation

    HYDRAULICS Backlap Circuit Schematic and Oil Return Theory of Operation Oil returning from the motors enters the reel valves at port “B” and flows through the solenoid valves, exiting the System Conditions: valves at port “T.” • Engine running Front Reels: The oil from the front reel motors is routed •...

  • Page 216: Backlap Circuit Hydraulic Schematic

    HYDRAULICS Backlap Circuit Hydraulic Schematic See Figure 6-11. Mesh Screen 2.14 ci 4060 psi Gear 3000 .39 ci .39 ci .39 ci Pump 4060 psi 200 psi Charge Filter 25 psi Crack Cooler Bypass Micron Left Front Reel Motor 0.651 ci Front Center Reel...

  • Page 217: Field Test Procedures

    HYDRAULICS Field Test Procedures When a hydraulic system failure occurs, some simple effective tests can be performed prior to using a test instrument. The results of these tests can lead you to the suspected component failure. More extensive test procedures, using test instruments, are presented later in this section.
  • Page 218 HYDRAULICS MAR0159 Figure 6-13 IMPORTANT Cutting units must be lowered to the ground. 13. Remove check valves (3) from the lift valve body (4). 14. Clean and inspect check valves for damage. Replace as necessary. 15. Start the engine and raise the cutting units. 16.

  • Page 219: Steering Leakage Test

    HYDRAULICS Steering Leakage Test  WARNING See Figures 6-14 or 6-15. 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 220: Reel Motor Case Drain Test

    HYDRAULICS Reel Motor Case Drain Test 11. Measure the amount of oil that flowed from the case drain. The amount x 4 = amount per minute. The cutting units system consists of two circuits: the front Is the oil captured from the case drain within a cutting units circuit and the rear cutting units circuit.

  • Page 221: Instrument Test Procedures

    HYDRAULICS Instrument Test Procedures Calculations: Front Cutting Units Circuit Test Instrument Test Overview No Load Flow = 5.2 gpm The following tests are specifically designed to approach Loaded Flow = 3.7 gpm hydraulic testing on a system level. Each component 5.2 –...

  • Page 222: Front Cutting Units Circuit Test

    HYDRAULICS Front Cutting Units Circuit Test See Figures 6-16 through 6-18. IMPORTANT 3000 • Performing this test will isolate the front cutting units pump, front reel valve, and right front reel motor from the rest of the front cutting units circuit.

  • Page 223: Front Cutting Units Pump Test

    HYDRAULICS Front Cutting Units Pump Test 10. Bypass seat switch. See Figures 6-19 through 6-21. NOTE IMPORTANT Verify engine rpm is within specification (3000 rpm ± 50) to ensure accurate hydraulic test results. • Performing this test will isolate the front cutting 11.
  • Page 224 HYDRAULICS NOTE Verify engine rpm is within specification (3000 rpm ± 50) 3000 to ensure accurate hydraulic test results. 7. Start engine and run at full throttle (3000 rpm ± 50).  CAUTION Do not exceed 2200 psi (251 bar) as this test does not utilize system relief, and damage may occur to hydraulic system components.

  • Page 225: Front Reel Valve Test

    HYDRAULICS Front Reel Valve Test 3. Install blocking disk at fitting (1) on right front reel motor, blocking oil flow from entering right front reel See Figures 6-22 through 6-24. motor. IMPORTANT • Performing this test will isolate the front reel valve from the rest of the front cutting units 3000 circuit.

  • Page 226: Front Reel Motors Test

    HYDRAULICS Front Reel Motors Test 9. Engage the mow switch, engage and release the lift/lower joystick to the lower position twice, and See Figures 6-25 through 6-28. operate the reels. 10. Slowly close flow meter valve (2) until a pressure of IMPORTANT 1650 psi (114 bar) or 75% of the relief valve rating is •...
  • Page 227 HYDRAULICS 6. Open flow meter valve (1) completely. 12. Calculate right front reel motor leakage. (Step 10 of front reel valve test – Step 10 / Step 10 of front reel valve test x 100 = Leak Percentage) Is right front reel motor leakage 10% or less? The right front reel motor is good.
  • Page 228 HYDRAULICS 17. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve until a reading of 1100 psi (75 bar) or one-half of the relief valve rating is reached. Warm oil to 120–150° F (49–65° C); open valve fully after operating temperature is reached.

  • Page 229: Rear Cutting Units Circuit Test

    HYDRAULICS 31. Remove blocking device or tool from left front reel motor. 32. Disconnect and remove test equipment. Install all hoses, lines, and fittings as noted prior to removal. 33. Install and connect all components as noted prior to test. 34.
  • Page 230 HYDRAULICS MAR0171 Figure 6-32: Rear Cutting Units Circuit Test—Right Rear Reel Motor Blocked 9. Block both sides of rear wheels using suitable wheel blocks. 10. Bypass seat switch. MAR0170 NOTE Figure 6-31 Verify engine rpm is within specification (3000 rpm ± 50) 5.

  • Page 231: Rear Cutting Units Pump Test

    HYDRAULICS Rear Cutting Units Pump Test 17. Calculate rear cutting units circuit leakage. (Step 14 – Step 15 / Step 14 x 100 = Leak See Figures 6-33 through 6-35. Percentage) IMPORTANT Is rear cutting units circuit leakage 10% or less? The rear cutting units circuit is good.
  • Page 232 HYDRAULICS 9. Slowly close flow meter valve (2) until a pressure of 1650 psi (114 bar) or 75% of the relief valve rating is 3000 reached. Read and record the rear cutting units pump loaded flow. 10. Open flow meter valve, disengage mow switch, and stop engine.

  • Page 233: Rear Reel Valve Test

    HYDRAULICS Rear Reel Valve Test 3. Install blocking disk at fitting (1) on right rear reel motor, blocking oil flow from entering right rear reel See Figures 6-36 through 6-38. motor. IMPORTANT • Performing this test will isolate the rear reel valve from the rest of the rear cutting units circuit.

  • Page 234: Rear Reel Motors Test

    HYDRAULICS Rear Reel Motors Test  CAUTION See Figures 6-39 through 6-41. Do not exceed 2200 psi (251 bar) as this test does IMPORTANT not utilize system relief, and damage may occur to hydraulic system components. • Performing this test will isolate the rear reel motors from the rest of the rear cutting units circuit.
  • Page 235 HYDRAULICS  WARNING Safely block cutting unit from rotating using a suitable device or tool. Failure to follow appropriate safety precautions may result in death or serious injury. 14. Install suitable blocking device or tool in left rear cutting unit, preventing left rear reel motor from turning.

  • Page 236: Lift/Steering Relief Valve Pressure Test

    HYDRAULICS Lift/Steering Relief Valve Pressure 21. Calculate left rear reel motor leakage. (Step 10 – Step 19 / Step 10 x 100 = Leak Test Percentage) See Figures 6-42 through 6-44. Is left rear reel motor leakage 10% or less? The left rear reel motor is good.
  • Page 237 HYDRAULICS 11. Stop engine. Is lift relief pressure 2030-2100 psi (140-145 bar)? Proceed to step 12. Test lift/steer pump. (See “Lift/Steer Pump Test” on page 6-47.) Test lift cylinders. (See “Lift Cylinder Leakage Test” on page 6-23.) Adjust lift/steering relief valve. (See “Lift/Steering Relief Valve Adjustment”...

  • Page 238: Lift/Steering Relief Valve Adjustment

    HYDRAULICS Lift/Steering Relief Valve Adjustment 5. Using 8 mm Allen wrench (2), adjust lift/steering relief valve: See Figure 6-45. Turning adjusting screw (3) clockwise increases  pressure. WARNING Turning adjusting screw (3) counterclockwise The hydraulic system is under pressure, and the decreases pressure.
  • Page 239 HYDRAULICS Page Intentionally Blank 673831-Rev A 6-45...

  • Page 240: Lower Relief Valve Pressure Test

    HYDRAULICS Lower Relief Valve Pressure Test See Figures 6-46 through 6-47. NOTE Before performing this test, perform field test procedures. (See “Field Test Procedures” on page 6-23.)  WARNING The hydraulic system is under pressure, and the oil will be hot. •...

  • Page 241: Lift/Steer Pump Test

    HYDRAULICS Lift/Steer Pump Test See Figures 6-48 through 6-50. 3000 NOTE Before performing this test, perform field test procedures. (See “Field Test Procedures” on page 6-23.)  WARNING The hydraulic system is under pressure, and the oil will be hot. •...
  • Page 242 HYDRAULICS 9. Open flow meter valve (4) completely. Read and record the lift/steer pump no load flow. 10. Slowly close flow meter valve (4) until a pressure of 1575 psi (109 bar) or 75% of the relief valve rating is reached.

  • Page 243: Repair

    HYDRAULICS Repair Installation Notes • Ensure new O-ring is in place before installing hose on suction manifold. Hydraulic Oil Tank—Drain Procedure • Connect hose (1). Tighten connection to 95 lb-ft (129 See Figure 6-51. N·m) 1. Park the mower safely. (See “Park Mower Safely” on •...
  • Page 244 HYDRAULICS MAR0183 Figure 6-53 9. Remove two screws (9) and lock washers (10). 10. Remove gear pump (8). 11. Remove O-ring (11). Installation Notes • Install gear pump by reversing the order of removal. • Tighten screws (9) to 47 lb-ft (64 N·m) •...
  • Page 245 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-54 and 6-55. MAR0184 Section 1, 0.403 in Body 0.403 in Drive Gear (2) Section Seal (2) Flange (Section 2-3) Section 2, 0.403 in Body 0.403 in Input Shaft Section Seal (4) 38 mm Drive Hub Section 3, 0.403 in Body 0.403 in...
  • Page 246 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 247: Reel Motors

    HYDRAULICS Reel Motors 11. Remove four one-way orifice plates (11). 12. Remove four one-way orifice fittings (12) Removal and Installation NOTE See Chapter 8—Cutting Units for reel motor service information. (See “Reel Drive Motor” on page 8-24.) Lift Valve Removal and Installation See Figure 6-56.
  • Page 248 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-58. MAR0187 Relief Valve Solenoid Coil (2) Pilot Piston (3) Check Valve Plug (4) Solenoid Screw (4) D03 Solenoid Valve Coil Nut (2) Gauge Port Plug Figure 6-58 NOTE • Repair of the lift valve is limited to replacing valves and cartridges or replacing O-rings.

  • Page 249: Reel Valves

    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 250 HYDRAULICS Installation Notes NOTE • Install the rear reel valve by reversing the order of Label connectors before disconnecting to ensure correct removal. installation. • Make sure new O-rings are in place before installing 5. Disconnect electrical connectors (1) from solenoid. hoses on fittings.
  • Page 251 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-61. MAR0190 Flow Control Valve -4 ORB Plug (3) Relief Valve Gauge Port Plug D03 Solenoid Valve -6 ORB Plug (3) Solenoid Screw (4) Mow Solenoid Coil Coil Nut (2) Backlap Solenoid Coil Figure 6-61 NOTE •...

  • Page 252: Charge Pressure Filter

    HYDRAULICS Charge Pressure Filter Assembly Notes NOTICE Removal and Installation See Figure 6-62. It is important that all component parts are absolutely clean, as contamination can result in 1. Park the mower safely. (See “Park Mower Safely” on serious damage and/or improper operation. page 1-6.) Never use shop towels or rags to dry parts after 2.

  • Page 253: Lift Cylinders

    HYDRAULICS Lift Cylinders NOTES • Label all hydraulic hoses before disconnecting to Removal and Installation ensure correct installation. See Figure 6-63. • The rear lift cylinders have an one-way orifice fitting  installed between the hose and the cylinder rod end CAUTION fitting.
  • Page 254 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-64. NOTE The machine has five lift cylinders. All of the lift cylinders are the same. MAR0193 Cylinder Barrel Piston Wear Ring Gland Back-Up Ring Wiper Seal Piston Cylinder Gland Gland Wear Ring (2) Rod, Cylinder Piston Seal Gland O-Ring...

  • Page 255: Hydraulic Oil Cooler

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

  • Page 256: Hydraulic Oil Tank

    HYDRAULICS Hydraulic Oil Tank Removal and Installation See Figures 6-65 through 6-66. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Disconnect the negative (–) battery cable from the battery. 3. Remove the hood. (See “Hood” on page 9-4.) 4.
  • Page 257 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 258 HYDRAULICS Page Intentionally Blank 6-64 673831-Rev A...
  • Page 259 Chapter 7 Steering Specifications ..............7-2 Component Location .
  • Page 260 STEERING Specifications Test and Adjustment Specifications Steering System Leakage Test—Cylinder Leakage Zero–Nominal Amount pt (L) Rear Axle Alignment Toe-In Measurement 0.0625 (1.6) in. (mm) (4WD Option) Rear Axle Spindle Arm-to-Axle Stop Measurement 0.0625 to 0.125 (1.6 to 3.2) in. (mm) (4WD Option) Repair Specifications Steering Wheel Nut...

  • Page 261: Component Location

    STEERING Component Location See Figure 7-1. 3WD Option 4WD Option MAR0221 Tie Rod (4WD Option Only) Tilt Lever Steering Unit Steering Axle/Steering Yoke Steering Wheel Steering Column Steering Cylinder Steering Tower Cover Figure 7-1 673831-Rev A...

  • Page 262: Tests And Adjustments

    STEERING Tests and Adjustments Turn Stop Adjustment IMPORTANT Steering Linkage Adjustments The steering linkage must be adjusted in proper (4WD Option Only) sequence. Do not perform this procedure until the tie rod adjustment has been performed. (See “Tie Rod See Figures 7-2 through 7-3. Adjustment”...

  • Page 263: Steering Relief Valve Pressure Test

    STEERING Steering Relief Valve Pressure Test See Figures 7-4 through 7-6. NOTE Before performing this test, perform field test procedures. (See “Field Test Procedures” on page 6-23.)  WARNING The hydraulic system is under pressure, and the oil will be hot. •...

  • Page 264: Steering Leakage Test

    STEERING 11. Stop engine. Is steering relief pressure 2030-2100 psi (140-145 bar)? Lift/steering relief valve is good. Proceed to step 12. Test steer cylinder. (See “Steering Leakage Test” on page 7-6.) Adjust lift/steering relief valve. (See “Lift/Steering Relief Valve Adjustment” on page 6-44.) 12.

  • Page 265: Repair

    STEERING Repair Steering Wheel Removal and Installation Steering Tower Cover See Figure 7-10. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 7-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) MAR0203 Figure 7-10...

  • Page 266: Steering Column

    STEERING Steering Column Removal and Installation See Figures 7-11 through 7-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) NOTE If available, use a portable hydraulic filtering unit to remove the hydraulic oil from the hydraulic tank. Place the filtering unit suction hose in the tank, and pump the oil into a clean and sealable container.
  • Page 267 STEERING Disassembly See Figure 7-14. MAR0207 Pivot Base Universal Joint Pivot Screw (2) Rubber Bellows Cap Nut (2) Roll Pin Pedal Pad Pivot Bushing (2) Column Pivot (2) Gas Spring Cap Nut (2) Figure 7-14 673831-Rev A...
  • Page 268 STEERING  CAUTION Wear eye protection when assembling and disassembling the steering column. Pins and other objects may be propelled into the air, causing eye injury. 1. Slide rubber bellows (13) as far as possible up column (7). 2. Drive roll pin (6) out of universal joint. 3.

  • Page 269: Steering Unit

    STEERING Steering Unit Removal and Installation See Figures 7-15 through 7-17. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) NOTE If available, use a portable hydraulic filtering unit to remove the hydraulic oil from the hydraulic tank. Place the filtering unit suction hose in the tank, and pump the oil into a clean and sealable container.
  • Page 270 STEERING Steering Unit Service Fixture See Figures 7-18 and 7-19. Required Tools or Equipment Steering Unit Service Fixture TN2142 0.165 in. (4.2 mm) 2.0 in. (50.8 mm) 0.250 in. (6.35 mm) Ø Hole (4) 4.0 in. (101.5 mm) 2.280 in. (58.0 mm) Ø 1.5 in.
  • Page 271 STEERING Disassembly See Figures 7-20 and 7-21. TN4339 Special Screw (3) Gearwheel Rim Spring Retaining Ring Ball Stop Special Screw (2) Distributor Plate Spool Emergency Steering Ball O-Ring (5) Cardan Shaft Thick Bearing Race Housing End Cover O-Ring Bearing Name Plate Spacer Sleeve Thin Bearing Race...
  • Page 272 STEERING  Steps 1-3 Steps 4-5 CAUTION Wear eye protection when assembling and disassembling the steering unit. Springs and other objects may be propelled into the air, causing eye injury. NOTES • Before attempting repairs or disassembly of any Scribe line hydraulic components, thoroughly clean the aligned with components and work area.
  • Page 273 STEERING Assembly See Figures 7-22 through 7-24. TN4339 Special Screw (3) Gearwheel Rim Spring Retaining Ring Ball Stop Special Screw (2) Distributor Plate Spool Emergency Steering Ball O-Ring (5) Cardan Shaft Thick Bearing Race Housing End Cover O-Ring Bearing Name Plate Spacer Sleeve Thin Bearing Race...
  • Page 274 STEERING 10. While holding the cross pin in place, guide the spool  CAUTION and sleeve assembly into housing (23). When installed, cross pin (12) must point towards port “P.” Wear eye protection when assembling and Spool will push seal guide (A) out of housing as it is disassembling the steering unit.
  • Page 275 STEERING 11. Place emergency steering ball (23) in port “P.”  WARNING 12. Place ball stop (22) in port “P.” 13. Place check valve ball (21) in port “P.” Keep hands and arms clear of steering wheel on initial startup of engine. Steering unit can 14.

  • Page 276: 3Wd Option Steering Cylinder

    STEERING 3WD Option Steering Cylinder NOTES • Label all hydraulic hoses and record their locations to Removal and Installation ensure correct installation. See Figures 7-25 through 7-26. • Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil. Required Tools or Equipment 3.
  • Page 277 STEERING NOTES Installation Notes • Install the steering cylinder by reversing the order of removal. • Using information recorded during disassembly, install rod end (13) onto steering cylinder with the correct number of turns. • Tighten fittings (3) to 15 lb–ft (19 N·m). •...
  • Page 278 STEERING Disassembly, Inspection, and Assembly See Figure 7-27. MAR0213 Barrel Piston Wiper Gland Rod Seal Barrel Rod Wiper Rod and Piston Assembly Gland Gland Rod Wiper Piston Seal O-Ring Barrel Rod Seal Figure 7-27 1. Remove gland (5) from barrel (1). NOTICE 2.

  • Page 279: 4Wd Option Steering Cylinder

    STEERING Assembly Notes NOTES • Label all hydraulic hoses and record their locations to Required Materials ensure correct installation. Seal Kit (Jacobsen PN TBD) • Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil. • Assemble the steering cylinder by reversing the order 3.
  • Page 280 STEERING Disassembly, Inspection, and Assembly See Figure 7-29. MAR0215 Barrel Piston Wear Ring Back-up ring Piston Wear Ring (2) Grease Fitting O-ring Gland Rod Seal Piston Seal O-ring Rod Wiper Figure 7-29 1. Remove the gland (7 through 12) from barrel (1). NOTICE 2.

  • Page 281: Tie Rod Assembly (4Wd Option Only)

    STEERING Assembly Notes Installation Notes • Install the tie rod by reversing the order of removal. Required Materials • Before installing the tie rod assembly, verify that the ball joint tapers and the mating tapered surfaces in Seal Kit (Jacobsen PN 4276851) the steering arms are free of burrs, dirt, and debris.
  • Page 282 STEERING Disassembly, Inspection, and Assembly See Figure 7-31. MAR0217 Threaded Ball Joint, Right Threaded Ball Joint, Left LH Threaded Nut Castle Nut Castle Nut RH Threaded Nut Castle Nut Castle Nut Tie Rod Figure 7-31 Disassembly Note • Record the number of turns required to remove ball joints from tie rod.

  • Page 283: 3Wd Option Rear Yoke

    STEERING 3WD Option Rear Yoke 9. Remove the upper (8) and lower (9) bearings. 10. Remove the nilos ring (10) and collar (11). Removal and Installation Installation Notes See Figure 7-32. • Install the rear axle assembly by reversing the order 1.

  • Page 284: 4Wd Option Rear Axle

    STEERING 4WD Option Rear Axle 11. Remove the tie rod assembly (10). Installation Notes Removal and Installation • Install the rear axle assembly by reversing the order See Figure 7-32. of removal. 1. Park the mower safely. (See “Park Mower Safely” on •...
  • Page 285 STEERING Disassembly, Inspection, and Assembly See Figure 7-34. MAR0220 Rear Axle E-clip (2) Lock Washer (4) Grease Fitting (3) Pivot Bushing (2) Motor Support Spacer (2) Right Steering Arm Left Steering Arm Pivot Bushing (4) Hex-Head Bolt (4) Motor Mount (2) Figure 7-34 1.
  • Page 286 STEERING Page Intentionally Blank 7-28 673831-Rev A...
  • Page 287 Chapter 8 Cutting Units Specifications ..............8-2 Component Location .

  • Page 288: Specifications

    CUTTING UNITS Specifications See Figures 8-1 and 8-2. MAR0300 MAR0301 Bedknife Front Face Height Bedknife Top Face Angle Reel Blade Relief Angle Reel Blade Land Height Bedknife Front Face Angle Figure 8-2: Reel Blade Figure 8-1: Bedknife Checks and Adjustments Specifications Cutting Unit Down Pressure Adjustment—Initial Ball 8.94 ±...
  • Page 289 CUTTING UNITS Repair Specifications Reel Drive Motor—Rear Cover-to-Body Retaining 18.5 (25) lb-ft (N·m) Screw Torque Reel Drive Motor with -4 ORFS Case Drain—Case 11 (14.9) lb-ft (N·m) Drain Fitting Torque Reel Drive Motor with -6 ORFS Case Drain—Case 17 (23) lb-ft (N·m) Drain Fitting Torque Reel Drive Motor—IN/OUT Port Fittings...
  • Page 290 CUTTING UNITS Component Location See Figure 8-3. MAR0302 Right Front Cutting Unit Left Rear Cutting Unit Pivot Yoke Lift Arm Center Cutting Unit Right Rear Cutting Unit Lift Yoke Front Roller Left Front Cutting Unit Lift Cylinder Counterweight Reel Drive Motor Figure 8-3: Component Location 673831-Rev A...

  • Page 291: Troubleshooting

    CUTTING UNITS Troubleshooting Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Even though the cutting units are properly sharpened and adjusted, some mowing practices and turf conditions can cause poor cutting results. These include: • Repetitious mowing patterns—tires running over the same path—may cause depressions and ruts.
  • Page 292 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. Ragged Cut Ragged cutting occurs when blades of grass are torn or damaged rather than cut. This is usually caused by incorrect height-of-cut adjustment, incorrect bedknife-to-reel adjustment, or dull blades.
  • Page 293 CUTTING UNITS Washboarding Washboarding is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is approximately 6–8 in. (15–20 cm). Color variation (light-to-dark) may also be noticed. This condition is usually caused by a rocking motion in the cutting unit(s).
  • Page 294 CUTTING UNITS Marcelling Marcelling is a wave-like cut appearance similar to washboarding but with a uniform cutting height and smaller wave tip-to-tip distance. In most cases, the wave tip-to-tip distance is 2 in. (5 cm) or less. Color variation (light-to-dark) may also be noticed. This condition is usually caused by an incorrect frequency-of-clip.
  • Page 295 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of the reel than the other. This is usually caused by mechanical wear or an incorrect roller adjustment. TN0221 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
  • Page 296 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 297 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Bedknife improperly adjusted. Adjust bedknife. (See “Bedknife-to-Reel Clearance Adjustment” on page 8-18.) Dull cutting edges.
  • Page 298 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife. TN0224 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 8-30.) Damaged or unevenly worn reel.
  • Page 299 CUTTING UNITS Windrowing Windrowing is the deposit of clippings concentrated at one end of the cutting unit, forming a line in the direction of travel. TN0225 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall.
  • Page 300 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units cause a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to a different HOC (height-of-cut) adjustment from one cutting unit to another. TN1278 NOTE: Arrow indicates direction of travel. Probable Cause Remedy HOC inconsistent from one cutting unit to another.
  • Page 301 CUTTING UNITS Rifling or Tramlining Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife. TN0987 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Reel and/or bedknife unevenly worn.

  • Page 302: Mechanical Troubleshooting

    CUTTING UNITS Mechanical Troubleshooting Condition Probable Cause Remedy Reel drive motor does not turn. Mow switch not engaged. Engage mow switch. (Refer to “Safety and Operation Manual.”) Mow speed lever not in mow position. Move mow speed lever to mow position. (Refer to “Safety and Operation Manual.”) Seat switch faulty.

  • Page 303: Checks And Adjustments

    CUTTING UNITS Checks and Adjustments 7. Grass conditions will also affect the adjustment. a. Dry, sparse grass requires a wider clearance to prevent heat buildup and damage to the reel and Reel and Bedknife Inspection bedknife. See Figure 8-4. b. High-quality grass with a good moisture content 1.

  • Page 304: Bedknife-To-Reel Clearance Adjustment

    CUTTING UNITS Bedknife-to-Reel Clearance Adjustment See Figures 8-5 and 8-6.  Decrease Increase CAUTION Clearance Clearance To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.

  • Page 305: Height-Of-Cut (Hoc) Adjustment

    CUTTING UNITS Height-of-Cut (HOC) Adjustment 8. Repeat steps 2 through 7 on opposite end of front roller (7). See Figure 8-7. 9. Recheck each end with height-of-cut bar and  readjust as necessary. CAUTION NOTES To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.

  • Page 306: Down Pressure Adjustment

    CUTTING UNITS Down Pressure Adjustment Grass Shield Adjustment See Figure 8-8. See Figure 8-9.  1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 1.
  • Page 307 CUTTING UNITS Reel Bearing Pre-Load Adjustment See Figures 8-10 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Back the bedknife away from reel. (See “Bedknife-to-Reel Clearance Adjustment” on page 8-18.) MAR0321 Figure 8-10 3. Remove two screws (1), two lock washers (2), and counterweight (3).

  • Page 308: Repair

    CUTTING UNITS Repair Lift Yoke Removal and Installation Cutting Unit See Figure 8-12. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) See Figure 8-11. 2. Remove cutting unit from mower. (See “Cutting Unit” 1.

  • Page 309: Lift Arms

    CUTTING UNITS Lift Arms Spring Arms Removal and Installation Removal and Installation See Figure 8-13. See Figure 8-14. NOTE NOTE Front right lift arm is shown; all other lift arms are similar. Front right spring arm is shown; all other spring arms are similar.

  • Page 310: Motor Shields

    CUTTING UNITS Motor Shields Reel Drive Motor Removal and Installation Removal and Installation See Figure 8-15. See Figure 8-16. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Motor shields are only installed on the left front reel and 2.
  • Page 311 CUTTING UNITS Disassembly, Inspection, and Assembly See Figures 8-17 and 8-18. MAR0326 Mount O-Ring Upper Seal Anti-Extrusion Ring Rear Cover Snap Ring Thrust Plate O-Ring Washer (4) Shaft Seal Gear Set Dowel Pin (4) Retaining Screw (4) Front Cover Thrust Plate Body Anti-Extrusion Ring Seal...
  • Page 312 CUTTING UNITS 5. Inspect seal kit components (1, 2, 3, 5, 6, 10, 11, 12, and 15) and front cover (4) for cracks, nicks, burrs, and excessive wear. Inspect surfaces for scoring, galling, and scratches. Replace as necessary. 6. Inspect remaining reel drive motor components for excessive wear or damage.

  • Page 313: Grass Shield

    CUTTING UNITS Grass Shield Bedknife Backing Assembly Removal and Installation Removal See Figure 8-19. See Figure 8-20. 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 314 CUTTING UNITS Installation NOTES See Figure 8-21. • Do not over tighten slotted nut (10) during installation. Over tightening the slotted nut will make Required Materials it more difficult to turn the bedknife adjustment rod (1) during bedknife-to-reel adjustment. Anti-Seize Compound •...

  • Page 315: Bedknife Adjustment Assembly

    CUTTING UNITS Bedknife Adjustment Assembly Assembly See Figure 8-23. Disassembly See Figure 8-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-22.) 10 9 3. Place cutting unit on a solid work surface. 4.

  • Page 316: Bedknife

    CUTTING UNITS Bedknife 9. Install bedknife adjustment gear (7) with embossed ring on bedknife adjustment gear facing toward compression spring (4). Be sure bedknife adjustment Removal and Installation gear is positioned against the shoulder of the See Figure 8-24. bedknife adjustment rod (1). NOTE 10.

  • Page 317: Reel Bearing Housing Assembly

    CUTTING UNITS Reel Bearing Housing Assembly Bedknife Specifications Bedknife Front Face Height 0.035 (0.9) Removal and Installation—Drive Side in. (mm) (Minimum) See Figures 8-25 and 8-26. Bedknife Front Face Angle degrees Bedknife Top Face Angle 8–10 degrees Required Tools or Equipment (Rear Relief) •...
  • Page 318 CUTTING UNITS Installation Notes Disassembly and Assembly • Inspect bearing cone (9) for wear or damage. See Figure 8-27. Replace as needed. • Pack bearing cone (9) with grease that meets or exceeds NLGI Grade 2 LB specifications before assembly. MAR0316 Bearing Cup and Cone Grease Fitting...
  • Page 319 CUTTING UNITS Removal—Non-Drive Side 12. Disengage reel bearing housing (15) from reel shaft using reel bearing housing puller (14) (Jacobsen PN See Figure 8-28. JAC5085). Then rotate reel bearing housing (15) to align grease fitting with the clearance hole in the Required Tools or Equipment frame, and remove reel bearing housing.
  • Page 320 CUTTING UNITS Installation—Non-Drive Side See Figure 8-30. MAR0319 Figure 8-30 1. Install reel bearing housing assembly (15). 2. Install spring (13) and nut (12). 3. Tighten adjuster nut (12) until the spring (13) is completely collapsed and the bearing is seated on the shaft, then back the nut out 2–3 turns, or until there is 0.040 in.

  • Page 321: Reel Assembly

    CUTTING UNITS Reel Assembly Installation Notes • Install reel assembly by reversing the order of Removal and Installation removal. • Adjust reel bearing pre-load. (See “Reel Bearing See Figure 8-31. Pre-Load Adjustment” on page 8-21.) 1. Park the mower safely. (See “Park Mower Safely” on •...

  • Page 322: Front Roller

    CUTTING UNITS Front Roller Front Roller Bearings Removal and Installation Removal See Figure 8-32. See Figure 8-33. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.

  • Page 323: Rear Roller

    CUTTING UNITS Rear Roller 4. Using a suitable press, install new outer seal (5) with the lip facing the inside. Removal and Installation 5. Install lock nut (6). Do not tighten lock nut. 6. Press one bearing (4) onto the other end of roller See Figure 8-34.

  • Page 324: Rear Roller Bearings

    CUTTING UNITS Rear Roller Bearings Installation NOTES Removal • Clean and inspect bearings for wear or damage. See Figure 8-35. Replace if necessary. 1. Park the mower safely. (See “Park Mower Safely” on • Pack bearings (3) with grease that meets or exceeds page 1-6.) NLGI Grade 2 LB specifications prior to installation.
  • Page 325 Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Component Location .

  • Page 326: Specifications

    ACCESSORIES AND MISCELLANEOUS REPAIR Specifications ROPS Mounting Hardware Mounting Hardware Torque 65 (88) lb-ft (N·m) Fuel Tank Capacity 7.6 (28.7) gal (L) Front Tires Size 22 x 12-12 Type 4-Ply Treaded or 4-Ply Smooth Air Pressure 16 (1.1) psi (bar) Mounting Bolt Torque 85–90 (115–120) lb-ft (N·m)
  • Page 327 ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 9-1. MAR0369 ROPS (Roll Over Protective Structure) Hood Right Side Fender Seat Assembly Left Side Fender Fuel Tank Rear Wheel (1 or 2) Traction Pedal Front Wheel (2) Figure 9-1 673831-Rev A...

  • Page 328: Repair

    ACCESSORIES AND MISCELLANEOUS REPAIR Repair Hood Removal and Installation ROPS See Figure 9-3. Removal and Installation 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.) 12 13 12 13...

  • Page 329: Fuel Tank

    ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes 6. Remove fuel tank cap (1). Use a siphon pump to drain fuel into a suitable container • Support the hood with a suitable lifting device to aid in installation. 7. When fuel tank is completely empty, assemble and tighten fuel cap.
  • Page 330 ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Disassembly and Assembly See Figure 9-5. 24 25 MAR0353 Traction Cable Screw Washer (4) Nut (2) Bracket Bushing (2) Washer (3) Flange Nut (4) Pedal Switch Screw (4) Jam Nut Forward Pedal Grip Washer (8) Rod End Forward Stop Screw Reverse Pedal Grip...
  • Page 331 ACCESSORIES AND MISCELLANEOUS REPAIR Mow/Transport Speed Lever 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) Removal and Installation 2. Remove the mow/transport speed lever. (See “Mow/Transport Speed Lever” on page 9-7.) See Figure 9-6. 3. Disconnect mow speed switch (29) from mower 1.

  • Page 332: Armrest

    ACCESSORIES AND MISCELLANEOUS REPAIR Armrest Removal and Installation See Figure 9-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove instrument panel. (See “Instrument Panel” on page 4-64.) MAR0355 MAR0356 Figure 9-7 Figure 9-8 3. Remove two screws (1) and cover (2). 1.

  • Page 333: Seat Assembly

    ACCESSORIES AND MISCELLANEOUS REPAIR Seat Assembly 7. Using a suitable lifting device, remove seat assembly from the machine. Removal and Installation 8. Remove four screws (2)and washers (3). Lift the seat (28) off the seat support (15). See Figure 9-9. 9.

  • Page 334: Operator Platform

    ACCESSORIES AND MISCELLANEOUS REPAIR Operator Platform Removal and Installation See Figures 9-10 through 9-11. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove steering column. (See “Steering Column” on page 7-8.) 3. Remove seat assembly. (See “Seat Assembly” on page 9-9.) 4.

  • Page 335: Rear Wheels

    ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheels Front Wheels Removal and Installation Removal and Installation See Figure 9-12. See Figure 9-13. 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 336: Chassis

    ACCESSORIES AND MISCELLANEOUS REPAIR Chassis Removal and Installation See Figures 9-14 through 9-19. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove the cutting units. (See “Cutting Unit” on page 8-22.) 3. Remove the front and rear lift arms. (See “Lift Arms” on page 8-23.) 4.
  • Page 337 ACCESSORIES AND MISCELLANEOUS REPAIR 13 14 MAR0362 Figure 9-16 31. Remove four screws (12), four lock washers (13), MAR0360 four flat washers (14), drain manifold (15) and Figure 9-18 junction block (16). 35. Remove four screws (34) and AV washer (35). 36.
  • Page 338 ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes Disassembly and Assembly Install the chassis components by reversing the order of See Figure 9-20. removal. TN2113 Left Side Chassis Rail M10 x 25 mm Screw (2) M12 Flange Nyloc Nut (30) Left Inside Chassis Rail Right Side Chassis Rail Washer (2) M12 x 30 Screw (30)
  • Page 339 INDEX INDEX Alternator Brush Holder Inspection ....4-77 Disassembly and Assembly ... . 4-76 Rectifier Inspection ....4-78 Numerics Removal and Installation .
  • Page 340 INDEX Checks and Adjustments Bedknife-to-Reel Clearance ... . . 8-18 Bedknife-to-Reel Clearance Adjustment . . . 8-18 Deck Valve Cutting Units ......8-17 Disassembly, Inspection, and Assembly .
  • Page 341 INDEX Engine Oil Pressure Switch Front Mow Solenoid Coil Removal and Installation ....4-72 Removal and Installation ....4-70 Repair .
  • Page 342 INDEX Fuse Hydraulics Component Location ....6-7 Test ....... 4-53 Field Test Procedures .
  • Page 343 INDEX Instrument Test Procedures Lift Cylinders Removal and Installation ....6-59 3WD System Test ....5-31 4WD System Test .
  • Page 344 INDEX Mechanical Troubleshooting Outer Roller Bearing—Inner Race Installation Tool Troubleshooting ..... . 8-16 Front Wheel Motor ....5-48 Miscellaneous Symbols Outer Roller Bearing—Outer Race Installation Tool Component Symbols .
  • Page 345 INDEX Rear Backlap Solenoid Coil Reel Drive Motor Disassembly, Inspection, and Assembly . . 8-25 Removal and Installation ....4-72 Repair ......4-72 Removal and Installation .
  • Page 346 INDEX Repair Mow/Transport Speed Lever ... . . 9-7 Muffler and Exhaust Assembly ... 3-7 3WD Option Rear Yoke ....7-25 3WD Option Steering Cylinder .
  • Page 347 INDEX Schematic, Hydraulic Backlap Circuit ..... . 6-22 Lift Circuit ......6-14 Safety Lower Circuit .
  • Page 348 INDEX Starter Motor Armature Inspection ....4-81 Brush Holder Inspection ....4-80 Test Clutch Inspection .
  • Page 349 INDEX Theory of Operation and Sub Circuit Schematics Troubleshooting Charging Circuit ..... 4-47 Electrical ......4-12 Cutting Units .
  • Page 350 INDEX IX-12 673831-Rev A...
  • Page 352 A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. When Performance Matters. ™ Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

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