To change the hydraulic filter and fluid on a Textron Turfcat 600 Series 628D:

1. Drain the hydraulic oil from the tank by removing the drain plug.
2. Replace the hydraulic oil filter.
3. Reinstall the drain plug.
4. Fill the hydraulic tank with recommended hydraulic oil (Jacobsen 10W30 or GreensCare 68 for biodegradable use). The tank holds 6.8 U.S. gallons (25.7 liters).
5. Connect the recovery tank hose to the radiator filler neck.
6. Connect the air cleaner intake hose to the bulkhead.
7. Start the engine and check for component operation and hydraulic leaks.
8. Inspect the oil for contamination (water, air, or debris) and replace components or oil if needed. Always use clean oil and a clean system.

This answer is automatically generated

Summary of Contents for Textron Jacobsen Turfcat 600 Series

Page 1 Technical Repair Manual Hydraulic Drive Models 600 Series Turfcat 700 Series Frontline...
Page 3 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS AND TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS...
Page 5 SECTION 1 INTRODUCTION General Information ............................1 Contents ..............................1 Index Numbers............................1 Replacement Parts........................... 1 California Proposition 65 Warning......................2 Specifications ............................2 Serial Numbers ............................4 General Cleaning ............................. 4 Safety ............................... 4 Torque Values ............................5...
Page 7 INTRODUCTION SECTION 1A. GENERAL INFORMATION CONTENTS Where the sequence of procedures is not important or self-evident (e.g. linkages, hoses, clamps, etc.) index This manual contains repair instructions for major trac- numbers are not included. tor components, attachments, and options. The Table Repair procedures for items not subject to wear (e.g.
Page 8 60 in rear discharge Number of blades & size per deck ......(3) ® ....0.25 in (6.4 mm) thick x 21 in (533 mm) long A Textron Company Blade tip speed ...... 12744 ft/min (4189 m/m) CHARLOTTE, NC MADE IN U.S.A.
Page 9 INTRODUCTION Weights Deck material thickness ..10 gauge 0.135 in (3.4 mm) Height of cut range....1-4.75 in (25.4-121 mm) Tractor only 60 in Flail 2WD ...........1440 lbs (653 kg) Number of blades............ 144 4WD ...........1490 lbs (676 kg) Blade speed ......8042 ft/min (2451 m/m) Deck material thickness ..
Page 10 INTRODUCTION SERIAL NUMBERS WARNING See Figure 1A-2 for location of tractor assembly serial number. Hazards or unsafe practices which could result in severe personal injury or death. Serial No. Plate On Right Side of Frame CAUTION Hazards or unsafe practices which may result in per- sonal injury, or product or property damage.
Page 11 INTRODUCTION TORQUE VALUES Torque values are given in the “Torque Specifications Chart.” Special torque values are called out in illustra- tions and text throughout this manual. Torque Specifications – Standard AMERICAN NATIONAL STANDARD FASTENERS SIZE UNITS GRADE 5 GRADE 8 Lubricated Lubricated #6-32...
Page 12 INTRODUCTION Torque Specifications – Metric METRIC FASTENERS Critical 10.9 12.9 SIZE UNITS Fasteners into Aluminum Lubricated Lubricated Lubricated Lubricated – – – – – – 3.83 5.11 (in-lb) (34) (45) (18) 1.80 2.40 4.63 6.18 6.63 8.84 7.75 10.3 (in-lb) (16) (21) (41)
Page 13: Table Of Contents
CONTROLS SECTION 2 CONTROLS Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 Control Adjustments ............................5 General ..............................5 Throttle ..............................5 Neutral Switch ............................6 Traction Pedal Neutral Adjustment......................6 Maximum Transport Speed ........................
Page 14 CONTROLS...
Page 15: Service Tools, Materials, And Specifications
CONTROLS SECTION 2A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning materials: Detergent and water Refer to Section 11 Lubricants: SPECIFICATIONS Traction Pedal Transport speed ......10 mph (16.1 km/h) Throttle Parking Brake Engine low idle speed ........
Page 16 CONTROLS 2A-2...
Page 17: Failure Analysis
CONTROLS SECTION 2B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Engine does not turn over a. Not in neutral a.
Page 18 CONTROLS 2B-4...
Page 19: Control Adjustments
CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GENERAL THROTTLE Repair of controls is limited to adjustment of linkages Located to the right of the operator’s seat, the throttle and cables, straightening of bent rods, or replacement. control is used to regulate engine rpm. Replace a worn Replace, do not adjust, worn or damaged components.
Page 20: Neutral Switch
CONTROLS NEUTRAL SWITCH Neutral Adjustment 1. Disconnect the control cable swivel joint from the The neutral switch is located on the traction pedal and traction pedal (Figure 2C-3). is controlled by the pedal latch. The switch is normally closed and should have continuity when the pedal latch is released and open when the latch is pressed.
Page 21: Maximum Transport Speed
CONTROLS PARKING BRAKE 4. Once obtained, hold the adjusting nut with a wrench and tighten the jam nut against the adjust- ing nut to lock the adjustment in place. Adjust the parking brake (Figure 2C-6) after replacing or servicing the brake assembly, or if pedal travel 5.
Page 22: Brake Interlock Switch
CONTROLS 5. Pull the linkage away from the pedal until the other wire will only have current available when brake shoes just contact the brake drum the parking brake is depressed. (Figure 2C-8). Thread the end yoke onto the link- Engage the parking brake and adjust the brake switch age rod until there is a 0.75 - 1.0 in of free pedal as required to close the contacts when the pedal is...
Page 23: Gauges And Instruments
CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS REPAIR 2. Label the wires for proper identification and dis- connect wiring. NOTE: 3. Remove the attached hardware and replace the Refer to Section 10 for test and repair procedures component. of switches. 4. Using the labels created in Step 2, install the hard- Instrument repair is limited to replacement of the com- ware and connect the wiring.
Page 24 CONTROLS 2D-10...
Page 25 ENGINE SECTION 3 ENGINE Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 General Instructions............................5 Contents ..............................5 Cleaning ..............................5 Engine................................7 General ..............................7 Engine Belt............................... 7 Engine Oil..............................
Page 26 ENGINE...
Page 27: Service Tools, Materials, And Specifications
ENGINE SECTION 3A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning Detergent and water materials: Anti-Seize Refer to Section 11 Lubricants: Compressed air source Other service Engine hoist items: SPECIFICATIONS Fuel System Fuel restriction at supply pump at high idle speed ..
Page 28 ENGINE 3A-2...
Page 29: Failure Analysis
ENGINE SECTION 3B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Engine will not start a. Parking brake disengaged or a.
Page 30 ENGINE 3B-4...
Page 31: General Instructions
ENGINE SECTION 3C. GENERAL INSTRUCTIONS CONTENTS NOTE: Testing of the alternator, starter, and fuel solenoid A Kubota three cylinder, diesel engine is used in the are included in Section 10. If the components are Turfcat 600 Series Mower. The Kubota D1105-EB liquid faulty, refer to the engine manufacturer’s manual cooled engine is used for all mower operations.
Page 32 ENGINE 3C-6...
Page 33: General
ENGINE SECTION 3D. ENGINE GENERAL 1. Adjust the alternator drive belt to deflect 0.25 to 0.31256 in (6 to 8 mm) with a force of 20 lbs. Push An engine operator’s manual, prepared by the engine at the midpoint between pulleys (Figure 3D-1). manufacturer is supplied with the machine.
Page 34: Engine Oil
ENGINE ENGINE OIL Use engine oils with API classification CD/CE. Check the engine oil each day before starting the Ambient Temperature Oil Weight engine. If the oil level is low, remove the oil filler cap and add oil as required (Figure 3D-3). Above 77°F (25°C) SAE 30W or SAE 10W30/10W40...
Page 35: Radiator Service
ENGINE During normal maintenance inspections or when the 3. Inspect the air inlet and intake hoses for wear and engine indicates a possible air filter restriction, clean damage, replace all damaged hoses. Ensure the the outside of the air cleaner assembly, and gently hose clamps secure the hoses without leaks.
Page 36 ENGINE Changing Coolant 5. Install the radiator cap and start the engine follow- ing the instructions in the Safety & Operation man- 1. Shut down the engine and remove the ignition ual. key. Allow the engine to cool completely. 6. The engine allows air to circulate through the radi- 2.
Page 37 ENGINE Hydraulic Oil Cooler Radiator Core Coolant Reservoir Hose Figure 3D-8. Radiator, Hydraulic Oil Cooler, and Dust Screen Removal 3. Remove the dust screen (Figure 3D-8). 4. Disconnect the coolant reservoir hose at the radia- 1. Shut down the engine and remove the ignition tor overflow outlet.
Page 38: Exhaust System
ENGINE 5. Fill with a 50/50 mixture of ethylene glycol base Fresh Air Intake Hose Shroud antifreeze and clean fresh water. 6. Carefully inspect the radiator cap for wear and damage, replace if necessary. Install the radiator cap on the radiator. 7.
Page 39: Fuel System
ENGINE FUEL SYSTEM The fuel system includes the fuel tank, inline fuel filter, mechanical fuel pump, fuel/water separator, and engine injection system (Figure 3D-12). Primer Fuel/Water Injection Pump Injection Button Separator Vent Air Vent Pump Figure 3D-10. Exhaust System Exploded View Clamp Bowl Inline...
Page 40 ENGINE 3. Loosen the filter clamp ring. WARNING 4. Loosen the fuel filter hose clamps. 5. Remove the fuel line from the filter. Immediately Never remove the fuel cap from the fuel tank or add plug the hose to prevent contamination. fuel when the engine is running or hot.
Page 41 ENGINE 16.Open the drain valve on the bottom of the fuel/ Primer water separator. Vent Button 17.Operate the primer lever on the fuel pump to fill the fuel/water separator with fuel (Figure 3D-15). When fuel begins to flow from the fuel/water sepa- rator bowl close the drain valve.
Page 42: Engine Removal
ENGINE 20.Operate the primer button on top of the fuel/water 6. Drain the fuel tank. separator to fill the fuel lines with fuel. 7. Disconnect the fuel outlet hose from the fuel tank 21.Allow fuel to flow from the injection pump vent until to the inline filter.
Page 43: Engine Installation
ENGINE Drive Coupler/ Traction Pump Traction Pump Frame Support Engine Support Bell Housing Mounting Bolts Figure 3D-21. Lower Rear Engine Support Figure 3D-19. Traction Pump Mounting 16.Remove one bolt, nut, and flat washer on both sides of the engine at the engine support frame. 14.Using an engine hoist, support the engine and Swing the engine support down and away from remove the lower front engine mounting bolts...
Page 44 ENGINE 6. Reconnect the wiring harness to the fuel solenoid, 11. Remove any fuel outlet hose plugs and connect starter, oil sender, coolant temperature sender, the fuel outlet hose from the fuel tank to the inline and alternator. Reattach the wiring harness and filter.
Page 45 ENGINE Radiator Hoses Alternator Throttle Cable and Clamp Exhaust Fuel Filter and Traction Pump Engine Mount Air Cleaner Fuel/Water Separator Battery Figure 3D-22. Engine Components 3D-19...
Page 46 ENGINE 3D-20...
Page 47 DRIVE TRAIN SECTION 4 DRIVE TRAIN Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 Drive System Repairs and Adjustments ......................5 General ..............................5 Drive System ............................5 Hydrostatic Pump Coupling........................
Page 48 DRIVE TRAIN...
Page 49: Drive Train
DRIVE TRAIN SECTION 4A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning materials: Detergent and water Refer to Section 11 Lubricants: 242 Blue Loctite Other service items: 290 Green Loctite SPECIFICATIONS Front Axle Wheel motor mounting bolt torque ..65 ft-lbs (88 Nm)
Page 50 DRIVE TRAIN 4A-2...
Page 51: Failure Analysis
DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Heavy impact or “bang” a. Drive coupling worn or loose a.
Page 52 DRIVE TRAIN 4B-4...
Page 53: Drive System Repairs And Adjustments
DRIVE TRAIN SECTION 4C. DRIVE SYSTEM REPAIRS AND ADJUSTMENTS GENERAL Repair of the hydrostatic drive pump is limited to adjustment of linkages and cables, tightening of fasten- ers, and repair or replacement of components. Replace, do not adjust worn or damaged components. WARNING To prevent injury, lower implements to the ground, disengage all drives, engage parking brake, stop...
Page 54: Hydraulic Wheel Motors
DRIVE TRAIN 4. Install the hydrostatic pump onto the engine bell 2. Install the brake adaptor plate onto the wheel housing. Torque retaining bolts to 60 ft-lbs (81 motor and apply 290 Loctite on bolts and torque Nm). the retaining bolts to 18 ft-lbs (24 Nm). 3.
Page 55 BRAKE SYSTEM SECTION 5 BRAKE SYSTEM Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 Parking Brake ..............................5 General ..............................5 Linkage..............................5...
Page 56 BRAKE SYSTEM...
Page 57: Brake System
BRAKE SYSTEM SECTION 5A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning materials: Refer to Section 11 Lubricants: Brake shoes Other service items: SPECIFICATIONS Adapter plate mounting bolt torque** ..18 ft-lbs (24 Nm) Brake assembly mounting bolt torque* ......
Page 58 BRAKE SYSTEM 5A-2...
Page 59: Failure Analysis
BRAKE SYSTEM SECTION 5B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Parking brake does not hold a. Brake is misadjusted a.
Page 60 BRAKE SYSTEM 5B-4...
Page 61: General
BRAKE SYSTEM SECTION 5C. PARKING BRAKE GENERAL LINKAGE The brake system used on the TurfCat 600 series is a The brake linkage (Figure 5C-1) is connected between mechanical drum brake system actuated by a left and the brake pedal and the actuating lever. When pushed, right brake linkage.
Page 62 BRAKE SYSTEM Disassembly 2. Inspect the brake shoes, holder springs, holder pins, and tension springs for wear and distortion. 1. Using a suitable jack, lift the front wheels off the Replace as necessary (Figure 5C-3). ground. Support the tractor with jack stands. Upper Tension Holding Holding...
Page 63 BRAKE SYSTEM 4. Install the rod linkage and return spring. 2. Use a tape measure to gauge the free travel movement. 5. Adjust the parking brake as needed. 3. Use the rod end coupling nut to adjust the free 6. Lift the tractor and remove the jack stands. travel and actuating lever position.
Page 64 BRAKE SYSTEM 5C-8...
Page 65 STEERING SECTION 6 STEERING Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................2 Failure Analysis .............................. 3 General ..............................3 Steering Unit ..............................5 General ..............................5 Removal ..............................5 Steering Valve Disassembly ........................7 Steering Valve Inspection ......................... 9 Steering Valve Assembly..........................
Page 66 STEERING...
Page 67: Service Tools, Materials, And Specifications
STEERING SECTION 6A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning materials: Refer to Section 11 Lubricants: 6 pieces 0.007 in (0.18 mm) shim stock, 0.5 in (13 Other service mm) wide and 1.5 in (38 mm) long items: Portable hydraulic filtering unit...
Page 68: Specifications
STEERING SPECIFICATIONS Steering Axle Rear wheel toe-in ..0.625 to 0.125 in (1.6 to 3.2 mm) Steering Valve Torques Relief valve pressure ......1000 psi (69 bar) Steering circuit flow ..5.5 gpm @ 3000 rpm (20 lpm) Steering valve cover nuts ..22 to 24 ft-lbs (30 to 32 Nm) Steering cylinder - axle bolt ...........
Page 69: Failure Analysis
STEERING SECTION 6B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Noisy when steering wheel is a. Low hissing sound a.
Page 70 STEERING PROBLEM PROBABLE CAUSE REMEDY 7. No steering a. Inlet filter blocked a. Change filter b. Steering relief stuck open b. Test (Section 8L) c. Steering unit excessive inter- c. Test (Section 8L) nal leakage d. Steering cylinder faulty d. Test (Section 8L) e.
Page 71: General
STEERING SECTION 6C. STEERING UNIT GENERAL REMOVAL The power steering unit uses hydraulic flow produced NOTE: by the charge pump in the traction pump. A pressure The following steps reference Figure 6C-2 unless relief valve located in the traction pump protects the otherwise noted.
Page 72 STEERING Figure 6C-2. Steering Unit 6C-6...
Page 73: Steering Valve Disassembly
STEERING STEERING VALVE DISASSEMBLY 1. Place the power steering service fixture securely in a vise (Figure 6A-1). NOTE: 2. Remove the nuts (1) and cover (2). Before attempting repairs or disassembly of any hydraulic components, thoroughly clean the com- 3. Remove the nine needle rollers (5). ponents and work area.
Page 74 STEERING Figure 6C-3. Steering Valve Exploded View NOTE: The metering package should be disassembled for inspection purposes only. Proceed with STEP 9 for disassembly and inspection proce- dures. NOTE: The following steps reference Figure 6C-4 unless otherwise noted. 9. Remove the socket head capscrews (1), commu- tator cover (2), commutator ring (3), and commu- tator (4).
Page 75: Steering Valve Inspection
STEERING NOTE: The following steps reference Figure 6C-3 unless otherwise noted. 12.Remove the face seal (20) and seal spacer (22). 13.Remove the thrust bearing (19) and spacer (18). 14.Remove the upper cover plate (23) and retaining ring (24). 15.Remove the special bolts (25). 16.Remove the steering shaft (26) out of tube (27).
Page 76 STEERING 8. Place the stator (8) on the drive plate (9) and 15.Place a 0.007 in (0.18 mm) shim shock, 0.5 in (13 insert the rotor (7) into the stator. mm) wide by 1.5 in (38 mm) long in three places, equal distance apart, between the metering ring 9.
Page 77 STEERING Figure 6C-6. Steering Valve Assembly 22.Place the isolation manifold (13) on the metering 24.Install the valve plate (9) as shown (closed cylin- ring (15) with the alignment pin holes up. Install der up) in the valve ring (8), aligning the spring the alignment pins (12).
Page 78 STEERING Figure 6C-7. Metering Package Assembly 27.Install the o-rings (4) and seal ring (3) on the port cover (2). 28.Install the needle rollers (5) in the port manifold (6). 29.Install the port manifold (6). 30.Install the lock nuts (1). Tighten the lock nuts grad- ually in sequence to 20-24 ft-lbs (27-33 Nm) torque (Figure 6C-8).
Page 79: Installation
STEERING INSTALLATION 1. Place the steering valve in the steering unit bracket with the four studs protruding through the bracket. 2. Install the steering unit column, mounting nuts, and steering column clamp. 3. Install the steering wheel. 4. Align the steering wheel with the column hole and install the roll pin.
Page 80 STEERING 6C-14...
Page 81 STEERING SECTION 6D. STEERING CYLINDER GENERAL REMOVAL The steering cylinder is attached to the steering axle 1. Shut down the engine and remove the ignition between the right side of the axle and the left steering key. arm. The steering cylinder is actuated using hydraulic 2.
Page 82 STEERING DISASSEMBLY 5. Remove the rod guide from the rod assembly. 6. Place the rod in a soft jaw vise or place wooden blocks between the vise jaws and rod. WARNING 7. Remove the piston nut. NOTE: Use appropriate eye protection when using com- pressed air for cleaning or drying purposes.
Page 83 STEERING Figure 6D-3. Steering Cylinder ASSEMBLY 4. Replace the piston seals and backup rings. 5. Position the piston on the rod and secure with the 1. Clean all components thoroughly. piston nut. Place the rod assembly in a soft jaw vise or place wooden blocks between the vise 2.
Page 84 STEERING 7. Lubricate the inside of the barrel with clean 8. Push the rod guide down into the barrel and clear hydraulic oil. Install the rod assembly and rod of the lock ring groove (Figure 6D-4). guide carefully into the barrel. Figure 6D-4.
Page 85 STEERING SECTION 6E. STEERING AXLE ADJUSTMENT STEERING ADJUSTMENTS 1. Turn the wheels to the straight ahead position. 2. Loosen the jam nuts (Q) on both sides of the tie rod (R) (Figure 6E-1). 3. Turn the tie rod (R) to provide proper toe-in. Toe-in must not exceed 0.0625 in (1.5 mm) (S).
Page 86 STEERING 6E-20...
Page 87 WHEELS AND TIRES SECTION 7 Section 7 WHEELS AND TIRES Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 Tire Service..............................5 General ..............................5 Service ..............................5...
Page 88 WHEELS AND TIRES...
Page 89 WHEELS AND TIRES SECTION 7A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: Stoddard solvent or equivalent Cleaning materials: Refer to Section 11 Lubricants: Commercial tire sealant Other service items: Tire pressure gauge Compressed air source with inflation tool SPECIFICATIONS Tire Size Front..........
Page 90 WHEELS AND TIRES 7A-2...
Page 91 WHEELS AND TIRES SECTION 7B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Tractor rides hard a. Over-inflated tires a.
Page 92 WHEELS AND TIRES 7B-4...
Page 93 WHEELS AND TIRES SECTION 7C. TIRE SERVICE GENERAL reduce the tire pressure to the desired level for opera- tion (Figure 7C-1). The tires are subject to damage from sharp objects. If NOTE: large punctures or tears occur, take the tire (on the Never use grease or oil on the wheel rim when wheel) to a qualified tire repair shop.
Page 94 WHEELS AND TIRES 7C-6...
Page 95 HYDRAULICS SECTION 8 HYDRAULICS Repair, Service Tools, and Materials ......................1 Materials Required ........................... 1 Specifications ............................3 Failure Analysis .............................. 5 General ..............................5 General Instructions............................7 General ..............................7 Hydraulic Tube and Hose Fittings ......................7 37° Flare Fittings ............................8 Hose Installation Instructions ........................
Page 96 HYDRAULICS Disassembly............................49 Inspection............................... 49 Assembly..............................49 Installation .............................. 50 Hydraulic Oil Cooler............................51 General ..............................51 Removal ..............................51 Installation .............................. 51 Hydraulic Field Test Procedures ........................53 General ..............................53 Safety Reminder ............................ 53 Preliminary Checks ..........................53 Charge Pump Test ..........................
Page 97 HYDRAULICS SECTION 8A. REPAIR, SERVICE TOOLS, AND MATERIALS MATERIALS REQUIRED Standard automotive hand tools, including torque wrench, seal drivers, snap ring pliers, and bearing driver Hydraulic fitting and gauge kit (#JAC5001A) Tachometer Hydra sleuth or in-line tester equipped with load valve Tools required: (#JAC5095) Wheel restraint (Figure 8A-2)
Page 98 HYDRAULICS Figure 8A-2. Wheel Restraint 8A-2...
Page 99: Steering Cylinder
HYDRAULICS SPECIFICATIONS Hydraulic System Implement Pump (Deck Drive) Capacity ......6.8 US gallons (25.7 liters) Displacement ......1.01 cu. in/rev. (16.6 cc) Hydraulic fluid (standard) ....Jacobsen 10W30 Flow @ 3150 rpm......13.7 gpm (51.8 lpm) ............... hydraulic fluid Maximum allowable leakage Hydraulic fluid –...
Page 100 HYDRAULICS 8A-4...
Page 101: General
HYDRAULICS SECTION 8B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. System noisy a. Oil cold a. Let oil warm up b.
Page 102 HYDRAULICS PROBLEM PROBABLE CAUSE REMEDY 6. No steering a. Faulty charge pump a. Test charge pump (Section 8L and Section 8M) b. Faulty implement relief valve b. Perform implement relief test in hydro (Section 8M) c. Faulty steering valve c. Perform leakage test (Section 8M) d.
Page 103 HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS GENERAL • Do not force components together or pry apart. Light tapping with a plastic mallet is recommended unless NOTE: otherwise specified in the repair instructions. Component location illustrations and hydraulic • Unless otherwise indicated, apply a light coat of system diagrams are located at the end of this clean hydraulic...
Page 104 HYDRAULICS 37° FLARE FITTINGS Table 8C-2: Rotation of Hex Screws Tube O.D. or Hose I.D. Rotate No. of Hex Flats Torque Recommendations 3/8” 1. Assemble the tube nut adapter to the fitting with a 1/2” minimum torque (finger tight) until the flare con- 5/8”...
Page 105 HYDRAULICS O-rings should be lubricated with the fluid to be SAE Dash Thread Torque Tube O.D. used in the system prior to assembly Size Size In-lbs (Figure 8C-2). 1 1/16-12 0.750 1500-1620 1 3/8-12 0.875 1920-2160 1 5/16-12 1.000 2400-2640 1 5/8-12 1.250 2520-3360...
Page 106 HYDRAULICS Table 8C-5: Replacement O-Ring for ORS Fittings Table 8C-6: O-Ring Face Seal Torque Recommendations ORS O-Ring Jacobsen ORS Tube Size Size Part No. SAE Dash Thread Torque Tube O.D. Size Size In-lbs 339908 339909 9/16 0.250 120-144 339910 339911 11/16 0.375 216-240...
Page 107 HYDRAULICS SECTION 8D. HYDROSTATIC TRACTION PUMP GENERAL A set of eight pistons and barrel assembly produce pump suction and pressure. The pistons have shoes hydrostatic traction pump (Figure 8D-1) that ride against a swiveling swashblock. By swiveling mounted underneath the seat pan and in front of the the swashblock, the piston stroke is extended on one engine.
Page 108 HYDRAULICS Figure 8D-2. Traction Pump Assembly 8D-12...
Page 109: Removal
HYDRAULICS Figure 8D-3. Traction Pump – Exploded View REMOVAL 3. Unlatch the seat platform. Pivot the seat and seat platform to the full upward position. 4. Thoroughly clean the implement pump and trac- CAUTION tion pump, especially the area surrounding the hydraulic hoses, tubes, and fittings.
Page 110: Disassembly
HYDRAULICS DISASSEMBLY 6. While supporting the traction pump and implement pump, remove the two hex-head mounting bolts and washers (Figure 8D-4). Control Group and Valve Plate Mounting Implement Traction 1. Place traction pump on a workbench with input Bolts Pump Pump shaft down.
Page 111 HYDRAULICS Valve Plate and Gerotor Figure 8D-7. Valve Plate and Gerotor Pump Disassembly 8D-15...
Page 112 HYDRAULICS Rotating Group Figure 8D-8. Rotating Group Disassembly Drive Shaft Group Figure 8D-9. Drive Shaft Group Disassembly 8D-16...
Page 113 HYDRAULICS Swashblock Group 1. Place square end of piston on a bench and hold firmly. See Figure 8D-10 for swashblock group disassembly. 2. Pull on the end of the hose with the other hand and note the end play. A good piston/shoe fit will have no end play with the shoe free to rotate and pivot on the piston ball.
Page 114: Assembly
HYDRAULICS ASSEMBLY Swashblock Position the hydrodynamic bearing in the housing so that the pin is at the 8 o’clock position between protru- sion and pump housing to assure CCW rotation (Figure 8D-12). Figure 8D-12. Swashblock Group Assembly Drive Shaft Group NOTE: When installing the bearing, press on the outer face.
Page 115 HYDRAULICS Rotating Group Assembly NOTE: Do not force pistons into barrel. The pistons Install the shoe retainer with the center curved surface should fit loosely. toward the fulcrum ball (Figure 8D-14). Figure 8D-14. Rotating Group Assembly Valve Plate, Gerotor Pump, Rear Plate Assembly See Figure 8D-15 for valve plate, gerotor pump, and rear plate assembly.
Page 116 HYDRAULICS INSTALLATION Control Group Assembly See Figure 8D-16 for control group assembly. 1. Using a new o-ring lubricated with clean hydraulic oil, position the implement pump on the traction pump and secure with two hex-head cap screws. 2. Place the traction pump/implement pump in the frame, align the traction pump spline shaft and insert to the face of the bell housing (Figure 8D-5).
Page 117: Traction Circuit
HYDRAULICS SECTION 8E. FRONT AND REAR TRACTION MOTORS TRACTION CIRCUIT FRONT TRACTION MOTOR The traction circuit is a parallel/series circuit in which The traction pedal and traction pump control the front the oil being delivered by the hydrostat to the front traction motors.
Page 118: Rear Traction Motor
HYDRAULICS REAR TRACTION MOTOR The traction pedal and traction pump control the rear traction motors. The motor is mounted inside a swivel- ing motor mount, which is mounted to the steering axle with a hub mounted on the output shaft (Figure 8E-3). The hub is used to mount the wheels.
Page 119: Traction Motor Repair
HYDRAULICS TRACTION MOTOR REPAIR Disassembly 1. Scribe an alignment mark down the side of the motor (see Figure 8E-5). Figure 8E-4. Traction Motor Mounting Refer to “Traction Motor Repair” on page 23 for traction motor repair. Installation 1. While supporting the traction motor, install the four mounting bolts, lock washers, and nuts to secure the motor to the motor mount.
Page 120 HYDRAULICS 3. The following disassembly steps include the removal of bearings. If bearings are not to be removed, and only a seal kit is to be installed, omit Steps 10 and 13. Step 3 Step 1 Remove commutator ring (6). Remove special housing bolts (1).
Page 121 HYDRAULICS Step 7 Step 5 Match mark drive link (10) with coupling Remove wear manifold (7). shaft (12); then remove drive link (10). Step 6 Remove rotor (8) as a set. Step 8 NOTE: Do not disassemble. Remove thrust bearing (11). Figure 8E-7.
Page 122 HYDRAULICS Step 11 Step 9 Remove seal (16) and two backup washers (17 and 21), working them around thrust Remove coupling shaft (12). washers and thrust bearing. Step 10 NOTE: To remove thrust bearing (15) and thrust washers (14), bearing (13) must be removed first.
Page 123 HYDRAULICS Step 12 Step 13 Turn housing around. Remove shaft seal (20). CAUTION: If bearing is removed, it must be replaced with a new bearing. Remove bearing (19) using a blind hole puller. Figure 8E-9. Traction Motor Disassembly (4 of 4) 8E-27...
Page 124 HYDRAULICS Inspection 7. Inspect coupling shaft (12, Figure 8E-11), bearing and seal area for galling, nicks, grooves, severe 1. Inspect special bolts (1) for damaged threads or wear, or corrosion and discoloration (heat). seal ring. Inspect for damaged or worn internal and external splines or keyway.
Page 125 HYDRAULICS Step 1 Step 3 NOTE: Pack bearing with grease. Install seal (20) so it is flush with housing. Press bearing (19) into housing using installation tool. Step 4 Step 2 Install backup washers (21 and 17), seal (16) Check bearing depth 0.290 to 0.310” (7.4 to 7.8 mm). (lip facing out).
Page 126 HYDRAULICS Step 5 Step 7 Install new thrust washer (14) and bearing (15). Tape spline of coupling shaft (12) and install. Step 6 Step 8 Press bearing assembly (13) into housing (18) using installation tool. Press to a depth of Check to see that the coupling shaft (12) is 0.105 to 0.125”...
Page 127 HYDRAULICS Step 11 Step 9 Align match marks and install drive link (10), Install thrust bearing (11). with long splined end down, into mesh with coupling shaft (12). Step 10 Step 12 Lightly grease seal ring (4) and install. Install wear plate (9). Figure 8E-14.
Page 128 HYDRAULICS Step 13 Apply a small amount of grease to seal ring (4) and install on rotor set (8). Step 15 Apply a small amount of grease to seal rings Step 14 (4) and install on each side of manifold (7). Install manifold (7) to rotor set (8).
Page 129 HYDRAULICS Step 16 Step 18 Install commutator ring (6). Install commutator (5) in commutator ring (6). Step 19 Step 17 Apply a small amount of grease to seal ring (4) and install on end Install new seal ring (3) to commutator (5). cover (2).
Page 130 HYDRAULICS Step 20 Step 21 Install special bolts (1). Alternately and progressively tighten bolts (1) to a final torque of 45 to 55 ft-lbs (61 to 75 N-m). Figure 8E-17. Traction Motor Reassembly (6 of 6) 8E-34...
Page 131: Four Wheel Drive Rear Wheel Motor Check Valves
HYDRAULICS FOUR WHEEL DRIVE REAR WHEEL MOTOR CHECK VALVES The rear wheel motors on the four-wheel-drive Turfcat are equipped with check valves (Figure 8E-18). The check valves allow the oil to bypass the rear wheel motors when the operator puts the tractor in reverse. The result is four-wheel drive when traveling forward and two-wheel drive when in reverse.
Page 132: Traction Circuit Hot Oil Shuttle Valve
HYDRAULICS TRACTION CIRCUIT The hot oil shuttle spool is opened with oil pressure from the forward circuit of the traction pump and allows SHUTTLE VALVE a certain amount of hot oil to return to the tank from the reverse (return) circuit of the traction pump when trav- The traction drive circuit on the four-wheel-drive Turfcat eling forward.
Page 133 HYDRAULICS DIFFERENTIAL LOCK VALVE Figure 8E-20 shows an adaptation of a portion of the hydraulic diagram from the parts manual showing The differential lock system is intended for use when where the differential lock system is inserted into the one of the front drive wheels slips relative to the other standard hydraulic system.
Page 134 HYDRAULICS 8E-38...
Page 135: General
HYDRAULICS SECTION 8F. IMPLEMENT PUMP GENERAL through a spline shaft direct coupling. The implement pump provides hydraulic pressure for operating the The implement pump is mounted on the rear of the deck motor. Repairs to the implement pump are limited traction pump.
Page 136: Repair
HYDRAULICS 7. Remove the pump and o-ring from the traction 5. Disassemble the remainder of the pump as shown pump (Figure 8F-3). in Figure 8F-1. Inspection 1. Check parts for signs of wear, burrs, scores, nicks, damaged or broken parts. 2.
Page 137 HYDRAULICS 4. Pivot the seat and seat platform to the lower posi- 6. Start engine and check operation. Check for leaks tion for normal operation. Latch into position. and repair as necessary. 5. Replace the hydraulic filter and fill the hydraulic tank with hydraulic oil.
Page 138 HYDRAULICS 8F-42...
Page 139: General
HYDRAULICS SECTION 8G. DECK VALVE GENERAL REPAIR The deck valve is used to control the rotation of the Repair of the deck valve is limited to replacement of deck motor. The valve is mounted under the seat plat- valve components (Figure 8G-2). form (Figure 8G-1).
Page 140: Installation
HYDRAULICS INSTALLATION Deck Hose Connections 1. Position the deck valve on the mounting surface. 2. Install two mounting screws and lock washers (Figure 8G-1). 3. Remove the plugs and, using the tags created during removal, connect the hydraulic hoses to the valve fittings (Figure 8G-3).
Page 141: General
HYDRAULICS SECTION 8H. DECK MOTOR GENERAL and is controlled by the deck control valve. Repairs to the deck motor are limited to replacing seals. The deck motor is mounted on the deck to drive the blades. The motor is driven with the implement pump Figure 8H-1.
Page 142: Installation
HYDRAULICS Reassembly CAUTION 1. Apply a coat of clean hydraulic oil to all parts to ease assembly. Never pry motor sections apart, as damage to seal- 2. Assemble motor one section at a time, building up ing areas can result. Use of a soft face hammer to from flange section (Figure 8H-1).
Page 143: General
HYDRAULICS SECTION 8I. LIFT/LOWER VALVE GENERAL REMOVAL The lift valve is used in conjunction with the charge 1. Shut down the engine and remove the ignition pump and lever to lift and lower the deck. The lift/lower key. valve is a three position non-detent valve that is spring 2.
Page 144 HYDRAULICS 8I-48...
Page 145: General
HYDRAULICS SECTION 8J. LIFT CYLINDER GENERAL DISASSEMBLY The mower uses a single lift cylinder to lift and lower 1. Clean and air dry the exterior of the cylinder. the mowing deck. 2. Drain the oil from the cylinder. REMOVAL 3. Disassemble the lift cylinder (Figure 8J-1). See Section 9E.
Page 146: Installation
HYDRAULICS Figure 8J-2. Seal Kit Installation Figure 8J-3. Lift Cylinder Assembly INSTALLATION See Section 9E. 8J-50...
Page 147: General
HYDRAULICS SECTION 8K. HYDRAULIC OIL COOLER GENERAL 3. Lift the engine cover to allow access to the hydraulic oil cooler inlet and outlet hoses. The hydraulic oil cooler is located directly behind the 4. Disconnect the negative battery cable from the dust screen and radiator.
Page 148 HYDRAULICS 8K-52...
Page 149: Safety Reminder
HYDRAULICS SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES GENERAL 2. Check all lines and fittings for leakage and tighten as necessary. When a hydraulic failure occurs, some simple, effective 3. Eliminate all possible mechanical problems before tests can be performed prior to using a test instrument. starting the hydraulic tests.
Page 150: Lift System Test
HYDRAULICS Front Motor Test Conclusion • If the mark on the cylinder rod is visible, the lift 1. Install wheel restraints on the front wheels and system has normal internal leakage. lock parking brake. • If the mark on the cylinder rod disappears into the 2.
Page 151: Power Steering System Test
HYDRAULICS POWER STEERING SYSTEM TEST the maximum right and/or left, the steering unit is not at fault. The purpose of this test is to determine if the steering • If the steering wheel continues to turn, proceed with cylinder and the steering unit are operating properly the test.
Page 152 HYDRAULICS 8L-56...
Page 153: General
HYDRAULICS SECTION 8M. HYDRAULIC INSTRUMENT TESTS GENERAL CAUTION The tests in this section are provided as a means of isolating problems in the hydraulic system. When using a plug to block a pressure line the plug This section uses two test methods to identify a prob- must be able to withstand the pressure developed in lem or to evaluate a hydraulic circuit.
Page 154: Pressure Tests
HYDRAULICS PRESSURE TESTS 5. Set the parking brake, start the engine, and advance the engine speed to the full throttle posi- The pressure tests are frequently inconclusive in isolat- tion. ing a faulty component. A flow test is recommended for 6.
Page 155 HYDRAULICS Charge Relief Valve 1. Drain the hydraulic fluid from the tank. 2. Remove the charge relief valve plug, spring, and cone (Figure 8M-4). 3. Inspect for debris and damage. Clean or replace as necessary. 4. If the relief valve is not sticking or damaged, install shims to increase pressure or remove shims to decrease pressure.
Page 156 HYDRAULICS • If the implement relief valve pressure is within range 4. Replace the relief valve cartridge or valve body as at high engine rpm and out of range at low engine required. rpm, perform charge pump flow test. 5. Fill hydraulic tank with proper fluid. •...
Page 157 HYDRAULICS Conclusion 8. Pressure should be 3500 psi (172 Bar). • If pressure cannot be obtained in both forward and Traction Circuit Pressure Test (Reverse) reverse directions, perform flow test on hydrostat and leakage test on wheel motors. 9. Install wheel restraints on the front wheels. •...
Page 158 HYDRAULICS Deck Motor Pressure Hose Figure 8M-10. High Pressure Relief Valve 4. Inspect the valve for debris and damage. Inspect the seat in the body for damage. Clean or replace as necessary. 5. Replace the hydraulic fluid in the tank. Deck Relief Valve Test 1.
Page 159: Flow Tests
HYDRAULICS Conclusion 5. Using a socket, remove the relief valve (RV1) from the deck valve. Replace seals or relief valve as • If gauge reading is within specification at both high required. and low idle positions, pump and relief valve are okay.
Page 160 HYDRAULICS Figure 8M-14. Charge Pump, Steering, and Lift Circuit Test 5. Read and record the charge pump no load pres- 7. Subtract flow, Step 6; from the no load flow, Step sure A) and Flow B) on Flow Test Report 1. 6.
Page 161 HYDRAULICS 15.After performing Step 14, hold steady hand pres- Example: sure on steering wheel against the stop and 5.7 GPM Step 5 observe steering wheel rotation. If steering wheel 5.0 GPM Step 6 makes more than 1 revolution in 30 seconds, the steering valve is leaking internally.
Page 162 HYDRAULICS Conclusion 20.At the deck lift/lower lever, hold the lever in the raise position. Read and record pressure reading • If pressures recovered in STEP 20 and matched the K) on Flow Test Report 1. charge pump implement relief valve pressure, lift cylinder is at fault.
Page 163: Flow Test Report 1
HYDRAULICS FLOW TEST REPORT 1 Turfcat Hydraulic Pressure and Flow Record Charge Pump, Steering and Lift Circuit Model:_____________ Serial:____________________ Hours of Use:__________ Date:_______________ Hydraulic oil temperature when test performed _______________ Engine high idle speed _______________ Charge Pump Test A) Step 5 – Charge pump no load pressure (Hydrostat Charge Pressure) _______________ B) Step 5 –...
Page 164 HYDRAULICS Implement Pump Test 7. Slowly close tester load valve until a reading of 2000 psi (138 Bar) is obtained. Read and record 1. Disconnect pressure hose from implement pump flow B) on Flow Test Report 2. (Figure 8M-15). NOTE: 2.
Page 165 HYDRAULICS Figure 8M-15. Implement Pump Test 8M-69...
Page 166 HYDRAULICS Deck Valve Test 10.Make sure blocking disc is removed from the tee fitting on the implement pump (Figure 8M-16). 9. Leave flow meter connected as in the implement 11. Disconnect the pressure hose from the deck pump test (Figure 8M-16). motor (M1 port on deck valve), insert a blocking disc, and reconnect the hose (Figure 8M-16).
Page 167 HYDRAULICS 12.Open the tester load valve, set the parking brake, deck motor is leaking internally while performing start the engine, and advance the engine speed to this test. full throttle. 17.Leave flow meter connected as in the deck valve 13.Engage the front deck. and pump tests (Figure 8M-17).
Page 168 HYDRAULICS Figure 8M-17. Deck Motor Test 8M-72...
Page 169: Flow Test Report 2
HYDRAULICS FLOW TEST REPORT 2 Turfcat Hydraulic Pressure and Flow Record Implement Pump, Deck Valve and Motor Circuit Model:_____________ Serial:____________________ Hours of Use:__________ Date:_______________ Hydraulic oil temperature when test performed _______________ Engine high idle speed _______________ Implement Pump Test A) Step 6 – Implement pump no load flow _______________ B) Step 7 –...
Page 170 HYDRAULICS Traction Circuit Flow Test 6. Connect the OUT ports of the flow meter to the reverse pressure port on the traction pump and NOTE: onto the disconnected reverse traction hose Before performing this test, make sure the tow (Figure 8M-19) valve is closed located on the side of the 7.
Page 171 HYDRAULICS Figure 8M-19. Traction Pump Test 8M-75...
Page 172 HYDRAULICS Traction Motor Test – Left Side age or leaking seals prior to repairing the rear wheel motor. A leaking check valve will affect this Left Front Motor test. 12.Perform traction pump test first and leave flow Left Rear Motor meter hoses connected as outlined in Traction 21.Perform traction pump test first and leave flow Pump Test.
Page 173 HYDRAULICS Figure 8M-20. Traction Motor Test – Left Side 8M-77...
Page 174 HYDRAULICS Traction Motor Test – Right Side 42.Install blocking discs in tee fittings on hydrostat to block oil flow to the left side wheel motors Right Front Motor (Figure 8M-21). 30.Perform traction pump test first and leave flow 43.Install blocking disc on the P and PLT ports on the meter hoses connected as outlined in Traction hot oil shuttle valve (Figure 8M-21).
Page 175 HYDRAULICS Figure 8M-21. Traction Motor Test – Right Side 8M-79...
Page 176: Flow Test Report 3
HYDRAULICS FLOW TEST REPORT 3 Turfcat Hydraulic Pressure and Flow Record Traction Pump and Wheel Motors Model:_____________ Serial:____________________ Hours of Use:__________ Date:_______________ Hydraulic oil temperature when test performed _______________ Engine high idle speed _______________ Traction Pump Test 10 gpm A) Step 9 – Traction pump no load flow (use Hydro Lock Linkage) _______________ B) Step 10 –...
Page 177 HYDRAULICS SECTION 8N. HYDRAULIC SCHEMATICS HYDRAULIC SCHEMATIC COLOR CODES Use the following table to define the color coding used in the hydraulic schematics. Table 8N-1: Hydraulic Color Guide Color Code Green Suction Blue Return/Free Flow Yellow Metered Oil (Orifices) Orange Charge Pressure Pressure 8N-81...
Page 178 HYDRAULICS Figure 8N-1. Hydraulic Schematic 8N-82...
Page 179 HYDRAULICS Figure 8N-2. Steering Right 8N-83...
Page 180 HYDRAULICS Figure 8N-3. Steering Left 8N-84...
Page 181 HYDRAULICS Figure 8N-4. Deck Working 8N-85...
Page 182 HYDRAULICS Figure 8N-5. Deck Lift 8N-86...
Page 183 HYDRAULICS Figure 8N-6. Deck Lower 8N-87...
Page 184 HYDRAULICS Figure 8N-7. Traction Forward 8N-88...
Page 185 HYDRAULICS Figure 8N-8. Traction Reverse 8N-89...
Page 186 HYDRAULICS 8N-90...
Page 187 CHASSIS SECTION 9 CHASSIS Service Tools, Materials, and Specifications....................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 Fuel Tank ................................ 5 General ..............................5 Removal ..............................5 Installation ..............................6 Hydraulic Tank ..............................9 General ..............................
Page 188 CHASSIS...
Page 189: Materials Required
CHASSIS SECTION 9A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS MATERIALS REQUIRED Standard automotive hand tools Tools required: including bearing pullers Stoddard solvent or equivalent Cleaning and Detergent and water refinishing Paint, Jacobsen orange materials: Paint, Jacobsen black Anti-rust, Never-Seize Refer to Section 11 Lubricants: SPECIFICATIONS Steering Axle...
Page 190 CHASSIS 9A-2...
Page 191 CHASSIS SECTION 9B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Lift/lower functions do not a. Hydraulic lines are kinked a.
Page 192 CHASSIS 9B-4...
Page 193 CHASSIS SECTION 9C. FUEL TANK GENERAL NOTE: Dispose of unwanted fuel properly. Check with The fuel tank is located to the left of the operator. A local environmental officials for information on sender mounted in the fuel tank controls the fuel gauge properly disposing of fuel products.
Page 194 CHASSIS Mounting Mounting Bolts Rear Mounting Bracket Seat Platform Door Latches Figure 9C-5. Rear Mounting Bracket Figure 9C-3. Seat and Seat Platform 9. While supporting the tank, remove one mounting 6. Tag and disconnect the wiring harness from the bolt from inside the rear mounting bracket behind fuel sending unit (Figure 9C-4).
Page 195 CHASSIS 3. Using the tags created during removal, remove 6. Inspect the filter cap for wear, damage, or clog- the plugs and connect the fuel return hose, fuel ging and replace if necessary. outlet hose, and vent hose. 7. Connect the negative cable to the battery. 4.
Page 196 CHASSIS 9C-8...
Page 197 CHASSIS SECTION 9D. HYDRAULIC TANK GENERAL The hydraulic tank is mounted to the right of the opera- tor’s seat. The tank is a single piece molded plastic tank with a filler cap, breather/vent, and site gauge (Figure 9D-1). The tank should require little service other than cleaning unless punctured or otherwise accidentally damaged.
Page 198 CHASSIS REMOVAL ronmental officials for information on properly dis- posing of oil products. NOTE: 2. After draining, replace the hydraulic tank drain If available, use a portable filtering unit when plug. draining the hydraulic oil. If a portable filter is not NOTE: available, the oil should be drained into a clean container and filtered for use.
Page 199 CHASSIS 2. Place the hydraulic tank on the frame. Secure the hydraulic tank with two mounting bolts through the rear mounting bracket and two mounting bolts through the upper front mounting bracket. 3. Remove the plugs from the outlet hose and return hoses.
Page 200 CHASSIS 9D-12...
Page 201 CHASSIS SECTION 9E. LIFT CYLINDER GENERAL REMOVAL The lift cylinder is used to lift and lower the mowing 1. Start the engine and lift the mower deck com- deck. The lift arm, pulleys, chains, and cylinder are pletely. mounted using nuts and bolts (Figure 9E-1). 2.
Page 202: Inspection
CHASSIS NOTE: Chains Lift Lift chains must pivot on the retaining bolts and Pulley should be adjusted with the use of the self locking nuts on the chain retaining bolts. Bolts should be tightened as tight as possible and still allow the chain to pivot with the weight of the deck on the chains.
Page 203 CHASSIS 2. Install the roll pin in the end of the pulley shaft. 7. Position the lift chains over the pulleys and hang- ing toward the front of the tractor. 3. Insert the lift cylinder assembly through the upper front portion of the steering tower. 8.
Page 204 CHASSIS 9E-16...
Page 205: Steering Axle
CHASSIS SECTION 9F. STEERING AXLE GENERAL STEERING AXLE REPAIR The steering axle is mounted to the rear of the frame. A 1. Shut down the engine and remove the ignition hydraulic cylinder actuates the steering (Figure 9F-1). key. The steering cylinder is attached to the right hand arm 2.
Page 206 CHASSIS 14.Adjust equal turning radius by adjusting ball joint 15.Start the engine and test all components for on steering cylinder rod. proper operation. Figure 9F-3. Steering Axle Exploded View 9F-18...
Page 207 ELECTRICAL SYSTEM SECTION 10 ELECTRICAL SYSTEM Repair, Service Tools, and Materials ......................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 General Instructions............................5 General ..............................5 Using a Multimeter ........................... 5 Wire Continuity Test ..........................6 Resistance Test ............................
Page 208 ELECTRICAL SYSTEM Gauges ................................. 33 General ..............................33 Gauge Test............................. 33 10M Wiring Diagrams and Component Locations ....................35...
Page 209 ELECTRICAL SYSTEM SECTION 10A. REPAIR, SERVICE TOOLS, AND MATERIALS MATERIALS REQUIRED Multimeter Tools required: Jumper wire 60 amp ammeter Baking soda and water Cleaning materials: SPECIFICATIONS Senders Temperature Gauge Sender..33Ohm (Hot) 240Ohm Electrical System (Cold) Temperature Alarm Switch ..220° F (104° C) Normally Battery........12V, 450CCA, Group 26 open Alternator ........3 Phase, 12V, 40Amp...
Page 210 ELECTRICAL SYSTEM 10A-2...
Page 211 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Battery charge is low a. Buildup of corrosive acid a.
Page 212 ELECTRICAL SYSTEM PROBLEM PROBABLE CAUSE REMEDY 4. Engine will not turn over a. Dead battery a. Charge or replace battery when ignition switch is (Section 10D) engaged b. Neutral start switch faulty or b. Test switch as described in out of adjustment Section 10G.
Page 213 ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS GENERAL NOTE: Before performing any component or wiring test, Repair of the electrical system is generally limited to check for corrosion and loose or missing connec- the replacement of defective components or wiring. tions. Wiring diagrams and Component Location illustrations If a component (switch, relay, etc.) is removed for test are provided in Section 10L for troubleshooting and...
Page 214: Troubleshooting
ELECTRICAL SYSTEM Ω WIRE CONTINUITY TEST 1. Set the multimeter to the (Ohms) scale. 2. Connect the positive (+POS) lead to one terminal Set the multimeter to the ohm scale and touch the on the wire or switch. Connect the (-NEG) lead to meter leads together, the meter should read 00.0 and the other end of the wire or switch terminal.
Page 215: Battery
ELECTRICAL SYSTEM SECTION 10D. BATTERY GENERAL 2. Connect the charger leads to the battery. Connect the positive (+ POS) connector from the charger to For normal service, use a battery rated 12V, 450 cold the positive battery terminal. Connect the negative cranking amps at 0°F (-18°C) Group BCI26.
Page 216: Testing
ELECTRICAL SYSTEM 2. Keep the terminals and the top of the battery (+) POS (-) NEG clean. Wash with baking soda and rinse with clean water. Do not allow baking soda solution to enter the cells as this will destroy the electrolytes. 3.
Page 217: General
ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM GENERAL (+) POS (-) NEG The charging system consists of a 40 amp alternator with a built-in rectifier/regulator. The alternator must be disassembled to test the stator, rotor, and rectifier. Refer to the engine manufacturer’s service manual for detailed test and repair instructions.
Page 218: Regulator Test
ELECTRICAL SYSTEM REGULATOR TEST 6. Touch the POS (+) lead to the plug terminal of the ORG wire (Figure 10E-2). 1. Remove the plug from the back of the alternator The multimeter should display battery voltage. (Figure 10E-3). If there is no or low voltage, check for faulty wiring, battery, 20 amp fuse, or key switch.
Page 219: General
ELECTRICAL SYSTEM SECTION 10F. STARTER GENERAL The repair of the starter is covered in the engine manu- facturer’s service manual, which can be obtained through your local Jacobsen dealer. FIELD TEST Starter Motor Solenoid 1. Disconnect the brown wire from the starter motor solenoid (Figure 10F-1).
Page 220: Starter Motor
ELECTRICAL SYSTEM 9. With the multimeter POS (+) lead, connect to the 5. Connect the other end of the POS (+) jumper white wire from the starter motor. The NEG (-) cable to the POS (+) terminal of the battery. Con- lead should be connected to a good ground.
Page 221: General
ELECTRICAL SYSTEM SECTION 10G. SWITCHES GENERAL This section provides instructions for testing the vari- ous switches in the electrical system. Repair is limited to replacement of components found faulty during test- ing. See Section 10M for location of components. Switches can be defined as NO (normally open) or NC (normally closed).
Page 222 ELECTRICAL SYSTEM positions. Continuity should be available between termi- nals 30, AC, 50, and 19. Continuity should be available between termi- NOTE: nals 30, AC, and 19. If the ignition switch fails any of the above tests, d. Hold the ignition switch in the START position. replace the switch.
Page 223 ELECTRICAL SYSTEM Step 5a. Ignition Switch in OFF Position (0) Step 5b. Ignition Switch in RUN Position (1) Step 5c. Ignition Switch in GLOW PLUG Position (2) Step 5d. Ignition Switch in START Position (3) Figure 10G-3. Ignition Switch Positions 10G-15...
Page 224: Parking Brake Switch
ELECTRICAL SYSTEM PARKING BRAKE SWITCH NEUTRAL SWITCH General General The parking brake switch (Figure 10G-4) is a single The neutral switch (Figure 10G-5) is a double pole nor- pole normally open (SPNO) switch, which means no mally closed (DPNC) switch, which means current can current can travel through the switch until activated.
Page 225: Mow (Deck) Switch
ELECTRICAL SYSTEM MOW (DECK) SWITCH Continuity should be available with the switch in the ON position. If not, replace the switch. The mow switch is mounted on the control panel. When 6. Place one test lead on terminal 4 and one test up, a set of contacts are closed.
Page 226: Deck Safety Switch - E.c
ELECTRICAL SYSTEM Figure 10G-9. Mow (Deck) Switch Terminals DECK SAFETY SWITCH – E.C. General The deck safety switch is a single pole normally open (SPNO) switch, which means no current can travel through the switch until activated. When the switch is mechanically actuated (depressed) by the lift cylinder linkage, a set of contacts is closed.
Page 227: Deck Foot Switch - E.c. Optional Differential Lock Switch
ELECTRICAL SYSTEM DECK FOOT SWITCH – E.C. HORN SWITCH – OPTIONAL OPTIONAL DIFFERENTIAL LOCK General SWITCH The horn switch is a single pole normally open (SPNO) switch, which means no current can travel through the General switch until activated. When the switch is mechanically The foot switch is a single pole normally open (SPNO) actuated (depressed) by the operator, a set of contacts momentary switch, which means no current can travel...
Page 228 ELECTRICAL SYSTEM 10G-20...
Page 229: Coolant Temperature Sender Test
ELECTRICAL SYSTEM SECTION 10H. SENDERS GENERAL COOLANT TEMPERATURE SWITCH TEST Senders are used to activate a light or gauge to warn the operator of a condition in the engine. A temperature The temperature switch is located on the injection sender monitors engine coolant temperature and dis- pump side of the engine in the thermostat housing.
Page 230 ELECTRICAL SYSTEM ENGINE OIL PRESSURE SENDER 5. Start the engine and perform the continuity test again. TEST Continuity should not be available between the The oil pressure sender is pressure sensitive and acts sender end and the base with the engine running. as a ground for the oil pressure light on the control NOTE: panel.
Page 231 ELECTRICAL SYSTEM Fuel Sender Fuel Sender Ground Fuel Gauge Fuel Sender Test Figure 10H-4. Fuel Sender Test 10H-23...
Page 232 ELECTRICAL SYSTEM 10H-24...
Page 233 ELECTRICAL SYSTEM SECTION 10I. RELAYS AND SOLENOIDS RELAYS Relay Test Check the relays for proper operation as follows: Relays are electromechanical devices that control the transmission of electrical current with a circuit. A sche- 1. Remove the relay from the relay box. matic of the internal movement of the relay is printed on the relay itself.
Page 234 ELECTRICAL SYSTEM SEAT TIME DELAY MODULE The seat time delay module allows for a 0.5 second delayed opening. The module will allow the engine to run in the event that an operator encounters a bounce situation and momentarily comes off the seat cushion. This prevents immediate shut off of the engine.
Page 235 ELECTRICAL SYSTEM If the other coil tests are satisfactory, the component 3. Remove the connector from the solenoid valve. needs to be tested to determine if the fluid is present at 4. Set the multimeter to the 20 volts DC scale. the solenoid and if the poppet or plunger is moving to allow the fluid to flow through the component.
Page 236 ELECTRICAL SYSTEM 10I-28...
Page 237 ELECTRICAL SYSTEM SECTION 10J. FUSES FUSE TEST b. Connect one test lead to each fuse blade, see Figure 10J-1. The fuse is located in the fuse block mounted on the Continuity should be available between the right side of the mower frame in front of the engine fuse blades.
Page 238 ELECTRICAL SYSTEM 10J-30...
Page 239 ELECTRICAL SYSTEM SECTION 10K. GLOW PLUGS GLOW PLUG TEST 4. Place one test lead to the glow plug connector stud and the other test lead to the base of the The glow plugs warm the engine precombustion cham- glow plug or a good ground (Figure 10K-1). ber and help the engine to start during cold weather.
Page 240 ELECTRICAL SYSTEM 10K-32...
Page 241 ELECTRICAL SYSTEM SECTION 10L. GAUGES GENERAL GAUGE TEST Repair of gauges and sending units are limited to the Test the water temperature and fuel gauge using the replacement of faulty components or wiring. Before following procedure (Figure 10L-1). replacing a gauge that is not working, make sure to 1.
Page 242 ELECTRICAL SYSTEM 10L-34...
Page 243 ELECTRICAL SYSTEM SECTION 10M. WIRING DIAGRAMS AND COMPONENT LOCATIONS 10M-35...
Page 244 ELECTRICAL SYSTEM Alternator Temperature Sender Starter Battery Relays and Fuse Brake Switch Neutral Start Switch Deck Valve Control Panel Figure 10M-1. Electrical Component Location 10M-36...
Page 245 ELECTRICAL SYSTEM Figure 10M-2. Electrical Schematic 10M-37...
Page 246 ELECTRICAL SYSTEM Figure 10M-3. Electrical Schematic 10M-38...
Page 247 ELECTRICAL SYSTEM Figure 10M-4. Hot Circuit 10M-39...
Page 248 ELECTRICAL SYSTEM Figure 10M-5. Hot Circuit 10M-40...
Page 249 ELECTRICAL SYSTEM Figure 10M-6. Ignition Circuit 10M-41...
Page 250 ELECTRICAL SYSTEM Figure 10M-7. Ignition Circuit 10M-42...
Page 251 ELECTRICAL SYSTEM Figure 10M-8. Preheat Circuit 10M-43...
Page 252 ELECTRICAL SYSTEM Figure 10M-9. Preheat Circuit 10M-44...
Page 253 ELECTRICAL SYSTEM Figure 10M-10. Starting Circuit - Operator in Seat 10M-45...
Page 254 ELECTRICAL SYSTEM Figure 10M-11. Starting Circuit - Operator in Seat 10M-46...
Page 255 ELECTRICAL SYSTEM Figure 10M-12. Starting Circuit - Operator Out of Seat 10M-47...
Page 256 ELECTRICAL SYSTEM Figure 10M-13. Starting Circuit - Operator Out of Seat 10M-48...
Page 257 ELECTRICAL SYSTEM Figure 10M-14. Engine Run Circuit -Operator in Seat 10M-49...
Page 258 ELECTRICAL SYSTEM Figure 10M-15. Engine Run Circuit -Operator in Seat 10M-50...
Page 259 ELECTRICAL SYSTEM Figure 10M-16. Engine Run Circuit -Operator Out of Seat 10M-51...
Page 260 ELECTRICAL SYSTEM Figure 10M-17. Engine Run Circuit -Operator Out of Seat 10M-52...
Page 261 ELECTRICAL SYSTEM Figure 10M-18. Mowing Circuit - Deck Engaged 10M-53...
Page 262 ELECTRICAL SYSTEM Figure 10M-19. Mowing Circuit - Deck Engaged 10M-54...
Page 263 ELECTRICAL SYSTEM Figure 10M-20. Alarm Circuit - Parking Brake 10M-55...
Page 264 ELECTRICAL SYSTEM Figure 10M-21. Alarm Circuit - Parking Brake 10M-56...
Page 265 ELECTRICAL SYSTEM Figure 10M-22. Alarm Circuit - Engine Overheat 10M-57...
Page 266 ELECTRICAL SYSTEM Figure 10M-23. Alarm Circuit - Engine Overheat 10M-58...
Page 267 PREVENTIVE MAINTENANCE SECTION 11 PREVENTIVE MAINTENANCE General ................................1 Specifications ............................1 Scheduling ............................... 1 Administration ............................1 Lubrication and Maintenance Schedules......................3 General ..............................3 Maintenance Schedule..........................4...
Page 268 PREVENTIVE MAINTENANCE...
Page 269 PREVENTIVE MAINTENANCE SECTION 11A. GENERAL SPECIFICATIONS Belts - Decks Belt deflection - RD & SD Envirodeck ......Fuel System ..........0.5 in (13mm) with 4-6 lbs Belt- flail deck - tensioner spring length ......Capacity ........9 US gallons (34 liters) ........3.939-4.062 in (100-103 mm) Fuel ............
Page 270 PREVENTIVE MAINTENANCE 11A-2...
Page 271 PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION AND MAINTENANCE SCHEDULES GENERAL WARNING This section contains lubrication and maintenance schedules. Intervals in the lubrication chart, based on Before cleaning, adjusting, or repairing the machine, operating hours, can be altered when experience is disengage all drives, lower the decks to the ground, gained in machine operation, terrain, and environment.
Page 272 PREVENTIVE MAINTENANCE MAINTENANCE SCHEDULE After the first 50 hours of operation, replace the engine oil, hydraulic oil, and related filters. Verify proper adjustment of the cutter deck belts regu- Use Table 11B-1 and Figure 11B-2 to locate and ser- larly during the first 5, 10, and 15 hours of operation. vice the mower.
Page 273 PREVENTIVE MAINTENANCE 2 WD Numbers above show service locations in accompanying chart. Arrows show lubrication points. Figure 11B-1. Tractor Lubrication Chart Table 11B-2: Fluid Specifications Fluids Quantity Type Engine Oil 5.4 quarts (5.1 liters) 10W30 SF-CD Hydraulic Oil 6.8 gallons (25.7 liters) 10W30 SF-CD Radiator Coolant 1.7 gallons (6.4 liters)
Page 274 PREVENTIVE MAINTENANCE Lubricate grease fittings every 50 hours of operation or Flail Mowers more frequently when operating in extremely dusty con- (1) Caster Spindles ditions. (2) Rotor Bearings (3) Roller Bearings 1. Always clean grease fittings before and after libri- (4) Push Arm Pivots cating.
Page 275 ATTACHMENTS SECTION 12 ATTACHMENTS Repair, Service Tools, and Materials ......................1 Materials Required ........................... 1 Specifications ............................1 Failure Analysis .............................. 3 General ..............................3 General Instructions............................5 Contents ..............................5 Preparation for Repair ..........................5 Mower Deck..............................7 General ..............................7 Mower Deck Inspection ..........................
Page 276 ATTACHMENTS...
Page 277 ATTACHMENTS SECTION 12A. REPAIR, SERVICE TOOLS, AND MATERIALS MATERIALS REQUIRED Standard automotive hand tools Tools required: Cutting blade grinder Stoddard solvent or equivalent Cleaning materials: Molybdenum disulfides EP grease Lubricants: Grease gun grease (e.g. Sunray DX671 or Gulf Supreme) SPECIFICATIONS Deck material thickness ........11 gauge 0.1196 in (3.74 mm) .......7 gauge skirts 0.1875 in (4.76 mm)
Page 278 ATTACHMENTS 12A-2...
Page 279 ATTACHMENTS SECTION 12B. FAILURE ANALYSIS GENERAL The following table lists common problems, probable causes, and suggested remedies with section refer- ences to detailed descriptions of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Cutting blades do not turn a. Mower switch not on a.
Page 280 ATTACHMENTS 12B-4...
Page 281 ATTACHMENTS SECTION 12C. GENERAL INSTRUCTIONS CONTENTS 1. A qualified technician should always perform adjustments and maintenance. If proper adjust- This section covers descriptions and service of the ment cannot be made, contact an authorized Dis- attachments for the TurfCat mower. tributor.
Page 282 ATTACHMENTS Table 12C-1: Mower Specifications (Continued) Cutting Width of Deck Cutting Shipping Mowing Model Type Units Width* Height Weight Rate 957234 72 in (183 3 - 25 in 72 in 73 in 1-4.75 in 438 lbs 4.0 acres/hr Rotary cm) rear (63.5 cm) (183 cm) (185 mm)
Page 283: General
ATTACHMENTS SECTION 12D. MOWER DECK GENERAL lic hoses. The deck is raised and lowered using the hydraulic lift cylinder mounted inside the steering tower. Safety/lift chains wrapped around the lift cylinder frame WARNING provide stability and safe suspension for lifting the deck.
Page 284: Removal
ATTACHMENTS REMOVAL WARNING CAUTION Never open or loosen hydraulic lines under pres- sure. Hydraulic fluid escaping under pressure can Allow hydraulic components to cool completely have sufficient force to penetrate skin. If fluid is before removal from the tractor. injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form 1.
Page 285: Cutting Height Adjustment
ATTACHMENTS 4. Position the front pivot of the push arms • The caster wheel can be mounted to the deck (Figure 12D-4) inside the deck hanger brackets. mounting plates (P, Figure 12D-5). Select Insert the pins through the brackets and push either the HIGH or LOW mounting position.
Page 286 ATTACHMENTS • Hanger Brackets 11. If the original hole position was selected to control pitch, repeat steps 3 – 7. • Proper height of cut adjustment can be adjusted by selecting the proper pin position in 12.Check that the deck is level from the right side to the deck hanger brackets (Y, Figure 12D-7).
Page 287: Drive Motor Removal
ATTACHMENTS Caster Mount Spacers Hanger Hole Height of Cut 1.0 in 0.25 in (1) 1.25 in 0.5 in (1) 1.5 in 0.5 in (1); 0.25 in (1) 1.75 in 0.5 in (2) 2.0 in 0.5 in (2); 0.75 in (1) 2.25 in 0.5 in (3) 2.5 in...
Page 288: Drive Motor Installation
ATTACHMENTS Figure 12D-11. Drive Motor Mounting 7. Loosen the drive pulley setscrew (A, Figure 12D-11). Figure 12D-12. Caster Wheel 8. Remove the pulley and key (B) from the drive motor shaft. REMOVING BLADES 9. Remove two bolts (C) and nuts (D) from the drive motor.
Page 289 ATTACHMENTS WARNING WARNING Never attempt to inspect, repair or remove the blade Bent, grooved, or cracked blades can cause a piece from the deck with the engine running. Serious per- of the blade to break away and be thrown from the sonal injury can occur from contact with the blade mower deck injuring bystanders or causing property and from debris discharged from the mower deck.
Page 290: Removal And Installation Of Rollers
ATTACHMENTS SHARPENING BLADES 3. Remove equal amount of blade material from each side to maintain a balanced blade. Unbal- Blades may be sharpened by filing or grinding. When anced blades cause vibration and mower dam- sharpened, maintain blade balance with 1/8 oz/in (19.4 age.
Page 291: Storage
ATTACHMENTS DECK CASTER WHEEL If there is more than ½” deflection, remove the spring and move bolt (X, Figure 12D-18) to the next hole. Attach spring to bolt. Figure 12D-18. Belt Tension If necessary, loosen bolt. While holding bracket (S) move bracket to obtain a 0 –...
Page 292 ATTACHMENTS BLADE SPINDLES Late Style Tighten spindle nut to 100-150 ft. lbs. (135-203 Nm) Early Style Tighten spindle nut to 100-150 ft. lbs. (135-203 Nm) Figure 12D-20. Side and Rear Discharge Blade Spindle 12D-16...
Page 293 ATTACHMENTS Late Style Tighten spindle nut 100-150 ft. lbs. (135-203 Nm) Early Style Tighten spindle nut to 100-150 ft. lbs. 135-203Nm) Figure 12D-21. Envirodeck Blade Spindle 12D-17...
Page 294: Side Discharge Deck
ATTACHMENTS SIDE DISCHARGE DECK Figure 12D-22. Side Discharge Deck 12D-18...
Page 295 ATTACHMENTS Figure 12D-23. Side Discharge Deck – Components 12D-19...
Page 296 ATTACHMENTS Figure 12D-24. Side Discharge Deck – Hydraulic Motor Mounting 12D-20...
Page 297: Rear Discharge Deck
ATTACHMENTS REAR DISCHARGE DECK Figure 12D-25. Rear Discharge Deck 12D-21...
Page 298 ATTACHMENTS Figure 12D-26. Rear Discharge Deck – Components 12D-22...
Page 299 ATTACHMENTS Figure 12D-27. Rear Discharge Deck – Hydraulic Motor Mounting 12D-23...
Page 300: Envirodeck
ATTACHMENTS ENVIRODECK Figure 12D-28. Envirodeck 12D-24...
Page 301 ATTACHMENTS Figure 12D-29. Envirodeck – Components 12D-25...
Page 302 ATTACHMENTS Figure 12D-30. Envirodeck – Mulching Insert 12D-26...
Page 303: General
ATTACHMENTS SECTION 12E. FLAIL MOWER GENERAL rotor bearings for excessive wear and damage. Check belt tension. Check for proper lubrication. The flail mower is mounted on the front of the tractor and driven by a hydraulic motor connected to the deck WARNING valve by hydraulic hoses.
Page 304: Installation
ATTACHMENTS 3. Using tags created during removal, remove plugs and connect hoses to the deck valve (Figure 12E- WARNING 4. Position the front pivot of the push arms Never open or loosen hydraulic lines under pres- (Figure 12E-3) inside the mower hanger brackets. sure.
Page 305: Cutting Height Adjustment
ATTACHMENTS CUTTING HEIGHT ADJUSTMENT To improve anti-scalping control or create striping effects, remove adjusting pin from push arm and adjust The cutting height for vertical mowers can be adjusted height using only rear roller and caster wheel – bottom between 0-4 inches (0-102 mm). Actual cutting height portion of Table 12E-1.
Page 306: Drive Belt
ATTACHMENTS 1. Locate height of cut in Table 12E-1. Quick Pin Spacers 2. Position push arm adjustment pin in hole 4. 3. Adjust rear roller in hole (A). 4. Place four spacers on bottom of caster wheel spindle as shown. Store remaining spacers and washers on top portion of spindle.
Page 307: Flail Blade Inspection
ATTACHMENTS CAUTION Operating the mower with missing or damaged parts can cause severe vibration and damage to other components. Figure 12E-8. Drive Belt 1. To replace belt, remove belt cover, loosen hex nuts (A, Figure 12E-9) to relieve belt tension. Install new belt as shown.
Page 308: Drive Motor Installation
ATTACHMENTS 2. Lubricate with grease that meets or exceeds NLGI Belt and Drive Mounting Grade 2 specifications. Pulley Screw Motor Bolt 3. Apply grease with a manual grease gun and fill slowly until grease begins to seep out or pressure is felt.
Page 309: Flail Deck
ATTACHMENTS FLAIL DECK Figure 12E-13. Flail Deck – Push Arms and Hydraulics 12E-33...
Page 310 ATTACHMENTS Figure 12E-14. Flail Housing 12E-34...
Page 311 ATTACHMENTS Figure 12E-15. Flail Drive Assembly 12E-35...
Page 312 ATTACHMENTS 12E-36...
Page 313 OPTIONS SECTION 13 OPTIONS Specifications..............................1 Options..............................1 Rollover Protection Structure (ROPS) ......................3 General ..............................3 Safety ............................... 3 Installation ..............................4 Spark Arrestor..............................5 General ..............................5 Differential Lock .............................. 7 General ..............................7 Flow Divider ............................7 Tie Down Brackets............................11 General ..............................11...
Page 314 OPTIONS...
Page 315: Options
OPTIONS SECTION 13A. SPECIFICATIONS OPTIONS ROPS .........ANSI/ASAE Standard S547 Seat Belt......Required with ROPS structure ..........Sections 10.2 and 10.3 Seat Belt Bolt Torque – Dry....48 ft-lbs (65 Nm) ROPS Bolt Torque – Dry ....150 ft-lbs (203 Nm) Rear Weight ..........23 lbs (10 Kg) 13A-1...
Page 316 OPTIONS 13A-2...
Page 317: General
OPTIONS SECTION 13B. ROLLOVER PROTECTION STRUCTURE (ROPS) GENERAL make sure the instructions are understood before mounting the Roll Over Protection Structure (ROPS). The optional Roll Over Protection Structure (ROPS) is intended for installation on the Turfcat. The structure is CAUTION used to protect the operator in the event of a machine rollover (Figure 13B-1).
Page 318: Installation
OPTIONS WARNING Before attempting to clean, adjust, or repair the equipment, disengage all drives, shut down the engine and allow the unit to cool completely. Remove the ignition key and disconnect the nega- tive battery terminal to prevent accidental discharge and possible bodily injury.
Page 319: General
OPTIONS SECTION 13C. SPARK ARRESTOR GENERAL The optional spark arrester (Figure 13C-1) is mounted on the muffler exhaust pipe. A screening system in the spark arrester prevents sparks from exiting the exhaust system and igniting materials in the mowing area. The spark arrester is clamped to the end of the muffler exhaust pipe using screws.
Page 320 OPTIONS 13C-6...
Page 321: General
OPTIONS SECTION 13D. DIFFERENTIAL LOCK GENERAL An optional differential lock system (Figure 13D-1) is available on two wheel drive models. The differential lock includes a flow divider mounted on the front axle. The flow divider is positioned between oil flow from traction pump forward port and the left and right trac- tion motors.
Page 322 OPTIONS Figure 13D-2. Differential Lock Off 13D-8...
Page 323 OPTIONS Figure 13D-3. Differential Lock On 13D-9...
Page 324 OPTIONS 13D-10...
Page 325: General
OPTIONS SECTION 13E. TIE DOWN BRACKETS GENERAL The optional tie down brackets are mounted on the rear of the tractor frame (Figure 13E-1). These brackets are secured to the frame using two bolts and nuts for each bracket. The brackets can be used to secure the tractor for transport or other situations requiring tie down support.
Page 326 OPTIONS 13E-12...
Page 327 MISCELLANEOUS SECTION 14 MISCELLANEOUS Precaution Decal Locations ..........................1 Conversion Charts ............................3 Millimeters to Decimals Conversion ......................3 US to Metric Conversion .......................... 7...
Page 328 MISCELLANEOUS...
Page 329 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS Under Hood Under Hood Under Hood Behind Steering Cover Figure 14A-1. Precaution Decals 14A-1...
Page 330 MISCELLANEOUS 14A-2...
Page 331 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS MILLIMETERS TO DECIMALS CONVERSION Table 14B-1: Millimeters to Decimals Decimal Decimal Decimal Decimal Decimal 0.01 0.00039 0.41 0.01614 0.81 0.03189 0.82677 2.40157 0.02 0.00079 0.42 0.01654 0.82 0.03228 0.86614 2.44094 0.03 0.00118 0.43 0.01693 0.83 0.03268 0.90551 2.48031...
Page 332 MISCELLANEOUS Table 14B-1: Millimeters to Decimals Decimal Decimal Decimal Decimal Decimal 0.23 0.00906 0.63 0.02480 0.11811 1.69291 3.26772 0.24 0.00946 0.64 0.02520 0.15748 1.73228 3.30709 0.25 0.00984 0.65 0.02559 0.19685 1.77165 3.34646 0.26 0.01204 0.66 0.02598 0.23622 1.181102 3.38583 0.27 0.01063 0.67 0.02638...
Page 333 MISCELLANEOUS Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters (Continued) Decimal Decimal Fraction Decimal Fraction Decimal 0.005 0.1270 0.540 13.7160 0.006 0.1524 0.550 13.9700 1/16 0.0625 1.5875 9/16 0.5625 14.2875 0.007 0.1778 0.560 14.2240 0.008 0.2032 0.570 14.4780 0.009 0.2286 0.580...
Page 334 MISCELLANEOUS Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters (Continued) Decimal Decimal Fraction Decimal Fraction Decimal 0.200 5.0800 0.750 19.0500 0.210 5.3340 0.760 19.3040 0.220 5.5880 0.770 19.5580 17/64 0.2656 6.7469 49/64 0.7656 19.4469 0.230 5.8420 0.780 19.8120 9/32 0.2812 71438...
Page 335 MISCELLANEOUS Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters (Continued) Decimal Decimal Fraction Decimal Fraction Decimal 0.450 11.4300 0.960 24.3840 15/32 0.4688 11.9062 31/32 0.9688 24.6062 0.460 11.6840 0.970 24.6380 31/64 0.4844 12.3031 63/64 0.9844 25.0031 0.470 11.9380 0.980 24.8920 0.480...
Page 336 MISCELLANEOUS 14B-8...
Page 337 ISO 9001 and ISO14001 Registration at all of our manufacturing locations. A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

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Textron Jacobsen Turfcat 600 Series Repair Manual

Section 2 Controls 2

Section 3 Engine

Section 4 Drive Train

Section 5 Brake System

Section 6 Steering

Section 8 Hydraulics

Section 9 Chassis

Section 10 Electrical System

Section 12 Attachments

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