Page 1 Technical Repair Manual 600 Series Turfcat Models 69168 & 69169...
Page 5 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS AND TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS...
Page 7 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...
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Page 9 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 10 INTRODUCTION CALIFORNIA PROPOSITION Traction System WARNING Drive..Hydrostatic Traction Pump to front wheel motors in a parallel-series flow to rear wheel motors (4WD). Forward speed ......0-10 mph (0-16.1 kph) WARNING Mow speed........0-6 mph (0-9.6 kph) Reverse speed .......0-3 mph (0-4.8 kph) Certain vehicle components contain or emit chemi- Traction Pump max flow....
Page 11 INTRODUCTION 60 in Flail Weights Number of blades............ 144 Tractor only Blade speed ......8042 ft/min (2451 m/m) Deck material thickness ..10 gauge 0.135 in (3.4 mm) 2WD ...........1440 lbs (653 kg) Height of cut range......0-4 in (0-102 mm) 4WD ...........1490 lbs (676 kg) Lift System Decks...
Page 12 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 13 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 14 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 15: 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 ........................
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Page 17: 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 ........
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Page 19: 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.
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Page 21: 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 22: 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 23: 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 24: Brake Interlock Switches
CONTROLS 5. Pull the linkage away from the pedal until the and to open the switch contacts when the brake pedal brake shoes just contact the brake drum is unlocked and released (Figure 2C-8). (Figure 2C-8). Thread the end yoke onto the link- age rod until there is a 0.75 - 1.0 in of free pedal movement.
Page 25: Gauges And Instruments
CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS REPAIR 1. Disconnect the battery ground (black) cable. 2. Label the wires for proper identification and dis- NOTICE connect wiring. 3. Remove the attached hardware and replace the Refer to Section 10 for test and repair procedures of component.
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Page 27 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..............................
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Page 29: Materials Required
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 Thermostat completely open temp...
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Page 31: 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.
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Page 33: General Instructions
ENGINE SECTION 3C. GENERAL INSTRUCTIONS CONTENTS ered in this manual. Engine repair is not included in this manual; refer to the manufacturer’s instructions. A Kubota three cylinder, diesel engine is used in the Turfcat 600 Series Mower. The Kubota D1305-E3B liq- NOTICE uid cooled engine is used for all mower operations.
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Page 35: 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 36: 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 37: 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 38 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 39 ENGINE Debris Screen Radiator Core Fan Shroud Recovery Tank Bulkhead Hydraulic Oil Cooler Figure 3D-8. Radiator/Hydraulic Oil Cooler, and Debris Screen 3D-11...
Page 40 ENGINE Bulkhead Radiator Upper Radiator Hose Hydraulic Oil Cooler Fan Shroud Lower Radiator Hose Coolant Recovery Tank Frame Rear Cover Figure 3D-9. Radiator Mounting Removal CAUTION 1. Shut down the engine and remove the ignition key. Allow the engine coolant to completely cool before removing the radiator cap.
Page 41 ENGINE 2. Using a portable filtering unit, pump the hydraulic 13.Remove mounting hardware from the engine fan oil from the hydraulic oil tank into a suitable clean shroud and separate the shroud from the radiator/ container. The tank holds 6.8 U.S. gallons (25.7 oil cooler an move forward away from the radiator.
Page 42: Exhaust System
ENGINE EXHAUST SYSTEM Removal and Installation Remove and install the exhaust system components as CAUTION shown in Figure 3D-11. Do not attempt to service the exhaust system when the engine is hot. Serious personal injury can occur. NOTICE If a change in the color or sound of the exhaust occurs, stop the engine immediately, identify the problem and repair as necessary.
Page 43 ENGINE The inline fuel filter is mounted on the left side of Hose Hose Hose Inline the engine to the left of the throttle cable mounting. Clamp Clamp Clamp Filter The fuel/water separator is mounted in the engine com- partment on the left side above the engine. Moisture and other foreign matter can accumulate in the fuel fil- ter.
Page 44 ENGINE 6. Remove the filter from the filter clamp. 12.Close the drain valve on the bottom of the bowl. 7. Lightly lubricate the new seals with clean diesel 13.Purge any air from the fuel system after installing fuel and install in the mounting. the new filter.
Page 45: Engine Removal
ENGINE Fresh Air Fuel Injection Air Vent Positive Battery Negative Intake Solenoid Pump Plug Cable Clamp Cable Figure 3D-17. Battery Cables and Clamp Figure 3D-16. Injection Pump Air Vent 3. Using suitable containers, drain the radiator, 18.Operate the primer button on top of the fuel/water engine block, engine oil and hydraulic oil.
Page 46 ENGINE Throttle Throttle Throttle Throttle Drive Coupler/ Traction Pump Traction Pump Cable Cable Cable Lever Bell Housing Mounting Bolts Housing Clamp Figure 3D-19. Traction Pump Mounting Figure 3D-18. Throttle Cables 16.Using an engine hoist, support the engine and 11. Remove the fuel supply hose from the fuel pump remove the lower front engine mounting bolts to the fuel/water separator at the fuel pump.
Page 47: Engine Installation
ENGINE 3. Install four bolts and lock washers on both sides of the engine at the lower rear engine supports. 4. Install the lower front engine mounting bolts. 5. Install the traction pump. See Section 8. 6. Reconnect the wiring harness to the fuel solenoid, starter, oil sender, coolant temperature sender, and alternator.
Page 48 ENGINE Alternator Radiator Hoses Throttle Cable and Clamp Exhaust Fuel Filter and Traction Pump Engine Mount Air Cleaner Fuel/Water Separator Battery Figure 3D-22. Engine Components 3D-20...
Page 49 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 traction Pump Coupling ..........................
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Page 51: Service Tools, Materials, And Specifications
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)
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Page 53: 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.
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Page 55: Drive System Repairs And Adjustments
DRIVE TRAIN SECTION 4C. DRIVE SYSTEM REPAIRS AND ADJUSTMENTS GENERAL Repair of the traction drive pump is limited to adjust- ment of linkages and cables, tightening of fasteners, 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 56: Hydraulic Wheel Motors
DRIVE TRAIN 4. Install the traction 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 57 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...
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Page 59: 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* ......
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Page 61: 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.
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Page 63: 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 64 BRAKE SYSTEM Disassembly Upper Tension Holding Holding Spring Springs 1. Using a suitable jack, lift the front wheels off the ground. Support the tractor with jack stands. 2. Release the parking brake. NOTICE Removing the wheels allows access to the brake assembly.
Page 65 BRAKE SYSTEM 5. Adjust the parking brake as needed. 2. Use a tape measure to gauge the free travel movement. 6. Lift the tractor and remove the jack stands. 3. Use the rod end coupling nut to adjust the free Adjustment travel and actuating lever position.
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Page 67 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..........................
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Page 69: 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 70: 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 71: 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 72 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 73: General
STEERING SECTION 6C. STEERING UNIT GENERAL REMOVAL The power steering unit uses hydraulic flow produced NOTICE by the charge pump in the traction pump. A pressure relief valve located in the traction pump protects the The following steps reference Figure 6C-2 unless steering system from pressure damage.
Page 74 STEERING Figure 6C-2. Steering Unit 6C-6...
Page 75: Steering Valve Disassembly
STEERING STEERING VALVE DISASSEMBLY 2. Remove the nuts (1) and cover (2). 3. Remove the nine needle rollers (5). NOTICE 4. Carefully remove the port manifold (6). Be pre- pared to catch the three springs (7). Remove the Before attempting repairs or disassembly of any springs.
Page 76 STEERING 1. Nut 2. Port Cover 3. Seal Ring 4. O-Ring 5. Needle Roller 6. Port Manifold 7. Spring 8. Valve Ring (Matched Set) 9. Valve Plate (Matched Set) 10. Spring 11. Hex Drive Assembly 12. Alignment Pin 13. Isolation Manifold 14.
Page 77: Steering Valve Inspection
STEERING 5. Inspect the isolation manifold (13) for nicks, scratches, and scoring. A polished wear pattern NOTICE due to valve plate rotation is normal. 6. Inspect the drive link (14) for wear and damage. The following steps reference Figure 6C-3 unless 7.
Page 78 STEERING 3. Install a new retaining ring (24) on the shaft (26) 12.Install the commutator ring (3) and commutator cover (2), flat surface down with ring screw and attach to tube (27). recesses, stator screw slots, and cover screw NOTICE holes aligned.
Page 79 STEERING STEP 30 STEP 25 STEP 24 STEP 5 Steering Wheel Nut 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 80 STEERING STEPS 13, 14, 15 STEP 16 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).
Page 81: 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.
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Page 83: Steering Cylinder
STEERING SECTION 6D. STEERING CYLINDER GENERAL REMOVAL The steering cylinder is attached to the steering axle 1. Shut off the engine and remove the ignition key. between the right side of the axle and the left steering 2. Block the wheels and set the parking brake. arm.
Page 84: Disassembly
STEERING DISASSEMBLY 7. Remove the piston nut. NOTICE WARNING Small scratches and burrs can be removed with emory cloth or light sand paper. Use appropriate eye protection when using com- pressed air for cleaning or drying purposes. Com- 8. Inspect the cylinder components for excessive pressed air can cause serious personal injury.
Page 85: Assembly
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 86: Installation
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. Back up Ring Back up Ring O-Ring...
Page 87: Steering Axle Adjustment
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).
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Page 89 WHEELS AND TIRES 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...
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Page 91: Wheels And Tires
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..........
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Page 93: General
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.
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Page 95: General
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 large punctures or tears occur, take the tire (on the NOTICE wheel) to a qualified tire repair shop.
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Page 97 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 ......................8 37° Flare Fittings ............................8 Hose Installation Instructions ........................
Page 98 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 99: Repair, Service Tools, And Materials
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 100 HYDRAULICS 12" 2" 1" 2" 12" 14" 16" 3/4" NC Ready Rod 15" Long 36" 1" Pipe Cut to Fit Between Runners 2-3/4" NC Nuts 12" 1" Pipe 2" 13-1/2" Long Two Cargo Straps 3" Wide 12' Long Figure 8A-2. Wheel Restraint 8A-2...
Page 101: Specifications
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 –...
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Page 103: 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 104 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 105: General
HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS GENERAL • All parts should be thoroughly cleaned in a suitable non-flammable solvent and air blown dry before beginning repair or reassembly. NOTICE • Perform repair procedures in a clean work area using clean tools. Component location illustrations and hydraulic sys- tem diagrams are located at the end of this section.
Page 106: Hydraulic Tube And Hose Fittings
HYDRAULICS HYDRAULIC TUBE HOSE Thread Tube Torque In- # of Flat FITTINGS Dash Size O.D. Rotations Size 3/8-24 0.188 95-105 1 1/2:1 3/4 WARNING 7/16-20 0.250 135-145 2 1/4:2 3/4 1/2-20 0.312 170-190 3 1/4:3 3/4 To avoid serious bodily injury, always lower mower 9/16-18 0.375 215-245...
Page 107: Ors (Face Seal) Fittings
HYDRAULICS Table 8C-4: O-Ring Boss Torque Recommendations Tubing O.D. Jacobsen SAE Dash Thread Torque Thread Size Tube O.D. or Hose I.D. Part No. Size Size In-lbs 5/16-24 459290 3/8-24 0.188 96-120 3/16 3/8-24 459291 7/16-20 0.250 168-192 7/16 339896 1/2-20 0.312 216-240 5/16...
Page 108 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 109: Hydrostatic Traction Pump
HYDRAULICS SECTION 8D. HYDROSTATIC TRACTION PUMP GENERAL that ride against a swiveling swashblock. By swiveling the swashblock, the piston stroke is extended on one hydrostatic traction pump (Figure 8D-1) side of the barrel assembly and shortened on the other mounted underneath the seat pan and in front of the side.
Page 110 HYDRAULICS Control Valve Plate/Charge Housing Pump Assembly Rotating Rear Valve Group Plate Coupling Assembly Input Shaft & Bearing Assembly Rear Cover (Not Used on Jacobsen Applications) Main Case & Input Shaft Swashblock Gerotor Pump Rear Valve Plate Assembly Main Case and Input Shaft Valve Plate Charge Pump...
Page 111: Removal
HYDRAULICS Spline Shaft Valve Plate Gasket Valve Plate Coupling Charge Pump Traction Pump Housing Housing Rotor Relief Valve Relief Valve Swashblock Retaining Piston/Shoe Shoe Ring Assembly Retainer Figure 8D-3. Traction Pump – Exploded View REMOVAL 4. Thoroughly clean the implement pump and trac- tion pump, especially the area surrounding the hydraulic hoses, tubes, and fittings.
Page 112: 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 113 HYDRAULICS Valve Plate and Gerotor Bypass Pressure Relief Valve Rear Valve Plate O Rings Coupler Gerotor Pump Bushing Cross-Port Steering Relief Valve Relief Valve Retaining Ring Valve Plate Cross-Port Tow Valve Relief Valve Figure 8D-7. Valve Plate and Gerotor Pump Disassembly 8D-15...
Page 114 HYDRAULICS Rotating Group Shoe Retainer Spring Shoe Retainer Cylinder Barrel Pistons Ball Retaining Fulcrum Ring Hydrodynamic Bearing O-Ring Figure 8D-8. Rotating Group Disassembly Drive Shaft Group Figure 8D-9. Drive Shaft Group Disassembly 8D-16...
Page 115: Inspection
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 Swashblock have no end play with the shoe free to rotate and pivot on the piston ball.
Page 116: 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 NOTICE When installing the bearing, press on the outer face.
Page 117 HYDRAULICS Rotating Group Assembly Install the shoe retainer with the center curved surface NOTICE toward the fulcrum ball (Figure 8D-14). Do not force pistons into barrel. The pistons should fit loosely. 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 118: Installation
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 119: Front And Rear Traction Motors
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 traction pump to the front traction motors.
Page 120: Rear Traction Motor
HYDRAULICS REAR TRACTION MOTOR Traction Motor The traction pedal and traction pump control the rear traction motors. The motor is mounted inside a swivel- Adapter ing motor mount, which is mounted to the steering axle Plate with a hub mounted on the output shaft (Figure 8E-3). The hub is used to mount the wheels.
Page 121: Traction Motor Repair
HYDRAULICS TRACTION MOTOR REPAIR Traction Motor Disassembly 1. Scribe an alignment mark down the side of the motor (see Figure 8E-5). Wheel/Tire Assembly Mounting Hardware Figure 8E-4. Traction Motor Mounting Refer to “Traction Motor Repair” on page 23 for traction motor repair.
Page 122 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 123 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 124 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 125 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 126 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 127 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 128 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 129 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 130 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 131 HYDRAULICS Step 18 Step 16 Install commutator (5) in commutator ring (6). Install commutator ring (6). Step 19 Step 17 Apply a small amount of grease to Install new seal ring (3) to commutator (5). seal ring (4) and install on end cover (2).
Page 132 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 133: Four Wheel Drive Rear Wheel Motor Check Valves
HYDRAULICS FOUR WHEEL DRIVE REAR WHEEL Check Valve 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 134 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 135: Differential Lock Valve
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 136 HYDRAULICS Page Intentionally Blank 8E-38...
Page 137 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 138: Implement Pump
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 Bell Housing 1. Check parts for signs of wear, burrs, scores, nicks, damaged or broken parts. Traction 2.
Page 139 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.
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Page 141 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 142 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 143: 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 144: 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 145: General
HYDRAULICS SECTION 8I. LIFT/LOWER VALVE GENERAL REMOVAL The lift valve is used in conjunction with the charge 1. Shut off the engine and remove the ignition key. pump and lever to lift and lower the deck. The lift/lower 2. Unlatch the seat platform. Pivot the seat and seat valve is a three position non-detent valve that is spring platform to the full upward position.
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Page 147: 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 148: Installation
HYDRAULICS Figure 8J-2. Seal Kit Installation STEP 3 Lubricate assembly. Push rod into barrel. STEP 1 Using a spanner wrench, Assemble piston tighten the rod guide. as shown. Backup Ring Lock Barrel Ring Wiper O-Ring Seal Piston Guide O-Ring STEP 2 Assemble rod guide and install on rod.
Page 149: Hydraulic Oil Cooler
HYDRAULICS SECTION 8K. HYDRAULIC OIL COOLER GENERAL 1. Using a portable filtering unit, pump the hydraulic oil from the hydraulic oil tank into a suitable clean The hydraulic oil cooler is located directly behind the container. The tank holds 6.8 U.S. gallons (25.7 engine fan and is integrated with the radiator.
Page 150 HYDRAULICS 3. Secure the radiator fan shroud to the radiator with 8. Connect both upper and lower radiator hoses. mounting bolts. 9. Fill radiator with 50/50 mixture of anti-freeze and 4. Remove the plugs from the inlet and outlet hoses. water.
Page 151: General
HYDRAULICS SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES GENERAL NOTICE When a hydraulic 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 sus- Use only the recommended hydraulic oil (see pected component failure.
Page 152: Lift System Test
HYDRAULICS Front Motor Test • If the mark on the cylinder rod disappears into the barrel of the cylinder, proceed with STEP 5. 1. Install wheel restraints on the front wheels and NOTICE lock parking brake. 2. Jack up rear of tractor and support with stands so Use a floor jack and board to support the deck, being that both rear wheels are off the ground.
Page 153: 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.
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Page 155: General
HYDRAULICS SECTION 8M. HYDRAULIC INSTRUMENT TESTS GENERAL A test record has been provided at the end of this sec- tion. Make copies of the record for future use. Use the The tests in this section are provided as a means of form to record test results.
Page 156: 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 157 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 158 HYDRAULICS • If the implement relief valve pressure is within range 3. Inspect the relief valve and relief valve seat in the at high engine rpm and out of range at low engine valve body for damage. rpm, perform charge pump flow test. 4.
Page 159 HYDRAULICS 7. Slowly push traction pedal forward and observe 16.Pressure should be 3500 psi (172 Bar). pressure gauge. 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 traction pump and leakage test on wheel motors.
Page 160 HYDRAULICS 2. Drain the hydraulic fluid from the tank. 3. Remove the high pressure relief valves (Figure 8M-10). Traction Pump Deck Motor Pressure Hose Relief Valve 0 to 5000 psi (0 to 344 Bar) Gauge Figure 8M-10. High Pressure Relief Valve 4.
Page 161: 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 162 HYDRAULICS Charge Pump Flow Test Steering Lift Cylinder Cylinder .070 6.6 ci CAP LINES Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci...
Page 163 HYDRAULICS 16.Turn the steering wheel completely to the right, Example: then to the left, and hold each position. Read and 5.7 GPM Step 5 record pressure readings G) and H) on Flow Test 5.0 GPM Step 6 Report 1. 0.7 GPM leakage 17.After performing Step 14, hold steady hand pres- sure on steering wheel against the stop and 8.
Page 164 HYDRAULICS • If relief pressure did not match the relief valve 25.Shut off the engine. pressure on the charge pump test, lift cylinder or lift valve is leaking. Proceed to STEP 22. Conclusion 22.At the lift cylinder, disconnect the hose at the base •...
Page 165: 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 (Traction Pump Charge Pressure) _______________ B) Step 5 –...
Page 166 HYDRAULICS Implement Pump Test 8. 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). CAUTION 2.
Page 167 HYDRAULICS Implement Pump Test Steering Lift Cylinder Cylinder .070 Install 6.6 ci Blocking Disc Lift Line Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci...
Page 168 HYDRAULICS Deck Valve Test 12.Make sure blocking disc is removed from the tee fitting on the flow meter (Figure 8M-15). 11. Leave flow meter connected as in the implement 13.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 169 HYDRAULICS 14.Open the tester load valve, set the parking brake, Deck Motor Test start the engine, and advance the engine speed to full throttle. CAUTION 15.Engage the front deck. Remove the deck cutting blades or remove the 16.Slowly close tester load valve until a reading of spindle drive belt, as the blades may turn if the 2000 psi (138 Bar) is obtained.
Page 170 HYDRAULICS Deck Motor Test Steering Lift Cylinder Cylinder .070 6.6 ci Install Lift Blocking Line Valve Disc Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump...
Page 171: 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 172 HYDRAULICS Traction Circuit Flow Test 6. Connect the “OUT” ports of the flow meter to the reverse pressure port on the traction pump and onto the disconnected reverse traction hose NOTICE (Figure 8M-19). Before performing this test, make sure the tow 7.
Page 173 HYDRAULICS Traction Pump Test Steering Lift Cylinder Cylinder .070 Install 6.6 ci Blocking Disc Lift Valve Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor Forward 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump...
Page 174 HYDRAULICS Traction Motor Test – Left Side Left Rear Motor 21.Perform traction pump test first and leave flow Left Front Motor meter hoses connected as outlined in Traction Pump Test. Do not disturb the hydro lock linkage, 12.Perform traction pump test first and leave flow as it must remain set at 10 gpm (37.8 lpm).
Page 175 HYDRAULICS Left Side Traction Motor Test Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Steering Valve 1.27 ci Install Blocking Disc 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor Forward 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci...
Page 176 HYDRAULICS Traction Motor Test – Right Side 41.Lift right front of tractor and install stand under axle on right front wheel so that right front wheel is off the ground and can rotate without interference. Right Front Motor 42.Install blocking discs in tee fittings on traction 30.Perform traction pump test first and leave flow pump to block oil flow to the left side wheel motors meter hoses connected as outlined in Traction...
Page 177 HYDRAULICS To test, insert blocking disc on the P port of the hot oil shuttle and operate the unit in reverse direction to see if machine performance has recovered. Right Side Traction Motor Test Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out...
Page 178: 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 179 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 180 HYDRAULICS 69168 (2WD) Hydraulic Schematic Lift Steering Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci Flow Divider Valve 11.9 ci 11.9 ci Wheel Wheel 3200 psi Motor Motor Deck Valve 2WD Units with optional Differential Lock Kit 915 psi 1.35 ci 3625 psi...
Page 181 HYDRAULICS 68169 (4WD) Hydraulic Schematic Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi...
Page 182 HYDRAULICS Steering - Right Turn Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi...
Page 183 HYDRAULICS Steering - Left Turn Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi...
Page 184 HYDRAULICS Deck “ON” Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi .425 ci...
Page 185 HYDRAULICS Deck - Lift Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi .425 ci...
Page 186 HYDRAULICS Deck - lowering Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi .425 ci...
Page 187 HYDRAULICS Traction Forward Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi .425 ci...
Page 188 HYDRAULICS Traction Reverse Steering Lift Cylinder Cylinder .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve 11.9 ci 11.9 ci Wheel Wheel Motor Motor 915 psi 1.35 ci 3625 psi Gear 3100 1.01 ci Pump 3625 psi .425 ci...
Page 189 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 ..............................
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Page 191 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 ROPS Protective Structure...
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Page 193 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.
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Page 195 SECTION 9C. FUEL TANK GENERAL The fuel tank is located to the left of the operator. A NOTICE sender mounted in the fuel tank controls the fuel gauge mounted in the control panel. The fuel tank holds 9 Dispose of unwanted fuel properly. Check with local U.S.
Page 196 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 197 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.
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Page 199 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 200 REMOVAL 2. After draining, replace the hydraulic tank drain plug. NOTICE NOTICE If available, use a portable filtering unit when drain- The seat and seat platform must be pivoted upward ing the hydraulic oil. If a portable filter is not avail- to allow access to the hydraulic hoses.
Page 201 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.
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Page 203 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 204 Chains Lift Pulley INSPECTION Inspect the lift arm, pulleys, and chains for sloppy or loose operation (Figure 9E-2 and Figure 9E-3). Replace damaged or worn parts and components. NOTICE Lift chains must pivot on the retaining bolts and should be adjusted with the use of the self locking nuts on the chain retaining bolts.
Page 205 11. Attach the weight transfer springs to the upper anchor bolts. Pivot Bolt Lift Pulley Roll Pin Guide Lift Arm Spacer Lift Cylinder Pivot Shaft Lift Chain Slack Arm Bracket Chain Slack Arm Figure 9E-4. Lift Cylinder Assembly Exploded View 9E-15...
Page 206 Page Intentionally Blank 9E-16...
Page 207 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 208 14.Adjust equal turning radius by adjusting ball joint 15.Start the engine and test all components for on steering cylinder rod. proper operation. Mounting Bolt Rear Axle Pivot Hex Nut Steering Axle Ball Joint Tie Rod Steering Traction Cylinder Motor Steering Ball Joint Tie Rod Steering...
Page 209 SECTION 9G. ROLLOVER PROTECTION STRUCTURE (ROPS) GENERAL CAUTION The optional Roll Over Protection Structure (ROPS) is intended for installation on the Turfcat. The structure is The Roll Over Protection Structure (ROPS) should used to protect the operator in the event of a machine be installed on units designed for proper installation, rollover (Figure 9G-1).
Page 210 3. Locate the ROPS mounting holes on the side of the frame behind the fuel and hydraulic tanks WARNING (Figure 9G-2). 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 211 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 212 ELECTRICAL SYSTEM Glow Plugs..............................31 Glow Plug Test (R1) ..........................31 Gauges ................................. 33 General ..............................33 Gauge Test (U3 & U4)..........................33 10M Wiring Diagrams and Component Locations ....................35...
Page 213 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 214 ELECTRICAL SYSTEM Page Intentionally Blank 10A-2...
Page 215 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 216 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 217 ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS GENERAL wiring to the component. A common method of testing wires or circuits is to perform a continuity check as Repair of the electrical system is generally limited to described below. the replacement of defective components or wiring. Wiring diagrams and Component Location illustrations NOTICE are provided in Section 10L for troubleshooting and...
Page 218 ELECTRICAL SYSTEM  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 219 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 220 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 221 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM GENERAL ALTERNATOR (U1) VOLTAGE TEST The charging system consists of a 40 amp alternator with 1. Set the multimeter to 20 DC volts. a built-in rectifier/regulator. 2. Connect the NEG (-) lead of multimeter to a good The alternator must be disassembled to test the stator, ground.
Page 222 ELECTRICAL SYSTEM 7. With the alternator connected to the wire harness, 2. Set the multimeter to the 20 Volt DC scale. turn the key to the ignition position. The alternator 3. With the engine off, touch red lead to exposed bat- light (L1) should illuminate.
Page 223 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. STARTER (M1) FIELD TEST Starter Motor Solenoid 1. Disconnect the brown wire from the starter motor solenoid (Figure 10F-1).
Page 224 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 225 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 226 ELECTRICAL SYSTEM c. Hold the ignition switch in the GLOW PLUG lead to terminal 50. Test all pin positions. position and connect one test lead to terminal Continuity should be available between termi- 30 and one lead to terminal 19. Test all pin nals 30, AC, 50, and 19.
Page 227 ELECTRICAL SYSTEM No Continuity Between Contacts. B - 30 S - 50 1 - AC GP - 19 Step 5a. Ignition Switch in OFF Position (0) Continuity Between Contacts 30 and AC. B - 30 S - 50 1 - AC GP - 19 Step 5b.
Page 228 ELECTRICAL SYSTEM PARKING BRAKE SWITCHES (SW5 NEUTRAL SWITCH (SW3) & SW11) General General The neutral switch (Figure 10G-5) is a double pole nor- mally closed (DPNC) switch, which means current can The parking brake switches (Figure 10G-4) are a single travel through the switch until the switch is depressed.
Page 229 ELECTRICAL SYSTEM MOW (DECK) SWITCH (SW4) 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 230 ELECTRICAL SYSTEM Terminal 2 Yellow Wire Terminal 5 Blue Wire Terminals Rows Terminal 4 Not Used Orange Wire Figure 10G-9. Mow (Deck) Switch Terminals PTO ENABLE SWITCH (SW10) General The PTO enable switch is a single pole normally closed (SPNC) switch, which means current can travel through the switch until activated.
Page 231 ELECTRICAL SYSTEM DIFFERENTIAL LOCK SWITCH HORN SWITCH (SW8) - OPTIONAL (SW9) - OPTIONAL General General The horn switch is a single pole normally open (SPNO) switch, which means no current can travel through the The foot switch is a single pole normally open (SPNO) switch until activated.
Page 232 ELECTRICAL SYSTEM Page Intentionally Blank 10G-20...
Page 233 ELECTRICAL SYSTEM SECTION 10H. SENDERS GENERAL COOLANT TEMPERATURE SWITCH TEST (SW6) 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 234 ELECTRICAL SYSTEM ENGINE OIL PRESSURE SWITCH 5. Start the engine and perform the continuity test again. TEST (SW7) Continuity should not be available between the The oil pressure switch 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 panel.
Page 235 ELECTRICAL SYSTEM Fuel Sender Fuel Sender Ground Fuel Gauge Fuel Sender Test Figure 10H-4. Fuel Sender Test 10H-23...
Page 236 ELECTRICAL SYSTEM Page Intentionally Blank 10H-24...
Page 237 ELECTRICAL SYSTEM SECTION 10I. RELAYS AND SOLENOIDS RELAYS (K1- K5) 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 238 ELECTRICAL SYSTEM SEAT TIME DELAY MODULE (U5) 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 239 ELECTRICAL SYSTEM If the other coil tests are satisfactory, the component 5. Connect the test leads: red test lead to dark blue/ needs to be tested to determine if the fluid is present at white wire at the wiring harness connector and the solenoid and if the poppet or plunger is moving to black test lead to the black wire.
Page 240 ELECTRICAL SYSTEM FUEL SOLENOID TEST (K7) • There should be battery voltage reading on the multimeter. When the ignition switch is placed in the START posi- FUEL SOLENOID (K7) RESISTANCE tion, the fuel solenoid plunger is drawn open allowing fuel to flow to the engine fuel system. TEST ...
Page 241 ELECTRICAL SYSTEM SECTION 10J. FUSES & CIRCUIT BREAKERS FUSE (F1) TEST CIRCUIT BREAKER (CB1) TEST The fuse is located in the fuse block mounted on the A 40 Amp circuit breaker (CB1) protects the electrical right side of the mower frame in front of the engine system between the alternator and battery voltage cir- compartment.
Page 242 ELECTRICAL SYSTEM Page Intentionally Blank 10J-30...
Page 243 ELECTRICAL SYSTEM SECTION 10K. GLOW PLUGS GLOW PLUG TEST (R1) 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 244 ELECTRICAL SYSTEM Page Intentionally Blank 10K-32...
Page 245 ELECTRICAL SYSTEM SECTION 10L. GAUGES GENERAL GAUGE TEST (U3 & U4) 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 246 ELECTRICAL SYSTEM Page Intentionally Blank 10L-34...
Page 247 ELECTRICAL SYSTEM SECTION 10M. WIRING DIAGRAMS AND COMPONENT LOCATIONS Alternator Temperature Sender Starter Battery Relays and Fuse Brake Switches Neutral Start Switch PTO Enable Switch Deck Valve Figure 10M-1. Electrical Component Location 10M-35...
Page 248 ELECTRICAL SYSTEM Turfcat - Electrical Schematic Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5) Sender (R3) Temp Guage (U4)
Page 249 ELECTRICAL SYSTEM Turfcat - Unswitched Power Schematic Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5) Sender (R3)
Page 250 ELECTRICAL SYSTEM Turfcat - Ignition Circuit Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5) Sender (R3) Temp Guage (U4)
Page 251 ELECTRICAL SYSTEM Turfcat - Preheat Circuit - Glow Plugs Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5)
Page 252 ELECTRICAL SYSTEM Turfcat - Start Circuit Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Horn (U6) Temperature Switch (SW6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5) Sender (R3) Temp Guage (U4)
Page 253 ELECTRICAL SYSTEM Turfcat - Run Circuit - Operator In Seat Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5)
Page 254 ELECTRICAL SYSTEM Turfcat - Run Circuit - Operator Out of Seat Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Horn (U6) Temperature Switch (SW6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel...
Page 255 ELECTRICAL SYSTEM Turfcat - Mowing Circuit Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Horn (U6) Temperature Switch (SW6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel Parking Brake Switch (SW5) Sender (R3) Temp Guage (U4)
Page 256 ELECTRICAL SYSTEM Turfcat - Alarm Circuit - Mowing - Engine Overheat Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye Fuel...
Page 257 ELECTRICAL SYSTEM Turfcat - Alarm Circuit - Forward - Parking Brake On Differential Lock Switch (SW9) Flow Divider Solenoid (K8) V V V Og/Ye Og/Ye Light Connector Temperature Switch (SW6) Horn (U6) Hour Meter (U2) Og/Ye Horn Button Switch (SW8) Bk/Wh Fuel Gauge (U3) Og/Ye...
Page 258 ELECTRICAL SYSTEM 10M-46...
Page 259 PREVENTIVE MAINTENANCE SECTION 11 PREVENTIVE MAINTENANCE General ................................1 Specifications ............................1 Scheduling ............................... 1 Administration ............................1 Lubrication and Maintenance Schedules......................3 General ..............................3 Maintenance Schedule..........................4 Flail Mower............................... 6...
Page 260 PREVENTIVE MAINTENANCE Page Intentionally Blank...
Page 261: Specifications
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 262 PREVENTIVE MAINTENANCE Page Intentionally Blank 11A-2...
Page 263: General
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 264: Maintenance Schedule
PREVENTIVE MAINTENANCE MAINTENANCE SCHEDULE hours of operation, replace the engine oil, and related filters. Refer to the Maintenance Section of the Parts Verify proper adjustment of the cutter deck belts daily and Maintenance Manual for additional maintenance during the first 15 hours of operation. After the first 50 infromation.
Page 265 PREVENTIVE MAINTENANCE Arrows show lubrication points. Figure 11B-2. Tractor Lubrication Points Table 11B-1: Fluid Specifications Fluids Quantity Type Engine Oil 6 quarts (5.7 liters) 10W30 CD or CE Hydraulic Oil 6.8 gallons (25.7 liters) Jacobsen 10W30 Hydraulic Fluid 2500548 GreensCare 68 Biodegradable Oil 5003103 GreensCare 68 Plus Biodegradable Oil 4219860 Radiator Coolant 1.7 gallons (6.4 liters)
Page 266: Flail Mower
PREVENTIVE MAINTENANCE FLAIL MOWER Flail Mowers (1) Caster Spindles Lubricate grease fittings every 50 hours of operation or (2) Rotor Bearings more frequently when operating in extremely dusty con- (3) Roller Bearings ditions. (4) Push Arm Pivots (5) Motor Spline Adaptor 1.
Page 267 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 268 ATTACHMENTS Page Intentionally Blank...
Page 269: Materials Required
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)
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Page 271: General
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.
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Page 273: Contents
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 274 ATTACHMENTS Table 12C-1: Mower Specifications (Continued) Cutting Width of Deck Cutting Shipping Mowing Model Type Units Width* Height Weight Rate 956023 60 in (153 3 - 21 in 60 in 61 in 1-4.75 in 390 lbs 3.2 acres/hr Rotary mm) rear (53.3 mm) (153 cm) (155 mm)
Page 275: Mower Deck
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 276: 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 277: 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 278 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 279: Drive Motor Removal
ATTACHMENTS Caster Mount Spacers Hanger Hole Height of Cut Caster Mount 1.0 in 0.25 in (1) 1.25 in 0.5 in (1) 1.5 in High Spacers 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 280: Drive Motor Installation
ATTACHMENTS Support Cutter Deck Yoke Tire 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 281: Inspecting Blades
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 282: Sharpening Blades
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 283: 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. Cutter Deck Figure 12D-18. Belt Tension If necessary, loosen bolt. While holding bracket (S) move bracket to obtain a 0 –...
Page 284: Blade Spindles
ATTACHMENTS BLADE SPINDLES Pulley Tighten spindle nut to 100-150 ft. lbs. (135-203 Nm) Cutter Deck Figure 12D-20. Side and Rear Discharge Blade Spindle 12D-16...
Page 285 ATTACHMENTS Tighten spindle nut to 100-150 ft. lbs. 135-203Nm) Figure 12D-21. Envirodeck Blade Spindle 12D-17...
Page 286: Side Discharge Deck
ATTACHMENTS SIDE DISCHARGE DECK Figure 12D-22. Side Discharge Deck 12D-18...
Page 287 ATTACHMENTS Figure 12D-23. Side Discharge Deck – Components 12D-19...
Page 288 ATTACHMENTS Attach To Spring Bracket On Tractor Tower (Chain) Figure 12D-24. Side Discharge Deck – Hydraulic Motor Mounting 12D-20...
Page 289: Rear Discharge Deck
ATTACHMENTS REAR DISCHARGE DECK Figure 12D-25. Rear Discharge Deck 12D-21...
Page 290 ATTACHMENTS Figure 12D-26. Rear Discharge Deck – Components 12D-22...
Page 291 ATTACHMENTS Figure 12D-27. Rear Discharge Deck – Hydraulic Motor Mounting 12D-23...
Page 292: Envirodeck
ATTACHMENTS ENVIRODECK Figure 12D-28. Envirodeck 12D-24...
Page 293 ATTACHMENTS Figure 12D-29. Envirodeck – Components 12D-25...
Page 294 ATTACHMENTS Figure 12D-30. Envirodeck – Mulching Insert 12D-26...
Page 295: 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 296: 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 297: Cutting Height Adjustment
ATTACHMENTS CUTTING HEIGHT ADJUSTMENT reduces wear to the rear roller and provides anti-scalp- ing control. The cutting height for vertical mowers can be adjusted To improve anti-scalping control or create striping between 0-4 inches (0-102 mm). Actual cutting height effects, remove adjusting pin from push arm and adjust may vary somewhat from the heights given depending height using only rear roller and caster wheel –...
Page 298: Drive Belt
ATTACHMENTS The rear roller can be adjusted by inserting the bolts 1. Locate height of cut in Table 12E-1. into one of six holes. Use the Table 12E-1 (column #3) 2. Position push arm adjustment pin in hole 4. for bolt placement. The bolts must be inserted into the same holes on both sides of the mower.
Page 299: 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 300: 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 301: Flail Deck
ATTACHMENTS FLAIL DECK LIFT CHAIN ON TRACTOR SPRING MOUNT ON TRACTOR PUSHARM MOUNT ON TRACTOR SERIAL PLATE DECK DRAIN HOSE ON TRACTOR Figure 12E-13. Flail Deck – Push Arms and Hydraulics 12E-33...
Page 302 ATTACHMENTS Figure 12E-14. Flail Housing 12E-34...
Page 303 ATTACHMENTS Figure 12E-15. Flail Drive Assembly 12E-35...
Page 304 ATTACHMENTS Page Intentionally Blank 12E-36...
Page 305 OPTIONS SECTION 13 OPTIONS Specifications..............................1 Options..............................1 Rear CounterWeights ............................. 3 General ..............................3 Spark Arrestor..............................5 General ..............................5 Differential Lock .............................. 7 General ..............................7 Flow Divider ............................7 Tie Down Brackets............................11 General ..............................11...
Page 306 OPTIONS Page Intentionally Blank...
Page 307: Options
OPTIONS SECTION 13A. SPECIFICATIONS OPTIONS Rear Counterweight ........ 23 lbs (10 Kg) 13A-1...
Page 308 OPTIONS Page Intentionally Blank 13A-2...
Page 309: General
OPTIONS SECTION 13B. REAR COUNTERWEIGHTS GENERAL Rear counterweights can be added to the rear of the machine to improve balance of the machine. Adding additional counterweights can improve traction on rear axle of four wheel drive machines. Two wheel drive machines come standard with 9 counterweights.
Page 310 OPTIONS Page Intentionally Blank 13B-4...
Page 311: Spark Arrestor
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 312 OPTIONS Page Intentionally Blank 13C-6...
Page 313: General
OPTIONS SECTION 13D. DIFFERENTIAL LOCK GENERAL From the Traction Pump An optional differential lock system (Figure 13D-1) is FWD Port To the Right Front available on two wheel drive models. The differential Traction Motor lock includes a flow divider mounted on the front axle. To the Left Front The flow divider is positioned between oil flow from Traction Motor...
Page 314 OPTIONS 69168 2WD Units with Optional Lift Steering Cylinder Cylinder Differential Lock Kit - “OFF” .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve Flow Divider Valve 915 psi 1.35 ci 3625 psi 11.9 ci 11.9 ci Gear 3100...
Page 315 OPTIONS 69168 2WD Units with Optional Lift Steering Cylinder Cylinder Differential Lock Kit - “ON” .070 6.6 ci Lift Valve Aux Out Steering Valve 1.27 ci 3200 psi Deck Valve Flow Divider Valve 915 psi 1.35 ci 3625 psi 11.9 ci Gear 11.9 ci 3100...
Page 316 OPTIONS Page Intentionally Blank 13D-10...
Page 317: 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 318 OPTIONS Page Intentionally Blank 13E-12...
Page 319 MISCELLANEOUS SECTION 14 MISCELLANEOUS Decal Locations .............................. 1 Conversion Charts ............................5 Millimeters to Decimals Conversion ......................5 Decimals to Millimeters, Fractions to Decimals to Millimeters Conversion ..........7 US to Metric Conversion ........................10...
Page 320 MISCELLANEOUS Page Intentionally Blank...
Page 321 MISCELLANEOUS SECTION 14A. DECAL LOCATIONS Figure 14A-1. Decals - Refer to the “Safety and Operation Manual” for decal descriptions 14A-1...
Page 322 MISCELLANEOUS Figure 14A-2. Decals and Serial Plate 14A-2...
Page 323 MISCELLANEOUS Refer to the “Safety and Operation Manual” for decal descriptions Figure 14A-3. Decals - Side and Rear Discharge Decks 14A-3...
Page 324 MISCELLANEOUS ROTATING BLADES THROWN OBJECTS KEEP HANDS AND FEET AWAY. KEEP AREA CLEAR OF PEOPLE STOP ENGINE AND LET BLADES AND PETS. STOP BEFORE REMOVING REMOVE OBJECTS BLADE MAY GRASS COLLECTION OR STRICK AND THROW. UNCLOGGING. STOP BLADES TO CROSS GRAVEL AREAS DO NOT OPERATE WITHOUT CHUTE, MULCHER OR ENTIRE GRASS...
Page 325 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 326 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 327 MISCELLANEOUS DECIMALS TO MILLIMETERS, FRACTIONS TO DECIMALS TO MILLIMETERS CONVERSION Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters Decimal Decimal Fraction Decimal Fraction Decimal 0.001 0.0254 0.500 12.7000 1/64 0.0156 0.3969 33/64 0.5156 13.0969 0.002 0.0508 0.510 12.9540 1/32 0.0312 0.7938...
Page 328 MISCELLANEOUS Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters (Continued) Decimal Decimal Fraction Decimal Fraction Decimal 0.150 3.8100 13/64 0.2031 5.1594 45/64 0.7031 17.8594 0.160 4.0640 0.700 17.7800 7/32 0.2188 5.5562 23/32 0.7188 18.2562 0.170 4.3180 0.710 18.0340 15/64 0.2344 5.9532...
Page 329 MISCELLANEOUS Table 14B-2: Decimals to Millimeters, Fractions to Decimals to Millimeters (Continued) Decimal Decimal Fraction Decimal Fraction Decimal 0.900 22.8600 0.400 10.1600 0.910 23.1140 0.410 10.4140 0.920 23.3680 7/16 0.4375 11.1125 15/16 0.9375 23.8125 0.420 10.6680 0.930 23.6220 0.430 10.9220 0.940 23.8760 0.440...
Page 330 MISCELLANEOUS US TO METRIC CONVERSION Table 14B-3: US to Metric To Convert Into Multiply By Miles Kilometers 1.609 Yards Meters 0.9144 Feet Meters 0.3048 Linear Measurement Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Square Miles Square Kilometers 2.59 Square Feet...
Page 331 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 600 Series Manual

Section 2 Controls

Section 3 Engine

Section 4 Drive Train

Section 5 Brake System

Section 6 Steering

Section 7 Wheels and Tires

Section 8 Hydraulics

Section 11 Preventive Maintenance

Section 12 Attachments

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