Page 1 AR-5™ and AR-522™ Rotary Mower Technical/Repair Manual 68080, 68082, 68098...
Page 5 This manual provides detailed information and procedures to safely repair and maintain the following: WARNING Jacobsen AR-5 and AR-522 rotary mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user...
Page 6 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2008, Jacobsen, a Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.”...
Page 7: Table Of Contents
Table of Contents Safety Specifications and General Information Engine Electrical Hydrostatic Power Train Hydraulics Steering Cutting Unit Accessories and Miscellaneous Repair...
Page 9 Chapter 1 Safety Introduction ..............1-2 Prepare for the Job .
Page 10: Introduction
SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
Page 11 SAFETY TN1443, TN1444 Figure 1-1 4181383 First Edition...
Page 12 8. Do not use on slopes greater than 20 °. 4131828 OPERATION READ MANUAL BEFORE OPERATING REPLACEMENT MANUAL AVAILABLE FROM: JACOBSEN TEXTRON - CHARLOTTE, NC DANGER DANGER To Start To Stop / Park Parking Brake....On Traction Pedal..Neutral KEEP HANDS AND FEET AWAY Traction Pedal..Neutral...
Page 13: Inspect Safety Labels
SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figure 1-3. mower. Inspect the mower for any damaged, missing, or WARNING unreadable decals. Replace decals as needed before placing the mower back in service. Before cleaning, adjusting, or repairing this equipment, disengage all drives, engage park Keep Work Area Clean...
Page 14: Use Lifting Equipment Safely
SAFETY Use Lifting Equipment Safely Use Compressed Air and Air Tools Safely WARNING WARNING Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Always wear approved eye and ear protection Using underrated or worn lifting components can while using compressed air.
Page 15: Service Tires Safely
SAFETY Service Tires Safely Handle Fuel Safely Handle fuel with care—it is highly flammable. WARNING WARNING An inflated tire contains explosive force. Use care when handling wheels and tires. • Never remove the fuel cap from the fuel tank, or add fuel, when the engine is running or while the engine is hot.
Page 16: Handle Chemical Products Safely
SAFETY Handle Chemical Products Service Hydraulic System Safety Safely WARNING WARNING The hydraulic system is under pressure, and the oil may be hot! Exposure to chemical products could result in • Always allow the machine to cool completely serious injury. Handle chemical products with before performing service.
Page 17: Service Electrical Components Safely
SAFETY Service Electrical Components Safely WARNING Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury. •...
Page 18 SAFETY Page Intentionally Blank 1-10 4181383 First Edition...
Page 19 Chapter 2 Specifications and General Information Mower Identification ............2-2 Model Identification Number .
Page 20 SPECIFICATIONS AND GENERAL INFORMATION Mower Identification Serial Number An identification plate (1) listing the serial number is See Figures 2-1 through 2-3. attached to the frame of the tractor and is located just over the rear axle on the right side. The serial number plate indicates the year of manufacture (3) and the model/serial number (4).
Page 21 SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figures 2-4 and 2-5. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN1443 Seat Left Front Cutting Unit Control Panel Center Front Cutting Unit Steering Wheel Right Front Cutting Unit Traction Pedal Right Rear Cutting Unit...
Page 22 SPECIFICATIONS AND GENERAL INFORMATION TN1444 Hydraulic Oil Tank Rear Wheel Motor (2) Left Rear Cutting Unit 4WD Valve Front Wheel Motor (2) Figure 2-5: Component Location—Left Side 4181383 First Edition...
Page 23 SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Electrical Test Specifications Resistance Across Solenoid Coil— 7.0 ± 10% ohms Raise Solenoid Coil at 68°F Resistance Across Solenoid Coil— 6.0 ± 10% ohms Lower Solenoid Coil at 68° F Resistance Across Solenoid Coil— 9.8 ±...
Page 24 SPECIFICATIONS AND GENERAL INFORMATION Hydraulics Test and Adjustment Specifications Front Cutting Unit Pump Flow 10.8 (40.8) at 2850 rpm gpm (lpm) Rear Cutting Unit Pump Flow 10.8 (40.8) at 2850 rpm gpm (lpm) Lift/Steer Pump Flow 6.1 (23) at 2850 rpm gpm (lpm) Hydraulic Leakage Percentage Ranges 0–10% = Good...
Page 25 SPECIFICATIONS AND GENERAL INFORMATION Steering Test Specifications Steering System Leakage Test— Zero—Nominal Amount pt (L) Cylinder Leakage Repair Specifications Steering Wheel Nut Torque 25—30 (34—41) lb-ft (N·m) Steering Cylinder Ball Joint-to- 80—110 (108—149) lb-ft (N·m) Steering Arm Torque Tie Rod Ball Joint-to-Steering Arm 30—35 (41—47) lb-ft (N·m) Torque...
Page 26 SPECIFICATIONS AND GENERAL INFORMATION Rear Tire AR-5 Model 68080 Size 20 x 12.00-8 Early Models Size 22.5 x 10.00-8 Late Models Type Turf Trac, 4-Ply Air Pressure 12 (83) psi (kPa) Mounting Bolt Torque 85—95 (115—128) lb-ft (N·m) Rear Tire AR-522 Model 68082 and 68098 Size 22.5 x 10.00-8...
Page 27 SPECIFICATIONS AND GENERAL INFORMATION AR-5 Model 68080 and AR-522 Model 68082 ® Manufacturer/Model Kubota Tier 2/V2003-M-T E2B Engine Type 4-stroke, diesel Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45) Number of Cylinders/Configuration 4, in-line Displacement 112 (1835) cu in. (cc) Bore x Stroke 3.27 x 3.64 (83 x 92.4) in.
Page 28 SPECIFICATIONS AND GENERAL INFORMATION Weights and Dimensions— AR-5 Model 68080 Overall Weight 3951 (1792) lb (kg) Width of Cut 90 (2286) in. (mm) Overall Width 98 (2489) in. (mm) Overall Height with OPS 83 (2108) in. (mm) Overall Height with OPS & Canopy 89 (2260) in.
Page 29 SPECIFICATIONS AND GENERAL INFORMATION Standard Torque Values NOTE NOTICE Jacobsen uses Grade 5 plated bolts as standard, unless All torque values included in these charts are otherwise noted. When tightening plated bolts, use the approximate and are for reference only. Use of value given for lubricated.
Page 30 SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-12 4181383 First Edition...
Page 31 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .
Page 32: Specifications
ENGINE Specifications General Engine Specifications Engine AR-5 Model 68080 and AR-522 Model 68082 ® Manufacturer/Model Kubota V2003-M-T E2B Engine Type 4-stroke, diesel Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45) Number of Cylinders/Configuration 4, in-line Displacement 121.9 (1999) cu in. (cc) Bore x Stroke 3.27 x 3.64 (83 x 92.4) in.
Page 33: Component Location
ENGINE Component Location Kubota V2003-M-T E2B See Figures 3-1 and 3-2. TN1447, TN1449 Radiator/Hydraulic Oil Cooler Hydraulic Oil Filter Thermostat Alternator Air Cleaner Assembly Fan Drive Belt Turbocharger Coolant Overflow Reservoir Muffler Starter Motor Exhaust Pipe Oil Pressure Sending Unit Figure 3-1: Component Location—Right Side 4181383 First Edition...
Page 34 ENGINE TN1448, TN1467 Dust Evacuator Battery Engine Oil Filter Fuel Pump Oil Filter Adapter Fuel Filter Throttle Cable Engine Oil Cooler Figure 3-2: Component Location—Left Side 4181383 First Edition...
Page 35: Checks And Adjustments
ENGINE Checks and Adjustments 5. Place the engine throttle lever (4) against the max speed screw (5). Throttle Cable Adjustment See Figures 3-3 through 3-5. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Stop the engine and remove the ignition key. TN1487 Figure 3-5 6.
Page 36: Repair
ENGINE Repair Fan Belt Removal and Installation See Figures 3-6 and 3-7. NOTE Inspect and adjust the new engine belt after the first 50 hours of operation. Check and adjust annually thereafter. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.
Page 37: Air Cleaner Assembly
ENGINE Air Cleaner Assembly Removal and Installation See Figures 3-8 through 3-10. CAUTION • Do not open the air cleaner assembly for inspection and cleaning until the air filter restriction gauge indicates air filter restriction. Removing the air filter increases the possibility of dust, dirt, and contaminants entering the engine.
Page 38: Muffler
ENGINE Muffler Removal, Inspection, and Installation See Figures 3-11 and 3-12. CAUTION Do not attempt to service the exhaust system when the engine is hot. Serious personal injury can occur. NOTES • If a change in the color or sound of the exhaust occurs, stop the engine immediately, identify the TN1470 problem and repair as necessary.
Page 39: Exhaust Manifold And Turbocharger
ENGINE Exhaust Manifold and Turbocharger Removal and Installation See Figures 3-13 and 3-14. WARNING Engine components will become hot during operation. Allow engine components to cool before performing service. Failure to follow safety recommendations may result in injury. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.
Page 40: Radiator/Hydraulic Oil Cooler
ENGINE Radiator/Hydraulic Oil Cooler Removal and Installation See Figures 3-15 through 3-19. TN1478 Figure 3-15 NOTE WARNING Label all hoses before removing to ensure correct Never remove the radiator cap when the coolant installation. is hot. The engine must be shut down and cooled 6.
Page 41 ENGINE TN1509 TN1510 Figure 3-16 Figure 3-18 10. Loosen hose clamp (9) and disconnect overflow hose 12. Disconnect hydraulic hose (11) from the bottom of (8) from the radiator/hydraulic cooler. the radiator/hydraulic cooler. TN1508 TN1481 Figure 3-17 Figure 3-19 11. Disconnect hydraulic fitting (10) from the top of the 13.
Page 42: Thermostat
ENGINE 16. While supporting the radiator, remove two screws, 2. Stop the engine and remove the ignition key. Allow four nuts, and the flat washers from each side of the the engine to cool completely. radiator. The sheet metal splash guards will fall away 3.
Page 43: Throttle Cable And Control Lever
ENGINE Throttle Cable and Control Lever and Installation Removal 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Stop the engine and remove the ignition key. TN1496 Figure 3-23 5. Remove the cable clamp (7) and the wire stop screw (4).
Page 44: Fuel Filter
ENGINE Fuel Filter 10. Lightly lubricate the filter seal with clean oil and install. Tighten the filter hand tight plus one-half turn. Removal and Installation 11. Open the petcock on the bottom of the fuel tank. 12. Purge air from the fuel system after installing the new See Figure 3-24.
Page 45: Engine
ENGINE NOTE Record the orientation of the fuel pump before removing to ensure correct installation. 10. Remove two lock nuts (4), two screws (5), and four flat washers (6). 11. Remove fuel pump (10). Installation Note Install the fuel pump by reversing the order of removal. Engine Removal and Installation TN1516...
Page 46 ENGINE 16. Remove the fuel filter mounting screws (8) and fuel WARNING outlet hose (9). Support and move the fuel filter assembly away from the engine. Prevent personal injury. Use a properly rated 17. Remove the battery box (7). lifting device. Always be sure the load is balanced before lifting.
Page 47: Engine Service
ENGINE Engine Service 18. Using an engine hoist, support the engine (10) and remove the four engine mounting bolts (11). A separate engine manual, prepared by the engine 19. Check for any connected wires and components, manufacturer, is supplied with this machine. Refer to the carefully remove the engine from the machine.
Page 48 ENGINE Page Intentionally Blank 3-18 4181383 First Edition...
Page 49 Chapter 4 Electrical Specifications ..............4-4 Test and Adjustment Specifications .
Page 50 ELECTRICAL Troubleshooting ............. . 4-46 Control Module .
Page 51 ELECTRICAL Repair ..............4-66 Battery and Battery Tray .
Page 52: Specifications
ELECTRICAL Specifications Test and Adjustment Specifications Specifications Resistance Across Solenoid Coil— 7.0 ± 10% ohms Raise Solenoid Coil at 68°F Resistance Across Solenoid Coil— 6.0 ± 10% ohms Lower Solenoid Coil at 68° F Resistance Across Solenoid Coil— 9.8 ± 10% ohms Mow Solenoid Coil at 68°...
Page 53: Theory And Diagnostic Information
ELECTRICAL Theory and Diagnostic Information Electrical Component Symbols The following symbols are used in the electrical schematics to represent various electrical components. Switches Single Pole, Single Throw Double Pole, Single Throw (SPST) (DPST) Single Pole, Double Throw Double Pole, Double Throw (SPDT) (DPDT) Proximity Switch...
Page 54 ELECTRICAL Motors and Generating Devices Electric Motors (may also Stator include “AC” or “DC.”) Alternator Actuating Devices Solenoid Valve PTO Clutch Engine-Related Devices Ignition Coil Spark Plug Regulator Fuel Shutoff Solenoid Pull-In Hold-In Lights Single-Element Light Dual-Element Light 4181383 First Edition...
Page 55 ELECTRICAL Miscellaneous Symbols Enclosure Wires (crossing but not (cabinet, housing, etc.) connected) Ground (to earth) Wiring Connections Ground (to chassis) Coil Direct Current (DC) Battery (as shown on an oscilloscope) Alternating Current (AC) Diode (as shown on an oscilloscope) Resistor Pin and Socket Connector 4181383 First Edition...
Page 56: Electrical Schematic Component Identification
ELECTRICAL Electrical Schematic Component Identification Electrical components shown in the main schematic are identified with an alpha-numeric callout. All electrical components shown in the electrical schematic are listed below. • A1—Control Module (See Figure 4-2.) • J2—Control Module Connector (See Figure 4-2.) •...
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Page 58: Electrical Schematic
ELECTRICAL Electrical Schematic See Figures 4-1 through 4-4. Org/Yel Org/Yel Splice 90 Splice 90 Horn Org/ Switch Switch Horn Org/Wht Pnk/Blk Pnk/Blk Org/ Start Pnk/Blk Org/Yel Org/Yel Pnk/Blu Pnk/Blu Org/ Org/ Org/ Org/ Org/ Org/ Org/ Engine Hydraulic Filter Glow Alternator Pressure Pressure...
Page 59 ELECTRICAL Electrical Schematic Continued Org/Yel Splice 90 Splice 90 Splice 90 Org/ Pnk Org/ Pnk Org/Blk Org/Blk Org/ Org/ J3-3 J3-5 J3-6 J3-7 J3-4 Fuse Fuse Org/Yel J3-2 Switch Power (+) Brn/Wht Brn/Wht Pnk/Blk Neutral Switch Input J1-2 J3-10 Horn Output (+) Brn/Red Brn/Red Org/Yel...
Page 60 ELECTRICAL Electrical Schematic Continued Splice 90 Splice 90 Splice 100 Org/ Pnk Org/Blk Org/Blk Brn/Red Org/ Neutral Park Proximity Org/ Hydraulic Oil Brake Switch Level Proximity Brn/ Brn/Wht Seat Switch Switch Switch N.O. Gry/Wht Org/Pnk Brn/Red Org/Pnk N.O. Gry/Wht Org/ Switch Gry/Yel Org/Pnk...
Page 61 ELECTRICAL Electrical Schematic Continued Splice 90 Splice 90 Org/Wht Org/Blk Org/Blk Brn/Red Cruise Control Switch (Optional) Cruise Org/Wht Control Module Org/ (Optional) Org/Pnk Power Input Brn/Red Cancel Input Brn/Tan Magnet Output (+) Ground Brn/ Cruise Control Magnet (Optional) Light Switch Blu/Tan Org/Blk Org/Wht...
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Page 63: Theory Of Operation And Sub Circuit Schematics
ELECTRICAL Theory of Operation and Sub Splice 90 also provides switched power to the following: • Traction control switch Circuit Schematics • Engine temperature gauge B+ terminal • Cruise control switch (optional) Power Circuit—Theory of Operation Switched power is also provided from engine temperature gauge to the fuel gauge B+ terminal and Unswitched Power Circuit then from the fuel gauge B+ terminal to the hour meter.
Page 64: Power Circuit Schematic
ELECTRICAL Power Circuit Schematic See Figures 4-5 through 4-8. Org/Yel Org/Yel Splice 90 Splice 90 Horn Org/ Switch Switch Horn Org/Wht Pnk/Blk Pnk/Blk Org/ Start Pnk/Blk Org/Yel Org/Yel Pnk/Blu Pnk/Blu Org/ Org/ Org/ Org/ Org/ Org/ Org/ Engine Hydraulic Filter Glow Alternator Pressure...
Page 65 ELECTRICAL Power Circuit Schematic Continued Org/Yel Splice 90 Splice 90 Splice 90 Org/ Pnk Org/ Pnk Org/Blk Org/Blk Org/ Org/ J3-3 J3-5 J3-6 J3-7 J3-4 Fuse Fuse Org/Yel J3-2 Switch Power (+) Brn/Wht Brn/Wht Pnk/Blk Neutral Switch Input J1-2 J3-10 Horn Output (+) Brn/Red Brn/Red Org/Yel...
Page 66 ELECTRICAL Power Circuit Schematic Continued Splice 90 Splice 90 Splice 100 Org/ Pnk Org/Blk Org/Blk Brn/Red Org/ Neutral Park Proximity Org/ Hydraulic Oil Brake Switch Level Proximity Brn/ Brn/Wht Seat Switch Switch Switch N.O. Gry/Wht Org/Pnk Brn/Red Org/Pnk N.O. Gry/Wht Org/ Switch Gry/Yel...
Page 67 ELECTRICAL Power Circuit Schematic Continued Splice 90 Splice 90 Org/Wht Org/Blk Org/Blk Brn/Red Cruise Control Switch (Optional) Cruise Org/Wht Control Module Org/ (Optional) Org/Pnk Power Input Brn/Red Cancel Input Brn/Tan Magnet Output (+) Ground Brn/ Cruise Control Magnet (Optional) Light Switch Unswitched Power Circuit Switched Power Circuit...
Page 68: Charging Circuit-Theory Of Operation
ELECTRICAL Charging Circuit—Theory of Operation Power Circuit Unswitched power is available from the battery positive terminal to the starting motor battery terminal and then from the starting motor battery terminal to 50 amp thermal circuit breaker battery terminal. Unswitched power is available from 50 amp thermal circuit breaker battery terminal to key switch terminal A and control module terminal J3-6.
Page 69: Charging Circuit Schematic
ELECTRICAL Charging Circuit Schematic See Figure 4-9. Org/ Org/ Switch J3-3 J3-6 Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Control Module Ground J3-8 Org/ Splice 90 Org/ Org/ Org/ Org/ Org/ Org/ Org/ Org/ Engine Hydraulic Filter Glow...
Page 70: Start And Glow Plug Circuit-Theory Of Operation
ELECTRICAL Start and Glow Plug Circuit—Theory With the brake pedal in the locked position, the brake pedal linkage is brought near the magnetic target zone of of Operation the park brake proximity switch, activating the switch. With the switch activated, voltage is provided from the Power Circuit proximity switch to control module park brake switch input Unswitched power is available from the battery positive...
Page 71 ELECTRICAL With the starter solenoid energized, voltage is also provided from the starter solenoid contacts to control module fuel pull-in input terminal, activating the input. With the fuel pull-in input activated, control module fuel pull-in output terminal J3-12 provides voltage to the fuel shutoff solenoid pull-in coil, energizing the coil.
Page 72: Start And Glow Plug Circuit Schematic
ELECTRICAL Start and Glow Plug Circuit Schematic See Figures 4-10 through 4-11. Org/Yel Org/Yel Org/Wht Org/ Switch Org/ Start Org/Yel Org/Yel Pnk/Blu Pnk/Blu Org/ Org/ Org/ Org/ Unswitched Power Circuit Org/ Engine Hydraulic Switched Power Circuit Filter Glow Pressure Pressure Start Circuit Plug Light...
Page 73 ELECTRICAL Start and Glow Plug Circuit Schematic Continued Org/Yel Splice 90 Org/Wht Splice 100 Org/ Pnk Org/ Pnk Org/ Pnk Org/ Org/ J3-3 J3-5 J3-6 Fuse Org/Yel J3-2 Switch Power (+) Org/Yel J4-2 Select 2 Input Org/ Neutral Pnk/Blu J1-5 Start Input Proximity Switch Brn/Wht...
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Page 75: Run Circuit-Theory Of Operation
ELECTRICAL Run Circuit—Theory of Operation The control module will de-energize the fuel shutoff solenoid approximately 1 second after the seat switch contacts open. The time delay is to compensate for seat Power Circuit bounce when operating the machine over rough terrain. Unswitched power is available from the battery positive When the operator stops moving the machine and locks terminal to the starting motor battery terminal and then...
Page 76: Run Circuit Schematic-On Seat
ELECTRICAL Run Circuit Schematic—On Seat See Figure 4-12. Splice 100 Org/ Pnk Org/ Pnk Org/ Switch Hydraulic Oil J3-5 J3-6 Level Switch Org/ Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Seat Switch Org/ Control Seat Switch Input J1-8 Module Fuel J2-7 Fuel Hold Output (+)
Page 77: Run Circuit Schematic-Off Seat
ELECTRICAL Run Circuit Schematic—Off Seat See Figure 4-13. Splice 100 Org/ Pnk Org/ Pnk Org/ Switch Hydraulic Oil J3-5 J3-6 Level Switch Org/ Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Seat Switch Org/ Control Seat Switch Input J1-8 Module Fuel J2-7 Fuel Hold Output (+)
Page 78: Raise/Lower Circuit-Theory Of Operation
ELECTRICAL Raise/Lower Circuit—Theory of Note: While mowing the raise/lower function will be in “one touch crosscut” mode, meaning the raise/lower lever Operation only needs to be tapped to move the cutting units to a pre-determined position. When not mowing the Power Circuit raise/lower lever must be held until the cutting units reach Unswitched power is available from the battery positive...
Page 79: Raise Circuit Schematic
ELECTRICAL Raise Circuit Schematic See Figure 4-14. Splice 100 Org/ Pnk Org/ Pnk Hydraulic Oil Level Org/ Switch Switch Org/ J3-6 J3-5 Fuse Org/Yel J3-2 Switch Power (+) Start Seat Switch Org/Yel J4-2 Select 2 Input Org/ Seat Switch Input J1-8 Control Switch Module...
Page 80: Lower Circuit Schematic
ELECTRICAL Lower Circuit Schematic See Figure 4-15. Splice 100 Org/ Pnk Org/ Pnk Hydraulic Oil Level Org/ Switch Switch Org/ J3-6 J3-5 Fuse Org/Yel J3-2 Switch Power (+) Start Seat Switch Org/Yel J4-2 Select 2 Input Org/ Seat Switch Input J1-8 Control Switch Module...
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Page 82: Mow Circuit-Theory Of Operation
ELECTRICAL Mow Circuit—Theory of Operation Mow Circuit When the mow switch is in the mow position, voltage is Power Circuit provided to the control module mow switch input terminal J1-10, activating the input. When the raise/lower switch is Unswitched power is available from the battery positive momentarily placed in the lower position, voltage is terminal to the starting motor battery terminal and then provided to control module lower input terminal J1-12,...
Page 83: Mow Circuit Schematic
ELECTRICAL Mow Circuit Schematic See Figure 4-16. Splice 100 Org/ Pnk Org/ Switch Hydraulic Oil J3-6 J3-5 Level Switch Org/ Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Seat Switch Org/ Control Seat Switch Input J1-8 Module Gry/Yel Mow Switch Input J1-10...
Page 84: Traction Control Circuit-Theory Of Operation
ELECTRICAL Traction Control Circuit—Theory of Note: The height the cutting units are raise to can be calibrated. Calibration is required after hydraulic Operation components are replaced or when the control module is replaced. Power Circuit Unswitched power is available from the starting motor battery terminal to 50 amp thermal circuit breaker battery terminal.
Page 85: Traction Control Circuit Schematic
ELECTRICAL Traction Control Circuit Schematic See Figure 4-17. Splice 90 Org/Wht Splice 100 Org/ Pnk Org/ Org/ Switch Hydraulic Oil J3-6 J3-3 J3-5 Level Switch Org/ Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Seat Switch Tan/Blu J2-3 Raise Solenoid Output (+) Org/...
Page 86: Instrumentation Circuit-Theory Of Operation
ELECTRICAL Instrumentation Circuit—Theory of Hydraulic Filter Pressure Light Operation The hydraulic filter switch is a differential pressure switch. The switch closes when there is a 25 psi (1.724) drop between the inlet and outlet pressures of the filter. Power Circuit When the hydraulic filter pressure switch closes, a Unswitched power is available from the starting motor ground is also provided from the switch to control module...
Page 87 ELECTRICAL Hydraulic Oil Level Light When the hydraulic level switch closes, voltage is provided to control module hydraulic oil level switch input terminal J1-1, activating the input. With the input activated and after a 5 second delay, the control module hydraulic oil level light output terminal J2-9 provides a ground to the hydraulic oil level light, turning on the light.
Page 88: Instrumentation Circuit Schematic
ELECTRICAL Instrumentation Circuit Schematic See Figures 4-18 through 4-19. Splice 90 Org/Wht Org/ Pnk Org/ Org/ Org/ Switch J3-3 J3-5 J3-6 Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Gry/Wht Control Pnk/Blk Hyd Oil Level Sw Input J1-1 J3-10 Horn Output (+) Module Horn...
Page 89 ELECTRICAL Instrumentation Circuit Schematic Continued Org/Wht Splice 100 Org/ Pnk Org/ Pnk Traction Hydraulic Oil Control Level Switch Switch Org/Wht Gry/Wht Org/Pnk Org/Wht Pur/Yel Pur/Yel Org/Wht Hydraulic Level Light Org/Wht Engine Temperature Gauge Back Light Org/Wht Signal Gnd Fuel Org/ Gauge Back Light Signal Gnd...
Page 90: Horn And Light Circuit-Theory Of Operation
ELECTRICAL Horn and Light Circuit—Theory of Operation Power Circuit Unswitched power is available from the battery positive terminal to the starting motor battery terminal and then from the starting motor battery terminal to 50 amp thermal circuit breaker battery terminal. Unswitched power is available from 50 amp thermal circuit breaker battery terminal to key switch terminal A and control module terminals J3-6 and J3-7.When the...
Page 91: Horn And Light Circuit Schematic
ELECTRICAL Horn and Light Circuit Schematic See Figure 4-20. Org/Blk Org/ Org/ Switch Splice 90 J3-3 J3-6 J3-7 J3-4 Org/ Fuse Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Control Pnk/Blk J3-10 Horn Output (+) Module Horn Switch Ground...
Page 92: Optional Cruise Control-Theory Of Operation
ELECTRICAL Optional Cruise Control—Theory of Operation Power Circuit Unswitched power is available from the starting motor battery terminal to 50 amp thermal circuit breaker battery terminal. Unswitched power is available from 50 amp thermal circuit breaker battery terminal to key switch terminal A and control module terminal J3-6.
Page 93: Cruise Control Circuit Schematic
ELECTRICAL Cruise Control Circuit Schematic See Figure 4-21. Splice 90 Splice 100 Org/ Pnk Org/ Pnk Org/ Org/ Org/ Switch J3-3 J3-5 J3-6 Fuse Org/Yel J3-2 Switch Power (+) Start Org/Yel J4-2 Select 2 Input Control Module Cruise Control Switch (Optional) Brn/Red Park Brake Switch Input J1-7...
Page 94: Troubleshooting
ELECTRICAL Troubleshooting Control Module Symptom: Control module does not power up. Probable Cause Remedy Open fuse 20A fuse F2. Test fuse. (See “Fuse Test” on page 4-57.) Faulty control module unswitched power Measure voltage between control module terminal J3-5 and ground. circuit.
Page 95: Charging Circuit
ELECTRICAL Charging Circuit Symptom: Battery not charging. Probable Cause Remedy Faulty alternator output circuit. Make sure alternator output cable and battery positive (+) cable terminals are clean and tight. Check continuity between starter battery terminal and battery positive (+) terminal. Continuity must be indicated.
Page 96: Glow Plug Circuit
ELECTRICAL Glow Plug Circuit Symptom: Glow plugs do not get hot. Probable Cause Remedy Faulty control module output circuit. Cycle key switch between the run and start positions and check control module glow plug relay output LED. If the LED does not come on, substitute the control module with a known good control module.
Page 97: Run Circuit
ELECTRICAL Run Circuit Symptom: Engine stops running when the park brake is released. Probable Cause Remedy Faulty seat switch. With the seat cushion depressed, check control module seat sw input LED. If the LED does not light test the seat switch. Faulty switched power circuit.
Page 98: Mow Circuit
ELECTRICAL Symptom: Raise solenoid does not energize. Probable Cause Remedy Faulty raise/lower switch. With the raise/lower switch in the lower position, check control module joystick raise sw LED. If the LED does not light, test the switch. (See “Raise/Lower Switch Test” on page 4-59.) Faulty switched power circuit.
Page 99: Traction Control Circuit
ELECTRICAL Traction Control Circuit Symptom: Traction control circuit will not operate. Probable Cause Remedy Faulty traction control switch. With the traction control switch in the on position, check control module lvl/deck lift sw input LED. If the LED does not come on, test the switch. (See “Traction Control Switch Test”...
Page 100: Instrumentation Circuit
ELECTRICAL Instrumentation Circuit Lamp and Audible Alarm Check Circuit The control module provides a lamp and audible alarm check circuit. When the key switch is turned to the run position the control module turns on the following for approximately 3 seconds: •...
Page 101 ELECTRICAL Symptom: Hydraulic filter pressure light does not turn on with a blocked filter. Probable Cause Remedy Faulty Control module output circuit. With the key switch in the run position, check control module hydr fltr lamp output LED. If the LED turns on for approximately 3 seconds, check continuity between hydraulic filter pressure light pur/grn wire terminal and control module hydraulic filter pressure light output terminal J2-8.
Page 102: Horn And Audible Alert Circuit
ELECTRICAL Symptom: Engine temperature gauge does not indicate a temperature. Probable Cause Remedy Faulty engine temperature sensor. With a jumper wire, connect the engine temperature sensor to ground. With the key switch in the run position, check the gauge. If the gauge is indicating full scale, replace the engine temperature sensor.
Page 103: Light Circuit
ELECTRICAL Symptom: Horn does not sound with engine temperature reaches overtemp. Probable Cause Remedy Faulty engine temperature sensor input Check continuity between engine temperature sensor grn wire terminal and control circuit. module engine temperature sensor input terminal J2-12. Continuity must be indicated. Light Circuit Symptom: Work lights do not turn on.
Page 104: General Information
ELECTRICAL Component Testing 6. Test the function of the circuit. Does the circuit now operate properly? Electrical System and Component Replace the wire. Testing Continue testing other wires and components in the circuit. General Information Resistance Test Repair of the electrical system, for the most part, is limited to the replacement of defective components or Required Tools or Equipment wiring.
Page 105: Fuse Test
ELECTRICAL Fuse Test Relay Tests Plug-In Fuses Start Relay See Figure 4-22. See Figure 4-23. 1. Park the mower safely. (See “Park Mower Safely” on Required Tools or Equipment page 1-5.) 2. Remove the start relay. (See “Start Relay” on Digital Multimeter, Ohmmeter, or Continuity Tester page 4-70.) 1.
Page 106: Key Switch Test
ELECTRICAL Key Switch Test Glow Plug Relay See Figure 4-24. See Figure 4-25. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, or Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 12-Volt DC Power Source and Leads 1.
Page 107: Raise/Lower Switch Test
ELECTRICAL Raise/Lower Switch Test 5. Check for continuity. Is continuity indicated? See Figure 4-26. Proceed to step 6. Required Tools or Equipment The switch is faulty; replace the raise-lower switch assembly. Digital Multimeter, Ohmmeter, or Continuity Tester 6. Return the raise-lower lever to the center (neutral) position.
Page 108: Traction Control Switch Test
ELECTRICAL Traction Control Switch Test Light Switch Test See Figure 4-27. See Figure 4-28. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 109: Horn Switch
ELECTRICAL Horn Switch Seat Switch Test See Figure 4-29. See Figure 4-30. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 110: Hydraulic Oil Level Switch Test
ELECTRICAL Hydraulic Oil Level Switch Test See Figures 4-31 and 4-32. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Check to make sure hydraulic oil is at the correct level.
Page 111: Solenoid Test
ELECTRICAL Solenoid Test 3. With the ignition key turned to the ON position, use a multimeter to check for battery voltage at the See Figure 4-35. orange/pink wire (1). 4. Battery voltage should be available at terminal (1). If Required Tools or Equipment not, check the wiring harness for loose, broken, or dirty connections.
Page 112: Engine
ELECTRICAL Hydraulic Filter Pressure Switch Test See Figure 4-36. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Shut down the engine and remove the ignition key. 3. Set the multimeter to the continuity setting. TN1596 Figure 4-37 3.
Page 113: Circuit Breaker Test
ELECTRICAL Circuit Breaker Test See Figure 4-39. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Allow engine to cool completely. 3. Set the multimeter to 20 volts DC. 4.
Page 114: Repair
ELECTRICAL Repair Battery and Battery Tray Removal and Installation See Figures 4-42 and 4-43. WARNING • Battery posts, terminals, and related accessories contain lead and lead compounds. Wash your hands after handling. • Always wear eye protection when servicing battery. TN1616 Figure 4-40 1.
Page 115: Alternator
ELECTRICAL Alternator NOTICE Removal and Installation Never place used batteries in the garbage. See Figures 4-44 and 4-45. Dispose of used batteries in accordance with all applicable regulations. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.
Page 116: Starter Motor
ELECTRICAL 13 14 TN1454 TN1455 Figure 4-46 Figure 4-45 4. Remove the boot (6) from the terminal, and slide it 7. Loosen screw (6) and push the alternator (10) toward down the wire (3). the engine. NOTE 8. Remove the fan drive belt (15). 9.
Page 117: Plug-In Fuses
ELECTRICAL Plug-In Fuses Circuit Breaker Removal and Installation Removal and Installation See Figures 4-48 and 4-49. See Figures 4-50 and 4-51. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) page 1-5.) 2.
Page 118: Start Relay
ELECTRICAL Start Relay Glow Plug Relay Removal and Installation Removal and Installation See Figures 4-52 and 4-53. See Figures 4-54 and 4-55. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) page 1-5.) 2.
Page 119: Instrument Panel
ELECTRICAL Instrument Panel Key Switch Removal and Installation Removal and Installation See Figure . See Figures 4-57 and 4-58. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-5.) If servicing individual components, it is not necessary to 2.
Page 120: Rocker Switches
ELECTRICAL Rocker Switches See Figure 4-59. TN1608 Figure 4-60 4. Disconnect the switch (4) from the connector wires TN1626 (5). Figure 4-59 5. Depress tabs (6) on each side of the rocker switch and lift out of the instrument panel. This procedure applies to the following switches: •...
Page 121: Park Brake Proximity Switch
ELECTRICAL Removal and Installation 5. Press in on tabs (3) on each side of the indicator lamp module (4), and push module up through the See Figures 4-62 and 4-63. instrument panel. NOTE Installation Note Restricted hydraulic filter warning/engine temperature Install indicator lamp modules by reversing the order of warning module shown.
Page 122: Raise/Lower Switch
ELECTRICAL 5. Remove park brake proximity switch (6). Installation Note Install the park brake proximity switch by reversing the order of removal. Raise/Lower Switch Removal and Installation See Figures 4-66 and 4-67. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.
Page 123: Solenoid Coils
ELECTRICAL Solenoid Coils See Figures 4-70 and 4-71. TN1469 Figure 4-68 3. Disconnect the wiring connector (1) for the neutral TN1489 proximity switch (2). Figure 4-70: Mow Solenoid Coil TN1483 Figure 4-69 TN1407 4. Remove two screws (3), four washers (5), and two Figure 4-71: Raise and Lower Solenoid Coils nuts (4), and remove neutral proximity switch (6).
Page 124: Fuel Solenoid
ELECTRICAL Fuel Solenoid Removal and Installation See Figure 4-72. Removal and Installation NOTE See Figure 4-73. The raise and lower solenoid coils are shown; all 1. Park the mower safely. (See “Park Mower Safely” on solenoids are removed and installed the same way. page 1-5.) 1.
Page 125: Hydraulic Oil Filter Switch
ELECTRICAL Hydraulic Oil Filter Switch 5. Remove the hydraulic filter switch (2) from the filter head (1). Removal and Installation Installation Notes See Figure 4-74. Required Materials WARNING ® Telfon Tape The hydraulic system is under pressure, and the oil may be hot! •...
Page 126: Engine Temperature Switch
ELECTRICAL 4. Remove screw (1), and disconnect wire (2) from the NOTE oil pressure switch (3). Label all wires before disconnecting to ensure correct 5. Remove the oil pressure switch (3) from the engine installation. block. 4. Remove nut (1), and disconnect wire (2) from the Installation Notes engine temperature switch (3).
Page 127: Fuel And Water Gauge
ELECTRICAL Fuel and Water Gauge Removal and Installation See Figures 4-80 and 4-81. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Disconnect the negative (–) battery cable at the battery. 3. Remove the instrument panel. (See “Instrument Panel”...
Page 128: Fuel Level Sender
ELECTRICAL NOTE Label all wires before disconnecting to ensure correct installation. 5. Remove nut (3), and disconnect wires (1) from fuel level sender (4). 6. Remove five screws (2). 7. Remove fuel level sender (4). Installation Note Install the fuel level sender by reversing the order of removal.
Page 129: Hydrostatic Power Train
Chapter 5 Hydrostatic Power Train Specifications ..............5-2 Test and Adjustment Specification .
Page 130: Specifications
HYDROSTATIC POWER TRAIN Specifications Test and Adjustment Specification Specification Traction Pump Flow 35 (132) at 2850 rpm gpm (lpm) Charge Pump Flow 10.5 (40) at 2850 rpm gpm (lpm) Forward System Relief Pressure 3625 (250) at 2850 rpm psi (bar) Reverse System Relief Pressure 3625 (250) at 2850 rpm psi (bar)
Page 131: Component Location
HYDROSTATIC POWER TRAIN Component Location See Figure 5-2. TN1484, TN1443, TN1395 Left Rear Wheel Motor 4WD Valve Right Rear Wheel Motor Hydrostatic Pump Left Front Wheel Motor Traction Pedal Right Front Wheel Motor Figure 5-2: Power Train Component Location 4181383 First Edition...
Page 132: Theory Of Operation And Sub-Circuit Schematics
HYDROSTATIC POWER TRAIN Theory of Operation and Hot Oil Shuttle Sub-Circuit Schematics The hot oil shuttle is located in the 4WD valve. The hot oil shuttle is held open when there is operating pressure oil in the forward direction. This allows a small amount of Traction Circuit Forward Schematic charge pressure oil to drain to the hydraulic tank for oil and Theory of Operation...
Page 133 HYDROSTATIC POWER TRAIN Traction Circuit—Forward Schematic See Figure 5-3. 3625 psi Tow Valve 2.81 ci Gear Pump 0.85 ci 0.88 ci 0.88 ci 0.5 ci 2850 ±50 RPM 3625 psi Displacement Control Valve Drain 0.31” Supply 0.28” Hydrostatic Traction 285 psi Pump Left Front Left Rear...
Page 134: Traction Circuit Reverse Schematic And Theory Of Operation
HYDROSTATIC POWER TRAIN Traction Circuit Reverse Schematic and Theory of Operation See Figure 5-4. System Conditions: • Engine running • Park brake released • Traction pedal depressed (reverse position) Charge Pressure Circuit The charge pump and traction pump are both driven by the engine.
Page 135 HYDROSTATIC POWER TRAIN Traction Circuit—Reverse Schematic See Figure 5-4. Tow Valve 3625 psi 2.81 ci Gear Pump 0.85 ci 0.88 ci 0.5 ci 2850 ±50 RPM 0.88 ci 3625 psi Drain 0.31” Supply 0.28” Displacement Control Valve Hydrostatic Traction 285 psi Pump Left Front Left Rear...
Page 136: Troubleshooting
HYDROSTATIC POWER TRAIN Troubleshooting Symptom: Mower Will Not Move Forward or Reverse Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Tow valve open.
Page 137 HYDROSTATIC POWER TRAIN Symptom: Excessive Pump Noise Probable Cause Remedy Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and Maintenance Manual” for the correct oil specifications.) Hydraulic oil cold. Warm hydraulic oil to operating temperature. Pump damage.
Page 138: Tests And Adjustments
HYDROSTATIC POWER TRAIN Tests and Adjustments WARNING Transmission Neutral Adjustment Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled. Adjust Transmission Neutral (Creep) See Figures 5-5 and 5-6. CAUTION 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) Engine component will become hot during 2.
Page 139 HYDROSTATIC POWER TRAIN TN1702 Figure 5-6 20. Remove control spool (6) as an assembly. Clean and WARNING inspect. Never operate the engine without proper NOTE ventilation; exhaust fumes can be fatal if inhaled. Control sleeve (7) may be difficult to remove. If needed, use a blind race puller with a slide hammer to remove.
Page 140: Field Test Procedures
HYDROSTATIC POWER TRAIN Field Test Procedures 34. Move the traction pedal to the forward and reverse positions and release the pedal. Pedal should return When a hydraulic system failure occurs, some simple to the neutral position. effective tests can be performed prior to using a test When in the neutral position, there should be no instrument.
Page 141: Wheel Motor Test
HYDROSTATIC POWER TRAIN 2. Install wheel restraints (1) to both front wheels. 10. Measure the amount of oil collected from the case drain. Amount x 4 = amount per minute. 3. Lift the machine so that rear wheels are off the ground and support with stands.
Page 142: Instrument Test Procedures
HYDROSTATIC POWER TRAIN Instrument Test Procedures Calculations: System Test Instrument Test Overview No Load Flow = 15 gpm The following tests are specifically designed to approach Loaded Flow = 9.4 gpm hydraulic testing on a system level. Each component 15 – 9.4 / 10 x 100 = Total System Leakage 37% within the system represents a portion of the total system leakage.
Page 143: Charge Pressure Test
HYDROSTATIC POWER TRAIN Charge Pressure Test See Figures 5-9 and 5-11. WARNING The hydraulic system is under pressure, and the oil will be hot. • Always relieve pressure in the hydraulic system before performing service. • Failure to follow appropriate safety precautions may result in death or serious injury.
Page 144: Traction System Test
HYDROSTATIC POWER TRAIN 9. Retest charge pressure. Is charge pressure 275–285 psi (19–20 bar)? Charge pump is good. Inspect, repair, or replace charge pump as needed. (See “Traction Pump” on page 5-27.) 10. Disconnect and remove test equipment. Install all hoses and fittings as noted prior to removal.
Page 145 HYDROSTATIC POWER TRAIN TN1705 Figure 5-13 7. Install flow lock tool (1) and secure to pump control TN1357 arm. Figure 5-15 8. Close tow valve completely by turning clockwise. 11. Connect test hose (13) of flow meter inlet to fitting (5).
Page 146: Traction Pump Tests
HYDROSTATIC POWER TRAIN 23. Calculate traction system leakage. (Step 20 – Step 21 / Step 20 x 100 = Leakage Percentage) Is traction system leakage 10% or less? The traction system is good. Additional testing is required. Proceed to “Wheel Motors Test”...
Page 147 HYDROSTATIC POWER TRAIN 12. Calculate traction pump leakage. 21. Start engine, release brake, and run at full throttle (2850 rpm ± 50). (Step 9 – Step 10 / Step 9 x 100 = Leak Percentage) 22. Adjust flow lock tool to 15 gpm (57 lpm) in reverse Is traction pump leakage 10% or less? direction.
Page 148: Wheel Motors Test
HYDROSTATIC POWER TRAIN Wheel Motors Test See Figures 5-18 through 5-23. IMPORTANT • This test works together with the traction system test to isolate a problem within the hydrostatic power train. • Performing this test will isolate the wheel motors and 4wd valve from the rest of the hydrostatic system.
Page 149 HYDROSTATIC POWER TRAIN 14. Calculate left front wheel motor leakage. WARNING (Step 10 of previous test – Step 12 / Step 10 of previous test x 100 = Leak Percentage) Prevent personal injury. Use properly rated lifting Is left front wheel motor leakage 10% or less? devices.
Page 150 HYDROSTATIC POWER TRAIN 19. Start engine, release brake, and run at full throttle 33. Slowly close flow meter valve until pressure reaches (2850 rpm ± 50). 2700 psi (186 bar). Read and record loaded flow. 20. Adjust flow lock tool (3) to allow pump to produce 15 34.
Page 151 HYDROSTATIC POWER TRAIN 47. Calculate right front wheel motor leakage. WARNING (Step 10 of traction pump test on page 5-18 – Step 45 / Step 10 of traction pump test on page 5-18 Prevent personal injury. Use properly rated lifting x 100 = Leak Percentage) devices.
Page 152: Neutral Adjust-Servo
HYDROSTATIC POWER TRAIN 52. Start engine, release brake, and run at full throttle 66. Slowly close flow meter valve until pressure reaches (2850 rpm ± 50). 2700 psi (186 bar). Read and record loaded flow. 53. Adjust flow lock tool (3) to allow pump to produce 15 67.
Page 153 HYDROSTATIC POWER TRAIN WARNING Prevent personal injury. Use properly rated lifting devices. Always be sure load is balanced before lifting. Support the machine properly using jack stands. IMPORTANT It is important to lift and support the machine or the machine will move. 3.
Page 154: Repair
HYDROSTATIC POWER TRAIN Repair Drive Shaft Removal and Installation See Figure 5-26. TN1519 Figure 5-26 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove nut (1) and screw (7). 3. Disconnect drive shaft (2) from traction pump input shaft (5).
Page 155: Traction Pump
HYDROSTATIC POWER TRAIN Traction Pump Removal and Installation See Figures 5-27 and 5-28. Figure 5-27 1. Park the mower safely. (See “Park Mower Safely” on 5. Disconnect hoses (1 and 2). page 1-5.) 6. Disconnect tee fitting (9). 2. Remove the center floorboard and the seat. 7.
Page 156 HYDROSTATIC POWER TRAIN TN1398 Figure 5-28 8. Disconnect control rod (12). 9. Disconnect drive shaft (3). WARNING The traction pump weighs approximately 131 lb (59 kg). Prevent personal injury. Use a properly rated lifting device. Always be sure the load is balanced before lifting.
Page 157 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-29 and 5-30. TN1394 Relief Valve Cylinder Block Kit Ring Bypass Valve Pump Shaft Roller Bearing Charge Pressure Relief Valve Ring Plug Variable Swash Plate Retaining Ring Front Cover Gasket Journal Bearing Shaft Seal Needle Bearing Screw...
Page 158 HYDROSTATIC POWER TRAIN TN1393 Screw O-Ring Piston Screw Plug Piston Ring Kit Washer Flange Cover O-Ring Control Handle Flange Plug Screw Pad Adapter Snap Ring Servo Cover Gasket Neutral Bracket Temper Load Ring Spring Servo Cover Screw O-Ring Screw Screw (5) Plug Plug Plug...
Page 159 HYDROSTATIC POWER TRAIN 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove traction pump. (See “Traction Pump” on page 5-27.) 3. Disassemble traction pump as shown in Figure 5-30 on page 5-30. 4. Place parts in assembly order on a clean work area as they are removed.
Page 160: 4Wd Valve
HYDROSTATIC POWER TRAIN 4WD Valve Removal and Installation See Figure 5-31. TN1511, TN1484 Figure 5-31 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Drain hydraulic tank. 3. Label all hydraulic hoses to ensure correct installation. 4.
Page 161 HYDROSTATIC POWER TRAIN Installation Notes NOTICE • Install the 4WD valve by reversing the order of removal. It is important that all component parts are • Ensure new O-rings are in place before installing absolutely clean, as contamination can result in hoses on fittings.
Page 162: Front Wheel Motor
HYDROSTATIC POWER TRAIN Front Wheel Motor Removal and Installation See Figure 5-34. TN1520 Figure 5-34 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-5.) 2. Remove front wheel. (See “Front Wheels” on The wheel hub may move unexpectedly when page 9-12.) using a puller.
Page 163 HYDROSTATIC POWER TRAIN Installation Notes Required Materials Anti-Seize Compound • Install the front wheel motor by reversing the order of removal. • Apply anti-seize compound to the motor shaft threads (3). Be careful not to apply anti-seize compound to the motor shaft. •...
Page 164 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-35 through 5-38. TN1521 Screw (4) Seal Seal Seal Spring Balance Ring and Pins Seal Seal Check Plug Assembly (2) Valve Seal Seal Ball, Steel Valve Plate Seal Front Retainer Plug Seal Spring (2) Seal...
Page 165 HYDROSTATIC POWER TRAIN Front Wheel Motor Timing NOTICE It is important that motor parts are marked and placed in assembly order to aid in assembly. It is important that all motor parts are absolutely clean, as contamination can result in serious damage and/or improper operation.
Page 166 HYDROSTATIC POWER TRAIN Retainer Screw Torque Sequence Valve Housing Screw Torque Sequence See Figure 5-37. See Figure 5-38. TN1529 TN1530 Figure 5-37 Figure 5-38 1. Install retainer screws (1—8) finger tight in sequence 1. Install valve housing screws (1—4) finger tight in as shown above.
Page 167: Rear Wheel Motor
HYDROSTATIC POWER TRAIN Rear Wheel Motor Removal and Installation See Figure 5-39. TN1532 Figure 5-39 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-5.) 2. Remove rear wheel. (See “Rear Wheels” on The wheel hub may move unexpectedly when page 9-11.) using a puller.
Page 168 HYDROSTATIC POWER TRAIN Installation Notes Required Materials Anti-Seize Compound • Install the rear wheel motor by reversing the order of removal. • Apply anti-seize compound to the motor shaft threads (10). Be careful not to apply anti-seize compound to the motor shaft. •...
Page 169 HYDROSTATIC POWER TRAIN Disassembly, Inspection, and Assembly See Figures 5-40 and 5-41. TN1539 Dust Seal Wear Plate Valve Drive Plug Bearing Housing Seal Valve Plate Outer Face Seal Seal Ring Drive Balance Ring Backup Ring Geroler Spring Valve Shaft Seal Shaft Seal Valve Housing Screw (4) Seal...
Page 170 HYDROSTATIC POWER TRAIN Rear Wheel Motor Timing NOTICE It is important that motor parts are marked and placed in assembly order to aid in assembly. It is important that all motor parts are absolutely clean, as contamination can result in serious damage and/or improper operation.
Page 171: Hydraulics
Chapter 6 Hydraulics Specifications ..............6-3 Test and Adjustment Specifications .
Page 172 HYDRAULICS Repair ..............6-41 Gear Pump .
Page 173: Specifications
HYDRAULICS Specifications Test and Adjustment Specifications Specifications Front Cutting Unit Pump Flow 10.8 (40.8) at 2850 rpm gpm (lpm) Rear Cutting Unit Pump Flow 10.8 (40.8) at 2850 rpm gpm (lpm) Lift/Steer Pump Flow 6.1 (23) at 2850 rpm gpm (lpm) Hydraulic Leakage Percentage Ranges 0—10% = Good 11—20% = Marginal...
Page 174: Component Location
HYDRAULICS Component Location See Figures 6-1 and 6-2. TN1417, TN1443 Gear Pump Center Cutting Unit Motor Lift Valve Right Front Lift Cylinder Left Front Lift Cylinder Right Front Cutting Unit Motor Left Front Cutting Unit Motor Right Rear Lift Cylinder Center Lift Cylinder Figure 6-1: Component Location—Right Side 4181383 First Edition...
Page 175 HYDRAULICS TN1472 Radiator/Hydraulic Oil Cooler Hydraulic Oil Filter Deck Valve Right Rear Cutting Unit Motor Figure 6-2: Component Location—Left Side 4181383 First Edition...
Page 176: Hydraulic Schematic
HYDRAULICS Hydraulic Schematic See Figures 6-3 through 6-6. 3625 psi Tow Valve 2.81 ci Gear Pump 2850 ±50 RPM 0.88 I 0.85 ci 0.88 ci 0.5 ci 3625 psi Displacement Control Valve Drain 0.31” Supply 0.28” Hydrostatic Traction 285 psi Pump 25 psi Micron...
Page 177 HYDRAULICS Hydraulic Schematic Continued Lift Valve Check Valve CV1 0.040 in. 0.040 in. 0.040 in. 0.040 in. 0.040 in. Orifice Orifice Orifice Orifice Orifice Lower/Proportional Raise Left Front Solenoid Valve Solenoid Cylinder Right Front Left Rear Center Front Right Rear Valve Cylinder Cylinder...
Page 178 HYDRAULICS Hydraulic Schematic Continued Right Rear Motor 0.90 ci Left Rear Motor Logic Check Valve 0.90 ci Solenoid Valve Relief Valve 2600 psi Left Front Motor Shuttle Shuttle Valve 2 0.90 ci Valve 1 Deck Valve 0.90 ci Center Front Motor 0.90 ci Right...
Page 179 HYDRAULICS Hydraulic Schematic Continued Left Rear Left Front 24.0 ci 30.0 ci Wheel Motor Wheel Motor 0.050” Orifice Right Rear Right Front 24.0 ci 30.0 ci Wheel Motor Wheel Motor Four Wheel Drive Valve TN1368D Figure 6-6 4181383 First Edition...
Page 180: Theory Of Operation And Diagnostic Information
HYDRAULICS Theory of Operation and Diagnostic Information Steering Circuit Schematic and Theory of Operation See Figure 6-7. System Conditions: • Engine running • Steering wheel turned to the right or left (left turn shown) Hydraulic oil is drawn from the hydraulic oil tank by the steering section of the gear pump assembly.
Page 181: Steering Circuit Schematic
HYDRAULICS Steering Circuit Schematic See Figure 6-7. Gear Pump 0.5 ci 0.88 ci 2850 ±50 RPM 0.88 ci Steering Unit 4.13 ci 1740 psi Steering Cylinder Micron 25 psi Return Oil Crack Filter Bypass 25 psi Hydraulic Mesh Crack Oil Cooler Bypass Screen Hydraulic...
Page 182: Raise Circuit Schematic And Theory Of Operation
HYDRAULICS Raise Circuit Schematic and Theory of Operation See Figure 6-8. System Conditions: • Engine running • Traction control switch in the OFF position • Raise/lower joystick in the RAISE position NOTES • See “Raise/Lower Circuit—Theory of Operation” on page 4-30 for the electrical operation of this circuit. •...
Page 183: Raise Circuit Schematic
HYDRAULICS Raise Circuit Schematic See Figure 6-8. Lift Valve 0.040 in. Orifice Check Valve CV1 Lower/Proportional Raise Solenoid Solenoid Valve Valve Left Rear Cylinder C1 = Left Rear Cylinder—Rod End C2 = Right Rear Cylinder—Rod End C3 = Center Front Cylinder—Rod End C4 = Right Front Cylinder—Rod End C5 = Left Front Cylinder—Rod End C6 = Left Front Cylinder—Piston End...
Page 184: Lower Circuit Schematic And Theory Of Operation
HYDRAULICS Lower Circuit Schematic and Theory of Operation See Figure 6-9. System Conditions: • Engine running • Traction control switch in the OFF position • Raise/lower joystick in the LOWER position NOTES • See “Raise/Lower Circuit—Theory of Operation” on page 4-30 for the electrical operation of this circuit. •...
Page 185: Lower Circuit Schematic
HYDRAULICS Lower Circuit Schematic See Figure 6-9. Lift Valve 0.040 in. Orifice Check Valve CV1 Raise Solenoid Lower/Proportional Valve Solenoid Valve Left Rear Cylinder C1 = Left Rear Cylinder—Rod End C2 = Right Rear Cylinder—Rod End C3 = Center Front Cylinder—Rod End C4 = Right Front Cylinder—Rod End C5 = Left Front Cylinder—Rod End C6 = Left Front Cylinder—Piston End...
Page 186: Traction Control Circuit Schematic And Theory Of Operation
HYDRAULICS Traction Control Circuit Schematic and Theory of Operation See Figure 6-10. System Conditions: • Engine running • Traction control switch on the ON position NOTES • See “Traction Control Circuit—Theory of Operation” on page 4-36, for the electrical operation of this circuit.
Page 187 HYDRAULICS Traction Control Circuit Schematic See Figure 6-10. Lift Valve 0.040 in. Orifice Check Valve CV1 Lower/Proportional Raise Solenoid Solenoid Valve Valve Left Rear Cylinder C1 = Left Rear Cylinder—Rod End C2 = Right Rear Cylinder—Rod End C3 = Center Front Cylinder—Rod End C4 = Right Front Cylinder—Rod End C5 = Left Front Cylinder—Rod End C6 = Left Front Cylinder—Piston End...
Page 188: Mow Circuit Schematic And Theory Of Operation
HYDRAULICS Mow Circuit Schematic and Theory of sides of the valve, and spring pressure on one side of the valve, the valve will remain closed, preventing oil flow. Operation The orifice helps maintain equal pressure on either side of the shuttle valve. Oil is also supplied to the solenoid Mow Circuit (On) Theory of Operation ON valve and logic check valve, seating the logic check See Figure 6-11.
Page 189: Mow Circuit (On) Schematic
HYDRAULICS Mow Circuit (On) Schematic See Figure 6-11. Right Rear 0.90 I Motor Left Rear Motor Logic Check Valve Solenoid 0.90 I Valve Relief Valve 2600 psi Left Front Shuttle Check Valve 2 Valve 1 Motor Check Shuttle Valve 2 0.90 I Valve 1 Center...
Page 190: Mow Circuit (Off) Schematic
HYDRAULICS Mow Circuit (Off) Schematic See Figure 6-12. Right 0.90 I Rear Motor Left Rear Motor Logic Check Valve Solenoid Valve 0.90 I Relief Valve 2600 psi Left Front Check Valve 1 Motor Shuttle Valve 2 Shuttle Check Valve 1 Valve 2 0.90 I Center...
Page 191: Field Test Procedures
HYDRAULICS Field Test Procedures 8. Remove support from cutting unit lift arm being tested. After 15 minutes, does cutting unit drift down? Lift Cylinder Leakage Test Cylinder is bypassing oil. Replace lift See Figures 6-13 and 6-14. cylinder. (See “Lift Cylinders” on page 6-49.) Repeat the test for all of the lift cylinders.
Page 192: Power Steering Circuit Test
HYDRAULICS Power Steering Circuit Test 1. Operate the machine until hydraulic oil reaches operating temperature, 120—150°F (49—65°C). The purpose of this test is to determine if the steering 2. Stop the engine and remove the key. cylinder and the steering valve are operating properly. 3.
Page 193: Instrument Test Procedure
HYDRAULICS Instrument Test Procedure Circuit and Rear Cutting Unit Pump No Load Flow – Loaded Flow / No Load Flow x 100 = Leak Percentage Instrument Test Overview Calculations: The following tests are specifically designed to approach hydraulic testing on a system level. Each component Circuit Test within the system represents a portion of the total system No Load Flow = 10 gpm...
Page 194: Front Cutting Units Circuit
HYDRAULICS Front Cutting Units Circuit IMPORTANT See Figures 6-15 and 6-16. Depending on the machine model number and production date, the possibility exists that the hoses IMPORTANT connected to the center and rear sections of the gear • This test works together with the front cutting pump could be reversed.
Page 195: Front Cutting Units Pump Test
HYDRAULICS 6. Connect flow meter outlet hose (3) to the hydraulic 17. Disconnect and remove test equipment. Remove tank. blocking device or tool from cutting unit. Install all hoses and fittings as noted prior to removal. WARNING 18. Install and connect all components as noted prior to test.
Page 196: Front Cutting Units Circuit Valve Tests
HYDRAULICS 10. Calculate front cutting units pump leakage. (Step 14 of previous test – Step 8 / Step 14 of previous test x 100 = Leak Percentage) Is front cutting units pump leakage 10% or less? The front cutting units pump is good. Proceed to next test.
Page 197 HYDRAULICS 11. Calculate front cutting units circuit valve leakage. (Step 8 of previous test – Step 10 / Step 8 of previous test x 100 = Leak Percentage) Is front cutting units circuit valve leakage 10% or less? The front cutting units circuit valve is good. Proceed to step 12.
Page 198: Adjust Cutting Unit System Relief Valve Pressure
HYDRAULICS Adjust Cutting Unit System Relief • To decrease the pressure setting: Turn the screw out (counterclockwise). Valve Pressure 5. Install cap (1). See Figure 6-21. Could relief valve be adjusted to 2600 psi (179 bar)? WARNING Cutting unit system relief valve is good. The hydraulic system is under pressure, and the Proceed to step 6.
Page 199 HYDRAULICS 11. Open flow meter valve (1) and stop engine. IMPORTANT 12. Calculate right front cutting unit motor leakage. • If performing this test after performing front (Step 10 of front cutting units circuit valve tests – cutting units circuit test and test proved front Step 10 / Step 10 of front cutting units circuit valve cutting units pump, deck valve, and right front tests x 100 = Leak Percentage)
Page 200: Rear Cutting Units Circuit Test
HYDRAULICS Rear Cutting Units Circuit Test 23. Calculate left front cutting unit motor leakage. (Step 10 – Step 21 / Step 10 x 100 = Leak See Figures 6-23 and 6-24. Percentage) IMPORTANT Is left front cutting unit motor leakage 10% or less? •...
Page 201 HYDRAULICS 6. Connect flow meter outlet hose (3) to the hydraulic IMPORTANT tank. Depending on the machine model number and production date, the possibility exists that the hoses WARNING connected to the center and rear sections of the gear Safely block cutting unit from rotating using a pump could be reversed.
Page 202: Rear Cutting Units Pump Test
HYDRAULICS 18. Install and connect all components as noted prior to test. 19. Check hydraulic oil level. Add oil as needed. (Refer to “Safety, Operation, and Maintenance Manual” for correct oil specifications.) Rear Cutting Units Pump Test See Figures 6-25 and 6-26. WARNING The hydraulic system is under pressure, and the oil will be hot.
Page 203: Rear Cutting Units Circuit Valve Tests
HYDRAULICS 10. Calculate rear cutting units pump leakage. (Step 14 of previous test – Step 8 / Step 14 of previous test x 100 = Leak Percentage) Is rear cutting units pump leakage 10% or less? The rear cutting units pump is good. Proceed to next test.
Page 204: Rear Cutting Units Motors Test
HYDRAULICS Rear Cutting Units Motors Test 11. Calculate rear cutting units circuit valve leakage. (Step 8 of previous test – Step 10 / Step 8 of See Figure 6-29. previous test x 100 = Leak Percentage) IMPORTANT Is rear cutting units circuit valve leakage 10% or less? •...
Page 205 HYDRAULICS 11. Open flow meter valve (3) and stop engine. IMPORTANT 12. Calculate left rear cutting unit motor leakage. • If performing this test after performing rear (Step 10 of rear cutting units circuit valve tests – cutting units circuit test and test proved rear Step 10 / Step 10 of rear cutting units circuit valve cutting units pump, deck valve, and left rear tests x 100 = Leak Percentage)
Page 206: Lift/Steer System Relief Valve Pressure Test
HYDRAULICS 23. Calculate center cutting unit motor leakage. 34. Calculate right rear cutting unit motor leakage. (Step 10 – Step 21 / Step 10 x 100 = Leak (Step 21 – Step 32 / Step 21 x 100 = Leak Percentage) Percentage) Is center cutting unit motor leakage 10% or less?
Page 207: Lift System Test
HYDRAULICS 2. Park the mower safely. (See “Park Mower Safely” on 10. Stop engine. page 1-5.) Is lift/steer system relief pressure 1595 psi (110 3. Remove the center floorboard. bar)? Lift/steer system relief valve is good. Proceed to step 11. Test lift/steer pump.
Page 208 HYDRAULICS CAUTION Do not exceed 1800 psi (124 bar) as this test does not utilize system relief. 10. Use the flow meter to warm the hydraulic oil. Turn the flow meter valve (4) until a reading of 900 psi (62 bar) or one half of the relief valve rating is reached.
Page 209: Lift/Steer Pump Test
HYDRAULICS Lift/Steer Pump Test 10. Calculate lift/steer pump leakage. (Step 7 – Step 8 / Step 7 x 100 = Leak Percentage) WARNING Is lift/steer pump leakage 10% or less? The lift/steer pump is good. Proceed to The hydraulic system is under pressure, and the step 11.
Page 210 HYDRAULICS 11. Calculate lift valve leakage. (Step 8 of previous test – Step 9 / Step 8 of previous test x 100 = Leak Percentage) Is lift valve leakage 10% or less? The lift valve is good. Proceed to step 12. Proceed to next question.
Page 211: Repair
HYDRAULICS Repair Installation Notes • Install gear pump by reversing the order of removal. • Ensure new O-rings are in place before installing Gear Pump hoses on fittings. Removal and Installation • Replace hydraulic oil filter. • Refill hydraulic tank. (Refer to “Safety, Operation, and See Figure 6-36.
Page 212 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-37. TN1383 Retaining Ring Seal (6) Dowel Pin (4) Rear Cover Seal Thrust Plate (6) Splined Connecting Shaft (2) Bolt (4) O-Ring Gear Set (Drive Shaft) Dowel Pin (4) Washer (4) Front Cover/Flange Body (3) Spacer (2) Gear Set, End...
Page 213: Cutting Unit Motors
HYDRAULICS Disassembly Notes Assembly Notes • Do not disassemble pump for repair unless test NOTICE procedures indicate internal leakage. • Never pry components apart. Use a soft face It is important that all component parts are hammer, and gently tap housing and shaft to absolutely clean, as contamination can result in separate pump bodies.
Page 214: Lift Valve
HYDRAULICS Lift Valve 5. Disconnect hydraulic hoses (14 and 16). 6. Support lift valve (13). Removal and Installation 7. Remove the two mounting screws (15). See Figures 6-39 and 6-40. 8. Remove lift valve (13). 1. Park the mower safely. (See “Park Mower Safely” on Installation Notes page 1-5.) •...
Page 215: Deck Valve
HYDRAULICS Assembly Notes NOTICE It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.
Page 216 HYDRAULICS Disassembly, Inspection, and Assembly See Figures 6-44 and 6-45. TN1429 Figure 6-43 NOTE Label connector before disconnecting to ensure correct installation. TN1430 4. Disconnect electrical connector (4) from solenoid. Figure 6-44 NOTES 1. Remove fittings (1—7) from the lift valve. •...
Page 217: Hydraulic Filter
HYDRAULICS Assembly Notes NOTICE It is important that all component parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages. Dry parts using compressed air.
Page 218 HYDRAULICS TN1436 Figure 6-46 4. Disconnect electrical connectors (2 and 5). NOTES • Label all hydraulic hoses and tubes to aid in installation. • Close all openings with caps or plugs to prevent contamination. 5. Disconnect hydraulic hose (1). 6. Disconnect hydraulic tube (4). 7.
Page 219: Lift Cylinders
HYDRAULICS Lift Cylinders Installation Notes • Install lift cylinder by reversing the order of removal. Removal and Installation • Ensure new O-rings are in place before installing hoses on fittings. See Figure 6-47. • Replace hydraulic oil filter. CAUTION • Refill hydraulic tank. (Refer to “Safety, Operation, and Maintenance Manual”...
Page 220 HYDRAULICS Disassembly, Inspection, and Assembly See Figure 6-48. TN1378, TN1379 Barrel O-Ring Rod Guide Piston Ring O-Ring Rod Guide Assembly Piston Seal Ring Rod Wiper Piston Assembly Figure 6-48 4. Remove nut (2). NOTE 5. Remove the piston assembly (12) and rod guide During repair of the cylinder, use extreme care not to assembly (11) from the rod (10).
Page 221: Hydraulic Oil Cooler
HYDRAULICS Hydraulic Oil Tank NOTICE Removal and Installation It is important that all component parts are See Figures 6-49 through 6-51. absolutely clean, as contamination can result in serious damage and/or improper operation. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) Never use shop towels or rags to dry parts after cleaning, as lint may clog passages.
Page 222 HYDRAULICS Installation Notes Required Materials Anti-Seize Compound • Install hydraulic oil tank by reversing the order of removal. CAUTION • When connecting fittings to the tank, be sure to hold the tank fitting with the proper wrench. If the proper wrench is not used, the fitting in the tank might break loose from the TN1477 plastic and cause it to leak.
Page 223: Steering
Chapter 7 Steering Specifications ..............7-2 Component Location .
Page 224 STEERING Specifications Test Specifications Steering System Leakage Test— Zero—Nominal Amount pt (L) Cylinder Leakage Repair Specifications Steering Wheel Nut 25—30 (34—41) lb-ft (N·m) Steering Cylinder Ball Joint-to- 80—110 (108—149) lb-ft (N·m) Steering Arm Torque Tie Rod Ball Joint-to-Steering Arm 30—35 (41—47) lb-ft (N·m) Torque Rear Axle Alignment Toe-In...
Page 225: Component Location
STEERING Component Location See Figure 7-1. TN1443,1417,1389,1422 Steering Unit Pump Tilt Bracket Steering Cylinder Steering Column Steering Valve Tie Rod Steering Tower Steering Wheel Steering Axle Figure 7-1 4181383 First Edition...
Page 226: Tests And Adjustments
STEERING Tests and Adjustments Tie Rod Adjustment See Figure 7-2. TN1480 Figure 7-2 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Turn the wheels to the straight-ahead position. 3. Loosen the jam nuts (2) on both sides of the tie rod (3).
Page 227: Steering Relief Valve Pressure Test
STEERING Steering Relief Valve Pressure Test See Figures 7-3 and 7-4. WARNING • The hydraulic system is under pressure, and the oil will be hot. • Always relieve pressure in the hydraulic system before performing service. • Failure to follow appropriate safety precautions may result in death or serious injury.
Page 228: Steering Leakage Test
STEERING Steering Leakage Test Is steering cylinder leakage a nominal amount of oil or less? See Figure 7-5. Go to step 10. 1. Operate hydraulic system until oil temperature is at Repair or replace steering cylinder. (See 120—150°F (49—65°C). “Steering Cylinder” on page 7-19.) 2.
Page 229: Repair
STEERING Repair Steering Valve Removal and Installation Steering Wheel See Figures 7-7 through 7-10. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) See Figure 7-6. 2. Remove the steering wheel. (See “Steering Wheel” 1.
Page 230: Steering Valve Service Fixture
STEERING TN1389 TN1224 Figure 7-9 11. Support the steering valve (9). 12. Remove four lock nuts (6) and flat washers (7). 13. Remove steering valve (9) from bracket (8). Installation Notes • Install the steering valve by reversing the order of removal.
Page 231 STEERING NOTICE Do not clamp the steering valve assembly directly into a vise. Clamping the steering valve directly into a vise may damage or distort the steering valve. TN1437 Figure 7-11 1. Place the steering valve service fixture (2) securely in a vise.
Page 232 STEERING Disassembly See Figure 7-12. TN1428 Valve Plate (Matched Set) Commutator Seal Face Seal Port Cover Spring Commutator Cover Seal Spacer Relief Valve Assembly Seal Ring Commutator Ring Upper Cover Plate Seal Ring Hex Drive Assembly Commutator Retaining Ring Ball 9/32 inch Isolation Manifold Alignment Pin Steering Shaft...
Page 233 STEERING 10. Remove the drive link spacer (28), rotor (29), and CAUTION stator (30) from the drive plate (31). 11. Remove the face seal (34) and seal spacer (35). Wear eye protection when assembling and 12. Remove the thrust bearing (33) and spacer (32). disassembling the steering valve.
Page 234 STEERING Inspection See Figures 7-13 and 7-14. 26 27 36 37 TN1428 Valve Plate (Matched Set) Commutator Seal Face Seal Port Cover Spring Commutator Cover Seal Spacer Relief Valve Assembly Seal Ring Commutator Ring Upper Cover Plate Seal Ring Hex Drive Assembly Commutator Retaining Ring Ball 9/32 inch...
Page 235 STEERING 1. Inspect the springs (9 and 13) for bent, broken, or Assembly distorted coils. See Figures 7-15 through 7-18. Always replace springs as a set. 2. Inspect the finished ground surfaces of all the Service Part Kits components. Seal Kit (Jacobsen P/N 557738) 3.
Page 236 STEERING TN1439 Spring (3) Metering Ring Upper Cover Plate Port Cover Valve Plate (Matched Set) Seal Ring Special Bolt Relief Valve Assembly Seal Ring Commutator Seal Retaining Ring O- Ring (4) Hex Drive Assembly Metering Package Steering Shaft Seal Ring Alignment Pin Spacer Steering Tube...
Page 237 STEERING 15. Place a 0.007 in. (0.18 mm) shim stock, 0.5 in. (13 NOTE mm) wide by 1.5 in. (38 mm) long, in three places, equal distance apart, between the metering ring and If the metering package was disassembled, proceed metering package.
Page 238 STEERING 25. Install the valve plate (11) as shown (closed cylinder up) in the valve ring (9), aligning the spring slots with the springs. Install the seal ring (12). TN1440 Figure 7-18 26. Place the three springs (7) in the port manifold (6). 27.
Page 239: Steering Tower
STEERING Steering Tower Removal and Installation See Figure 7-19. TN1445 Hex Bolt Tilt Cable Tilt Spring Release Bracket Hex Bolt Steering Tower Platform Lock Nut Lock Nut Steering Tilt Control Flanged Lock Nut (4) Tilt Gas Spring Steering Column Figure 7-19 4181383 First Edition 7-17...
Page 240 STEERING 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove the steering valve. (See “Steering Valve” on page 7-7.) 3. Using the steering tilt control (3), tilt the steering column (12) toward the rear of the mower. 4.
Page 241: Steering Cylinder
STEERING Steering Cylinder 4. Support the steering cylinder (7). 5. Remove cotter pins (5 and 10) and castle nuts (6 and Removal and Installation 9) from both ends of the steering cylinder (7). 6. Using a ball joint removal tool, remove the ball joint See Figures 7-20 through 7-22.
Page 242 STEERING Installation Notes • Install the steering cylinder by reversing the order of removal. • Tighten castle nuts (6 and 9) to 80—110 lb-ft (108— 149 N·m). Adjust nuts as needed to align the slots with the hole in the rod ends. •...
Page 243 STEERING Disassembly, Inspection, and Assembly See Figure 7-23. TN1471 Barrel Pistion Seal Ring Rod Wiper O-Ring Rod Guide Ball Joint, Left Piston Ring O-Ring Ball Joint, Right Figure 7-23 1. Use a spanner wrench to remove rod guide (10) from 4.
Page 244: Tie Rod Assembly
STEERING WARNING Use appropriate eye protection when using compressed air for cleaning or drying purposes. Compressed air can cause serious personal injury. Use safety reduction valves to reduce the air pressure to a safe level before use. NOTICE It is important that all components are absolutely clean, as contamination can result in serious damage and/or improper operation.
Page 245 STEERING Disassembly, Inspection, and Assembly See Figure 7-25. TN1387 Castle Nut Tie Rod Grease Fitting Ball Joint Measurement Lock Washer Lock Washer Threaded Ball Joint, Left Hex Head Bolt Tie Rod Clamp Grease Fitting Tie Rod Clamp Castle Nut Hex Head Bolt Threaded Ball Joint, Right Figure 7-25 Disassembly Notes...
Page 246: Rear Axle
STEERING Rear Axle 4. Support the rear axle assembly using an appropriate lifting device. Removal and Installation 5. Remove cotter pin (8), two jam nuts (7), and flat washer (6), and remove the axle assembly (4) and See Figures 7-26 and 7-27. spacer (10) from mower.
Page 247 STEERING Disassembly, Inspection, and Assembly See Figure 7-28. TN1388 Bushing (4) Thrust Washer (6) Steering Arm, Left Castle Nut (2) Axle Grease Fitting (2) Motor Mount (2) Steering Cylinder Cotter Pin (2) Thrust Bearing (2) Cotter Pin (2) Ball Joint (2) Castle Nut (2) Hex Bolt (6) Thrust Washer (2)
Page 248 STEERING Assembly Notes • Replace any bushings, bearings, and ball joints that were damaged or had excessive wear. • Replace or repair steering cylinder if dented or leaking. • Never reuse cotter pins; use new cotter pins of correct size. •...
Page 249 Chapter 8 Cutting Units Component Location ............8-2 Troubleshooting .
Page 250: Component Location
CUTTING UNITS Component Location See Figure 8-1. TN1443, TN1497, TN1501 Right Rear Cutting Unit Right Front Cutting Unit Deck Frame Left Front Cutting Unit Deck Roller Drive Motor Center Cutting Unit Deck Caster Wheel Deck Yoke Figure 8-1: Component Location 4181383 First Edition...
Page 251: Troubleshooting
CUTTING UNITS Troubleshooting Mechanical Troubleshooting Condition Probable Cause Remedy Drive motors do not reach full speed. Engine speed is insufficient, not set to Check/adjust engine speed. (Refer to specification. “Safety, Operation, and Maintenance Manual.”) Rotary drive motors and/or hydraulic Check hydraulic system performance system performance is reduced.
Page 252: Quality Of Cut Troubleshooting
CUTTING UNITS Quality of Cut Troubleshooting Factors That Affect Cut Appearance In most cases, information provided by the user/customer will provide the basis for the repairs and adjustments that are required. However, it is recommended that a “test cut” be performed to evaluate the mower’s performance before beginning repairs.
Page 253 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. Washboarding Washboarding is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is approximately 6—8 in.
Page 254 CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a cutting unit than on the other, or on one side of the mower than on the other. This is usually caused by mechanical wear or an incorrect roller or deck caster adjustment.
Page 255 CUTTING UNITS Scalping Scalping is a condition in which areas of grass are cut noticeably shorter than the surrounding areas, resulting in a light green or even brown patch. This is usually caused by an excessively low height-of-cut setting and/or uneven turf.
Page 256 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Dull cutting blade(s). Sharpen blade(s). (Refer to “Safety, Operation, and Maintenance Manual.”) Mowing (ground) speed is too fast. Reduce mowing (ground) speed.
Page 257 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a damaged blade. TN0224 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Damaged blade(s). Replace blade(s). (See “Blade” on page 8-14.) Turning too aggressively. Cutting units don’t overlap during turns Turn less aggressively to allow cutting units to overlap.
Page 258 CUTTING UNITS Windrowing Windrowing is the deposit of clippings concentrated at one end of cutting unit(s) or between cutting units, forming line(s) in the direction of travel. TN0225 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall. Mow more often.
Page 259 CUTTING UNITS Mismatched Cutting Units Mismatched cutting units cause a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to a different HOC (height-of-cut) adjustment from one cutting unit to another. TN1278 NOTE: Arrow indicates direction of travel. Probable Cause Remedy HOC inconsistent from one cutting unit to another.
Page 260: Repair
CUTTING UNITS Repair Installation Notes • Install the deck motor by reversing the order of removal. Deck Motor • Install the motor on the deck, making sure that it is in proper orientation with the marks made on removal. Removal and Installation •...
Page 261 CUTTING UNITS Disassembly and Assembly See Figure 8-3. TN1518 Shaft Seal Sleeve Bearing Holder Screw (4) Gasket Retaining Ring Check Valve Backing Seal Shaft Seal Support Shaft Spring Seal Retaining Ring Sleeve Bearing Plug Thrust Plate Shaft Seal Front Cover Pump Body Driven Gear Seal (2)
Page 262: Rotary Deck
CUTTING UNITS 2. Remove deck yoke. (See “Front Deck Yoke” on NOTICE page 8-15.) (See “Rear Deck Yoke” on page 8-16.) It is important that all motor parts are absolutely clean, as contamination can result in serious damage and/or improper operation. Never use shop towels or rags to dry parts after cleaning, as lint may clog passages.
Page 263: Front Deck Yoke
CUTTING UNITS TN1408 Figure 8-5 CAUTION Blades are extremely sharp and can cause severe injury. 4. Remove blade screw (4), washer (5), blade (1), blade TN1411 adapter (3), and key (2) from hydraulic motor spindle Figure 8-6 (not shown). 2. Remove cotter pin (11), slotted hex nut (12), and plastic washer (3) from lift arm pivot shaft (2).
Page 264: Rear Deck Yoke
CUTTING UNITS Rear Deck Yoke Installation Notes • Install the rear deck yoke by reversing the order of Removal and Installation removal. • Apply grease on lift arm pivot shaft bushings (4) and See Figure 8-7. lift arm pivot shaft (2) before installation. (Refer to 1.
Page 265 CUTTING UNITS Disassembly and Assembly See Figures 8-11 and 8-12. TN1325 Figure 8-9 7. Inspect caster wheel yoke shaft (6) and washer (7) TN1707 for wear and damage, and replace as necessary. Torsion Pin Flat Washer Yoke Spacer Caster Wheel Yoke Caster Wheel Flat Washer Screw...
Page 266: Deck Roller
CUTTING UNITS TN1418 Figure 8-13 NOTE Record the location and number of shims (7) prior to disassembly. 4. Remove four screws (1) and nuts (8), two spacers TN1708 (5), and six shims (7) from deck frame weldments (2, Torsion Pin 3, and 4) on each side of deck frame (6).
Page 267: Mower Deck Housing
CUTTING UNITS 8. Remove lock nut (14) and washer (15) from scraper shaft (13). 9. Remove weldment (10) from roller shaft (11) and scraper shaft (13). Installation Notes • Install the roller by reversing the order of removal. • Apply grease to fitting. Disassembly, Inspection, and Assembly See Figure 8-15.
Page 268 CUTTING UNITS Page Intentionally Blank 8-20 4181383 First Edition...
Page 269: Accessories And Miscellaneous Repair
Chapter 9 Accessories and Miscellaneous Repair Specifications ..............9-2 Component Location .
Page 270 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications OPS Mounting Hardware 1/2-13 Mounting Hardware Torque 80 (108) lb-ft (N·m) Fuel Tank Capacity 17 (64) gal (L) Front Tires Size 26.5 x 14.00-12 Type Ultra Trac, 6-Ply Air Pressure 16 (110) psi (kPa) Mounting Bolt Torque 85—95 (115—128) lb-ft (N·m) Rear Tire AR-5 Model 68080...
Page 271 ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 9-2. TN1443 Hood Brake Control Pedal Wheel Weight (2) Work Light Kit Fuel Tank Seat and Mount Plate Brake Assembly (2) Rear Wheel (2) Traction Pedal Front Wheel (2) Figure 9-1 4181383 First Edition...
Page 272: Checks And Adjustments
ACCESSORIES AND MISCELLANEOUS REPAIR Checks and Adjustments 4. Use the cable nuts (3) to adjust the actuating lever and brake pedal free travel. 5. Brake pedal free travel, 1.5 in. (38 mm) is measured Brake Pedal/Linkage Adjustment between pedal grip and mower floor pan. See Figures 9-2 and 9-3.
Page 273: Ops
ACCESSORIES AND MISCELLANEOUS REPAIR 5. Remove the canopy (1). 5. Support the OPS (4) using a suitable lifting device. 6. Remove four OPS mounting bolts (6) from left and Installation Notes right sides of mower frame. • Center the canopy before tightening the mounting 7.
Page 274: Fuel Tank
ACCESSORIES AND MISCELLANEOUS REPAIR Fuel Tank 8. Tag and disconnect fuel outlet (3) and fuel return (1) lines. Plug lines and cap fittings to prevent leakage and contamination. Removal and Installation See Figures 9-9 through 9-11. CAUTION Diesel fuel is highly flammable. Do not drain fuel indoors.
Page 275 ACCESSORIES AND MISCELLANEOUS REPAIR Figure 9-11 4181383 First Edition...
Page 276 ACCESSORIES AND MISCELLANEOUS REPAIR 10. Tag and disconnect the fuel sending unit (7) wire harness and set harness aside. 11. Support the fuel tank (8) and remove the five mounting bolts (10) from the bottom and two bolts (9) between the seat and tank. 12.
Page 277: Traction Pedal
ACCESSORIES AND MISCELLANEOUS REPAIR Traction Pedal Disassembly and Assembly See Figure 9-12. Pedal Grip Rod End (2) Hex Bolt (4) Traction Pedal Hex Bolt Treadle Pivot Bushing Hex Bolt (2) Locking Hex Nut Grease Fitting Mow Speed Stop Treadle Pivot Bracket Treadle Pivot Bushing Pedal Grip Reverse Pedal Stop...
Page 278: Seat And Mount Plate
ACCESSORIES AND MISCELLANEOUS REPAIR 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove two hex bolts (3) and two locking flange nuts (6), and remove traction pedal from treadle pivot (19). Inspect pedal grips (1 and 5); replace if worn or cracked.
Page 279: Work Light Kit
ACCESSORIES AND MISCELLANEOUS REPAIR Work Light Kit Rear Wheels Removal and Installation Removal and Installation See Figure 9-15. See Figure 9-16. 1. Park mower safely. (See “Park Mower Safely” on 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) page 1-5.) 2.
Page 280: Front Wheels
ACCESSORIES AND MISCELLANEOUS REPAIR Front Wheels Installation Notes • Inspect and clean any rust from hub (5) or wheel Removal and Installation mounting area. Apply Anti-Seize compound to lug bolts. See Figure 9-17. • Install wheel by reversing the order of removal. 1.
Page 281 ACCESSORIES AND MISCELLANEOUS REPAIR 9. Inspect brake pads (3 and 6) for excessive or uneven wear. Replace as a set if necessary. 10. Repeat repair procedure for other side. Assembly Notes • Assembly is done by reversing the order of disassembly.
Page 282 ACCESSORIES AND MISCELLANEOUS REPAIR Page Intentionally Blank 9-14 4181383 First Edition...
Page 283 INDEX INDEX Charging Circuit Schematic ......4-21 Theory of Operation ....4-20 Troubleshooting .
Page 284 INDEX Cutting Unit Motors Removal and Installation ....6-43 Electrical Cutting Units Component Symbols ....4-5 Component Location .
Page 285 INDEX Field Test Procedures Glow Plug Circuit Charge Pump Test ....5-12 Troubleshooting ..... 4-48 Hydraulics .
Page 286 INDEX Hydrostatic Power Train Component Location ....5-3 Field Test Procedures ....5-12 Key Switch Instrument Test Procedures .
Page 287 INDEX Mower Identification Quick Reference Specifications Engine Serial Number ....2-2 Accessories and Miscellaneous ..Model Identification Number .
Page 288 INDEX Repair ........3-8 Rotary Deck 4WD Valve ......5-32 Removal and Installation .
Page 289 INDEX Schematic Starter Motor Charging Circuit ..... . 4-21 Removal and Installation ....4-68 Cruise Control .
Page 290 INDEX Tie Rod Assembly Removal and Installation ....7-22 Steering ......7-22 Test Circuit Breaker .
Page 291 INDEX Troubleshooting Charging Circuit ..... . 4-47 Control Module ..... . . 4-46 Cutting Units .
Page 292 INDEX Page Intentionally Blank IX-10 4181383 First Edition...
Page 294 A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support. When Performance Matters. ™ Jacobsen, A Textron Company 11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com 800-848-1636...

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Jacobsen ar-522 68080 68082 68098

Textron JACOBSEN AR-5 Technical/Repair Manual

Table of Contents

Chapter 3 Engine

Chapter 4 Electrical

Chapter 5 Hydrostatic Power Train

Chapter 6 Hydraulics

Chapter 7 Steering

Chapter 8 Cutting Units

Chapter 9 Accessories and Miscellaneous Repair

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