Page 1 E-Walk Technical/Repair Manual 63290...
Page 5 Foreword General CALIFORNIA Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: ® WARNING Jacobsen E-Walk™ greens mowers and associated accessory attachments Certain vehicle components contain or emit This manual is intended to introduce and guide the user chemicals known to the State of California to through the latest factory-approved troubleshooting and cause cancer and birth defects or other...
Page 7 Table of Contents Safety Specifications and General Information Electrical Power Train Handle and Controls Brakes Cutting Unit Miscellaneous Accessories 4171984 First Edition...
Page 8 FOREWORD 4171984 First Edition...
Page 9: Table Of Contents
Chapter 1 Safety Introduction ..............1-2 Prepare for the Job .
Page 10: Introduction
SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
Page 11: Safety Label Locations
SAFETY Safety Label Locations Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. TN0605 TN0604 Figure 1-1 Figure 1-2 WARNING ADVERTENCIA 1. Read operators 1. Leer el manual del operador. No permitir que personas no manual.
Page 12: Inspect Safety Labels
SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figures 1-3 through 1-5. mower. Inspect the mower for any damaged, missing, or WARNING unreadable decals. Replace decals as needed before placing the mower back into service. Before cleaning, adjusting, or repairing this equipment, disengage reel drive switch, engage Keep Work Area Clean...
Page 13: Use Lifting Equipment Safely
SAFETY Use Lifting Equipment Safely WARNING Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Using underrated or worn lifting components can result in death or serious injury. • Always use a lifting device with a lifting capacity greater than the weight of the item being lifted.
Page 14: Use Compressed Air And Air Tools Safely
SAFETY Use Compressed Air and Air Service Tires Safely Tools Safely WARNING WARNING An inflated tire contains explosive force. Use care when handling wheels and tires. Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious •...
Page 15: Handle Chemical Products Safely
SAFETY Handle Chemical Products Dispose of Waste Materials Safely Safely Routine service can produce waste products such as WARNING used oil, grease, and used batteries. If not handled properly, these materials can pose a threat Exposure to chemical products could result in to the environment.
Page 16 SAFETY Page Intentionally Blank 4171984 First Editiion...
Page 17 Chapter 2 Specifications and General Information Mower Identification ............2-2 Model Identification Number .
Page 18: Mower Identification
If the machine requiring service is equipped with an accessory kit, see Section 9, “Accessories” for troubleshooting, removal, repair, and installation procedures. ® A Textron Company CHARLOTTE, NC MADE IN U.S.A. YEAR OF 2006 PRODUCTION: 63290...
Page 19: Component Location
SPECIFICATIONS AND GENERAL INFORMATION Component Location CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0605 Handle Traction Drum Speed Control Paddle Product Identification Plate Operator Presence Control Kickstand (OPC) Bail Transport Wheel (Optional) Battery Power Meter Belt Cover Control Module...
Page 20: Specifications
SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Power Train Traction (Transfer) Drive Belt 0.14 (3.5) in. (mm) Maximum Deflection with 3.5—6.3 pounds (1.59—2.86 kg) of force applied at the midpoint between pulleys. Traction (Final) Drive Belt Maximum 0.10 (2.5) in.
Page 21: General Specifications
SPECIFICATIONS AND GENERAL INFORMATION General Specifications Electrical Power Removable Battery Pack Four 12-Volt, Sealed Lead Acid Batteries, Wired in Series, with Battery Gauge and Protective Box Motors 48-Volt, Brushless, Keyed Shaft Motor Power Rating 0.75 (0.54) hp (kW) Motor Operating Speed 2200 (Factory Setting) Motor Rotation Counterclockwise (Facing Shaft)
Page 22: Standard Torque Values
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 23: Lubricant Specifications
SPECIFICATIONS AND GENERAL INFORMATION Lubricant Specifications Operational Checks Grease WARNING Lubricate fittings with grease that meets or exceeds NLGI Never attempt to operate the machine unless you Grade 2 LB specifications. Apply grease with a manual have read the Operator’s Manual and know how grease gun;...
Page 24: Key Switch Check
SPECIFICATIONS AND GENERAL INFORMATION Key Switch Check Operator Presence Control (OPC) System Check See Figures 2-5 and 2-6. The unit is equipped with a key switch to stop the traction See Figures 2-7 and 2-8. and reel drive motors from the operator’s position. WARNING Never operate equipment with the Operator Presence Control (OPC) system disconnected or...
Page 25: Reel Drive Switch Check
SPECIFICATIONS AND GENERAL INFORMATION 5. Release the OPC bail. Bail will disengage, and traction drive will stop. Does the traction drive continue turning after the OPC bail is released? Move the key switch to the OFF position immediately, and repair the system. Reel Drive Switch Check See Figure 2-8.
Page 26 SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-10 4171984 First Editiion...
Page 27 Chapter 3 Electrical Component Location ............3-3 Electrical Component Symbols .
Page 28 ELECTRICAL Battery Tray ............. . . 3-32 OPC Bail Control .
Page 29: Component Location
ELECTRICAL Component Location See Figure 3-1. TN0604, 0605 Speed Control Paddle Key Switch Reel Drive Switch Circuit Breaker Battery Power Meter Traction Drive Motor Battery Pack Reel Drive Motor LCD Display and Controls Control Module Figure 3-1 4171984 First Editiion...
Page 30: Electrical Component Symbols
ELECTRICAL 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) Double Pole, Double Throw Single Pole, Double Throw (DPDT) (SPDT) 1 The sample switch symbols shown are just a few of the many switch configurations. Switches are designated by the number of “poles”...
Page 31 ELECTRICAL Motors and Generating Devices Electric Motors (may also Stator include “AC” or “DC”) Alternator Actuating Devices Solenoid Valve PTO Clutch Lights Single-Element Light Dual-Element Light 4171984 First Editiion...
Page 32 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 Potentiometer 4171984 First Editiion...
Page 33: Harness Connector Identification
ELECTRICAL Harness Connector Identification See Figure 3-2. TN0689 Reel Switch Connector (S2) Circuit Breaker Connector (CB1) LCD Display Connector (J4) Control Module Connector (J2) LCD Display Connector (J5) Traction Motor Connector (M1) Speed Control Paddle Connector (R1) Control Module Connector (J3) OPC Bail Connector (R2) Reel Drive Motor Connector (M2) Key Switch Connector (S1)
Page 34: Main Schematic
ELECTRICAL Main Schematic See Figure 3-3. Splice 1 Battery 20-Amp Meter Circuit Breaker Enable Org/Grn Switch Low Bat (Not Used) Start Org/Yel Pnk/Blu Control Module Traction Reel Motor J2-1 J1-1 Switch +48V +48V J2-2 J1-2 +48V Not Used J2-3 Not Used Shield Org/Yel J2-4...
Page 35: Theory And Diagnostic Information
ELECTRICAL Theory and Diagnostic Traction Drive Circuit—Theory of Information Operation Traction Drive Circuit Components 48-Volt Power Circuit—Theory of Speed Paddle Control Operation The speed paddle control (R1) sends a voltage signal from 0—5 VDC to the LCD display. 48-Volt Power Circuit Components OPC Control Battery Pack The OPC control (R2) sends a voltage signal from 0—5...
Page 36: Reel Drive Circuit-Theory Of Operation
ELECTRICAL Reel Drive Circuit—Theory of Operation Reel Drive Circuit Components OPC Control The OPC control (R2) sends a voltage signal from 0—5 VDC to the LCD display. Reel Switch The reel switch (S2) is a two position switch, used to control the LCD display mow input terminal.
Page 37: Troubleshooting
ELECTRICAL Troubleshooting Symptom: Machine will not power up. Probable Cause Remedy Faulty battery pack. Test battery pack. (See “Battery Pack Test” on page 3-19.) Faulty battery pack fuse. Test fuse. (See “Battery Pack Fuse Test” on page 3-21.) Faulty circuit breaker. Test circuit breaker.
Page 38 ELECTRICAL Symptom: Traction drive will not engage. Probable Cause Remedy Faulty OPC bail control. Test OPC bail control. (See “OPC Bail Control Test” on page 3-23.) Faulty OPC bail control power circuit. Measure voltage between LCD display connector (J5) terminal 4 and ground. Measure voltage between OPC bail control connector (R2) terminal 1 and ground.
Page 39 ELECTRICAL Symptom: Reel drive will not engage. Probable Cause Remedy Faulty reel drive switch. Test reel drive switch. (See “Reel Drive Switch Test” on page 3-21.) Faulty reel drive switch power circuit. Measure voltage between LCD module connector (J4) terminal 6 and ground. Measure voltage between reel drive switch connector (S2) terminal 3 and ground.
Page 40: Lcd Display-Modes
ELECTRICAL LCD Display—Modes WARNING See Figure 3-4. To prevent personal injury, release OPC bail, disengage reel drive, move key switch to the OFF position, and disconnect battery pack connector before checking for obstructions in reel or traction drive systems. Low Voltage LOW BATTERY 42.0 VDC TN0609...
Page 41: Viewing Operational Values And System Data
ELECTRICAL Viewing Operational Values and Reel Speed System Data REEL SPEED Operational values and system data can be viewed in both mechanic and superintendent modes. 2200 RPM Use the orange buttons to navigate the system data menu. Use the black button to select or accept. The The reel speed screen displays the reel rotation speed.
Page 42: Setting Operational Values
ELECTRICAL Press the black button to change the setting. Use the Set Maintenance Password orange buttons to increase or decrease the maximum mow speed value. Press the black button to accept. SET MAINT PASSWORD? Setting Operational Values MAINT PIN Operational values can be set only in superintendent mode.
Page 43 ELECTRICAL OPC Bail Lever Calibration BAIL LEVER CALIBRATE? BAIL LEVER 040 DONE 096 The bail lever calibrate screen displays the option to calibrate the OPC bail rotary switch values. Press the black button to calibrate the OPC bail. The bail lever screen displays the minimum and maximum values for the OPC bail rotary switch.
Page 44: Component Testing
ELECTRICAL Component Testing 6. Test the function of the circuit. Does the circuit now operate properly? Electrical System and Component Replace the wire. Testing Continue testing other wires and components in the circuit. General Information Resistance Test Repair of the electrical system, for the most part, is limited to the replacement of defective components or Required Tools or Equipment wiring.
Page 45: Battery Pack Test
ELECTRICAL Battery Pack Test 7. Disengage the OPC bail lever, move the key switch to the OFF position, and disconnect the battery pack connector. Required Tools or Equipment Do all batteries test within 1.5 VDC of the highest Digital Multimeter reading? The batteries are good.
Page 46: Key Switch Test
ELECTRICAL Key Switch Test Circuit Breaker Test See Figure 3-5. See Figure 3-6. 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 47: Battery Pack Fuse Test
ELECTRICAL Battery Pack Fuse Test 3. Remove reel drive switch. (See “Reel Drive Switch” on page 3-28.) See Figure 3-7. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2.
Page 48: Traction Drive Motor Test
ELECTRICAL Traction Drive Motor Test Reel Drive Motor Test See Figure 3-9. See Figure 3-10. 1. Park mower safely. (See “Park Mower Safely” on 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) page 1-4.) 2. Back bedknife away from reel. (See “Bedknife-to-Reel Adjustment”...
Page 49: Speed Paddle Control Test
ELECTRICAL Speed Paddle Control Test 6. Measure resistance between terminals (1 and 3) while rotating stem (4). Low end resistance must See Figure 3-11. range between 18.9 and 35.1 ohms. High end resistance must range between 3710 and 6890 Required Tools or Equipment ohms.
Page 50: Lcd Display Test
ELECTRICAL Control Module Test 5. Measure resistance between terminals (1 and 2) while rotating stem (4). Low end resistance must range between 770 and 1430 ohms. High end Required Tools or Equipment resistance must range between 4060 and 7540 ohms. Digital Multimeter or Continuity Tester Is resistance measurement within specification? 1.
Page 51: Component Removal And Installation
ELECTRICAL Component Removal and Disassembly Installation See Figures 3-14 through 3-16. WARNING Battery Pack Always disconnect the negative terminal first, and the positive terminal last. Connect the Removal and Installation positive terminal first, and the negative terminal See Figure 3-13. last.
Page 52: Battery Gauge
ELECTRICAL Battery Gauge Removal and Installation See Figure 3-18. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove battery pack cover. (See “Battery Pack” on page 3-25.) NOTES Label all wires before disconnecting, to ensure correct installation.
Page 53: Battery Pack Fuse
ELECTRICAL Battery Pack Fuse Removal and Installation See Figure 3-19. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove battery pack cover. (See “Battery Pack” on page 3-25.) NOTE TN0613 Label all wires before disconnecting, to ensure correct Figure 3-20 installation.
Page 54: Reel Drive Switch
ELECTRICAL Reel Drive Switch Removal and Installation See Figure 3-22. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) TN0631 Figure 3-23 2. Disconnect reel drive motor harness connector (1). 3. Remove three screws (2) and reel drive motor (3). TN0613 Figure 3-22 NOTE...
Page 55 ELECTRICAL TN0614 Figure 3-25 TN0622 2. Remove nut (2), lock washer (3), flat washer (4), Figure 3-27 clamp (1), and flat washer (5). 3. Remove belt cover. (See “Traction Drive Belt Cover” 9. Rotate pulley (20) until set screw (22) is aligned with on page 4-7.) groove (21).
Page 56 ELECTRICAL 24 25 26 TN0630 TN0632 Figure 3-29 Figure 3-31 12. Remove screws (24), lock washers (25), nuts (26), and motor mount assembly (27). Installation See Figures 3-30 through 3-33. Required Materials Loctite® 242 (Blue) Thread Sealant 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 1 2 3 TN0622...
Page 57: Speed Paddle Control
ELECTRICAL Speed Paddle Control Removal and Installation See Figure 3-34. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove rear half of handle cover. (See “Handle Cover” on page 5-3.) 3. Remove handle and Operator Presence Control (OPC) bail.
Page 58: Lcd Display
ELECTRICAL LCD Display Removal and Installation See Figure 3-35. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove handle cover. (See “Handle Cover” on page 5-3.) TN0625 Figure 3-36 2. Disconnect wire harness connectors (1, 5, and 6). 3.
Page 59 ELECTRICAL OPC Bail Control Disassembly and Assembly See Figure 3-38. Removal and Installation See Figures 3-40 through 3-42. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove handle cover. (See “Handle Cover” on page 5-3.) TN0642 Figure 3-38 TN0626 Figure 3-40...
Page 60 ELECTRICAL 10 11 12 TN0628 Figure 3-42 6. Remove two screws (8), spacers (9), nuts (10), lock washer (11), flat washers (12), and OPC bail control (7). Installation Note Install OPC bail control by reversing the order of removal. 3-34 4171984 First Editiion...
Page 61 Chapter 4 Power Train Specifications ..............4-2 Component Location .
Page 62: Specifications
POWER TRAIN Specifications Adjustments Traction Drive (Transfer) Belt 9/64 (3.5) in. (mm) Maximum Deflection with 3.5—6.3 Pounds (1.59—2.86 kg) of Force Applied at the Midpoint between Pulleys Traction Drive (Final) Belt Maximum 1/10 (2.5) in. (mm) Deflection with 12.5—15.2 Pounds (5.5—7.4 kg) of Force Applied at the Midpoint between Pulleys 4171984 First Editiion...
Page 63: Component Location
POWER TRAIN Component Location TN0604, 0605, 0663 Traction Drive Motor Traction Drive (Outer Transfer) Pulley Traction Drive Motor Harness Connector Traction Drive (Inner Transfer) Pulley Traction Drum/Differential Assembly Traction Drive (Traction Drum) Pulley Traction Drive Motor Pulley Traction Drive Belt (Final Drive) Traction Drive Belt (Transfer) Figure 4-1: Power Train Component Location 4171984 First Editiion...
Page 64: Troubleshooting
POWER TRAIN Troubleshooting Condition Probable Cause Remedy Traction drive does not engage when OPC System voltage too low. Check battery pack voltage. bail is engaged. Park brake engaged. Release park brake. (Refer to Operator’s Manual.) Speed paddle setting is too low. Increase machine speed.
Page 65 POWER TRAIN Adjustments 3. Place a straightedge (1) against the traction drive outer (transfer) pulley (3) and traction motor drive pulley (2). Traction Drive Belt Tension Check 4. Apply approximately 3.5—6.3 pounds (1.59— and Adjustment 2.86 kg) of force at the midpoint of the traction drive (transfer) belt.
Page 66 POWER TRAIN Adjustment Procedure See Figures 4-4 and 4-5. Required Tools and Materials • Height-of-Cut Gauge Bar • 5/16-18 x 1” Hex Screw • 5/16-18 Hex Nut NOTE Minor adjustments to the traction drive (transfer) belt can be made by pivoting the traction drive motor mount assembly.
Page 67: Repair
POWER TRAIN Repair Traction Drive Belts Removal Traction Drive Belt Cover See Figures 4-7 and 4-8. Removal and Installation 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) See Figure 4-6. 2. Remove the traction drive belt cover. (See “Traction 1.
Page 68 POWER TRAIN Component Inspection Inner Transfer Pulley See Figures 4-9 through 4-11. Outer Transfer Pulley Required Materials ® Lubriplate Marine Grease TN0180 Figure 4-11 4. Inspect the needle bearing (5) for signs of wear or damage. Replace as needed. ® 5.
Page 69 POWER TRAIN Installation See Figures 4-12 through 4-15. TN0666 Figure 4-14 2. Install traction drive (final drive) belt (10). TN0176 NOTE Figure 4-12 Be sure to guide traction drive (final drive) belt (10) over inner transfer pulley (7) while installing transfer pulley/shaft assembly.
Page 70: Traction Drive Drum And Bearing Housing Assembly
POWER TRAIN Traction Drive Drum and Bearing 6. Support the traction drive drum (13). 7. Remove key (9) from traction drum shaft (14). Housing Assembly 8. Remove two screws (10) and lock washers (11) from bearing housing (12). Removal and Installation See Figures 4-16 through 4-19.
Page 71: Traction Drum Left Bearing Housing
POWER TRAIN Installation Note Installation is done by reversing the order of removal. Traction Drum Left Bearing Housing Removal See Figures 4-20 through 4-24. TN0237 Figure 4-22 5. Remove two washers (8). TN0235 Figure 4-20 1. Remove two socket-head screws (2) and lock washers (3), and remove the seal cover (1).
Page 72 POWER TRAIN Installation See Figures 4-25 through 4-29. Required Materials ® Loctite Aviation Gasket Sealer (Loctite P/N 30516) TN0249 Figure 4-27 3. Clean the mating surfaces of the seal cover (7) and ® bearing housing (5), and apply a thin film of Loctite Aviation Gasket Sealer to the mating surfaces.
Page 73: Traction Drum Right Bearing Housing
POWER TRAIN TN0242 Figure 4-31 2. Remove nut (2) 14 15 TN0235 Figure 4-29 8. Install seal cover (13) using two socket-head screws (14) and lock washers (15). Traction Drum Right Bearing Housing Removal See Figures 4-30 through 4-34. TN0243 Figure 4-32 3.
Page 74 POWER TRAIN Installation See Figures 4-35 through 4-39. Required Materials ® Loctite Aviation Gasket Sealer (Loctite P/N 30516) TN0244 Figure 4-33 5. Remove grease seal (6) from the seal cover (7). TN0244 Figure 4-35 1. Install a new grease seal (1) in the seal cover (2). TN0247 Figure 4-34 6.
Page 75: Traction Drum Assembly
POWER TRAIN TN0241 Figure 4-39 7. Install the seal cover (11). Traction Drum Assembly Removal and Installation See Figure 4-40. TN0243, 0240 NOTE Figure 4-37 The right and left traction drum assemblies are removed 4. Install bearing and housing assembly (6). and installed the same way.
Page 76: Differential Assembly
POWER TRAIN Differential Assembly Disassembly and Assembly See Figure 4-41. Disassembly and Assembly See Figure 4-42. TN0246 Retaining Ring Grease Seal Grease Seal Pin (Press Fit) Bushing (Press Fit) Differential Gear Roller Bushing (Press Fit) Figure 4-41 TN0248 1. Remove retaining ring (1), grease seal (2), and Figure 4-42 bushing (3) from roller (4).
Page 77 Chapter 5 Handle and Controls Adjustments ..............5-2 Handle Height Adjustment .
Page 78: Adjustments
HANDLE AND CONTROLS Adjustments Handle Height Adjustment See Figure 5-1. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) TN0659 Figure 5-2 TN0610 Figure 5-1 2. Loosen screws (2) on both sides of mower and adjust handle stops (1) evenly until desired handle height is obtained.
Page 79: Repair
HANDLE AND CONTROLS Repair Handle Cover Removal See Figures 5-4 through 5-6. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) TN0611 Figure 5-6 6. Remove four screws and washers (6) and front half of handle cover (7). Installation See Figures 5-8 through 5-10.
Page 80: Handle Assembly
HANDLE AND CONTROLS 2. Disconnect both park brake cables at brake bands. (See “Park Brake Cable” on page 6-5.) TN0613 Figure 5-8 TN0614 2. Connect circuit breaker wire connectors (5). Figure 5-10 3. Connect reel drive switch wire connectors (4). 3.
Page 81 HANDLE AND CONTROLS Installation See Figures 5-14 through 5-18. 11 12 13 TN0615 Figure 5-12 TN0062 7. Remove screw (11), lock washer (12), and washer Figure 5-14 (13) from handle stop (10). 8. Remove retaining ring (7), washer (8), and torsion 1.
Page 82 HANDLE AND CONTROLS 11 12 13 TN0615 Figure 5-16 TN0614 Figure 5-18 NOTES 7. Connect main harness connector (20). • Support handle assembly until mounting hardware is 8. Connect battery pack connector (19) and install installed. clamp (18). • Steps 4 through 6 apply to both sides of the handle 9.
Page 83: Handle And Opc Bail
HANDLE AND CONTROLS Handle and OPC Bail Removal See Figures 5-19 through 5-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove rear half of handle cover. (See “Handle Cover” on page 5-3.) TN0618 Figure 5-21 6.
Page 84: Opc Cable
HANDLE AND CONTROLS OPC Cable Removal and Installation See Figure 5-25. 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove handle cover. (See “Handle Cover” on page 5-3.) 3. Remove handle and Operator Presence Control (OPC) bail. (See “Handle and OPC Bail” on page 5-7.) TN0617 Figure 5-23...
Page 85: Speed Paddle
HANDLE AND CONTROLS Speed Paddle Brake Control Lever Removal and Installation Removal See Figure 5-26. See Figure 5-27. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) page 1-4.) 2.
Page 86 HANDLE AND CONTROLS Installation See Figure 5-28. TN0613 Figure 5-28 1. Install flanged bearings (7). 2. Install spring washer (6) over end of brake lever (5), and install lever into flanged bearings (7). 3. Install lever arm (9) onto brake lever shaft, and secure by driving pin (8) through lever arm and shaft.
Page 87 Chapter 6 Brakes Specifications ..............6-2 Troubleshooting .
Page 88: Specifications
BRAKES Specifications Brakes Park Brake Lever Actuating Force 10 (4.5) lb (kg) Park Brake Band—Anchor Pin 1.50 (38) in. (mm) Center-to-Center Distance (Park Brake Released) 4171984 First Editiion...
Page 89: Troubleshooting
BRAKES Troubleshooting Condition Probable Cause Remedy Park brake does not engage when lever is Park brake cables not adjusted properly. Adjust park brake cables. (See “Park engaged. Brake Check and Adjustment” on page 6-4.) Park brake cables damaged. Replace park brake cables. (See “Park Brake Cable”...
Page 90: Checks And Adjustments
BRAKES Checks and Adjustments 5. Attach a scale to top of brake lever (2). Record force required to engage park brake. A properly adjusted brake requires 10 lb (4.5 kg) pull to engage brake. Park Brake Check and Adjustment 6. If brakes do not meet specifications, proceed to “Adjustment Procedure.”...
Page 91: Repair
BRAKES 5. Install rear half of handle cover. (See “Handle Cover” on page 5-3.) 6. Install transport wheels (if equipped). (See “Transport Wheels (Optional)” on page 8-2.) Repair Park Brake Cable Removal See Figures 6-5 through 6-7. 1. Park the mower safely. (See “Park Mower Safely” on TN0655 page 1-4.) Figure 6-6...
Page 92: Park Brake Band
BRAKES Installation 7. Move free end of brake band until distance between center of park brake band pins (13 and 16) is See Figures 6-8 and 6-9. approximately 1.50 in. (38 mm). Tighten set screw (12). 8. Check brake adjustment. (See “Park Brake Check and Adjustment”...
Page 93 BRAKES Installation See Figures 6-11 and 6-12. TN0655 Figure 6-11 1. Install park brake band (5) on bracket (1). 2. Install wheel hub (3). (See “Wheel Hubs and Bearings” on page 8-3.) 3. Install lower brake band pin (4) into brake band (5). 4.
Page 94 BRAKES Page Intentionally Blank 4171984 First Editiion...
Page 95 Chapter 7 Cutting Unit Specifications ..............7-2 Component Location .
Page 96: Specifications
CUTTING UNIT Specifications Adjustments Flat Surface Height at the Front of the 1/32 (0.8) in. (mm) Bedknife (Minimum) Reel-to-Bedknife Gap 0.001—0.003 (0.025—0.076) in. (mm) Reel Side-to-Side Clearance (Reel 0.040 (1.27) in. (mm) Bearing Pre-Load) 4171984 First Editiion...
Page 97: Component Location
CUTTING UNIT Component Location Troubleshooting See Figure 7-1. Cutting unit troubleshooting is broken down into two areas: Quality of Cut Appearance and Mechanical. Quality of Cut Appearance Troubleshooting, as the name states, evaluates the mower’s performance by the visual appearance of the cut delivered by the mower. Undesirable patterns and other conditions noted may be caused by various mechanical, environmental (variations in turf, grass conditions, weather, etc.), or operating...
Page 98 CUTTING UNIT 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 99 CUTTING UNIT Marcelling Marcelling, like 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 2 inches (5 cm) or less. TN0220 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Page 100 CUTTING UNIT Step Cutting Step cutting occurs when grass that is cut taller on one side of the reel than the other. This is usually caused by mechanical wear or an incorrect roller adjustment. TN0221 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Page 101 CUTTING UNIT 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 102 CUTTING UNIT Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Bedknife improperly adjusted. Adjust bedknife. (See “Bedknife-to-Reel Adjustment” on page 7-15.) Dull cutting edges. Sharpen reel and bedknife.
Page 103 CUTTING UNIT Streaks A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife. TN0224 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 7-21.) Damaged or unevenly worn reel.
Page 104 CUTTING UNIT Windrowing Windrowing is the deposit of clippings concentrated at one end of the cutting unit, forming a line in the direction of travel. TN0225 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall.
Page 105 CUTTING UNIT Rifling or Tramlining Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife. TN0987 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Page 106: Mechanical Troubleshooting
CUTTING UNIT Mechanical Troubleshooting Cutting Unit Condition Probable Cause Remedy Reel drive does not engage when System voltage too low. Check system charge. (See “Battery Pack Operator Presence Control (OPC) bail is Test” on page 3-19.) engaged. Reel drive switch not engaged. Engage reel drive switch.
Page 107: Checks And Adjustments
CUTTING UNIT Checks and Adjustments 7. Grass conditions will also affect the adjustment. a. Dry, sparse conditions will require a wider gap to prevent heat build-up and damage to the reel and Reel and Bedknife Inspection bedknife. See Figure 7-2. b.
Page 108: Frame Alignment Adjustment
CUTTING UNIT Frame Alignment Adjustment See Figures 7-4 through 7-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Relieve bedknife adjuster spring tension, and back bedknife away from reel. (See “Bedknife-to-Reel Adjustment” on page 7-15.) NOTICE To prevent personal injury and damage to the TN0635...
Page 109: Bedknife Initial Adjustment
CUTTING UNIT Bedknife-to-Reel Adjustment 11. Tighten eight crossmember bolts (4 and 5) and remove gauge blocks. See Figures 7-9 and 7-10. 12. Adjust bedknife-to-reel contact. (See 1. Inspect reel and bedknife before performing “Bedknife-to-Reel Adjustment” on page 7-15.) adjustment. (See “Reel and Bedknife Inspection” on page 7-13.) Bedknife Initial Adjustment See Figure 7-8.
Page 110: Backlapping Procedure
CUTTING UNIT Backlapping Procedure See Figures 7-11 and 7-12. Whenever a reel and bedknife have been ground, or a new reel and/or bedknife have been installed, the assembled reel should be backlapped using an electric-powered bench lapper. Required Tools and Materials •...
Page 111: Front Roller Fore And Aft Check And Adjustment
CUTTING UNIT NOTE Before the roller can be adjusted, all bedknife adjustments must be completed. (See “Bedknife-to-Reel Adjustment” on page 7-15 and “Height-of-Cut Adjustment” on page 7-16.) 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels.
Page 112: Grass Shield Adjustment
CUTTING UNIT Grass Shield Adjustment Adjustment Procedure See Figure 7-15. See Figure 7-16. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) TN0646 TN0645 Figure 7-16 Figure 7-15 2. Loosen nuts (1) on both sides of the mower. 1.
Page 113: Reel Bearing Pre-Load Adjustment
CUTTING UNIT Reel Bearing Pre-Load Adjustment See Figures 7-17 through 7-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Back bedknife away from reel. (See “Bedknife-to-Reel Adjustment” on page 7-15.) TN0651 Figure 7-19 6. Tighten adjuster nut (7) until the spring (8) is completely collapsed, then back the nut 2—3 turns, or until there is 0.040 in.
Page 114: Battery Tray Adjustment
CUTTING UNIT Repair Grass Shield Removal and Installation See Figures 7-23 and 7-24. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 1 2 3 4 TN0649 Figure 7-21 9. Install cover (14) and two socket-head screws (13). 10.
Page 115: Bedknife
CUTTING UNIT Bedknife Bedknife Shoe Removal and Installation Removal See Figures 7-26 through 7-29. NOTE 1. Park the mower safely. (See “Park Mower Safely” on This procedure is intended for use with machines page 1-4.) equipped with standard fastener type bedknives. If the machine requiring service is equipped with an optional MAGKnife™...
Page 116 CUTTING UNIT Installation See Figures 7-30 through 7-32. Required Materials Anti-Seize Compound TN0644 Figure 7-28 5. Turn the front adjuster (6) counterclockwise to back the bedknife away from the reel blades. 6. Turn the rear adjuster (5) clockwise to relieve spring tension.
Page 117: Right Reel Bearing Housing Assembly
CUTTING UNIT TN0649 Figure 7-32 TN0639 Figure 7-34 NOTES 4. Remove snap ring (7). Apply anti-seize compound to the threads of the bedknife 5. Remove screw (4), lock washer (5), and nut (6). shoe mounting screws before installing. 6. Remove bedknife shoe mounting screw (9) and 3.
Page 118 CUTTING UNIT Disassembly and Assembly Installation See Figure 7-35. See Figures 7-36 and 7-37. Required Materials Anti-Seize Compound TN0638 TN0219 Figure 7-36 Bearing Cup and Cone Bushing (Press Fit) Grease Seal Reel Bearing Housing Grease Fitting NOTE Figure 7-35 • Always use new O-rings and seals. Assembly Notes •...
Page 119: Left Reel Bearing Housing Assembly
CUTTING UNIT Left Reel Bearing Housing Assembly Removal See Figures 7-38 through 7-41. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) TN0651 Figure 7-40 4. Remove nut (10). 5. Remove three socket-head screws (7), lock washers (8), and seal carrier (9).
Page 120 CUTTING UNIT Disassembly and Assembly Installation See Figure 7-42. See Figures 7-43 through 7-47. 2 3 4 TN0652 Figure 7-43 1. Install reel bearing housing assembly (7) using screw TN0653 (5) and shakeproof cone washer (6). Bearing Housing Bearing Cup and Cone Bushing (Press Fit) Grease Seal 2.
Page 121: Reel Assembly
CUTTING UNIT TN0649 Figure 7-47 TN0651 9. Install cover (18) using screws (17). Figure 7-45 Reel Assembly 5. Install seal carrier (14) using three socket-head screws (12) and lock washers (13). Removal 6. Install nut (15). See Figure 7-48. 7. Adjust the reel bearing pre-load. (See “Reel Bearing Pre-Load Adjustment”...
Page 122 CUTTING UNIT CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 5. Remove the reel (2) from the frame (1). Installation See Figure 7-49. TN0648 Figure 7-49 CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.
Page 123 Chapter 8 Miscellaneous Specifications ..............8-2 Repair .
Page 124 MISCELLANEOUS Specifications Transport Tires Transport Tire Air Pressure 6—8 (41—55) psi (kPa) Repair Transport Wheels (Optional) Removal and Installation See Figures 8-1 and 8-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) TN0657 Figure 8-2 3. To Install Wheels: Set the park brake, pull the retaining clip back and hold.
Page 125 MISCELLANEOUS Wheel Hubs and Bearings Disassembly See Figure 8-6. Removal See Figures 8-4 and 8-5. NOTE The hub assemblies are unique to each side and are marked “L” and “R.” Do not exchange them side-for-side. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2.
Page 126 MISCELLANEOUS TN0189 * Item 5 left-side only, as needed. TN0056 Figure 8-10 Figure 8-8 2. Install bushing (5) and latching collar (6). NOTE Always use new seals. 3. Apply a thin film of lithium grease NLGI Grade 2 to the lips of the seals (8). 4.
Page 127 MISCELLANEOUS Kickstand Removal and Installation See Figures 8-12 and 8-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels. TN0658 Figure 8-12: Left Side 3.
Page 128 MISCELLANEOUS Page Intentionally Blank 4171984 First Editiion...
Page 129 Chapter 9 Accessories Specifications ..............9-2 Repair—MAGKnife™...
Page 130: Specifications
ACCESSORIES Specifications Assembly and Disassembly Solid Tube Roller Lock Nut Torque 10—30 (13.5—40.6) lb-ft (N•m) Solid Tube Roller Rotational 0—6 with No End Play lb-in. (N•m) Resistance (0—0.68 with No End Play) 4171984 First Editiion...
Page 131: Repair-Magknife™ Bedknife
ACCESSORIES Repair—MAGKnife™ Bedknife 1. Park mower safely. (See “Park Mower Safely” on page 1-4.) 2. Remove bedknife shoe. (See “Bedknife Shoe” on Removal page 7-21.) See Figures 9-1 through 9-3. Required Tools (2) Bedknife Installation Removal Tool (BIRT) (Jacobsen P/N 4131219) WARNING Always keep bedknife shoe assembly away from anything sensitive to magnetic fields.
Page 132: Installation
ACCESSORIES TN0684 TN0684 Figure 9-3 Figure 9-4 6. Remove bedknife (5) from bedknife shoe (6). NOTE Installation Clear bedknife shoe and bedknife mounting face of all debris before installation. See Figures 9-4 through 9-6. 1. Fasten BIRTs (1) to bedknife (2). CAUTION 2.
Page 133: Repair-Magknife™ Bedknife Shoe
ACCESSORIES Inspection Notes • Inspect magnets (1) for cracks, peeling of the nickel plating, or other damage. Replace as needed. • Inspect dowl pins (2) for signs of wear. Replace as needed. CAUTION • Avoid personal injury; always wear safety glasses.
Page 134: Repair-Front Rollers
ACCESSORIES Repair—Front Rollers Front Roller—Solid Tube and Segmented Removal See Figures 9-8 and 9-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-4.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels. TN0672 Figure 9-9 3.
Page 135 ACCESSORIES Assembly—Solid Rollers See Figures 9-11 through 9-15. Required Materials ® Permatex Anaerobic Sealer (or equivalent) TN0316 TN0314 Figure 9-13 Figure 9-11 2. Install the roller shaft (9) with bearing (6) into the roller (8) until the bearing is seated against the NOTES shoulder (7) in the roller.
Page 136 ACCESSORIES Disassembly—Solid Tube and Grooved Rollers See Figure 9-16. TN0318 Figure 9-15 NOTE Always use new grease seals for installation. ® 5. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seal (14).
Page 137 ACCESSORIES Assembly—Solid Tube and Grooved Rollers NOTE See Figure 9-17. Solid tube roller shown; grooved roller is similar. 1. Using a puller, remove the adapter seals (4) from both ends of the roller assembly. 2. Remove lock nuts (3) and bearings (2) from both ends of the roller assembly.
Page 138 ACCESSORIES Disassembly—Grooved Disc Roller NOTES See Figure 9-18. • Bearings and bearing cups should always be replaced as a set. • Always use new grease seals for installation. 1. If removed, press new bearing cups (1) in the roller (6). 2.
Page 139 ACCESSORIES Assembly—Grooved Disc Roller Disassembly—Grooved Segmented Roller See Figure 9-19. See Figures 9-20 and 9-21. TN0251 TN0251 TN0254 Figure 9-20 TN0254 1. Remove hex-jam, nylon-insert nut (10) from the roller Figure 9-19 shaft (2) while holding the nut (1) at the other end of 1.
Page 140 ACCESSORIES 2. Apply NLGI Grade 2 grease to the inside of the spacer (3), and install the spacer (3) into the roller segment (4). 3. Install a ball bearing (6) and grease seal (5) in the other end of the roller segment (4). 4.
Page 141 ACCESSORIES Installation See Figures 9-24 through 9-26. TN0671 Figure 9-26 3. Install the adjuster bracket (9) to the frame and roller shaft using a carriage bolt (4) and flange nut (5). 4. Center the roller between the adjuster brackets, and TN0207 tighten the square head bolts (6) and jam nuts (7) on Figure 9-24...
Page 142: Scraper Blade Assembly
ACCESSORIES Scraper Blade Assembly Removal and Installation See Figure 9-27. TN0346 TN0346 360 X 290 360 X 290 TN0346 Figure 9-27 1. Park the mower safely. (See “Park Mower Safely” on Installation Notes page 1-4.) • Install the scraper assembly by reversing the order of 2.
Page 143: Light Kit Assembly
ACCESSORIES Light Kit Assembly Push Brush Assembly Disassembly and Assembly Disassembly and Assembly See Figure 9-28. See Figure 9-29. TN0681 Figure 9-29 NOTE Disassemble and replace parts as needed. Install parts in the reverse order of removal. TN0680 Figure 9-28 NOTE Disassemble and replace parts as needed.
Page 144 ACCESSORIES Page Intentionally Blank 9-16 4171984 First Editiion...
Page 145 INDEX Numerics Brake Control Lever Installation ......5-10 Removal ......48-Volt Power Circuit Repair .
Page 146 INDEX Component Symbols Actuating Devices ..... . 3-5 Circuit Protection Devices ....3-4 Electrical Electrical .
Page 147 INDEX Handle Cover Installation ......5-3 Removal ......5-3 Machine Components Location .
Page 148 INDEX Park Brake Cable Repair Bedknife ......7-21 Installation ......6-6 Removal .
Page 149 INDEX Safety Theory and Diagnostic Information Dispose of Waste Materials Safely ..1-7 Electrical ......Handle Chemical Products Safely .
Page 150 INDEX Waste Material Disposal Safety ....... 1-7 Wheel Hubs and Bearings Assembly .
Page 152 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...

Textron JACOBSEN 63290 Technical/Repair Manual

Chapter 1 Safety 1

Chapter 2 Specifications and General Information

Chapter 3 Electrical

Chapter 4 Power Train

Chapter 5 Handle and Controls

Chapter 6 Brakes

Chapter 7 Cutting Unit

Chapter 9 Accessories

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