Textron JACOBSEN Eclipse 118F Technical/Repair Manual
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Textron JACOBSEN Eclipse 118F Technical/Repair Manual

Textron JACOBSEN Eclipse 118F Technical/Repair Manual

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Eclipse
Technical/Repair Manual
Floating Head Models
118F 122F

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  • Page 1 Eclipse Technical/Repair Manual Floating Head Models 118F 122F...
  • Page 3 ©2008 Jacobsen, A Textron Company. All rights reserved.
  • Page 5 Foreword General CALIFORNIA Proposition 65 Warning This manual provides detailed information and procedures to safely repair and maintain the following: ® WARNING Jacobsen Eclipse™ 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 6 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2008 Textron Inc. “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4181381 First Edition...
  • Page 7 Table of Contents Safety Specifications and General Information Engine Electrical Power Train Handle and Controls Brakes Cutting Unit Miscellaneous Accessories 4181381 First Edition...
  • Page 8 FOREWORD 1-iv 4181381 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 Gen-Set Models See Figures 1-1 and 1-2. Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. TN0775 TN0776 Figure 1-2 Figure 1-1 WARNING Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling.
  • Page 12 SAFETY Battery Pack Models See Figures 1-3 and 1-4. Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. TN0761 TN0762 Figure 1-3 Figure 1-4 STOP 4170001 4169840 4181381 First Edition...

  • Page 13: Battery Pack Models

    SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the Battery Pack Models mower. Inspect the mower for any damaged, missing, or unreadable decals. Replace decals as needed before See Figures 1-5 through 1-7. placing the mower back into service.

  • Page 14: Gen-Set Models

    SAFETY Gen-Set Models See Figures 1-8 through 1-10. WARNING Before cleaning, adjusting, or repairing this equipment, disengage all drives, engage park brake, and stop engine to prevent injuries. When performing maintenance other than adjustments that require the engine to be running, disconnect gen-set connector, remove the spark plug wire, and place the wire away from the plug to prevent accidental starting and bodily...

  • Page 15: Use Lifting Equipment Safely

    SAFETY Support Machine Securely WARNING • Support the machine using properly rated jackstands. Never work under a machine supported only by a jack. • Do not use wood or concrete blocks to support the machine. Failure to properly support the machine may result in death or serious injury.

  • Page 16: 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 17: 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 and 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 18 SAFETY Page Intentionally Blank 1-10 4181381 First Edition...
  • Page 19 Chapter 2 Specifications and General Information Mower Identification ............2-2 Serial Number .

  • Page 20: Mower Identification

    If the machine requiring service is equipped with an accessory kit, see Section 10, “Accessories” for troubleshooting, removal, repair, and installation ® procedures. A Textron Company CHARLOTTE, NC MADE IN U.S.A. Cutting Unit Identification YEAR OF 2008 PRODUCTION: See Figure 2-2.

  • Page 21: Component Location

    SPECIFICATIONS AND GENERAL INFORMATION Component Location Gen-Set Models See Figures 2-3 and 2-4. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0776 TN0775 Operator Handle Reel Speed Control Paddle Reel Drive Motor Key Switch Floating Head Frame Roller Operator Presence Control...

  • Page 22: Battery Pack Models

    SPECIFICATIONS AND GENERAL INFORMATION Battery Pack Models See Figures 2-5 and 2-6. CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0761 TN0762 Operator Handle Reel Speed Control Paddle Kickstand Key Switch Floating Head Frame Roller Operator Presence Control Product Identification Plate (OPC) Bail...

  • Page 23: Specifications

    SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Power Train Traction (Transfer) Drive Belt Maximum 0.14 (3.5) in. (mm) 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 24: 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 Gen-Set Nominal 48 VDC Motors 48-Volt, Brushless, Keyed Shaft Motor Power Rating 0.75 (0.54) hp (kW) Motor Operating Speed 2200 (Factory Setting)

  • Page 25: 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 26: 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 27: Key Switch Check

    SPECIFICATIONS AND GENERAL INFORMATION Key Switch Check See Figures 2-8 through 2-10. The unit is equipped with a key switch to stop the traction and reel drive motors from the operator’s position. TN0772 Figure 2-10: Gen-Set Models If the traction drive does not stop, disconnect the battery pack/gen-set connector (4) to stop the traction drive and immediately repair the system.

  • Page 28: Operator Presence Control (Opc) System Check

    SPECIFICATIONS AND GENERAL INFORMATION Operator Presence Control (OPC) 6. Release the OPC bail. Bail will disengage, and traction drive will stop. System Check Does the traction drive continue turning after the See Figures 2-11 and 2-12. OPC bail is released? WARNING Move the key switch to the OFF position immediately and repair the system.

  • Page 29: Backlap Switch Check

    SPECIFICATIONS AND GENERAL INFORMATION Backlap Switch Check See Figures 2-13. TN0766 Figure 2-13 1. Place the mower securely on the kickstand. 2. Move key switch (4) to the ON position and enter mechanic mode on the LCD display (3). (See “LCD Display—Modes”...
  • Page 30 SPECIFICATIONS AND GENERAL INFORMATION Page Intentionally Blank 2-12 4181381 First Edition...
  • Page 31 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .

  • Page 32: Specifications

    ENGINE Specifications General Engine Specifications Engine Eclipse 118, 122, 126 Manufacturer/Model Honda/GX120 Engine Type 4-Stroke, Overhead Valve, Single Cylinder Displacement 7.3 (118) cu in. (cc) Bore x Stroke 2.4 x 1.7 (60 x 42) in. (mm) Cooling System Forced Air Ignition System Transistorized Magneto PTO Shaft Rotation...

  • Page 33: Troubleshooting

    ENGINE Troubleshooting This troubleshooting chart will cover basic engine troubleshooting information. A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for further engine troubleshooting information. Condition Probable Cause Remedy Engine does not start.

  • Page 34: Repair

    ENGINE Repair Disassembly and Assembly See Figure 3-3. Engine Removal See Figures 3-1 and 3-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0777 Figure 3-1 NOTE TN0804 Mount Plate Upper Isolator (4 used) Label all wires before disconnecting to ensure correct Engine Assembly Lower Isolator (4 used) installation.
  • Page 35 Chapter 4 Electrical Component Location ............4-3 Battery Pack Models .
  • Page 36 ELECTRICAL Component Testing ............4-33 Electrical System and Component Testing .

  • Page 37: Component Location

    ELECTRICAL Component Location Battery Pack Models CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0761, 0762 Speed Control Paddle Key Switch Reel Drive Switch 25A Circuit Breaker Battery Power Meter Traction Drive Motor Control Module Reel Drive Motor Battery Pack...

  • Page 38: Gen-Set Models

    ELECTRICAL Gen-Set Models CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN0775, 0776 Speed Control Paddle 25A Circuit Breaker Reel Drive Switch Traction Drive Motor Control Module Reel Drive Motor LCD Display and Controls Gen-Set Key Switch Figure 4-2...

  • Page 39: 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 40 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 4181381 First Edition...
  • Page 41 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 4181381 First Edition...
  • Page 42 ELECTRICAL Page Intentionally Blank 4181381 First Edition...

  • Page 43: Harness Connector Identification

    ELECTRICAL Harness Connector Identification See Figure 4-3. TN0845 Reel Drive Switch Connector (S2) Battery Pack/Gen-Set Connector (PM1) LCD Display Connector (J4) Control Module Connector (J1) LCD Display Connector (J5) Control Module Connector (J2) Speed Control Paddle Connector (R1) Traction Drive Motor Connectors (M1) OPC Bail Connector (R2) Floating Head Ground Terminal Key Switch Connector (S1)

  • Page 44: Main Schematic

    ELECTRICAL Main Schematic See Figures 4-4 and 4-5. Lights (+) PM1 (+) 25-Amp Circuit Switch Breaker Start Org/Yel Pnk/Blu Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap...
  • Page 45 ELECTRICAL PM1 (+) Battery Meter Enable Org/Grn Low Bat Light (Not Used) Switch Light (+) Light (-) Work Light PM1 (-) PM1 (+) PM1 (-) Voltage Regulator Stator Engine On/Off Switch Ignition Coil Spark Plug Figure 4-5 4181381 First Edition 4-11...

  • Page 46: Theory And Diagnostic Information

    ELECTRICAL Theory and Diagnostic 48-Volt Power Circuit Operation—Battery Pack Information See Figure 4-6. With the key switch in the OFF position, voltage is 48-Volt Power Circuit—Theory of available to the 25-amp circuit breaker from the battery Operation pack. From the 25-amp circuit breaker, voltage is available to key switch terminals B and C, and control 48-Volt Power Circuit Components module connector J1 terminals 1 and 2.

  • Page 47: 48-Volt Power Circuit Schematic-Battery Pack

    ELECTRICAL 48-Volt Power Circuit Schematic—Battery Pack PM1 (+) 25-Amp Battery Circuit Meter Breaker Enable Org/Grn Switch Low Bat Start (Not Used) Org/Yel 50-Amp Pnk/Blu Fuse PM1 (-) Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V...

  • Page 48: 48-Volt Power Circuit Schematic-Gen-Set

    ELECTRICAL 48-Volt Power Circuit Schematic—Gen-Set PM1 (+) 25-Amp PM1 (-) Circuit Breaker Switch Start Voltage Org/Yel Regulator Pnk/Blu Stator Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap...

  • Page 49: Ignition Shutoff Circuit Schematic-Gen-Set

    ELECTRICAL Ignition Shutoff Circuit Schematic—Gen-Set Lights (+) Engine On/Off Switch PM1 (+) 25-Amp Circuit Switch Breaker Start Ignition Coil Org/Yel Pnk/Blu Spark Plug Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control...

  • Page 50: Power-Up Circuit-Theory Of Operation

    ELECTRICAL Power-Up Circuit—Theory of Power-Up Circuit Operation Operation See Figure 4-9. Voltage is available to the 25-amp circuit breaker from the Power-Up Circuit Components battery pack or gen-set (engine running). From the 25-amp circuit breaker, voltage is available to key switch Gen-Set—If Equipped terminals B and C, and control module connector J1 The gen-set consists of a stator, rotor, and an internal...

  • Page 51: Power-Up Circuit Schematic

    ELECTRICAL Power-Up Circuit Schematic Lights (+) PM1 (+) 25-Amp Circuit Switch Breaker Start Org/Yel Pnk/Blu Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap Org/Yel J1-3 J2-2...

  • Page 52: Traction Drive Circuit-Theory Of Operation

    ELECTRICAL Traction Drive Circuit—Theory of Traction Drive Circuit Operation Operation See Figure 4-10. Voltage is provided from LCD display +5V to speed Traction Drive Circuit Components paddle control terminal 3. The LCD display also provides ground to speed paddle control terminal 1. Speed Paddle Control When the speed paddle control is adjusted, a signal is The speed paddle control (R1) sends a voltage signal...

  • Page 53: Traction Drive Circuit Schematic

    ELECTRICAL Traction Drive Circuit Schematic Lights (+) PM1 (+) 25-Amp Circuit Switch Breaker Start Org/Yel Pnk/Blu Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap Org/Yel J1-3...

  • Page 54: Reel Drive Circuit-Theory Of Operation

    ELECTRICAL Reel Drive Circuit—Theory of Reel Drive Circuit Operation Operation See Figure 4-11. Voltage is provided from LCD display +5V to OPC bail Reel Drive Circuit Components control terminal 1. The LCD display also provides ground to OPC bail control terminal 3. OPC Control When the OPC bail control is adjusted, a signal is The OPC control (R2) sends a voltage signal from 0—5...

  • Page 55: Reel Drive Circuit Schematic

    ELECTRICAL Reel Drive Circuit Schematic Lights (+) PM1 (+) 25-Amp Circuit Switch Breaker Start Org/Yel Pnk/Blu Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap Org/Yel J1-3...

  • Page 56: Backlap Drive Circuit-Theory Of Operation

    ELECTRICAL Backlap Drive Circuit—Theory of Backlap Drive Circuit Operation Operation See Figure 4-12. IMPORTANT Backlap Drive Circuit Components Backlap operation requires the LCD display to be set OPC Control to superintendent mode. (See “LCD Display— The OPC control (R2) sends a voltage signal from 0—5 Modes”...

  • Page 57: Backlap Drive Circuit Schematic

    ELECTRICAL Backlap Drive Circuit Schematic Lights (+) PM1 (+) 25-Amp Circuit Switch Breaker Start Org/Yel Pnk/Blu Yel/Org Yel/Org Control Module Traction Reel Motor J1-1 J2-1 Switch +48V +48V J1-2 J2-3 +48V +48V Display Shield J2-4 Motor Control J2-5 Motor Control Backlap Org/Yel J1-3...

  • Page 58: Troubleshooting

    ELECTRICAL Troubleshooting Symptom: Machine will not power up. Probable Cause Remedy Faulty battery pack. Test battery pack. (See “Battery Pack Test” on page 4-34.) Faulty battery pack fuse. Test fuse. (See “Battery Pack Fuse Test” on page 4-37.) Faulty circuit breaker. Test circuit breaker.
  • Page 59 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 4-40.) 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 60 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 4-37.) 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 61 ELECTRICAL Symptom: Backlap drive will not engage. Probable Cause Remedy LCD display not set to superintendent Set LCD to superintendent mode. (See “LCD Display—Modes” on page 4-28.) mode. Reel drive switch not in backlap position. Perform proper backlap procedure. (See “Backlapping Procedure” on page 8-16.) Faulty reel drive switch.

  • Page 62: Lcd Display-Modes

    ELECTRICAL LCD Display—Modes Component Fault Modes The LCD display is equipped to alert the user of a See Figure 4-13. component fault via an audible alarm and/or a component fault display. WARNING 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.

  • Page 63: Viewing Operational Values And System Data

    ELECTRICAL Reel Motor Fault Maintenance Hours REEL MOTOR MNT 100.9 HR FAULT RESET? A reel motor fault screen will be displayed if reel motor The maintenance hours screen displays the machine current draw exceeds 30 amps for more than one hours of operation since the last machine maintenance.

  • Page 64: Setting Operational Values

    ELECTRICAL Travel Motor Factory Reset TRAVEL MOTOR FACTORY 08.5 A RESET? RESET? The travel motor screen displays the traction motor amperage draw. Reel Motor The factory reset screen displays the option to reset the maximum mow speed, reel speed, and display units to REEL MOTOR the factory defaults.
  • Page 65 ELECTRICAL Motor Type Select Speed Paddle Calibration THUMB LEVER MOTOR TYPE CALIBRATE? SELECT? THUMB LEVER 4160533/4153940 000 DONE 120 < > The motor type select screen displays the option to NOTE change the drive motor model used. Refer to the machine parts book to determine the drive motors used Adjust speed paddle stops before performing calibration for your application.
  • Page 66 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 67: Component Testing

    ELECTRICAL Component Testing 3. Disconnect the ends of the wire being tested. 4. Touch meter leads to the ends of the wire or to the terminals of the component to be tested. Electrical System and Component Does meter read less than 0.5 ohm, and/or does Testing the buzzer sound? The wire is good.

  • Page 68: 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 69: Engine On/Off Switch

    ELECTRICAL Engine On/Off Switch See Figures 4-17 and 4-18. Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0872 Figure 4-15 3. Connect multi-meter leads (2) to gen-set connector (3).

  • Page 70: Key Switch Test

    ELECTRICAL 5. Move engine on/off switch to the ON position and 6. Move key switch to the RUN position. Check check for continuity. continuity between terminals (3 and 4). Is continuity indicated? Is continuity indicated? The switch is faulty; replace the switch. Proceed to step 8.

  • Page 71: Circuit Breaker Test

    ELECTRICAL Circuit Breaker Test Battery Pack Fuse Test See Figure 4-20. See Figure 4-21. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park mower safely. (See “Park Mower Safely” on 1.

  • Page 72: Traction Drive Motor Test

    ELECTRICAL Traction Drive Motor Test 3. Remove reel drive switch. (See “Reel Drive Switch” on page 4-46.) See Figure 4-23. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) TN0810 Figure 4-22 TN0875 4. Move reel drive switch to the MOW position. Figure 4-23 5.

  • Page 73: Reel Drive Motor Test

    ELECTRICAL Reel Drive Motor Test Speed Paddle Control Test See Figure 4-24. See Figure 4-25. 1. Park mower safely. (See “Park Mower Safely” on Required Tools or Equipment page 1-5.) 2. Back bedknife away from reel. Digital Multimeter or Ohmmeter (See “Bedknife-to-Reel Adjustment”...

  • Page 74: Opc Bail Control Test

    ELECTRICAL 6. Measure resistance between terminals (1 and 3) 4. Measure resistance between terminals (1 and 3). while rotating stem (4). Low end resistance must Resistance must range between 3640 and 6760 range between 18.9 and 35.1 ohms. High end ohms.

  • Page 75: Control Module Test

    ELECTRICAL Control Module Test 2. Start engine, if equipped, and move key switch to the START/ON position. Does LCD display illuminate and enter operator Required Tools or Equipment mode? Digital Multimeter or Continuity Tester LCD display is good. LCD display is faulty; replace LCD module. 1.

  • Page 76: Component Removal And Installation

    ELECTRICAL Component Removal and Disassembly Installation See Figures 4-28 through 4-30. 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 4-27. last.
  • Page 77 ELECTRICAL Assembly See Figure 4-31. TN0675 Figure 4-30 5. Disconnect battery gauge positive leads (6). 6. Disconnect battery gauge negative lead (7). 7. Disconnect battery gauge signal wire lead (8). 8. Remove battery pack cover (9). Disassembly Note Disconnect remaining wire leads, as needed, to service individual batteries.

  • Page 78: Battery Gauge

    ELECTRICAL Battery Gauge Battery Pack Fuse Removal and Installation Removal and Installation See Figure 4-32. See Figure 4-33. 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 79: Generator

    ELECTRICAL Generator Removal and Installation See Figures 4-34 through 4-36. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) TN0870 Figure 4-36 6. Remove four socket-head screws and lock washers (7). 7. Remove adapter plate (8). TN0777 Figure 4-34 Installation Note 2.

  • Page 80: Circuit Breaker

    ELECTRICAL Reel Drive Switch 4. Remove key switch nut (1) and key switch assembly (3). Removal and Installation Installation Notes See Figure 4-39. • Install the key switch by reversing the order of 1. Park mower safely. (See “Park Mower Safely” on removal.

  • Page 81: Traction Drive Motor

    ELECTRICAL 4 5 6 7 12 13 14 15 9 10 11 TN0812 Figure 4-42 TN0874 Figure 4-40 2. Disconnect traction drive motor connectors (2). 2. Disconnect reel drive motor harness connectors (1). 3. Remove belt cover. (See “Traction Drive Belt Cover” on page 5-7.) 3.
  • Page 82 ELECTRICAL Installation See Figures 4-46 through 4-49. Required Materials Loctite® 242 (Blue) Thread Sealant 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 1 2 3 TN0623 Figure 4-44 10. Remove pulley (19) using a knife-edge puller. 20 21 22 TN0630 Figure 4-46 2.

  • Page 83: Speed Paddle Control

    ELECTRICAL Speed Paddle Control Removal and Installation See Figure 4-50. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove rear half of handle cover. (See “Handle Cover” on page 6-3.) 3. Remove handle and Operator Presence Control (OPC) bail.

  • Page 84: Lcd Display

    ELECTRICAL LCD Display Removal and Installation See Figure 4-51. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove handle cover. (See “Handle Cover” on page 6-3.) TN0875 Figure 4-52 2. Disconnect wire harness connectors (1, 7, and 8). 3.

  • Page 85: Opc Bail Control

    ELECTRICAL Installation Installation Note Install the battery tray and mount plate by reversing the order of removal. OPC Bail Control Removal and Installation See Figures 4-56 through 4-58. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove handle cover. (See “Handle Cover” on page 6-3.) TN0828 Figure 4-54...
  • Page 86 ELECTRICAL 10 11 12 10 11 12 TN0825 Figure 4-58 6. Remove two screws (8), spacers (9), nuts (10), lock washer (11), flat washers (12), and OPC bail control (7). Installation Notes • Install OPC bail control by reversing the order of removal.
  • Page 87 Chapter 5 Power Train Specifications ..............5-2 Component Location .

  • Page 88: Specifications

    POWER TRAIN Specifications Adjustments Traction Drive (Transfer) Belt Maximum 9/64 (3.5) in. (mm) 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 4181381 First Edition...

  • Page 89: Component Location

    POWER TRAIN Component Location See Figure 5-1. TN0761, 0762, 0808 Traction Drive Motor Traction Drive (Outer Transfer) Pulley Traction Drive Motor Harness Connector Traction Drive (Inner Transfer) Pulley Traction Drum/Differential Assembly Traction Drive Belt (Final Drive) Traction Drive Motor Pulley Traction Drive (Traction Drum) Pulley Traction Drive Belt (Transfer) Figure 5-1: Power Train Component Location...

  • Page 90: 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 91: Adjustments

    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 92 POWER TRAIN Adjustment Procedure See Figures 5-4 and 5-5. 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 93: Repair

    POWER TRAIN Repair Traction Drive Belts Removal Traction Drive Belt Cover See Figures 5-7 and 5-8. Removal and Installation 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) See Figure 5-6. 2. Remove the traction drive belt cover. (See “Traction 1.
  • Page 94 POWER TRAIN Component Inspection Inner Transfer Pulley See Figures 5-9 through 5-11. Outer Transfer Pulley Required Materials ® Lubriplate Marine Grease TN0180 Figure 5-11 4. Inspect the needle bearing (5) for signs of wear or damage. Replace as needed. ® 5.
  • Page 95 POWER TRAIN Installation See Figures 5-12 through 5-15. TN0817 Figure 5-14 2. Install traction drive (final drive) belt (10). NOTE TN0176 Be sure to guide traction drive (final drive) belt (10) over Figure 5-12 inner transfer pulley (7) while installing transfer pulley/shaft assembly.

  • Page 96: Traction Drive Drum And Bearing Housing Assembly

    POWER TRAIN Traction Drive Drum and Bearing Housing Assembly Removal and Installation See Figures 5-16 through 5-19. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove traction drive belts. (See “Traction Drive Belts” on page 5-7.) 3.

  • Page 97: Traction Drum Left Bearing Housing

    POWER TRAIN Traction Drum Left Bearing Housing Removal See Figures 5-20 through 5-24. TN0822 Figure 5-19 10. Remove key (20) from traction drum shaft (21). TN0235 11. Remove three socket-head screws (17) and lock washers (18) from bearing housing (19). Figure 5-20 12.
  • Page 98 POWER TRAIN Installation See Figures 5-25 through 5-29. Required Materials ® Loctite Aviation Gasket Sealer (Loctite P/N 30516) TN0237 Figure 5-22 5. Remove two washers (8). TN0238 Figure 5-25 1. Install a new grease seal (1) in the seal cover (2). TN0238 Figure 5-23 6.

  • Page 99: Traction Drum Right Bearing Housing

    POWER TRAIN TN0249 Figure 5-27 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. 4. Pack bearing (6) with NLGI Grade 2 grease before 14 15 installation.
  • Page 100 POWER TRAIN TN0242 Figure 5-31 TN0244 2. Remove nut (2) Figure 5-33 5. Remove grease seal (6) from the seal cover (7). TN0243 TN0247 Figure 5-32 Figure 5-34 3. Loosen set screw (3) and remove the locking collar 6. Inspect bearing (8) for wear or damage. Remove the (4).
  • Page 101 POWER TRAIN Installation See Figures 5-35 through 5-39. Required Materials ® Loctite Aviation Gasket Sealer (Loctite P/N 30516) TN0244 TN0243, 0240 Figure 5-35 Figure 5-37 1. Install a new grease seal (1) in the seal cover (2). 4. Install bearing and housing assembly (6). 5.

  • Page 102: Traction Drum Assembly

    POWER TRAIN Disassembly and Assembly See Figure 5-41. TN0241 Figure 5-39 7. Install the seal cover (11). Traction Drum Assembly TN0246 Retaining Ring Grease Seal Removal and Installation Grease Seal Pin (Press Fit) See Figure 5-40. Bushing (Press Fit) Differential Gear Roller Bushing (Press Fit) NOTE...

  • Page 103: Differential Assembly

    POWER TRAIN Differential Assembly Disassembly and Assembly See Figure 5-42. TN0248 Figure 5-42 1. Remove two set screws (1), pinion shaft (2), two thrust washers (5), and pinion gears (6) from differential (3). 2. Remove differential (3) from the traction drum shaft (4).
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  • Page 105 Chapter 6 Handle and Controls Adjustments ..............6-2 Handle Height Adjustment .

  • Page 106: Adjustments

    HANDLE AND CONTROLS Adjustments Handle Height Adjustment See Figure 6-1. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0659 Figure 6-2 TN0863 Figure 6-1 2. Loosen screws (2) on both sides of mower and adjust handle stops (1) evenly until desired handle height is obtained.

  • Page 107: Speed Paddle Stop Adjustment

    HANDLE AND CONTROLS Speed Paddle Stop Adjustment Repair See Figure 6-4. Handle Cover 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) Removal See Figures 6-5 through 6-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0766 Figure 6-4...
  • Page 108 HANDLE AND CONTROLS TN0766 TN0799 Figure 6-7 Figure 6-9 6. Remove four screws and washers (6) and front half 2. Connect circuit breaker wire connectors (5). of handle cover (7). 3. Connect reel drive switch wire connectors (4). Installation 4. Connect key switch wire connector (3). See Figures 6-8 through 6-10.

  • Page 109: Handle Assembly

    HANDLE AND CONTROLS Handle Assembly 9. Remove harness tie (8). See Figures 6-11 through 6-15. Removal 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Disconnect both park brake cables at brake bands. (See “Park Brake Cable” on page 7-5.) TN0863 Figure 6-13 10.
  • Page 110 HANDLE AND CONTROLS TN0866 TN0866 Figure 6-15 Figure 6-17 13. Remove handle assembly by pressing in on handle 2. Slide one handle tube (5) onto stud (6). Repeat tube (19) until end of tube clears stud (20). Repeat procedure for the opposite side of handle. procedure for the opposite side of handle.
  • Page 111 HANDLE AND CONTROLS TN0863 TN0867 Figure 6-19 Figure 6-21 6. Connect torsion spring (15) to handle stop (16). 10. Connect battery pack connector (23). 11. Connect reel motor connectors (21). 12. Connect ground lead terminal (24). 13. Install harness tie (22). 14.

  • Page 112: Handle And Opc Bail

    HANDLE AND CONTROLS Handle and OPC Bail Removal See Figures 6-22 through 6-24. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove rear half of handle cover. (See “Handle Cover” on page 6-3.) TN0618 Figure 6-24 6.

  • Page 113: Opc Cable

    HANDLE AND CONTROLS OPC Cable Removal and Installation See Figure 6-28. 1. Park mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove handle cover. (See “Handle Cover” on page 6-3.) 3. Remove handle and Operator Presence Control (OPC) bail. (See “Handle and OPC Bail” on page 6-8.) TN0617 Figure 6-26...

  • Page 114: Speed Paddle

    HANDLE AND CONTROLS Speed Paddle Brake Control Lever Removal and Installation Removal See Figure 6-29. See Figure 6-30. 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 115 HANDLE AND CONTROLS Installation See Figure 6-31. Figure 6-31 1. Install flanged bushings (7). 2. Install spring washer (6) over end of brake lever (5), and install lever into flanged bushings (7). 3. Install lever arm (9) onto brake lever shaft, and secure by driving pin (8) through lever arm and shaft.
  • Page 116 HANDLE AND CONTROLS Page Intentionally Blank 6-12 4181381 First Edition...
  • Page 117 Chapter 7 Brakes Specifications ..............7-2 Troubleshooting .

  • Page 118: 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) 4181381 First Edition...

  • Page 119: 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 7-4.) Park brake cables damaged. Replace park brake cables. (See “Park Brake Cable”...

  • Page 120: 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 121: Repair

    BRAKES 5. Install rear half of handle cover. (See “Handle Cover” on page 6-3.) 6. Install transport wheels (if equipped). (See “Transport Wheels (Optional)” on page 9-2.) Repair Park Brake Cable Removal See Figures 7-5 through 7-7. 1. Park the mower safely. (See “Park Mower Safely” on TN0655 page 1-5.) Figure 7-6...

  • Page 122: Park Brake Band

    BRAKES Installation 8. Check brake adjustment. (See “Park Brake Check and Adjustment” on page 7-4.) See Figures 7-8 and 7-9. Park Brake Band Removal See Figure 7-10. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove transport wheels (if equipped). (See “Transport Wheels (Optional)”...
  • Page 123 BRAKES Installation See Figures 7-11 and 7-12. TN0655 Figure 7-11 1. Install park brake band (5) on bracket (1). 2. Install wheel hub (3). (See “Wheel Hubs and Bearings” on page 9-3.) 3. Install lower brake band pin (4) into brake band (5). 4.
  • Page 124 BRAKES Page Intentionally Blank 4181381 First Edition...
  • Page 125 Chapter 8 Cutting Unit Specifications ..............8-2 Component Location .

  • Page 126: 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 Bearing 0.040 (1.27) in. (mm) Pre-Load) 4181381 First Edition...

  • Page 127: Component Location

    CUTTING UNIT Component Location Troubleshooting See Figure 8-1. 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 128 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 129 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 130 CUTTING UNIT Step Cutting Step cutting occurs when grass is cut taller on one side of the reel than the other. This is usually caused by mechanical wear or an incorrect roller adjustment. TN0221 NOTE: One cutting unit width shown. Arrow indicates direction of travel.
  • Page 131 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 132 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 8-13.) Dull cutting edges. Sharpen reel and bedknife.
  • Page 133 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 8-19.) Damaged or unevenly worn reel.
  • Page 134 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 135 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 136: 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 4-34.) engaged. Reel drive switch not engaged. Engage reel drive switch.

  • Page 137: 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 8-2. b.

  • Page 138: Battery Tray Fore/Aft Adjustment

    CUTTING UNIT TN0893 TN0780 Figure 8-5 Figure 8-6 3. Loosen nuts (1) and slide battery tray (2) forward to CAUTION increase the weight over the front roller. 4. Move battery tray (2) back to decrease the weight To prevent personal injury and damage to cutting over the front roller.

  • Page 139: Backlapping Procedure

    CUTTING UNIT Backlapping Procedure See Figure 8-8. BACKLAP? Whenever a reel and bedknife have been ground, or a new reel and/or bedknife have been installed, the assembled reel should be backlapped. The backlap yes/no screen will be displayed. Required Tools and Materials 7.

  • Page 140: Height-Of-Cut Adjustment

    CUTTING UNIT Height-of-Cut Adjustment 7. Slide screw head over bedknife (3) and adjust knob (1) so roller just contacts the gauge bar. Tighten nut See Figure 8-9. (6). 8. Repeat steps 6 and 7 on the opposite end of the reel, Required Tools then tighten nuts (6).

  • Page 141: Reel Bearing Pre-Load Adjustment

    CUTTING UNIT Reel Bearing Pre-Load Adjustment See Figures 8-10 through 8-14. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Back bedknife away from reel. (See “Bedknife-to-Reel Adjustment” on page 8-13.) TN0900 Figure 8-12 6. Tighten adjuster nut (8) until the spring (9) is completely collapsed, then back the nut 2—3 turns, or until there is 0.040 in.

  • Page 142: Repair

    CUTTING UNIT Repair Cutting Unit Removal and Installation See Figures 8-15 and 8-16. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels. 15 16 TN0895 Figure 8-14...

  • Page 143: Grass Shield

    CUTTING UNIT Bedknife 9. Push the limit bracket (5) in and tip mower back on traction drum or tires. Support the mower to prevent it from tipping. Removal and Installation 10. Remove cutting unit. See Figure 8-19. 1. Park the mower safely. (See “Park Mower Safely” on Installation Note page 1-5.) Install the cutting unit by reversing the order of removal.

  • Page 144: Bedknife Shoe

    CUTTING UNIT Bedknife Shoe Removal See Figures 8-20 through 8-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-18.) TN0938 Figure 8-22 5. Remove the bedknife shoe assembly (4). TN0893 Figure 8-20 NOTE...

  • Page 145: Right Reel Bearing Housing Assembly

    CUTTING UNIT Installation See Figures 8-23 through 8-25. Required Materials Anti-Seize Compound TN0937 Figure 8-25 NOTES Apply anti-seize compound to the threads of the bedknife shoe mounting screws (5) before installing. 2. Install the bedknife shoe mounting screws (5) in the TN0938 frame and bedknife shoe.
  • Page 146 CUTTING UNIT TN0907 Figure 8-26 6. Remove socket-head screws (2) and adapter plate TN0908 (1). Figure 8-28 8. Remove snap ring (4). 9. Remove screws (5), washers (6), and nuts (7). 10. Using a puller, remove reel bearing housing assembly (8). 11.
  • Page 147 CUTTING UNIT Disassembly and Assembly Installation See Figure 8-29. See Figures 8-30 through 8-32. Required Materials ® Loctite 242 (Blue) Thread Sealant TN0940 TN0940 Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting Figure 8-29 Assembly Notes •...

  • Page 148: Left Reel Bearing Housing Assembly

    CUTTING UNIT Left Reel Bearing Housing Assembly Removal See Figures 8-33 through 8-35. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-18.) 3. Remove cutting unit front roller. (See “Cutting Unit Front Roller”...
  • Page 149 CUTTING UNIT Disassembly and Assembly See Figure 8-36. TN0904 Figure 8-34 8. Remove screw (10), lock washer (11), washer (9), and spacer (8). 9. Remove screws (5), washers (6), and nuts (7). TN0941 10. Remove seal (12). Bearing Housing Bearing Cup and Cone Vent Fitting Grease Fitting Grease Seal...

  • Page 150: Reel Assembly

    CUTTING UNIT Installation 13 14 See Figures 8-37 through 8-39. 13 14 TN0905 Figure 8-39 6. Install counterweight (15) using screws (13) and TN0903 washers (14). Figure 8-37 7. Install grease fitting (16). 1. Install reel bearing housing assembly (1). 8.
  • Page 151 CUTTING UNIT 5. Install grass shield. (See “Grass Shield” on page 8-19.) 6. Install cutting unit front roller. (See “Cutting Unit Front Roller” on page 8-28.) 7. Install bedknife shoe assembly. (See “Bedknife Shoe” on page 8-20.) 8. Install cutting unit to mower. (See “Cutting Unit” on page 8-18.) TN0902 Figure 8-40...

  • Page 152: Floating Head

    CUTTING UNIT Floating Head Installation Note Install the floating head by reversing the order of removal. Removal and Installation Cutting Unit Front Roller See Figures 8-42 and 8-43. 1. Park the mower safely. (See “Park Mower Safely” on Removal and Installation page 1-5.) See Figure 8-44.

  • Page 153: Cutting Unit Rear Roller

    CUTTING UNIT Cutting Unit Rear Roller Floating Head Roller Removal and Installation Removal and Installation See Figure 8-45. See Figure 8-46. 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 154 CUTTING UNIT Page Intentionally Blank 8-30 4181381 First Edition...
  • Page 155 Chapter 9 Miscellaneous Specifications ..............9-2 Repair .
  • Page 156 MISCELLANEOUS Specifications Transport Tires Transport Tire Air Pressure 6—8 (41—55) psi (kPa) Repair Transport Wheels (Optional) Removal and Installation See Figures 9-1 and 9-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0657 Figure 9-2 3. To Install Wheels: Set the park brake, pull the retaining clip back and hold.
  • Page 157 MISCELLANEOUS Wheel Hubs and Bearings Disassembly See Figure 9-6. Removal See Figures 9-4 and 9-5. 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 1-5.) 2.
  • Page 158 MISCELLANEOUS Installation NOTE See Figures 9-9 through 9-11. The bearing used in the wheel hub is directional and must be installed in the correct direction of rotation. 2. Install bearing (2) in the hub (1): Right Wheel Hub: Install the bearing with the word “LOCK”...
  • Page 159 MISCELLANEOUS Kickstand Removal and Installation See Figures 9-12 and 9-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Retract the kickstand and allow the mower to rest on the traction roller or transport wheels. TN0826 Figure 9-11 3.
  • Page 160 MISCELLANEOUS Page Intentionally Blank 4181381 First Edition...
  • Page 161 Chapter 10 Accessories Specifications ..............10-2 Repair .

  • Page 162: 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) Repair Disassembly—Solid Rollers See Figure 10-2. Cutting Unit Front Roller Removal See Figure 10-1.
  • Page 163 ACCESSORIES Assembly—Solid Rollers See Figures 10-3 through 10-7. Required Materials ® Permatex Anaerobic Sealer (or equivalent) TN0316 TN0314 Figure 10-5 Figure 10-3 4. Install the roller shaft (9) with bearing (6) into the 1. Remove the shield (1) from one side of each new roller (8) until the bearing is seated against the bearing (2).
  • Page 164 ACCESSORIES Disassembly—Solid Tube and Grooved Rollers See Figure 10-8. TN0318 Figure 10-7 NOTE Always use new grease seals for installation. ® 7. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seal (14).
  • Page 165 ACCESSORIES 4. Inspect the bearings (2 and 9). If replacement is NOTE required, use a blind hole bearing puller to remove the bearing cups (1 and 8) from both ends of the Always use new grease seals for installation. roller (7). ®...
  • Page 166 ACCESSORIES Disassembly—Grooved Disc Roller Assembly—Grooved Disc Roller See Figure 10-10. See Figure 10-11. TN0254 TN0254 TN0254 TN0254 Figure 10-10 Figure 10-11 1. Remove grease fittings (1 and 8) from the roller shaft 1. Install bearing (3) in the roller (5). (4).
  • Page 167 ACCESSORIES Disassembly—Grooved Segmented Roller See Figures 10-12 and 10-13. TN0252 TN0252 Figure 10-13 NOTE All three roller segment assemblies are disassembled in the same way. 5. Remove grease seals (11 and 15), ball bearings (12 and 16), and spacer (13) from the roller segment (14).
  • Page 168 ACCESSORIES 2. Apply NLGI Grade 2 grease to the inside of the Installation spacer (3), and install the spacer (3) into the roller See Figure 10-16. segment (4). 1. Park the mower safely. (See “Park Mower Safely” on 3. Install a ball bearing (6) and grease seal (5) in the page 1-5.) other end of the roller segment (4).

  • Page 169: Scraper Blade Assembly

    ACCESSORIES Scraper Blade Assembly Removal and Installation See Figure 10-17. TN0346 TN0346 360 X 290 360 X 290 TN0346 Figure 10-17 1. Park the mower safely. (See “Park Mower Safely” on Installation Notes page 1-5.) • Install the scraper assembly by reversing the order of 2.

  • Page 170: Light Kit Assembly

    ACCESSORIES Light Kit Assembly Push Brush Assembly Removal and Installation Disassembly and Assembly See Figure 10-18. See Figure 10-19. TN0681 TN0898 Figure 10-19 Figure 10-18 1. Park mower safely. (See “Park Mower Safely” on NOTE page 1-5.) Disassemble and replace parts as needed. Install parts 2.
  • Page 171 INDEX Numerics Bedknife Shoe Installation ......8-21 Removal ......8-20 48-Volt Power Circuit Repair .
  • Page 172 INDEX Component Symbols Actuating Devices ..... . 4-6 Circuit Protection Devices ....4-5 Electrical Electrical .
  • Page 173 INDEX Grooved Disc Roller Assembly ......10-6 Disassembly ......10-6 Label Locations-Battery Pack Safety .
  • Page 174 INDEX OPC Cable Quality of Cut Symptoms Removal and Installation ....6-9 Marcelling ......8-5 Repair .
  • Page 175 INDEX Repair Bedknife ......8-19 Bedknife Shoe ..... . . 8-20 Safety Brake Control Lever .
  • Page 176 INDEX Specifications Traction Drive Drum and Bearing Housing Accessories ......10-2 Assembly Brakes ......7-2 Removal and Installation .
  • Page 178 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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