Textron JACOBSEN Eclipse 2 Technical/Repair Manual
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Textron JACOBSEN Eclipse 2 Technical/Repair Manual

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Eclipse
®
2
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 ©2012 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 2 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 2012, Jacobsen, A Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4262930-Rev A...
  • Page 7 Table of Contents Safety Specifications and General Information Engine Electrical Power Train Handle and Controls Brakes Cutting Unit Miscellaneous Accessories 4262930-Rev A...

  • 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. TN4412 TN4411 Figure 1-2 Figure 1-1 WARNING Gasoline is highly flammable and explosive. Turn engine off and let cool before refueling.

  • Page 12: Battery Pack Models

    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. TN4453 TN4454 Figure 1-3 Figure 1-4 STOP 4170001 4169840 4262930-Rev A...

  • Page 13: Inspect Safety Labels

    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 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 16: Support Machine Securely

    SAFETY Support Machine Securely Service Tires Safely WARNING WARNING • Support the machine using properly rated An inflated tire contains explosive force. Use care jackstands. Never work under a machine when handling wheels and tires. supported only by a jack. •...

  • Page 17: Handle Fuel Safely

    SAFETY Handle Fuel Safely Handle Chemical Products Safely Handle fuel with care—it is highly flammable. WARNING WARNING • Never remove the fuel cap from the fuel tank, Exposure to chemical products could result in or add fuel, when the engine is running or serious injury.

  • Page 18: Dispose Of Waste Materials Safely

    SAFETY Dispose of Waste Materials Safely Routine service can produce waste products such as used oil and grease and used batteries. If not handled properly, these materials can pose a threat to the environment. Collect fluids in well-marked, approved storage containers.
  • Page 19 Chapter 2 Specifications and General Information Mower Identification ............2-2 Serial Number .

  • Page 20: Mower Identification

    Eclipse 2 118F Battery Pack powered (15-blade, 18-inch floating head reel) with InCommand™ ® 11524 WILMAR BLVD, control system, Operator Presence Control (OPC), CHARLOTTE, NC 28273 A Textron Company PRODUCT OF U.S.A. 1-800-848-1636 (US) brakes, and kickstand. XX.X XXXX 63349 ®...

  • Page 21: Cutting Unit Identification

    SPECIFICATIONS AND GENERAL INFORMATION Cutting Unit Identification See Figure 2-2. A Textron Company CHARLOTTE, NC MADE IN U.S.A. 6330801652 TN0768 Figure 2-2 Serial Number An identification plate like the one shown, listing the serial number, is attached to the reel left side frame.

  • Page 22: 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. TN4411 TN4412 Operator Handle Front Roller Speed Control Paddle Kickstand Key Switch Traction Motor Controller Operator Presence Control Product Identification Plate...

  • Page 23: 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. TN4453 TN4454 Operator Handle Floating Head Frame Speed Control Paddle Kickstand Roller Operator Presence Control Product Identification Plate Key Switch...

  • Page 24: Specifications

    SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications General Specifications Engine 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 25 SPECIFICATIONS AND GENERAL INFORMATION Front Roller Weights 18 Inch Grooved Machined Aluminum Roller 7 (3.18) lb (kg) (PN 063318) 18 Inch Grooved Machined Steel Roller 16 (7.26) lb (kg) (PN 068616) 18 Inch Heavy Smooth Roller with Scraper 20 (9.07) lb (kg) (PN 068626) 18 Inch Light Smooth Roller...
  • Page 26 SPECIFICATIONS AND GENERAL INFORMATION Engine Repair Specifications Engine Mounting Carriage Bolt Torque 13 (17.7) lb-ft (N·m) Electrical Test and Adjustment Specifications Ceramic Resistor Resistance at 68° F 5 ± 5% ohms 120 Ohm Resistor Connector Resistance at 68° F 120 ± 10% ohms Throttle Potentiometer Low End Resistance at 68°...
  • Page 27 SPECIFICATIONS AND GENERAL INFORMATION Cutting Unit Check and Adjustment Specifications Bedknife-to-Reel Gap 0.001–0.003 (0.025–0.075) in. (mm) Reel Bearing Pre-Load 0.040 (1.0) in. (mm) Bedknife Front Face Height (minimum) 0.035 (0.9) in. (mm) Bedknife Front Face Angle (all bedknives) degrees Bedknife Top Face Angle (rear relief) (all bedknives 8–10 degrees except Super Tournament)

  • Page 28: 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 29: 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 30: 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 motors from the operator’s position. TN4431 Figure 2-9: Battery Pack Models TN4388 Figure 2-8 1.

  • Page 31: 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 32 SPECIFICATIONS AND GENERAL INFORMATION 2-14 4262930-Rev A...
  • Page 33 Chapter 3 Engine Specifications ..............3-2 General Engine Specifications .

  • Page 34: Specifications

    ENGINE Specifications General Engine Specifications Specification 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 Counterclockwise Recommended Spark Plug...

  • Page 35: 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 36: Repair

    ENGINE Repair Engine Removal See Figures 3-1 through 3-3. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4397 Figure 3-3 4. Disconnect gen-set harness connector (4). 5. Remove four screws (5), lock washers (5), and flat washers (6).
  • Page 37 ENGINE Installation Notes • Install engine by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. • Tighten carriage bolts (5) to 13 lb-ft (17.7 N·m). 4262930-Rev A...
  • Page 38 ENGINE 4262930-Rev A...
  • Page 39 Chapter 4 Electrical Specifications ..............4-3 Test and Adjustment Specifications .
  • Page 40 ELECTRICAL Component Testing ............4-44 Electrical System and Component Testing .

  • Page 41: Specifications

    ELECTRICAL Specifications Test and Adjustment Specifications Specification Ceramic Resistor Resistance at 68° F 5 ± 5% ohms 120-Ohm Resistor Connector Resistance at 68° F 120 ± 10% ohms Throttle Potentiometer Low End Resistance at 68° F 18.9–35.1 ohms Throttle Potentiometer High End Resistance at 68° F 3710–6890 ohms Bail Potentiometer Resistance at 68°...

  • Page 42: Component Location

    ELECTRICAL Component Location Battery Pack Models CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN4454, TN4453 Speed Control Paddle Traction Motor Mow Switch Traction Motor Controller Battery Gauge Reel Motor Controller Reel Motor Battery Pack LCD Display and Controls 30A Fuse...

  • Page 43: Gen-Set Models

    ELECTRICAL Gen-Set Models CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. TN4412, TN4411 Speed Control Paddle Traction Motor Mow Switch Traction Motor Controller Engine On/Off Switch Reel Motor Controller Reel Motor Gen-Set LCD Display and Controls 30A Fuse Key Switch...

  • Page 44: 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 45 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 4262930-Rev A...
  • Page 46 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 4262930-Rev A...

  • Page 47: Harness Connector Identification

    ELECTRICAL Harness Connector Identification See Figure 4-3. TN4430 Mow Switch Connector (SW1) Reel Motor Controller Connectors (J6 and J7) Key Switch Connector (SW2) Traction Motor Controller Connectors (J8 and J9) Main Control Unit Connector (J1) Ground Terminals (GC1 and GC2) Main Control Unit Connector (J2) Engine On/Off Switch Connector (J22) 30A Fuse (F2)

  • Page 48: Electrical Schematic Component Identification

    ELECTRICAL Electrical Schematic Component Identification Electrical components shown in the main schematic are identified with an alphanumeric call out. All electrical components shown in the electrical schematic are listed below. • B1—12V Battery (See Figure 4-4.) • B2—12V Battery (See Figure 4-4.) •...
  • Page 49 ELECTRICAL Page Intentionally Blank 4262930-Rev A 4-11...

  • Page 50: Main Schematic

    ELECTRICAL Main Schematic See Figures 4-4 and 4-5. Battery Pack Engine Control (Hybrid Genset) Brn J22 Battery Gauge Spark Ignition Plug Coil Splice D Red/Yel Red/Yel Engine On/Off Switch Generator Generator (Hybrid Genset) Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 +48V Reel Motor Switch...
  • Page 51 ELECTRICAL Main Schematic Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield Shield Motor...
  • Page 52 ELECTRICAL Page Intentionally Blank 4-14 4262930-Rev A...

  • Page 53: Theory And Diagnostic Information

    ELECTRICAL Theory and Diagnostic 48-Volt Power Circuit Operation—Battery Pack Information See Figures 4-6 and 4-7. With the key switch in the off position, voltage is available 48-Volt Power Circuit—Theory of to the 30A fuse from the battery pack. From the 30A fuse, Operation voltage is available to key switch terminal B and main control unit connector J1-3.

  • Page 54: 48-Volt Power Circuit Schematic-Battery Pack

    ELECTRICAL 48-Volt Power Circuit Schematic—Battery Pack See Figures 4-6 and 4-7. Splice D Battery Pack Red J23 Red/Yel Red/Yel Battery Gauge Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 Switch +48V Reel Motor J1-3 Red/Blu +48V Input Red/Wht J2-25 Key-Ignition Wht/Red...
  • Page 55 ELECTRICAL 48-Volt Power Circuit Schematic—Battery Pack Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel...

  • Page 56: 48-Volt Power Circuit Schematic-Gen-Set

    ELECTRICAL 48-Volt Power Circuit Schematic—Gen-Set See Figures 4-8 and 4-9. Brn J22 Spark Ignition Plug Coil Splice D Sp D Red/Yel Red/Yel Engine On/Off Switch Generator Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 +48V Reel Motor Switch J1-3 Red/Blu +48V Input...
  • Page 57 ELECTRICAL 48-Volt Power Circuit Schematic—Gen-Set Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield...

  • Page 58: Ignition Shutoff Circuit Schematic-Gen-Set

    ELECTRICAL Ignition Shutoff Circuit Schematic—Gen-Set See Figures 4-10 and 4-11. Spark Ignition Plug Coil Splice D Red/Yel Red/Yel Engine On/Off Switch Generator Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 +48V Reel Motor Switch J1-3 Red/Blu +48V Input Red/Wht J2-25 Key-Ignition...
  • Page 59 ELECTRICAL Ignition Shutoff Circuit Schematic—Gen-Set Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield...
  • Page 60 ELECTRICAL Page Intentionally Blank 4-22 4262930-Rev A...

  • Page 61: Switched Power Circuit-Theory Of Operation

    ELECTRICAL Switched Power Circuit—Theory of Operation Switched Power Circuit Components Gen-Set—If Equipped The gen-set consists of a generator with an internal voltage regulator. As the engine turns, the generator provides voltage to the voltage regulator. The voltage regulator maintains voltage at or near 48 VDC. Battery Pack—If Equipped The battery pack consists of four 12-VDC sealed lead acid batteries (B1–B4) wired in series.

  • Page 62: Switched Power Circuit Schematic

    ELECTRICAL Switched Power Circuit Schematic See Figures 4-12 and 4-13. Splice D Battery Pack Red J23 Red/Yel Red/Yel Battery Gauge Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 Switch +48V Reel Motor J1-3 Red/Blu +48V Input Red/Wht J2-25 Key-Ignition Wht/Red J2-24...
  • Page 63 ELECTRICAL Switched Power Circuit Schematic Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield...
  • Page 64 ELECTRICAL Page Intentionally Blank 4-26 4262930-Rev A...

  • Page 65: Traction Circuit-Theory Of Operation

    ELECTRICAL Traction Circuit—Theory of Operation The traction motor controller (U2) provides +5 volts and a signal ground to the traction motor (M2), powering the motor hall effect and temp sensors. Traction Circuit Components The hall A, B, and C sensor output terminals provide a Main Control Unit signal to the traction motor controller hall A, B, and C The main control unit (MCU) manages all machine...

  • Page 66: Traction Circuit Schematic

    ELECTRICAL Traction Circuit Schematic See Figures 4-14 and 4-15. Splice D Battery Pack Red J23 Red/Yel Red/Yel Battery Gauge Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 Switch +48V Reel Motor J1-3 Red/Blu +48V Input Red/Wht J2-25 Key-Ignition Wht/Red J2-24 Wht/Red...
  • Page 67 ELECTRICAL Traction Circuit Schematic Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield Shield...
  • Page 68 ELECTRICAL Page Intentionally Blank 4-30 4262930-Rev A...

  • Page 69: Reel Motor Circuit-Theory Of Operation

    ELECTRICAL Reel Motor Circuit—Theory of Reel Motor Circuit Operation Operation See Figures 4-16 and 4-17. Main control unit (MCU) terminal J1-1 provides +48 VDC Reel Motor Circuit Components to reel motor controller terminal J7-1. MCU terminal J2-31 provides +5 VDC to bail Main Control Unit potentiometer terminal 3.

  • Page 70: Reel Motor Circuit Schematic

    ELECTRICAL Reel Motor Circuit Schematic See Figures 4-16 and4-17. Splice D Battery Pack Red J23 Red/Yel Red/Yel Battery Gauge Red/Blu Red/Wht Splice A Start J1-2 +48V Traction Motor J1-1 Switch +48V Reel Motor J1-3 Red/Blu +48V Input Red/Wht J2-25 Key-Ignition Wht/Red J2-24 Wht/Red...
  • Page 71 ELECTRICAL Reel Motor Circuit Schematic Continued Optional Light Work Light Switch Work Light J15-1 J15-2 Splice F Engine Ground J9-1 J12-1 +48V Input Phase A Phase A J9-2 J12-2 Phase B Phase B J12-3 Phase C Phase C Traction Grn/Yel J12-4 Grn/Yel Shield...

  • Page 72: Troubleshooting

    ELECTRICAL Troubleshooting Symptom: Machine will not power up. Probable Cause Remedy Faulty battery pack. Test battery pack. (See “Battery Pack Test” on page 4-45.) Faulty battery pack fuse. Test fuse. (See “Battery Pack Fuse Test” on page 4-50.) Faulty generator. Test generator.
  • Page 73 ELECTRICAL Symptom: Reel motor will not engage. Probable Cause Remedy Faulty reel motor connections. Check connections (moisture, loose or corroded pins, etc.) and repair as necessary. Faulty mow switch. Test mow switch. (See “Mow Switch Test” on page 4-49.) Faulty mow switch power circuit. Measure voltage between main control unit connector J2-13 and ground.

  • Page 74: Lcd Display-Modes

    ELECTRICAL LCD Display—Modes Alert Displays In addition to the standard displays for each mode, six displays are used to alert the operator of a problem that needs to be corrected. WARNING To prevent personal injury, release OPC bail, disengage reel motor, move key switch to the off position, and disconnect battery pack connector before checking for obstructions in reel or traction motor systems.
  • Page 75 ELECTRICAL Traction Motor Controller Fault Reel Motor Controller Fault TN4507 TN4509 A traction motor controller fault screen will be displayed if A reel motor controller fault screen will be displayed if the traction circuit exceeds 30 amps for more than one reel circuit current draw exceeds 30 amps for more than second.

  • Page 76: Operator Mode

    ELECTRICAL Operator Mode See Figure 4-19. Operator Mode is used by the operator for system voltage information, travel speed, FOC setting, reel speed, and total hours on mower. Press the orange buttons on the front handle cover to toggle between the different displays. Operator Mode is view only;...
  • Page 77 ELECTRICAL Daytime Illumination TN4476 When selected, LCD displays dark pixels on a light background. Press the black button to toggle between daytime and nighttime illumination. Nighttime Illumination TN4477 When selected, LCD displays light pixels on a dark background. Press the black button (J) to toggle between daytime and nighttime illumination.

  • Page 78: Maintenance Mode

    ELECTRICAL Maintenance Mode See Figure 4-20. Maintenance Mode is used to set and adjust all functional values for the Eclipse Mower. The LCD displays available in Maintenance Mode are maintenance hours, backlap, system voltage, travel speed, set FOC, reel speed, traction motor current draw, reel motor current draw, total motor current draw, set mow speed, set reel speed, set power source, set number of reel blades, calibrate speed paddle, calibrate bail lever, set display units, and factory reset.
  • Page 79 ELECTRICAL Maintenance Mode Set FOC TN4478, TN4465 TN4481, TN4482 To enter Maintenance Mode, press either orange button To set the fixed FOC, press either orange button (1 or 4) (1 or 4) until Maintenance Mode PIN screen is on the on the front cover until the FOC set screen is on the LCD display and press black button (3).
  • Page 80 ELECTRICAL Maximum Mow Speed Gen-Set Power Module TN4490 Used to indicate the gen-set power module is installed on the mower. This setting is used by system controllers and does not TN4486, TN4487 affect operation of mower. Do not operate mower with To set the maximum mow speed, press either orange incorrect power module setting.
  • Page 81 ELECTRICAL Speed Paddle Calibration Factory Reset TN4494, TN4495 TN4500, TN4501 To calibrate the paddle, press either orange button NOTE (1 or 4) on the front cover until the speed paddle Factory Reset will reset the controller to factory default calibration screen is on the LCD display. Press the black values for an 11-blade reel.

  • Page 82: 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 0.02 ohm, and/or does Testing the buzzer sound? The wire is good.

  • Page 83: 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? Batteries are good.

  • Page 84: Gen-Set Output Test

    ELECTRICAL Gen-Set Output Test 5. Adjust engine speed stop screw (1) clockwise to decrease engine speed and voltage output, and See Figures 4-21 through 4-23. counterclockwise to increase engine speed and 1. Park the mower safely. (See “Park Mower Safely” on voltage output.

  • Page 85: Engine On/Off Switch

    ELECTRICAL Engine On/Off Switch 5. Move engine on/off switch to the on position and measure resistance. See Figures 4-24 and 4-25. Is the resistance value 0.02 ohm or less? The switch is faulty; replace the switch. Required Tools or Equipment Proceed to step 6.

  • Page 86: Key Switch Test

    ELECTRICAL Key Switch Test 8. Move the key switch to the start position. Measure resistance between terminals (1 and 2). See Figure 4-26. Is the resistance value 0.02 ohm or less? Proceed to step 9. Required Tools or Equipment The key switch is faulty; replace the switch. Digital Multimeter, Ohmmeter, or Continuity Tester 9.

  • Page 87: Mow Switch Test

    ELECTRICAL Mow Switch Test Light Switch Test See Figure 4-27. See Figure 4-28. Required Tools or Equipment Required Tools or Equipment Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 88: 30A Fuse Test

    ELECTRICAL 30A Fuse Test Battery Pack Fuse Test See Figure 4-29. See Figure 4-30. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter, Ohmmeter, or Continuity Tester 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 89: Ceramic Resistor Test

    ELECTRICAL Ceramic Resistor Test 120-Ohm Resistor Connector Test See Figure 4-31. See Figure 4-32. 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 90: Traction Motor Test

    ELECTRICAL Traction Motor Test 12. For battery pack powered mowers, remove power module. (See “Battery Tray and Power Module See Figure 4-33. Mount” on page 4-69.) 1. Park the mower safely. (See “Park Mower Safely” on 13. For gen-set powered mowers, remove engine. (See page 1-5.) “Engine”...

  • Page 91: Reel Motor Test

    ELECTRICAL Reel Motor Test 12. Disengage OPC bail and move key switch to the off position. See Figure 4-34. 13. For battery pack powered mowers, remove power 1. Park the mower safely. (See “Park Mower Safely” on module. (See “Battery Tray and Power Module page 1-5.) Mount”...

  • Page 92: Throttle Potentiometer Test

    ELECTRICAL Throttle Potentiometer Test 5. Measure resistance between terminals (1 and 3) while rotating stem (4). Low end resistance must See Figure 4-35. range between 18.9 and 35.1 ohms. High end resistance must range between 3710 and 6890 Required Tools or Equipment ohms.

  • Page 93: Bail Potentiometer Test

    ELECTRICAL Bail Potentiometer Test 5. Measure resistance between terminals (2 and 3) while rotating stem (4). Low end resistance must See Figure 4-36. range between 1190 and 2210 ohms. High end resistance must range between 4410 and 8190 Required Tools or Equipment ohms.

  • Page 94: Repair

    ELECTRICAL Repair Disassembly See Figures 4-38 through 4-40. Battery Pack WARNING Removal and Installation Always disconnect the negative terminal first, and the positive terminal last. Connect the See Figure 4-37. positive terminal first, and the negative terminal last. Use care when testing or working around Required Materials live circuits to prevent arcing.
  • Page 95 ELECTRICAL Assembly NOTE See Figure 4-41. Label all wires before disconnecting to ensure correct installation. Required Materials 3. Disconnect main harness negative lead (4). Dielectric Grease (Jacobsen PN 365422) 4. Disconnect main harness positive lead (5). TN0675 Figure 4-40 5. Disconnect battery gauge positive leads (6). 6.

  • Page 96: Battery Gauge

    ELECTRICAL Battery Gauge Battery Pack Fuse Removal and Installation Removal and Installation See Figure 4-42. See Figure 4-43. Required Materials Required Materials Dielectric Grease (Jacobsen PN 365422) Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 97: Generator

    ELECTRICAL Generator Removal and Installation See Figures 4-44 and 4-45. Required Materials ® • Loctite 5900 FIPG (Jacobsen PN 4248230) • Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4458 Figure 4-45 3.

  • Page 98: Key Switch

    ELECTRICAL Key Switch 30A Fuse Removal and Installation Removal and Installation See Figure 4-46. See Figure 4-47. 1. Park the mower safely. (See “Park Mower Safely” on Required Materials page 1-5.) 2. Remove handle cover. (See “Handle Cover” on Dielectric Grease (Jacobsen PN 365422) page 6-4.) 1.

  • Page 99: Mow Switch

    ELECTRICAL Mow Switch Light Switch Removal and Installation Removal and Installation See Figure 4-48. See Figure 4-49. Required Materials Required Materials Dielectric Grease (Jacobsen PN 365422) Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on 1.

  • Page 100: Reel Motor

    ELECTRICAL Reel Motor Removal and Installation See Figures 4-50 and 4-51. Required Materials NLGI Grade 2 LB Grease 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4415 Figure 4-51 4. Remove coupler (8) from reel motor shaft (7). Installation Notes •...

  • Page 101: Traction Motor

    ELECTRICAL Traction Motor 6. Remove traction drive belt cover. (See “Traction Drive Belt Cover” on page 5-7.) Removal 7. Remove three nuts (4), lock washers (5), flat washers (6), and screws (7). See Figures 4-52 through 4-56. 8. Remove transfer belt (3). 1.
  • Page 102 ELECTRICAL 13 14 15 TN0632 Figure 4-58 TN0630 Figure 4-56 13. Remove screws (13), lock washers (14), nuts (15), and motor mount assembly (16). Installation See Figures 4-57 through 4-61. Required Materials ® • Loctite 242 (Blue) Thread Sealant • Dielectric Grease (Jacobsen PN 365422) 1.

  • Page 103: Throttle Potentiometer

    ELECTRICAL Throttle Potentiometer Removal and Installation See Figure 4-62. Required Materials Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on 12 13 14 15 page 1-5.) 16 17 18 19 2. Remove handle cover. (See “Handle Cover” on TN4636 page 6-4.) Figure 4-60...

  • Page 104: Main Control Unit

    ELECTRICAL Main Control Unit Installation Notes • Install main control unit by reversing the order of Removal and Installation removal. • Apply dielectric grease (Jacobsen PN 365422) to any See Figure 4-63. connectors removed. Required Materials Dielectric Grease (Jacobsen PN 365422) 1.

  • Page 105: Reel Control Unit

    ELECTRICAL Reel Control Unit 3. Cut cable ties (8). 4. Remove four screws (5) and one internal-tooth lock Removal and Installation washer (6), and remove reel control unit (7). See Figures 4-64 and 4-65. Installation Notes • Install reel control unit by reversing the order of Required Materials removal.

  • Page 106: Traction Control Unit

    ELECTRICAL Traction Control Unit NOTE Label all wires before disconnecting to ensure correct Removal and Installation installation. See Figures 4-66 through 4-68. 6. Disconnect traction control unit harness connectors (3). Required Materials Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4634 Figure 4-68...

  • Page 107: Battery Tray And Power Module Mount

    ELECTRICAL Battery Tray and Power Module 6. Remove four screws (5), lock washers (6), flat washers (7), power module mount (14), spacers (8), Mount and power module mounting plate (13). 7. Remove two rivets (10) and remove ceramic resistor Removal (11) from power module mounting plate (13).

  • Page 108: Bail Potentiometer

    ELECTRICAL Bail Potentiometer Installation Notes • Install bail potentiometer by reversing the order of Removal and Installation removal. • Apply dielectric grease (Jacobsen PN 365422) to any See Figure 4-71. connectors removed. Required Materials • Be sure bail potentiometer is not binding before tightening fasteners.
  • Page 109 Chapter 5 Power Train Specifications ..............5-2 Check and Adjustment Specifications .

  • Page 110: Specifications

    POWER TRAIN Specifications Check and Adjustment Specifications Specification Traction Drive (Transfer) Belt Maximum Deflection 0.14 (3.5) in. (mm) with 3.5–6.3 lb (15.6–28.0 N) of Force Applied at the Midpoint between Pulleys Traction Drive (Final) Belt Maximum Deflection with 0.10 (2.5) in.

  • Page 111: Component Location

    POWER TRAIN Component Location See Figure 5-1. TN4453, TN4454, TN4639 Traction Motor Traction Drive (Outer Transfer) Pulley Traction Motor Harness Connector Traction Drive (Inner Transfer) Pulley Traction/Drum/Differential Assembly Traction Drive Belt (Final Drive) Traction Motor Pulley Traction Drive (Traction Drum) Pulley Traction Drive Belt (Transfer) Figure 5-1: Power Train Component Location 4262930-Rev A...

  • Page 112: 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 113: Checks And Adjustments

    POWER TRAIN Checks and 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 lb (15.6–28.0 N) of and Adjustment force at the midpoint of the traction drive (transfer) belt.
  • Page 114 POWER TRAIN Adjustment Procedure 4. Tighten hex screw (2) until the traction drive (final drive) belt (7) deflects 0.10 in. (2.5 mm) when 12.5– See Figures 5-4 and 5-5. 15.2 lb (55.6–67.6 N) of force is applied at the midpoint of the belt. Required Tools and Materials 5.

  • Page 115: Repair

    POWER TRAIN Repair Traction Drive Belts Removal Traction Drive Belt Cover See Figures 5-7 and 5-8. Removal and Installation 1. Park the 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 116 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 117 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 118: 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 the 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 119: 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 screws (17) and lock washers (18) from bearing housing (19). Figure 5-20 12.
  • Page 120 POWER TRAIN Installation See Figures 5-25 through 5-29. Required Materials ® Loctite Aviation Gasket Sealer (Loctite PN 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 121: 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 grease that meets or exceeds 14 15 NLGI Grade 2 LB specifications before installation.
  • Page 122 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 123 POWER TRAIN Installation See Figures 5-35 through 5-39. Required Materials ® Loctite Aviation Gasket Sealer (Loctite PN 30516) TN0244 TN0243, TN0240 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 124: 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 125: 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).
  • Page 126 POWER TRAIN 5-18 4262930-Rev A...
  • Page 127 Chapter 6 Handle and Controls Checks and Adjustments ............6-2 Operator Presence Control (OPC) Cable Adjustment .

  • Page 128: Checks And Adjustments

    HANDLE AND CONTROLS Checks and Adjustments Operator Presence Control (OPC) Cable Adjustment See Figures 6-1 and 6-2. NOTE Initial OPC cable adjustments are made at the mounting bracket, prior to the OPC cable calibration procedure. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.

  • Page 129: Speed Paddle Stop Adjustment

    HANDLE AND CONTROLS Speed Paddle Stop Adjustment Handle Height Adjustment See Figure 6-3. See Figure 6-4. 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.) TN4392 Figure 6-4 2.

  • Page 130: Repair

    HANDLE AND CONTROLS Repair Handle Cover Removal and Installation Required Materials Dielectric Grease (Jacobsen PN 365422) See Figures 6-5 and 6-6. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4388 Figure 6-6 4. Remove four screws (4) and front half of handle cover (5).

  • Page 131: Handle Assembly

    HANDLE AND CONTROLS Handle Assembly NOTE See Figures 6-12 through 6-14. Label all wires before disconnecting to ensure correct installation. Required Materials 4. Disconnect engine harness wire connectors (1 and 2) if equipped. Dielectric Grease (Jacobsen PN 365422) 5. Disconnect ground wire ring terminal (3) if equipped. Removal and Installation 1.
  • Page 132 HANDLE AND CONTROLS TN4397 Figure 6-11: Gen-Set Models 10. Disconnect the battery pack/gen-set connector (8). TN4559 Figure 6-13 NOTE Note orientation of torsion spring (18) before removal to ensure correct installation. 13. Disconnect torsion spring (18) from handle stop (16). NOTE Support handle assembly before removing mounting hardware.
  • Page 133 HANDLE AND CONTROLS Installation Notes • Install handle assembly by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. • Adjust handle height as needed. (See “Handle Height Adjustment” on page 6-3.) • Check brake cable adjustment. Adjust as needed. (See “Park Brake Check and Adjustment”...

  • Page 134: Handle And Opc Bail

    HANDLE AND CONTROLS Handle and OPC Bail 5. Remove handle assembly (4). Removal See Figures 6-15 through 6-17. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove handle cover. (See “Handle Cover” on page 6-4.) TN0618 Figure 6-17 6.
  • Page 135 HANDLE AND CONTROLS TN4432 Figure 6-19 NOTE Be sure potentiometer wires are routed through passage (10) to prevent pinching wires. 3. Install handle assembly (7) and secure with four screws (8) and nuts (9). TN4629 Figure 6-20 4. Apply dielectric grease (Jacobsen PN 365422) to any connectors removed.

  • Page 136: Opc Cable

    HANDLE AND CONTROLS OPC Cable Removal and Installation See Figures 6-21 and 6-22. Required Materials Dielectric Grease (Jacobsen PN 365422) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove handle cover. (See “Handle Cover” on page 6-4.) 3.

  • Page 137: Speed Paddle

    HANDLE AND CONTROLS Speed Paddle Brake Control Lever Removal and Installation Removal and Installation See Figure 6-23. See Figure 6-24. 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 138 HANDLE AND CONTROLS 6-12 4262930-Rev A...
  • Page 139 Chapter 7 Brakes Specifications ..............7-2 Repair Specifications .

  • Page 140: Specifications

    BRAKES Specifications Repair Specifications Specification Park Brake Lever Actuating Force 10 (4.5) lb (kg) Park Brake Band—Anchor Pin Center-to-Center 1.50 (38) in. (mm) Distance (Park Brake Released) 4262930-Rev A...

  • Page 141: 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 142: Checks And Adjustments

    BRAKES Checks and Adjustments Park Brake Check and Adjustment NOTE Right-side brake assembly shown; left-side assembly is similar. See Figures 7-1 through 7-4. Check Procedure 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove transport wheels (if equipped). (See TN4388 “Transport Wheels (Optional)”...
  • Page 143 BRAKES TN4407 Figure 7-4 3. Loosen screw (7) and pull cable (8) to obtain desired brake tension. Tighten screw (7). 4. Repeat “Check Procedure.” 5. Install handle cover. (See “Handle Cover” on page 6-4.) 6. Install transport wheels (if equipped). (See “Transport Wheels (Optional)”...

  • Page 144: Repair

    BRAKES Repair Park Brake Cable Removal See Figures 7-5 through 7-7. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove transport wheels (if equipped). (See “Transport Wheels (Optional)” on page 9-2.) 3. Release park brake. 4.
  • Page 145 BRAKES Installation 7. Move free end of brake band until distance between center of park brake band pins (13 and 16) is See Figures 7-8 and 7-9. approximately 1.50 in. (38 mm). Tighten set screw (12). 8. Check brake adjustment. (See “Park Brake Check and Adjustment”...

  • Page 146: Park Brake Band

    BRAKES Park Brake Band Installation See Figures 7-11 and 7-12. 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)” on page 9-2.) 3. Release park brake. TN4407 Figure 7-11 1.
  • Page 147 Chapter 8 Cutting Unit Specifications ..............8-2 General Specifications .
  • Page 148 CUTTING UNIT Specifications General Specifications Specification Height-of-Cut Range (Bench Setting) 1/16–7/16 (1.6–11.1) in. (mm) High-Profile Cut Yield 5/32–7/16 (3.96) in. (mm) Low-Profile Cut Yield 1/8–7/32 (3.17) in. (mm) Tournament Cut Yield 3/32–5/32 (2.38) in. (mm) Super Tournament Cut Yield 5/64–7/64 (1.58) in.

  • Page 149: Component Location

    CUTTING UNIT Component Location Troubleshooting See Figure 8-1. Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Even though the cutting units are properly sharpened and adjusted, some mowing practices and turf conditions can cause poor cutting results. These include: • Repetitious mowing patterns—tires running over the same path—may cause depressions and ruts.
  • Page 150 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 151 CUTTING UNIT Marcelling Marcelling is a wave-like cut appearance similar to washboarding but with a uniform cutting height and smaller wave tip-to-tip distance. In most cases, the wave tip-to-tip distance is 2 in. (5 cm) or less. Color variation (light-to-dark) may also be noticed. This condition is usually caused by an incorrect frequency-of-clip.
  • Page 152 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 153 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 154 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 8-14.) Dull cutting edges. Sharpen reel and bedknife.
  • Page 155 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 Backing Assembly” on page 8-22.) Damaged or unevenly worn reel.
  • Page 156 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 157 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 158: 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 4-45.) engaged. Mow switch not engaged. Engage mow switch.

  • Page 159: Checks And Adjustments

    CUTTING UNIT Checks and Adjustments 5. Proper reel-to-bedknife adjustment is critical. A gap of 0.001–0.003 in. (0.025–0.075 mm) must be maintained across the entire length of the reel and Reel and Bedknife Inspection bedknife. See Figure 8-2. 6. The reel must be parallel to the bedknife. An improperly adjusted reel will lose its sharp edges 1.

  • Page 160: Bedknife-To-Reel Adjustment

    CUTTING UNIT Bedknife-to-Reel Adjustment See Figures 8-3 through 8-5. 1. Inspect reel and bedknife before performing adjustment. (See “Reel and Bedknife Inspection” on page 8-13.) TN0081 TN0893 Figure 8-3 Figure 8-5 2. Start adjustment at the leading edge (1) of the reel, CAUTION followed by the trailing edge.

  • Page 161: Battery Tray Adjustment

    CUTTING UNIT Battery Tray Adjustment 2. Loosen four engine mount nuts (2) and slide engine assembly (1) forward to increase the weight over the See Figure 8-6. front roller. 1. Park the mower safely. (See “Park Mower Safely” on 3. Move engine assembly (1) backward to decrease the page 1-5.) weight over the front roller.
  • Page 162 CUTTING UNIT 5. Press either orange button (3 or 4) until Maintenance Mode PIN screen is displayed. 6. Press black button (6). TN4468 Figure 8-13 The LCD display will prompt the operator to engage and release the Operator Presence Control (OPC) bail (1). TN4465 11.

  • Page 163: Height-Of-Cut Adjustment (Hoc)

    CUTTING UNIT Height-of-Cut Adjustment (HOC) 4. Loosen lock nut (9) on the side of front roller bracket (8) just enough to allow adjusting knob (1) to raise or See Figure 8-15. lower the bracket. 5. Set height-of-cut bar (6) to desired height-of-cut (2) CAUTION by measuring between the underside of screw head and height-of-cut bar surface and tighten wing nut...

  • Page 164: Reel Bearing Pre-Load Adjustment

    CUTTING UNIT Reel Bearing Pre-Load Adjustment See Figures 8-16 through 8-20. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Back the bedknife away from the reel. (See “Bedknife-to-Reel Adjustment” on page 8-14.) TN0900 Figure 8-18 6.
  • Page 165 CUTTING UNIT 15 16 TN0895 Figure 8-20 8. Install counterweight (14) and two screws (15) and lock washers (16). 9. Adjust bedknife-to-reel contact. (See “Bedknife-to-Reel Adjustment” on page 8-14.) Grass Shield Adjustment See Figure 8-21. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0901 Figure 8-21...
  • Page 166 CUTTING UNIT Repair Cutting Unit Removal and Installation See Figures 8-22 through 8-24. 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. 3.

  • Page 167: Grass Shield

    CUTTING UNIT 12. Remove cutting unit. Installation Note Install cutting unit by reversing the order of removal. Grass Shield Removal and Installation See Figure 8-25. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 1 2 3 4 TN0901 Figure 8-25 2.

  • Page 168: Bedknife Backing Assembly

    CUTTING UNIT Bedknife Backing Assembly Removal See Figures 8-26 through 8-28. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-20.) TN0938 Figure 8-28 5. Remove the bedknife backing assembly (4). TN0893 Figure 8-26 NOTE...
  • Page 169 CUTTING UNIT Installation See Figures 8-29 through 8-31. Required Materials Anti-Seize Compound TN0937 Figure 8-31 NOTES Apply anti-seize compound to the threads of the bedknife backing mounting screws (5) before installing. 2. Install the bedknife backing mounting screws (5) in TN0938 the frame and bedknife backing.

  • Page 170: Bedknife

    CUTTING UNIT Bedknife Installation Notes Removal and Installation Required Materials Anti-Seize Compound NOTE This procedure is intended for use with machines • Install bedknife by reversing the order of removal. equipped with standard fastener type bedknives. For • Apply anti-seize compound to screws (2). machines equipped with an optional MAGKnife™...

  • Page 171: Right Reel Bearing Housing Assembly

    CUTTING UNIT Right Reel Bearing Housing Assembly Removal See Figures 8-33 through 8-35. Required Tools or Equipment Reel Bearing Housing Puller (Jacobsen PN JAC5085) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-20.) 3.
  • Page 172 CUTTING UNIT Disassembly and Assembly Installation See Figure 8-36. See Figures 8-37 and 8-38. Required Tools or Equipment Bearing Assembly Tool (Jacobsen PN JAC5084) Required Materials ® Loctite 242 (Blue) Thread Sealant TN0940 Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting...
  • Page 173 CUTTING UNIT TN0907 Figure 8-38 NOTE ® Apply Loctite 242 (Blue) to the threads of screws (8) before installing. 5. Install adapter plate (7) using screws (8). 6. Install O-ring (9), and lubricate with grease that meets or exceeds NLGI Grade 2 LB specifications. 7.

  • Page 174: Left Reel Bearing Housing Assembly

    CUTTING UNIT Left Reel Bearing Housing Assembly Removal See Figures 8-39 through 8-41. Required Tools or Equipment Reel Bearing Housing Puller (Jacobsen PN JAC5085) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove cutting unit from mower. (See “Cutting Unit” on page 8-20.) 3.
  • Page 175 CUTTING UNIT Disassembly and Assembly Installation See Figure 8-42. See Figures 8-43 through 8-45. TN0903 Figure 8-43 1. Install reel bearing housing assembly (1). TN0941 2. Install spring (2), washer (3), and nut (4). Bearing Housing Bearing Cup and Cone Vent Fitting Grease Fitting Grease Seal...
  • Page 176 CUTTING UNIT 13 14 13 14 TN0905 Figure 8-45 6. Install counterweight (15) using screws (13) and washers (14). 7. Lubricate grease fitting (16) with grease that meets or exceeds NLGI Grade 2 LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only.

  • Page 177: Reel Assembly

    CUTTING UNIT Reel Assembly Installation See Figure 8-47. Removal See Figure 8-46. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) NOTICE Gen-Set Models: Before tipping mower back for service, the fuel lever must be moved to the OFF position to prevent fuel from leaking into the crankcase.

  • Page 178: Floating Head

    CUTTING UNIT Floating Head 3. Remove clip (6) and washer (7) from each side of mower. Removal and Installation 4. Disconnect arm (5) from each side of mower. 5. Disconnect arms (1 and 3) from floating head (2). See Figures 8-48 and 8-49. 6.

  • Page 179: Cutting Unit Front Roller

    CUTTING UNIT Cutting Unit Front Roller Cutting Unit Rear Roller Removal and Installation Removal and Installation See Figure 8-50. NOTE 1. Park the mower safely. (See “Park Mower Safely” on Removal and installation of the cutting unit front roller is page 1-5.) described in Chapter 10—Accessories.

  • Page 180: Floating Head Roller

    CUTTING UNIT Floating Head Roller Cutting Unit Rear Roller and Floating Head Roller—Roller Bearings Removal and Installation Removal See Figure 8-51. 1. Park the mower safely. (See “Park Mower Safely” on See Figure 8-52. page 1-5.) 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) NOTICE 2.
  • Page 181 Chapter 9 Miscellaneous Specifications ..............9-2 Repair .
  • Page 182 MISCELLANEOUS Specifications Transport Tires Transport Tire Air Pressure 6–8 (41–55) psi (kPa) Repair Disassembly and Assembly See Figure 9-3. 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.) TN0028 TN4406...
  • Page 183 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 interchange them side-for-side. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2.
  • Page 184 MISCELLANEOUS 2. Align the groove (2) in the hub (3) with the keyway (1) in the transport roller shaft (4), and install the hub assembly on the shaft. * Item 5, left-side only, as needed. TN0056 Figure 9-8 NOTE Always use new seals. TN4410 3.
  • Page 185 MISCELLANEOUS Kickstand Assembly Installation Notes • Install kickstand assembly by reversing the order of Removal and Installation removal. • Tighten screw and nut (10 and 13) during installation See Figures 9-12 and 9-13. just enough to enable kickstand to spring up with 1.
  • Page 186 MISCELLANEOUS 4262930-Rev A...
  • Page 187 Chapter 10 Accessories Specifications ..............10-2 Check and Adjustment Specifications .

  • Page 188: Specifications

    ACCESSORIES Specifications Check and Adjustment Specifications Specification Turf Groomer Eccentric Mounting Screw Torque 8–10 (10.8–13.6) lb-ft (N·m) Turf Groomer Belt Tension Link Mounting Screw Torque 20 (27.1) lb-ft (N·m) Repair Specifications Specification Solid Front Roller Assembly Maximum Rotational 6 (0.68) Maximum with No End Play lb-in.

  • Page 189: Checks And Adjustments

    ACCESSORIES Checks and Adjustments Turf Groomer Raising the Groomer See Figure 10-1. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) NOTE The groomer is designed to be always on whenever the reel is turning. TN4545 Figure 10-1 CAUTION Do not adjust groomer height by loosening screw (1) and pivoting groomer assembly (4).
  • Page 190 ACCESSORIES Height-of-Cut Adjustment CAUTION See Figure 10-2. Do not set the turf groomer blades at ground Required Tools level or below. Mowing at this level may damage the machine as well as the turf. The Turf Groomer Height-of-Cut Gauge Bar (Jacobsen PN 158568) is designed to allow maximum groomer depth of one-half height of cut and is to be used as a 1.
  • Page 191 ACCESSORIES Bearing Adjustment 4. Tighten turf groomer bracket screws (9) and carriage bolt (12) on both sides of the cutting unit to close the See Figure 10-3. gap between the turf groomer brackets (11) and 1. Park the mower safely. (See “Park Mower Safely” on frame (10).
  • Page 192 ACCESSORIES Belt Adjustment 7. Install groomer cover (6), pulley cover (5), four flat washers (1), four lock washers (2), two screws (4), See Figures 10-5 and 10-6. and two screws (3). 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN4539 Figure 10-5...
  • Page 193 ACCESSORIES Blade-to-Roller Alignment See Figures 10-7 and 10-8. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN2618 Belt Cover End of Cutting Unit Turf Groomer Blades Front Roller Lock Nuts Front Roller Turf Groomer Motor End of Cutting Unit Roller Discs Figure 10-7 2.

  • Page 194: Repair

    ACCESSORIES Repair Cutting Unit Front Roller Removal Light Kit Assembly See Figure 10-10. Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) See Figure 10-9. NOTICE Required Materials Gen-Set Models: Before tipping mower back for Dielectric Grease (Jacobsen PN 365422) service, the fuel lever must be moved to the OFF position to prevent fuel from leaking into the...
  • Page 195 ACCESSORIES Disassembly—Solid Rollers Assembly—Solid Rollers See Figure 10-11. See Figures 10-12 through 10-16. Required Materials ® Permatex Anaerobic Sealer (or equivalent) TN0314 Figure 10-12 TN0312 1. Remove the shield (1) from one side of each new Figure 10-11 bearing (2). 1.
  • Page 196 ACCESSORIES TN0318 TN0316 Figure 10-16 Figure 10-14 4. Install the roller shaft (9) with bearing (6) into the NOTE roller (8) until the bearing is seated against the Always use new grease seals for installation. shoulder (7) in the roller. ®...
  • Page 197 ACCESSORIES Disassembly—Solid Tube and Grooved 4. Inspect the bearings (2 and 9). If replacement is required, use a blind hole bearing puller to remove Rollers the bearing cups (1 and 8) from both ends of the See Figure 10-17. roller (7). 5.
  • Page 198 ACCESSORIES Disassembly—Grooved Disc Roller NOTE See Figure 10-19. Always use new grease seals for installation. ® 1. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seals (4 and 11), and install the grease seals in the adapter seals (5 and 12).
  • Page 199 ACCESSORIES Assembly—Grooved Disc Roller 6. Apply grease that meets or exceeds NLGI Grade 2 LB specifications to both grease fittings (1 and 8). See Figure 10-20. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop—do not over-grease.
  • Page 200 ACCESSORIES 4. Remove short spacer (3) from roller shaft (2). Assembly—Grooved Segmented Roller See Figures 10-23 and 10-24. TN0252 TN0252 TN0252 Figure 10-22 TN0252 Figure 10-23 NOTE NOTES All three roller segment assemblies are disassembled in the same way. • All three roller segment assemblies are assembled in the same way.
  • Page 201 ACCESSORIES Installation See Figure 10-25. 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) TN0895 Figure 10-25 2. Install height-of-cut brackets (8) to both ends of front roller (4). 3. Rotate shaft (7) until flat on shaft is aligned with screw (5) and tighten screws (5) and jam nuts (6) on both ends of front roller.

  • Page 202: Scraper Blade Assembly

    ACCESSORIES Scraper Blade Assembly Removal and Installation See Figure 10-26. TN0346 Figure 10-26 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. Retract the kickstand and allow the mower to rest on removal.

  • Page 203: Push Brush Assembly

    ACCESSORIES Push Brush Assembly Disassembly and Assembly See Figure 10-27. TN4520 Nut (4) Nut (4) Screw (2) Nut (2) Brush Lock Washer (4) Lock Washer (4) Cam (2) Lock Washer (2) Flat Washer (4) Flat Spring (2) Push Brush Mount (2) Lock Washer (2) Mounting Plate (2) Lock Washer (4)
  • Page 204 ACCESSORIES 5. Remove screws (19), flat washers (22), lock washers (23), nuts (24), and brackets (18) from brush. 6. Remove nuts (1), washers (2), flat springs (3), spacers (4), flat washers (5), brush mounting rods (15), and U-bolts (10). 7. Remove screws (11), nuts (14), lock washers (13), and cams (12).

  • Page 205: Turf Groomer

    ACCESSORIES Turf Groomer Removal and Installation See Figures 10-28 and 10-29. Drive Side TN4569 Figure 10-28 4262930-Rev A 10-19...
  • Page 206 ACCESSORIES 1. Park the mower safely. (See “Park Mower Safely” on page 1-5.) 2. Remove two screws (39), lock washers (38), and flat washers (37). 3. Remove two screws (41), lock washers (38), and flat washers (37). 4. Remove pulley cover (40) and groomer cover (36). 5.
  • Page 207 ACCESSORIES Driven Side TN4570 Figure 10-29 4262930-Rev A 10-21...
  • Page 208 ACCESSORIES 27. Remove screw (68), washer (69), spacer (70), and remove components (64–67) as an assembly. 28. Remove screw (81), lock washer (80), and spacer (79). 29. Remove guide wheel (78). 30. Remove nut (77) and two washers (76) from groomer roller (56).
  • Page 209 ACCESSORIES Turf Groomer—Drive and Driven Assemblies Disassembly and Assembly See Figure 10-30. TN4530 Carriage Bolt (2) Knob Adjustment (2) Flat Washer (4) Flat Washer (4) Groomer Bracket (2) Cotter Pin (2) Adjuster Bracket (2) Lock Washer (4) Lift Bracket Lift Bracket Flat Washer (4) Stud (2) Screw (2)

  • Page 210: Turf Groomer-Groomer Blade Assembly

    ACCESSORIES Turf Groomer—Groomer Blade Assembly Disassembly and Assembly See Figure 10-31. TN4531 Spacer (2) Grease Seal (2) Pulley Grease Fitting (2) Shaft Spacer (2) Ball Bearing (2) Flat Washer (2) Spacer, 22 x 1/4 in. Spacer Blade Spacing (70) Lock Nut Bearing Housing (2) Lock Washer (2) Blade, 22 x 1/4 in.

  • Page 211: Turf Groomer-Roller Assembly

    ACCESSORIES Turf Groomer—Roller Assembly Disassembly and Assembly See Figure 10-32. TN4532 Roller Tube Flat Washer (2) Grease Seal (2) Shaft Jam Nut (2) Ball Bearing (2) Snap Ring (2) Set Screw (4) Lock Washer (2) Nylos Ring (2) Grease Fitting (2) Nut (4) Figure 10-32 4262930-Rev A...
  • Page 212 ACCESSORIES 10-26 4262930-Rev A...
  • Page 213 INDEX Battery Pack Fuse Removal and Installation ....4-58 Repair ......4-58 Test .
  • Page 214 Component Inspection Cutting Unit Rear Roller Bearings Installation ......8-34 Inner Transfer Pulley ....5-8 Outer Transfer Pulley .
  • Page 215 Fuel, Safety ......1-9 Inspect Safety Labels ......Generator Removal and Installation .
  • Page 216 Park Mower Safely-Battery Pack Safety ......1-5 Machine Components Park Mower Safety-Gen-Set Location .
  • Page 217 Reel Motor Removal and Installation ....4-62 Repair ......4-62 Test .
  • Page 218 Repair Traction Motor ..... . . 4-63 Transport Wheels ..... 9-2 30A Fuse .
  • Page 219 Scraper Blade Assembly Torque Values Inch Fasteners ..... . 2-10 Removal and Installation ....10-16 Repair .
  • Page 220 Troubleshooting Brakes ......7-3 Cutting Unit ......8-3 Cutting Unit, Mechanical .
  • Page 222 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...
  • Page 224 www.jacobsen.com/dealer-locator...

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