Page 1 Eclipse 322 Riding Greens Mower Technical/Repair Manual 62801, 62803, 62805 Second Edition...
Page 5  ® WARNING Jacobsen Eclipse 322™ riding greens mower 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...
Page 6 Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2010 Jacobsen, A Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4222983 Second Edition...
Page 7 Table of Contents Safety Specifications and General Information Genset and Battery Pack Electrical Chassis Cutting Units Accessories and Miscellaneous Repair 4222983 Second Edition...
Page 9: Table Of Contents
Chapter 1 Safety Introduction ..............1-2 Prepare for the Job .
Page 10: Introduction
SAFETY Introduction Safety Notices Safety is the most important element of any repair Throughout this manual, the following key safety words procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards. and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
Page 11: Safety Label Locations
SAFETY Safety Label Locations Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine. See Figure 1-1. TN2746 Figure 1-1 4222983 Second Edition...
Page 12 SAFETY 4181861 4181862 4181860 4216820 Rev A 4222983 Second Edition...
Page 13 SAFETY 4127335 41 8 1 8 64 4181865 4222983 Second Edition...
Page 14: Inspect Safety Labels
SAFETY Inspect Safety Labels Park Mower Safely Safety decals are critical to the safe operation of the See Figure 1-2. mower. Inspect the mower for any damaged, missing, or  WARNING unreadable decals. Replace decals as needed before placing the mower back in service. Before cleaning, adjusting, or repairing this equipment, disengage all drives and stop engine Keep Work Area Clean...
Page 15: Use Lifting Equipment Safely
• When using a lifting device, always connect the load so it is balanced. 7. Disconnect the 12-volt connector (5) [Eclipse 322 Model 62803 (Gas) and Model 62805 (Diesel)]. • Always use a lifting device on a hard, level surface.
Page 16: Use Compressed Air And Air Tools Safely
SAFETY Use Compressed Air and Air Service Tires Safely Tools Safely  WARNING  WARNING An inflated tire contains explosive force. Use care when handling wheels and tires. Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious •...
Page 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: Service Electrical Components Safely
SAFETY Service Electrical Components  WARNING Safely The electrolyte in a storage battery is a dilute acid  which can cause severe burns to the skin and WARNING eyes. Treat all electrolyte spills to the body and eyes with extended flushing with clear water. Always disconnect the negative terminal first and Contact a physician immediately.
Page 19: Dispose Of Waste Materials Safely
SAFETY Dispose of Waste Materials Safely Routine service can produce waste products such as used oil, coolant 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 20 SAFETY Page Intentionally Blank 1-12 4222983 Second Edition...
Page 21: Specifications And
Chapter 2 Specifications and General Information Machine Identification ............2-2 Machine Serial Number .
Page 22: Machine Identification
® P.O. BOX 7708, CHARLOTTE, A Textron Company NC 28241, USA Jacobsen.com 1-800-848-1636 (US) TN2129,TN2735 Figure 2-2 A machine identification plate (1) listing the serial number (3) and a label (2) indicating the machine weight are attached to the rear frame of the mower near the steering yoke.
Page 23: Engine Identification Number-Model 62803 (Gas)
SPECIFICATIONS AND GENERAL INFORMATION Engine Identification Number—Model 62803 (Gas) See Figure 2-4. XXXXXX XXXX-XX XXXXXXXX TN2736 Figure 2-4 The engine identification number (1) is located on the side of the engine and identifies the engine model (2), type (3), and code number (4). Optional Machine Accessories This manual is structured to cover all basic machine components and repair.
Page 24: Component Location
SPECIFICATIONS AND GENERAL INFORMATION Component Location See Figures 2-5 through 2-7.  CAUTION Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures. All Models TN2745 Steering Tower Front Wheel (2) Seat Traction Pedal Center Cutting Unit Steering Wheel Right Reel Leveling Rod Center Reel Leveling Rod...
Page 25 SPECIFICATIONS AND GENERAL INFORMATION TN2746 Brake Pedal Assembly Rear Axle Assembly Front Axle Assembly Steering Chain and Gear Starter Battery Left Cutting Unit Rear Wheel Buffer Battery Pack Left Reel Leveling Rod Figure 2-6: Component Location—Left Side 4222983 Second Edition...
Page 26: Model 62801 (Electric)
SPECIFICATIONS AND GENERAL INFORMATION Model 62801 (Electric) TN2311 Battery Charger Battery Filling System Battery Pack Figure 2-7: Component Location—Left Side 4222983 Second Edition...
Page 27: Quick Reference Specifications
SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Fuel Tank Capacities Model 62805 (Diesel) Fuel Tank Capacity 5.3 (20) gal (L) Model 62803 (Gas) Fuel Tank Capacity 5.3 (20) gal (L) General Engine/Motor Specifications Model 62805 (Diesel) Manufacturer/Model Kubota/Z482-E3B 2-Cylinder; Liquid Cooled Engine Type 4-stroke, diesel Fuel Requirement...
Page 28 SPECIFICATIONS AND GENERAL INFORMATION Model 62801 (Electric) Battery Pack 48V (six 8-volt Trojan T890 deep cycle lead acid batteries) with single point watering system Traction Drive System (All Models) Traction Drive Motor 48-volt AC Traction Drive Motor Power Rating 3 (2.2) continuous hp (kW) Genset and Battery Pack Repair Specifications...
Page 29: Electrical
SPECIFICATIONS AND GENERAL INFORMATION Electrical Test and Adjustment Specifications Resistance Across Resistor 1 at 68° F 2 (approximately) ohms Resistance Across Brake Coil at 68° F 25.5 ± 10% ohms Resistance Across Fuel Shutoff Pull-In Coil at 68° F 0.5 ± 10% ohms (Diesel Model) Resistance Across Fuel Shutoff Hold-In Coil at 68°...
Page 30: Chassis
SPECIFICATIONS AND GENERAL INFORMATION Chassis Check and Adjustment Specifications Steering Chain Deflection 0.0625–0.250 (1.6–6.4) in. (mm) [with 2–10 lb (9–45 N) push at mid-span of chain] Repair Specifications Front Wheel Hub Castle Nut Torque 95–115 (10.7–13.0) lb-ft (N·m) Front Axle Assembly— 65 (88) lb-ft (N·m) Mounting Screw Torque...
Page 31: Accessories And Miscellaneous
SPECIFICATIONS AND GENERAL INFORMATION Accessories and Miscellaneous Repair Specifications OPS Mounting Bolt Torque 25 (39) lb-ft (N·m) Steering Wheel Nut Torque 28–30 (38–41) lb-ft (N·m) Rear Axle Assembly Mounting Nut Torque 150 (203) lb-ft (N·m) Steering Tower Mounting Screw Torque 55–60 (75–81) lb-ft (N·m) Front Tires...
Page 32: 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 33 Chapter 3 Genset and Battery Pack Specifications ..............3-3 Fuel Tank Capacities .
Page 34 GENSET AND BATTERY PACK Repair—Batteries ............. 3-36 Battery Pack, Battery Pack Tray, and Battery Filling System .
Page 35: Specifications
GENSET AND BATTERY PACK Specifications Fuel Tank Capacities Model 62805 (Diesel) Fuel Tank Capacity 5.3 (20) gal (L) Model 62803 (Gas) Fuel Tank Capacity 5.3 (20) gal (L) General Engine/Motor Specifications Model 62805 (Diesel) Manufacturer/Model Kubota/Z482-E3B 2-Cylinder; Liquid Cooled Engine Type 4-stroke, diesel Fuel Requirement No.
Page 36 GENSET AND BATTERY PACK Model 62801 (Electric) Battery Pack 48V (six 8-volt Trojan T890 deep cycle lead acid batteries) with single point watering system Traction Drive System (All Models) Traction Drive Motor 48-volt, brushless, keyed shaft Traction Drive Motor Power Rating 3 (2.2) continuous hp (kW) Repair Specifications...
Page 37: Component Location
GENSET AND BATTERY PACK Component Location Model 62805 (Diesel) See Figures 3-1 and 3-2. TN2436,TN2750,TN2443 Fuel Tank Muffler Throttle Actuator Fuel Filter Figure 3-1: Component Location—Right Side 4222983 Second Edition...
Page 38: Figure 3-20
GENSET AND BATTERY PACK TN2751,TN2441,TN2442 48-Volt Connector Radiator Overflow Bottle Fan Belt Air Cleaner Assembly Fuel Shutoff Solenoid Oil Pressure Switch Radiator Oil Fill Cap Genset 12-Volt Connector Thermostat Starter Motor Buffer Battery Pack Engine Temperature Switch Oil Filter Starter Battery Alternator Figure 3-2: Component Location—Left Side 4222983 Second Edition...
Page 39: Model 62803 (Gas)
GENSET AND BATTERY PACK Model 62803 (Gas) See Figures 3-3 and 3-4. TN2793,TN2798 Fuel Tank Throttle Actuator Oil Filter Muffler Oil Pressure Switch Genset Figure 3-3: Component Location—Right Side 4222983 Second Edition...
Page 40 GENSET AND BATTERY PACK TN2794,TN2796,TN2797 48-Volt Connector Buffer Battery Pack Oil Fill Cap Air Cleaner Assembly Starter Battery Fuel Filter 12-Volt Connector Oil Dipstick Starter Motor Figure 3-4: Component Location—Left Side 4222983 Second Edition...
Page 41: Model 62801 (Electric)
GENSET AND BATTERY PACK Model 62801 (Electric) See Figure 3-5. TN2804 Battery Filling System 48-Volt Connector Battery Pack Figure 3-5: Component Location 4222983 Second Edition...
Page 42: Checks And Adjustments-Model 62805 (Diesel)
GENSET AND BATTERY PACK Checks and Adjustments— Model 62805 (Diesel) Purging the Fuel System (Diesel) See Figures 3-6 through 3-8.  CAUTION Do not purge fuel system when engine is hot. NOTE Whenever the fuel filter or fuel lines are removed, the fuel TN2690 tank is completely emptied, or the engine has not been used for an extended time, purge the system of air.
Page 43: Throttle Actuator Adjustment (Diesel)
GENSET AND BATTERY PACK Checks and Adjustments— 11. Repeat steps 9 and 10 for fuel injector line nut (4). 12. When both fuel injector lines have been purged and Model 62803 (Gas) the engine is running, listen to the engine. If the engine is misfiring, repeat steps 9 and 10 for both Throttle Actuator Adjustment (Gas) fuel injector lines.
Page 44: Repair-Model 62805 (Diesel)
GENSET AND BATTERY PACK Repair—Model 62805 (Diesel) Fan Belt (Diesel) Removal See Figures 3-11 and 3-12. NOTE Inspect and adjust the new engine belt after the first 50 hours of operation. Check and adjust annually thereafter. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
Page 45: Air Filter Assembly (Diesel)
GENSET AND BATTERY PACK Air Filter Assembly (Diesel) Removal and Installation See Figures 3-13 and 3-14.  CAUTION • Do not open the air filter assembly for inspection or cleaning. Unnecessary removal of the air filter increases the risk of injecting dust and other impurities into the engine.
Page 46: Alternator (Diesel)
GENSET AND BATTERY PACK Alternator (Diesel) Removal and Installation See Figures 3-17 and 3-18. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood. TN2687 Figure 3-15 4. Remove steering cover (1). 2 3 4 TN2430 Figure 3-17 NOTE...
Page 47: Radiator (Diesel)
GENSET AND BATTERY PACK 4. Disconnect wire connector (7). Radiator (Diesel) 5. Remove nut (8), lock washer (9), and wire connector Removal (10). 6. Loosen screws (12 and 15), push the alternator (11) See Figures 3-19 through 3-23. toward the engine, and disengage the fan belt (18) 1.
Page 48 GENSET AND BATTERY PACK 11 12 7 8 9 10 28 29 30 13 14 15 29 30 31 32 TN2699 Figure 3-20 TN2692 9. Remove nuts (7), lock washers (8), flat washers (9), Figure 3-22 and screws (10). 14. Remove wing nuts (31) and washers (32), and 10.
Page 49: Thermostat (Diesel)
GENSET AND BATTERY PACK 24. Move fan shroud (39) toward engine enough to clear Thermostat (Diesel) the radiator (35). Removal and Installation 25. Remove radiator screen (45). 26. Remove radiator (35). See Figures 3-24 and 3-25. 1. Park the mower safely. (See “Park Mower Safely” on Installation page 1-6.) 1.
Page 50: Throttle Actuator (Diesel)
GENSET AND BATTERY PACK Throttle Actuator (Diesel) Removal and Installation See Figure 3-26. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2438 Figure 3-25 8. Remove two screws (7), two lock washers (8), and bracket (9). 9.
Page 51: Fuel Tank (Diesel)
GENSET AND BATTERY PACK Fuel Tank (Diesel) Removal and Installation See Figures 3-27 through 3-29.  CAUTION Diesel fuel is highly flammable. Do not drain fuel indoors. Heaters can ignite fuel vapors. Use extreme caution when draining fuel. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
Page 52: Fuel Filter (Diesel)
GENSET AND BATTERY PACK Fuel Filter (Diesel) Removal and Installation See Figure 3-30.  CAUTION Diesel fuel is highly flammable. Handle with care. Use an approved container with a spout that will fit inside the fuel filler neck. Avoid using unapproved containers to transport fuel.
Page 53: Fuel Pump (Diesel)
GENSET AND BATTERY PACK Fuel Pump (Diesel)  CAUTION Removal and Installation Dispose of fuel properly. Contact the local See Figure 3-31. environmental department for instructions on disposing of unwanted fuel products.  CAUTION Installation Notes Diesel fuel is highly flammable. Handle with care. Use an approved container with a spout that will •...
Page 54: Fuel Shutoff Solenoid (Diesel)
GENSET AND BATTERY PACK Fuel Shutoff Solenoid (Diesel) Genset (Diesel) Removal and Installation Removal and Installation See Figures 3-32 and 3-33. See Figures 3-34 through 3-44.  1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2.
Page 55 GENSET AND BATTERY PACK TN2712 TN2713 Figure 3-35 Figure 3-37 12. Tag and disconnect the generator positive (+) output 14. Tag and disconnect rectifier connector (10). cable (6) and 12 VOLT POS connector (7) from PDU (5). Carefully guide the cables away from the PDU 15.
Page 56 GENSET AND BATTERY PACK 29. Loosen hose clamps (29) and remove air intake hoses (27 and 28) from air cleaner and bracket assembly (30). 30. Remove screws (31), lock washers (32), and flat washers (33). 31. Remove air cleaner and bracket assembly (30). 19 20 21 22 38 39 40 TN2707...
Page 57 • Use new gaskets when installing the exhaust system. 60 61 • Use new cable ties to secure wire connectors and wire harnesses. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. • Fill the radiator with a 50/50 mixture of ethylene TN2715 glycol-base antifreeze and clean, fresh water.
Page 58: Disassembly And Assembly
GENSET AND BATTERY PACK Disassembly and Assembly See Figure 3-45. 38 32 39 TN2716 TN2716 Temperature Sender L.S. Engine Mount Flat Washer (5) Flat Washer Screw (4) Nut (4) R.S. Engine Mount Lock Washer (4) Cotter Pin Lock Washer (4) Lock Washer (20) Isolation Mount (2) Nut (4)
Page 59: Engine Service (Diesel)
(51) to 13.0 lb-ft (17.6 N·m). • Install genset fan by reversing the order of removal. • Secure bell housing cover plate (10) to engine bell • Apply dielectric grease (Jacobsen PN 365422) to housing using 3M double-sided tape—trim wire connector (3).
Page 60: Repair-Model 62803 (Gas)
GENSET AND BATTERY PACK Repair—Model 62803 (Gas) Installation Notes • Wash air filter pre-cleaner in a liquid detergent and water. Squeeze dry in a clean cloth. Saturate in clean Air Filter Assembly (Gas) engine oil and squeeze out excess oil in a clean, absorbent cloth.
Page 61: Throttle Actuator (Gas)
GENSET AND BATTERY PACK 7. Separate the muffler (6) from the exhaust pipe (2). 8. Inspect the exhaust system for cracks, holes, and distortion. Replace exhaust gaskets and exhaust clamps. Installation Notes • Install muffler in the reverse order of removal. •...
Page 62 GENSET AND BATTERY PACK 3. Raise the hood. 10. Close fuel shutoff valve (1). (Turn clockwise until valve bottoms lightly.) 11. Plug fuel hose (2) to prevent leakage and contamination. TN2696 Figure 3-51 4. Close fuel shutoff valve (1). (Turn clockwise until valve bottoms lightly.) TN2704 Figure 3-53...
Page 63: Fuel Filter (Gas)
GENSET AND BATTERY PACK Fuel Filter (Gas) Genset (Gas) Removal and Installation Removal and Installation See Figure 3-54. See Figures 3-55 through 3-64.  1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2. Allow the engine to cool completely. Be sure that the key switch is off, all electrical accessories are turned off, and the 12-volt and 3.
Page 64 GENSET AND BATTERY PACK TN2798 Figure 3-55 TN2714 14. Tag and disconnect genset-to-main harness Figure 3-57 connectors (1 and 2). 18. Tag and disconnect the generator negative (–) output 15. Cut cable ties (3). cable (8) from ground stud (9). Carefully guide the 16.
Page 65 GENSET AND BATTERY PACK TN2756 Figure 3-61 TN2754 27. Remove four screws (23), flat washers (24), nuts Figure 3-59 (25), and SCU cover (26). 23. Tag and disconnect genset connector (17) and genset fan connector (16). 24. Cut cable tie (15). 25.
Page 66 • Use new gaskets when installing the exhaust system. • Use new cable ties to secure wire connectors and wire harnesses. TN2719 • Apply dielectric grease (Jacobsen PN 365422) to any Figure 3-64 connectors removed. • Replace the engine oil filter and fill engine with oil.
Page 67 GENSET AND BATTERY PACK Disassembly and Assembly See Figure 3-65. TN2758 TN2758 Screw Flat Washer (4) Screw (7) Lock Washer Screw (2) Mounting Flange Screw Flat Washer (9) Screw Lock Washer (4) Heat Shield Engine Coupler Right Side Gas Cradle Left Side Gas Cradle Lock Washer (3) Engine Coupler Element...
Page 68: Engine Service (Gas)
GENSET AND BATTERY PACK Repair—Batteries Assembly Notes • Required Materials Battery Pack, Battery Pack Tray, and ® Loctite 242 (Blue) Battery Filling System ® • Apply Loctite 242 (Blue) to screw (42) prior to Removal and Installation assembly. See Figures 3-66 through 3-70. ®...
Page 69 GENSET AND BATTERY PACK NOTE Label all wires before disconnecting to ensure correct installation.  WARNING Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing 23 24 could result in death or serious injury.
Page 70: Buffer Battery Pack And Buffer Battery Pack Tray
GENSET AND BATTERY PACK Buffer Battery Pack and Buffer Battery Pack Tray Removal and Installation See Figures 3-71 and 3-72.  WARNING Be sure that the key switch is off, all electrical 27 28 29 30 accessories are turned off, and the 12-volt and 48-volt power connectors are disconnected before starting work on vehicle.
Page 71: Starter Battery
GENSET AND BATTERY PACK Starter Battery  WARNING Removal and Installation Always disconnect the negative terminal first and See Figure 3-73. positive terminal last. Connect positive terminal first and negative terminal last. Use care when NOTE testing live circuits to prevent arcing. Arcing could result in death or serious injury.
Page 72: Starter Battery Tray
GENSET AND BATTERY PACK Installation Note  WARNING Install starter battery tray by reversing the order of removal. Always disconnect the negative terminal first and positive terminal last. Connect positive terminal Model 62803 (Gas) first and negative terminal last. Use care when See Figure 3-75.
Page 73: Battery Charger
GENSET AND BATTERY PACK Battery Charger Removal and Installation See Figure 3-76. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood. TN2708 TN2708 Figure 3-76 NOTE Label all wires before disconnecting to ensure correct installation.
Page 74 GENSET AND BATTERY PACK  WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the 48-volt power connector is disconnected before starting work on vehicle.  WARNING Always disconnect the negative terminal first and positive terminal last.
Page 75 Chapter 4 Electrical Specifications ..............4-4 Test and Adjustment Specifications .
Page 76 ELECTRICAL Troubleshooting ............. . 4-73 LCD Display Maintenance Mode .
Page 77 ELECTRICAL Repair ..............4-137 Electrical Connectors Inspection .
Page 78: Specifications
ELECTRICAL Specifications Test and Adjustment Specifications Specification Resistance Across Resistor 1 at 68° F 2 (approximately) ohms Resistance Across Brake Coil at 68° F 25.5 ± 10% ohms Resistance Across Fuel Shutoff Pull-In Coil at 68° F 0.5 ± 10% ohms (Diesel Model) Resistance Across Fuel Shutoff Hold-In Coil at 68°...
Page 79: Component Location
ELECTRICAL Component Location See Figures 4-1 and 4-2. TN2744,TN2389,TN2418,TN2419 TCU (Traction Control Unit) Fan Steering Input Device Brake Coil TCU (Traction Control Unit) RCU (Reel Control Unit) Traction Pedal Position Sensor OLM (Over Limit Monitor) AC Traction Motor Assembly Resistor Bank Assembly Figure 4-1: Component Location—Right Side 4222983 Second Edition...
Page 80 ELECTRICAL TN2746,TN2369,TN2420,TN2417 MCU (Main Control Unit) GCU (Genset Control Unit) LCD (Liquid Crystal Display) PDU (Power Distribution Unit) SCU (Steering Control Unit Ground Figure 4-2: Component Location—Left Side 4222983 Second Edition...
Page 81: J79 Interface Connector Location
ELECTRICAL J79 Interface Connector Location See Figure 4-3. TN2823,TN2824 J79 Interface Connector (disconnected) J79 Interface Connector (connected) Figure 4-3: J79 Interface Connector Location 4222983 Second Edition...
Page 82: Main Harness Splice Identification And Locations
ELECTRICAL Main Harness Splice Identification and Locations See Figure 4-4. TN3373 Splice A Splice H Splice B Splice O Splice C Splice T Splice E Reel Motor Harness Splice Figure 4-4: Main Harness Splice Identification and Location 4222983 Second Edition...
Page 83: Theory And Diagnostic Information
ELECTRICAL Theory and Diagnostic Information Electrical Component Symbols The following symbols are used in the electrical schematics to represent various electrical components. Switches Single Pole, Single Throw Double Pole, Single Throw (SPST) (DPST) Single Pole, Double Throw Double Pole, Double Throw (SPDT) (DPDT) 1 The sample switch symbols shown are just a few of the many switch configurations.
Page 84 ELECTRICAL Motors and Generating Devices Electric Motor (may also include Stator “AC” or “DC.”) Alternator Actuating Devices Solenoid Valve PTO Clutch Engine-Related Devices Ignition Coil Spark Plug Regulator Lights Single-Element Light Dual-Element Light 4-10 4222983 Second Edition...
Page 85 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 4222983 Second Edition 4-11...
Page 86: Electrical Schematic Component Identification
ELECTRICAL Electrical Schematic Component Identification Electrical components shown in the main schematic are identified with an alpha-numeric callout. All electrical components shown in the electrical schematic are listed below. • A1—Power Distribution Unit (PDU) (See Figures 4-6 • F8—150A Fuse (48V Switched Power) (See through 4-18.) Figure 4-6.) •...
Page 87 ELECTRICAL • J49—Brake Pedal Position Sensor Connector (See • J122—Power Distribution Unit Connector (RCU 48V Figure 4-12.) Power) (See Figure 4-15.) • J50—3WD Motor Connector (See Figure 4-13.) • J122—Optional Light Connector (See Figure 4-11.) • J51—3WD Motor Connector (See Figure 4-12.) •...
Page 88: Reel Motor Connector Pin Locations
ELECTRICAL • Splice C (See Figure 4-13.) Reel Motor Connector Pin Locations • Splice E (See Figure 4-10.) See Figure 4-5. • V3—Switched Power Contactor Diode (See NOTE Figure 4-6.) • V4—Start Relay Diode (See Figure 4-9.) The right, left, and center reel motor connectors are configured the same.
Page 89: Electrical Schematic
ELECTRICAL Electrical Schematic See Figures 4-6 through 4-18. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus 124 Red 48V Unswitched Power J1-12 Switch Red/ J91-1 146 Wht Power Start Distribution Unit 60 Red Splice B...
Page 90 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus 124 Red 124 Red Seat Work Switch Light Switch 146 Wht J15-3 J15-2 128 Red J91-3 60 Drk Grn J41-1 J41-2 71 Drk Grn 129 Red J91-4...
Page 91 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus Power Diesel Distribution Engine Unit Select (PDU) Jumper Stud 1 Diesel Engine 339 Yel J66-12 J66-10 J83 (IG) 6A Red J83B 283 Blu...
Page 92 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus Power Start Glow Distribution Relay Plug Unit Relay (PDU) J1-9 J1-6 J104-H J1-7 14 Wht/Brn Brn/ Wht/ J66-1 To Glow Plugs 13 Wht/Red 13 Wht/Red...
Page 93 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus J1-5 Power Distribution 150 Red Unit J106-1 Resistor (PDU) Fuse J1-10 5A Red/Blk 14 Wht/Brn Red/Grn J2-8 Splice E 9A Pnk 13 Wht/Red 12V Power Input J2-6...
Page 94 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus Power 300A Distribution Fuse Circuit Traction Unit Contactor Breaker Brake (PDU) Pedal Switch Stud 5 J1-3 J104-B J104-G 81A Brn J73-NC1 J73-NC2 10 Wht 5A Red/Blk...
Page 95 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution 3B Red/Wht To Steering Control Unit Unit Resistor Splice B J1-2 3 Red 3C Red/Wht To Steering Proximity Switch 1 (PDU) 3D Red/Wht To Steering Proximity Switch 2 3E Red/Wht To Traction Control Unit...
Page 96 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power J104-F Red/ 4C Red Optional Splice C Third Left Wheel Splice B Steering Stud 5 Drive Proximity Switch Red/ Red/ 3A Red J57-B 48V Input J64-1 48V Input 10B Wht 90 Wht/Pnk...
Page 97 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Steering Breaker (PDU) Relay 21 Wht J53-B+ 3B Red/Wht 48V Power Input J20-1 Splice B J65-1 48V Input Left 26 Blk Tachometer Output J67-2 Reel 90 Wht/Pnk...
Page 98 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power J122 J5-3 Power Input 21 Wht 22 Wht J9-A 48V Left Reel Motor Power Output 48V Center Reel Motor Power Output J9-B 26 Blk 38 Blk J7-3 Left Reel Motor Tachometer Input Center Reel Motor Tachometer Input J6-3 30 Brn 42 Brn...
Page 99 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 22 Wht J21-1 48V Power Input Center 38 Blk J68-2 Tachometer Output Reel 42 Brn Motor J68-8 Temperature Output 45 Yel J68-3 Speed Signal Input 46 Org J68-4 Speed Signal Ground 43 Grn 12V Switched Power Circuit J68-7 Reel Direction Input...
Page 100 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power 12V Switched Power Generator 28 Red 12V Switched Power Circuit 013 Blk Diode Blocks Permanent Magnet Generator +48V Stud 3 150A 13 Brn Shunt Resistor J102 (Connects to TCU +48V B+ Terminal) 94 Red 95 Blk 101 Red...
Page 101 ELECTRICAL Electrical Schematic Continued 12V Switched Power 12V Switched Power Power Distribution Unit Resistor (PDU) J1-8 J1-11 Red/ Generator J92-2 Control J92-1 Unit (GCU) 19A Red 28 Red J36-J1 12V Power 19B Red 013 Blk J36-K1 12V Power J36-K1 12V Power 118 Red Fan Relay Output (-) J36-B1 Genset...
Page 102: Theory Of Operation And Sub-Circuit Schematics
ELECTRICAL Theory of Operation and Work Light Circuit Sub-Circuit Schematics When the work light switch is in the on position, 12 volts is provided to LCD work light switch input terminal J12-9, activating the input. With the input activated, the LCD Horn and Work Light Circuit—Theory communicates the work light switch status to the main of Operation...
Page 103: Horn And Work Light Circuit Schematic
ELECTRICAL Horn and Work Light Circuit Schematic See Figures 4-19 and 4-20. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Unswitched Power J1-12 Switch Red/ 124 Red J91-1 Power Start Distribution Unit 60 Red Splice B 135 Yel (PDU) Harness...
Page 104 ELECTRICAL Horn and Work Light Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Resistor Breaker (PDU) J104-G J104-B J1-5 J1-10 124 Red 124 Red Work Splice E Splice A Light Switch Red/ J28-1...
Page 105: Diesel Engine Circuit-Theory Of Operation
ELECTRICAL Diesel Engine Circuit—Theory of With the key switch (status) in the start position, 12 volts is provided from the MCU fuel hold output terminal (J2-4) Operation to the fuel shutoff solenoid’s hold-in coil. Current also momentarily flows from the MCU fuel pull-in output Power Circuit terminal J2-5 to the fuel shutoff solenoid’s pull-in coil, Unswitched 48V power is available from stud 3 through...
Page 106 ELECTRICAL Charging Circuit With the engine running, voltage is supplied from 12 volt switched power to the alternator field terminal, exciting the alternator. With the alternator field terminal excited, the alternator produces three-phase alternating current (AC). The AC voltage is provided to voltage regulator (N1).
Page 107: Diesel Engine Circuit Schematic
ELECTRICAL Diesel Engine Circuit Schematic See Figures 4-21 through 4-23. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus Stud 1 48V Unswitched Power J1-12 Switch Red/ J91-1 Power Start Distribution Unit 60 Red Splice B...
Page 108 ELECTRICAL Diesel Engine Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Start Glow Distribution Relay Plug Unit Relay (PDU) J1-9 J1-6 J104-H J1-7 14 Wht/Brn Brn/ Wht/ J66B-1 13 Wht/Red 13 Wht/Red J26-2 Brn/ 6A Red...
Page 109 ELECTRICAL Diesel Engine Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Resistor Breaker (PDU) J1-5 J1-10 J104-B 14 Wht/Brn Red/Grn J2-8 9A Pnk 13 Wht/Red Splice E J2-6 12V Power Input Power Input 14 Wht/Brn...
Page 110 ELECTRICAL Page Intentionally Blank 4-36 4222983 Second Edition...
Page 111: Gasoline Engine Circuit-Theory Of Operation
ELECTRICAL Gasoline Engine Circuit—Theory of The MCU will only engage the starter for 10 seconds. If the engine fails to start, the key switch must be turned to Operation the off position before attempting to start again. Power Circuit Run Circuit Unswitched 48V power is available from stud 3 through The engine continues to operate when the key switch is 150A fuse (F8) and 0.02 ohm resistor (R6) to key switch...
Page 112: Gasoline Engine Circuit Schematic
ELECTRICAL Gasoline Engine Circuit Schematic See Figures 4-24 through 4-26. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus Stud 1 48V Unswitched Power J1-12 Switch Red/ J91-1 Power Start Distribution Unit 60 Red Splice B...
Page 113 ELECTRICAL Gasoline Engine Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Start Distribution Relay Unit (PDU) J1-9 J1-6 Wht/ 13 Wht/Red 13 Wht/Red J26-2 Stator Voltage Regulator J32-1 J32-2 J59-Output 273 Red Stud 6 312 Brn Fuel...
Page 114 ELECTRICAL Gasoline Engine Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Resistor Breaker (PDU) J1-5 J1-10 J104-B Red/Grn J2-8 9A Pnk 13 Wht/Red Splice E J2-6 12V Power Input Power Input 5A Red/Blk...
Page 115: Raise/Lower Circuit-Theory Of Operation
ELECTRICAL Raise/Lower Circuit—Theory of When the right reel enable switch is in the on position, voltage is provided to the LCD right reel enable input Operation terminal J12-6, activating the input. When the center reel enable switch is in the on position, voltage is provided to The following text outlines the operation of one actuator.
Page 116: Lower Circuit
ELECTRICAL Lower Circuit When the raise/lower switch is placed in the lower position, voltage is provided to the LCD lower input terminal J12-8, activating the input. With the input activated, the LCD communicates the status of the lower switch to MCU. The MCU now instructs the reel control unit (RCU) to lower the reels through the controller area network (CAN).
Page 117: Raise Circuit Schematic
ELECTRICAL Raise Circuit Schematic See Figures 4-27 through 4-29. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Unswitched Power J1-12 Switch Red/ J91-1 Power Start Distribution 124 Red Unit 60 Red Splice B 135 Yel (PDU) Harness 136 Wht...
Page 118 ELECTRICAL Raise Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power Power Circuit 48V Switched Power Circuit Distribution Breaker 12V Switched Power Circuit Unit Resistor (PDU) 12V Power Supply Reel Enable Circuit J1-5 J1-10 Raise Circuit Ground Circuit 127 Red Splice E 124 Red...
Page 119 ELECTRICAL Raise Circuit Schematic Continued 48V Switched Power 48V Switched Power Power Distribution Unit (PDU) J122 J5-3 Power Reel Input Control J23-1 Unit 48V Motor Terminal B J7-2 Left Lift Motor Control Output (RCU) Left J23-2 48V Motor Terminal A J7-1 Left Lift Motor Control Output Reel J70-4...
Page 120: Lower Circuit Schematic
ELECTRICAL Lower Circuit Schematic See Figures 4-30 through 4-32. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Unswitched Power J1-12 Switch Red/ J91-1 Power Start Distribution 124 Red Unit 60 Red Splice B 135 Yel (PDU) Harness 136 Wht...
Page 121 ELECTRICAL Lower Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power Power Circuit 48V Switched Power Circuit Distribution Breaker 12V Switched Power Circuit Unit Resistor (PDU) 12V Power Supply Reel Enable Circuit J1-5 J1-10 J104-B Lower Circuit Ground Circuit 127 Red Splice E...
Page 122 ELECTRICAL Lower Circuit Schematic Continued 48V Switched Power 48V Switched Power Power Distribution Unit (PDU) J122 J5-3 Power Reel Input Control J23-1 Unit 48V Motor Terminal B J7-2 Left Lift Motor Control Output (RCU) Left J23-2 48V Motor Terminal A J7-1 Left Lift Motor Control Output Reel J70-4...
Page 123: Mow Circuit-Theory Of Operation
ELECTRICAL Mow Circuit—Theory of Operation When the raise-lower switch is placed in the lower position, voltage is sent to the LCD lower input J12-8. The LCD then communicates the status of the switch to Power Circuit MCU. (See “Raise/Lower Circuit—Theory of Operation” Unswitched 48V power is available from stud 3 through on page 4-41.) 150A fuse (F8) and 0.02 ohm resistor (R6) to key switch...
Page 124 ELECTRICAL Backlap Circuit The RCU right reel motor direction output terminal J8-8 connects to the right reel motor reel direction input terminal J69-7. The direction output terminal controls the direction of the motor, forward for cutting and reverse for backlapping. With no output to the reel motor, the reel operates in the forward direction.
Page 125: Mow Circuit Schematic
ELECTRICAL Mow Circuit Schematic See Figures 4-33 through 4-35. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Unswitched Power J1-12 Switch Red/ J91-1 Power Start Distribution 124 Red Unit 60 Red Splice B 135 Yel (PDU) Harness 136 Wht...
Page 126 ELECTRICAL Mow Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution 48V Switched Power Circuit Circuit Unit Seat Switch Breaker (PDU) Seat Resistor 12V Switched Power Circuit J1-5 J1-10 J104-B Switch 12V Power Supply Reel Enable Circuit J91-3 60 Drk Grn J41-1...
Page 127 ELECTRICAL Mow Circuit Schematic Continued 48V Switched Power 48V Switched Power Reel Control Unit J122 (RCU) 6 Red J5-3 48V Power Input 21 Wht 48V Power Input J20-1 J9-A 48V Left Reel Motor Power Output Left 26 Blk Tachometer Output J67-2 J7-3 Left Reel Motor Tachometer Input Reel 30 Brn...
Page 128 ELECTRICAL Page Intentionally Blank 4-54 4222983 Second Edition...
Page 129: Traction Circuit-Theory Of Operation
ELECTRICAL Traction Circuit—Theory of Operation With the seat switch input activated, MCU traction contactor output terminal J3-6 provides a ground to PDU 48 volt traction contactor terminal J1-3, energizing the Power Circuit contactor. With the 48 volt traction contactor energized, Unswitched 48V power is available from stud 3 through voltage is provided to TCU J43-B+ terminal, the TCU 150A fuse (F8) and 0.02 ohm resistor (R6) to key switch...
Page 130 ELECTRICAL With the traction pedal in the forward or reverse position, AC power is provided from TCU AC motor output terminals J43-U, J43-V, and J43-W to traction motor AC motor terminals J45-U, J45-V, and J45-W. To control the speed of the traction motor, the TCU varies the frequency of the AC voltage applied to the AC motor terminals.
Page 131: Traction Circuit Schematic
ELECTRICAL Traction Circuit Schematic See Figures 4-36 through 4-41. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus 48V Unswitched Power Circuit 48V Unswitched Power J1-12 48V Switched Power Circuit Switch 12V Switched Power Circuit Red/ 12V Power Supply...
Page 132 ELECTRICAL Traction Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus Power Distribution Circuit 48V Unswitched Power Circuit Unit Breaker Resistor 48V Switched Power Circuit (PDU) 12V Switched Power Circuit 12V Power Supply J104-G J104-B...
Page 133 ELECTRICAL Traction Circuit Schematic Continued 48V Switched Power 48V Switched Power 48V Power Bus Power 300A Distribution Fuse Traction Unit Contactor Brake (PDU) Pedal Switch Stud 5 J1-3 81A Brn J73-NC1 J73-NC2 10 Wht Splice A 2D Red 2B Pnk Traction Pedal Splice B...
Page 134 ELECTRICAL Traction Circuit Schematic Continued 48V Switched Power 48V Switched Power Power Distribution 3B Red/Wht Resistor To Steering Control Unit Unit Splice B J1-2 3 Red 3C Red/Wht (PDU) To Steering Proximity Switch 1 3D Red/Wht To Steering Proximity Switch 2 3E Red/Wht To Traction Control Unit 3A Red...
Page 135 ELECTRICAL Traction Circuit Schematic Continued Optional Third Wheel Stud 5 Drive 48V Switched Power Circuit 3A Red J64-1 48V Input 10B Wht J64-2 Brake Output (-) 77B Brn J64-9 Throttle Sensor 78B Blu J64-12 Forward Input 80B Brn J64-20 Reverse Input 76B Grn J64-7 Brake Sensor Traction...
Page 136 ELECTRICAL Traction Circuit Schematic Continued J102 (Connects to TCU +48V B+ Terminal) 101 Red J100-1 48V Input 101A Red J100-2 48V Input 102 Brn J100-3 Resistor Output 1 107 Org/Grn J100-12 Resistor Output 2 106 Yel/Wht J100-11 Resistor Output 3 105 Grn/Blk J100-10 Resistor Output 4 Overvoltage...
Page 137: Steering Circuit-Theory Of Operation
ELECTRICAL Steering Circuit—Theory of Operation Steering Circuit The operator must be on the seat before the main control Power Circuit unit (MCU) allows the steering control unit (SCU) to operate the steering motor when the steering wheel is Unswitched 48V power is available from stud 3 through turned.
Page 138 ELECTRICAL As the steering wheel is turned to the right, the SCU will continue to move the steering motor to the right until the steering wheel stops turning or when the steering fork reaches the magnetic trip zone of the right steering proximity switch.
Page 139: Steering Circuit Schematic
ELECTRICAL Steering Circuit Schematic See Figures 4-42 through 4-44. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Unswitched Power Circuit 48V Switched Power Circuit 48V Unswitched Power J1-12 12V Switched Power Circuit Switch Red/ 12V Power Supply J91-1 Contactor Output Circuit Ground Circuit...
Page 140 ELECTRICAL Steering Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Resistor Breaker 48V Switched Power Circuit (PDU) J104-B J1-5 J1-10 12V Switched Power Circuit 12V Power Supply Red/ Seat Switch 3D Red/Wht Proximity Switch Splice E...
Page 141 ELECTRICAL Steering Circuit Schematic Continued 48V Switched Power 48V Switched Power Power Distribution Circuit Unit Steering Breaker (PDU) Resistor Relay J104-F J1-2 J104-A 3 Red Red/ 3D Red/Wht 3D Red/Wht Splice B Left J53-B+ 3B Red/Wht Splice C J65-1 48V Input Steering Steering Proximity...
Page 142: Genset Circuit-Theory Of Operation
ELECTRICAL Genset Circuit—Theory of Operation If the GCU determines that one or both temperature sensors are not within the normal operating range, a fault code is outputted. The GCU will set the engine speed to Power Circuit idle when a fault occurs. Unswitched 48V power is available from stud 3 through GCU turns on the genset fan as needed.
Page 143: Genset Circuit Schematic
ELECTRICAL Genset Circuit Schematic See Figures 4-45 through 4-48. 12V Switched Power 12V Switched Power 48V Switched Power 48V Switched Power 48V Power Bus 48V Power Bus 48V Unswitched Power J1-12 48V Unswitched Power Circuit Switch Red/ 48V Switched Power Circuit Contactor Output Circuit J91-1 12V Switched Power Circuit...
Page 144 ELECTRICAL Genset Circuit Schematic Continued 12V Switched Power 12V Switched Power 48V Switched Power 48V Power Bus Power Distribution Unit Circuit (PDU) Breaker Resistor Stud 1 J104-B J1-5 J1-10 Red/ Splice E Red/ J2-6 J2-8 Power Power Input Input 5A Red/Blk 48V Power Input J2-7 Battery Pack...
Page 145 ELECTRICAL Genset Circuit Schematic Continued 12V Switched Power 12V Switched Power 12V Switched Power Power Power Distribution Distribution Unit Unit (PDU) (PDU) Generator 28 Red 013 Blk Diode Blocks Whisper Mode Circuit Permanent Magnet Temperature Sensor Circuit Generator Tachometer Circuit +48V 48V Unswitched Power Circuit Gen Current Sense Circuit...
Page 146: Fan Relay
ELECTRICAL Genset Circuit Schematic Continued 12V Switched Power 12V Switched Power Power Distribution Unit Resistor (PDU) J1-8 J1-11 Red/ Generator J92-2 Control J92-1 Unit (GCU) 19A Red 28 Red J36-J1 12V Power 19B Red 013 Blk J36-K1 12V Power J36-K1 12V Power 118 Red Fan Relay Output (-) J36-B1 Genset...
Page 147: Troubleshooting
“Safety and Operations Manual” or “Parts and See Figure 4-50. Maintenance Manual” for information on machine configuration. SYSTEM VOLTS 48.0 VDC JACOBSEN 12 V VERSION X.XX 48 V TN2771 Figure 4-50 Cycle through the LCD menu until the system voltage screen is displayed.
Page 148 ELECTRICAL Fault: 48 Volt System Low or Short Run Fault: Vehicle Will Not Start – Gas and Time – All Electric Units Only Diesel Hybrid Units Only 1. Fault: System voltage drops to 43VDC for 10 1. Fault: System voltage is below 38VDC, hence not seconds or more.
Page 149 ELECTRICAL Fault: Engine RPM Fluctuates (Hunting) – between J35-pinC1 and J37-pin1 and J35-pinC2 and J37-pin8. Gas and Diesel Hybrid Units Only Measure continuity: DMV-Ohms should be 1. Fault: Under stable loads, engine behaves erratically less than 0.5 Ohms and no crossover with engine RPM changes from Low-High and between J35-pinA1 and J37-pin4.
Page 150 ELECTRICAL Reel Motor Amps Reel Motor Speed See Figure 4-51. See Figure 4-52. 00 REEL 00 1900 REEL 1900 1900 RPM 00 AMPS TN2772 TN2773 Left Reel Motor Amps Center Reel Motor Amps Left Reel Motor RPM Center Reel Motor RPM Right Reel Motor Amps Right Reel Motor RPM Figure 4-51...
Page 151 ELECTRICAL Reel Motor Temperature iii. Check wiring routing and securing as specified in dealer’s manual. See Figure 4-53. e. Motor is faulty Swap motor with known good motor Motor controller is faulty (Split-motor design ONLY) 80 REEL 80 Swap motor controller with known good TEMP 80 F motor controller g.
Page 152 ELECTRICAL g. For issue 2.g: Repair or replace jumper cable or Lift Actuator Amps Molex connector. See Figure 4-54. h. For issue 2.h: Repair main harness or connectors to RCU. For issue 2.i: Refer to Page 2 “Check Actuator” ACTUATOR AMPS for repair instructions.
Page 153 ELECTRICAL Fault: Check Actuator Physically verify traction pedal is not mechanically held out of neutral. Also verify 1. Fault: RCU did not recognize actuator position while voltage is between 0.3 and 0.8VDC with in automatic mode (PTO ON). pedal in neutral. 2.
Page 154 ELECTRICAL TCU and Traction Motor Temperature Extremely Slow Traction, No Fault See Figure 4-55. 1. Fault: Slow traction (less than 1 MPH) with no fault(s) shown in LDU 2. Possible root cause(s) and troubleshooting procedure: a. Motor speed sensor signal not reaching TCU TCU HS 80 F Visually inspect for damaged cable or MOTOR 80 F...
Page 155 ELECTRICAL Traction Surging During Mow/Transport, No Traction Fault 6211 Fault 1. Fault: No traction with a 6211 fault shown in LDU 1. Fault: Traction surge noted during transport, 2. Possible root cause(s) and troubleshooting especially while going uphill, with no fault shown in procedure: LDU and engine speed (RPM) is stable.
Page 156 ELECTRICAL Traction Fault 6214 3WD Fault 7310 1. Fault: No traction with a 6214 fault shown in LDU 1. Fault: No traction in 3WD mode with a 7310 fault shown in LDU. 2. Possible root cause(s) and troubleshooting procedure: 2. Possible root cause(s) and troubleshooting procedure: •...
Page 157 ELECTRICAL No Steering, No Fault: Traction Operational Steering Fault: 2310, 2340, 4210, 4310, 7310 1. Fault: Intermittent loss of steering with no fault(s) in 1. Fault: Intermittent steering fault(s) with one of more LDU or data log. of the above codes recorded in the data fault log. Fault(s) may not be displaying in LDU.
Page 158 ELECTRICAL Steering Fault: 7380 4. If unit still does not operate after performing all the above procedures, please contact Technical Support 1. Fault: Loss of steering/traction with 7380 fault. Note immediately. that the steering input device is also known as the LORD device.
Page 159 ELECTRICAL e. For issue 2.c.i: Go to Step 2.c.ii. CAN Bus Status For issue 2.c.ii: Replace proximity switch. If issue See Figure 4-58. is corrected, reinstall old proximity switch to verify fault returns. 4. If unit still does not operate after performing all the above procedures, please contact Technical Support immediately.
Page 160: Basic Can System Troubleshooting
ELECTRICAL Basic CAN System Troubleshooting 3. Move the raise/lower switch to the raise position and observe the digit at position (2). Move the raise/lower The following real world scenarios are intended to switch to the lower position and observe the digit at provide the technician with a simplified method of CAN position (3).
Page 161 ELECTRICAL 7. Move the raise/lower switch to the raise position. 12. Move the raise/lower switch to the lower position and Observe the left actuator raise output LED (4). observe the voltage measurement. Does the left actuator raise output LED Does the multimeter display 48VDC (+ or -) in illuminate? both switch positions? The left actuator raise output signal is good.
Page 162 ELECTRICAL 3. Move the mow switch to the run position and observe the digit at position (2). CENTER REEL DIR +48VDC INPUT Does the zero change to a one when the mow switch is moved to the on position? CENTER REEL TYPE LEFT REEL MOTOR CENTER ACT RAISE RIGHT REEL MOTOR...
Page 163: Traction Circuit
ELECTRICAL Traction Circuit PROGRAM SELECT 2 PROGRAM SELECT 3 PROGRAM SELECT 4 Symptom: Machine Will Not Move INPUTS 1. Turn the key to the run position. Enter the OUTPUTS maintenance mode. Toggle the LCD to the switch GENSET STATUS status screen. SPARE 12V DGTL LO IN SILENT MODE OUTPUT SPARE OUTPUT 2...
Page 164 ELECTRICAL 9. Test the brake coil. Does the multimeter indicate an ohms value of approximately 25.5? The brake coil is good. Proceed to the next SWITCH STATUS step. Check brake coil harness and connectors. 000 0000 001 Replace brake coil as needed. 10.
Page 165 ELECTRICAL 6. Measure voltage at B+ 48VDC input at SCU. Does the multimeter display 48VDC? The PDU voltage output good. Proceed to the next step. SWITCH STATUS Check PDU to SCU harness and connections. If harness and connections are 000 0001 001 good, printed circuit board in PDU is faulty.
Page 166 ELECTRICAL 8. Place the key switch in the off position to reset the INPUTS controller. Place the key switch in the start position OUTPUTS and observe the fuel pull solenoid output LED (4) and GENSET STATUS the fuel hold solenoid output LED (3). SPARE 12V DGTL LO IN SILENT MODE OUTPUT Does the fuel pull solenoid LED illuminate for...
Page 167 ELECTRICAL 2. Sit in the seat and observe the digit at position (1). 5. Place the key switch in the on position and observe the +12 volt power in LED (3). Does the zero change to a one when the key switch is move to the start position? Is the +12 volt power in LED illuminated? Key switch is good.
Page 168: System Diagnostic Trouble Codes (Dtc)
MCU, RCU, OLM – input/output status ii. TCU, SCU, 3WD – solid or blinking status This information needs to be collected before LED? troubleshooting or calling Jacobsen’s Technical Support team. 5. Vehicle system voltage (LCD VDC with engine off and running) 1.
Page 169 ELECTRICAL : 12 Volt System Low (Hybrid Models) 12 VDC system below 12.5 VDC. Probable Cause Remedy Faulty alternator output circuit (diesel Make sure alternator output cable and battery positive (+) cable terminals are clean and models). tight. Faulty 12V battery ground circuit. Make sure 12V battery negative (–) cable terminals are clean and tight.
Page 170: Reel Control Unit Diagnostic Trouble Codes (Dtc)
ELECTRICAL Reel Control Unit Diagnostic Trouble Codes (DTC) DTC: Left Reel Temperature Reel motor temperature above 266° F (130° C). Probable Cause Remedy Excessive debris lodged in cutting unit. Clear cutting unit of all debris. Cutting too much plant leaf. Check height-of-cut adjustment.
Page 171 ELECTRICAL DTC: Right Reel Temperature Reel motor temperature above 266° F (130° C). Probable Cause Remedy Excessive debris lodged in cutting unit. Clear cutting unit of all debris. Cutting too much plant leaf. Check height-of-cut adjustment. Check for correct reel blade count. Adjust ground speed.
Page 172 ELECTRICAL DTC: Right Reel Fault Reel motor short circuit. Probable Cause Remedy Jammed cutting unit. Clear cutting unit of all debris. Make sure cutting unit rotates without excessive resistance. Faulty connections. Check connections; make sure connections are dry, clean of corrosion and tight. Shorted wiring harness.
Page 173 ELECTRICAL DTC: Right Reel Overcurrent Reel motor current over 35A for 30 seconds. Probable Cause Remedy Excessive debris lodged in cutting unit. Clear cutting unit of all debris. Cutting excessive grass height. Select correct cutting unit configuration. Excessive mechanical resistance in cutting Check bedknife adjustment and reel bearing;...
Page 174 ELECTRICAL DTC: Right Reel Volts Low Right reel voltage below 43 volts. Probable Cause Remedy Faulty connections. Check connections; make sure connections are dry, clean of corrosion and tight. Faulty wiring harness. Check reel motor wiring harness for stretched wires. Blown 150A reel motor fuse in PDU.
Page 175 ELECTRICAL DTC: Check Right Reel Reel motor RPM is not within the range of the setpoint. Probable Cause Remedy Cutting excessive grass thickness. If in FOC mode, change frequency of clip (FOC) setting. If in manual mode, decrease ground speed. Excessive debris lodged in cutting unit.
Page 176 ELECTRICAL DTC: R Actuator Overcurrent R Actuator current over 10A for 30 seconds. Probable Cause Remedy Lift arm mechanical binding. Check lift arm pivot points for binding. Check up-stop, transport lock, or bumper adjustments. Faulty wiring/connections Check all wiring and connections for contaminants/damage and faulty connections. Fix and repair as needed.
Page 177 ELECTRICAL DTC: Check Left Actuator Actuator did not reach position within 6 seconds. Probable Cause Remedy Lift arm mechanical binding. Check lift arm pivot points for binding. Up-stop adjustments. Check up-stop adjustments. Incorrect cut position. Calibrate actuator. Faulty connections. Check connections; make sure connections are dry, clean of corrosion and tight. Low 48V system voltage.
Page 178: Traction Control Unit Diagnostic Trouble Codes (Dtc)
ELECTRICAL Traction Control Unit Diagnostic Trouble Codes (DTC) DTC: Traction Fault 2310 Software detected short circuit in cabling, controller or motor. Probable Cause Remedy Faulty connections. Check connections; make sure connections are dry, clean of corrosion and tight. Shorted wiring harness. Make sure traction motor wiring harness is free of nicks and cuts and not pinched to machine frame.
Page 179 ELECTRICAL DTC: Traction Fault 3212 DC voltage is above the hardware defined trip level. Probable Cause Remedy Stuck throttle. Check throttle linkage; adjust and repair. Faulty traction control unit. Substitute the traction control unit with a known good traction control unit. If system now works, re-install old component to verify fault returns.
Page 180 ELECTRICAL DTC: Traction Fault 6210 Direction error. Probable Cause Remedy Faulty wiring or connections. Check traction pedal position sensor connector; make sure connector is clean and tight. Make sure pedal position sensor wiring harness is free of nicks and cuts and not pinched to machine frame.
Page 181 ELECTRICAL DTC: Traction Fault 6213 Mechanical brake test failed. Probable Cause Remedy Brake screws installed. Remove brake screws. Faulty brake. Check for broken brake disk. Check brake for weak springs. Faulty traction control unit. Substitute the traction control unit with a known good traction control unit. If system now works, re-install old component to verify fault returns.
Page 182: Steering Control Unit Diagnostic Trouble Codes (Dtc)
ELECTRICAL Steering Control Unit Diagnostic Trouble Codes (DTC) DTC: Steering Fault 2310 Software detected short circuit in controller, cabling to motor or in motor. (See “Steering Fault: 2310, 2340, 4210, 4310, 7310” on page 4-83.) Probable Cause Remedy Moisture in steering motor connector. Make sure steering motor connectors are clean and dry.
Page 183 ELECTRICAL DTC: Steering Fault 3211 DC voltage is above the high trip level. Probable Cause Remedy Stuck throttle. Check throttle linkage; adjust and repair. Faulty throttle actuator. Test actuator. (See “Throttle Actuator Test (Diesel)” on page 4-134.) (See “Throttle Actuator Test (Gas)” on page 4-135.) Faulty steering control unit.
Page 184 ELECTRICAL DTC: Steering Fault 4310 Heatsink temperature is above 185° F (85° C). Probable Cause Remedy Rear wheel obstructed. Check rear wheel for obstruction. Debris on or around SCU. Remove debris and clean the SCU. Steering motor chain. Check steering motor chain tension. Check steering motor chain for binding or damage.
Page 185 ELECTRICAL DTC: Steering Fault 5410 Current is above the error limit. Probable Cause Remedy Rear wheel obstructed. Check rear wheel for obstruction. Steering motor chain. Check steering motor chain tension, mechanical binding or obstruction. Steering yoke bearing. Check steering yoke bearing. Faulty steering motor.
Page 186 ELECTRICAL DTC: Steering Fault 7310 Speed sensor feedback error. (See “Steering Fault: 2310, 2340, 4210, 4310, 7310” on page 4-83.) Probable Cause Remedy Voltage spike in 5V signal ground. Verify that the grounding modification has been completed. If not, contact Customer Care. Faulty connections.
Page 187 ELECTRICAL DTC: Steering Fault 8010 Difference between set value and actual value for current regulator is above limit. Probable Cause Remedy Faulty wiring harness. Check wiring between steering input device and steering control unit. Steering wheel input device. Substitute the steering wheel input device with a known good steering wheel input device. If system now works, re-install old component to verify fault returns.
Page 188 ELECTRICAL DTC: Steering Fault 8100 Controller has not received an expected CAN open message within the time-out time. Probable Cause Remedy CAN termination resistor faulty or missing. Measure between CAN termination resistor terminals A and B. Resistance must be 120 ohms.
Page 189: Overvoltage Limit Monitor (Olm) Diagnostic Trouble Codes (Dtc)
ELECTRICAL Overvoltage Limit Monitor (OLM) Diagnostic Trouble Codes (DTC) DTC: OLM Warning 05 OLM internal temperature high. Probable Cause Remedy Stuck throttle. Check throttle linkage; adjust and repair. Faulty overvoltage limit monitor. Substitute the overvoltage limit monitor with a known good overvoltage limit monitor. If system now works, re-install old component to verify fault returns.
Page 190 ELECTRICAL DTC: OLM Warning 21 OLM detects a short circuit to ground in resistor 2. Probable Cause Remedy Moist debris between resistor and frame. Clear debris. Ring terminal touching frame. Check ring terminal connection. Faulty resistor. Measure resistance between the resistor terminals. Resistance must be approximately 2 ohms.
Page 191 ELECTRICAL DTC: OLM Warning 33 OLM detects less current than expected through resistor 3. Probable Cause Remedy Faulty connection. Check the resistor for loose terminals. Make sure the resistor terminals are clean and tight. Moist debris between resistor and frame. Clear debris.
Page 192: Generator Control Unit Diagnostic Trouble Codes (Dtc)
ELECTRICAL Generator Control Unit Diagnostic Trouble Codes (DTC) DTC: Generator Fault 14 Pack voltage too high, greater than 64 volts for 5 seconds. Probable Cause Remedy 48V battery pack charged over 64 volts. Remove battery charger. Stuck throttle. Check throttle linkage; adjust and repair. Faulty throttle actuator.
Page 193 ELECTRICAL DTC: Generator Fault 23 Throttle actuator fault. Probable Cause Remedy Faulty connections. Check steering motor connections; make sure connections are dry, clean of corrosion and tight. Faulty throttle actuator. Test actuator. (See “Throttle Actuator Test (Diesel)” on page 4-134.) (See “Throttle Actuator Test (Gas)”...
Page 194 ELECTRICAL DTC: Generator Fault 56 Generator temperature greater than 340° F (171° C). Probable Cause Remedy Running on high load (150A continuous). Remove load. Debris on or around genset fan. Remove debris and clean the genset fan. Faulty connections. Check steering motor connections; make sure connections are dry, clean of corrosion and tight.
Page 195: Power Circuit
ELECTRICAL DTC: Generator Fault 59 Rectifier temperature less than –20° F (–29° C). Probable Cause Remedy Faulty connections. Check steering motor connections; make sure connections are dry, clean of corrosion and tight. Faulty wiring harness. Make sure wiring harness is free of nicks and cuts and not pinched to machine frame. Faulty generator control unit.
Page 196: Horn Circuit
ELECTRICAL Horn Circuit Horn does not turn on. Probable Cause Remedy Faulty horn switch. Test horn switch using LCD display “Switch Test”. (See “Switch Test” on page 4-85.) If the horn switch does not activate during the LCD “Switch Test”, bench test the switch. (See “Rocker Switches Test”...
Page 197: Start Circuit
ELECTRICAL Start Circuit Starter motor solenoid does not engage. Probable Cause Remedy 48 volt battery low. Charge battery. Mow switch is in the mow position. Place the mow switch in the off position. Faulty start relay output. Turn the key switch to the start position; check the main control unit (MCU) start relay output LED.
Page 198: Raise/Lower Circuit
ELECTRICAL Raise/Lower Circuit Perform a factory reset and actuator calibration before replacing RCU. Cutting units will not raise. Probable Cause Remedy Faulty raise switch. Test raise switch using LCD display “Switch Test”. (See “Switch Test” on page 4-85.) If the raise switch does not activate during the LCD “Switch Test”, bench test the switch. (See “Raise/Lower Switch Assembly Test”...
Page 199: Mow Circuit
ELECTRICAL Right cutting unit will not raise and lower. Probable Cause Remedy Actuator Not Calibrated Complete maintenance mode calibration or factory reset. Verify fault is eliminated. Faulty connections. Check connections; make sure connections are clean and tight. Faulty wiring harness. Make sure wiring harness is free of nicks and cuts and not pinched to machine frame.
Page 200: Component Tests And Adjustments
When replacing either electrical components or Does the circuit now operate properly? wiring, be sure to apply dielectric grease (Jacobsen PN Replace the wire. 365422) to all connector terminals to prevent corrosion.
Page 201: Circuit Breakers Test
ELECTRICAL Circuit Breakers Test 150A and 300A Fuses Test See Figure 4-78. See Figure 4-79.   WARNING WARNING Be sure that the key switch is off, all electrical Use care when testing live circuits to prevent accessories are turned off, and the 12-volt and arcing.
Page 202: Accessory Socket Fuse Test
ELECTRICAL Accessory Socket Fuse Test Fan Relay Test See Figure 4-80. See Figure 4-81. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter • Digital Multimeter or Ohmmeter • 12-Volt DC Power Source 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 1.
Page 203: Key Switch Test
ELECTRICAL Key Switch Test Mow Switch Test See Figure 4-82. See Figure 4-83. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) Test the component utilizing the LCD switch status menu 2.
Page 204: Rocker Switches Test
ELECTRICAL Rocker Switches Test 8. Measure the resistance between terminals (1 and 2). Is the resistance value 0.02 ohms or less? See Figure 4-84. Rocker switch is faulty; replace rocker switch. Required Tools or Equipment Rocker switch is good. Digital Multimeter or Ohmmeter NOTE This procedure applies to the following switches: •...
Page 205: Raise/Lower Switch Assembly Test
ELECTRICAL Raise/Lower Switch Assembly Test 5. Measure the resistance between terminals (2 and 3). Is the resistance value 0.02 ohms or less? See Figure 4-85. Switch is faulty; replace raise/lower switch assembly. Required Tools or Equipment Proceed to step 6. Digital Multimeter or Ohmmeter Move and hold the raise/lower switch assembly in the lower position and measure the resistance...
Page 206: Brake Pedal Switch Test
ELECTRICAL 9. Depress the seat switch and measure the resistance between terminals (3 and 4). Is the resistance value 0.02 ohms or less? Switch is good. Switch is faulty; replace switch. Brake Pedal Switch Test See Figure 4-88. Required Tools or Equipment Digital Multimeter or Ohmmeter 1.
Page 207: Brake Coil Test
ELECTRICAL Brake Coil Test Fuel Shutoff Solenoid Test (Diesel) See Figures 4-89. See Figures 4-90 and 4-91. Required Tools or Equipment Required Tools or Equipment Digital Multimeter or Ohmmeter Digital Multimeter or Ohmmeter 1. Park the mower safely. (See “Park Mower Safely” on 1.
Page 208: Fuel Shutoff Solenoid Test (Gas)
ELECTRICAL 5. Measure the resistance between terminal (4) and Fuel Shutoff Solenoid Test (Gas) ground (2). See Figure 4-92. Is the resistance value approximately 10 ohms at 68° F? Required Tools or Equipment Proceed to step 6. Digital Multimeter or Ohmmeter Fuel shutoff solenoid is faulty;...
Page 209: Throttle Actuator Test (Gas)
ELECTRICAL 7. Connect the throttle actuator wire connector (1). Cycle the key switch while observing actuator movement. Verify full stroke of the actuator. Replace actuator as necessary. Throttle Actuator Test (Gas) See Figures 4-95 and 4-96. Required Tools or Equipment Digital Multimeter or Ohmmeter 1.
Page 210: Traction Pedal Adjustment
8. Loosen jam nut (1) and turn stop screw (2) clockwise • Pedal Adjustment Harness until voltage value is within 4.3–4.4 volts. (Jacobsen PN 4225240) 9. Tighten jam nut. 10. Proceed to step 13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.)
Page 211: Repair
Replace as necessary. • Inspect connectors (3 and 8) and seal (13) for wear or damage and replace as necessary. NOTE • Apply dielectric grease (Jacobsen PN 365422) to connectors prior to assembly. Turck Connectors See Figures 4-100 and 4-101. ...
Page 212: Mcu
• Do NOT apply dielectric grease or any lubricant to Installation Notes turck connectors. • Install MCU by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. 4-138 4222983 Second Edition...
Page 213: Pdu
9. Remove PDU (3). Installation Notes • Install PDU by reversing the order of removal. TN2424 • Apply dielectric grease (Jacobsen PN 365422) to any Figure 4-103 connectors removed. • Tighten nut at 12 VOLT POS connectors (5 and 7) to NOTE 150 lb-in.
Page 214 ELECTRICAL Disassembly and Assembly See Figure 4-105. NOTE Highlighted items require a specific torque value. See the assembly notes on the next page for more information. TN2787 TN2787 PDU Cover 12-Volt 50A Circuit Breaker Flange Nut (2) Stud (3) 48-Volt Fuse Busbar Screw (6) Flange Nut (6) Flange Nut (2)
Page 215: Tcu Fan
4. Remove four nuts (1), lock washers (2), flat washers (3), and screws (4). 5. Remove TCU fan (6). Installation Notes • Install TCU fan by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. 4222983 Second Edition 4-141...
Page 216: Tcu
 WARNING • Install TCU by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any Be sure that the key switch is off, all electrical connectors removed. accessories are turned off, and the 12-volt and •...
Page 217: Rcu
5. Remove screws (1), two flat washers (2), lock washers (3), and nuts (4). 6. Remove RCU (7). Installation Notes • Install RCU by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. 4222983 Second Edition 4-143...
Page 218: Gcu
4. Disconnect GCU connectors (2). 5. Remove screw (6) and connector (5). 6. Swing out GCU shield (4) and remove from machine. NOTE For Eclipse 322 Model 62805 (Diesel), lift air intake hose (1) up to allow sufficient clearance for GCU shield removal. 4-144...
Page 219: Olm
Secure dome light assembly (6) out of the way. 4. Remove OLM (7). Installation Notes • Install OLM by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. TN2390 Figure 4-116 5. Carefully guide the wire harness (10) up and through the steering column weldment (11).
Page 220: Resistor Bank Assembly And Jumper Harness
(14) to be rotated about shoulder bolt (16).  CAUTION • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. Resistor bank assembly components will become hot during operation. Allow resistor bank assembly components to cool before performing service.
Page 221: Circuit Breakers
ELECTRICAL Circuit Breakers NOTE For Eclipse 322 Model 62801 (Electric), support the Removal and Installation battery tray using a suitable lifting device. See Figures 4-119 and 4-120. 5. Support the resistor bank assembly (6) using a  suitable lifting device.
Page 222: Contactors
6. Repeat steps 4 and 5 to remove the 30A circuit breaker (6) and 50A circuit breaker (7). Installation Notes • Install circuit breakers by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. TN2834 Contactors Figure 4-122...
Page 223 • Tighten flange nut (8) to 80 lb-in. (9 N·m). • Tighten nuts (4) to 35 lb-in. (4.0 N·m). • Tighten nuts (5) to 15 lb-in. (1.7 N·m). • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. 4222983 Second Edition...
Page 224: Fuses
Be sure that the key switch is off, all electrical • Install fuses by reversing the order of removal. accessories are turned off, and the 12-volt and • Apply dielectric grease (Jacobsen PN 365422) to 48-volt power connectors are disconnected fuse socket prior to installation.
Page 225: 48-Volt Connector
ELECTRICAL 48-Volt Connector Installation Notes • Install the 48-volt connector by reversing the order of Removal and Installation removal. • Route cables between the battery and battery tray to See Figure 4-127. avoid pinch points.  WARNING Instrument Panel • Battery posts, terminals, and related accessories contain lead and lead Removal and Installation compounds.
Page 226: Lcd
Installation Notes • Anti-seize must be applied to screw threads when installing instrument panel. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. • Use new cable ties to secure wire connectors and wire harness.
Page 227: Rocker Switches
4. Depress tabs (9) on each side of the rocker switch and remove from the instrument panel. Installation Notes • Apply dielectric grease (Jacobsen PN 365422) to connections. • Use new cable ties to secure wire connectors and wire harness.
Page 228: Raise/Lower Switch Assembly
ELECTRICAL 5. Remove retaining nut (3). NOTES 6. Remove key switch assembly (4). • For installation purposes, note orientation of the raise/lower switch assembly. Installation Note • Label all wires before disconnecting to ensure correct Install key switch assembly by reversing the order of installation.
Page 229: Horn
• Use new cable ties to secure wire connectors and wire harness. • Install the 12 VDC accessory plug by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. TN2351 Figure 4-140 NOTE Label all wires before disconnecting to ensure correct installation.
Page 230: Brake Pedal Switch
3. Remove two screws (1). 4. Remove brake pedal switch (2). Installation Notes • Install brake pedal switch by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. TN2408 Brake Pedal Position Sensor Figure 4-143 Removal and Installation 4.
Page 231: Steering Proximity Switches
(3). 4. Tighten adjusting nut (1). NOTE Apply dielectric grease (Jacobsen PN 365422) to wire connector (4) prior to installation. 5. Connect wire connector (4). 4222983 Second Edition...
Page 232: Engine Oil Pressure Switch (Diesel)
ELECTRICAL Engine Oil Pressure Switch (Diesel) Engine Temperature Switch (Diesel) Removal and Installation Removal and Installation See Figure 4-147. See Figure 4-148.   CAUTION WARNING Engine components will become hot during Engine coolant is hot and under pressure! Allow operation.
Page 233: Traction Pedal Position Sensor
(18), and accelerator mount (21) from traction pedal sensor (20). Installation Notes • Install traction pedal position sensor by reversing the order of removal. • Apply dielectric grease (Jacobsen PN 365422) to any TN2407 connectors removed. Figure 4-150 4222983 Second Edition...
Page 234: Rectifier Repair Kit (Gas And Diesel)
48-volt power connectors are disconnected before starting work on machine. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. For Eclipse 322 Model 62803 (Gas), proceed to step 6. 3. Remove fuel tank. (See “Fuel Tank (Diesel)” on page 3-19.)
Page 235 ELECTRICAL Disassembly and Assembly See Figure 4-154. TN2722 To PDU Rectifier Temperature Sensor Black Cable 150A Shunt Red Cable Rectifier Harness Bus Bar 3/8” Cable Grip Screw (2) Generator Output Rectifier Diode Housing Rectifier Shunt Cable Screw (3) Conduit Nut 1/2”...
Page 236: Fuel Level Switch
ELECTRICAL Assembly Notes AC Traction Motor Assembly • Required Materials Removal and Installation ® • Loctite 518 Gasket Eliminator See Figures 4-156 and 4-157. ®  • Loctite 242 (Blue) WARNING ® Be sure that the key switch is off, all electrical •...
Page 237: Brake Coil
ELECTRICAL Brake Coil NOTE Label all wires before disconnecting to ensure correct Removal and Installation installation. See Figure 4-158. 5. Disconnect wire connectors (1).  WARNING 6. Remove cable ties securing the AC traction wire harness to the frame. Be sure that the key switch is off, all electrical accessories are turned off, and the 12-volt and 48-volt power connectors are disconnected before starting work on machine.
Page 238: Sensor Bearing
ELECTRICAL 4. Disconnect wire connector (2). 5. Remove three screws (1). 6. Remove brake coil (3) from AC traction motor (4). Installation Notes • Install brake coil by reversing the order of removal. • Tighten screws (5) to 65 lb-in. (7.3 N·m). Sensor Bearing Removal and Installation See Figures 4-159 through 4-162.
Page 239: Steering Motor
ELECTRICAL Steering Motor Removal and Installation See Figures 4-163 through 4-166.  WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the 12-volt and 48-volt power connectors are disconnected before starting work on machine. 1.
Page 240 ELECTRICAL 3. Disconnect wire connector (5) from steering motor Installation Notes (6). • Install steering motor by reversing the order of removal. • Use new cable ties to secure wire connectors and wire harness. • Adjust the steering tension. (See “Steering Chain Tension Adjustment”...
Page 241 ELECTRICAL Page Intentionally Blank 4222983 Second Edition 4-167...
Page 242 ELECTRICAL 4-168 4222983 Second Edition...
Page 243 Chapter 5 Chassis Specifications ..............5-2 Checks and Adjustments Specifications .
Page 244: Specifications
CHASSIS Specifications Checks and Adjustments Specifications Specification Steering Chain Deflection 0.0625–0.250 (1.6–6.4) in. (mm) [with 2–10 lb (9–45 N) push at mid-span of chain] Repair Specifications Specification Front Wheel Hub Castle Nut Torque 95–115 (10.7–13.0) lb-ft (N·m) Front Axle Assembly— 65 (88) lb-ft (N·m) Mounting Screw Torque...
Page 245: Component Location
CHASSIS Component Location See Figures 5-1 and 5-2. TN2744 Floorboard Assembly Left Cutting Unit Right Lift Arm Front Axle Assembly Center Cutting Unit Traction Pedal Right Reel Lift Actuator Right Cutting Unit Right Fender Center Reel Lift Actuator Figure 5-1: Component Location—Right Side 4222983 Second Edition...
Page 246 CHASSIS TN2746 Brake Pedal Assembly Steering Yoke Left Lift Arm Steering Chain and Gear Left Fender Left Reel Lift Actuator Figure 5-2: Component Location—Left Side 4222983 Second Edition...
Page 247: Checks And Adjustments
CHASSIS Checks and Adjustments Steering Chain Tension Adjustment See Figures 5-3 and 5-4.  WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the 12-volt and 48-volt power connectors are disconnected before starting work on machine. 1.
Page 248: Repair
4. Remove cotter pin (5) and flat washer (6). 5. Remove the reel lift actuator. Installation Notes • Install reel lift actuator by reversing the order of removal. • Apply dielectric grease (Jacobsen part number 365422) to connections. 4222983 Second Edition...
Page 249 • Install lift arm by reversing the order of removal. • Use new cable ties to secure the wire connectors and wire harness. • Apply dielectric grease (Jacobsen part number 365422) to connections. • Lubricate grease fittings. 4222983 Second Edition...
Page 250 CHASSIS Disassembly and Assembly See Figure 5-8. TN2785 TN2785 Screw Cotter Pin Front Reel Steering Pivot Flat Washer Stop Bracket Link Arm Left Front Lift Arm Grease Fitting Lock Washer Bushing Flat Washer Polygon Bushing Right Front Lift Arm Screw Flat Washer Lock Washer Shim Washer (as required)
Page 251: Center Lift Arm
3. Remove reel leveling rod. (See “Reel Leveling Rod” removal. on page 6-23.) • Use new cable ties to secure the wire connectors and wire harnesses. • Apply dielectric grease (Jacobsen part number 365422) to connections. • Lubricate grease fittings. TN2410 Figure 5-9...
Page 252 CHASSIS Disassembly and Assembly See Figure 5-11. TN2786 TN2786 Lock Pin Flat Washer Thrust Washer Locking Collar Screw Polygon Bushing Grease Fitting Link Arm Polygon Bushing Lock Washer Flat Washer Center Reel Steering Pivot Screw Bushing Flat Washer Cotter Pin Shim Washer (as required) Flat Washer Center Swing Arm...
Page 253: Steering Yoke
CHASSIS Disassembly Notes • Before disassembly, clean the center lift arm and center swing arm—removing all dirt and debris. • Inspect link arm, center lift arm, center swing arm, reel steering pivot, and all bushings for damage or wear. Remove bushings only if replacement is required.
Page 254: Steering Chain And Gears
CHASSIS Steering Chain and Gears Removal and Installation See Figures 5-15 through 5-17.  WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the 12-volt and 48-volt power connectors are disconnected before starting work on machine. 1.
Page 255: Front Fenders
CHASSIS Front Fenders NOTE For installation purposes, note orientation of the chain Removal and Installation before removing. See Figure 5-18. 5. Loosen two screws (8) and slide the steering motor NOTE bracket to remove the chain. 6. Remove chain from gears. The left fender is shown;...
Page 256: Traction Pedal
CHASSIS Traction Pedal Brake Pedal Assembly Removal and Installation Removal and Installation See Figure 5-19. See Figures 5-20 and 5-21. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.
Page 257 CHASSIS 7 8 9 7 8 9 TN2414 Figure 5-21 9. Remove pedal grip (5). NOTE Move floor mat aside to access screws (7). 10. Support brake pedal assembly (6) and remove screws (7), lock washers (8), and flat washers (9). 11.
Page 258 CHASSIS Disassembly and Assembly See Figure 5-22. TN2415 Screw (4) Brake Arm Weldment Switch Arm Spring Brake Pedal Position Sensor Spring Roll Pin (2) Brake Pedal Switch Spacer (4) Brake Plate (2) Pedal Grip Screw (4) Nut (4) Bushing (2) Figure 5-22 5-16 4222983 Second Edition...
Page 259: Axle Shield And Front Splash Shield
CHASSIS Axle Shield and Front Splash Shield Removal and Installation See Figure 5-23. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2412 Figure 5-23 2. Remove four lock nuts (5), four screws (1), and shield mounting strap (2). 3.
Page 260: Floorboard
CHASSIS Floorboard Removal and Installation See Figures 5-24 through 5-26. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove front fenders. (See “Front Fenders” on page 5-13.) 3. Remove front cover. (See “Front Cover” on page 7-16.) 4.
Page 261: Front Wheel Hub
CHASSIS Front Wheel Hub Front Axle Assembly Removal and Installation Removal and Installation See Figure 5-27. See Figures 5-28 through 5-30.  1. Park the mower safely. (See “Park Mower Safely” on WARNING page 1-6.) 2. Remove front wheel. (See “Front Wheels” on Be sure that the key switch is off, all electrical page 7-14.) accessories are turned off, and the 12-volt and...
Page 262 CHASSIS 5 6 7 8 TN2365 Figure 5-29 NOTE TN2406 Label all wires before disconnecting to ensure correct Figure 5-30 installation. 5. Disconnect brake coil wire connector (2), traction 8. Cut cable ties (9). Carefully guide the AC traction pedal position sensor wire connector (3), and AC motor power cables (10) through the machine and traction motor wire connectors (4).
Page 263 CHASSIS Disassembly and Assembly See Figure 5-31. TN2783 Snap Ring O-Ring Left-Side Axle Shaft Differential Case Assembly Axle Shaft Bearing Input Shaft Ball Bearing Bearing Cap Cover Screw Snap Ring Input Shaft Bearing Cap Screw Cover Axle Shaft Seal Input Shaft Ball Bearing Differential Ball Bearing Right-Side Axle Shaft Snap Ring...
Page 264 CHASSIS Assembly Notes 9. Remove four bearing cap screws (13) and two bearing caps (12). • Assemble axle shaft bearings in reverse order of removal. 10. Remove differential case assembly (15) from axle housing (10). • Clean and inspect axle shaft bearings and seals (2 and 4) for wear or damage.
Page 265 CHASSIS Assembly Notes • Assemble input shaft ball bearings in reverse order of removal. • Clean and inspect input shaft ball bearings (7 and 9) for wear or damage. Replace as needed. • Lubricate input shaft ball bearings (7 and 9) with Mobilfluid 424 or SAE 30 oil prior to installation.
Page 266 CHASSIS Page Intentionally Blank 5-24 4222983 Second Edition...
Page 267 Chapter 6 Cutting Units Specifications ..............6-2 Component Location .
Page 268 CUTTING UNITS Specifications Checks and Adjustments Bedknife Front Face Height 0.0625 (1.59) in. (mm) Bedknife Front Face Angle degrees Bedknife Top Face Angle (rear relief) degrees 8–10 Super Tournament Bedknife Top Face Angle degrees 5–7 (rear relief) Reel Blade Relief Angle degrees Reel-to-Bedknife Gap 0.001–0.003 (0.025–0.076)
Page 269: Component Location
CUTTING UNITS Component Location See Figure 6-1. TN2744,TN2648,TN2650 Left Cutting Unit Center Cutting Unit Reel Assembly Yoke Cutting Unit Rear Roller Grass Catchers Center Reel Leveling Rod Counterweight Lift Arm Bedknife Backing Assembly Right Reel Leveling Rod Drive Motor Grass Shield Adjusters Cutting Unit Frame Right Cutting Unit...
Page 270: Troubleshooting
CUTTING UNITS Troubleshooting Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Some of the mowing practices and turf conditions that can cause poor cutting results even though the mower is properly sharpened and adjusted are: • Repetitious mowing patterns— tires running over the same path causing depressions and ruts.
Page 271: Cutting Units
CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. Ragged Cut Ragged cutting occurs when blades of grass are torn or damaged rather than cut. This is usually caused by incorrect height-of-cut adjustment, incorrect bedknife-to-reel adjustment, or dull blades.
Page 272 CUTTING UNITS 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. (15–20 cm). Color variation (light-to-dark) may also be noticed. This condition is usually caused by a rocking motion in the cutting unit(s).
Page 273 CUTTING UNITS Marcelling Marcelling is a wave-like cut appearance similar to wasboarding 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 274: Step Cutting
CUTTING UNITS Step Cutting Step cutting occurs when grass is cut taller on one side of a cutting unit than on the other, or on one side of the mower than on the other. This is usually caused by mechanical wear or an incorrect roller or adjustment. TN0221 NOTE: Arrow indicates direction of travel.
Page 275 CUTTING UNITS Scalping Scalping is a condition in which areas of grass are cut noticeably shorter than the surrounding areas, resulting in a light green or even brown patch. This is usually caused by an excessively low height-of-cut setting and/or uneven turf.
Page 276 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. TN0223 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Bedknife improperly adjusted. Adjust bedknife. (See “Bedknife-to-Reel Clearance Adjustment” on page 6-16.) Dull cutting edges. Sharpen reel and bedknife. (Refer to “Safety, Operation, and Maintenance Manual.”) Mowing (ground) speed is too fast.
Page 277 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a damaged bedknife or reel blade. TN0224 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Damaged bedknife. Replace bedknife. (See “Bedknife” on page 6-27.) Damaged or unevenly worn reel.
Page 278 CUTTING UNITS Windrowing Windrowing is the deposit of clippings concentrated at one end of cutting unit(s) or between cutting units, forming line(s) in the direction of travel. TN0225 NOTE: Arrow indicates direction of travel. Probable Cause Remedy Grass is too tall. Mow more often.
Page 279: Mismatched Cutting Units
CUTTING UNITS Mismatched Cutting Units Mismatched cutting units cause a pattern of varying cutting heights, resulting in a stepped cut appearance, usually due to a different HOC (height-of-cut) adjustment from one cutting unit to another. TN1278 NOTE: Arrow indicates direction of travel. Probable Cause Remedy HOC inconsistent from one cutting unit to another.
Page 280: Rifling Or Tramlining
CUTTING UNITS 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 281: Mechanical Troubleshooting
CUTTING UNITS Mechanical Troubleshooting Condition Probable Cause Remedy Reel drive does not engage. Reel enable switch and mow switch not Engage reel enable switch and mow engaged. switch. (Refer to Operator’s Manual.) Machine set to FOC mode and machine Engage traction pedal and move machine. not moving.
Page 282: Checks And Adjustments
CUTTING UNITS Checks and Adjustments NOTE The bedknife-to-reel adjustment should be made by Bedknife-to-Reel Clearance starting with the leading end of the reel (5) and following Adjustment with the trailing end (6). The leading end of the reel blade is that end which passes over the bedknife first during See Figures 6-2 through 6-4.
Page 283: Height-Of-Cut (Hoc) Adjustment
CUTTING UNITS Height-of-Cut (HOC) Adjustment NOTES See Figure 6-5. • Check the position of each reel for desired  height-of-cut. CAUTION • All reels must be accurately adjusted to exactly the To prevent personal injury and damage to the same height for proper cutting. cutting edges, handle the reel with extreme care.
Page 284: Grass Catcher Yoke Adjustment
CUTTING UNITS Grass Catcher Yoke Adjustment Reel Bearing Pre-Load Adjustment See Figure 6-7. See Figures 6-8 through 6-12.  1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2. Back bedknife away from reel. (See To prevent personal injury and damage to the “Bedknife-to-Reel Clearance Adjustment”...
Page 285 CUTTING UNITS 15 16 15 16 TN2650 Figure 6-12 TN2652 7. Install counterweight (14), screws (15), and lock Figure 6-10 washers (16). 5. Tighten adjuster nut (8) until the spring (9) is 8. Adjust bedknife-to-reel contact. (See completely collapsed, then back the nut 2–3 turns, or “Bedknife-to-Reel Clearance Adjustment”...
Page 286: Right And Left Reel Stop Bracket Adjustment
CUTTING UNITS Right and Left Reel Stop Bracket Right and Left Reel Bumper Adjustment Adjustment See Figure 6-13. See Figure 6-14. 1. Park the mower safely. (See “Park Mower Safely” on NOTE page 1-6.) The left reel stop bracket is shown; the right reel stop bracket is similar.
Page 287: Center Reel Bumper Adjustment
TN2781 TN2781 Figure 6-16: Model 62801 (Electric) NOTE For Eclipse 322 Models 62803 (Gas) and 62805 (Diesel), see figure 6-15. For Eclipse 322 Model 62801 (Electric), see figure 6-16. 3. Loosen two screws (1). 4. Engage the mow switch and raise the center cutting unit (3) to the fully up position.
Page 288: Reel Leveling Rod Pre-Adjustment
CUTTING UNITS Reel Leveling Rod Pre-Adjustment Cutting Unit Leveling Adjustment See Figure 6-18. See Figure 6-19. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.
Page 289: Repair
CUTTING UNITS Repair Installation Notes • Required Materials Reel Leveling Rod ® Loctite 242 (Blue) Removal and Installation • Apply marine lubrication grease to I.D. of rod See Figure 6-20. connecting pin (3) and reel leveling rod (5) at area NOTE beneath the springs.
Page 290: Center Cutting Unit
CUTTING UNITS TN2646 TN2645 Figure 6-23 Figure 6-22 2. Remove pin (1) on right side of machine. 4. Remove coupler (5) from reel drive motor shaft (4). Installation Notes • Install reel drive motor by reversing the order of removal. •...
Page 291: Right And Left Cutting Units
CUTTING UNITS Right and Left Cutting Units Grass Shield Removal and Installation Removal and Installation See Figure 6-25. See Figure 6-26. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.
Page 292: Bedknife Backing Assembly
CUTTING UNITS Bedknife Backing Assembly Installation Notes Removal and Installation Required Materials See Figures 6-27 and 6-28. Anti-Seize Compound 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) • Install bedknife backing assembly by reversing the 2. Remove cutting unit from mower. (See “Center order of removal.
Page 293: Bedknife
1-6.) 2. Remove bedknife backing assembly. (See “Bedknife • Bearing Assembly Tool Backing Assembly” on page 6-26.) (Jacobsen PN JAC5084) • Reel Bearing Housing Puller (Jacobsen PN JAC5085) 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2.
Page 294 Installation Notes • Install reel bearing housing assembly by reversing the order of removal. • Use bearing assembly tool (Jacobsen PN JAC5084) to install reel bearing housing assembly onto the reel shaft. • Install new O-ring (6) and lubricate with grease that meets or exceeds NLGI Grade 2 LB specifications.
Page 295 12. Remove washer (8) and spring (9). 13. Remove reel bearing housing assembly (14) using reel bearing housing puller (Jacobsen PN JAC5085). 14. Inspect reel shaft (12) for wear or damage. Replace reel if needed. (See “Reel Assembly” on page 6-30.) Disassembly and Assembly See Figure 6-34.
Page 296: Reel Assembly
11. Install cutting unit to mower. (See “Center Cutting 1. Install reel bearing housing assembly (9) using Unit” on page 6-24 or “Right and Left Cutting Units” bearing assembly tool (Jacobsen PN JAC5084). on page 6-25.) 2. Install spring (6), washer (5), and nut (4).
Page 297: Front Roller
CUTTING UNITS Front Roller Removal and Installation See Figure 6-38. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller.
Page 298: Rear Roller
CUTTING UNITS Rear Roller Roller Bearings Removal and Installation Removal See Figure 6-39. See Figure 6-40. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2.
Page 299 Chapter 7 Accessories and Miscellaneous Repair Specifications ..............7-2 Component Location .
Page 300 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications Repair Specifications OPS Mounting Screw Torque 25 (39) lb-ft (N·m) Steering Wheel Nut Torque 28–30 (38–41) lb-ft (N·m) Rear Axle Assembly Mounting Nut Torque 150 (203) lb-ft (N·m) Steering Tower Mounting Screw Torque 55–60 (75–81) lb-ft (N·m) Front Tires Size...
Page 301: Component Location
ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure 7-1. TN2744 OPS (Operator Protective Structure) Steering Tower Front Wheel (2) Seat and Seat Platform Left Side Cowling Right Side Cowling Armrest Assembly Work Light Rear Wheel Steering Wheel Dome Light Hood Figure 7-1: Component Location 4222983 Second Edition...
Page 302: Repair
ACCESSORIES AND MISCELLANEOUS REPAIR Repair Disassembly and Assembly See Figure 7-3. Work Light Assembly Removal and Installation See Figure 7-2. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove front cover. (See “Front Cover” on page 7-16.) TN2360 Figure 7-2...
Page 303: Dome Light
ACCESSORIES AND MISCELLANEOUS REPAIR Dome Light OPS Light Removal and Installation Removal and Installation See Figure 7-4. See Figure 7-5. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) TN2657...
Page 304: Ops
ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes • Install OPS by reversing the order of removal. Removal and Installation • Tighten OPS mounting screws (3) to 25 lb-ft (39 N·m). See Figures 7-6 and 7-7. 1. Park the mower safely. (See “Park Mower Safely” on Hood page 1-6.) 2.
Page 305: Armrest Assembly
See Figures 7-9 and 7-10. Installation Notes NOTE • Apply dielectric grease (Jacobsen PN 365422) to any connectors removed. Armrest and instrument panel is removed as one assembly. • Use new cable ties to secure wire connectors and wire harness.
Page 306: Seat And Seat Platform
ACCESSORIES AND MISCELLANEOUS REPAIR Seat and Seat Platform Removal and Installation See Figures 7-11 through 7-13. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Remove cowlings. (See “Cowlings” on page 7-18.) 3. Remove armrest assembly. (See “Armrest Assembly” on page 7-7.) 4 5 6 TN2403...
Page 307 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figure 7-14. TN2422 Seat Spacer Seat Switch Flange Nut (8) Lock Washer (4) Screw (6) Seat Belt Assembly Seat Switch Harness Seat Adjuster Rod Armrest and Seat Base Flat Washer (8) Nut (2) Latching Seat Track Seat Adjuster Handle Cable Tie (2)
Page 308: Seat Switch
ACCESSORIES AND MISCELLANEOUS REPAIR Seat Switch Removal and Installation Standard Seat See Figure 7-15. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN2402 Figure 7-16 2. Tag and disconnect the seat switch wire harness connector (2). 3.
Page 309: Rear Fender
ACCESSORIES AND MISCELLANEOUS REPAIR Rear Fender Removal and Installation See Figure 7-19. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) TN1989 Figure 7-18 8. Disengage switch cover tabs (8) and remove cover (9). 9. Raise end of switch actuator (6) and remove seat switch (7).
Page 310: Rear Wheel And Axle Assembly
ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheel and Axle Assembly Installation Notes • Inspect and clean any rust from rear axle assembly Removal and Installation (4) or wheel mounting area. • Install rear wheel and axle assembly by reversing the See Figure 7-20. order of removal.
Page 311 ACCESSORIES AND MISCELLANEOUS REPAIR Rear Axle Disassembly and Assembly See Figure 7-21. TN2784 TN2784 Seal Axle Tube Axle Shaft Wheel Bolt (4) Bearing Adjuster Nut Bearing Cup and Cone Bearing Backing Ring Flat Washer Grease Fitting Figure 7-21: Rear Axle Assembly 4222983 Second Edition 7-13...
Page 312: Front Wheels
ACCESSORIES AND MISCELLANEOUS REPAIR Front Wheels Steering Wheel Removal and Installation Removal and Installation See Figure 7-22. Required Tools or Equipment 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) NAPA Puller BK7763908 2. Block front and rear of rear wheel using suitable wheel blocks.
Page 313 ACCESSORIES AND MISCELLANEOUS REPAIR TN3238 Figure 7-26 5. Place screw (10) on the steering column shaft, using nut (5) as a pilot. Position the jaws to grasp the lip on the bottom of the steering wheel (12) with the top of the jaws resting on the bottom of the steering wheel.
Page 314: Front Cover
ACCESSORIES AND MISCELLANEOUS REPAIR Front Cover Rear Cover Removal and Installation Removal and Installation See Figure 7-27. See Figure 7-28. 1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) page 1-6.) 2 3 4...
Page 315: Steering Tower
TN2734 Figure 7-29 NOTE Steps 7 through 11 are for the Eclipse 322 Model 62803 (Gas) only. For the Eclipse 322 Model 62805 (Diesel) and Eclipse 322 Model 62801 (Electric), proceed to step 12. 7. Hold nut (5) and remove knob (4).
Page 316: Cowlings
TN2666 Figure 7-31 NOTE Steps 3 and 4 are for the Eclipse 322 Model 62805 (Diesel) only. For the Eclipse 322 Model 62801 (Electric) and Eclipse 322 Model 62803 (Gas), proceed to step 5. 3. Loosen hose clamp (3) and disconnect hose (4) from plenum (2).
Page 317 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly See Figures 7-33 and 7-34. TN2769 TN2769 Cup Holder Support Plate Eclipse 322 Decal Cover Gasket Left Side Cowling Flat Washer Cup Holder Drain Hose Access Cover Left Side Cowling Molding Lock Washer...
Page 318 ACCESSORIES AND MISCELLANEOUS REPAIR TN2770 TN2770 Right Side Cowling Molding Right Side Cowling Body Cover Plug Eclipse 322 Decal Plug (Not used on Model 62805 [Diesel]) Figure 7-34: Right Side Cowling 7-20 4222983 Second Edition...
Page 319 INDEX INDEX Alternator (Diesel) Removal and Installation ....3-14 Repair ......3-14 Numerics Armrest Assembly Removal and Installation .
Page 320 INDEX Component Identification Electrical ......4-12 CAN System Component Location Troubleshooting ..... . 4-86 Accessories and Miscellaneous Repair .
Page 321 INDEX Electrical Connectors Inspection Deutsch Connectors ....4-137 Repair ......4-137 Definition of Terms Turck Connectors .
Page 322 INDEX Front Wheel Hub Generator Control Unit Diagnostic Trouble Codes Removal and Installation ....5-19 Generator Fault 14 ....4-118 Repair .
Page 323 INDEX Low Fuel Warning System Diagnostic Trouble Codes ..4-95 Hazardous Materials Storage ....1-9 Lower Circuit Schematic, Electrical ....4-46 Height-of-Cut (HOC) Adjustment Checks and Adjustments .
Page 324 INDEX Removal and Installation ....7-6 Repair ....... 7-6 Radiator (Diesel) Installation .
Page 325 INDEX Reel Bearing Pre-Load Adjustment Checks and Adjustments ....6-18 Reel Control Unit Diagnostic Trouble Codes C Actuator Fault ..... 4-102 C Actuator Overcurrent .
Page 326 INDEX Repair Grass Shield ......6-25 12 VDC Accessory Plug ....4-154 Hood .
Page 327 INDEX Repair—Model 62803 (Gas) Genset and Battery Pack ....3-28 Safety Repair—Model 62805 (Diesel) Chemical Products Handling ... . . 1-9 Genset and Battery Pack .
Page 328 INDEX Seat and Seat Platform Steering Chain and Gears Disassembly and Assembly ....7-9 Removal and Installation ....5-12 Removal and Installation .
Page 329 INDEX Steering Yoke Units Only ....4-74 Removal and Installation ....5-11 Fuel Shutoff Solenoid (Diesel) .
Page 330 INDEX Throttle Actuator (Gas) Only ..... . 4-75 Removal and Installation ....3-29 Engine RPM Fluctuates (Hunting) –...
Page 331 INDEX Turck Connectors Electrical Connectors Inspection ..4-137 Volatile Materials Storage ....1-9 Waste Materials Safe Disposal ......1-11 Work Area Cleanliness .
Page 332 INDEX IX-14 4222983 First Edition...
Page 334 Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations. A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support.

This manual is also suitable for:

Eclipse 322 62801 Eclipse 322 62803 Eclipse 322 62805

Jacobsen Eclipse 322 Repair Manual

Chapter 1 Safety 1

Chapter 2 Specifications and General Information

Chapter 3 Genset and Battery Pack

Chapter 4 Electrical

Chapter 5 Chassis

Chapter 6 Cutting Units

Chapter 7 Accessories and Miscellaneous Repair

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Summary of Contents for Jacobsen Eclipse 322