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Trademark Acknowledgement to the operator’s manual and parts manual for specific information on these topics. Jacobsen acknowledges the following trademarks for THE INFORMATION CONTAINED IN THIS MANUAL IS company names or products mentioned within this BASED ON MACHINES MANUFACTURED UP TO THE publication: TIME OF PUBLICATION.
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Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter. Copyright 2012, Jacobsen, A Textron Company “All rights reserved, including the right to reproduce this material or portions thereof in any form.” 4271491-Second Edition...
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Table of Contents Safety Specifications and General Information Genset and Battery Pack Electrical Chassis Cutting Units Accessories and Miscellaneous Repair 4271491-Rev A...
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.
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 4271491-Second Edition...
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...
SAFETY Use Lifting Equipment Safely WARNING Always check the lifting capacity and condition of hoists, slings, cables, or chains before use. Using underrated or worn lifting components can result in death or serious injury. • Always use a lifting device with a lifting capacity greater than the weight of the item being lifted.
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 •...
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.
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.
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.
SPECIFICATIONS AND GENERAL INFORMATION Machine Identification Engine Serial Number—(Diesel Models) Machine Serial Number See Figure 2-3. See Figures 2-1 and 2-2. TN2435 Figure 2-3 The engine serial number (1) is attached to the top of the rocker arm cover. The plate also includes the engine model number and the engine code number.
SPECIFICATIONS AND GENERAL INFORMATION Engine Identification Number— (Gasoline Models) 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.
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...
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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 4271491-Second Edition...
SPECIFICATIONS AND GENERAL INFORMATION Electric Models TN2311 Battery Charger Battery Filling System Battery Pack Figure 2-7: Component Location—Left Side 4271491-Second Edition...
SPECIFICATIONS AND GENERAL INFORMATION Specifications Quick Reference Specifications Fuel Tank Capacities Diesel Models Fuel Tank Capacity 5.3 (20) gal (L) Gasoline Models Fuel Tank Capacity 5.3 (20) gal (L) General Engine/Motor Specifications Diesel Models Manufacturer/Model Kubota/Z482-E3B 2-Cylinder; Liquid Cooled Engine Type 4-stroke, diesel Fuel Requirement No.
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SPECIFICATIONS AND GENERAL INFORMATION Electric Models 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...
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SPECIFICATIONS AND GENERAL INFORMATION Electrical Test and Adjustment Specifications 120-Ohm Resistor Connector Resistance 120 ± 10% ohms at 68° F (20° C) Resistance Across Brake Coil 25.5 ± 10% ohms at 68° F (20° C) Resistance Across Fuel Shutoff Pull-In Coil 0.5 ±...
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SPECIFICATIONS AND GENERAL INFORMATION Repair Specifications PDU 12 Volt POS Connector Nut (5 and 7) Torque 12.5 (16.9) lb-ft (N·m) (See page 4-149.) PDU 48 VDC BAT POS Connector Nut (6) Torque 80 (9) lb-in. (N·m) (See page 4-149.) PDU 48 VDC BAT Generator Connector Nut (8) 80 (9) lb-in.
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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...
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SPECIFICATIONS AND GENERAL INFORMATION Cutting Units Check and Adjustment Specifications Reel-to-Bedknife Gap 0.001–0.003 (0.025–0.075) in. (mm) Reel Bearing Pre-Load 0.040 (1.27) in. (mm) Right/Left Reel Leveling Rod—Rod End-to-Nut Face 1.625 (41.3) in. (mm) Measurement (non-spring side) Center Reel Leveling Rod—Rod End-to-Nut Face 1.00 (25.4) in.
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SPECIFICATIONS AND GENERAL INFORMATION Accessories and Miscellaneous Check and Adjustment Specifications Turf Groomer Eccentric Mounting Screw Torque 8–10 (10.8–13.6) lb-ft (N·m) Turf Groomer Belt Tension Link Mounting Screw 20 (27.1) lb-ft (N·m) Torque Repair Specifications Solid Front Roller Assembly Maximum Rotational 6 (0.68) Maximum with No End Play lb-in.
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SPECIFICATIONS AND GENERAL INFORMATION Mower Speed Transport 0–9.0 (0–14.5) mph (km/h) Mowing 0–5.0 (0–8.9) mph (km/h) Reverse 0–4.0 (0–6.4) mph (km/h) Front Roller Weights 22 Inch Grooved Assembly Steel Disc Roller 10 (4.54) lb (kg) (PN 068527) 22 Inch Grooved Segmented Machined Aluminum 8 (3.63) lb (kg) Roller (PN 068673)
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.
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SPECIFICATIONS AND GENERAL INFORMATION 2-16 4271491-Second Edition...
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Chapter 3 Genset and Battery Pack Specifications ..............3-3 Fuel Tank Capacities .
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GENSET AND BATTERY PACK Repair—Batteries ............. 3-39 Battery Pack, Battery Pack Tray, and Battery Filling System .
GENSET AND BATTERY PACK Electric Models 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...
GENSET AND BATTERY PACK Checks and Adjustments— 5. When the bubbles disappear from fuel coming out of the air vent screw hole, tighten air vent screw and Diesel Models turn ignition switch to the off position. Purging the Fuel System (Diesel Models) See Figures 3-6 through 3-8.
GENSET AND BATTERY PACK Throttle Actuator Adjustment (Diesel Models) See Figure 3-9. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood. TN2689 Figure 3-8 9. Loosen fuel injector line nut (3) and crank the engine. 10.
GENSET AND BATTERY PACK Repair—Diesel Models Fan Belt (Diesel Models) 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.
GENSET AND BATTERY PACK Air Filter Assembly (Diesel Models) 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.
GENSET AND BATTERY PACK Muffler (Diesel Models) 6. Remove four nuts (3) and lock washers (4). 7. Remove muffler (7) from exhaust manifold (2). Removal and Installation 8. Inspect the exhaust system for cracks, holes, and distortion. Replace exhaust gaskets and exhaust See Figures 3-15 and 3-16.
GENSET AND BATTERY PACK Alternator (Diesel Models) 4. Disconnect wire connector (7). 5. Remove nut (8), lock washer (9), and wire connector Removal and Installation (10). 6. Loosen screws (12 and 15), push the alternator (11) See Figures 3-17 and 3-18. toward the engine, and disengage the fan belt (18) 1.
GENSET AND BATTERY PACK Radiator (Diesel Models) Removal See Figures 3-19 through 3-22. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Allow the engine to cool completely. 3. Raise the hood. 4. Remove cowlings. (See “Cowlings” on page 7-33.) 5.
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GENSET AND BATTERY PACK 15. Loosen hose clamp (19), and disconnect upper radiator hose (18) from radiator. 16. Remove two screws (22) and lock washers (21), and 13 14 15 remove baffle (20). 13 14 15 17. Remove screw (29) and lock washer (30). 18.
GENSET AND BATTERY PACK Thermostat (Diesel Models) Removal and Installation See Figures 3-23 and 3-24. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Allow the engine to cool completely. 3. Raise the hood. WARNING Never remove the radiator cap when the coolant is hot.
GENSET AND BATTERY PACK Throttle Actuator (Diesel Models) Fuel Tank (Diesel Models) Removal and Installation Removal and Installation See Figure 3-25. See Figures 3-26 through 3-28. 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) Diesel fuel is highly flammable.
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GENSET AND BATTERY PACK TN2702 Figure 3-28 TN2443 13. Loosen hose clamps (6) and remove air intake hose Figure 3-27 (15). 14. Cut cable tie (14). 5. Turn the fuel filter shutoff lever (2) to the horizontal (OFF) position. 15. Tag and disconnect wire connector (12). 16.
GENSET AND BATTERY PACK Fuel Filter (Diesel Models) CAUTION Removal and Installation Dispose of fuel properly. Contact the local See Figure 3-29. 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 •...
GENSET AND BATTERY PACK Fuel Pump (Diesel Models) Fuel Shutoff Solenoid (Diesel Models) Removal and Installation Removal and Installation See Figure 3-30. See Figures 3-31 and 3-32. 1. Park the mower safely. (See “Park Mower Safely” on CAUTION page 1-6.) 2.
GENSET AND BATTERY PACK Genset (Diesel Models) Removal and Installation See Figures 3-33 through 3-44. 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 vehicle.
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GENSET AND BATTERY PACK TN4573 TN2713 Figure 3-38 Figure 3-36 21. Tag and disconnect engine harness-to-main harness 13. Tag and disconnect rectifier connector (11). connectors (19 and 20). 14. Cut cable tie (12). 15. Remove fan relay (13). 16. Remove screw (14) and fan relay base (15). 17.
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GENSET AND BATTERY PACK 33 34 35 33 34 35 TN4574 Figure 3-41 30. Disconnect overflow hose (37) and secure out of the way. 31. Remove two screws (33), lock washers (34), and flat washers (35). 32. Remove air cleaner bracket assembly (32). 33.
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GENSET AND BATTERY PACK 35. Remove screw (47) and lock washer (48). 44. Tag and disconnect hose (58) from radiator overflow bottle (60). Cap fitting and plug hose to prevent 36. Remove screw (43), lock washer (44), and flat leakage and contamination. washer (45), and remove air deflector (46).
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• 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 glycol-base antifreeze and clean, fresh water.
• Install genset fan by reversing the order of removal. ® • Apply Loctite 242 (Blue) to six generator flange • Apply dielectric grease (Jacobsen PN 365422) to mounting screws (43) prior to assembly. wire connector (3). • Tighten six generator flange mounting screws (43) to 13.0 lb-ft (17.6 N·m).
GENSET AND BATTERY PACK Repair—Gasoline Models 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 (Gasoline Models) engine oil and squeeze out excess oil in a clean, absorbent cloth.
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. •...
GENSET AND BATTERY PACK Fuel Tank (Gasoline Models) NOTE Fuel tank capacity is 5.3 gal (20 L). Have suitable Removal and Installation container(s) available that can hold up to 6 gal (23 L) of See Figures 3-51 through 3-53. fuel. ...
GENSET AND BATTERY PACK 18. Lift and disengage strap (12) from fuel tank bracket Installation Notes (14) and secure out of the way. • Install fuel filter by reversing the order of removal. 19. Remove fuel tank (11) from machine. •...
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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.
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GENSET AND BATTERY PACK TN2756 Figure 3-61 TN2754 27. Remove four screws (21) and flat washers (22), and Figure 3-59 remove rear controller cover (23). 23. Tag and disconnect genset connector (17) and genset fan connector (16). 24. Cut cable tie (15). 25.
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• Use new gaskets when installing the exhaust system. • Use new cable ties to secure wire connectors and wire harnesses. • Apply dielectric grease (Jacobsen PN 365422) to any TN2719 connectors removed. Figure 3-63 • Replace the engine oil filter and fill engine with oil.
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GENSET AND BATTERY PACK Disassembly and Assembly See Figure 3-64. TN4557 Screw (7) Engine Coupler Screw (2) Snubber Washer (4) Gasoline Engine Engine Coupler Element Gas Genset Support Isolation Mount (4) Bracket Gas Generator Assembly Screw Gas Throttle Link Screw (8) Screw (8) Nut (4) Flat Washer...
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 (36) prior to Removal and Installation assembly. See Figures 3-65 through 3-69. ®...
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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 could result in death or serious injury.
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GENSET AND BATTERY PACK 25 26 TN2800 Figure 3-69 20. Support battery pack tray (27) with a suitable lifting device. 21. Remove two nuts (25) and screws (26). 22. Repeat step 21 for other side of machine. 23. Remove battery pack tray (27). NOTICE Never place used batteries in the garbage.
GENSET AND BATTERY PACK Buffer Battery Pack and Buffer WARNING Battery Pack Tray Always disconnect the negative terminal first and Removal and Installation positive terminal last. Connect positive terminal first and negative terminal last. Use care when See Figures 3-70 and 3-71. testing live circuits to prevent arcing.
GENSET AND BATTERY PACK Starter Battery WARNING Removal and Installation Always disconnect the negative terminal first and See Figure 3-72. positive terminal last. Connect positive terminal first and negative terminal last. Use care when NOTE testing live circuits to prevent arcing. Arcing Diesel model is shown;...
GENSET AND BATTERY PACK Battery Charger Removal and Installation See Figure 3-73. 1. Park the mower safely. (See “Park Mower Safely” on page 1-6.) 2. Raise the hood. TN4555 Figure 3-73 NOTE Label all wires before disconnecting to ensure correct installation.
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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.
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GENSET AND BATTERY PACK 3-46 4271491-Second Edition...
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