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4179483-GB-Rev B Parts & Maintenance Manual AR-522 ™ ® 68098 – AR-522, Kubota V2403-MT, 4WD, with ROPS WARNING WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain this machine should be trained in its proper use, warned of its dangers and should read the entire manual before attempting to set up, operate, adjust When Performance Matters.
Jacobsen Dealer. Suggested Stocking Guide To keep your equipment fully operational and productive, Jacobsen suggests you maintain a stock of the more commonly used maintenance items. We have included part numbers for additional support materials and training aids. To order any of the following material: 3.
(vertically), not across the face (horizontally). the job. Only use accessories and attachments approved by Jacobsen. 21. To prevent tipping or loss of control, do not start or stop suddenly on slopes. Reduce speed when making sharp Stay alert for holes in the terrain and other hidden turns.
Adjustments and maintenance should always be performed by a qualified technician. If additional information or service is needed, contact your Authorized Jacobsen Dealer who is kept informed of the latest methods to service this equipment and can provide prompt and efficient service.
SPECIFICATIONS SPECIFICATIONS PRODUCT IDENTIFICATION_________________________________________________ 68098 ......AR-522, 5 Gang 4WD with ROPS Serial Number ....An identification plate, like the one ® 11524 WILMAR BLVD, CHARLOTTE, NC 28273 shown, listing the serial number, is A Textron Company 1-800-848-1636 (US) PRODUCT OF U.S.A.
1/4 in. (6 mm) increments ACCESSORIES____________________________________________________________ Refer to the Parts Catalog and contact your Jacobsen Dealer for a complete listing of accessories and attachments. CAUTION Use of other than Jacobsen authorized parts and accessories may cause personal injury or damage to the equipment.
Producentens firmanavn og fulde adresse Bedrijfsnaam en volledig adres van de fabrikant Tootja ärinimi ja täielik aadress Valmistajan toiminimi ja täydellinen osoite Nom commercial et adresse complète du fabricant Firmenname und vollständige Adresse des Herstellers Jacobsen, A Textron Company A gyártó üzleti neve és teljes címe Ragione sociale e indirizzo completo del fabbricante 11524 Wilmar Blvd.
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Místo a datum prohláení Sted og dato for erklæringen Plaats en datum van de verklaring Deklaratsiooni väljastamise koht ja kuupäev Vakuutuksen paikka ja päivämäärä Lieu et date de la déclaration Jacobsen, A Textron Company Ort und Datum der Erklärung A nyilatkozat kelte (hely és id ) Luogo e data della dichiarazione 11524 Wilmar Blvd.
ADJUSTMENTS ADJUSTMENTS GENERAL ________________________________________________________________ adjustment cannot be made, contact an authorized Jacobsen Dealer. WARNING Replace, do not adjust, worn or damaged components. To prevent injury, lower implements to the ground, Do not wear jewelry or loose fitting clothing when disengage all drives, engage parking brake, stop engine making adjustments or repairs.
ADJUSTMENTS BRAKES _________________________________________________________________ Adjust brakes after replacing or servicing brake assembly, or Start mower and check operation of brakes. Park if pedal travel becomes excessive. mower on an incline (approximately. 16.7° slope) and engage parking brake. Brake must prevent mower from When installing new brake pads, burnish pads by rolling.
ADJUSTMENTS FORWARD / REVERSE SPEED ______________________________________________ Forward and reverse speeds are adjusted at the traction Start engine and check reverse travel speed with pedal. Set forward speed before adjusting reverse. engine at full throttle. Reverse speed should measure 3.5 mph (5.6 kph). To adjust forward speed: Stop engine.
ADJUSTMENTS CUTTING HEIGHT _________________________________________________________ Cutting height for decks can be adjusted from 3/4 to 5-1/4 in. (19-133 mm) in 1/4 in. (6 mm) increments. Actual NOTICE cutting height may vary somewhat from the heights given depending on turf conditions and other factors. For best quality of cut, always place the same number of spacers under deck housing on all three spindles.
ADJUSTMENTS TRACTION CONTROL SYSTEM CALIBRATION _________________________________ The Traction Control System (TCS) will need to be NOTICE calibrated when a system component has been replaced or the system is not working correctly. System components Do not rush through steps 5 and 6. System will not be include controller, lift valve, lift cylinders, or hoses.
All torque values included in these charts are approximate and are for reference only. Use of these torque values is at your sole risk. Jacobsen is not responsible for any loss, claim, or damage arising from the use of these charts.
If the injection pump, injectors or the fuel system require engine. service, contact an authorized Jacobsen Dealer. During the break-in period, Jacobsen recommends the NOTICE following: The mower is designed to operate and cut most During the first 50 hours of operation, a new engine efficiently at the preset governor setting.
MAINTENANCE AIR FILTER_______________________________________________________________ Check the service indicator daily. If red band appears in the Reassemble cap making sure it seals completely window (B) replace the element. around the filter housing. Dust evacuator must be facing down. Do not remove the element for inspection or cleaning. Check all hoses and air ducts.
MAINTENANCE BATTERY ________________________________________________________________ Make absolutely certain the ignition switch is OFF position Verify battery polarity before connecting or disconnecting the battery cables. and the key has been removed before servicing the battery. When installing the battery, always assemble the RED, positive (+) battery cable first and the ground, BLACK, CAUTION negative (-) cable last.
MAINTENANCE 4.10 MUFFLER AND EXHAUST___________________________________________________ To protect from carbon monoxide poisoning, inspect the complete exhaust system regularly and always replace a WARNING defective muffler. Exhaust fumes contain carbon monoxide that is toxic and If you notice a change in the color or sound of the exhaust, can be fatal when inhaled.
If the interlock does not function properly and the problem cannot be corrected, contact an authorized Jacobsen Dealer. Keep the wire harness and all individual wires away from moving parts to prevent damage. Make sure the seat switch harness is connected to the main wire harness.
If you have to add coolant more than once a month, or engine block drain and the radiator drain. Empty and clean add more than one quart at a time, have a Jacobsen the recovery bottle. Dealer check the cooling system.
MAINTENANCE 4.18 WHEEL MOUNTING PROCEDURE ____________________________________________ Remove dirt, grease and oil from stud thread. Do not lubricate threads. WARNING Position wheel on hub and inspect to insure full contact between mounting surface of wheel and hub or brake Make sure the mower is parked on a solid and level drum.
One-Step NOTICE cleaner wax. Repair damaged metal surfaces and use Jacobsen Do not wash any portion of the equipment while it is touch-up paint. Wax the equipment for maximum paint hot. Do not use high pressure spray or steam. Use protection.
MAINTENANCE 4.22 STORAGE________________________________________________________________ General Wash the mower thoroughly and lubricate. Repair and After Storage paint damaged or exposed metal. Check and reinstall battery Inspect the mower, tighten all hardware, replace worn Check or service fuel filter and air cleaner. or damaged components. Check the radiator coolant level.
TROUBLESHOOTING TROUBLESHOOTING GENERAL ________________________________________________________________ The troubleshooting chart below lists basic problems that may occur during start-up and operation. For more detailed information regarding the hydraulic and electrical systems contact your area Jacobsen Dealer. Symptoms Possible Causes Action Engine will not start.
TROUBLESHOOTING CONTROLLER LAMPS _____________________________________________________ The controller is a solid state device that monitors and It is important to note that in some cases a lamp or group of controls electrical functions. The controller receives input lamps must be on or off for a condition to be true. For signals from various switches and sensors throughout the example, to start the mower the Mow Switch must be OFF machine and transmits output signals to operate relays,...
TROUBLESHOOTING ELECTRICAL CIRCUITS ____________________________________________________ When troubleshooting the machine using the controller always check that Program Active lamps (2) is on. This indicates that the controller has power and the program is active. NOTICE The controller requires a minimum of six volts to operate. Individual circuits can be tested by operating an input switch, checking for the required input signal and looking for a corresponding output.
**** Inspect electrolyte level. See 4.7 Pack bearings with NLGI Grade 2 (Service Class GB) Manual grease gun with NLGI Grade 2 (Service Class LB). III Engine Oil - See Section 4.3 IV Jacobsen Hydraulic Oil - SAE 10W30 or Greens Care 68 en-28...
Transportation 4. Order by the quantity desired, the part number, and charges must be prepaid. description of the part as given in the parts list. Use of other than Jacobsen authorized parts will void the warranty. en-30...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 4196101 Hood Includes Decals 4196103 • Foam, Front 4196105 • Foam, Right Side 4196106 • Foam, Left Side 4196104 • Foam, Top 557620 • Molding 4196102 • Foam, Hood Mount 4129680 Seal, Right Side Air...
AR-522 Serial No. All 7.1 Frame WARNING This structure's proctective capability may be impaired by structural damage, overturn, or alteration. If any of these conditions occur, the structure must be replaced. 557844 5002952...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 4169363 Frame 366871 • Bushing 4113047 Screw, 5/8-18 x 1-1/2” Hex Head Grade 8 Bolt 4140094 Flat Washer, 5/8 452016 Flat Washer, 5/8 443128 Nut, 5/8-18 Hex 445795 Nut, 5/16-18 Spiralock Flange 441602 Bolt, 5/16-18 x 3/4”...
AR-522 Serial No. All 11.1 Tie Rod Part Number 4132688 Item Part No. Qty. Description Serial Numbers/Notes 4118210 Tie Rod 4121828 Ball Joint, Left Hand Thread 4121986 • Dust Cover 471214 • Straight Grease Fitting, 1/4-28 4121829 Ball Joint, Right Hand Thread 4121986 •...
AR-522 Serial No. All 15.1 Pump Mounting and Engine Exhaust...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 362743 O-Ring Seal 400264 Screw, 3/8-16 x 1-1/4” Hex Head 400286 Screw, 3/8-16 x 2-3/4” Hex Head 400410 Screw, 1/2-13 x 1-3/4” Hex Head 4118252 Pump, Traction See 39.1 and 40.1 4174880...
AR-522 Serial No. All 16.1 Fuel and Hydraulic Tanks Connect to engine fuel injector overflow. Connect to engine fuel pump...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 132647 Valve, Shut Off 3001279 Switch, Float REFERENCE SW-9, See 41.1 3002397 Plug, Magnetic 339899 • O-Ring 3009204 Fuel Tank 3005871 Hydraulic Tank 3005872 Shell, Tank Cover 3006243 Plate, Tank Mounting 3009347...
AR-522 Serial No. All 19.1 Hydraulic Valves and Filter Item Part No. Qty. Description Serial Numbers/Notes 400258 Screw, 3/8-16 x 3/4” Hex Head 409811 Screw, 5/16-18 x 5/8” Thread Cutting 4121554 Hydraulic Filter Assembly 4121552 • Filter Head 555771 • Filter Element 556419 •...
AR-522 Serial No. All 24.1 Wheel Motor Case Drains Item Part No. Qty. Description Serial Numbers/Notes 4137634 Hose, LH Rear Motor to Drain Tube Included in hose bundle 4137625 4137624 Hose, RH Rear Motor to Drain Tube Included in hose bundle 4137623...
AR-522 Serial No. All 25.1 Deck Motor Case Drain Item Part No. Qty. Description Serial Numbers/Notes 4137561 Hose, Front Motor to Front Motor 4137562 Hose, Front Motors to Drain Tube 4129600 Hose, Rear Motors to Drain Tube 4129603 Hose, Rear Motor to Rear Motor...
AR-522 Serial No. All 26.1 Steering Hydraulics To Return Tube From Pump To Lift Valve To Steering Cylinder To Steering Cylinder Item Part No. Qty. Description Serial Numbers/Notes 4129028 Hose, Lift Valve to Steering Valve Lift Valve Port T, Steering Valve Aux...
AR-522 Serial No. All 28.1 Electrical Harness P a r t o f A - Headlight B - Lift A r m Limit Switc h C - Fuel L e v el Sender/ Inst r ument P ane l D - Seat Switch...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 2810424 Cable, Engine Ground Engine Mount to Frame 4122840 Headlight REFERENCE L-1 & L-2, See 41.1 4123183 • Bulb 4122841 Controller REFERENCE U-6, See 41.1 5003282 • Fuse, 20 Amp REFERENCE F-1 & F-2, See 41.1...
AR-522 Serial No. All 31.1 Deck Housing and Caster Wheels...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 3004894 Pin, 7/16 x 1-3/4” Snap Ring 3007764 Washer, Blade 3008388 Adapter, Blade 400410 Screw, 1/2-13 x 1-3/4” Hex Head 450062 Screw, M12-1.75 x 130 mm Hex Head 4117807 Spacer 4163107 Deck Housing...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 452411 Screw, M12-1.75 x 40 mm Hex Head 4161960 Spacer, Deck HOC Bracket 452415 Screw, M12-1.75 x 80 mm Hex Head 4137665 Deck Frame Front Decks 4137674 Deck Frame Rear Decks 4127478 •...
AR-522 Serial No. 68098 - 1651 ~ 1825 33.1 Deck Valve Part Number H Item Part No. Qty. Description Serial Numbers/Notes 4175181 Vented Logic Element Valve 5003579 • Seal Kit 4175183 Relief Valve, 2600 psi 5003578 • Seal Kit 4175184...
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AR-522 Serial No. 68098 - 1826 and Up 33.2 Deck Valve Part Number 4217900 3 / 6 Item Part No. Qty. Description Serial Numbers/Notes 4223600 Solenoid Valve 4223640 • Seal Kit 4223620 Relief Valve, 2600 psi 5003579 • Seal Kit...
AR-522 Serial No. All 34.1 Front Wheel Motor Part Number 4203160 ❍ ◆ ◆ ◆ ❍ ◆ ◆ ◆ Included In Seal Kit 4178564 Included In Seal Kit 4200921 Item Part No. Qty. Description Serial Numbers/Notes 558066 Screw, Torx Front Retainer...
AR-522 Serial No. All 35.1 Rear Wheel Motor Part Number 4118255 Item Part No. Qty. Description Serial Numbers/Notes Seal Exclusion Seal, 3” I.D. Back Up Ring Shaft Seal 4134525 Shaft and Bearing Kit 554780 554779 Hex Nut Shaft Face Seal...
AR-522 Serial No. All 36.1 Lift Valve Part Number 4129069 Item Part No. Qty. Description Serial Numbers/Notes 4134528 Check Valve 5003579 • Seal Kit 4134529 Solenoid Valve 5003579 • Seal Kit 4136067 Solenoid Valve 5003578 • Seal Kit 4134530 Coil REFERENCE K-5, See 41.1...
AR-522 Serial No. All 37.1 4WD Valve Part Number 4129071 Item Part No. Qty. Description Serial Numbers/Notes 4134541 Check Valve 5003579 • Seal Kit 4134535 Pilot Operated Internal Vent Valve 5003579 • Seal Kit > Change from previous revision...
AR-522 Serial No. All 38.1 Steering Valve Part Number 4138567...
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AR-522 Item Part No. Qty. Description Serial Numbers/Notes 443108 Locknut, 5/16-18 Center Port Cover Seal, O-Ring Seal, O-Ring Seal, O-Ring 443828 Nut, 5/8-18 Hex Jam Special Bolt Port Manifold Spring, Port Side Hex Drive A and E Needle Roller 503398...
AR-522 Serial No. All 41.1 Electrical Schematic A B C D E F G H J K L M N Og/Wh Og/Wh LB/Tn Og/Wh Og/Wh SW-13 LB/Tn LB/Tn SW-3 Og/Wh SW-6 Lb/Bk Og/Bu Lb/Bk Bn/Ye Og/Bu Pu/Wh RD B SW-2...
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AR-522 Pk/Bk Og/Wh Og/Bk Og/Wh Gauges Switches Grd-1 Battery A B C D E F G H J K L M N...
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AR-522 Reference Part Item Description Serial Numbers/Notes Illustration Number See 28.1 Battery CB-1 See 28.1 361439 50 Amp Circuit Breaker (Alternator) See 28.1 5003282 20 Amp Fuse (Ignition Circuit) Included in Controller See 28.1 5003282 20 Amp Fuse (Lights) Included in Controller See 28.1...
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AR-522 Reference Part Item Description Serial Numbers/Notes Illustration Number See 4.1 3005121 Temperature Gauge See 4.1 365943 Fuel Gauge See 4.1 4129683 Hour Meter See 4.1 366670 Horn Not Shown Cruise Control Module (Option) See 28.1 4122841 Controller Not Shown...
AR-522 Serial No. Steering Valve:68098 - 1651 ~ 1808 42.1 Hydraulic Schematic Serial No. Deck Valve: 68098 - 1651 ~1825 Valve 3625 psi 2.81 ci Gear 3000 .88 ci .88 ci .5 ci Pump 5.47 ci 3625 psi Drain Supply .031...
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AR-522 Rear Front Wheel Wheel 24.0 ci 30.0 ci Motors Motors .050 24.0 ci 30.0 ci 4WD Valve Lift Valve .040 .040 .040 .040 .040 Left Right Front Front Cylinder Cylinder Center Right Left Front Rear Rear Cylinder Cylinder Cylinder...
AR-522 Serial No. All 44.1 O-Ring Chart O-Ring Face O-Ring Boss O-Ring Face O-Ring Face O-Ring Boss O-Ring Boss Seal Size Dash Size Seal Size Seal Size Dash Size Dash Size Straight Adapter 45° Adapter 90° Adapter W-X-Y W-X-Y W-X-Y...
Fluids and Compounds Hydraulic Fluid* 5001405 Two 2-1/2 Gallon Container of ISO VG68 Oil 5001404 One 5 Gallon Pail of ISO VG68 Oil 2500548 Two 2-1/2 Gallon Container of 10W30 Oil 2500546 One 5 Gallon Pail of 10W30 Oil 503409 Two 2-1/2 Gallon Container of ATF Fluid 503407 One 5 Gallon Pail of ATF Fluid...
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World Class Quality, Performance and Support 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 Genuine Parts provide reliable, high-quality product support.