Ransomes 66132, 66127 TurfCat 400 Series Service Manual

JACOBSEN SERVICE & REPAIR INSTRUCTIONS TURF CAT 14220 Product No. 66132 T436G Product No. 66127 Register Your Manual > Use the registration a ae 00° card at the back of this illustration. Includes Attachments and Product Options JACOBSEN TEXTRON Jacobsen Division of Textron inc. Copyright 1995 Jacobsen Div. of Textron Inc. Litho in U.S.A. 5/94 “All rights reserved, including the right to reproduce 2/96 this material or portions thereof in any form.” Suggested Retail Price A WARNING: If incorrectly used this machine can cause severe injury. Those who $60.00 use and maintain the 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 or service the machine. INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS & TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS O auch IN | SN += а N N GG SECTION 1 INTRODUCTION 1A. General Information .............eoeooorcoogcece,ewcooceooocorecocconcarrccroaracacece.. 1A-1 Contents ..........oeooeoeccacxaarcoacccacocacacacacar ocorrecrcac e rarecconarecen. 1A-1 Index Numbers .......eo_ocoocxccxoccccccaroreocacaanraraconoracarcaracarcrrecarcerero. 1A-1 Replacement Parts ............000000000 00e a 0000000000 000000000000 000000000000 1A-1 Serial Numbers .............22200 0000000 ea eee a eee ea a 000 0 00e 0e eee 000000000000 1A-1 General Cleaning ............ooeeosssrccocorrocrorerocrererececacacenererecnecene. 1A-2 Safety ............eeeocccrccoocecric. racer ee roo orocorcacrrerrccecaracacacrere. 1A-2 Torque Values ............40000000 see eee ane 0 eee 0000 0e 00 eee 0000000 00000000 0 1A-2 Fenders, Hood, and Grill Removal and Installation ............0.0000000000000 0000000 1A-4 INTRODUCTION SECTION 1A. GENERAL INFORMATION CONTENTS This manual contains repair instructions for major tractor components, attachments and options. The Table of Contents at the start of each section lists contents of that section. Sections are identified by tabs in the right hand margin. This manual is to be used in conjunction with the Operator's Manual and Parts Catalog. Normal maintenance, adjustment, and operating procedures are also covered in the user Operator's Manual and are only included where appropriate in this Service and Repair Manual. Engine repair is not covered in this manual. Refer to the appropriate engine manufacturers instructions for engine service and repair. This manual includes all removal, disassembly, inspection, repair, reassembly, installation adjustment, and testing procedures. If you, as user of this machine, do not consider yourself or your repair facilities capable of a given procedure, please consult your distributor. Information, specifications, illustrations, and procedures in this manual are based on information in effect at the time this manual was published. Improvements and product changes due to continual advancements of the product design may cause changes to your product that may not be included in this manual. Each manual is reviewed and updated as required to include changes and product improvements. Read each section completely before proceeding with specific repairs in that section. You will minimize errors by understanding what you will be doing and how the component relates to others in its system. Lists of repair tools and materials for each section of the manual are given at the start of that section. \ The designations L.H. (left hand) and R.H. (right hand used throughout this manual refer to the operator's left or right when seated in the normal operating position. INDEX NUMBERS lilustrations showing removal, disassembly, reassembly and installation may have index numbers to call out the sequence of procedure. Where the sequence of procedure is not important or self-evident (eg. linkages, hoses, clamps, etc.) index numbers are not included. Repair procedures for items not subject to wear (eg. panels, brackets, frames) are not included in this manual except for the general procedures given below. Exercise common sense during disassembly or reassembly; remove only the items required to accomplish necessary repair or service. 1A-1 REPLACEMENT PARTS Use the appropriate Parts Catalog when ordering replacement parts. Follow installation instructions shipped with service parts or kits. When ordering parts, always give the serial number and product number of your machine as well as quantity, part number and description of the parts needed. To eliminate error and speed delivery: 1. Write your NAME and ADDRESS on your order plainly. Explain WHERE and HOW to make shipment. Give PRODUCT NUMBER, NAME, and SERIAL NUMBER thatis stamped on the NAME and SERIAL PLATE of your product. Order by QUANTITY DESIRED, the PART NUMBER and the DESCRIPTION OF PART. Send your order to or visit your nearest AUTHO- RIZED JACOBSEN TURF EQUIPMENT DISTRIBU- TOR. INSPECT ALL SHIPMENTS ON RECEIPT. If any parts are damaged or missing, file a claim with the carrier before accepting. _ Do not return material to your AUTHORIZED JA- COBSEN DISTRIBUTOR without a letter of expla- nation. Make a list of all returned parts, show your name and address, and include it with the shipment. TRANSPORTATION CHARGES MUST BE PRE- PAID. SERIAL NUMBERS See Figure 1A-1 for location of tractor assembly serial number. Figure 1A-1. Serial Number Location INTRODUCTION SECTION 1A. GENERAL INFORMATION GENERAL CLEANING Improper cleaning and lubrication of your machine results in many equipment failures. Before any repairs are undertaken, thoroughly clean the exterior of the component to be removed. Use a clean surface to lay out parts being removed. Keep lubricants clean and cover containers not being used. Plug or cap all hydraulic lines and ports to hydraulic components immediately after disconnecting. SAFETY Safety should always be the rule when working on or with machinery. Always use safe practices and common sense when using hand or power tools. Use the suggested procedures in this manual when working with the tractor. Throughout this manual signal words will be used to highlight special procedures. The signal words and their meaning are as follows: NOTE Any procedure needing special care when performing a procedure. A CAUTION Hazards or unsafe practices which could result in personal injury or product or property damage. A WARNING Hazards or unsafe practices which could result in severe personal injury or death. A DANGER Imminent hazards which will result in severe personal injury or death if precautions are not taken. 1A-2 Decals on the machine denote cautions, warnings, and dangers. These cautions, warnings, and danger decals must be on the machine at all times. If they become worn, torn or painted over, new decals should be installed as shown in Section 14 of this manual. A CAUTION Disconnect leads at rectifier-regulator before elec- tric welding is done on components in common ground with engine. A DANGER This machine is equipped with an interlock system which is intended to protect the operator and others from injury, by preventing the engine from starting, unless the implement lever is in the “Off” position, traction pedal is in the “Neutral” position and the brake set. The system also shuts off the engine if the operator leaves the seat with the lever in “Engaged” position. In the interest of safe operating conditions, this machine must never be operated with the interlock relays or interlock system disconnected or malfunctioning. TORQUE VALUES Torque values are given in the following “Torque Speci- fication Chart”. Special torque values are called out on illustrations and text throughout this manual. INTRODUCTION SECTION 1A. GENERAL INFORMATION TORQUE SPECIFICATIONS FOR STANDARD MACHINE HARDWARE SAE GRADE #5 SCREWS Size Torque Values Size Torque Values 8-32 27-33 in-Ibs. (3-4 N.m) %-13 67-83 ft-Ibs. (90-113 N.m) 8-36 28-34 in-Ibs. (3-4 N.m) 1-20 81-99 ft-Ibs. (110-134 N.m) 10-24 39-47 in-Ibs. (4-5 N.m) %:-12 99-121 ft-Ibs. (134-164 N.m) 10.32 44-54 in-Ibs. (5-6 N.m) 96-18 108-132 ft-lbs. (146-179 N.m) 1,-20 7-9 ft-Ibs. (9-12 N.m) %-11 135-165 ft-Ibs. (183-223 N.m) 1-28 9-11 ft-Ibs. (12-15 N.m) 5-18 162-198 ft-Ibs. (220-268 N.m) %s-18 15-18 ft-Ibs. (20-24 N.m) %-10 234-286 ft-Ibs. (317-388 N.m) 5,6—24 17-21 ft-lbs. (23-28 N.m) 3,-16 270-330 ft-lbs. (366-447 N.m) 3-16 27-33 ft-Ibs. (37-45 N.m) 7-9 360-440 ft-Ibs. (488-597 N.m) 3-24 31-39 ft-Ibs. (42-53 N.m) 76-14 396-484 ft-Ibs. (537-656 N.m) 7%s-14 45-55 ft-Ibs. (61-75 N.m) 1-8 522-638 ft-Ibs. (708-865 N.m) 7e-20 49-61 ft-Ibs. (66-83 N.m) 1-12 576-704 ft-Ibs. (780-954 N.m) NOTE: These torque values are to be used for all hardware excluding: locknuts, self-tapping screws, thread forming screws, sheet metal screws and socket head setscrews. TORQUE SPECIFICATIONS — METRIC Metric Grade Diameter — 5.0 8.8 10.9 12.9 Coarse Thread | N.m | ft-lbs. | N.m ft-Ibs. | N.m | ft-lbs. | N.m | ft-lbs. M6 4.6 3.3 10.5 7.7 15 11 18 13 M7 7.8 5.6 17.5 | 12.9 26 18.4 29 21.3 M8 11 8.1 26 19 36 26 43 31 M10 22 16 51 37 72 53 87 64 M12 39 28 89 66 125 92 150 110 M14 62 45 141 103 198 146 240 177 M16 95 | 70 215 158 305 224 365 269 M18 130 95 295 217 420 309 500 368 M20 184 135 470 309 590 435 710 623 1A-3 INTRODUCTION SECTION 1A. GENERAL INFORMATION FENDERS, HOOD, AND GRILL REMOVAL AND INSTALLATION Most service and repair of the Turf Cat can be accom- plished by opening the hood and/or seat pan or removing the floor pan or fenders as shown in Figure 1A-2. Mark all attaching hardware to simplify installation. Figure 1A-2. Hood, Seat Pan, Floor Pan and Fenders 1A-4 2A. 2B. 2C. 2D. SECTION 2 CONTROLS Repair and Service Tools and Materials ................ eerie 2A-1 Failure Analysis ..........2000000000 00e eee 00e eee eee ee 00 eee ee eee eee eee eee eee 2B-1 ce DE 2B-1 Control Adjustments .............00000000 0000 eee eee ce 0e eee eee ee eee ee eee e ee eee 2C-1 = DE 2C-1 Throttie (Gas) .............22000000 000 00e ea na eee ee 0e ae eee eee ee 00e eee eee 00000 2C-1 Idle Adjustment (Gas)..................... LL LL ALL aa a ae a 0 0 a 0 aaa 2С-2 Full Open Throttle Adjustment (Gas) .............0.0.0.000000 00H er HEHE nennen 2C-3 Choke Adjustment (Gas) .............00000000 eee eee eee ee eee eee nee tete teens 2C-4 Governor Adjustment (Diesel) ..............0.000000000 00H EEE nee tea eee eee 2C-5 Throttle (Diesel) .............000000000 0000 ee ee eee ec a eee a eee eee eee ce ee eee eee 2C-5 Traction Pedal ............0420200000 0000 a 0000 see ee see ae 0 00 0 0e eee 0e 0000000000 2C-6 Neutral Adjustment ............00400000 00000 eee eee 0000 eee ee eee ce eee tee eee 2C-6 Speed Limit Adjustment ..............000000eee eee eee eee 2C-6 Reverse ...........120200100 00000020 ea sa 0 ea ee ee 0e 0 a sea 0 ee 00 0e ee 0100000000 2C-6 Forward ........122000 0000000 aa 0e a ae eee eee ee 0 0 ae ee ea 00000 0e See 00000000 2С-7 Traction Assist Pedal ..............0240000000 00000000 00e 0e 0 0 00000000 eee 0 00000000 2C-7 Lift and Lower Pedal ...........020204000000 00e 0e ea ea 00 00 00e ee 00 ce 000 ee 10 0000000 2C-8 Parking Brake Pedal ...........0000000000 00e eee een eee eee eee tete eee eee 2C-8 Seat Switch Adjustment ............00000000 0000 ee eee eee eee ee eee eee eee tete eee 2C-9 Switch Ne 2C-9 = AA tes 2C-9 PTO Lever .........eeeeoeccororocrcarocrorecano rro recrcacarerecacermececene. 20-10 Motor Valve ..........m__eeoseseceroorcorecerererrocerarerarecacarermeene. 20-10 Interlock ...........eoeoosoccccoreccrrooreororrecracacreraracacecacecarerererc 20-11 Gauges and Instruments .............0000000 eee eee eee eee eee eee eee ea eee eee 2D-1 Repair EE EERE EERE RR REEL 2D-1 CONTROLS SECTION 2A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Refer to Section 11. 2A-1 CONTROLS SECTION 2B. FAILURE ANALYSIS GENERAL The following table gives common problems, probable causes, and suggested remedies with page references to detailed description of remedial procedures. PROBLEM PROBABLE CAUSE REMEDY 1. Engine does not turn over. | a. Transaxle not in neutral. a. Put shift lever in neutral. b. Electrical fault. b. See Electrical Failure Analysis (Section 10B). c. PTO interlock switch not c. Adjust (Section 2C). adjusted or faulty. Check (Section 10). d. Dead battery. d. Charge battery or replace as necessary. 2. Engine speed does not a. Throttle control is not properly a. Adjust (Section 2C). increase when throttle adjusted. control is moved. b. Throttle control is broken. b. Repair or replace (Section 2C). c. Governor faulty. c. Repair (Section 3D). d. Carburetor faulty (Gas). d. Repair (Section 3D). 3. The unit “creeps” in a. Treadle pedal linkage out of a. Adjust traction (Section 2C). either direction when the adjustment. treadle pedal is not depressed. 4. Parking brake fails. a. Brake not adjusted. a. Adjust brake (Section 2C). b. Worn brake shoes. b. Replace lining (Section 5B). c. Damaged or broken linkage. c. Repair as necessary. 5. Implement does not lift a. Lift/lower pedal out of adjustment. | a. Adjust pedal (Section 2C). ear ativated. b. Control valve leaking or defec- b. Test valve (Section 81). tive. Repair valve (Section 8H). c. Valve relief too low. c. Adjust (Section 8F). d. System relief too low. d. Adjust (Section 8F). e. Faulty lift cylinder. e. Test cylinder (Section 81). f. Faulty charge pump. f. Test pump (Section 8M). . Slow traction speed. a. Engine rpm not set. a. Adjust (Section 2C). b. Treadle pedal not adjusted. b. Adjust (Section 2C). c. Parking brake not releasing. c. Adjust (Section 2C). d. Faulty hydro. d. Test hydro pump (Section 8L). . Tractor pulls to a. Traction assist not adjusted. a. Adjust (Section 2C). one side. b. Improper “toe-in” adjustment. b. Adjust “toe-in” (Section 6D). 2B-1 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GENERAL The repair of controls is limited to adjustment of linkages, straightening of bent rods or replacement of defective parts and hardware. THROTTLE — GAS (See Figure 2C-1) Located to the right of the operators seat, the throttle control is used to regulate engine speed. Replace a defective throttle as shown in Figure 2C-1. 2C STEP 1 Install lever assembly with lever in ~ the fully SLOW position. D) Attaching Hardware STEP 2 + Loosen the throttle cable clamp. ~~ Attaching Push the governor throttle lever rear- Hardware ward and connect control wire. / STEP 3 Position cable in clamp so throttle is held closed. Tighten clamp. STEP 4 Push throttle to full open position and check that governor throttle lever moves forward until high speed screw contacts its stop. STEPS Start engine and check idle and high speed settings. Figure 2C-1. Throttle Control Repair 2C-1 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS IDLE ADJUSTMENT — GAS (See Figure 2C-2) STEP 1 Put throttle in full idie position. > _ ~ La Pe - A7 Idle > и” Position _- ий 7 — ñ —— | / en | A | 7 и” | / i 7 LO | | / т / 7 / - / / / STEP 3 Adjust idle screw so engine rpm is STEP 2 approximately 1150 rpm. Start engine and hold throttle cam NOTE against idle screw. Do not exceed 1200 rpm for idle. 4 Decreases X Increases Figure 2C-2. Idle Adjustment 2C-2 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS FULL OPEN THROTTLE ADJUSTMENT — GAS (See Figure 2C-3) STEP 1 „” Startengine and allow it to warm up. Push throttle full open. Pre ~~ > Pa 207 7 ~ ~ So Full Open a Position > sv Pal AS u „” ~ и” „X - | pacs | и - | VA / J 7 | VA L | | / / 17 / > AT / / / / / / _/ ——— STEP 2 Adjust high idle screw to obtain 3150-3200 engine rpm. NOTE If engine surges (hunts) more than4 or 5 times, refer to Governor Adjust- ment in this section. bh ( | mA - Figure 2C-3. Full Open Throttle Adjustment 2C-3 CONTROLS CHOKE ADJUSTMENT — GAS SECTION 2C. CONTROL ADJUSTMENTS (See Figure 2C-4) Ra LA Pl 7 и ~ Я | ~~ ий 7 _ > 17 STEP 1 „” - ! ps ! Po Pull choke knob out. STEP 2 SN Remove the air intake hose from the > 7 top of carburetor. >< и” 7 7 „X STEP 3 277 , pa | 7 Note the position of the choke plate. - / It should be completely closed. | и” 4 STEP 4 | Loosen choke cable clamp and move | cable until choke plate is closed. / / / / © / | STEP 5 Push choke knob down. Throttle В” plate should now be fully open. If 7 necessary, readjust. == (OH | Fully O > y — Closed NI o feb O Fully Open — — © A O do O — анннннсниии J 2C-4 Figure 2C-4. Choke Adjustment CONTROLS SECTION 2C. CONTROL ADJUSTMENTS GOVERNOR ADJUSTMENT — GAS (See Figure 2C-5) NOTE If the anti-surge screw is turned in too far the governor response will be less effective and the throttle control arm travel will be reduced effect- ing the maximum engine rpm adjustment. 1. Remove carburetor linkage from throttle control arm. 2. Adjust the surge screw to obtain a 1-5/8 throttle control arm travel. 3. Reconnect carburetor linkage. 4. Start engine and allow to warm up to operating temperature. Adjust idle speed to a maximum 1200 rpm by turning the idle adjustment screw on the carburetor. 5. Adjust maximum enginerpmto 3150-3200 by adjusting the high speed adjustment screw on governor. 6. Advance the throttle quickly a few times. If engine surges (hunts) more than 4 or 5 times, turn surge screw in 1/8 turn and recheck. Repeat this step until surge (hunt) is at 4 to 5 times. 1-5/8" Travel “= >= | A 7 Tg —_ | \ a. ~ Èy 220 ^^ Arm e a Anti-Surge 2 Screw Carburetor | a — {1 Linkage > Figure 2C-5. Governor Adjustment THROTTLE — DIESEL (See Figure 2C-6) Located to the right of the operators seat, the throttle control is used to regulate engine speed. Replace a defective throttle as shown in Figure 2C-6. Idle Position STEP 3 Position cable in clamp so throttle is held closed. Tighten clamp. Install lever assembly with lever in the fully SLOW position. STEP 1 STEP 2 Close throttle lever fully at engine и” and connect control wire. Figure 2C-6. Throttle Control Repair 2C-5 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS TRACTION PEDAL NEUTRAL ADJUSTMENT (See Figure 2C-7) 1. 2. 3. Raise front tractor wheels off ground. Start engine, advance throttle to full open. Adjust nut clockwise (CW) to eliminate forward creep. Turn counterclockwise (CCW) to eliminate reverse creep. Figure 2C-7. Traction Pedal Neutral Adjustment SPEED LIMIT ADJUSTMENT Reverse (See Figure 2C-8) 1. 2. Disconnect traction control rod ball joint from pivot arm. Push the pivot arm and control rod forward as far as they will go. Adjust the rod ball joint until it lines up with hole in control rod. Then turn ball joint one complete turn CCW. . Connect ball joint to pivot arm. Proceed with the forward adjustment. Traction Control 2C-6 Figure 2C-8. Treadle Pedal Reverse Adjustment CONTROLS SECTION 2C. CONTROL ADJUSTMENTS Forward (See Figure 2C-9) 1. Loosen the stop bolt jam nuts and screw stop bolt down so it will not interfere with treadle pedal maximum travel. 2 Push treadle pedal down as far as it will go. 3. Adjust the stop bolt until it contacts the treadle pedal, turn one more complete turn CCW lengthen- ing it. Lock in position with the jam nuts. Stop Jam Treadle Bolt Nuts Pedal Figure 2C-9. Treadle Pedal Forward Adjustment 2C-7 TRACTION ASSIST PEDAL (See Figure 2C-10) Adjust brake rod yoke to allow 3/4 to 1" free travel of the pedal. 3/4-1" (19-25 mm) У 9 © NS N S 92 Figure 2C-10. Traction Assist Pedal Adjustment CONTROLS SECTION 2C. CONTROL ADJUSTMENTS LIFT AND LOWER PEDAL PARKING BRAKE PEDAL (See Figure 2C-11) (See Figure 2C-12) Adjust yoke to obtain full travel of the valve spool in 1. Adjust locking nuts to allow a 3/4 to 1" free travel of the pedal with brake in the released position. 2. As brake pads wear, shorten brake rod by adjusting locking nuts. both directions. é—___ Figure 2C-11. Lift and Lower Pedal Adjustment Figure 2C-12. Parking Brake Pedal Adjustment 2C-8 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS | SEAT SWITCH ADJUSTMENT SWITCH (See Figure 2C-13) 1. Assemble two flat washers (1) to switch. The seat switch should stop the engine if the operator 2. Position switch (plunger down) in hole of bracket. leaves the seat with the transaxle shift lever or PTO 3. Install internal tooth lockwasher (2) and jam nut (3). lever engaged. The switch should make contact with Tighten nut (3). the fender and close switch contacts when pressure is applied to seat, seat pan in its lowest position. With no 4. Install large nut (4) and tighten. pressure on seat the seat return spring slightly raises BUMPER the seat pan opening switch contacts. A CAUTION Proper assembly of the seat switch and bumpers 1. Install nut (3) onto bumper stud (4). 2. Position bumper (4) in hole of bracket and install lockwasher (2) and remaining nut (1) finger tight. 3. Adjust bumper (4) to achieve 1/4" (6.35 mm) clearance between the bottom of the bumper (4) and the top of the fender when seat is in the down position is necessary in order for the seat switch to func- with no pressure applied. tion properly. Bumper Switch | = | | .— 3 Seat Pa Qe" y n В a . — S— — | 1/4" (6.35 mm) ; $ | 1 Rubber Stop _— Figure 2C-13. Seat Switch Adjustment 2C-9 e CONTROLS SECTION 2C. CONTROL ADJUSTMENTS PTO LEVER (See Figure 2C-14) MOTOR VALVE 1. Disconnect interlock yoke from the valve arm assembly. 2. Disconnect PTO lever yoke from valve arm assembly. 3. Pull motor valve spool rearward (off position). 4. Adjust PTO lever yoke so lever pushes neutral start switch plunger, reconnected to valve arm assembly. 5. Adjust and connect interlock yoke to valve arm assembly. Check interlock adjustment. PTO Lever Neutral \ Start Switch >< f A DD. Valve Arm #7 - ‚ NN > LGA e RN Assembly Yoke Хо 0° > > > NO ~ No >< NI > > > > ~ | > Sa NS ~ Tx 4> SS ~ Na > E Le ~ Ny So > Li Na ~ NS Vi > i RN \ Ia ~ Г >> ~ Ia > - NA > > > > >. | > nu \ SS ~ ~ Sa "= = > > > ~~. © = N gz > > ~ RN 3 ТЕ =- < > 7 23833 Sim = DOS = > ~ > =? q << > ~ ~ ~ ` ~ ~ interlock Rod Figure 2C-14. PTO Lever and Motor Valve Adjustment 2C-10 CONTROLS SECTION 2C. CONTROL ADJUSTMENTS | INTERLOCK (See Figure 2C-15) 3. Slowly allow seat pan to raise. PTO lever should be 1. Make sure PTO lever and motor valve are adjusted disengaged within 1/4" rise of seat pan. properly. 4. If PTO lever disengages too soon, lengthen inter- > push down on seat pan compressing seat pan lock rod. If PTO disengages after the 1/4" seat pan return spring. Engage PTO lever. rise, shorten interlock rod. e PTO Seat Pan Adjustment Yoke Interlock Rod Figure 2C-15. PTO Interlock Adjustment 2C-11 CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS REPAIR NOTE Refer to Section 10 for test/repair of switches. Repair of instruments is limited to replacement of defective components. See Figures 2D-1 and 2D-2 and replace defective component as follows: 1. Disconnect battery ground (black) cable. . Label wires for proper identification and disconnect wiring. . Remove attaching hardware and replace defective instrument. . Connect wiring. . Connect battery ground cable. Bracket иг 7 A Attaching H ardware Ц Water Temperature Gauge Voltmeter Oi Warning Light Hourmeter Figure 2D-1. Gauges and Instruments Removal and Replacement (Gas) 2D-1 CONTROLS SECTION 2D. GAUGES AND INSTRUMENTS Glow Plug Indicator Bracket \ N $ N Water \ Temperature „© Gauge Voltmeter Attaching Hardware Hourmeter Figure 2D-2. Gauges and Instruments Removal and Replacement (Diesel) 2D-2 3A. . Failure Analysis ..........0000000000 eee eee 000000 00m 00e 0 ee 0 000000000000 00000000 3C. 3D. 3E SECTION 3 ENGINE Repair and Service Tools and Materials ...............000000000 0 caen eee ee eee 00000 General Instructions ..............20000000000 0000000000 0 000000 00000000 0000000 Contents ...............10101000000 0000000 0e 00e 0000 ae 000000000000 0000000 00000000 Cleaning and Lubrication ...............000000000 0000 nee 0000000 000000000000 Gasoline Engine (Product No. 66127) .............00000000 00e ce nec na cc e ee 0000000 General ............122000000 0000000 ae een 0 0e 0 0e sa eue 0 a 000000000000 0000000000 Air Cleaner ...............2220 0000000 a 000 00 0 sa aa sa 00e ee 000000000000 0000000000 2910) U N Inspection ........... oii, LA La a eee a ea a ee 0 ee 0 a ee se aa 0e 000 0000000000 Installation .........111222000000 000 aa aa 000000 0e 000 0000000000 000000 0000000000 0 Yo ua 00000 0 00e 000 000000000000 0000000000 00000 Changing Coolant ...............0000000e eee eee 0e eee eee ee ea 0000 000 0e 00005 Cleaning Radiator Core ............222000000 000000 eee ee eee 00000 00000000 000000 Removal ............1220202000 000000 0 0 a 0e ae 000 a aa 0000 0 0000000000 000 0000000008 Installation ........10202022100000 000 eee 0 ea aa 0000 sa 000000 000 00000 000000000000 00 0 Exhaust System Inspection .............04000000 0000 ee ee eee 000000 eee 00 ee ce eee 000 Muffler Removal and Installation .................2.0.0000000 000000000000 0000000000 Fuel Filter Service ...............0022000000 000 00e 00000 00000000 0000000 00000000 0 Engine Removal EE RE EE REEEEEEREEEREERE Engine Installation... ee Governor Repair ..........e....eec000cecociorrrrrretacaceceare rr rtececarerenee Disassembly ..........ñoceeocrescscocarereocrrrocarecacacorer ce arecreaceree Inspection .........000000000 00e eee ee 000 000000 m0 eee 000000000000 000000000000 Reassembly ...........00000 000000 ana a eee 0000000 see ee 0000000000 A0 0000000000 ‘Adjustment .............00000000 000 eee ss ee 0000 nee eee eee 000000000000 00000005 Diesel Engine (Product No. 66132) ............-00000000 0000000000 eee ee 00e 000000 (ET at 1 € 1 RS A AAA A NN Air Cleaner ................222000 0000 a 0000 a 00000 00e 0000 0 0 0000000000 000000000000 27-14 110,171 BA AAA ES Inspection .........000000000 000000 eee 000 0000000000 ae sees кб б оо Installation ..........420202020000 00000 ea a na 00 00 se 0000000 0 000000 00000000 0000000 Radiator .............202020000 00000 a eee ee ea 0 000 see 000 0000000000 0000000 0000000 Changing Coolant .:...........0000000000 00000 ae ee 0e es 0000000000 e ee A0 000 Cleaning Radiator Core ..............eeeeeeocsococeccacerrecececererere оо оо Removal ........__essasee ea 000000 0000000000 000000000000 0001000000 Installation ............22020000000 0000 een 000000000000 0 0 000000 00000 0000000000 0 Muffler Removal and Installation ..................00000000 000000000000 0000000000 Exhaust System Inspection ........0..000000000000000 000000 EEE EHEN Fuel Filter Service ................000000000 0000 cam 00000 00000000 000 000 0000000000 Purging The Fuel System .............000000 00000000 en 0000 0000000 0000000 0000000 Engine Removal ...........000000000 0000000000 e eee nee 000 0000000000 000000000005 Engine Installation ..............000000000 0000000000 eee 00000000 00000000 00000000 ENGINE SECTION 3A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Donaldson D1400 cleaning solution. Detergent and water. Anti-rust Never-Seize. Lubricants: Grease gun grease (eg. Sunray DX671 or Gulf Supreme No. 0). Hydraulic Oil Options: Jacobsen Part No. 502692, 5 gal. (19 liter). Jacobsen Part No. 502695, 2.5 gal. (9.5 liter). Sunoco H.P. Engine Oil SAE 20W20. Mobil Delvac (Special) SAE 20W20. Diesel: Engine Oil Options — API Classification CC/CD grades: 77° and above SAE 30, 32°-77°F SAE 20 or SAE 20W40, below 32° F SAE 10, 20 or SAE 10-30. Gas: Engine Oil Options — API Classification SE, SF, SG grades: 77° and above SAE 30, 32°-77°F SAE 20 or SAE 20W40, below 32°F SAE 10, 20 or SAE 10-30. Other service items: Compressed Air Source, Engine hoist. 3A-1 ENGINE SECTION 3B. FAILURE ANALYSIS PROBLEM | PROBABLE CAUSE | REMEDY CONTROLS . Engine will not start. a. Electrical system malfunctioning. a. See Section 10. b. Fuel strainer or filter dirty. b. Clean strainer and/or replace filter (Section 3D). c. Defective engine. c. See engine manufacturers service manual. - d. Fuel tank empty. d. Check fuel level. e. Air in fuel line. e. Purge air (Section 3D). f. Fuel petcock closed. f. Open petcock. . Engine not running a. Dirty fuel filter or strainer. a. Clean strainer and/or replace smoothly. filter (Section 3D). b. Defective engine component. b. See engine manufacturers service manual. . Full load surge. a. Throttle rod adjustment. a. Adjust (Section 3D). b. Carburetor too rich or too lean b. Adjust. See engine manufac- fuel/air mixture (Gas). turer's manual. c. Loose intake manifold. c. Check manifold for loose hardware, tighten. d. Loose or worn governor or d. Inspect (Section 3D). carburetor linkage. . No load surge. a. Governor surge not adjusted. a. Adjust “surge screw” (Section 3D). b. Loose or worn governor or b. Inspect (Section 3D). carburetor linkage. . Part load surge. a. Throttle rod adjustment. a. Adjust (Section 3D). d. Loose or worn governor or d. Inspect (Section 3D). carburetor linkage. c. Loose or worn governor c. Inspect/repair (See Section 3D). flyweight. . Governor unresponsive a. Throttle linkage adjustment. a. Adjust (Section 8C). to changing loads. b. Surge screw adjusting too b. Adjust surge screw (Section 3D). far in. c. Loose or worn governor c. Inspect/repair (Section 3D). flyweight. d. Damaged or worn flyweight а. Inspect/repair (Section 3D). carrier. . Engine dies down a. Throttle rod adjustment. a. Adjust (Section 3D). under load. b. Engine ignition faulty. b. Inspect. See engine manufacturers manual. c. Binding in governor and/or c. Inspect/repair. (Section 2C carburetor linkage. and/or 3D.) d. Load heavier than engine can d. Increase engine throttle full handle. open position. Adjust maximum engine RPM (Section 2). Reduce load. e. Partially blocked fuel line or e. Check fuel line and filter for filter. blockage. 3B-1 ENGINES SECTION 3B. FAILURE ANALYSIS PROBLEM | PROBABLE CAUSE | REMEDY CONTROLS (Continued) 8. Engine overspeeds a. Governor belt slipping. a. Adjust belt (Section 3D). when load is removed. b. Surge screw out of adjustment. b. Adjust surge screw (Section 3D). c. Throttle linkage adjustment. c. Adjust (Section 8C). 9. Governor does not a. Carburetor throttle shaft sticking. | a. Inspect/adjust (Section 2C). ho load or no load b. Throttle linkage adjustment. b. Ajdust (Section 8C). C. Loose or worn governor с. Inspect/repair (Section 3D). flyweight. 10. Excessive governor a. Governor pulley loose. a. Repair (Section 3D). vibration. b. Governor shaft bent. c. Loose or worn governor flyweight. b. Repair (Section 3D). C. Inspect/repair (Section 3C). 11. Noisy governor operation. Governor bearing worn. Loose or worn governor flyweight. Governor thrust sleeve and/or bearing is worn. . Governor shaft bent. Replace (Section 3D). Inspect/repair (Section 3D). Replace (Section 3D). . Repair (Section 3D). 3B-2 ENGINE SECTION 3C. GENERAL INSTRUCTIONS CONTENTS NOTE The engine used in the Turf Cat Gas is a Teledyne Tests for alternators, starters, and regulator are Continental R-11, 4 cylinder in-line, liquid cooled included in Section 10 of this manual. If these engine. | components are found faulty, refer to the engine The engine used in the Turf Cat Diesel is a Kubota 950, manufacturers manual for repair instructions. 3 cylinder in-line, liquid cooled engine. CLEANING AND LUBRICATION This section covers repairs to the engine associated components (eg. exhaust system, air cleaners, radia- tors). Removal and installation of the engines is also covered but engine repair is not included in this manual. Refer to the engine manufacturer's instructions for engine service and repair. The engine manual is available from your Jacobsen Distributor. Thoroughly clean each component after removal from the machine. Follow instructions for lubrication of engine in Section 11. 3 e 3C-1 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) GENERAL A separate engine operators manual, prepared by the engine manufacturer is supplied with your tractor. Study the manual carefully until you are familiar with the maintenance, operation and adjustment of your equipment. Proper attention to engine manufacturers directions will assure maximum service life of engine and high operating efficiency. AIR CLEANER (See Figure 3D-1) 1. Loosen the retaining clamp (1) and slide the cover (2) off of the air cleaner assembly. Remove the baffle (3) and empty dust from the cover. Wipe clean with a clean damp cloth. A CAUTIÓN Wear eye protection when using compressed air. NOTE Air cleaner equipped with filter minders should not be serviced until minder indicates service is necessary. . Remove the wing nut and gasket (4), and slide the element (5) out of assembly. Remove dust by shak- ing the element or blowing compressed air into and around the element. Air pressure must be less than 40 psi (274 kPa). NOTE Check gasket (4) and element (5) for cracks and damage. Replace if necessary. NOTE If new element is to be installed, use a new gasket (4). - Install the element (5). Install the wing nut and gasket (4). Figure 3D-1. Air Cleaner Service 3D-1 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) 4. Install the baffle (3) in cover (2) making sure opening is up. 5. Secure cover (2) with retaining clamp (1). Removal 1. Loosen the clamp (6) which holds hose (7) to the air cleaner. Disconnect hose. 2. Remove nut (8), and capscrew (9) and clamps (10). Inspection 1. Inspect the hose (7) for cracks and wear, replace if damaged. 2. Inspectthe baffle (3), element (5), and air inlet cover (13) for cleanliness. Installation 1. Install the element (5), and baffle (3). 2. Install the air inlet cover (13) on the unit. . Install the air cleaner unit in the clamp (10) and secure with capscrew (8), and nut (9). . Secure the air cleaner hose (7) with clamps (6). . Check that all connections are tight. _A WARNING DO NOT USE STARTING ASSIST FLUIDS. Use of starting assist fluids in the air intake system may be potentially explosive or cause a “RUN- AWAY” engine condition. This could result in serious engine damage and/or personal injury. RADIATOR (See Figure 3D-2) A CAUTION Never open radiator cap (2) while engine is running or soon after it stops. Hot water sometimes shoots out if the radiator cap is opened while the engine is hot. Changing Coolant 1. Open drain cock (1) and radiator cap (2) and drain coolant into a clean container. 2. Flush the inside of the radiator (3) with clean water. NOTE Always mix anti-freeze with the cooling water. Mixture ratios differ with the anti-freeze manufacturer and temperature. Follow the instructions of each manufacturer. However, do not exceed a 50/50 mixture of antifreeze to water. 3D-2 Figure 3D-2. Radiator Service Cleaning Radiator Core When dust enters between fins and tubes, wash out with tap water under pressure. NOTE Never use a screwdriver or other pointed tool for cleaning. It may damage the special tubes or cause the radiator to lose its function. Removal (See Figure 3D-2) 1. Remove wing nuts holding oil cooler in place and tilt oil cooler out of the way. Remove hardware securing fan shroud to radiator and move shroud back over fan. Open drain cock (1), remove radiator cap (2) and drain the coolant. ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) — Disconnect the inlet and outlet hoses by loosening hose clamps (9). Disconnect overflow tube at radiator. Slide overflow bottle up off bracket. Remove attaching hardware (4 and 5). Inspect weatherstrip (6) and grommets (7 and 8). Replace if damaged. Installation (See Figure 3D-2) 1. 2. Install grommets (7 and 8) and weatherstrip (6) if removed. Place the radiator (3) on frame and secure with attaching hardware (4 and 5). Connect overflow coolant tube. Connect the inlet and outlet hoses; tighten hose clamps. Close drain cock (1) and fill the radiator with clean distilled water/anti-freeze mixture. NOTE Always mix anti-freeze with the cooling water. Mixture ratios differ with the anti-freeze manufacturer and temperature. Follow the instructions of each manufacturer. However, do not exceed a 50/50 mixture of antifreeze to water. 6. Secure fan shroud to radiator with attaching hardware. 7. Secure oil cooler in place with wing nuts and washers. EXHAUST SYSTEM INSPECTION 1. Clean all sections of the exhaust system of dirt, dust or other foreign material. 2. Inspect exhaust system for cracks, holes, distortion or deformation. MUFFLER REMOVAL AND INSTALLATION Remove and install the muffler on the engine as shown on Figure 3D-3. A CAUTION Do not attempt to service muffler while engine is hot from operation. Gasket 58 27-33 ft-Ibs. (37-45 N.m) Figure 3D-3. Muffler Removal and Installation 3D-3 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) FUEL FILTER SERVICE (See Figure 3D-4) The fuel filter is located on the left rear between engine and frame. Moisture and other foreign matter accumulate in the fuel filter. Periodically replace the filter element. 1. Close the fuel outlet at tank. 2. Remove and replace filter. Fuel Outlet ~~ Fuel Shutoff Figure 3D-4. Fuel Filter Service ENGINE REMOVAL (See Figures 3D-4 and 3D-6) 10. 11. 1. Disconnectand tag all electrical connections atthe engine. Shut off fuel at the tank. Disconnect air cleaner hose at intake manifold. Disconnect the throttle cable and choke cable. Remove the radiator as described in preceding paragraphs (see Figure 3D-2). NOTE When removing the engine, it. is advisable to remove all components (radiator brackets and supports, engine mount bolts, etc.) and lift the engine out of the machine with a hoist. 6. Remove the bolts (1) and lockwashers (2) that mount the hydraulic pump to the pump mounting plate (3). 7. Carefully pull the assembled hydraulic pump free of the pump mounting plate (3). Support the pump to relieve strain on the hydraulic hoses which are attached to the pump. 8. Remove the hydrostatic pump drive shaft as described in Section 4. 9. Attach a chain hoist to the engine (the engine weighs close to 200 Ibs.). Remove all bolts (4) and lockwashers (5) that hold the engine to the machine frame. Carefully lift the engine out of the machine. oO К © № Figure 3D-5. Throttle Cable Connections 3D-4 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) ENGINE INSTALLATION (See Figure 3D-6) 1. Move the engine into its approximate mounting position using a chain hoist. Align and loosely attach all bolts (4) and lockwashers (5) that secure the engine to the frame. Tighten mounting bolts (4) after all have been installed. _ Pack the hydraulic pump drive shaft spline with recommended grease (see “Recommended Lubri- cants,” Section 11). Install hydraulic pump to mounting plate (3). Secure with bolts (1) and washers (2). Install the radiator and muffler as described in preceding paragraphs of this section. _ Install the hydrostatic pump drive shaft as described in Section 4. _ Connect and adjust the throttle control (see Section 2 of this manual and Figure 3D-5). “Connect all electrical connections to the engine (see Section 10 for location and testing). _ Connect air cleaner hose at intake manifold. . Open the fuel supply at the tank. Drive Shaft Coupler 27-33 ft-Ibs. (37-45 N.m) NOTE Do not reuse drive coupling setscrews. Always replace these screws 5 with new ones. Apply Loctite to set- i screws at time of installation. Figure 3D-6. Engine Removal and Installation ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) GOVERNOR REPAIR The governor is a flyweight variable speed type. Ser- vice of the governor is handled in two ways, minor and major. A minor repair is replacement of oil seals and cover gasket. Major repair is replacement of flyweight and shaft assembly, oil seals and cover gasket. Disassembly 1. Remove governor from engine. Clean all grease and dirt from governor. Drain governor oil and back off all adjustment relieving all spring tension. (See Figure 3D-7.) 2. . Remove cover bolts. Use a soft face hammer and gently tap housing to loosen then remove cover. Measure from flat surface of governor cover to edge of pulley. Remove pulley retaining pin. Remove pulley. A CAUTION BE CAREFUL NOT TO DAMAGE PULLEY. PULLEY 15 NOT SERVICED SEPARATELY. 6. Remove 2-7/16" bearing plate screws. 7. Press the governor shaft out of the cover. A CAUTION Properly support cover to prevent cracking, bend- _ ing or damage. 8. Using a 1” diameter rod, press out old seal. 9. Using a 1/8" pin punch, remove buffer lever retaining pin. 10. Pull lever off shaft. NOTE Do not remove fork shaft from housing. 11. Remove old seal. Inspection Using a lint free rag, clean inside of governor housing. NOTE Do not use solvents. Check all parts for signs of excessive wear or damage. Check rear main needle bearing. Check governor shaft bearing. Check flyweights. They must pivot freely without any binding. Buffer Cover Bolts Ц Retaining Pin Figure 3D-7. Engine Governor 3D-6 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) Reassembly The following reassembly includes both minor and major repair procedures. Retaining — Pin ) STEP 4 | Ne и Press pulley onto shaft in the H N same position as measured in STEP 1 Step 4 disassembly. Drill a new : . . e-— Bearing hole through shaft and install pul- Install seal into housing over 1 ley retaining pin. > crossshaft and install lever and roll pin. Cross Shaft Flyweight Assembly STEPS Use #2 Permatex on cover gasket. Install shaft/cover assembly into housing. STEP 2 Install flyweight shaft assembly and bearing to cover. Install two 7/16" bearing plate screws. Fill with oil 10W-30, 3 az. STEP 3 STEP 7 Install seal into cover over shaft Install governor on engine and assembly. connect linkage. Figure 3D-8. Governor Reassembiy 3D-7 ENGINE SECTION 3D. GASOLINE ENGINE (Product No. 66127) ss me Anti-Surge U Screw Control Arm Carburetor —” Linkage Figure 3D-9. Governor to Engine Adjustment Decreases Nw Increases Figure 3D-10. Idle Adjustment 3D-8 Adjustment (See Figure 3D-9) NOTE If the anti-surge screw is turned in too far the governor response will be less effective and the throttle control arm travel will be reduced effect- ing the maximum engine rpm adjustment. . Remove carburetor linkage from throttle control arm. 2. Adjust the surge screw to obtain a 1-5/8 throttle control arm travel. 3. Reconnect carburetor linkage. 4. Start engine and allow to warm up to operating temperature. Adjust idle speed to a maximum 1200 rpm by turning the idle adjustment screw on the carburetor (see Figure 3D-10). 5. Adjust maximum engine rpm to 3150-3200 by adjusting the high speed adjustment screw on governor (see Figure 3D-11). 6. Advance the throttle quickly a few times. If engine surges (hunts) more than 4 or 5 times, turn surge screw in 1/8 turn and recheck. Repeat this step until surge (hunt) is at 4 to 5 times. DL О ) Figure 3D-11. ENGINE SECTION 3E. DIESEL ENGINE (Product No. 66132) GENERAL 2. Remove the wing nut and gasket (4), and slide the element (5) out of assembly. Remove dust by shak- ing the element or blowing compressed air into and around the element. Air pressure must be less than 40 psi (274 kPa). A separate engine operators manual, prepared by the engine manufacturer is supplied with your tractor. Study the manual carefully until you are familiar with the maintenance, operation and adjustment of your equipment. Proper attention to the engine manufactur- 3. The air cleaner element can be cleaned in Donald- er's directions will assure maximum service life of the son D1400 washing solution. Gently agitate element engine and highest operating efficiency. in solution. Rinse and allow element to air dry thoroughly before installation. AIR CLEANER (See Figure 3E-1) NOTE 1. Loosen the retaining clamp (1) and slide the cover (2) off of the air cleaner assembly. Remove the baffle (3) and empty dust from the cover. Wipe clean witha clean damp cloth. NOTE If new element is to be installed, use a new gasket A WARNING Na 4. Install the element (5). Install the wing nut and Wear eye protection when using compressed air. gasket (4). Check gasket (4) for cracks and damage. Re- place if necessary. Figure 3E-1. Air Cleaner Service 3E-1 ENGINE SECTION 3E. DIESEL ENGINE (Product No. 66132) 5. Install the baffle (3) in cover (2) making sure opening is up. (Rog 6. Secure cover (2) with retaining clamp (1). > ` Removal Ss, 1. Loosen the clamp (6) which holds hose (7) to the air xy cleaner. Disconnect hose. 8 2. Remove nut (8), and capscrew (9) and clamps (10). © 5) Inspection / Outlet 1. Inspect the hose (7) for cracks and wear, replace if damaged. 2. Inspect the baffle (3), element (5), and airinlet cover (2) for cleanliness. Installation 1. Install the element (5), and baffle (3). 2. Install the air inlet cover (2) on the unit. 3. Install the air cleaner unit in the clamp (10) and secure with capscrew (8), and nut (9). 4. Secure the air cleaner hose (7) with clamps (6). 5. Check that all connections are tight. A WARNING DO NOT USE STARTING ASSIST FLUIDS. Use of starting assist fluids in the air intake system may be potentially explosive or cause a “RUN- Wing Nuts AWAY” engine condition. This could result in serious engine damage and/or personal injury. Figure 3E-2. Radiator Service RADIATOR (See Figure 3E-2) NOTE Always mix anti-freeze with the cooling water. A CAUTION Mixture ratios differ with the anti-freeze manufacturer and temperature. Follow the instructions Never open radiator cap (2) while engine is run- of each manufacturer. However, do not exceed a 50/50 mixture of antifreeze to water. ning or soon after it stops. Hot water sometimes shoots out if the radiator cap is opened while the engine is hot. Cleaning Radiator Core When dust enters between fins and tubes; wash out with tap water under pressure. Changing Coolant NOTE 1. Open drain cock (1) and radiator cap (2) and drain Never use a screwdriver or other pointed tool for coolant into a clean container. cleaning. It may damage the special tubes or 2. Flush the inside of the radiator (3) with clean water. cause the radiator to lose its function. 3E-2 ENGINE SECTION 3E. DIESEL ENGINE (Product No. 66132) Removal (See Figure 3E-2) 3. Connect overflow coolant tube. 1. Remove wing nuts holding oil cooler in place and tilt 4. Connect the inlet and outlet hoses; tighten hose oil cooler out of the way. clamps. 2. Remove hardware securing fan shroud to radiator 5. Close drain cock (1) and fill the radiator with clean and move shroud back over fan. distilled water/anti-freeze mixture. 3. Open drain cock (1), remove radiator cap (2) and NOTE drain the coolant. Always mix anti-freeze with the cooling water. 4. Disconnect the inlet and outlet hoses by loosening Mixture ratios differ with the anti-freeze manu- hose clamps (3). facturer and temperature. Follow the instructions 5. Disconnect overflow tube at radiator. Slide overflow of each manufacturer. However, do not exceeda bottle up off bracket. 50/50 mixture of antifreeze to water. 6. Remove attaching hardware (4 and 5). 6. Secure fan shroud to radiator with attaching hard- 7 Inspect weatherstrip (6) and grommets (7 and 8). | . . . Р p (6) 9 7. Secure oil cooler in place with wing nuts and Replace if damaged. Installation (See Figure 3E-2) 1. Install grommets (7 and 8) and weatherstrip (6) if washers. MUFFLER REMOVAL AND INSTALLATION Remove and install the muffler on the engine as shown on Figure 3E-3. removed. 9 Place the radiator (3) on frame and secure with attaching hardware (4 and 5). Exhaust Pipe Gasket 27-33 ft-Ibs. «аа (37-45 N.M) ad Lcd a ase —— / / 27-33 ft-lbs. Ug, A (37-45 N.m) 5 Figure 3E-3. Muffier Removal and Installation 3E-3 ENGINE SECTION 3E. DIESEL ENGINE (Product No. 66132) A CAUTION Do not attempt to service muffler while engine is hot from operation. EXHAUST SYSTEM INSPECTION 1 2 . Clean all sections of the exhaust system of dirt, dust or other foreign material. . Inspect exhaust system for cracks, holes, distortion or deformation. FUEL FILTER SERVICE (See Figure 3E-4) The fuel filter is mounted on the right rear tractor frame. Moisture and other foreign matter accumulate in the fuel filter. Periodically clean and replace the filter element. (Refer to Section 11.) 1. 2. Close the fuel outlet at tank. Remove the retaining ring on the filter cup and clean the filter cup and element in light fuel oil. Reassemble the cup, element, seal, and retaining ring, being careful to keep dust and dirt out of the filter components. . Purge air from the fuel system. 71 O-Ring Seal ~~ ЗЕ-4 PURGING THE FUEL SYSTEM (See Figure 3E-5) Do not perform purging when the engine is hot. A CAUTION Whenever the fuel filter or fuel piping are removed, the fuel tank is completely emptied, or the engine has not been used for an extended time, vent the system as follows: 1. Fill the fuel tank with fuel, and open the fuel shut-off valve. Loosen the air vent screw at the top of the filter by turning it counterclockwise two turns. Use a suitable container to catch fuel which will flow from screw hole. Manually actuate the fuel pump priming lever. 4. When bubbles disappear from fuel coming out of the air vent screw hole, turn the screw back in. Open the air vent plug on the fuel injection pump. Se Air Vent Pump Priming “x. Screw Lever / Fuel Injector Line Nuts - un <> eo со Un = то ль A E UN 7 e > e E We SD Wn Gh Gh Cu WB TR UA ER om >> Injection Pump Figure 3E-5. Purging The Fuel System ENGINE SECTION 3E. DIESEL ENGINE (Product No. 66132) _ Close the air vent plug when air bubbles disappear from the fuel flow. A WARNING The engine may start during this process. Be careful of injury due to moving components. If the engine starts, continue purging the remaining fuel injector lines. _ One at atime, loosen the high pressure fuel injector line nuts at the injector while cranking the engine. _ When bubbles disappear, tighten the fuel line nuts. Repeat steps 7 and 8 for the remaining fuel injection lines. _ When all the lines have been purged and the engine is running, listen to the engine. If it sounds like its missing, repeat steps 7 and 8 for all the injector lines. ENGINE REMOVAL (See Figures 3E-6 and 3E-7) 1. Disconnect and tag all electrical connections atthe engine. - Shut off fuel at the filter by moving the fuel filter cock to the closed position (see Figure 3E-4). Disconnect air cleaner hose at intake manifold. - Disconnect the throttie cable at the fuel injection pump (Figure 3E-6). Fuel Throttle Injection Cable Pump & N Figure 3E-6. Fuel Shut-Off Solenoid and Throttle Cable Connections 10. 11. 3E-5 5. Remove the muffler and radiator described in preceding paragraphs (see Figure 3E-2 and 3E-3). NOTE When removing the engine, it is advisable to remove all components (radiator brackets and supports, engine mount bolts, etc.) and lift the engine out of the machine with a hoist attached to the eye bolts. Remove the bolts (1) and lockwashers (2) that mount the hydraulic pump to the pump mounting plate (3). Carefully pull the assembled hydraulic pump free of the pump mounting plate (3). Support the pump to relieve strain on the hydraulic hoses which are attached to the pump. Remove hydrostatic pump drive shaft as descr bed in Section 4. Attach a chain hoist to the engine (the engine weighs close to 200 Ibs.). Remove all bolts (4) and lockwashers (5) that hold the engine to the machine frame. Carefully lift the engine out of the machine. ENGINE INSTALLATION (See Figure 3E-7) 1. Move the engine into its approximate mounting position using a chain hoist. Align and loosely attach all bolts (4) and lockwashers (5) that secure the engine to the frame. Tighten mounting bolts (4) after all have been installed. 2. . Pack the hydraulic pump drive shaft spline with recommended grease (see “Recommended Lubri- cants,” Section 11). Install hydraulic pump to mounting plate (3). Secure with bolts (1) and washers (2). See Section 8E for alignment procedure. _ Install the radiator and muffler as described in preceding paragraphs of this section. . Install hydrostatic pump drive shaft as descri bed in Section 4. . Connect and adjust the throttle control (see Sec- tion 2 of this manual and Figure 3E-6). . Connect all electrical connections to the engine (see Section 10 for location and testing). Connect air cleaner hose at intake manifold. Open the fuel filter by moving the cock to the open position (see “Fuel Filter Service” illustration in this section). SECTION 3E. DIESEL ENGINE (Product No. 66132) ENGINE O 27-33 ft-Ibs. (37-45 N.m) . *. * . . . . * . % . e *. . *. + *. *% *. * Se + e *. *. *c *. *s . . . e e + Hydraulic Pump Spline Lubricate to Setscrews Setscrew Add Loctite NOTE Engine is shown turned 180° from air cleaner and radiator illustrations. CAUTION Do not reuse drive hub setscrews. Always replace these screws with new ones. Shaft Figure 3E-7. Diesel Engine Removal and Installation 3E-6 SECTION 4 DRIVE TRAIN Repair and Service Tools and Materials ..............0000000000 000000 4A-1 Failure Analysis ...........0000000 00000 see 0000 000000000000 0 00e 0000000000 4B-1 Hydrostatic Transmission Drive Shaft ............000000000000000 000000 нео о 4C-1 Removal .........02000000 0000 aa 0 eee 00000000 0000000000 000000000000 000000 4C-1 Repair ...........02000000000 0000 sa 000 nan 0 ee ea a 000000000000 0000000000 000000 4C-1 Installation .....0.000000000000000000000000000000000000000000000 0000000000000 4C-1 Transaxie ...........220000 0000 0e ea aa aa 0000 aa 00000000 0e 0000000000 0000000 4D-1 General ..........000200000 00e ae ea 00 0e 0000 000000 ue 000 es 0000000000 000000 4D-1 Removal ...........04202400000 see ea ee ae 0000000 0 aa 00000 000000000000 0000000000 4D-1 Installation ......0.0000000000000000000000000000000000000000000000 00000000000 4D-2 AX I 11.111010 aa aa aa 0 a 0 a 0 aa 00 000 0e 0e as a 0000000 00000000 0000000000 4D-2 Disassembly ..........222000 000000 00e a 00e 0 eee 000000 0000000000 0000000 4D-2 Inspection/Repair ............eeeeeocosercoccorerecrecrrecereec nece. 4D-3 Reassembly ............ñooeorceorcccorecarorecrorecacrrecerercreccea rene. 4D-3 Gear Case Assembly ...............000000 00e nee ea 00 000000000000 0000000000 4D-5 Disassembly ..........222000 0000000000 a 00e ea EE ER EERE 4D-5 Inspection/Repair .............00008000eee en ana 0000 000000000000 0000000000 4D-5 Reassembly ...........00000000 0000000 ane una na 00000 0000000000 0000000000 4D-6 Differential ...0..0..0000000000000 0000000 00000000000000000000000 0000000000000 4D-9 Disassembly EEE EE RRR о 4D-9 Inspection/Repair ...............000000ee 00e 0e 0000000 000000000000 0000000 4D-9 Reassembly ...........02200000 00e 00 ace ae ea aa 00000 00000000 0000000000 4D-10 DRIVE TRAIN SECTION 4A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard Automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Lubricants: Grease gun grease (eg. Sunray DX671 or Gulf Supreme No. 0). Gear Lube SAE 90EP. Special Tools: Seal sleeves P/N 670245, 670179, 670206 Seal driver P/N 670180, 670211 Above special tools can be purchased from: Tecumseh/Peerless Engine and Transmission Group Service Division Grafton, WI 53024 4A-1 DRIVE TRAIN SECTION 4B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Unit cannot be shifted a. Gears improperly installed. a. Check unit for correct assembly (or difficult to shift) of parts (Section 4D). Forks and rod assembly incorrectly installed. Shifting lever improperly positioned. Chamfer on shift gears on wrong side. Improper fit of case to cover. Dowel pins not installed. Differential installed improperly. Remove assembly. Recheck and correctly position parts. (Section 4D). Determine if finger or shifting lever is correctly installed. Check that bevels on shifter gears are correct (Section 4D). Recheck positioning of thrust washers. A misplacement or omission of washer can cause binding (Section 4D). Check unit for correct assembly of parts (Section 4D). . Recheck positioning of bolts in differential (Section 4D). 2. Unit is noisy. Gearing is overly noisy, chatter etc. Metallic pieces and/or other foreign objects in unit. Worn gears. . Worn bearings. Check oil level. Remove bits of broken metal, loose washers, etc. Inspect. Replace damaged parts. Remove and replace with new gears (Section 4D). Replace bearing (Section 4D). 3. Unit jumps out of gear. a. Shifting lever improperly assembled to housing. j Teeth of gears are worn beyond tolerances. | Spring in shifter fork weak or broken. Attaching screws for shift lever and housing assembly not properly torqued. Shift lever bent and hitting unit frame. Shift rod grooves worn. Disassemble shifting lever and check for proper assembly. Replace worn gears (Section 4D). Replace spring (Section 4D). Torque screws to 10 ft-lbs. (Section 4D). Replace shift lever. Replace shift rods (Section 4D). 4. Axles cannot be turned (same direction) with unit in neutral gear. Burrs on gearing. Thrust washers in wrong position. Bearings not pressed in deep enough. Remove gear and hone with a stone (Section 4D). Recheck thrust washer and reposition, if wrong. Use the proper bearing tool to seat the bearing. d. Parking brake not released. d. Release brake. 5. Unit does not drive. a. Differential bevel gears broken. a. Replace (Section 4D). b. Stripped teeth on gears. b. Replace (Section 4D). c. Broken input pinion. c. Replace (Section 4D). 4B-1 DRIVE TRAIN SECTION 4C. HYDROSTATIC TRANSMISSION DRIVE SHAFT REMOVAL (See Figure 4C-1) 1. Remove three axial screws from each end. 2. 3. Slip the drive shaft out. Remove fan hub assembly from the hydro shaft. Remove Woodruff key. Remove drive coupling flange from engine. Remove three radial screws from the rubber donut. Remove the donut from hub. Push down on fan and hold, remove snap ring, slowly release down pressure on fan. Remove fan, spring and flat washer. REPAIR Inspect all parts for damage or wear. Repair is limited to replacement of parts that may be worn or damaged. INSTALLATION (See Figure 4C-1) 1. On the fan hub, install flat washer, spring, and fan. 2. Push fan down against spring and hold. Install snap ring. 3. Lightly grease under the head of socket head SCrews. Install rubber donut on hub and loosely fasten with three radial socket head screws. Fan Hub Assembly Key Snap Ring Fan Washer "A 7 O: Lockwasher Capscrew Fan Ga Spring VA > fr Coupling © _ ub (< Shaft Coupler Washer | Hub Axial (Diesel) «78 Screws A 4 € > shaf / Ca > | Radial > Coupler / Drive Shaft 4 1 Щи ada Assembly A0 SA. Locti % ~ Loctite) Key 0 Y Drive Radial e DS Coupling Screws GE Flange Setscrew Drive Shaft Coupler (Gas) Figure 4C-1. Drive Shaft Assembly 4C-1 DRIVE TRAIN SECTION 4C. HYDROSTATIC TRANSMISSION DRIVE SHAFT 4. NOTE Radial screws are installed in the three threaded holes of the hub. Install woodruff key and fan assembly on hydro input shaft. Fasten with flat washer, lockwasher and capscrew. Torque capscrew to 17 ft-lbs (23 N.m). Install engine drive coupling to flywheel. Torque capscrews to 17-21 ft-lbs. (23-28 N.m). Install woodruff key and drive shaft hub onto drive shaft. Install setscrew, do not tighten. 4C-2 10. . Lightly grease under the head of socket head screws. Install rubber donut on hub and loosely fasten with three radial socket head screws. Install drive shaft assembly into place. Lightly grease under the head of socket head screws and fasten rubber donut to the drive flanges with 3 axial socket head screws. . Torque axial screws to 18 ft-lbs. (25 N.m). After axial screws have been torqued, torque radial screws to 18 ft-Ibs. (25 N.m). Tighten drive hub setscrew to 17 ft-lbs. (23 N.m). DRIVE TRAIN SECTION 4D. TRANSAXLE GENERAL REMOVAL (See Figure 4D-1) The transaxle is a two speed gear box with neutral and 1. Raise and securely support the tractor frame. a limited slip differential. The lubricant in the transaxle 2. Remove the hydrostat, all linkage and lift cylinder. is used to lubricate the transaxle only and is not used as NOTE the oil supply for the hydraulic system. | Wheels may be left on to aid in axle removal. 3. Remove transaxle mounting hardware. Mounting & Hardware y | Hydrostat Transaxle Mounting Hardware Figure 4D-1. Transaxle Removal and Installation 4D-1 DRIVE TRAIN SECTION 4D. TRANSAXLE INSTALLATION (See Figure 4D-1) 1. Securely support the tractor and transaxle, remove 1. the wheel axle nut, lockwasher, wheel hub and Position transaxle in tractor frame. Fasten using woodruff key. transaxle mounting hardware. . Remove the brake as described in Section 5. N 2. Connect brake linkage, adjust as described in Sec- tion 2C. 3. Removethe axle housing to tractor frame mounting 3. Install hydrostat and control linkage and adjust as hardware. described in Section 2C. 4. Remove the axle housing to gear box mounting 4. Install lift cylinder and wheels. hardware. 5. Remove the axle housing by pulling it straight off the AXLE axle. Disassembly (See Figure 4D-2) 6. The seal, bearings, thrust bearing and square cut NOTE seal ring can now be removed from the housing. It is not necessary to remove transaxle to service axles. Tractor Frame Mounting Bracket Square Cut Tractor Seal Ring Frame Ball | Bearings Axle CC т се o ewe te an wwe Bearing Axle Housing Figure 4D-2. Axle Disassembly 4D-2 DRIVE TRAIN SECTION 4D. TRANSAXLE Inspection/Repair 1. Inspect bearings and discard seal ring and oil seal. 2. Repair is limited to replacing damaged or worn parts. Reassembly (See Figure 4D-3) 1. Pack the ball bearing with grease. Install two bearings in the axle housing. 2. Pack the thrust bearing with grease. Install it in the flanged end of the axle housing. . Install wheel and torque wheel nuts to 40-50 ft-lbs. NOTE Install thrust bearing with thrust side (as shown) toward gear case. . Install square cut seal ring to axle housing, install oil seal. . Install axle housing to gear case. Torque screws to 60-65 ft-lbs. (81-88 N.m). . Install brake, woodruff key, wheel hub, lockwasher and axle nut. Torque nut to 90-120 ft-lbs. (122-163 N.m). (54-68 N.m). Square Cut Seal Ring Axle Housing Torque 90-120 ft-lbs. Key (122-163 N.m) Lockwasher Torque 40-52 ft-lbs. (54-68 N.m) Thrust Side > Bearings Ç \) NN > N A Torque 60-65 ft-Ibs. (81-88 N.m) Toward inside | of Gearcase Figure 4D-3. Axle Reassembly 4D-3 DRIVE TRAIN SECTION 4D. TRANSAXLE GEAR CASE ASSEMBLY Inspection/Repair Inspect all parts for signs of damage or wear. Discard old O-rings, gaskets and seals. Install new ones. See the following figures (Figures 4D-4 and 4D-5) for Replace worn or damaged parts. the disassembly procedure. Disassembly Spring Gear , — Ball Setscrew Fill Plug STEP 1 1. Drive dowel pin flush with case. 2. Remove cover screws and cover. 3. Remove old gasket and clean surface of cover. Thrust Input Washers Output Shaft Shaft Differential Assembly Shifter and Brake Shaft STEP 3 г Remove thrust washers. Tag, mark their location and wire each L- Removethe differential assembly. Refer thrust washer set together as they to differential disassembly in this sec- are removed. tion. Figure 4D-4. Gear Case Disassembly 4D-4 DRIVE TRAIN SECTION 4D. TRANSAXLE Pinion Thrust Washer STEPS 1. Remove output pinion, output gear and thrust washer. Tag and mark the thrust washer(s). 2. Remove the high range gear. 3. Remove the shift fork, shaft and high and low range gear cluster. Shifter Shaft Cover Bearings Case Shaft Spacer \ \ Thrust > Low Range Ny Drive Gear input (Bevel Side Onto A Drive Shaft First) Thrust Gear Washers input Low Range Spacer Drive Drive Gear ear | B Thrust earing L > | Washers Î Input Shaft - | haft Spacer ' o Shaft \¢ Provided) Drive Gear _- Spacer 5, | | e | INQ: Shifter and oT Brake Shaft STEP 6 | 1. Remove input shaft spacer, shaft, low range drive gear, and input drive gear. 2. Remove, tag, mark and wire together the spacer (if provided) thrust washers and thrust bearing. NOTE Some axles do not have a spacer between the low range drive gear and high range gear. 3. Remove shifter, brake shaft and drive gear. 4. Remove drive gear spacer. STEP 7 1. Needle bearing can be removed from the case and/or cover by using an arbor press and mandrel. Press bearing from the outside to the inside. 2 Remove and discard oil seals. Figure 4D-5. Gear Case Disassembly 4D-5 DRIVE TRAIN SECTION 4D. TRANSAXLE Reassembly See the following figures (Figures 4D-6, 4D-7 and 4D-8) for reassembly procedures. STEP 1 1. Using an arbor press, install needle bearings from the inside toward the outside. Bearing Letters NOTE Be careful that bearings are square when installing. 2. Install new seals so they are flush with cover and case. NOTE On open ended needle bearings always press on the letter side. Shifter and Oil Seal >. Seated Flush — Ts Oil Seal Figure 4D-6. Gear Case Reassembly Shaft © Spacer \ \ Input | ow Range Thrust > Low Range Spacer que Drive Gear Bearing Drive Gear Thrust | N O Input (Bevel Side Onto Thrust Bearing | ® Drive Shaft First) W. 2 eS ashers © Ï Input Shaft Thrust Gear PU Wash Shaft Spacer ashers (If Provided) Drive Xx STEP 2 1 Spacer da 1. Install drive gear and spacer on shifter and brake shaft. Install shifter and brake shaft into gear case. 2. Install low range gear (bevel first), input drive gear, spacer (if provided) thrust washer, thrust bearing, and thrust washer onto input shaft. In- stall input shaft into gear case. Brake Shaft Figure 4D-7. Gear Case Reassembly 4D-6 DRIVE TRAIN SECTION 4D. TRANSAXLE | High Range Gear (Bevel Toward Inside) | High Low Gear Cluster STEP 3 Install differential assembly into 1. Assemble output gear and thrust gear case. washer to output pinion. Install output pinion into gear case. Torque 15-18 ft-lbs. 2. Position the fork of shifter fork assem- (20-24 N.m) bly between the high low range gear cluster and install in gear case. 3. Install high range gear (bevel toward the inside) on input shaft. Input Output Thrust Shaft Shaft Washer(s) Thrust Washer(s) STEP 6 . Drive the dowel pins so they are flush with the inside case flange. . Apply Permatex #2 gasket compound to the gasket surface of the case cover. STEPS Install thrust washers on input shaft, shifter and brake shaft and output shaft. 3. Install cover gasket and cover torque cover screws to 15-18 ft-lbs. (20-24 8 se ZZ Spring 4 7 / ) STEP 7 1. Install detent ball, spring and setscrew. Turn setscrew So it is flush with the gear case. Ball 2. Install drain and fill plugs. 3. Fill the transaxle with the recommended lubricant after it has been installed on the tractor, refer to Sec- tion 11. Figure 4D-8. Gear Case Reassembly 4D-7 DRIVE TRAIN SECTION 4D. TRANSAXLE DIFFERENTIAL 3. Inspect ring gear and pinions for wear. Disassembly (See Figure 4D-9) 4. Inspect axles for straightness and for damaged threads and/or splines. | | 5. Inspect differential carrier for damaged bearing race Inspection/Repair surfaces. 1. Inspect thrust washers for wear. 6. Replace any parts that are damaged or worn. 2. Inspect retaining rings and the axle retaining ring grooves for wear or distortion. See the steps in Figure 4D-9 for disassembly. Short Hex —— Bearing Bolts Surface Pinions Ring | Сеаг STEP 1 1. Remove 4 hex head bolts. 2. Remove short carrier differential and axle. Remove ring gear and 8 pinions. Retaining Ring Drive Gear Thrust Washer STEP 3 The axle thrust washer and drive gear can be removed by first removing the axle retaining ring. Figure 4D-9. Differential Disassembly 4D-8 DRIVE TRAIN SECTION 4D. TRANSAXLE | Reassembly See the steps in Figure 4D-10 for reassembly. Axle Retaining Splined Rin O End 9 TE Ш Um TO Retaining | Y Ring Groove Thrust [| | il u | BR Washer | | | . | I) Drive Gear Flat Side ort Ng Differential Pinions (4) Carrier STEP 1 STEP 2 1. Install differential carrier (flat side toward splined end) thrust washer, drive gear (retaining ring counter- 1. Install pinions in the ring gear. Place the ring gear onto differential carrier. bore toward splined end) and re- 2. Install the remaining 4 pinions into taining ring. the ring gear. 2. Position the axle with long differen- 3. Turn the ring gear so the 4 core body tial carrier hub flat surface uprightin holes line up with the holes in the a vise. differential carrier. Hex Short Bolts Bearing = Surface | | STEP 3 Position the axle and differential carrier | onto the ring gear. Fasten in place with | the four hex head bolts. Torque bolts to | 35-40 ft-Ibs. (47-54 N.m). Figure 4D-10. Differential Disassembly 4D-9 DRIVE TRAIN SECTION 4D. TRANSAXLE Low Range Transmission Drive Gear High Range Transmission Driven Drive Gear Input Gear Input Shaft Shifter and Brake Shaft Beveled Sides of Gears Axle Differential Figure 4D-11. Transaxle 4D-10 5A. 5B. 5C. 5D. SECTIONS BRAKE SYSTEM Repair and Service Tools and Materials ...............0.000000000 000 HEHE Henne 5A-1 Failure Analysis ...........000000000 eee eee eee ca a 0000 eee ee cac 0000000 eee 0000000 5B-1 Parking Brake ............00000000 eee eee eee 000 00e e ee ee 00000 00000000 eee 0000000 5C-1 General ...........2202000000 000 0e 0e a 00e na sa 0 aa 0e sen a 0000000000 0000 0000000000 5C-1 2 T=Y oY 11 CE EE EEE EER ERE RREL RRR 5C-2 AdJUSIMENT «otitis ate 5C-3 Traction Assist .............1040000 000000 ea 000 00 0000 0 000000000000 0000 0000000000 5D-1 General ..........L.22220000 000 ea eee a ea ana 0e ea ae ae 0 ea 000000 0000000 0000000000 5D-1 21 01] A ARR A A A AE Ne 5D-2 Adjustments ..........e.ee.eereecorecoocoreerrcerceereetacacecareneeereeaee 5D-3 Left Wheel Brake (Standard) .............000000 00e eee ee 0000 scene eee eee 00 5D-3 110) AAA AN 5D-3 Minor ...........1202100000 000 ea 0 0e ae sa ae 0 0 ea 0e 0000000 ee 00 se 000000000000 0 о 5D-3 Right Wheel Brake (Optional) .............00000000 eee eee eee e eee eee ete eee ee 5D-4 1, ET 1e A CREE ER EEE ERE EERE ERR E U 5D-4 BRAKE SYSTEM SECTION 5A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard solvent or equivalent. Lubricants: Non-metallic additive wheel bearing grease (eg. Sun- ray DX692 or Enco Fibrox 280). Other service items: Brake linings. 5A-1 BRAKE SYSTEM SECTION 5B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Parking brake does not hold tractor in position when engine is off. a. Brake is maladjusted. b. Worn brake shoes. . Adjust brake. Refer to Section 5C. . Replace lining. Refer to Sec- tion 5C. 2. Tractor creeps with engine running and parking brake applied. a. Brake is maladjusted. b. Worn brake shoes. c. Traction control needs adjusting. . Adjust brake. Refer to Section 5C. . Replace lining. Refer to Sec- tion 5C. c. Adjust. Refer to Section 2. 3. Steering assist brake(s) do not hold. a. Brake is maladjusted. b. Worn brake shoes. c. Broken or worn brake cable (optional brake). a. Adjust brake. Refer to Section 5C. . Replace lining. Refer to Sec- tion 5C. . Replace cable. Refer to Section 5C. 5B-1 BRAKE SYSTEM SECTION 5C. PARKING BRAKE GENERAL The parking brake control assembly and linkage are During normal operation the hydro acts as a brake and shown in Figure 5C-1. lows th factor down go the rection pedals bravely Adiscbrakeonthe transaxie is usedto holdthetractor . os in the “Park” position. This is a static brake. for rapid stops or when being used as a parking brake. If the tractor “creeps” when the traction pedal is not engaged, the traction pedal linkage must be adjusted as described in Section 2. Brake Lock Disc. A < Brake 5 = Assembly Su © SS < Figure 5C-1. Parking Brake Assembly 5C-1 BRAKE SYSTEM SECTION 5C. PARKING BRAKE REPAIR Check the amount of brake lining left. Inspect brake linings, springs, actuating lever, and cam. Replace worn brake linings and other parts which show signs of wear. After replacing brake components, adjust brakes as described in “Brake Adjustment”. Mounting Bracket Linings Figure 5C-2. Parking Brake Repair 5С-2 BRAKE SYSTEM SECTION 5C. PARKING BRAKE ADJUSTMENT (See Figure 5C-3) 1. Adjust locking nuts to allow a 3/4 to 1” free travel of the brake pedal. 2. As brake pads wear, shorten brake rod by adjusting locking nuts. Locking 5 Nuts u — Figure 5C-3. Brake Pedal Adjustment 5C-3 BRAKE SYSTEM SECTION 5D. TRACTION ASSIST BRAKE GENERAL A left wheel traction assist brake is supplied with the tractor. An optional right assist brake can be installed. Both brakes are standard automotive type brakes. The left brake is operated by a pedal connected through a rod to the brake arm. The right brake is operated by a pedal connected through a cable to the right brake arm. Both brakes are serviced and adjusted inthe same manner. The traction assist brake control assembly and linkage are shown in Figure 5D-1. Right Traction Assist Pedal Left Traction ‘ Assist Pedal Figure 5D-1. Traction Assist Brake Assemblies SD-1 BRAKE SYSTEM SECTION 5D. TRACTION ASSIST BRAKE REPAIR | Whenever the wheels are pulled, check the amount of A CAU T | 0, À brake lining left. Inspect brake linings, springs, actuating lever, and cam. Replace worn brake linings and Do not use any type of anti-seize or lubricant on other parts which show signs of wear. After replacing taper or brake drum. brake components, adjust brakes as described in “Brake Adjustment”. Spring Actuating Arm Woodruff Backing Figure 5D-2. Traction Assist Brake Repair 5D-2 BRAKE SYSTEM SECTION 5D. TRACTION ASSIST BRAKE ADJUSTMENTS 2. Install and adjust brake link length so brake rod end LEFT WHEEL BRAKE (STANDARD) aligns with hole In actuating lever. Install cotter pin. Major (See Figure 5D-3) 3. Proceed with minor adjustment. NOTE If brake linkage has not been removed or damaged proceed with minor adjustment. Minor (See Figure 5D-3) 1. If removed, install brake actuating lever so itis posi- 1. Adjust yoke on brake rod to obtain a free pedal tioned 60° to the rear. movement of 3/4 to 1”. 3/4"to1" ® 9 Free Travel S O 9 Adjustment Yoke Actuating Lever D Figure 5D-3. Left Brake Adjustment (Major) 5D-3 BRAKE SYSTEM SECTION 5D. TRACTION ASSIST BRAKE RIGHT WHEEL BRAKE (OPTIONAL) 2. Position cable in slot of LH and RH brackets. Major (See Figure 5D-4) 3. Tighten nuts so there is equal amount of threads NOTE exposed on each side. 4. On the right side, connect cable yoke to brake actuating lever. 1. If removed, install brake actuating lever so it is posi- On left side, connect cable yoke to brake pedal. tioned straight up and down. 6. Proceed with minor adjustment. If brake linkage has not been removed or damaged proceed with minor adjustment. o Actuating Le Equal Amount g Lever of Threads on Both Sides Straight N CE 170 y Right Hand Bracket Equal Amount of Threads on Both Sides Figure 5D-4. Brake Arm Adjustment (Major) SD-4 BRAKE SYSTEM SECTION 5D. TRACTION ASSIST BRAKE Minor (See Figure 5D-5) 1. Adjust cable yoke to obtain a free pedal movement of 3/4 to 1”. S 3/4" to 1" Nr Y Adjustment Yoke Figure 5D-5. Brake Arm Adjustment (Minor) 5D-5 6A. 6B. 6C. 6D. 6E. SECTION 6 STEERING Repair and Service Tools and Materials ..............0000000 00e 0 00000000 c 000000 бА-1 Failure Analysis ..........04400100 000000 ae 0 na 0 00 000000000000 0e 0000000 0000000000 6B-1 Steering Unit ...........000000000 00e ee 0e aa a 0e es es een 00 0000000 1000000000 000000 6C-1 == DE 6C-1 Removal .............12241110 000000 ae eee ea 0 00 00 aa sue 000000 000000000000 00000000 6C-1 Disassembly .........2200000 0000 nee 0e ee aa 0e ae 000000000000 000000000000 000000 6C-2 Inspection ..........2.2200000 00000 eme sea 0 00000000 see eee 000000 0000000000 00000 6C-3 Assembly ...........22000000 00000000 ane 00000 case aa 00e een 0 eee 000000 00000000 0 6C-3 Installation .............1200000 0000000 0000 00000 a see 00 ea 000000000000 0000000000 6C-6 Steer Wheel Adjustments ................00000000 00000000 00e 00 00000000 00000000 6D-1 Toe-In .........eecoocoooccocrorecaanrencacecac o oaarececaararecacacacecarererere 6D-1 Turn Stop ............2000000 0000000 aa ee ee nee 00e see 0000000000 a 0000000000 00000 6D-1 Steering Cylinder ............20000000 00e ee ee 0000000 00e 00 ee ee eee 00000 0000000000 6E-1 Removal .........eeeooocrdeccooccrcocccorcoarrcocrroccrcacrrorer cara rec ecorecene. 6E-1 Repair ...........eeeoocsccorecaciorracr rar ecorererecanrcareraoerrecerecare 6E-2 Installation ..........oeooQocrcc..o..0.0..d06%00cscoecenmcocrococrcoacrcrana cocacacr eo reccec. 6E-2 STEERING SECTION 6A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard solvent or equivalent. Other service items: 6 pieces 0.007 inch (0.18 mm) shim stock 0.5 inch (13 mm) wide and 1.5 inch (38 mm) long. Service fixture for Power Steering Unit (see Figure 6A-1). Four Holes 3/8 (.375) Dia. Equally Spaced on a 3.25 Dia. Circle 8.00 \ - ps—2.00—== 18 od }— - | М Y be CAN io — 2.00 — — 7 >4.——— 4.0 ———— 1 Na | J Dimensions Shown in Inches 45° | \ 5 00 Dia. 4 _— Figure 6A-1. Service Fixture 6A-1 STEERING SECTION 6B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY . Noisy when steering wheel | a. Low hissing sound. a. Normal. is turned. b. Relief valve squeals when steering | b. Normal. to maximum turn. c. Relief valve squeals while turning. | c. Check auxiliary pump relief valve (Section 8R). . Steering wanders. a. Tire pressure incorrect. a. Properly inflate tires (Section 7C). b. Loose or worn steering cylinder. b. Tighten or repair (Section 6E). c. Steering cylinder internal leakage. | C. Repair (Section 6E). d. Steer wheels out of adjustment. d. Adjust (Section 6D). e. Worn or loose wheel bearings. e. Replace and/or adjust wheel bearings (Section 7D). f. Improper toe-in adjustment. f. Adjust toe-in (Section 6D). . Shimmy. a. Tire mounting nuts loose. a. Tighten (Section 7C). b. Loose or worn steering linkage. b. Tighten or repair (Section 6E). c. Wheel bearings worn. c. Repair (Section 7D). d. Steer wheels out of adjustment. d. Adjust (Section 6D). . Hard steering in one a. Internal failure of steering unit. a. Repair (Section 6C). direction. b. Loose or worn steering linkage. b. Tighten or repair (Section 6E). . Hard steering in both a. Tires under inflated. a. Inflate tires (Section 7C). directions. b. Low hydraulic oil level. b. Check level (Section 11C). c. Low oil pressure. c. Check auxiliary pump relief (Section 8R). d. Steering unit failure. d. Test steering unit (Section 8M). . Lost motion at steering a. Steering wheel loose. a. Tighten (Section 6C). wheel. b. Loosen or worn steering linkage. b. Tighten or repair (Section 6E). c. Steering cylinder internal leakage. | C. Repair (Section 6E). d. Steering unit internai leakage. d. Repair (Section 6C). e. Excessive heat. Hot oil. e. Check oil cooler and clean if necessary. . Steering “Locks” when mowers are being raised. Low oil pressure. Test auxiliary pump relief pressure (Section 8M). 6B-1 STEERING SECTION 6C. STEERING UNIT GENERAL REMOVAL (See Figure 6C-1) The power steering unit is supplied with oil from the 1. Remove steering wheel cap (1), nut (2) and steering charge pump. Power steering is provided as long as the wheel (3). engine is running. If an engine failure occurs, the steer- 5 Remove steering tower cover (5) ing unit provides manual steering. 3. Label and remove hydraulic lines from steering unit. 4. Remove steering unit attaching hardware and steering unit (6). Figure 6C-1. Steering Unit Removal and Installation 6C-1 STEERING SECTION 6C. STEERING UNIT DISASSEMBLY (See Figure 6C-2) NOTE Before disassembly, scribe a line from top to bottom of valve assembly. Use this for future reference to determine proper orientation of sections (see Figure 6C-7). 1. Securely place the power steering service fixture in a vise (see Figure 6A-1). 2. Remove port cover nuts (1) and port cover (2). Note position of ball check (5). 3. Carefully remove port manifold (6). Be prepared to catch three springs (7). Remove springs. . Remove valve ring (8), valve plate springs (10) and valve plate (9). . Remove hex drive (11) and isolation manifold (13). NOTE DO NOT LOSE ALIGNMENT PINS (12). . Remove drive link (14) and metering ring (15). 7. Remove metering package (17) and commutator seal (16). The metering package (17) is serviced as an assembly kit. Refer to your parts manual (proceed with step 11). Disassembly of metering package should be for inspection ONLY. To disassemble metering package, proceed with step 8. 16. Commutator Cover Seal 17. Commutator Assy. 27 18. Spacer 19. Thrust Bearing 20. Face Seal 21. Back-Up Ring 22. Seal Spacer 23. Upper Cover Plate 24. Retaining Ring 25. Washer 26. Retaining Plate 27. Steering Shaft 28. Steering Tube 29. Bushing 30. Special Bolt, 5/16-24UNF-2A Nut . Port Cover Seal Ring O-Ring Bail Port Manifold Spring . Valve Ring (Matched Set) . Valve Plate (Matched Set) 10. Spring 11. Hex Drive Assy. 12. Alignment Pin 13. Isolation Manifold 14. Drive Link оон лом + Figure 6C-2. Steering Unit Disassembly 6C-2 STEERING SECTION 6C. STEERING UNIT (See Figure 6C-3) 8. 9. 10. Remove socket capscrews (1), commutator cover (2), commutator ring (3) and commutator (4). Remove five alignment pins (5). Remove drive link spacer (6), rotor (7) and stator (8) from drive plate (9). Figure 6C-3. Metering Package Disassembly (See Figure 6C-2). 11. 12. 13. 14. 15. 16. Remove face seal (20), back up ring (21) and seal spacer (22). Remove thrust bearing (19) and spacer (18). Remove upper cover plate (23). Pull steering shaft (27) up out of tube (28). Remove washer (25) and retainer plate (26). Remove bushing (29). INSPECTION e Inspect springs (7) and (10) for bent, broken or distorted coils. NOTE Always replace springs as a set. e |nspect finished ground surfaces of all components. e Inspect the slot edges and surface for nicks or scoring, and rounding edges. 6C-3 Maximum Tip 500 Clearance (0.0037 (0.08 mm) Rotor Lobe Across From Lobe Being Gauged Must Be Centered Figure 6C-4. Rotor and Stator Inspection NOTE Valve ring (8) and valve plate (9) are a matched set and are not serviceable. e Inspect hex drive (11) for wear. e [Inspect isolation manifold (13). A normal polished pattern due to valve plate rotation will occur. Also, look for nicks, scratches or scoring. e Inspect drive link (14). e Inspect thrust bearing (19) for brinelling, spalling, or missing rollers. e Discard all seals and seal rings. (See Figure 6C-3) e Inspect commutator cover (2), drive plate (9). A normal polished pattern will occur. e Inspect the rotor (7) and stator (8) fit. ASSEMBLY (See Figure 6C-5) 1. Install a new bushing (29) in tube (28). Crimp the tube end in two places 90° apart. 2. Place tube (28) and spiral bolts (30) in the service fixture. 3. Place retainer plate (26) in tube (28) with flat side down. Install washer (25) into retainer plate (26). 4. Install a new snap ring (24) to shaft (27) and install into tube (28). STEERING SECTION 6C. STEERING UNIT 7. // Step 6 EN 26 pd 25 28 — 77 / Steps 3 and 4 Figure 6C-5. Steering Unit Assembly A CAUTION 7. Grease upper cover plate (23) and install assembled seal. If the metering package was disassembled, pro- In the following assembly steps, it is important to align components for proper operation of steering unit. The correct alignment is illustrated in Figure 6C-7. 5. Install upper cover plate (23). 6. Assemble seal spacer (22), seal ring (21) and seal (20) as shown. ceed with step 8. If the metering package was not disassembled ora new one is being installed, proceed with step 19. (See Figure 6C-6) 8. Place drive plate (9) on a flat lint free surface. 9. Place stator (8) on drive plate (9) and insert rotor (7) into stator. 10. Apply a small amount of grease to drive link spacer (6) and install in rotor (7). STEERING SECTION 6C. STEERING UNIT Figure 6C-6. Metering Package Assembly 11. Place commutator (4) ontop of rotor (7) with aligning pin holes up and place a few drops of oilineach recess of commutator. 12. Align the five holes of commutator (4) with holes in rotor (7) and install 5 pins (5). 13. Install commutator ring (3) and commutator cover (2) and eleven socket capscrews (1). NOTE DO NOT TIGHTEN CAPSCREWS. (See Figure 6C-2) 14. Place metering ring (15) on a hard flat surface. 15. Place the now assembled metering package in the center of metering ring (15) with commutator cover down. 16. Place shim stock 0.007 inch (0.18 mm) thick, 1/2 inch (13 mm) wide by 1-1/2 inch (38 mm) long in three places between the metering ring and metering package as shown. 6C-5 17. Tighten socket capscrews twice in sequence as 18. shown to a final torque of 11-13 in-Ibs (1.2-1.5 N.m). Remove the metering package and shims. Place drive link (14) in rotor and turn by hand to make sure there is no binding. (See Figure 6C-5 and 6C-6) 19. 20. 21. 22. 23. Place metering ring (15) on top of upper cover plate (23) with aligning pin holes up. Lubricate and install thrust bearing spacer (18) and thrust bearing (19) into metering ring (15). Place metering package (17) into metering ring (15) engaging the drive slot with the steering shaft. Install commutator ring (16) and seal ring (3). Install drive link (14). Place isolation manifold (13) on metering ring (15) with aligning pin holes up. Install aligning pins (12). STEERING SECTION 6C. STEERING UNIT Correct Assembly Alignment Grooves Scribe Line Figure 6C-7. Alignment Grooves 6C-6 24. 25. 26. 27. 28. 29. 30. 31. Install three 1/2 inch springs (10) in isolation manifold (13) and install valve ring (8). Install valve plate (9) as shown (port side up) in valve ring (8) aligning spring slots with springs. Install seal ring (3). Place three 3/4 inch springs (7) in port manifold (6) as shown. Carefully place port manifold (6) springs down onto valve ring (8). Install O-rings (4) and seal ring (3) to port cover (2). Install check ball (5) in inlet port of port manifold (6). Install port manifold (6). Install self-locking nuts (1) and tighten in sequence shown gradually until a final torque of 20-24 ft-lbs (27-33 N.m) is obtained. INSTALLATION (See Figure 6C-1) 1. Position and fasten steering unit with attaching hardware. Connect hydraulic lines to steering unit. Install steering tower cover (5). Install steering tube seal (4), steering wheel (3) and nut (2). Torque nut to 25-30 ft-lbs (34-41 N.m). Install steering wheel cap (1). ~ STEERING SECTION 6D. STEER WHEEL ADJUSTMENTS TOE-IN (See Figure 6D-1) TURN STOP (See Figure 6D-1) 1. Turn steer wheels to straight ahead position. 1. Loosen stop bolt nut and turn it completely in. 2. Loosen tie rod jam nuts. 2. Turn steering wheel to the LEFT until rod of steer 3. Turn tie rod so wheels toe-in 1/8 inch (9.5 mm). After making this adjustment, check the turn stop and adjust if necessary. cylinder is completely retracted. NOTE 3. Adjust stop bolt until it contacts the stop block. Tighten jam nut. 4. Repeat steps 2 and 3 turning the steering wheel to the RIGHT, cylinder rod extended. Left Turn Stop Bolt Top View Steering Cylinder Rod Right Turn Stop Bolt = — Steering Stop Block “Front” Top View R.H. Thread Jam Nut . L.H. Thread Tie Rod Jam Nut + 1/8" (9.5 mm) = Figure 6D-1. Steer Wheel Adjustment 6D-1 STEERING SECTION 6E. STEERING CYLINDER REMOVAL (See Figure 6E-1) 1. Block the wheel and set the parking brake. 2. Tag and remove hydraulic lines. Cap the cylinder ports and plug the lines. 3. Remove attaching hardware and remove cylinder. Torque to => 17-25 ft-Ibs. ——* (23-34 N.m) | a Torque to J 17-25 ft-Ibs. (23-34 N.m) Figure 6E-1. Steering Cylinder Removal and Installation 6E-1 STEERING SECTION 6E. STEERING CYLINDER REPAIR (See Figures 6E-2 and 6E-3) INSTALLATION (See Figure 6E-1) Clean and air dry exterior of cylinder. Drain all the oil 1. Install cylinder and secure with attaching hardware. from the cylinder. Disassemble following the steps as 2. Connect hydraulic hoses. 3. Start tractor and check for leaks. Repair as necessary. illustrated. Figure 6E-2. Steering Cylinder Wiper Seal Figure 6E-3. Steering Cylinder End Service 6E-2 7A. 7C. 7D. SECTION 7 WHEELS AND TIRES Repair and Service Tools and Materials .........eoocorecocccccorocerececorecacares 7A-1 Failure Analysis ..........0000000 00000 eee eee eee 0e tee ec ee eee eee et te TETE S 7B-1 Tire Service ..............2000 00000000 0 eee ee 00e eee eee ee eee C CRTC AE SCT S ETES 7C-1 General ..........22200000000000 00e een a ae 000 eee eee a 0e eee eee 0e eee eee 0e CT C0 TE 00 7C-1 Service 220000000000 0 0e 0 eee eee eee ee ee eee sss Ann UUU 7C-1 Rear Wheel Service ...........reooecscecccooreorecoceacercrrere reee erarenae 7D-1 Service .........eooconccacrrecrcoceracararecareacorecorrecerreterane ret 0 7D-1 WHEELS AND TIRES SECTION 7A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Lubricants: Non-metallic additive wheel bearing grease (eg. Sun- ray DX 692 or Enco Fibrox 280). Grease gun grease (eg. Sunray DX 671 or Gulf Supreme No. 0 [SAE 30 oil ]). Other service items: Commercially available tire sealant. Tire pressure gauge. Compressed air with tire valve fitting. 7A-1 WHEELS AND TIRES SECTION 7B. FAILURE ANALYSIS | PROBLEM PROBABLE CAUSE REMEDY 1. Tractor rides hard. a. Over inflated tires. a. Reduce tire pressure below 15 psi (1.0 bars) and preferably to 8 to 10 psi (.55 to .68 bars). 2. Tractor wanders. a. Under inflated tires. a. Inflate tires to 8 to 10 psi (.55 to .68 bars). b. Worn rear wheel bearings. b. Replace bearings. Refer to Sec- tion 7D. C. Steering malfunctioning. C. Steering test. Refer to Sec- tion 8L. d. Wheel nuts loose. d. Tighten rear nuts to 65-85 ft-Ibs. (90-113 N.m). Tighten front nuts to 40-50 ft-Ibs. (54-68 N.m). e. Steer wheels out of adjustment. e. Adjust. Refer to Section 6E. 3. Poor traction. a. Over inflated tires. a. Reduce tire pressure below 15 psi (10 bars) and preferably 8 to 10 psi (0.55 to 0.68 bars). 7B-1 WHEELS AND TIRES SECTION 7C. TIRE SERVICE GENERAL Tires are subject to damage from sharp objects. If large punctures or tears occur, it is advisable to take the tire (installed on the wheel) to a qualified tire repair shop. The front (drive) wheels are bolted directly to the wheel hub; there are no wheel bearings to repair or service on the front wheels. The rear wheel should be serviced as described in Section 7D. SERVICE Tires are inflated to 8 to 10 psi (.55 to .68 bars) pressure. This pressure gives the best results for average use. Tire pressure should never be more than 15 psi (1.0 bars) and should be equal in all tires. If a tire is removed from the rim it should be inflated to approximately 22 to 24 psi (1.5 to 1.7 bars), when itis replaced. This assures proper seating of the tire bead to the rim. Then reduce the pressure to the desired level before using. NOTE Never use grease or oil on the rim when mounting a tire. Bead sealing of the tires may be repaired by using tire sealants available from tire repair shops. To apply sealant: 1. Break one bead from seal on rim and pull out past rim flange at bottom or install through valve stem. 2. Pour sealant into tire cavity. 3. Reseat bead on rim by inflating the tire to 22 to 24 psi (1.5 to 1.7 bars). 4. Rotate tire slowly to spread compound. 5. Reduce tire pressure to 8 to 10 psi (.55 to .68 bars). Wheel Hub and Brake Drum Tire Bead Valve Stem H— Bolt Torque to Wheel 40-50 ft-Ibs. (54-68 N.m) Tightening Sequence Figure 7C-1. Front Wheel and Tire Removal and Installation WHEELS AND TIRES SECTION 7D. REAR WHEEL SERVICE SERVICE (See Figure 7D-1) The rear wheel bearings should be cleaned and re- packed yearly, as follows: NOTE The wheel bearing cups and cones are serviced as matched sets. Do notinterchange right and left Install a new seal, lip of seal toward wheel. . Install a bearing cone onto axle. . Install bearing cups into wheel hub. 10. Slide wheel hub over axle until bearing is seated in its cup. 11. Install the bearing cone, and nut to the axle shaft. bearing parts. Identify each cup and cone for proper reassembly. 12. Tighten the axle nut, then back off 1/2 to 1 turn. 1. Jack or hoist the rear wheel off the ground. 13. Install the wheel and tire. Torque wheel nuts to 2. Remove the four wheel nuts and remove the wheel. 65-85 ft-lbs. (88-115 N.m). 14. Spin the wheel to check for proper wheel bearing 3. Remove the dust Loi gotter Key and nut. Pull the adjustment. The wheel should turn freely with no wheel and bearing oft the axe. end play. Tighten or loosen the axle nut as re- 4. Remove the bearing cups and cones from the quired. wheel hub. Remove seal. 15. When the wheel end play has been adjusted. Install 5. Clean the bearing cups and cones in solvent and a new cotter key. dry. Replace worn or damaged bearings. 16. Recheck bearing adjustment after 5 hours of use 6. Pack the bearing cones with grease. and adjust end play as necessary. Wheel Hub ‘Bearing Hub Cap Cup „”^ - x Whee! Nut 85-90 ft-Ibs. (115-122 N.m) ® - «” Xo Cotter Key \ Bearing Bearing Cone Cup Bearing Cone Figure 7D-1. Rear Wheel and Bearing Removal (Two Wheel Drive) 7D-1 8A. Repair and Service Tools and Materials ............000000 00e ee ee 0 00e eee eee 8A-1 8B. Failure Analysis ...........0.00000000 00000000 eee ee eee 000 eee eee ne ec eee eee 8B-1 8C. General Instructions ..............440000000 0000 na 0000000 00e 00000 000000000000 8C-1 General ..........11202100000 000 aa aa aa 0 a 0e sa ae ea ea 00000 0000 00 000000000000 0 8C-1 Hydraulic Tube and Hose Fitting ............000000000 000000 e eee eee eee e ee 000 8C-1 37° Flare Fittings ............00000000000 0000 eee eee eee 00000000 ee eee eee eee = 8C-1 Torque Recommendations .............00000 00000 eee ec e eee e eee eee 000000 eee S 8C-1 Special Hose Installation Instructions ...............0.00000000 rer Hehe nen HEHE 8C-2 O-Ring BOSS Fittings «coconuts 8C-2 Replacement O-Rings for O-Ring Boss Fittings .........e.eeeeeeeeeerreeerene 8C-2 ORS (Face Seal) Fittings ..............0000000 0000 eee ee ee cena eee ee eee 0000000 « -8C-3 Torque Recommendations ..............000000 00e ee 0 eee cena ee ee nee eee eee 8C-3 Replacement O-Ring for ORS (Face Seal) Fitting ...........0.000000000 0000 HH ° 8C-3 8D. Hydrostatic Transmission .............0.00000000000 00 nr EEE EEE enes 8D-1 General ...........121210100 00000000 0 0000 aa 00e 0 ea 00000000 0000000000 0000000 8D-1 Removal A AAA AA A NN 8D-1 Вера eee es 00 0 ea eee ee eee ee 000 ec ee eee « 8D-2 TH AP NN 8D-5 Charge Pump ............000000000 eee nee see eee sec 00000 ee eee eee ere 8D-5 Installation ...........220210000 000000 00 000000000000 0 00 00e 000000000000 00000 8D-12 8E. Hydraulic Implement Pump ............000000e ee een 0e een 00e e HEHE UNE 8E-1 General ...........eoocoosccococrerorocorecrcacacereocacacararecrererecarcares 8E-1 Removal ............eeococococrcoreorrccorceceanre ora rcancanerecereracaceres 8E-1 Repair .........0000000000 00e aa eee ee sa eee eee ee eee ee ee nee nee eee eee ec 0e eee eee 8E-2 Disassembly ..........200000 000 ane ee 0e am 0 eee ee eee ee 0e 000000 ee 000000000000 8E-2 Inspection ................ ee eee eet tetas вина е оне новеее 8E-3 Reassembly ..........200000 0000 aan aa 00000 0 sa 0 eee eee eee eee 0 eee tete eee 0e 8E-3 Installation and Alignment .............000000000 00000 eee 00000000 eee ec 00000000 8E-3 8F. Steering/System Relief Valve ..............00000 00e ee 0000 eee eee ee 0000000 e ee eee 8F-1 8G. Check Valve ..........eeeoeosesecsoccorcoccrerorrorecocarererarerecacare rte. 8G-1 Repair .............eeeecccorerorrocoreccccrenerecereacecar enero Une 8G-1 8H. Lift and Lower Control Valve ...............200000000 000000 000000000000 0000000 8H-1 General ...........122120000 0000 na 0e 0 a 00e a ee na 0 se 00000000 0000000000 0000 8H-1 Removal ..........oeoccoscocorcccrecrrcroccererarrocror cerrar eecereracereces 8H-1 Repair .........._eeeecorocorocrcacororrcaerrr erecta recacerareraceterrerees 8H-2 Installation .............eoococcscreccocororerroecrcorocareceacarececeamecos: 8H-2 Relief Valve Adjustment .............e.eeeesecocecorecoreeerecrarer eee 0 8H-2 Bl. Lift Cylinder .........._e.eeocccorcororccoccccacer rece reccacerer rentar 81-1 General .........eoeoocccoccosecocrococrrocracacarrace a recarenarecareccareree 81-1 Disassembly .........2000000000 000 ee 00000 se eee 000 000000 000000000000 eee 81-1 Inspection ...........0000000e ee eee ee een ae 0 eee en 0000000 tee 00000 00e te eee 0 81-2 Reassembly .........22000000 00e eee ae 0000 a see 00000000 00e eee 000000001000 81-2 8J. Implement Motor Control Valve ..........0..000000000 0000 nennen nenn UNE 8J-1 General ............222000000 0000000 00 sa ce 0 ea 00000 0000000000 000000000000 0 8J-1 =7=1 24101171 D AAA RAA AS 8J-1 Repair .........2000000000 00e en ce ee 0000 00e eee ee ee 0e ce 0 00 0e een eee 0000000000 8J-2 Relief 122021000000 00e 0e ea 00e 000000 0e 0e 000000000000 000000000000 0 8J-2 Adjustment .............00000 0000000 can eee ee eee 00000 ea 0e eee eee 0000 00e eee 0 8J-2 8K. Implement Motor ..........e..ee..eerecoccrrecacerroaccaceceereaareeecacaes 8K-1 General ..........eoecccooscsersrcorocrocarecrcorarocrcacarcrenerrcarrecareene. 8K-1 Removal ............2212000 0000000 0e 00 ae 000 0e 000000000000 000000000000 00000 8K-1 SECTION 8 HYDRAULICS Repair ..........00000000 0000 ea eee 0 0000000 eee ee 000000 ee 0e eee 000000000000 8K-1 8L. 8M. 8N. ISAS EMDlY oe ee eee 8K-1 \1пересноп .......... ee eee. 8K-2 ReasSSemMbly «oe eee eee. 8K-2 Installation ........202000002 022 Le ea aa a eee a a ee ee ea a ea a ee a a ee ee ee a ee a a ea ae aan» 8K-2 Hydraulic Field Test Procedures ..........0202200000 0004 aa aa ae ee ea aa ea a aa a ane a» 8L-1 General ..............eeomeecccrcaroreroecorercacarorecrcanranecacranrecarecaaace, 8L-1 As A Safety Reminder ... coi i eee te tt etree aaa 8L-1 Preiiminary Checks es tet et etter a ea ee a ea aan 8L-1 Field TeSt er R RR RRRRR RR RR RER RR RR RER RRKRERE RE 8L-1 Hydrostatic Charge Pump ................eeeeeeencscccccroacraracocecae caen 8L-1 Hydrostatic Traction Pump ..........200202000 00e eee ana ae a ea a aa a en en an aan een 8L-1 Steering/System Relief Valve ...... iii eet eee 8L-1 Power Steering System oo. i eee. 8L-1 Lift and Lower Control Valve ..............eeeecorcocccccrocecrococecracecocencen. 8L-1 Lift Cylinder oo ee eee teeta. 8L-3 implement Circuit ..... xccococcsocococccrocecracocooorracoozoceaco.. 8L-4 Instrument Test ............eeereecooccroracorerecacocococonarociaocenmoacaaa 8M-1 General ..............eoeoereoccccecocacoaorcrooracarecocecoacecrecac.oracanneaa 8M-1 Relief Valve Pressure Tests ..............oeoeceeoccrooccororacoracocac.anrenaea. 8M-2 System/Steering Relief ................eereecocorcacocaraoracenreareocanaae 8M-2 Lift Relief Valve ...............o_.eeeeeececccccrccocarecacoronccoracecaceaco. 8M-3 Relief Valve Adjustment ...............eeeeeoocecccccoronorocaracareramernar. 8M-4 Implement System Test ............._eoeecocccocraarenacacancaacaacececraceae. 8M-5 Hydro Charge Pump Pressure Relief ................eeeeeenccccoroeccorerocasa. 8M-5 Charge Pump Test ................_eeocrocccccoccccorecaconecaracaocaceooaaco. 8M-6 System/Steering Relief Valve Test ..............oeeresereccococororercaroca, 8M-6 Steering System Test ............oeecocredecocrcosrerocaceoeecocacaracecanae, 8M-7 Lift Valve Test «oo i i i ete eter aaa. 8M-8 Implement System Test ..............eoeonococcccccrccrcoraacccacwaarwocaceceno 8M-9 PUMP EEE 8M-9 Hydraulic Diagrams, Schematics and Component Locations .................... 8N-1 Flow Diagram UP E 8N-1 SchematicC .................eeoceeeccccao a ee eee era. 8N-3 HYDRAULICS SECTION 8A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Cleaning materials: Lubricants: Other service items: Standard automotive hand tools, including torque wrench, seal drivers, snap ring pliers, bearing driver. Special Tool Kit, Kent Moore Part No. J26905 Kent-Moore Heavy Duty Division Sealed Power Corporation 29784 Little Mack Roseville, MI 48066-2298 Tachometer Hydra sleuth or in-line tester equipped with load valve Universal Pressure test kit Stoddard or equivalent solvent. Detergent and water. Hydraulic Oil Options: Jacobsen Part No. 502693, 5 gal. (19 liter). Jacobsen Part No. 502696, two 2-1/2 gal. (9.5 liter). Sunoco H.P. Engine Oil SAE 10W-30. Mobil Delvac (Special) SAE 10W-30. Grease: Sunray DX671 or Gulf Supreme No. 0 Seal Kits (available from Jacobsen distributors) Hydraulic Hoses and Fittings Required for Instrument Test 1. Hoses adaptable from the hydro-sleuth to the following 37 degrees flare sizes: a. #6 9/16-18 b. #8 3/4-16 c. #10 7/8-14 2. A jumper hose 4 feet long, size #8 3/4 -16 with #10 7/8 - 14 female 37 degrees flare swivels on each end. 3. #10 nipple. 8A-1 HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM REMEDY . System noisy. PROBABLE CAUSE Traction System Oil cold. Air in system. Let oil warm up. Low oil level (Section 11C). Loose inlet connection, tighten. c. Charge pump internal failure. c. Check charge pressure (Section 8M). d. Hydro internal damage. d. Repair (Section 8D, 8M). e. Faulty relief. e. Repair (Section 8F). . No traction in either a. Oil supply. a. Low oil level (Section 11C). direction. b. Faulty charge pump. b. Check charge pressure (Sec- tion 8M). Repair (Section 8D). c. Faulty charge relief. c. Check charge pressure (Sec- tion 8M). Repair (Section 8D). d. Hydro faulty. d. Repair (Section 8D). e. Traction pedal linkage. e. Repair (Section 5D). . Traction in one dirction a. Internal check valve in hydro. a. Repair (Section 8D). only. b. Pedal/linkage out of adjustment. b. Adjust (Section 2C). a. a. . Sluggish response to acceleration or deceler- ation. Air in system. Low charge pressure. Internal damage of hydro. Low oil level (Section 11C). Loose inlet line; tighten. Check charge pressure (Section 8M). Charge pump relief faulty (Section 8F). Internal charge pump damaged, replace. С. c. Repair (Section 8D). Power Steering (See Section 6B) Lift and Lower System — Attachments will not raise | a. Linkage damaged or out of a. Repair and/or adjust when lift pedal is depressed. adjustment. Low pump charge pressure. c. Lift valve relief set too low or faulty. (Section 2C). b. Repair (Section 8L). c. Reset (Section 8M). Repair (Sec- tion 8F). d. Attachment cylinder(s) internal d. Repair (Section 81). leakage. Attachment does not float. | a. Lift mechanism out of adjustment. | a. Adjust (Section 2C). b. Oil supply. b. Low oil level (Section 11C). . Noisy when raised or a. Lift valve out of adjustment. a. Adjust (Section 8M). b. b. lowered. Air in system. Valve relief set too low. Low oil level (Section 11C). Loose inlet connection, tighten. Adjust (Section 8M). 8B-1 HYDRAULICS SECTION 8B. FAILURE ANALYSIS PROBLEM | PROBABLE CAUSE | REMEDY Implement System 1. Implement does not come | a. Control linkage fault. a. Inspect and adjust. on when lever is activated. b. Pump coupling. b. Repair (Section 8E). c. Pump inlet clogged. c. Clean and inspect. d. Pump section faulty. d. Insolate faulty section (Section 8L). Repair (Section 8E). e. Faulty motor control valve. e. Repair (Section 8H). f. Faulty system relief valve. f. Test (Section 8M). Repair (Section 8F). g. Faulty Implement motor. g. Test (Section 8L). Repair (Section 8J). h. Air in system. h. Low oil level (Section 11C). Inlet strainer plugged (Section 8C). Loose inlet line, tighten. General 1. System runs hot. | a. Cooler plugged. a. Clean external area of cooler. 8B-2 HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS GENERAL e Hydraulic hose and tube lines should be inspected NOTE daily to check for loose connections, kinks, worn or cut hoses, etc. Be sure tubes and hoses do not con- Component location illustrations and hydraulic tact other frame parts which could cause abrasive diagrams are located at the end of this section. wear. Always replace worn hose or tube assemblies The following general instructions apply to all hydraulic system service procedures. Carefully read and adhere to each precaution. e Dirt in the hydraulic system will cause damage to system components and reduce the life of the machine. Clean all dirt from around fittings and components before disconnecting any hydraulic lines or removing components. e Relieve system pressure at com ponents or hydraulic lines by slightly loosening the line fitting before removing. e Immediately after disconnecting a hydraulic line, cap the line fitting and plug the port of the removed component from the machine. This not only pre- vents the entry of dirt into the system but also elimi- nates the loss of hydraulic fluid. e Identify and label all linkages, hydraulic lines and component parts. Mark the pump and valve sections before removal and disassembly. This will ensure the correct order of parts during reassembly and installation. e Drain hydraulic fluid from components before disassembly. e Discard all seals and O-rings as they are removed. Install new seals and O-rings during reassembly. Most seals are available in component kit form from your Jacobsen Distributor. A CAUTION Do not use steam or high pressure washers to clean hydraulic components. e All parts should be thoroughly cleaned in a suitable non-flammable solvent and air blown dried before beginning repair or reassembly. e Perform repair procedures in a clean work area using clean tools. e Do not force or pry components apart or together. Light tapping with a plastic mallet is recommended unless otherwise specified in the repair instruction. e Unless otherwise indicated, apply a light coat of clean hydraulic fluid to parts as each is reassem bled. Apply clean grease to O-rings, if necessary, to hold them in position during reassembly. 8C-1 before operating machine. A CAUTION If, during the disassembly of any hydraulic component metal chips or damage is found the hydraulic system must be drained, thoroughly flushed with clean oil and then refilled. A WARNING Always check hydraulic tank level after removing and installing a hydraulic component or line. Severe damage to system components can result if they are allowed to run dry. HYDRAULIC TUBE AND HOSE FITTING A WARNING To avoid serious bodily injury, always lower mowers fully, place all controls in neutral and shut off engine before inspecting hydraulic lines or hoses. Never run hands across tubes, hoses or fittings to check for leaks. Hydraulic fluid escap- ing under pressure can have sufficient force to penetrate skin and may cause infection in a minor cut or opening in the skin. 37% FLARE FITTINGS Torque Recommendations 1. Assemble tube nut adapter to fitting with minimum torque (finger tight) until flare contacts seat on fitting body. HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS 2. For tightening reference, mark a line lengthwise on Replace t O-Ri Ri 4; the flats of both the nut and adapter fitting with a pee ings for O-Ring Boss Fittings marker as shown in Figure 8C-1. A B O-Ring 3. Using a wrench, tighten the nut the amount shown Tubing O.D. Thread Jacobsen in the chart below. The line will show which fittings or Hose LD. Size Part No. have been tightened correctly and also indicates if a Y 5/, 5-24 459290 fitting is becoming loose. Ye 34-24 459291 Ya 7e-20 339896 %e 14-20 459293 % % 6-18 339897 Yo 3-16 339898 % 7-14 339899 Ya 11-12 339900 % 1346-12 459296 1 1546-12 339901 Assemble finger tight 1% 154-12 339902 and mark as shown. | 1% 1746-12 339903 2 2165-12 459300 Tighten per chart. NOTE O-rings should be lubricated with the fluid to be Figure 8C-1. Reference Marking used in the system prior to assembly. Tube O.D. or Hose 1.D. Rotate No. of Hex Flats 3/8" 2 1/2" 2 5/8" 1-2 1" Y%-1 Special Hose Installation Instructions 1. Holdthe fixed portion of the hose coupling with one wrench; use a second wrench to tighten or loosen the hose nut. This will avoid damaging the fitting seal. When tightening a hose, do not permit it to twist; hold it in a normal straight position. 2. When installing mower hoses, place fittings at angles to avoid contact with fixed parts when turning. Make sure hoses are assembled to proper “A” and “B” ports on components. O-RING BOSS FITTINGS Figure 8C-2. Boss Fitting O-Ring Installation On hoses with O-ring fittings, make sure O-rings are clean and hose fittings are properly seated before tightening. Always install new O-rings. See Figure 8C-2. 8C-2 HYDRAULICS SECTION 8C. GENERAL INSTRUCTIONS ORS (Face Seal) FITTINGS Torque Recommendations (See Figure 8C-3) И ‚ Ft-Lbs. Ft-Lbs. Face seal fittings have O-ring grooves machined into Size Minimum Maximum the flat male face. This O-ring and flat surface mate against the mating fittings machined face. 04 10 (13.5 N.m) 12 (16.2 N.m) 06 17 (23.0 N.m) 20 (27.1 N.m) The swivel nut can be retracted to inspect the O-ring 08 26 (35.2 N.m) 39 (52.8 N.m) and fitting face without removal of tubes or com- 10 46 (62.3 N.m) 56 (75.8 N.m) ponents. 12 64 (86.7 N.m) 79 (107.0 N.m) 16 93 (126.0 N.m) 105 (142.2 N.m) 20 125 (169.3 N.m) 140 (189.7 N.m) 24 150 (203.2 N.m) 182 (246.1 N.m) O-Ring Groove Metal Seal O-Ring Back Up N ^^ Replacement O-Ring for ORS (Face Seal) Fitting TEA ORS (Face Seal) | ORS (Face Seal) | Jacobsen N Tube Size O-Ring Size Part No. {== 4 11 339908 HL. 6 12 339909 8 14 339910 Flat Face 10 16 339911 12 18 339912 16 21 339913 20 25 339914 24 29 339915 Figure 8C-3. ORS (Face Seal) Fitting 8C-3 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION GENERAL The variable displacement hydrostatic pump supplies oil for both traction and lift cylinder. The pump is driven by the engine through a drive shaft. A fan blade attached to the drive shaft provides extra cooling. REMOVAL (See Figure 8D-1) NOTE Do not attempt to remove or disassemble hydro unit for repair until pump tests described in Sec- tion 8L or 8M are performed. 1. Remove seat and seat pan to gain access to the hydro. . Thoroughly clean outside of entire hydro with a suitable cleaning solvent. Do not use a solvent that will affect paint, gaskets, rubber seals or plastic. . Label all hydraulic lines at hydro for proper identification during installation and disconnect lines. Plug hydro ports and cap line fittings. . Disconnect traction control linkage and traction arm from hydro. . Remove drive shaft (Section 4C). . Support hydro and remove hardware securing hydro to transaxle. Plug Ports and Cap All Lines Transaxle ~ 9 № WU IP). cos mw mm e E ее ее = Hydro Actuating | Arm Seat and Seat Pan To Engine Coupler Figure 8D-1. Hydrostatic Pump Removal 8D-1 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION REPAIR If only the charge pump is to be repaired, proceed with steps 28-39 for disassembly and steps 49-60 for reassembly. 1. Drain all oil from hydro. 2. Place hydro input shaft side down, on work bench. A 2 x 6 x 10” block of wood with a 3/4” hole for pump shaft is recommended as a suitable bench fixture. 3. See Figure 8D-2. Remove two socket head screws to remove motor cover. Figure 8D-2. Body Cover Disassembly 4. Place a wide rubber band around the pump rotorto keep the ball pistons in place and remove. A CAUTION The pump ball piston assembly must remain intact as the ball pitons are matched to the pump rotor. A CAUTION If removed, each ball must be replaced in the same bore from which it was removed. Use a suitable container for piston ball storage such as an egg carton or ice cube tray. 5. Inspect the rotor assembly. Remove the piston balls from the rotor, one at a time, by working clockwise from the letter stamped in the face of the rotor and placing in a prepared container. 6. Inspect the piston balls. They must be smooth and completely free of any irregularities. 7. Inspect rotor bores, rotor bushing and pintle jour- nals for irregularities or excessive clearance. The ball piston to rotor bore clearance is select fit elec- tronically to .0002 to .0006 of an inch. When irregularities or excessive clearance are noted, replace the complete rotor assembly. Install pump ball pistons in their matching bores. Hold them in place with a rubber band until ready to reassemble. 8. Remove seal ring from body assembly. 9. Remove output pinion. 10. Remove bearing retaining ring. 11. Press output shaft toward inside of cover. 12. Press bearing and seal out of cover. Retaining Ring — Bearing — Seal Figure 8D-3. Motor Cover 13. See Figure 8D-4. Inspect motor race contact line. Only if damaged, remove and replace. HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION 14. Install new motor race by pressing squarely on ring. Motor Race Line | Figure 8D-4. Motor Race 15. Remove pintle assembly. If necessary to aid removal of pintle, use a soft faced hammer to tap on hydro cover. 16. Do not remove charge relief valve unless pump test has indicated damage. If damage is suspected see Figure 8D-5 and remove plug, spring and ball. Replace damaged parts and install plug to just below pintle surface. Do not tighten. Relief — Valve Plug Figure 8D-5. Charge Relief Valve Repair NOTE Remove dampening pistons only if face surface of pistons are scored. 17. Glue a bolt head to dampening piston, pull out. Do not tap on pintle or journal to remove. A CAUTION Dampening rn — 1 Bolt Guard ______ = To Piston a : Dampening CO. Pistons jar Back-Up WN Rings N î O-Ring Seals Figure 8D-6. Damping Piston Removal 18. If pump tests have indicated problems with the check valves or acceleration valves see Figures 8D-7 through 8D-10 and proceed as follows: (if disassembly is not required proceed to step 20). 8D-3 Coil Pin Solid Pin Acceleration Vaives Figure 8D-7. Check/Acceleration Valve Repair HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION a. Press solid pin from pintle housing (see Figure 8D-7). b. Insert 3/16” diameter rod through the check valve body as shown in Figure 8D-8. Tap rod against check valve ball to dislodge retaining rings. Repeat for second check valve ball and ring. Shake dislodged rings and balls out the large port area of pintel journal. Check Check Valve 3/16" Vaive do Rod Body CO O errante aro pe A ne 3 aa mage Retaining Ring Figure 8D-8. Check Ball and Retaining Ring Removal c. See Figure 8D-9. Push the rod through the check valve body against the acceleration valve body and drive both the valve body and ball out of the bore. Repeat method for second valve body and ball. Remove springs. NOTE Some models use different springs for forward and reverse. Be sure to keep the springs with the acceleration valves so they can be replaced in the same bore from which they were removed. Valves Figure 8D-9. Acceleration Valve Removal d. See Figure 8D-9. Press or drive coil pin from pintle housing. Place the used ball through the port into the check valve body. Place the 3/16” diameter rod through the acceleration valve bore against the check valve ball and drive the check valve body and ball from the pintle housing. Repeat this method for the second check valve body. Check Place Old Ball Valve in Check Body Valve Body Coil Rod Pin Figure 8D-10. Check Valve Body Removal 19. See Figures 8D-7 through 8D-10 and install check and acceleration valves as follows: a. Clean all parts thoroughly. Inspect parts for defects. Replace all defective parts, including retaining rings, which were damaged when driven out of their seats. b. Install acceleration valve springs and acceleration valves. Be sure that both acceleration valve bodies slide freely in the bores and that the orifices are clean. c. Press the two balls against the acceleration valve bodies until the solid pin will clear. Press or drive in the pin so it is flush with or slightly below the pintle surface.. d. Install new check valve retaining rings and balls in pintle bores. A CAUTION Use a press to install check valve bodies. Driving them into position may dislodge the retaining rings. e. Press new check valve bodies into bores until coil pin will clear. f. Press or drive the coil pin in to flush or slightly below pintle surface. HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION Pump 20. Place a wide rubber band around the pump rotor to keep the ball pistons in place and remove. A CAUTION The pump ball piston assembly must remain intact as the ball pistons are matched to the pump rotor. Pump Rotor Rubber Band Ball Piston ”. ~~ Figure 8D-11. Seal and Rotor Assembly Removal A CAUTION If removed, each ball must be replaced in the same bore from which it was removed. Use a suitable container for piston ball storage such as an egg carton or ice cube tray. 21. Inspect the rotor assembly. Remove the piston balls from the rotor, one at a time, by working clockwise from the letter stamped in the face of the rotor and placing in a prepared container. Inspect the piston balls. They must be smooth and completely free of any irregularities. Inspect rotor bores, rotor bushing and pintle jour- nals for irregularities or excessive clearance. The ball piston to rotor bore clearance is select fit elec- tronically to .0002 to .0006 of an inch. When irregularities or excessive clearance are noted, replace the complete rotor assembly. Install pump ball pistons in their matching bores. Hold them in place with a rubber band until ready to reassemble. 22. 23. 8D-5 24. See Figure 8D-12. Slide the cam ring from the pivot pin and control shaft in the body. Then lift ring from the cover. Control Race ——— Shaft Insert Cam < Ring Pivot | Gt Buttons Pi : Control Shaft Figure 8D-12. Cam Ring Removal 25. Remove the control shaft insert. 26. Inspect area where the ball pistons contact the race. This area must be smooth and completely free of irregularities. If it is not, replace the pump cam ring. NOTE The race is pressed fit into the cam ring. If the race is damaged, replace the cam race and ring as an assembly. 27. Remove two buttons. Charge Pump 28. See Figure 8D-13. Remove shield. 29. Use 1/4" Allen wrench, remove 5 socket head cap- CAUTION Remove paint, burrs and nicks from input shaft before removing charge pump assembly. A 30. Remove charge pump assembly, using a suitable bearing puller. HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION Socket Cil Seal —— > Head —m——— Capscrews (5) Shield Charge 7 Pump w/Bushing | Square LD Figure 8D-14. Seal Removal Cut | | Seal | Input Top Shaft Snap 7 Cover Carrier A Rolls (6) ee Carrier Lower Snap Figure 8D-13. Charge Pump Removal Ring Carrier Drive Pin A CAUTION = Do not pound on the bearing puller while remov- Square ing the charge pump body. Apply a steady pull Cut Seal only. Input Shaft A CAUTION Figure 8D-15. Carrier Assembly and Plate Removal/Inspection Do not damage the bore of the input shaft during removal of charge pump. A CAUTION 31. Remove the square cut seal from the pump assem- Do not mark the roll carrier in a way that would bly and discard. damage the carrier surface. 32. See Figure 8D-14. Remove oil seal from charge pump. Discard oil seal. 33. See Figure 8D-15 and remove six carrier rolls. 36. Remove carrier and carrier drive pin from input 34. Remove top snap ring. shaft. 35. Mark top of carrier indicating which side is up. 37. Remove lower pump plate and snap ring. 8D-6 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION 38. Inspect the carrier, rolls, inner race contact areasin a. Measure the distance between the dowel pin the charge pump housing and pump plate. If any and the end of the control shaft as shown in irregularities are found, replace the complete Figure 8D-17. charge pump assembly. 39. Remove square cut seal from cover and discard. 40. See Figure 8D-16. Clean the outside of the input an shaft of nicks and burrs that could damage the Measure this Distance shaft bushing. Remove the shaft. Control Shaft Dowel Pin Input Shaft ZZ Oil Seal Cover Assy. Figure 8D-17. Control Shaft Replacement (Step 45a) . b. Turn cover over. Use dimension obtained in Figure 8D-16. Input Shaft Removal Step a. to locate dowel pin in cover face. Drill 11/32" diameter hole at center point of dowel pin. Drill hole exactly in line with center of shaft 41. Inspect input shaft for stripped keyways or other . as shown in Figure 8D-18. irregularities. If found, replace the input shaft. 42. Inspect bushing located in face of cover for damage. If found, replace the entire cover assembly. 43. Use a sharp, narrow edged tool to pierce the top metal part of the oil seal and remove seal from the cover. A CAUTION © WO NA Do not scratch the control shaft or distort the seal counterbore when removing seal. 11/32" Dia. Same as Dim. Measured in Figure 8D-14 — Control Shaft 44. Inspect cover assembly, especially around the control shaft area. Replace the cover assembly if it is broken, cracked or if side clearance between control shaft and cover exceeds .006" (0.1524 mm). Figure 8D-18. Control Shaft Replacement (Step 45b) 45. In most cases, it will not be necessary to remove the control shaft from the cover. If the dowel is loose or broken in the control shaft, replace the c. Press damaged pin from control shaft. Remove shaft as follows: control shaft and washer. 80-7 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION d. Tap hole drilled with 1/8” pipe tap. Install 1/8” diameter flush type pipe plug as shown in Fig- oi Seal ure 8D-19. € | | 1/8" Pipe Plug 1-1/4" Figure 8D-21. Control Shaft Replacement (Step 45f) Figure 8D-19. Control Shaft Replacement (Step 45d) CAUTION Be careful not to damage the inner portion of the oil seal. Excessive pressing or driving of the oil seal will damage the rubber portion of the oil seal. Dowel Washer Pin ! 47. Install input shaft in cover. e. Install new control shaft and washer in cover as A shown in Figure 8D-20. 48. Turn cover over. Support input shaft from under- neath. Use a piece of steel bar stock or hard wood — 2" in diameter by at least 2-1/2" long to keep the shaft cross pin against the cover as shown in Fig- ure 8D-22. Control Shaft Input Figure 8D-20. Control Shaft Replacement (Step 45¢) Shaft Bushing f. Press new dowel pin through the shaft. Leave 1-1/4" of dowel extending from the shaft as shown in Figure 8D-21. 46. Lubricate 1.D. of new oil seal with clean lubricant. Then press or tap seal in bore until completely ] | seated. Figure 8D-22. Input Shaft Installation 8D-8 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION 49. See Figure 8D-23. Lightly lubricate new square cut 51. See Figure 8D-25. Install snap ring in lower snap seal and install in seal groove in cover. ring groove. | 52 Lubricate carrier drive pin and install in keyway of input shaft. Carr o arrier . Rolls (6) O. . Carrier Carrier Carrier —— CD Drive Pin Lower Snap Ring Lower Snap Ring Groove Figure 8D-23. Plate and Seal Installation Figure 8D-25. Carrier Assembly 50. Install pump plate on cover. Either side of the pump plate may face the cover regardless of input rotation as shown in Figure 8D-24. IMPORTANT For correct carrier rotation the leading edge of carrier must rotate in the same direction as the input shaft as shown in Figure 8D-26. O e rrocproscevacer + re... DT ine pena. NO CCW Rotation N e be Dean Za Figure 8D-24. Plate Installation — Rotation o - E DA ; а cow К” IMPORTANT 7 Stamping on cover indicates if charge pump rotation is clockwise or counterclockwise. Figure 8D-26. Carrier Rotation NOTE If the charge pump body is replaced, it may be 53. Install carrier on input shaft with side marked “up” necessary to check the input rotation before facing up. Be sure keyway in carrier fits over carrier assembly. drive pin in input shaft. 8D-9 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION 54. See Figure 8D-27 and install upper snap ring. 55. Lightly lubricate and install the six carrier rolls in the carrier. Use a small amount of petroleum jelly or equivalent to hold the rolls in place. Upper Snap Ring Carrier Lower Snap Ring с Figure 8D-27. Input Shaft Bearing Installation 56. Lubricate inner surface of new oil seal and install in charge pump housing as shown in Figure 8D-28 with the rubber lip toward the bore. Make sure seal is completely seated. 57. Lightly lubricate new square cut seal and install in seal groove of pump housing. IMPORTANT If an elbow fitting is used in the pump inlet, it must be installed before mounting charge pump. 58. See Figure 8D-29. Align charge pump dowel pins with holes in cover. Protect oil seal lip from keyways in shaft. Square DD Cut Seal Figure 8D-28. Seal Replacement A CAUTION Excessive pressing or force on oil seal may cause damage to rubber sealing portion or may distort counterbore of housing. Torque to 15 ft-lbs. (20 N.m) Screw (1) 5/16" x 1-3/4" Screw (4) = 5/16" x 1-1/4" — e Charge Housing Figure 8D-29. Charge Pump Installation A CAUTION Install 1-3/4" screw in thicker section of charge pump body. If installed and tightened in any of the other four holes, internal damage could occur. 59. Install four screws (5/16” x 1-1/4") and one screw (5/16” x 1-3/4") in pump housing. Torque to 15 ft-lbs (20 N.m). 60. Install protective shield on housing, making sure raised portion of shield is facing outward. 61. See Figure 8D-30. Install 2 buttons in the cover. 62. Install the cam ring insert with the hole away from the cam ring as shown. 63. Align the cam ring with the control shaft pin and the cam ring pivot pin. 8D-10 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION N on So Ring a Insert | Buttons Control Shaft Pin Cam Ring Pivot Pin Figure 8D-30. Cam Ring Installation Install the cam ring with the flush side of the bearing race facing the cover. Press in firmly until the cam ring has bottomed in the cover assembly. IMPORTANT Cam ring must move freely from stop to stop. If binding occurs at either stop, rotate the cam ring insert 180° . Check the cam ring movement again. A CAUTION Keep rotor assembly intact with wide rubber Figure 8D-32. Pintle Assembly Alignment band. Remove rubber band after installing rotor assembly in cover assembly. See Figure 8D-31. A CAUTION 64. Align the slotin the pump rotor with the input shaft cross pin. Install rotor assembly on shaft as shown Do not force pintle into pump rotor assembly. It is in Figure 8D-31. a slip fit. 65. If a new pintle assembly is installed, it may be necessary to check the pintle rotation before assembly. This is done by placing a small ruler or straightedge in the porting slot as shown in Figure 8D-32. 8D-11 HYDRAULICS SECTION 8D. HYDROSTATIC TRANSMISSION 66. Align dowel pin hole in pintle assembly with cam ring pivot pin. Install the pintle into the pump rotor assembly and pump housing as shown in Figure 8D-33. 67. Lightly grease a new square cut seal and install it around the pintle assembly. Square Cut Seal Pintle Assy. > Oo DA Figure 8D-33. Pintle Assembly Installation Cam Ring Pivot Pin oo 68. See Figure 8D-34. Install seal, bearing and bearing retaining ring in motor cover. 69. Install output shaft, press from inside out. 70. See Figure 8D-35. Remove rubber band from rotor. 71. Install the motor cover with two 5/16” x 1-1/4" socket head capscrews. Torque to 15 ft-Ibs. (20 N.m). 72. Install motor pinion and snap ring. 73. Fill hydro with oil through the case drain port. See Section 11 for oil recommendations. INSTALLATION 1. Clean mounting surface of hydro and transaxle. 2. Position hydro in transaxle and secure using the mounting hardware. 3. Install drive shaft as described in Section 4C. . Connect traction control linkage. . Connect hydraulic lines. Retaining -D Bearing © > | Ring Seal Figure 8D-34. Motor Cover Assembly Torque to 5/16" x 1-1/4" © am" 15 ft-lbs. Screw (2) $ (20 N.m) (7 Pintle _ N O Cover © o Cover 8D-12 Figure 8D-35. Pintle Cover Installation 6. Startengine and check operation and hydraulic system for leaks. Adjust traction linkage as described in Section 2C. HYDRAULICS SECTION 8E. HYDRAULIC IMPLEMENT PUMP GENERAL 1. The hydraulic implement pump supplies oil for the attachments. The pump is driven off the engine fly- 2. wheel. REMOVAL (See Figure 8E-1) NOTE Do not remove hydraulic pump for repair unless test procedures (Section 8L and/or 8M) indicate internal leakage. Lower attachment to ground and remove ignition key. Drain hydraulic tank. After tank is drained remove inlet and outlet hoses. Remove attaching hardware and pump. Mounting Bracket Outlet Bracket Mounting Bolts Inlet Figure 8E-1. Hydraulic Pump Removal 8E-1 HYDRAULICS SECTION 8E. HYDRAULIC IMPLEMENT PUMP REPAIR (See Figure 8E-2) Repair of the hydraulic pump is limited to the replacement of seals only. Disassemble and reassemble the pump as shown in Figure 8E-2 adhering to the important instructions and precautions. 2. Disassembly 1. Clean exterior of pump with suitable solvent before removing tie bolts. Before disassembly mark pump sections, starting at drive shaft end, to ensure correct order and position of part when reassembling. Recommended method of marking body sections is to use a fine point metal punch, making one indentation for section #1, two indentations for section #2, etc. Mounting Flange O-Rings O-Ring Tie Rod Cover Gear Set Pressure Block Figure 8E-2. Hydraulic Pump Repair 8E-2 HYDRAULICS SECTION 8E. HYDRAULIC IMPLEMENT PUMP A DANGER Never pry pump sections apart as damage to sealing areas can result. Use of a soft face hammer to tap sections apart is recommended. 3. After removing tie bolts, disassemble pump one section at a time. Before removing gear sets, mark aline across meshing teeth to ensure that gears are reassembled in the same position (see Figure 8E-3). 4. Place parts in assembly order, on a clean work area as they are removed. 5. Discard seals as they are removed. Inspection 1. Keeping parts in assembly order, clean and air dry each for inspection. Look for metal chips or slivers during cleaning (an indication of damage to pump or other hydraulic component). 2. Inspect all parts for cracks, nicks, burrs and excessive wear. Replace entire pump if found damaged or worn. Marker > Mark alignment mark across meshing teeth before disassembly. Figure 8E-3. Marking Gear Teeth Reassembly (See Figure 8E-2) 1. Apply a coat of clean hydraulic oil to all parts to ease assembly. 2. Assemble pump one section at a time, building up from flange section. 3 Use a new seal kit during assembly. Use clean grease to keep seals in position. 4. Remove alignment mark from gear sets after they have been installed with teeth in mesh. 5 Rotate drive shaft after assembling each section to make sure there is no binding between parts. 6. Use extreme care when installing shaft seal. It must seat squarely in seal bore. Use the double end seal. Use clean grease on shaft and put tape over keyway to avoid cutting seal during assembly. 7 Install the bolts, finger tight and rotate drive shaft to make sure it turns freely. Tighten tie bolts evenly and in steps to a final torque of 190-210 in-Ibs. (21.2-23.5 N.m). INSTALLATION AND ALIGNMENT (See Figure 8E-1) 1. Apply a coat of moly type grease to the pump shaft spline. 2. Install pump making sure inletis on the right side of tractor. | 3. Check for proper alignment. Pump shaft must slide freely in to coupling when mounting holes in pump flange and mounting plates are aligned. If pump mounting bolts can not be installed without apply- ing a side load to the pump, the pump must be aligned. NOTE Always apply an ample coat of moly type grease to the splined pump shaft. 4. To align the pump to the coupling, loosen the four (4) pump bracket mounting bolts until there is free play between the mounting bracket holes and mounting bolts. Slide the pump shaftinto the coupling. Move the mounting plate within the tolerance of the bolt holes until the pump mounting bolts can be easily installed with no side load. 5. Tighten pump mounting bolts and mounting bracket bolts to 27-33 ft-lbs (37-45 N.m). 6. Connect inlet and outlet hydraulic lines. 7. Fill hydraulic tank with clean oil (Section 11). 8. Start engine. Check for leaks and hydraulic tank level. Break in new or rebuilt pump slowly. NOTE At this point the pump can be tested as described under “Instrument Test” Section 8M. HYDRAULICS SECTION 8F. STEERING/SYSTEM RELIEF VALVE STEERING/SYSTEM RELIEF VALVE REPAIR Repair of the relief valve is limited to adjusting pressure only. Pressure is set at 900 + 90 psi. CW: Increase Pressure CCW: Decrease Pressure Pressure Adjustment Screw Figure 8F-1. Power Steering Relief Valve 8F-1 HYDRAULICS SECTION 8G. CHECK VALVE REPAIR Repair is limited to cleaning only. Use a punch, manually push poppet off its seat and flush with cleaning solvent. If the problem still exists, replace valve. 8G-1 Figure 8G-1. Check Valve HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE GENERAL | REMOVAL (See Figure 8H-1) The lift and lower control valve is a 3-position, 6-way 1. Lower implement to ground and remove ignition open center valve. It is connected to the lift/lower foot keys. pedal. In the neutral (center) position, oil flow is from the power steering unit, to the valve. When the lower 2. Remove the floorboard. pedal is depressed, oil flow from the valve is redirected 3. Label all hydraulic lines at valve for identification to the lift cylinder. Repair of the valve is limited to during installation. replacement of O-rings in the valve. Hydraulic testing 4. Disconnect hydraulic lines at valve. Plug valve ports of the valve is described in Sections 8L and/or 8M. and cap line fittings! 5. Disconnect pedal linkage. 6. Remove attaching hardware and valve. Yoke Pedal Control Rod Figure 8H-1. Lift/Lower Control Valve Removal and Installation 8H-1 HYDRAULICS SECTION 8H. LIFT AND LOWER CONTROL VALVE REPAIR (See Figure 8H-2) 1. 2. B © о ID ON Remove screw and spool cap. Carefully slide spool out of valve body just enough to expose O-ring. Discard O-rings. Install new O-rings on valve spool. Carefully slide spool through valve body until O-ring on clevis end is exposed. Discard O-ring. Install new O-ring. Carefully slide spool back into valve body. Inspect spring for distortion or breaks. Place a small amount of LOCTITE on the retaining screw. 9. Install spool cap and screw. Torque screw to 24-36 in. Ibs. INSTALLATION (See Figure 8H-1) 1. Install valve with attaching hardware. Tighten capscrews to 7-9 ft-lbs. (9-12 N.m). 2. Connect hydraulic lines to valve. Tighten line fittings as described in Section 8B. 3. Connect pedal linkage to valve. RELIEF VALVE ADJUSTMENT See Section 8M for adjustment procedure. O-Ring O-Ring | y Spool y fl Cap = ; <——— Retaining Screw Relief Valve Assembly Figure 8H-2. Lift/Lower Control Valve Repair 8H-2 HYDRAULICS SECTION 8l. LIFT CYLINDER GENERAL The Turf Cat tractor uses one hydraulic cylinder to raise and lower attachments. A CAUTION During repair of cylinder, use extreme care not to damage the body, rod or sealing surfaces of the cylinder. Disassembly (See Figure 81-1) 1. Clean and air dry exterior of cylinder. 2. Drain all the oil from the cylinder. 3. Disassemble following the steps in Figure 81-1. Barrel Piston DO kn T/ 9 Lock Ring ha e Lock Ring O-Rings STEP 2 Remove nylon spacer. XT 3/4" STEP 3 Push rod guide into cylinder approximately 3/4". O-Ring Rod Guide Code) a — 0 Lock Ring STEP 4 / Remove head lock ring from inside y cylinder body. Clg STEP 1 - Remove rod guide lock ring. STEP 5 Remove sharp edges from lock ring Spacer groove. T a Rod Assembly STEP 6 Pull rod assembly from cylinder body. Piston O-Ring nt —e (Y чае) STEP 7 Remove shaft nut, piston and O-ring. Figure 81-1. Lift Cylinder Disassembly 81-1 HYDRAULICS SECTION 81. LIFT CYLINDER Inspection 2. Install seal kit as shown in Figure 81-2. 1. Inspect all parts for excessive wear, cracks and NOTE broken parts. Do not install rod O-ring at this time. 2. Discard all O-rings, seals and backup rings. 3. Lubricate all parts before assembly Reassembly 4. Follow the steps as illustrated in Figure 81-3 for 1. Lightly lubricate O-rings, backup rings and seals. reassembly. Lock Ring Backup O-Ring Large Rings O-Ring Spacer Lock Ring Small NAL II NNN A ij \ O-Ring O-Ring Wipers Figure 81-2. Seal Kit Installation 81-2 HYDRAULICS SECTION 81. LIFT CYLINDER O-Rin Piston 9 Nut 0 5 Backup Washers Spa 7 pacer 7 Ring —' @ кА Lock Ring \ Rod Wipers O-Rings Guide Piston Rod Guide 7000 08080 © Do D" STEP 1 STEP 4 Push rod guide into cylinder ap- Install O-rings and wiper. Install proximately 3/4". rod guide on shaft. Lock 7 be e — X Nut —e STEP 2 Install piston and nut on shaft. STEPS Install large lock ring. Rod Assembly In | Spacer Lock Ring Jal —) Y9— > Le ea E STEP 3 Install rod assembly into barrel. STEP 6 Install spacer and small lock ring. Figure 81-3. Lift Cylinder Assembly 81-3 HYDRAULICS SECTION 8J. IMPLEMENT MOTOR CONTROL VALVE GENERAL REMOVAL (See Figure 8J-1) The control valve is a 2 position, 2 way open center 1. Label ali the hydraulic lines and disconnect. Cap or valve with a detent. It is connected to the PTO lever. In plug all the lines. the neutral (center) position oil flow is from the pump to . the valve. When the PTO lever is pushed, hydraulic oil is 2. Disconnect the linkage. supplied to the implement motor. 3. Remove attaching hardware and valve. Implement Motor To Hydraulic Tank Motor Valve Figure 8J-1. 8J-1 HYDRAULICS SECTION 8J. IMPLEMENT MOTOR CONTROL VALVE REPAIR NOTE 4A CAUTION Repairs are handled with three kits, seal kit, : : detent kit and relief valve kit. See Figures 8J-2, Refer to Section 8M for adjustment procedures. 8J-3 and 8J-4. NOTE Do not remove detent from Figure 8J-2. Seal Kit Installation Ball S-—— Plug Screwn —— © DA é Relief Cartridge Figure 8J-4. Relief Valve Assembly 8J-2 HYDRAULICS SECTION 8J. IMPLEMENT MOTOR CONTROL VALVE ADJUSTMENT (See Figure 8J-5) 1. Remove relief valve cap. 2. Loosen jam nut. 3. Turn adjusting screw clockwise (CW) to increase pressure or counterclockwise (CCW) to decrease pressure. e |f pressure changes, continue adjusting until Decrease proper setting is obtained. | CCW e |f correct pressure can not be obtained or no A adjustment is left; | S — Relief valve cartridge faulty. - «— - Motor valve faulty. Increase - Implement pump faulty. CW Figure 8J-5. Relief Valve Adjustment 8J-3 HYDRAULICS SECTION 8K. IMPLEMENT MOTOR GENERAL REPAIR (See Figure 8K-2) The hydraulic motor is supplied with oil from the Repair of the motor is limited to the replacement of engine driven pump through the motor control valve. seals and O-rings. The motor is unidirectional and turns CW. Disassemble as illustrated in Figure 8K-2 adhering to REMOVAL (See Figure 8K-1) important instructions. NOTE Disassembly 1. Clean exterior of motor with suitable solvent before removing tie bolts. 2. Before disassembly mark motor sections, starting at drive shaft end, to ensure correct order and position of parts when reassembling. Recommended method of marking body sections is to use a fine point metal punch, making one indentation for section #1, two indentations for section #2, etc. Do not disassemble motor for repair unless test procedures (Section 8L and/or 8M) indicate internal leakage. A CAUTION Never pry motor sections apart as damage to sealing areas can result. Use of a soft face hammer to tap sections apart is recommended. Body Mounting A Flange % Pressure Plates O-Ring Seal Rings Figure 8K-2. Implement Motor Repair 8K-1 HYDRAULICS SECTION 8K. IMPLEMENT MOTOR . After removing tie bolts, disassemble motor one section at a time. Before removing gear set, mark a line across meshing teeth to ensure that gears are reassembled in the same position (see Figure 8K-3). . Place parts in assembly order, on a clean work area as they are removed. . Discard seals as they are removed. Marker > Mark alignment mark across meshing teeth before disassembly. Figure 8K-3. Marking Gear Teeth Inspection 1. Keeping parts in assembly order, clean and air dry each for inspection. Look for metal chips or slivers during cleaning (an indication of damage to motor or other hydraulic component). . Inspect all parts for cracks, nicks, burrs and excessive wear. Replace entire motor if found damaged or worn. 8K-2 Reassembly (See Figure 8K-2) 1. 2. Apply a coat of clean hydraulic oil to all parts to ease assembly. Assemble motor one section at a time, building up from flange section. Use a new seal kit during assembly. Use clean grease to keep seals in position. Remove alignment mark from gear sets after they have been installed with teeth in mesh. . Rotate drive shaft after assembling each section to make sure there is no binding between parts. Use extreme care when installing shaft seal. It must seat squarely in seal bore. Use the double end seal. Use clean grease on shaft and put tape over keyway to avoid cutting seal during assembly. Install the bolts, finger tight and rotate drive shaft to make sure it turns freely. Tighten tie bolts evenly and in steps to a final torque of 190-210 in-Ibs. (21.2-23.5 N.m). INSTALLATION (See Figure 8K-1) 1. Install motor and tighten attaching hardware to 27-33 ft-lbs. (37-45 N.m) making sure the inlet port is on the right of tractor. . Connect inlet and outlet hydraulic lines. . Start engine. Check for leaks and hydraulic tank level. Break in new or rebuilt motor slowly. NOTE The motor can be tested as described in Section 8L and/or 8M. HYDRAULICS SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES GENERAL The purpose of this section is to provide a guide for field testing the hydraulic system. More extensive test procedures, using test instruments, are presented in Section 8M. Component location illustrations, hydraulic schematics and diagrams are presented in Section 8N. Before performing any tests see “Preliminary Checks” below. AS A SAFETY REMINDER Follow the procedures one step at a time. Observe all NOTES, CAUTIONS and WARNINGS. Pay attention to what you are doing. Work with a safety conscious attitude. | Use care working with HOT oil. Wear safety glasses at all times. Keep hands and feet away from the moving parts. Engine must be shut offand attachments loweredto ground when making adjustments or hydraulic connections unless otherwise specified in the test instructions. PRELIMINARY CHECKS The following preliminary checks should be made before performing any tests. 1. The reservoir should be checked for proper level, the presence of water (noted by a cloudy or milky appearance), air, (noted by a foaming appearance), or a rancid odor indicating excessive heat. If any of the above symptoms appear, or if the hydraulic oil becomes contaminated, or after a major component failure, the oil should be changed and system flushed. NOTE Use only the recommended hydraulic oil (see Section 11 — Preventive Maintenance). Always change the filter when changing the oil. “The filter should be changed after the initial 25 hours of operation. Thereafter, the filter should be changed approximately every 250 hours. . Check all lines and fittings for leakage and tighten as necessary (see Section 8C). . To eliminate all possible mechanical problems first, complete the steps presented in block form below before starting the hydraulic tests. FIELD TESTS When a hydraulic failure occurs, some simple, effective tests can be performed prior to using a test instrument. 8L-1 The results of these tests can lead you to the suspected component failure. If further testing is necessary, proceed to INSTRUMENT TESTS. HYDROSTATIC CHARGE PUMP The charge pump supplies oil for the power steering unit, lift and lower and for charging the hydrostat for traction. If a fault exists in all three systems proceed with an instrument test for the charge pump. If a fault exists in tho steering and/or lift proceed as follows (see Figure 8L-1): 1. Remove the inlet line to the relief valve. 2. Cap the valve and plug the line. 3. Start the tractor and operate the lift and lower system and steering. Conclusion e If the fault is still present, proceed with a charge pump instrument test. e [fthe fault no longer exists the steering/system relief valve is faulty. (See Section 8F). HYDROSTATIC TRACTION PUMP 1. To check the traction pump, be sure the oil is at operating temperature, 110-130°F (43-54° C). With the tractor on asphalt or concrete, chain the tractor to an unmovable object such as a pole or tree. With the engine throttle wide open, transaxle in low range, slowly step on the “forward” treadle pedal. 3. 4. If the traction wheels break traction, the traction pump is usually okay. Conclusion e If the traction wheels do not break traction, a fault exists in the hydrostat. STEERING/SYSTEM RELIEF VALVE Perform test as described in Hydrostatic Charge Pump. POWER STEERING SYSTEM There is no field test for the Power Steering System. Ма steering system problem is suspected, proceed with an Instrument Test Section 8M. LIFT AND LOWER CONTROL VALVE There is no field test on the lift and lower valve. Prior to instrument testing the control valve, check the linkage adjustment and be sure it moves freely and does not bind, proceed with instrument testing Section 8M. SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES «== Сар \ Steering Relief 7 == === == = | еее | == — 7 Figure 8L-1. Hydrostatic Charge Pump 8L-2 HYDRAULICS HYDRAULICS SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES 3. Remove the hydraulic line from the head end of the LIFT CYLINDER cylinder and quickly cap the port. Plug the line. This test should be performed if the attachment comes 4. Remove the supports and block the LOWER pedal down without depressing the lift and lower pedal. down. Prior to testing, check the valve control linkage and : adjust if necessary. Check linkage for binding. Check Conclusion spool in valve. Make sure it is in the center position e |fthe implement does not come down, the lift and when in neutral. lower control valve may be faulty. Proceed with an 1. Raise the implement (cylinder rod extended). instrument test as described in 8M. e |f the implement comes down, the cylinder may be 2. Securely support the implement. at fault. Refer to Section 81 for repair. \} N {> — — ) 1! / Figure 8L-2. Lift Cylinder Test 8L-3 HYDRAULICS SECTION 8L. HYDRAULIC FIELD TEST PROCEDURES IMPLEMENT CIRCUIT (See Figure 8L-3) The implement circuit consists of a pump, motor control valve and motor. Field testing is limited to determin- ing if the motor alone is at fault or motor valve and pump are at fault. There is no field test to isolate a motor valve from pump or vice versa, an instrument test will have to be performed as described in Section 8M. Prior to performing the test, check the motor control linkage and adjust if necessary. Check for binding linkage. Check to see if valve spool moves completely in the on and off position. 1. Remove the inlet line from the motor, plug the line and cap the motor part. 2. Start the tractor. Allow the oil to heat to operating temperature 110°-130°F (43°-54°C). 3. Slowly engage the PTO lever. Conclusion e |f the engine labors and oil is forced over the motor valve relief (squealing sound) the motor may be at fault. Refer to Section 8K or 8L. ® [f the engine doesn't labor the motor valve or pump may be at fault. Proceed with an instrument test as described in Section 8M. Motor N A \ | — < Figure 8L-3. Implement Circuit Test 8L-4 HYDRAULICS SECTION 8M. INSTRUMENT TEST GENERAL The tests in this section are provided as a means of isolating a problem in the hydraulic system. Make sure the tractor is secured and cannot roll. If interlock systems are bypassed, exercise caution when performing each test — do so in a safe manner. A CAUTION Make sure inter-lock system is reconnected after test has been completed. It is important to follow the instructions accurately and completely. Make sure to plug lines and cap ports when so instructed. Also, read and follow the Preliminary Checks provided in Section 8L before proceeding with the instrument tests. IMPORTANT All of the tests in this section use an in-line tester shown in Figure 8M-1. When using tester with variable GPM settings, make sure tester is set for the proper flow range to avoid damage to the test instrument. It is recommended that you record all readings obtained during these tests. It is important that you accurately run all tests at the same engine RPM and 110-130° F (45-54° C) oil temperature. Of mueva? e 18370 © vOLt BArTIGY 9:0 [NP Figure 8M-1. In-Line Tester 8M-1 HYDRAULICS SECTION 8M. INSTRUMENT TEST RELIEF VALVE PRESSURE TESTS (See Figure 8M-2) Steering/System Relief 1. Install a tee in outlet of charge pump. 2. Connect a 0-1000 psi gauge to tee. 3. Set brake, start engine and advance throttle to full open. 4. Turn steering wheel until it stops and holds. 5. Read/record pressure reading. Relief should open at approximately 800 psi + 10%. e |f relief opens at 800 psi, relief valve is OK. e |f relief opens above 800 + 10%, relief is faulty and should be replaced. e |f relief is less than 800 psi, relief or steering system could be faulty, proceed with step 6 or charge pump could be faulty (see charge pump test, Figure 8M-6). A CAUTION Caution MUST be used in conducting the next test. System relief valve has been isolated. Turn steering wheel very slowly while watching pressure gauge. 6. Disconnect outlet line between charge pump and system relief valve. Cap and plug lines. 7. Set the brake, start the engine and advance the throttle to full open. 8. SLOWLY turn the steering wheel until 800 psi = 10% is obtained. e |f800 psi + 10% can be obtained the relief valve is faulty. o |f 800 psi + 10% can not be obtained the steering system may be faulty, proceed with steering system test. Steering/ System === Relief ", ~ ZA = STEP 1-5 Figure 8M-2. Relief Valve Pressure Test 8M-2 HYDRAULICS SECTION 8M. INSTRUMENT TEST Lift Relief Valve (See Figure 8M-3) 1. 2. 3. Install a tee in outlet of charge pump. Connect a 0-1000 psi gauge to tee. Disconnect outlet line between charge pump and system relief valve. Cap and plug line. Set brake, start engine and advance throttle to full open. . Push the lower pedal and hold. A CAUTION Do not exceed 1000 psi in this test. 6. Read/record pressure reading. Relief valve should open at approximately 800-850 psi + 10%. e |frelief opens at 800-850 psi + 10%, relief is OK. Proceed with system/steering relief test. e If relief opens above 850 psi + 10%, relief should be adjusted or repaired. e |freliefis below 800 psi + 10%, proceed with step 7. 7. Remove the hydraulic line from the head end of the left cylinder. 8. Set brake, start engine and advance throttle to full open. 9. Push and hold raise pedal. . Read/record pressure reading. Relief valve should open at approximately 800-850 psi + 10%. e |f relief valve opens at 800-850 + 10%, relief is OK. The cylinder is at faultand should be rebuilt (See Section 81). e |f relief opens below 800 psi, relief should be adjusted or repaired. ! ! a c= Ih 1 A LE OY a << \ ~ AN IZ Х= ~~ 7 J Sa „” Ss > 7 a SAN \ ~ и оО и 7 NP & 7 7 \ me; ad 7 > e 7 7 - > - = 7 7 73 - > nm / 7 ‚7. q a но DES ‘ Nz - NX Ne == =~ > Ir Г - - жж \ — = =Оо= Pid | у TO 7 \ 7 к az: \ EN ! усл pL — ~ ‚” 7 Ad => >>. = ” s.- А > ~ ~ «sc. N и > Ох ~ ES WN ~ ‘5 ~ e \ N \ “ES > (4 De 7 Хе С» \ Na \ , €, VW МА / / NA НЕ / / “ло, / / -— ! / PE y Lift - ‚ Cylinder / . \ OO / < ” ‘ и a - >] “= EN Е VON = = = > vi -~ < = ! ~ =~ \ Sa Sy a sa N : Su eee ee О — N ~~ NN | <= > Plug С 0-1000 psi Gauge DIN < Doy PEN \ у STEP 1-2 A 4 \ NON \ 1 NN N SN! \ / N NS ss! ] | 7 N < = / 1 Figure 8M-3. Lift Valve Relief 8M-3 HYDRAULICS SECTION 8M. INSTRUMENT TEST Relief Valve Adjustment pressure or counterclockwise (CCW) to decrease 1. Remove acorn nut. pressure. 2 Loosen iam nut ¢ |f adjusting the relief valve does not change system relief pressure, lift control valve is at fault 3. Turn adjustment screw clockwise (CW) to increase (see Section 8H). Decrease (CCW) ‘7 Increase (CW) Figure 8M-4. Relief Valve Adjustment 8M-4 HYDRAULICS SECTION 8M. INSTRUMENT TEST IMPLEMENT SYSTEM TEST CHARGE PUMP TEST Refer to IMPLEMENT MOTOR VALVE test. (See Figure 8M-6) HYDRO CHARGE PUMP PRESSURE 1. pid inlet line from relief valve, cap valve, RELIEF (See Figure 8M-5) 2. Disconnect outlet line from charge pump. Ы sde tee in the tube between steering unit and 3. Connect a tee to the outlet port, cap the end of tee. 2. Install a 0-100 psi gauge to tee. 4. Connect the “IN” port line from tester to the tee. Install tank adapter and connect “OUT” line to tank 3. Set brake, start engine and advance throttle to full adapter. open. 4. Read/record charge pressure. Charge pressure relief should be set at 40 psi + 10%. e | charge pressure reads 40 psi. charge relief is OK. E САНТЮМ Do not step on traction pedal during this test. - # charge pressure reads more than 40 psi relief may be fauliy (see Section 8D). « If charge pressure is less than 40 psi, proceed 5. Open tester load valve, set brake, start tractor and with charge pump test. advance throttle full open (3200 engine RPM). Figure 8M-5. Hydro Charge Pump Pressure Relief 8M-5 HYDRAULICS SECTION 8M. INSTRUMENT TEST 6. Read/record no load flow (GPM). GPM should be Steering/System Relief Valve Test 3.0 GPM. | NOTE e |f no load flow is approximately 3.0 GPM, proceed with step 7. Before performing this test, a charge pump test * ¡flow is less than 3.0 GPM, check oil supply and should be performed. inlet hose for obstructions. If GPM is still less 10. Open tester load valve, set brake, start tractor and tion 8D). GPM, charge pump is faulty (see Sec- advance throttle full open (3200 engine RPM). 7. Slowly close tester load valve until 800 psi is 11. Slowly close tester load valve until 700 psi is obtained . obtained . 8. Read/record flow (GPM). GPM should not drop 12. Read/record flow (GPM). ha ! a than 1 GPM sed e If flow (GPM) does not drop more than 1 GPM, e If flow does not drop more than , proc eed with Steeri with System/Steering Relief Valve Test step 10. proceed with Steering System Tes! e If flow (GPM) drops more than 1 GPM or 800 psi e If flow drops more than 1 GPM, charge pump ` should be rebuilt. See Section 8D. cannot be obtained, relief valve should be . . . . cleaned or replaced. 9. Reconnect relief valve inlet line to relief valve. STEP1&9 STEP 4 ETE : A. | Outlet === Line Plug € Figure 8M-6. Charge Pump Test 8M-6 HYDRAULICS SECTION 8M. INSTRUMENT TEST Steering System Test 13. Reconnect charge pump outlet line to tee. NOTE Before performing this test a charge pump and System/Steering Relief Valve test should be performed. 14. Open tester load valve, set brake, start tractor and advance throttle full open (3200 engine RPM). 15. Turn steering wheel until it stops and holds. 16. Slowly close the tester load valve, until 800 psi is obtained. 17. Read/record flow (GPM). e If flow (GPM) does not drop more than 1/2 GPM, steering unit is OK. Proceed with Lift Valve test step 24. e If flow drops more than 1/2 GPM, proceed with step 18. 18. 19. 20. 21. 22. 23. Tag mark and remove hydraulic lines from steering cylinder. Open tester load valve, set brake, start tractor and advance throttle full open (3200 engine RPM). Turn steering wheel unit! it stops and holds. Slowly close the tester load valve, until 800 psi is obtained. Read/record flow (GPM). e |fflow (GPM) increases and is not less than 1/2 GPM, steering cylinder is faulty and should be replaced. See Section 6E. e if flow (GPM) drops more than 1/2 GPM the steering unit is at fault. See Section 6C. Reconnect lines to steering cylinder. STEP 12 Tank Adapter и Co Steering Cylinder STEP 17 & 23 Figure 8M-7. Steering System Test 8M-7 HYDRAULICS SECTION 8M. INSTRUMENT TEST Lift Valve Test 25. 26. 27. 28. 29. NOTE Before performing this test a charge pump and steering system test should be performed. 24. Open tester load valve, set brake, start tractor and advance throttle full open (3200 engine RPM). Push and hold lift pedal in the lower position. Slowly close tester load valve until 700 psi is obtained. Repeat step 26, push and hold pedal in the lift position. Read/record flow (GPM). e If flow (GPM) does not drop more than 1 GPM, lift system is OK. Check for mechanical binding. e If flow drops below 2 GPM, proceed with Lift Cylinder test step 29. Disconnect line from head end of cylinder. 30. 31. 32. 33. Plug line, cap cylinder port. Open tester load valve, set brake, start tractor and advance throttle full open (3200 engine RPM). Push and hold attachment pedal in the raise position. Read/record flow (GPM). e If flow (GPM) increases and is not less than 1/2 GPM, lift cylinder may be at fault. See Section 8l. e |fflow (GPM) drops below 2 GPM, proceed with Lift Valve Relief Adjustment, step a. a. Remove acorn nut. b. Loosen jam nut. c. Turn adjustment screw clockwise (CW) to increase pressure or counterclockwise (CCW) to decrease pressure. e |fadjusting the relief valve does not change system relief pressure, lift control valve is at fault (see Section 8H). nr --—-—— 1] “кое ое ое HY | Decrease (CCW) D O| — (CW) so 7’ © Figure 8M-8. Turf Cat 8M-8 HYDRAULICS SECTION 8M. INSTRUMENT TEST IMPLEMENT SYSTEM TEST Pump 1. Disconnect pump supply line at valve. 2. Cap valve port. 3. 4. Connect “IN” hose of tester to tee. Install tank Install atee in pump supply line. Cap the tee end. adapter and connect “OUT” line of tester to tank adapter. . Open tester load valve, set brake, start engine and advance throttle full open (3200 engine RPM). Read/record no load flow (GPM), GPM should be 13.0. ® 1113.0 СРМ = 10% is obtained, proceed with step 7. e If 13.0 GPM + 10% is not obtained, check oil supply and inlet hose for obstructions. If 13.0 GPM still cannot be obtained, pump is faulty (see Section 8E). . Slowly close the tester load valve until 2000 psi is obtained. . Read/record flow (GPM). e Ifflow (GPM) dropis 1 GPMor less, pump is ОК, proceed with step 9. e If flow (GPM) drops 1to 1-1/2, pump is marginal. e If flow (GPM) drops more than 1-1/2 GPM, pump should be rebuilt/replaced (see Section 8K). Motor Valve “< q 7 REX e Tee + am pars NO Cap = Plug N STEP 1-4 № aa Figure 8M-9. implement System Test HYDRAULICS SECTION 8M. INSTRUMENT TEST . Connect tee with pump outlet hose to motor valve. 10. 11. 12. 13. 14. 15. 16. 17. Remove interlock link between spring plunger and interlock control valve (see Figure 8M-11). Remove plug from interlock switch and install a jumper wire in plug. Disconnect supply line from implement motor, plug line, cap motor port. Open tester load valve, set brake, start engine and advance throttle full open (3200 engine RPM). Slowly engage PTO lever. Read/record no load flow GPM. It should be the same as step 6, 13 GPM. Slowly close the load valve until 2000 psi is obtained. Read/record flow (GPM). GPM should not drop more than 1 GPM. e |f flow (GPM) drop is less than 1 GPM valve is OK, proceed to step 18. 18. 19. ® |! flow (GPM) drops 1 to 1-1/2 GPM valve is marginal. ® More than 1-1/2 GPM drop, valve or relief valve may be at fault (see Section 8J). Continue closing tester load valve. Read/record highest pressure just before flow (GPM) drops. Relief setting should be 2800-2900 psi. e If relief valve opens between 2800-2900 psi, relief is OK, proceed with step 20. e Ifrelief cannot be obtained continue with adjustment a. a. Remove relief valve cap. b. Loosen jam nut. c. Turn adjusting screw clockwise (CW) to increase pressure or counterclockwise to decrease pressure. d. Tighten jam nut, recheck pressure setting. Tv БТЕР 12 №” ©” у .. Zz N N Motor A Cap Toe Plug 7 < o > + | = tel || || ANA | A -- Ng I eee 1 Ni >... CA au Relief Setting Should Be 2800-2900 PSI ' 1 ON E 7 7 “e Increase 2 = O0 © AN S 7 Jam Decrease CW Nut Figure 8M-10. Turf Cat 8M-10 HYDRAULICS SECTION 8M. INSTRUMENT TEST e. Install relief valve cap. e |f pressure change — continue to adjust until correct setting is obtained. e |f pressure setting does not change or no more adjustment is left: — Relief valve cartridge faulty (see Section 8J). 20. If flow (GPM) drop is less than 1 GPM and implement still runs slow: A CAUTION Perform the following test with the engine shut off and key removed. | a. Check free movement of blades, obstructed or tight bearings. b. Check for mechanical binding. If everything is free, the motor may be at fault, repair or replace. See Section 8K. 21. Reconnect mechanical interlock link and electrical plug to interlock switch. 22. Reconnect hydraulic line. STEP 11 Remove Plug Install Jumper Wire interlock Switch PTO Lever 71 71 / MZA Ku, 1 N д {@ Gi Figure 8M-11. Motor Interlock 8M-11 SECTION 9 CHASSIS 9A. Repair and Service Tools and Materials .............00000000000 0000 0000000000 9A-1 9B. Failure Analysis .........0000000 00e ee een eee 00000 sen 0 0e 00 eee 000 000000000000 9B-1 9C. Fuel Tank canrene. 9C-1 General ........ooooocoocococcorcccoccccorococacocrarecacranear ect ennece. 9C-1 Removal and Installation .................0000000 000000 00e 000000800000 000000 9C-1 9D. Hydraulic Tank ..........00000000 00e eee eee see 0 sa 00000 eee 000000000000 00000000 9D-1 General ......._î….L.222 0000000000 a 0000000000 0e u 000000000000 00000000 9D-1 Removal and Installation ...............2..2.2.0000000a 0000000000 0 000000 00000000 9D-1 9E. Seat NN 9E-1 Removal and Installation ......0.0000000000 000000000000 0000000000000 000000 Lee 9E-1 9F. Lift Assembly and Cylinder ............2.200000000 0000000000 000 0000000000 0000 9F-1 Removal and Installation ......0.0000000000000000000 0000000000000 9F-1 Lift Assembly ..........eooerconccocrrococoranrrncrra area rcanrerecarereccace. 9F-1 9G. Rear AXle .........eoeerocccococccocaaocacorererecacerr racer rrarerrecacerene. 9G-1 General ...........11221000 00000 0e ae ee 0 0 00 a 0 see ae 000 000000000000 0000000000 9G-1 Removal and Installation ..............0.0000000 0000 0e 0000000000 000000000000 0 9G-1 Spindle Removal and Installation .............00000000 00000 00e ec eme eee nec 00000 9G-2 CHASSIS SECTION 9A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Cleaning and refinishing materials: Lubricants: Other oil options: Standard automotive hand tools including bearing pullers. Stoddard or equivalent solvent. Detergent and water. Paint, Jacobsen orange. Paint, Jacobsen black. Anti-rust Never-Seize. Grease gun grease (eg. Sunray DX 671 or Gulf Supreme No. 0). Lithium based grease Jacobsen Part No. 502692, 5 gal. (19 liter). Jacobsen Part No. 502695, 2.5 gal. (9.5 liter). Sunoco H.P. Engine Oil SAE 20W20. Mobil Delvac (Special) SAE 20W20. 9A-1 CHASSIS SECTION 9B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 1. Lift/lower functions a. Pedal linkage is worn or out of a. Adjust or replace linkage do not occur when adjustment. (Section 2D). pedal is actuated. b. Hydraulic lines are kinked, b. Adjust or replace lines (Sec- worn or broken. tion 8C). c. Hydraulic pump faulty. c. Test pump (Section 8M). d. Hydraulic cylinder is not func- d. Test cylinder (Section 8L or 8M). tioning. e. Lift and lower control valve is e. Test valve (Section 8M). malfunctioning. 2. Slow or noisy drive or lift a. Low fluid level in hydraulic tank. a. Fill tank, check for hydraulic lower operation. leaks. b. Faulty hydraulic component. b. Test and repair (Section 8L or 8M). c. Loose connections on hoses and c. Repair connections (Sec- to components. tion 8C). d. Worn seals. d. Replace seals (Section 8). e. Air in system. e. Bleed system. f. Valves or motor malfunctioning. f. Test motor valve or motors (Section 8L or 8M). g. Lift pump relief too low. g. See adjustment (Section 8M). h. Lift valve relief too low. h. See adjustment (Section 8M). 3. Interlock function a. Disconnected or inoperative a. Check connections (Sec- does not operate. interlock switch. tion 2C or 101). Test and repair or replace switch or cables (Section 101.) b. Seat switch nut adjusted or faulty. | b. Adjust (Section 2C); Test (Sec- tion 101). c. Hydro neutral start switch not c. Adjust (Section 2C); Test (Sec- adjusted or faulty. tion 101). 4. Mower cuts lower on a. Improper height adjustment. a. Check height adjustment (Sec- one side. tion 12D). b. Tension spring not adjusted. b. Adjust deck torsion spring. c. Bushings need to be lubricated. c. See lubrication (Section 11B). d. Air pressure in tires is different d. Check air pressure per from side to side. specifications in Operators Manual. 9B-1 CHASSIS SECTION 9C. FUEL TANK GENERAL 2. After the tank is completely drained, remove the The fuel tank is a single piece tank which should attaching hardware holding the fuel tank to the require no servicing unless punctured or otherwise frame. accidentally damaged. The fuel tank should be drained 3. Remove the tank from the frame. whenever the machine is to be stored. o NOTE 4. Position the pads on the fuel frame. 5. Install the new or repaired fuel tank. Position the The cap used on the tank is a naturally aspirated tank on the frame making sure tank pads are first in cap. place. REMOVAL AND INSTALLATION 6. Reconnect fuel lines. (See Figure 9C-1) 1. Position a suitable container under tank and remove tank outlet and inlet line from tank. Allow tank to drain. NN a PRA 4 и” 7 ’ ” ` \ ` 4 »/, = — oem cm4 - Ve ав её «тю чит 68 A «ль as = Na == то Oo Gv on oom ant wo an = - er & I ¢ + Grommet Valve Figure 9C-1. Fuel Tank Removal and installation 9С-1 CHASSIS SECTION 9D. HYDRAULIC TANK GENERAL The hydraulic tank requires little or no service other than adding hydraulic oil when indicated by checking the dipstick. The hydraulic oil level should be checked daily for proper level. Use extreme care when checking oil level to prevent the entry of contaminates. Do not check oil level when oil is hot. Oil level should never be below the low level mark or more than 1/4 in. (6.35 mm) above the high level mark. Overfilling tank could result in oil coming out cap (breather). If you notice the presence of water (noted by a cloudy or milky appearance), or air (noted by a foamy appearance) or other contaminants, a rancid odor (indicating excessive heat), or after a major component failure, the hydraulic fluid should be changed. NOTE The cap on the hydraulic tank is a naturally aspirated cap. If water, air, or contamination is indicated, locate the source of the problem and take corrective action. REMOVAL AND INSTALLATION (See Figure 9D-1) If it is necessary to remove the hydraulic tank, remove the drain plug, drain the fluid into a suitable container, disconnect all hoses at the tank. When installing the hydraulic tank, install the drain plug and secure the tank with mounting clamps, connect hydraulic hoses to the tank and fill with approximately 7 gallons of fresh hydraulic oil. Ta ” DN at 11 “ ' vb IRN `` 7; \ К < Ñ == , у AS Na PT ho. NE ES) A Ea A Ci e PY INIA A 7 yn. NN eE Y <a quer. N } 7 US > e eo” EN NON 12 wv” пох ЗА ее Secs „” ON Os МИ 1 „> и”. Ne ГА Tal \ EN o a 4 ti / \ 7.7 Su es. N 27. Y ed gl Ho, a an 2010 PO ale у” АД 12 y, od >. - Az Lal La AN > "a { sy o e dE eT ! "o Sey és e UE: Ve _ fet. Tw > „> Ho e AE - 2 >, vi A e mm 07 _ < » . > .. . x “. ” > °° AL ai x eN ’ Pa `` so ANT ENS м о” `` A. ` 7» Sal 7 < \ e? AN 74 AN O N ‚обе; he NA 21e `` ` a \ / - Rs a o \\ VAN 7 / У“ ç NES Va Y / a N ie N e A. ; LU Sa >— 7 7 „” Ae \ \ Ne ’ € р И 7 NE. NS A -- и” e - \ „” ~ E .... y a ~ 1 \ „” и” . ` RELE E =. \ e 2 \ NS naaa, €. N° =~ 4 NO 2” AS (ALO E ^^ ~~ : ‘у ии „сб NN > TEN NDS -- “= > \ eT 7 ri у Мом Sa. -, ` INN -- Sew >= 7,7 „”, = Am) Ww | nn. у с ZA TN 4 ...[ ~ ~~." > «мл Ma + \ x 1 ‘ \ - “=. “Le > / 7 » Ma NON =-7 \ / A 7 7 Y “wn и! } x < -- 7 - - Na =” I, Sele TE Le =; иене ~ Ae < > A 7 <,” “ a Ce” Pe ” - “Ll ns ” ` Pa -. ` и“ - N Уи CTN E "a J У Vor « \ ‘ . OW Sr y \ ) AN ` ‘ + / , . RN в <: - Hydraulic Figure 9D-1. Hydraulic Tank Removal and Installation 9D-1 CHASSIS SECTION 9E. SEAT | REMOVAL AND INSTALLATION 2. Lift the seat and slide mounts off seat pan. (See Figure 9E-1) To install the seat, secure the seat assembly with at- 1. Remove the attaching hardware from the slide taching hardware. Lubricate as described in Section mounting brackets. Attaching HS Q Hardware 8— >.” ~_ A — 7 7 „” — Le > —_ > Y a.“ — — „” — / = = „” / Го _3 7 I ~~ —— — Attaching Hardware Figure 9E-1. Seat Assembly Removal and Installation 9E-1 CHASSIS SECTION 9F. LIFT ASSEMBLY AND CYLINDER REMOVAL AND INSTALLATION LIFT ASSEMBLY (See Figure 9F-2) (See Figure 9F-1) 1. Remove lift cylinder. 1. Lower implement to ground. 2. Remove left support bracket. 2. Disconnect hoses at cylinder; plug and cap at ports. 3. Remove lift assembly. A CAUTION Care must be taken to avoid damaging the surface of the cylinder rod. 3. Remove pins attaching cylinder to tractor and lift arm. Remove cylinder. NOTE _ See Section 81 for cylinder repair. | spring A 4. Install cylinder and secure with attaching hardware. 5. Connect hoses to cylinder. Bushing < 6. Operate unit and lift and lower implement. 7. Check hydraulic oil level. Lift | Figure 9F-2. Lift Assembly Spacers Figure 9F-1. Lift Cylinder Removal and Installation 9F-1 CHASSIS SECTION 9G. REAR AXLE | GENERAL 5. Remove capscrew. Repair of the rear axle is limited to replacement of 6. Making sure tractor and axle are well supported, broken parts and servicing wheel bearings (see Section remove pivot shaft and spacer to free axle from 7D, Steer Cylinder Service Section 6E and Adjustments tractor frame. Section 6D). 7. Remove pivot pin bushings. REMOVAL AND INSTALLATION 8. Inspect all parts for damage or excessive wear. (See Figure 9G-1) Replace as necessary. 9. Reassemble axle. 10. Install bushings and position axle under tractor 1. Block front wheels to prevent tractor movement. 2. Raise the rear of the tractor. Do not attach lifting device to axle or any component connected to axle frame. assembly. 11. Install spacer, pivot pin, slotted nut and a new 3. Disconnect hydraulic lines to steering cylinder. cotter pin. Cap or plug all fittings. 12. Install capscrew and torque to 15-18 ft-lbs (20-24 N.m). | 4. Remove cotter pin and slotted nut. Ww Jo u . ‘тете ое \ . . N Cotter Pin \ A Bushing Slotted Nut Bushing 1 Spacer Figure 9G-1. Removal and Installation 9G-1 CHASSIS SECTION 9G. REAR AXLE SPINDLE REMOVAL AND INSTALLATION (See Figure 9G-2) 1. Disconnect tie rod and rod end of the steering cylinder from the R.H. and L.H. steering assembly. Remove the groove pin from the top of the steering assemblies and remove the steering assemblies. Inspect steering assembly shafts for signs of wear and replace as necessary. Replace lower thrust bearing and thrust washers and spindle bushings as needed. Install thrust bearings and thrust washers on steering assembly. . Install steering assembly in to axle and lock in place by installing flat washer and new groove pin. Reconnect tie rods and steering cylinder. . Perform toe-in and steering stop adjustments as described in Section 6D. R.H. Steering Assembly DA Pin | e > 1/4" x 1-1/2" 1-1/16" Flat Washer Needle Thrust is Bearing L.H. Steering Assembly Spindie Bushing Figure 9G-2. Spindle Removal and Installation 9G-2 10A. 10B. 10C. 10D. 10E. 10F. 10G. 10H. 101. 10J. 10K. SECTION 10 ELECTRICAL SYSTEM Repair and Service Tools and Materials ...............eoeoeceeecroccococococo. 10A-1 Failure Analysis ...........ooecesccococccocococrrrocrrooraoaraooocanacroo. 10B-1 General Instructions .............eeeoocecesccooccorocrocecrecacrarecacaaoreo. 10C-1 General AS 10C-1 Wire Continuity Test ..............00200000000 000 eee 0 ee sa 0 se aa 0000 se 0 000000 0 10C-1 Battery .........i_eooeóoeocrecreccosrsccscccccrccrarecarracocacccacacocr EEE 10D-1 General .........ñeeooeeocdecosccocacorocccrocanecacocecanrcanoc acera annco. 10D-1 Charging a Maintenance Free Battery ...............coeecoccorecscccroooecrco. 10D-1 Maintenance/Cleaning .............42.20200000 0000 a 0e 0 sa 0000 000 0e a 00000000 10D-1 Testing .........eeeccorcccocccoaroroosccocero coran accanacacacarocanoceano.. 10D-2 Charging System (Diesel) ..............0.0002000000 00e nee eee a ea nee 0 ae 000000 0 10E-1 General iii AS 10E-1 Alternator Field Test .............oeoooococcsxccsccococoarcoanrecacoacoaraacoace.. 10E-1 Output Current ............e.eeoorccoocsocsracacacecacacecrancaconracanoncoa, 10E-1 Alternator Input Voltage ..............ememcoeeccoocrocorcccacrorcoraore ee. 10E-2 No Load Test ...............00000000 eee ee ea a ee eee eee 0 00e ae se 1000000000 10E-3 Rotor Coil, Slip Ring and Brush Test .............eoeocecococoocororocecoo. 10E-4 No Load Regulating Voltage Test ...................40.0000000 000000000000 10E-5 Regulator Test ............02000000 00 een a ae na a aa 0 0 a ae 0 eee a ee aa a eee a 00 sa 0000 6 10E-6 Charging System (Gas) .............2020200000 00e ea ee ea ea aa ee eee ae 0 00 a sa 00 0 0 10F-1 General ............eoeeeeeccccocorocacorocscoeccoacanracacamarocacaaocanne 10F-1 Alternator Output Test ...........0.02020000000 00000 ae 0 a aa a a ea a 0 ae a ae 0000000 10F-1 Regulator Test ............eeecoorecoccoccocoracocacrcacecracrocacraa no neco. 10F-2 Starter (Diesel) ...............eoereonccccacococsarcacrcoacecracacraco cananea. 10G-1 General EEE teeter aaa aa, 10G-1 Field Test .................ee.0000000000rceecoreronerereoeoecccereacecece.. 10G-1 Pull in Solenoid ............eeeoeoccooccroecccoccconecracraaccaaaeanaccoo, 10G-1 Starter Motor ...........ñ.eeoocreceoceoooreoecccccocccocacocracanacacaracaca. 10G-2 Starter (Gas) ............eeeoseoccccoococrconcroacecocecanerecacacanaco nano 10H-1 General ............oeceocoecocccroocccareraranecocaccvacccoccnAaccacananeoo 10H-1 Field Тез! .................. 2..5... 5 0555555 8вев канон бвеб ен ке бен б кво. 10H-1 Pull in Solenoid ............eoeoccoccccccccocacacrrcoacoaacoaacranaanena.. 10H-1 Starter Motor ............o_eeocecorecorocccococcocorcocoacrccacaceconacaceao. 10H-2 Switches ..........eoceoccccccccrccrocerocrcanacowcAsecracancacocAnocac anne, 101-1 General .........ñ..c_oecoccecccoocsccocoraraeracecorecacacnonracoano canarameo 101-1 Seat Switch Test ............eooccscccrcccsrecccconcocraocoanvacacacaTarecoceno 101-1 Ignition Switch Test .............c.oeecoocsecocccorecoconecacaraocacac oran. 101-2 Neutral Start Switch Test .............eooecoecocrecccracocroceracanoccocarac e 101-4 PTO Switch Test ...........eeoceeocrcccccrescococarovroconcaccacocacococacao 101-5 Glow Plug Switch Test (Diesel) ..................eoceereoccoocorcorecareceo. 101-6 Cruise Control Brake Switch Test ..............0020000000 0000000000 00000000 0 101-7 Relay .........eoeocecesccocorccocccrocacaraconeccacecocacacrrccacecacaname. 10J-1 General ............_.eeoecceccccoocscsarecosnccacecooracacecracac noo oaneneo 10J-1 Field Test ............eeecoseconocorecocaocacacocranmacavecaaraaoracanncacoae 10J-1 Horn Relay Test ...........00020000 0000 ee ae ee 0 0 ea a ae ea a a ae ea a 0e 0e ee een 00e 10J-1 Solenoids .........20200 02e see eee ae eee a ea ae ee a a ee a ee a ae een ea een a ea se ca 000 0 10K-1 Starter Solenoid Test ............eoeoooercoecccoocccoranococrocac.0cacaccnen 10K-1 Fuel Shutoff Solenoid (Diesel) ................eeeeee0eccoresccrcrroroc ene. 10K-1 General iii ee RER RER ta eee, 10K-1 Field Test A 10K-1 10L. 10M. 10N. 100. 10P. Circuit Breakers and FUSE .................44220000 0000000 000000 0000000000 0 10L-1 Circuit Breaker Test ...............0200000 ace sea 0e 0 ane 00000000 0000000000 10L-1 Fuse Test ..............2200000 00e ae se EEE EEE WERE EEE EEE EEE EEE 10L-2 Gauges .........eoceeoocooscocrccocrocrccreccearencaceracoca renacer. 10M-1 General ............200000000 0000 ea 0e see a 00000 em as 0 0e 0e 00000 000000000000 10M-1 Water Temperature Gauge Test ...............0000000 000 0e 0000 a 000000000000 10M-1 Ci), Ad ES 10N-1 Glow Plug Test (Diesel) .......0.0.0000000000000000 00000 EEE eee. 10N-1 Glow Plug Indicator ......0.000000000000000 000000000000 000000 0ER 100-1 Glow Plug Indicator Test (Diesel) ................20.00000000 0000000000 000000 100-1 Wiring Diagrams and Component Location lilustrations (Product No. 66132) .... 10P-1 Wiring Diagrams and Component Location Illustrations (Product No. 66127) .... 10P-3 ELECTRICAL SYSTEM SECTION 10A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Multi-meter. Jumper wires. 60 amp ammeter. Cleaning materials: Baking soda and water. Other Service Items: Electrical insulation compound P/N 365422 10A-1 SECTION 10B. FAILURE ANALYSIS ELECTRICAL SYSTEM PROBLEM PROBABLE CAUSE REMEDY 1. Battery charge is low. Buildup of corrosive acid across top of battery. Terminals are loose or corroded. Battery cables are frayed. d. Defective battery. e. Alternator belt not adjusted. Clean and recharge battery (Sec- tion 10D). Tighten or clean terminals and recharge battery (Section 10D). Replace cables and recharge battery (Section 10D). d. Replace battery (Section 10D). e. Adjust belt. f. Voltage regulator defective f. Test regulator (Section 10E). (diesel). g. Alternator defective (gas). g. Test alternator (Section 10F). h. Ignition switch and/or contacts п. Test ignition switch (Sec- X-Y damaged or corroded. tion 10G). i. Bad ground. i. Check ground connection. 2. Battery is not charging. a. The alternator belt is not properly | a. Adjust belt. adjusted. b. Defective alternator. b. Replace alternator (Section 10E or 10F). c. Defective gauge fuse, 6A (diesel). | c. Test/replace fuse (Section 10M). d. Ignition switch and/or contacts d. Test ignition switch (Section 101). X-Y damaged or corroded. | e. Defective battery. e. Test battery (Section 10D). f. Defective regulator (diesel). f. Test regulator (Section 10E). 3. Engine will not turnover a. Dead battery. a. Charge or replace (Section 10D). when non switch Is b. Neutral start switch defective b. Test switch as described in gaged. or out of adjustment. Section 101. See Section 2C for adjustment instructions. c. PTO interlock defective c. Test switch as described in or out of adjustment. Section 101. See Section 2C for adjustment instructions. d. Defective seat switch. d. Test switch (Section 101). e. Defective starter solenoid. e. Test solenoid (Section 10K). f. Defective ignition switch. f. Test ignition switch (Section 101). g. Defective starter. g. See engine manual. h. Defective wiring. h. Test wiring (Section 10C). 10B-1 ELECTRICAL SYSTEM SECTION 10B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE REMEDY 4. Engine turns over but a. Battery low. a. Charge battery (Section 10D). will not start. b. Defective glow plug (diesel). b. Test glow plug (Section 10N). с. Defective glow plug switch (diesel). | c. Test switch (Section 101). d. Defective glow plug indicator d. Test indicator (Section 100). (diesel). e. Fuel solenoid fuse (diesel). e. Test/charge (Section 10L). f. Defective fuel shut-off solenoid f. Test solenoid (Section 10K). (diesel). g. Ignition faulty. g. Check engine manufacturers manual for test procedures. h. Obstruction in fuel supply line. h. Check fuel supply line for obstructions. 5. Engine starts but a. Defective switch. a. Test ignition switch (Sec- shuts down when ignition tion 101). switch is released. b. Defective fuel shutoff solenoid. b. Test solenoid (Seciton 10K). (diesel). 6. Engine shuts down a. Interlock switches out of adjust- a. Adjust (Section 2). when PTO lever is moved to on position. ment. b. Interlock switch(es) defective. b. Test switch(es) (Section 10). 7. Engine does not shut down when operator leaves the seat with PTO lever on. Seat switch out of adjustment. Defective seat switch. a. Adjust switch (Section 2B). Test seat switch (Sec- tion 101). 10B-2 ELECTRICAL SYSTEM SECTION 10C. GENERAL INSTRUCTIONS GENERAL Repair of the electrical system, for the most part, is limited to the replacement of defective components or wiring. Wiring diagrams and Component Location illustrations are provided in Section 10P for trouble- shooting and/or testing the electrical system. Specific repair and replacement instructions, where applicable, are also provided in this section. NOTE The test instrument shown in the illustrations for this section is a digital multi-meter (DMM). How- ever, any test instrument capable of measuring the current resistance and continuity values specified for each test is acceptable. NOTE See engine manufacturers service manual for information on engine electrical components not covered in this section. In addition to testing a suspected faulty component it may be necessary to check for shorts or breaks in the wiring to the component. A common method of testing wires or circuits is to perform a continuity check as described below. NOTE Before performing any component or wiring test, check for corrosion and loose or missing connections. If a component (switch, relay, etc.) is removed for test or replacement make sure to identify and label wires so that the component can be installed correctly. WIRE CONTINUITY TEST (See Figure 10C-1) 1. Identify and locate the wire to be checked on the appropriate “Electrical System” illustration, located in Section 10P. Set multi-meter to ohms d” scale and touch leads to ends of wire. e There should be a reading (continuity) on the multi-meter. If not, proceed to 3. . Perform a second check by using a jumper wire to bypass the wiring being tested. If the component in question now functions normally, replace the original wire. Multi-meter 2e Test Lead (+) POS | > et. / Jumper Wire Y (-) NEG A Ce Figure 10C-1. Wire Continuity Test 10C-1 ELECTRICAL SYSTEM SECTION 10D. BATTERY GENERAL For normal service, use a battery rated 12V, 250 cold cranking amps at 0°F (-18°C) AABM Group #22NF. For continuous cold weather operation, use a battery with approximately 400 cold cranking amps at 0°F (-18° C). AABM group 22NF batteries meet this specifi- cation. “À WARNING Batteries contain sulfuric acid and generate explosive mixtures of hydrogen and oxygen gases. Keep any device which may cause sparks or flames away from the battery to prevent explosion. A WARNING Always wear protective glasses or goggles and protective clothing when working with batteries. You must follow the battery manufacturer's instructions on safety, maintenance and installation procedures. A CAUTION Always connect the “ground” (black) cable last and remove it first whenever performing any battery maintenance. When the battery is being removed or reinstalled, make sure the positive and negative terminals do not contact metal tractor parts at the same time or arcing will result. Battery connections must be kept clean and tight at all times. Loose cables will cause arcing and pitting of the connections and cause eventual failure. Keep positive terminal cover in place. CHARGING A MAINTENANCE FREE BATTERY NOTE Remove battery from tractor. 1. Be sure charger is “Off”. 2. Connectcharger leads to battery. Connect the positive (+) connector from the charger to the positive battery terminal. Connect the negative (—) connector of the charger to the negative battery terminal. A WARNING To avoid possible injury, stand away from battery when the charger is turned on. A damaged battery or a battery with an internal short could explode. 3. Charge the battery using one of the methods shown below. Follow the manufacturers instructions on the charger. Fast Charge 2% hours @ 20 amps 1% hours @ 30 amps 1 hour @ 45 amps Slow Charge 10 hours @ 5 amps 5 hours @ 10 amps 4. If, when charging the battery, violent gassing or spewing of electrolyte occurs, or the battery case feels hot 125°F (52°C), reduce or temporarily halt charging to avoid damaging the battery. 5. Always turn charger to “Off” before removing a charger lead from the battery. MAINTENANCE/CLEANING A buildup of corrosive acid across the top of the battery can cause the battery to self-discharge. Even a light coating of this grayish-white substance can complete a circuitto drain and exhaust the energy in the battery — especially bad when moisture is present. To maintain a battery in top condition, check and perform the following services at frequent intervals: 1. Regularly check level of electrolyte — add water as necessary to maintain level above plates — do not overfill as this can cause poor performance or early failure due to loss of electrolyte. 2. Keep terminals and top of battery clean. Wash with baking soda and rinse with clear water. Do not allow soda solution to enter cells as this will destroy the electrolyte. 3. Make sure battery terminals are tight and cables are in good condition. 10D-1 ELECTRICAL SYSTEM SECTION 10D. BATTERY TESTING (See Figure 10D-1) | 3. Crank the engine — if battery voltage falls below 9 volts while cranking, the battery is run-down or Test battery voltage as follows: defective. Charge battery and perform test again. 1. Connect DC Multi-meter to battery terminals. 2. Set voltmeter to 20 DCV. Da Multi-meter 4, (-) NEG (+) POS re Battery Figure 10D-1. Battery Test 10D-2 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) GENERAL The 24 amp charging system consists of an alternator and separate regulator. See the engine manufacturer's service manual for detailed repairs of the alternator. ALTERNATOR FIELD TEST Output Current (See Figure 10E-1) À WARNING Before breaking or installing test instruments, disconnect the negative battery cable from the battery. 1. Remove the red wire from terminal B of the alternator. 2 Connect an ammeter and voltmeter as shown. A WARNING Use an ammeter rated at 30 or more amps. 3. Start the engine. e Asengine rpm increases, voltage should increase to a maximum 14V at 1500 engine rpm. e Current output should also increase to a maximum 25 amps at 3250 engine rpm. NOTE Charge condition of battery will affect current (amp) output. As the battery begins to charge, the current output will slowly decrease. e |f no voltage and/or current is measured, the alternator is defective. AMMETER Figure 10E-1. Output Current 10E-1 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) Alternator Input Voltage (See Figure 10E-2) 3. Turn on the ignition switch. 1. Remove the alternator plug. e The multi-meter should read battery voltage. 2. Setthe multi-meter to 20 VDC and connect + lead to ® [If no voltage registers, continue with voltage regu- terminal F and - to terminal E. . lator test. (+) POS A Wht/Blk (-) NEG Wht/Grn Blk Figure 10E-2. Input Voltage 10E-2 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) No Load Test (See Figure 10E-3) 6. Disconnect the battery NEG cable. 1. Remove the electrical plug from the alternator. e Voltage should be about 17 VDC. 2. Using a jumper wire, connectthe F terminal to the B e Voltage should increase to 32 VDC as the engine terminal. rpm is increased. 3. Ground the E terminal. e If no voltage is recorded the alternator is defec- 4. Set the multi-meter to 200 VDC. tive. Start and run engine at approximately 1500 rpm. и С < 2? €} mai 7 B v-n 5 COM A A 104 | Us :Q: 0 =/S V = NE AL E / 04 Е ОЕМ1428 / I (-) NEG F Plug (+) POS Figure 10E-3. Alternator No-Load Test 10E-3 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) 3. Connect the multi-meter + lead to terminal F and the - lead to terminal E. e The resistance should be approximately 6.5-10 Q (ohms). Rotor Coil, Slip Ring and Brush Test (See Figure 10E-4) 1. Remove the plug from the alternator. 2. Set the multi-meter to 200 © range. Figure 10E-4. Rotor Coil, Slip Ring and Brush Test 10E-4 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) No Load Regulating Voltage (See Figure 10E-5) 5. Gradually accelerate the engine and watch the multi-meter. 1. Set the multi-meter to the 20 VDC range. _ e Voltage should rise as engine rpm increases. Vol- 2. Connect the multi-meter + lead to the B terminal tage should read 13.8 to 14.8 VDC. and the - lead to the ground. e |f voltage does not increase with increased engine 3. Start and run the engine, obtain 1300 rpm pulley rpm, the alternator should be repaired. speed at the alternator. 4. Remove the NEG battery cable. N 4 ©" 2001000/750 209 * 20 20 2 200m 20M. 24 я РО 2880008080, ay, A °° °° °° °° °° e” e° °° ss °° . ” .” 4 0 TIT TILL "sa, e MWe Figure 10E-5. No-Load Regulating Voltage Test 10E-5 ELECTRICAL SYSTEM SECTION 10E. CHARGING SYSTEM (DIESEL) REGULATOR TEST (See Figure 10E-6) The regulator regulates the output voltage and current according to the electrical demand. The regulator is rated 15 amps. Terminals and Voltage Color Codes Relay Points | Resistance MN (ohms) Failure and Probable Causes IG F OPEN О If reading is above O Q, low speed side Black/White | White/Green is faulty. CLOSED* 11 Q (ohms) If reading is infinity, control resistor is faulty. L E OPEN 0 If reading is over 0, bad contact on White/Red Black voltage relay. CLOSED* approx. 100 Q (ohms) | If reading is O voltage, relay contacts are bad. If reading is e, voltage coil is broken. N E approx. 23 Q (ohms) If reading is 0, relay coil shorted. White Black If reading is æ, pressure coil is broken. B E OPEN If reading is not æ, voltage relay White Black (open circuit) points melted and/or burned. B L CLOSED” 0 If reading is over 0, bad contacts White White/Red on voltage relay points. E L Wire Color Code IG — Blk/Wht N — Wht/Blk F — Wht/Grn E — Bik L — Wht/Red В — Wht * Push contact closed with finger. Figure 10E-6. Regulator Test 10E-6 ELECTRICAL SYSTEM SECTION 10F. CHARGING SYSTEM (GAS) GENERAL The 50 amp charging system consists of an alternator ALTERNATOR OUTPUT TEST Figure 10F-1 (See Figure ) 2. Connect a 60 amp ammeter between the B+ terminal and RED wire. A CAU T | 0, N 3. Connect a voltmeter + lead to > terminal B+ on alternator and - lead to a clean engine ground. Before disconnecting wires and installing test 4. Start engine instrument, disconnect negative (-) battery gine. cable. e Asengine rpmincreases, voltage should increase to a maximum of 15-16 volts. e Current output should also increase to a maxi- 1. Remove red wire from B+ terminal on alternator. mum of 50 amps. Alternator and regulator are OK. AMMETER A | —— POS 59 || (-) NEG a ~) AT \ «о Red Ns i - : Figure 10F-1. Output Test 10F-1 ELECTRICAL SYSTEM SECTION 10F. CHARGING SYSTEM (GAS) NOTE Charge condition of battery will affect current (amp) output. As battery begins to charge, the current output and voltage will decrease. e |f low voltage and no current is measured, proceed with Step 5. e |f voltage and current do not increase with increase of engine rpm, alternator and/or regulator are defective. NOTE A bad or defective battery will also give the same results. Check condition of battery first before repairing alternator/regulator. REGULATOR TEST (See Figure 10F-2) 5. 6. Disconnect RED wire from regulator on alternator. Connect a voltmeter + lead to RED wire and - lead to good engine ground. e No voltage should register, proceed with Step 7. e If voltage is present, a short in tractor wiring or - ignition switch has occurred. . Turn ignition switch to the RUN position. e Battery voltage should now register on voltmeter, if fault still exists battery may be at fault. e |fno voltage is measured, ignition switch (Section 10H), wiring (Section 10C), or battery (Section 10D) are defective. - ) <7 LI VON / a daa 1 1 CEM1428 Figure 10F-2. Regulator Test 10F-2 ELECTRICAL SYSTEM SECTION 10G. STARTER (DIESEL) GENERAL The repair of the starter is covered in the engine manufacturer's service manual which can be obtained through your local Jacobsen Distributor. FIELD TEST Pull In Solenoid (See Figure 10G-1) 1. Disconnect the NEG battery cable. 2. Disconnect the red battery leads from the coil and tape the ends together to ensure good contact. 3. Connect the NEG battery cable and turn the ignition switch to the START position. e Eachtime the ignition switch is turned to the start position, a “click” should be heard from the coil. e |f no click is heard the coil or electrical supply may be defective. Continue with the next step. . Remove the LT BLUE solenoid wire. . Set the multi-meter to 20 VDC and connect the + lead to the solenoid wire. Connect the - lead to a good ground. 6. Turn and hold the ignition switch in the start position. e The multi-meter should read battery voltage. e |f no voltage is measured, an open interlock switch (Section 10L), faulty wire (Section 10C) or ignition switch (Section 101), could be at fault. Lt. Blue Figure 10G-1. Pull in Coil Test 10G-1 ELECTRICAL SYSTEM SECTION 10G. STARTER (DIESEL) Starter Motor (See Figure 10G-2) 1. 2. Disconnect the NEG battery cable. Disconnect the LT BLUE solenoid wire from the starter solenoid. Install a 60 amp ammeter between the battery + and — of the solenoid. Touch the NEG cable to the NEG terminal on the battery. e The starter motor should turn and pull approximately 45 amps. e |fthestarter does not turn or turns slow connect a multi-meter set at 20 VDC to the battery and repeat step 4. Voltage should not drop below 10.5 volts. e |f amp draw is larger than 45 amps, the starter should be repaired. Lt. Blue (+) POS (+) POS AMMETER (=) NEG Figure 10G-2. Starter Motor Test 10G-2 ELECTRICAL SYSTEM SECTION 10H. STARTER (GAS) GENERAL The repair of the starter is covered in the engine manufacturers service manual which can be obtained through your local Jacobsen Distributor. FIELD TEST Pull In Solenoid (See Figure 10H-1) 1. 2. Disconnect the NEG battery cable. Disconnect the red and orange battery leads from the coil and tape the ends together to ensure good contact. Connect the NEG battery cable and turn the ignition switch to the START position. e Each time the ignition switch is turned to the start position, a “click” should be heard from the coil. e |f no click is heard the coil or electrical supply may be defective. Continue with the next step. Remove the WHT solenoid wire. Set the multi-meter to 20 VDC and connect the + lead to the solenoid wire. Connect the - lead to a good ground. 6. Turn and hold the ignition switch in the start position. e The multi-meter should read battery voltage. e |f no voltage is measured, an open interlock switch (Section 10L), faulty wire (Section 10C) or ignition switch (Section 101), could be at fault. Figure 10H-1. Pull in Coil Test 10H-1 ELECTRICAL SYSTEM SECTION 10H. STARTER (GAS) Starter Motor (See Figure 10H-2) | * The starter motor should turn and pull approxi- 1. 2. mately 45 amps. e |fthe starter does not turn or turns slow connecta multi-meter set at 20 VDC to the battery and repeat step 4. Voltage should not drop below 10.5 Disconnect the NEG battery cable. Disconnect the Lt. Grn. solenoid wire from the starter solenoid. . Install a 60 amp ammeter between the battery + and volts. — of the solenoid. e |f amp draw is larger than 45 amps, the starter . Touch the NEG cable to the NEG terminal on the should be repaired. battery. (+) POS AMMETER 25 O (+) POS ~ (-) NEG Figure 10H-2. Starter Motor Test 10H-2 ELECTRICAL SYSTEM SECTION 101. SWITCHES GENERAL 1. Remove the plug from the switch. ious switches that are part of the electrical system. Repair is limited to replacement of components found 3. Connect leads to switch as shown. defective during testing. See Figure 10N for location of e There should be no reading (no continuity) at components. multi-meter. SEAT SWITCH TEST 4. Depress switch (simulates operator in seat). e There should be a reading (continuity) at multi- The seat switch is a device which allows the engine to run when the operator is in the seat and implements are on. See Figure 101-1 and test switch as follows: NOTE Before testing, check to see if the switch is just out of adjustment. See Section 2C for adjustment procedures. meter. Multi-meter Side View Figure 101-1. Neutral Start Switch Test 101-1 ELECTRICAL SYSTEM SECTION 101. SWITCHES IGNITION SWITCH TEST (See Figure 101-2) 1. Disconnect ground (black) cable at battery. 2. Disconnect wiring connector at switch. 3. 4. See Figure 101-3 and check all switch positions as Set multi-meter to 200 «Л (Q) ohms scale. follows: a. With key switch in OFF position connect test leads to any two terminals — check all five. e There should be no reading on multi-meter. NOTE Ifthere is a reading of more than 3.0 ohms in any of the following tests the switch is defective and must be replaced. b. With key switch in RUN position, connect black test lead to termina! B and red lead to terminal |. e There should be a reading of 0.3-1.0 ohms on the multi-meter. . Move red lead to terminal A. e There should be a reading of 0.3-1.0 ohms on the multi-meter. | . Connect black lead to terminal X and red lead to terminal Y. e There should be a reading of 0.3-1.0 ohms on the multi-meter. . Hold switch in START position. Connect black lead to terminal B and red lead to terminal |. e There should be a reading of 0.3-1.0 ohms on multi-meter. Move red lead to terminal S. e There should be a reading of 0.3-1.0 ohms on multi-meter. Replace a switch that does not meet all of the above values (multi-meter readings). Multi-meter (+) POS Terminal Location Figure 101-2. Ignition Switch Test 101-2 ELECTRICAL SYSTEM SECTION 101. SWITCHES Contacts Open No Continuity OFF Step 4a Contacts Closed Continuity 0.3-1.0 Ohms OFF Step 4b Contacts Closed Continuity 0.3-1.0 Ohms OFF RUN . Z START Step 4c Contacts Closed Continuity 0.3-1.0 Ohms RUN @ START Step 4d Contacts Closed Continuity 0.3-1.0 Ohms OFF RUN SE Step 4e Contacts Closed Continuity 0.3-1.0 Ohms RUN S Cu Step 4f Figure 101-3. Ignition Switch Test Step 4 101-3 ELECTRICAL SYSTEM SECTION 101. SWITCHES NEUTRAL START SWITCH TEST 1. Remove the plug from the switch. The neutral start switch is an interlock allowing the J engine to start only with the transaxle shift lever in 2. Set multi-meter to 200 (2) ohms scale. neutral. It also causes engine shut down when operator Connect leads to switch as shown. leaves the seat with the shift lever in high or low range. e Th h RT See Figure 101-4 and test switch as follows: ere should be no continuity through the switch. 4. Depress switch (simulates operator in seat). © NOTE . . AA à e There sh . . Before testing, check to see if the switch is just There should be a reading of .3 to 1.0 (al out of adjustment. See Section 2C for adjustment procedures. — Multi-meter Lo Г | Figure 101-4. Neutral Start Switch Test 101-4 ELECTRICAL SYSTEM SECTION 101. SWITCHES PTO SWITCH TEST The PTO switch is a device which allows the engine to run when the operator is in the seat and implement IS on. lt also acts as an interlock allowing the engine to be started only with PTO lever in the off position. See Figure 101-5 and test switch as follows: NOTE Before testing, check to see if the switch is just out of adjustment. See Section 2C for adjustment procedures. . Remove the plug from the switch. 2 Set multi-meter to 200 «` (0) ohms scale. 3. Connect leads to switch as shown. e There should be no continuity through the switch. . Depress switch (simulates operator in seat). e There should be a reading of .3 to 1.0 Q at multi-meter. Multi-meter OEM1428 N.O. Side View N Figure 101-5. PTO Switch Test 101-5 ELECTRICAL SYSTEM SECTION 101. SWITCHES GLOW PLUG SWITCH TEST (DIESEL) 3. Connect multi-meter test leads to switch terminals The glow plug switch is pushed by the operator to allow with the switch in the OFF position. cur rent flow to the glow plugs, prior to starting the * There should be no reading on the multi-meter. machine. 4. Hold switch in the ON position. e There should be a reading of 0.3-1.0 ohms on the 1. Disconnect leads at switch. multi-meter. 2. Set multi-meter to 200 & (2) ohms. See Figure 101-6 and test switch as follows: — Muiti-meter 7 S © SW Y У com A 104 LO IR OO O ©) ve Figure 101-6. Glow Plug Switch Test 101-6 ELECTRICAL SYSTEM SECTION 101. SWITCHES | | CRUISE CONTROL BRAKE SWITCH TEST e There should be no continuity through the switch. NOTE 4. Actuate switch (simulates brake applied). (Refer to Before testing, check to see if the switch is just Figure 101-7 for proper position.) out of adjustment. See Section 2C for adjustment e There should be a reading of .3 to 1.0 Q at procedures. multi-meter. 1. Remove the wires from the switch. NOTE 2. Set multi-meter to 200 &* (2) ohms scale. If arm is pushed against its stop, contacts will 3. Connect leads to switch as shown. open. <— Multi-meter Closed Open Figure 101-7. Cruise Control Brake Switch Test 101-7 ELECTRICAL SYSTEM SECTION 10J. RELAY HORN RELAY TEST GENERAL 1. Connect a wire between battery (-) and case of The horn relay is a NO (normally open) contact relay. between the battery terminal and horn terminal. When 2. Connect multi-meter red (+) lead to relay horn ter- the switch terminal is grounded, usually through the . minal. Con i- | —) | to rela temperature switch, the contacts between the battery Connect multi-meter black (-) lead to relay terminal and horn terminal close, energizing the horn. ground (7). 3. Set multi-meter to 20 VDC range. FIELD TEST 4. Connect a wire between battery (+) and relay bat- 1. Turn ignition switch to ON position. tery terminal. 2. Remove (PUR) wire from temperature switch. e Multi-meter should not show any voltage, con- e Horn should not sound, proceed with Step 3. tinue with Step 5. e |fmulti-meter indicates voltage, relay is defective. e |f horn is sounding, relay is defective. sc | | | 3. Ground the (PUR) wire. and g 2 mere between relay switch termi- e Horn should sound. e An audible “click” should be heard and the multi- e |fhorn does not sound, relay or horn is defective. meter should indicate battery voltage. e |f multi-meter does not indicate battery voltage, relay is defective. (-) NEG „и - Q NE (+) p | J Os \ - | > и | | Horn (+) POS (-) NEG Bat. Gnd. Figure 101-1. Horn Relay 10J-1 ELECTRICAL SYSTEM SECTION 10K. SOLENOIDS STARTER SOLENOID TEST e If the plunger does not pull in the battery voltage I . may be low (Section 10D), ignition switch faulty Field testing of the starter solenoid is covered in Sec- (Section 101) or the coil may be faulty. tion 10K STARTER. | To check the solenoid coils, proceed with steps 4 FUEL SHUTOFF SOLENOID (DIESEL) thru 6 (see Figure 10K-1). General i 4. Turn the ignition switch OFF. The fuel shutoff solenoid is energized when the ignition switch is turned on. The solenoid plunger must travel 5. Remove both wires from the solenoid. its full 1” stroke in order to energize the holding coiland 6. Set the multi-meter to 200 ohm range. Connect shut off the pulling coil. the + and - multi-meter leads to the solenoid Field Test terminals. leid le e With the plunger pulled out a reading of 0.36 to 1. Disconnect the solenoid linkage from the injection 0.43 Q ohms should be obtained. rm. pump arm e With the plunger pushed in, a reading of 15.28 to 2. Turn on the ignition switch. 18.67 Q ohms should be obtained. 3. The coil should SNAP pulling the plunger in. If the ohms readings are not within range, the solenoid may be faulty. Figure 10K-1. Solenoid Coil Test 10K-1 ELECTRICAL SYSTEM SECTION 10K. SOLENOIDS Adjustment (See Figure 10K-2) Solenoid -06 to .09 (1.5 to 2.3 mm) Free Play Figure 10K-2. Fuel Solenoid Adjustment 10K-2 ELECTRICAL SYSTEM SECTION 10L. CIRCUIT BREAKERS & FUSE CIRCUIT BREAKER TEST 3. Depress button (close). See Figure 10L-1 and test circuit breaker as follows: e There should be a reading (continuity) on meter 1. Set meter to 200 «* (Q) ohms scale. scale. 9 Connect meter leads to terminals as shown. Replace a circuit breaker that does not meet these test results. e With the circuit breaker open (tripped) there should be no continuity on the meter scale. Multi-meter RE № ANE? Figure 10L-1. Circuit Breaker Test 10L-1 ELECTRICAL SYSTEM SECTION 10L. CIRCUIT BREAKERS & FUSE FUSE TEST 2. Connect meter leads to fuse as shown. See Figure 10L-2 and test fuse as follows: e There should be a reading (continuity) on the 1. Set meter to 200 «* (N) ohms scale. meter scale. If not, replace fuse. Multi-meter Glass Fuse wa LG. à OEM1428 Figure 10L-2. Fuse Test 10L-2 SECTION 10M. ELECTRICAL SYSTEM GAUGES GENERAL Repair of gauges and sending units are limited to the replacement of defective components or wiring. Before replacing a gauge that is not working make sure to perform a voltage check at the gauge wire. If voltage checks okay, a gauge that does not work is defective except for a water temperature gauge which can be tested as described below. NOTE See Section 10P for the location of all instruments and gauges. WATER TEMPERATURE GAUGE TEST (See Figure 10M-1) Test the water temperature gauge as follows: 1. Turn ignition switch to RUN (ON). 2. Disconnect lead wire to sending unit on engine and ground it. e The gauge indicator should go all the way up. If not, gauge or wiring is defective and must be replaced. If gauge needle does go to upper limit but does not work during operation, sending unit is defective. 4 , TT - - — , ça of ”, Z 7... ’ - WL Ch, Turn : ; ; “, * J J ó 1” e Gs % To ignition —l 4 , Fes, ; у seb aoe. ДНИ, чл / . RN Switch : “rd 77! Temperature VAS IRAN PENA “ON” _ p / AO NOUS pri Gauge A 7 , 17 1 a COL I/O py . ой Eno (peste * DES : 7/4 f/ / o 7 1 mat ; / e 7 - ‚ Ne = ay, уу „и; { 5 “° "7 es A Y 2 > / , e > Luu * ne 7 17 7 e o , . au VA о ... ; FLAT "er ; , / \ /, / / oa e i / ve 7 Gauge O.K. Gauge or Tests O.K. , .. , Wiring is But Does Not R d O "peo J Defective Work During emove an % ea ‚ 27 PE Operation. Ground 7 w, v7 4 Sending Unit Lead Wire и” Defective. Figure 10M-1. Water Temperature Gauge Test 10M-1 ELECTRICAL SYSTEM SECTION 10N. GLOW PLUGS | | GLOW PLUG TEST (DIESEL) 4. Connect one multi-meter test lead to glow plug ter- See Figure 10N-1 and test a suspected faulty glow plug minal and the other to housing. as follows: e The multi-meter reading should be approxi- 1. Shutdown and allow engine to cool. mately 0.8 ohms (cold). If the reading is at infinity or 0 ohms the glow plug is defective and must be 2. Disconnect glow plug lead wire. 3. Set multi-meter to 200 J* (9) ohms. replaced. Multi-meter Glow Plug Figure 10N-1. Glow Plug Test 10N-1 ELECTRICAL SYSTEM SECTION 100. GLOW PLUG INDICATOR GLOW PLUG INDICATOR TEST (DIESEL) 1. Disconnect wires from indicator. The glow plug indicator is a small coil located next to 2. Set multi-meter to 200 « (N) ohms. the glow plug switch on the control panel. It will light up 3. Connect one multi-meter test lead to each coil when the switch is depressed thereby indicating when terminal. the glow plugs are heated and the engine can be a started (from cold). e There should be a reading (continuity) on the . a multi-meter. If not, the coil is defective and must See Figure 100-1 and test indicator as follows: be replaced. | Multi-meter > © Indicator (A we Coil Figure 100-1. Glow Plug Indicator Test 100-1 SECTION 11 PREVENTIVE MAINTENANCE 11A. General .............222000000 000000 000000000000 000000 00 0 000000000000 000 11A-1 Preventive Maintenance .................0800000 000000000000 0000000000 000000 11A-1 Scheduling .............00000000 eee ee 0000 nee eee ee 000000 00000010 eee 00000 = 11A-1 Administration .............02000000000 0000000 0000000000 00000 0 000000000000 11A-1 PMMRS Program Kits ..............200000000 00e eee eee 000000 00000 te 0000 eee 0 11A-1 11B. Lubrication Schedules and Charts ............000000000000 00000000 Eee 11B-1 General ...........1202100000 0000000 0e a a 00 ne a ee 0e sa 000000 000000000000 00000 11B-1 Lubrication Schedules .................000000 000000000000 0000000 0000000000 11B-1 Tractor Grease Chart ...............2000000u 000000000000 000000 0000000 0000 11B-1 Tractor Oil Chart .............202000000 000000 00e 00e 000000 000 00000 00000000 11B-1 Tractor Lubrication Chart ...............00000000 000000 0000000 000000 00000000 11B-1 Deck Grease Chart ............20.0000000 00000 0e 00000000 00 0000 0000000 0000 11B-2 Flail Grease Chart ............20000000 0000000000 000 00e 000000 0000000 0000000 11B-3 11C. Maintenance Schedules ................020000000 00000000 0 0e 0000 0000000000 11C-1 General ............22000 000000 ana 000 0 000 se nee 000000 0000000 0000000000 000 11C-1 Maintenance Schedule Chart ...............00.00000000 000000000000 0000000000 11C-1 Tractor .............222020 000000000000 nas a sea ea 00000000 00000 000000000006 11C-1 Engine, Diesel ............00000000000 000000 ee eee 000000 0e eee 0000000 ete T0 0 11C-2 Engine, Gasoline ........... re RER 000000 ea estates aaa 11C-3 DECKS ..........100200010000 000 caca 0e 00 0 a 00000000 sa 0000 0000000000 000005 11C-4 == ET] EAN AA AAA AAA AA EN 11C-5 Footnotes .............2.20000 00000000 0000000 a ee ee sa 0000000 000000 0000000000 11C-6 PREVENTIVE MAINTENANCE SECTION 11A. GENERAL PREVENTIVE MAINTENANCE Preventive Maintenance (PM) is maintenance performed to prevent malfunctions and parts breakdowns by periodically and systematically checking equipment and its systems. Preventive Maintenance will cut back corrective maintenance. SCHEDULING Each machine should be scheduled for preventive maintenance according to the hours used, its severity of use, and the type of environment the machine is used in. Use the manufacturers recommendation of preventive maintenance. These recommendations can then be altered as experience is gained with the type of equipment and the type of environment in which it operates. While performing preventive maintenance tasks the individual should always be alert to conditions that may seem abnormal. If an abnormal condition is detected a determination must be made to either correct the condition immediately or schedule the tractor in the shop for necessary repairs. ADMINISTRATION Record keeping is an important and most often a for- gotten part of preventive maintenance. Jacobsen has developed a PMMRS (Preventive Main- tenance Management Record System). PMMRS PROGRAM KITS The PMMRS kits and replacement forms (see Figure 11A-1) are available directly from your local Jacobsen Distributor. Model No. ——— Senal No. Engine Model No. Na3saoovrn KY Wr LL T2004) PRODUCT © Figure 11A-1. PMMRS Kit Order Forms 11A-1 J0o9nguISIg Lesqooef 1noÁ 9ejuOS aBueys 0) 103[gns a9lid 0966-COMES UISUOISIM “aUPEY anusay prey>ed 1241 “up uosxa y JO LOJSTATQ Uasqo rf эзпувиб |5 рог | лоузпу CNE NS Y" 8966-COFES UISUOISIM “3UPEY эпиглу preyded 1701 “Jus Vo0sXa y JO LOISIATQ uIsqodef эапувиб цб рэг | лоцапу INOULXAL маса г 51° 1$ @ $39945 JAPUQ I9I1AJIS GI GL LS @ $389Ч$ 43paQ 3214135 GZ 00’1$ @ $32945 Хлешипс ээиечази ем Ol 00’1$ @ $1399Ч$ Хлешипб ээчечадитен OL — (540102 2383$) (540102 33835) 00'2$ @ S43p(04 § 00'2$ @ S43pL04 § 32194 “ALO AT31vuvdiS Y3AYO OL 3314d "ALD A13LVUYdIS 43040 OL juewdinb3 suaa1r us — juawdinb3 suee15) usa — syoniL 194000 — syoniL 1eddog— juowdinb3 Buswoo1r) HUM — juowdinb3 Gujuoosr) UM — s19MOIg pue siedeams MOIDSA— siemo|g pue siedeamg MON8A $18paag ета Nag — s19p3aS эт Xd — sAiejoy pay — SÁJejOy pay — siojelay ета 1 SIO)BIOY ета эт — SI9MON |98Y ABI — S19MON ЭН ABI — S1OJOBIL UNL eBue. OQ — S1OJOB1L UNI oBue.O — (pas;sap 40102 42349) SUMPLOJ S1-9/98 83 G $39945 13p4Q 3IFAJAS S1-//08 83 07 $733US A4euauns aduevajuieWw $51-9/98 Ea OL 30 SIS SUOI iN (pai sap 1O(LO9 YI9UI) SAIPLOJ S1-9/99 La G $19945 JIPJQ 3ILAJAS S1-//99 82 07 $1994ц$ Алешипб ээиечезч ен $1-9($8 23 OL :40 SISISUOI 313 0343040 SLIX “AD 114900988 LIN SUWWA 0343040 SLIY *ALD 314 404 0008 e LIN SUWWG ON 93H) 411 31415 “ON 93H 412 31415 LX XX RJ теч 58 “= Фото ее FSUUSUVHHFS > MINO ANVAMODIY SAN * MD 5 "43680 ANVANODIV 1SMW + MD $ Y93HI YIWOLSN) Ÿ SSTHOOY + XI3HI YIWOLSNI 3 SSYAAY SERIE SIBBBBB33333383383538058088 "ON ‘0 ‘4 3WvN "ON ‘0 ‘à INV YOLABINISIO YOLNGIYISIO “NVv18 У зао ANVS 33030 WI1SAS 040934 INIWIIVNVW IINVNILNIVW IATINIATYA WILSAS 040934 INIWIIVNVW IINVNILNIVW JAILNIATYd S Y NWd | S Y WNHNd 11A-2 | PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION SCHEDULES AND CHARTS LUBRICATION SCHEDULES The following lubrication charts outline grease and oil intervals. Intervals are based on a 40 hour week. These are suggested intervals only. As experience is gained in operating this machine, the schedule can be tailored to your operating time. Reference numbers are keyed to the illustration on page 11C-3. The footnotes on page 11C-3 (letters a thru k) give more detailed information. GENERAL This section contains lubrication and maintenance charts. For easy refernce a 25” x 19” wall chart can be obtained from your Jacobsen Distributor. TRACTOR GREASE CHART Ref. | Qty. | Description | Remarks 40 HOURS (Every Week) 1 1 о Brake arm pivot Use general purpose grease. 2 1 о Hydro linkage pivot Use general purpose grease. 3 3 о Steering and axle pivot Use general purpose grease. 4 1 Spring shaft under seat pan Use general purpose grease so shaft moves freely. ANNUALLY 16 | 2 | b Wheel bearings | Pack bearings. TRACTOR OIL CHART (Use SAE 30 Oil) Ref. Qty. Description Remarks 5 2 Hydraulic valve linkage Apply several drops of oil. 6 1 Transaxle shift lever Apply several drops of oil. 7 3 Brake arm linkage Apply several drops of oil. 8 1 Hydro pedal linkage Apply several drops of oil. 9 1 Hydro control linkage Apply several drops of oil. 10 1 Hydro spring adjustment rod Apply several drops of oil. 12 1 Traction assist linkage Apply several drops of oil. TRACTOR LUBRICATION CHART Ref. | Qty. | Description | Remarks WEEKLY 11 1 PTO lever pivot WD40 or equivalent. 13 1 Traction assist pivot WD40 or equivalent. ANNUALLY 14 1 Hydraulic pump shaft Coat liberally. 15 1 a Hydraulic motor shaft Coat liberally. 17 1 d Transaxle Drain and refill. 11B-1 PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION SCHEDULES AND CHARTS DECK GREASE CHART Ref. | Qty. | Description Remarks DAILY 26 3 Cutter drive spindles Use general purpose grease. 27 2 Caster wheels Use general purpose grease. EVERY TWO WEEKS (40 Hours) 28 2 Caster wheel support arms Use general purpose grease. 29 2 Push arms Use general purpose grease. 30 1 Idier pivot (under belt cover) Use general purpose grease. 31 1 Idier rod spring and spherical nut Use general purpose grease. EVERY THREE MONTHS 32 1 Splined teeth of drive pulley Use general purpose grease on rod area inside of spring. 11B-2 PREVENTIVE MAINTENANCE SECTION 11B. LUBRICATION SCHEDULES AND CHARTS FLAIL GREASE CHART Ref. | Qty. | Description | Remarks EVERY TWO WEEKS (40 Hours) 1 2 Caster wheels Use general purpose grease. 2 2 Caster wheel support hubs Use general purpose grease. 3 2 Push arm pivots 80-90 SAE gear lube. 4 8 Drive shaft 80-90 SAE gear lube. 5 1 Spindle housing Molybdenum disulfide EP lithium grease. EVERY THREE WEEKS 6 | 2 | o Rotor and roller bearings Use general purpose grease 118-3 PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES GENERAL operation between various procedures. Intervals are The following charts summarize maintenance to be based on a 40 hour week. per mes daily, Woo суету “но weeks, monthly, Reference numbers are keyed to the illustration on y y page 11C-3. Footnotes on page 11C-3 give additional The maintenance charts give recommended hours of information. MAINTENANCE SCHEDULE CHART > © = =|® [23| Е 8 = — © © Ref. | Qty. Description S|= SS asa Remarks TRACTOR 16 2 | b Steering wheel bearings X Check adjustment. 17 1 | d Transaxle X Check level. 18 1 | © Hydraulic reservoir X Check. f Hydraulic oil X | Change every 500 hours. 19 1 | 9 Hydraulic oil filter X Change the first 25 hours. X | Change every 250 hours thereafter. 20 10 Front drive wheel nuts X Torque to 40-50 ft-Ibs. (54-68 N.m). Retorque after first 20 hours. 21 8 Rear steer wheel bolts X Torque to 85-90 ft-lbs. (115-122 N.m). Retorque after | first 20 hours. 22 4 Tire pressure X Front: 10 psi (68.9 kPa). Rear: 10 psi (68.9 kPa). Hydraulic hoses and tubing X Inspect. 11C-1 PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE CHART > |N > © > > | 325 E15 2 Ref. | Qty. Description ë |#là2/2 Es Remarks ENGINE DIESEL 23 1 Fuel X Check. Fuel oil #2 Cetane rating 45. 24 Fuel filter X Clean 100 hours. X Replace 300 hours. Fuel lines and clamps X Check 50 hours. X | Replace every 2 years. Engine oil X Check. X Change first 35 hours. X Change 100 hrs. or more often if under dusty conditions. Engine oil filter cartridge X Change first 35 hours. X Change 100 hrs. or more often if under dirty conditions. Radiator screen X Check/clean. Radiator core X Check/clean. Radiator coolant X Check cooled. X | Change. Fan belt X Belt deflects 3/16” (4.8 mm) with 1.2 to 1.5 Ib. (0.54-0.68 kg) pull. 25 Air cleaner dust cup X Clean. Air cleaner element X Clean. X | Replace, more often if under dusty conditions. m Battery X Check. Water pump belt X Belt deflects 1/4-3/8” (6.3-9.5 mm) with 20 Ib. (9 kg) pull. Glow plugs X Preheating time (approximate) Above 32°F (0°C) 15 sec. Below 32°F (0°C) 30 sec. 11C-2 PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE CHART > la | = | © = > E IES E [ET — © © Ref. | Qty. Description 8 |2 33 S 25 € Remarks ENGINE GASOLINE 24 1 Fuel filter in-line X | Replace. Fuel pump filter screen X | Replace or clean. Engine oil X X Check daily, change every 50 hours or more often if operating in extremely dusty conditions. Engine oil filter cartridge X Change every 50 hours or more often if operating in extremely dusty conditions. Radiator screen X Check and/or clean. Radiator core X Check and/or clean. Radiator coolant X X | Check weekly, change annually. Fan belt X Adjust tension.so belt deflects 1/4" (6.35 mm) with 12 Ibs. (5.4 Kg) pull. Dust cup (bottom of air cleaner) X Clean daily. 25 Air cleaner element X X | Clean every two weeks. Replace annually. Alternator governor belt X Adjust tension so belt deflects 1/8" (3.2 mm) with 12 Ibs. (5.4 Kg) pull. Spark plugs X Clean and/or replace every 50 hours. Set gap at .025". Breaker points X Clean and/or replace every 50 hours. Set gap at .018”. Valve clearance X | Check intake (.006") and exhaust (.008") valves when cold. n Governor X | X | Check every 250 hours. Change annually. 11C-3 PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE CHART > IN о = |0 ® = > 325 E |B 2 Ref. | Qty. Description à |= 22/2 a2] < Remarks DECKS 26 3 | o Cutter drive spindles X General purpose gun grease. 27 2 o Caster wheels X General purpose gun grease. 28 2 O Caster wheel support arms X General purpose gun grease. 29 2 O Push arms X General purpose gun grease. 30 1 O |dler pivot (under belt cover) X General purpose gun grease. 31 1 Idler rod spring and spherical nut X General purpose gun grease. Apply on rod area inside of spring. 32 1 a Splined teeth of driver puliey X Remove motor. Coat liberally | every 300 hours. 33 1 Cutter deck belt tension X 60” Deck: Adjust spring length to 2.5” (7.25 cm) between stop bracket end collar. 72" Deck: Adjust spring length to 4” (10 cm) between the front of the hex portion of the nut and the rear of the deck. 34 3 | P Cutter bars (3 per deck) X Examine for condition of bar. 35 2 Tire psi (Pneumatic caster X 22-24 psi (1.52-1.65 bars). wheel Kit) 36 1 Serial number plate Located on the left side of the belt cover. 11C-4 PREVENTIVE MAINTENANCE SECTION 11C. MAINTENANCE SCHEDULES MAINTENANCE SCHEDULE CHART >| 325 3 Ref. | Qty. Description а $ 2 S ESE Remarks FLAIL 1 1 Rotor brake adjustment Stop rotor in 3-7 sec. 2 1 Drive belt X Check/adjust. 3 2 Tire pressure X 22 psi (154 kPa). 4 1 Rotor blades X As necessary. 11C-5 SECTION 12 ATTACHMENTS 12A. Repair and Service Tools and Materials ..............00000000 00H HN 12A-1 12B. Failure Analysis ..........0.0000000000 00000 nennen EEE EEE eee ee 12B-1 12C. General InstructionS .........0.0.0.00000000000 0000 nenn 12C-1 General ..........22000000 000000 ea ae ee ae 0 eee 0e eee eee 00e eee 00 eee ee EEE 12C-1 Preparation for Repair .............00000 0000 eee seen ee eee eee tete ee ee eee 12C-1 12D. Cutter Decks (Product Nos. 66120, 661 22, 66124, 66126) ..........eereoreeooo 12D-1 Carrier Frames (Product No. 66120, 66124, 66126) ..........0020000000000 00000 12D-1 Deck Fittings ..............000000000 00000 eee eee 0e eee eee ete ee eee eee eee eee 12D-2 General .........2220000 00000000 a eee ee eee eee eee ne eee eee ee eee eee 000010: 12D-2 Blade Spindie Assembly (All) ........00000 00000 eee eee eee nec e eee 12D-5 Disassembly ........20000 00000000 ee ee ee eee eee eee eee eee ee te eee ec et 12D-5 Reassembly ........000200000 00e eee eee eee eee een eee eee ec eee tete eee eee ee 12D-6 Drive Assembly (All) .........000000000 0000 eee eee eee ee eee eee ee eee 12D-8 Drive Belt (All) ............eeeoerroccoocereracocacecerer een 12D-9 Installation .........22200000000 000000 0e eee ee see eee 0000 eee 00e 0 eee 12D-9 Guide Adjustment .............00000000 eee ee eee eee eee tance ete eee eee 12D-9 Idier Assembly ..........000000 00000 eee se ee ea ee eee eee eee eee et eee eee 12D-10 Belt Adjustments ............0.00000 00e a eee eee 0e ae eee eee e ee te eee eee 12D-11 | Product No. 66120, 66122, 661224 and 66126 ...........0000000 0000000000 12D-11 12E. Flail Mower (Hydraulic) 66087 ..........00000000000 00e eee eee ace eee ee tee 12E-1 Housing 222000000000 eee eee see ae eee eee eee eee eee eee tete ee eee 12E-1 Rotor Assembly ..........000000 0000000 ee eee en eee eee eee ee ee tee eee eee eee 12E-2 Drive Assembly .........000000 000000 ae seen eee sea ee eee eee cette Tete 12E-3 Drive Belt Idier Assembly ..............errrrecccacecocorecrare tareas 12E-4 Drive Belt .........222000000 000000 eee ee ee eee eee ce eee eee tee tee eee S tete 12E-4 Adjustment © eevee ence canescens tete e eee ee 12E-4 Brake ........eoeeocsocccrcorearorarececanrtecacarcenoracerecearereeraeres 12E-5 Repair ........20200000 0000 eee eee nee ae eee ee eee aa eee eee eee tete eee eee 12E-5 Adjustments .............000000000e cena eee eee ae tee e eee e tete e tete eee 12E-6 19F. Cutter Bars ...........200000000 000 eee a ae 0 ca ee eee eee see 00e e 00000 T1 CCS 12F-1 CT ac EO ERR 12F-1 Sharpening ............0000000 00 0e nee eee eee ec ee eee eee ee eee eee eee 12F-1 ATTACHMENTS SECTION 12A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools, including driving tools and seal spreaders; Blade Grinder. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Non-metallic additive wheel bearing grease (eg. Sunray DX 692 or Enco Fibrox 280). Grease gun grease (eg. Sunray DX 671 or Gulf Supreme No. 0. Other service items: Service cutter bars. 12A-1 ATTACHMENTS SECTION 12B. FAILURE ANALYSIS PROBLEM PROBABLE CAUSE | REMEDY 1. Blades do not tum. a. Blades ¡ammed. a. Clean underside of deck. b. Drive motor malfunctioning. b. Repair/replace (Sections 8L, 8M and 8N). c. Tractor hydraulic system c. Test (Section 8M and 8N). malfunctioning. d. Drive belt broken. e. Spindle bearing failure. Drive assembly malfunctioning. d. Check belt (Section 12D). e. Check bearings, repair (Section 12D). Inspect, repair (Section 12D). 2. Blades run slow. Blades jammed. Drive motor malfunctioning. Tractor hydraulic system malfunctioning. d. Drive belt slipping. Clean underside of deck. Repair/replace (Section 8L, 8M and 8N). Test (Section 8M and 8N). d. Adjust (Section 12D). e. Spindle bearing failure. e. Check bearings, repair (Section 12D). f. Drive assembly malfunctioning. f. Inspect, repair (Section 12D). 3. Uneven cutting. a. Blades loose. a. Tighten (Section 12D). b. Blades bent. b. Replace. c. Spindle bearing failure. c. Check bearings, repair (Section 12D). d. Deck shell bent. d. Replace. e. Deck not adjusted level. e. Adjust deck (see Operators Manual). 4. Ragged cut. a. Blade dull. a. Sharpen/replace (Section 12F). b. Blades loose. b. Tighten (Section 12F). c. Blades installed wrong. c. Install correctly (Section 12F). d. Operating too fast for conditions. d. Slow down ground speed (see Operators Manual). 5. Excessive vibration. a. Blade not balanced. a. Balance (Section 12F). b. Spindle bearing failure. b. Check bearing, repair (Section 12D). c. Blades loose. c. Tighten (Section 12F). d. Blades bent. d. Replace. e. Spindle housing or deck shell e. Replace. cracked. 12B-1 ATTACHMENTS SECTION 12C. GENERAL INSTRUCTIONS GENERAL This section covers repair and adjustments of the attachments used with the Turf Cat. Even though there are a variety of attachments available, there are many similarities between them. For example: Decks are side discharge tunnel, rear discharge all having their own product number, yet all use the same blade spindle assembly. Illustrations used in this section will reflect differences between attachments by using insets along with the product number it is used on. Be familiar with the product being worked on and look closely at illustrations and their insets for correct identi- fications (see Figure 12C-1). PREPARATION FOR REPAIR Thoroughly clean attachments prior to removal, disassembly and/or repair. Coat bare metal parts with light oil to prevent rust and corrosion. Attachments are exposed to water, grass clippings, sand, corrosive fertilizers, and foreign objects. It may be necessary to use bearing pullers and/or wooden blocks and hammer to free up some parts. When such force is required to remove parts, those parts should be replaced rather than reinstalled on the machine. A WARNING Before removing components or performing repairs and adjustments, lower attachment, stop engine, set parking brake and remove key from ignition switch. Product No. 66122 Figure 12C-1. Deck Push Arms 12C-1 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) CARRIER FRAMES (Product No. 66120, 66124, 66126) Repair of the carrier frame consists of replacing bushings and worn or damaged components (see Figure 12D-1). NOTE Read Section 12C before continuing. Lock Pin | Bushing ————e Bushing Shim- D Product No. 66120 and 66126 Only № Carrier Frame Push Arm NLA Bushing Lock Push Arm Grease Fittings Rear Flap Bushings Product No. 66120, 66126 Only Figure 12D-1. Carrier Frame Assembly 12D-1 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) DECK FITTINGS GENERAL Removal and installation of deck fittings are illustrated in: Figure 12D-2 — 60” Side Discharge Deck Product No. 66122. E Stiffener Bar Belt Guide Bushing Grease Fittings Bolt Bolt Nut Chute N | Belt DZ Covers = Lo Arm Bushings Grease Cotter Fittings Figure 12D-2. Deck Fittings (Product No. 66122 Only) 12D-2 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) Figure 12D-3 — 72" Rear Discharge Deck Product No. 66120. 72" Tunnel Deck Product No. 66126. Lockwasher — / Flat Washer $ к © Belt Guide K Bolt Ja CA Roller Bracket Roller Front Shield 282—— ——— Bolt 7 Roller FT Bracket A Nut / ® Nut Roller — Nut AN Lockwasher € Bolt ——# Flap Figure 12D-3. Deck Fittings (Product No. 66120 and 66126) 12D-3 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) Figure 12D-4 — Rear Discharge Deck Product No. 66124. Belt Guide Setscrew Deflector Washer Bolt Figure 12D-4. Deck Fittings (Product No. 66124) 12D-4 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) BLADE SPINDLE ASSEMBLY (ALL) DISASSEMBLY Refer to Figures 12D-5 and 12D-7 for disassembly procedures. Bolt Ÿ_—Lockwasher @&)e— Washer Nut Deck ea 7 Lockwasher DE | “ Adapter | НО us Cutter Spindle -— Assembly Washer —$ Lockwasher—— ® Lockwasher Nut _ e A STEP 1 STEP 2 Key Remove cutter bar, adapter, pulley and hardware. Bearing Bearin da в WU — 9 el NS и | | al SN SD Y: N ) |! 8 _ 8 Л N \ | N | = CIÓN MY E i \ | К Drive out blade end bearing. STEP 3 NOTE Press out shaft and pulley end Using a hammer and punch or screwdriver to remove bear- bearing. ings will damage bearings. Always use new bearings. Figure 12D-5. Blade Spindle Disassembly 12D-5 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) REASSEMBLY Refer to Figures 12D-6 and 12D-7 for reassembly procedures. STEP 2 Press Bearing Press spindle shaft into blade end | => | of housing. (| 7 TEP 1 77 Press on blade end bearing. A Press STEP 3 Press bearing into pulley end of housing. No Bolt —y Washer 2 Product No. 66120 and 66126 STEP 4 1 } ‘ ° . у ус Reinstall housing on deck. и” ( 217 | d © Г 9 | Adapter = | ® ! | о Spindle NA No Cutter Bar Washer | Nut Lockwasher | » | 1 27 Ë ® и” A STEP 5 Blade Screw Blade Blade Screw Torque: Center 55-65 ft-lbs. (75-88 N.m) (Outer) Screw Outer 35-40 ft-lbs. (47-54 N.m) (CTR) Spindle Housing Torque: 17 ft-lbs. (23 N.m) Figure 12D-6. Blade Spindle Disassembly 12D-6 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 661 22, 66124, 66126) Pulley Bolt Torque 20 ft-lbs. (27 N.m) De Spacer Product No. 66120 and 66126 Lockwasher / © Product No. 66120 and 66126 OF > 7 Pulley | Figure 12D-7. Blade Spindle Assembly 12D-7 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) DRIVE ASSEMBLY (ALL) Refer to Figure 12D-8 for disassembly and reassembly procedures. Torque Motor NOTE Grease splines with Molybdenum Disulfide E.P. Grease. © © Bearings Housing Snap Ring Drive Pulley Snap Ring Large Snap Ring Groove Housing Snap Ring Groove Expansion Plug Figure 12D-8. Drive Assembiy 12D-8 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 661 22, 66124, 66126) DRIVE BELT (ALL) INSTALLATION Center Drive belt routing is the same on all decks (see Figure 12D-9). Belt Idler Pulley GUIDE ADJUSTMENT Belt guides should be correctly adjusted to assure maximum life of the belt. To properly adjust, refer to the figure which matches your product. LH > Belt Guides R.H. Pulley Figure 12D-9. Drive Belt Routing Product No. 66122 Product No. 66124 1/1 6"-1/8" 1/1 6” - 1/8" y a Belt , _ 5 — E Belt ото 3 Guide Guide Guide ‚№ Belt sis TC 1/16” Min. Clearance on Each Side В Product No. 66120 and 66126 Figure 12D-10. Belt Guide Adjustment 12D-9 ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) IDLER ASSEMBLY The belt idler assembly acts as a belt tensioning device. For service see Figure 12D-11 and see Figure 12D-12 for belt tension adjustment. Product No. 66122 Cotter Bushing Bolt Lockwasher ® ис Washer &— Adjustment Idler | Pulley и PS Spring o —— E | 2 OÙ Cotter Pin— — — 7 | Ds ~~" Adjustment ео) NN \ N Grease_— | \ 8 Arm Fitting 06 <) < O \ Setscrew ———— DI IS ZQ2 Product No. 66120, 66124 and 66126 US = — Do ‘ A0 q <> a d N. 44 ° = < Figure 12D-11. Idler Assembly 12D-10 \ ATTACHMENTS SECTION 12D. CUTTER DECKS (Product Nos. 66120, 66122, 66124, 66126) BELT ADJUSTMENTS Product No. 66122 (See Figure 12D-12) 1. Measure how. much the tension spring is compressed. It should be 2.25" to 2.5”. If dimension IS less than 2.25" or greater than 2.5”, proceed with Step 2. 2. Loosen setscrew in collar, adjust collar so spring is compressed between 2.25” and 2.5". NOTE Be sure belt guides are properly adjusted. Product Nos. 66120, 66124 and 66126 (See Figure 12D-12) 1. Measure how much the tension spring is compressed: Product 66120 and 66126 should be 4" - 4-1/8". Product 66124 should be 4-3/8" — 4-1/2". If dimensions are less or greater than what is specified, proceed with Step 2. 2. Adjust nut B and locknut A compressing spring to the specified length. 2.25"-2.50" Q (50-63 mm) ON o Product No. 66122 Bad ] Rear of Deck 4-3/8" — 4-1/2" (111 - 114 mm) Product No. 66124 Figure 12D-12. Belt Tension Adjustment 12D-11 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) HOUSING For service of the flail housing, refer to Figure 12E-1. a Front Shield Bushings Figure 12E-1. Flail Housing Assembly 12E-1 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) ROTOR ASSEMBLY The flail rotor is designed to be easily removed and installed. It is also designed to be turned 180° and reinstalled. This allows usage of the other side of flail blades to get double the life of blades. For removal, repair and installation, refer to Figure 12E-2. > Washers Bearing Figure 12E-2. Flail Rotor Assembly 12E-2 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) DRIVE ASSEMBLY Refer to Figure 12E-3 for service of the drive assembly. 7 CC Housing Motor Snap Ring O-Ring Pulley О Snap Ring Expansion Bearing NOTE i Plug Drive Grease splines with Molybdenum Disulfide E.P. Grease. Pulley Figure 12E-3. Flail Drive Assembly 12E-3 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) DRIVE BELT IDLER ASSEMBLY The drive belt idler assembly acts as a tensioning device. For service see Figure 12E-4 and Figure 12E-5 for belt adjustment. Adjustment Lockwasher Nut Adjustment CS Screw | 3 Adjustment Nut Spring Locknut Spacer = Idler B @» _ Е ~ Pulley olt | Pel 7 >. ol Bushing SA Idier Ÿ1 > Arm A N Bushing Spacer Bolt Washer Figure 12E-4. Idler Assembly DRIVE BELT Adjustment Nuts ADJUSTMENT (See Figure 12E-5) Remove belt cover and measure spring length. Spring length should be 3-7/16 to 4-1/2" (87-114 mm). (87 - 144 mm) Figure 12E-5. Belt Adjustment 12E-4 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) BRAKE REPAIR Refer to the steps in Figure 12E-6 for repair of brake components. Thrust Washer 0.063" Thick Outside Lining Plate Locknut Torque 22-30 ft-Ibs. (30-41 N.m) C-Clip STEP 3 Brake caliper repair. Brake O-Ring Backup Seal - Cotter Bolt 7 Y Caliper Washer Pin Ds, G Housing Setscrew Bracket ET A 2 Nuts pe Le Washer O-Ring _ & > OT = o Bolt Lockwasher g ; Bolt > Nut O-Ring Spring Hub Brak Backup Washer u rake Rin < Сар 9 | Drive Disc Key Y — 1-15/16" STEP 1 E (49 mm) STEP 2 . Cover | УДАР eme Yum Brake Removal and installation. Cylinder repair ON Cylinder Assembly Adjustment At assembly install washers as required to obtain a gap of 13/64" , Washers _ 15/64" , Lining ; = Plate x Bolt STEP 4 Engage brake lever by hand and adjust nut (B) to obtain a spring length of 1-11/16” (43 1-11/16" mm). Disc Brake Assembly i B A N © | / O O ó © | Brake Cylinder Assembly Figure 12E-6. Brake Assembly Repair 12E-5 ATTACHMENTS SECTION 12E. FLAIL MOWER (Product No. 66087) ADJUSTMENT Maintain a Spring Length of The brake is a mechanical type which remains engaged 1-11/16” - 1-3/4" (43-44 mm) until the PTO lever is engaged. . . Disc Brake Assembly When the PTO lever is engaged hydraulic pressure | L applied to the brake cylinder opens the brake. N The brake should be adjusted as necessary to stop the | rotor within 3 to 7 seconds after the brake is applied © (see Figure 12E-7). 7 O Perform the procedure in step 2 to maintain desired O stopping time. © | Brake Cylinder Assembiy © Figure 12E-7. Brake Adjustment 12E-6 ATTACHMENTS SECTION 12F. CUTTER BARS GENERAL Every 50 hours examine the cutter bars to make sure | they are in good operating condition. See Figure 12F-1. Г = = —z 1. The cutter bars should follow along a straight line Straight and should not be bent. Replace all bent cutter bars. The damage may | nn = include a microscopic crack which could grow, > allowing a piece of the bar to break off and be thrown out from under the mower, causing serious bodily injury. = 2. Examining the ends of the cutter bar and at the bend of the air vanes, inspect edge of bar to determine if =— bar is becoming thin. | | к тЫ Do not attempt to bend bar back to its original flat N condition. Replace bar. >. New Cutter Bar 3. If wear is allowed to continue, a slit will develop and A > grow, permitting a piece of the bar to break off. At 7 AN | the first sign of a slit in the bar, the bar must be sy) Early Wear replaced. SHARPENING Dangerous Wear When dressing or resharpening the cutter bar. DO NOT follow the original angle of grind “A”, Figure - — 19F-2. Figure 12F-1. Condition of Cutter Bars 1. Grind new cutting edges on a diagonal as shown in “В”. 2. Do not exceed 1/2" (12.7 mm) total metal removed at end of bar. 3. Make sure that each cutting edge receives an equal amount of grinding to prevent having an unbal- anced bar, which will cause excessive vibration at high speeds and may damage the mower. A DANGER Incorrect resharpening of the cutter bar beyond DO NOT Resharpen 1 to this Pattern Original Edge Metal removal not to exceed 1/2" (12.7 mm) from ALL resharpenings do DO NOT Resharpen fu + beyond this point Required Resharpening Pattern . Figure 12F-2. Sharpening the point illustrated in “B”, Figure 12F-2, may result in a broken blade tip which may be dis- charged from under the mower. Balanced — NN anced (see Figure 12F-3). 5. If bar is out of balance remove metal on the heavy end by grinding until bar is balanced. 4. After cutter bar has been sharpened it must be bal- —— < — a Figure 12F-3. Cutter Bar Balance 12F-1 SECTION 13 OPTIONS 13A. Repair and Service Tools and Materials ..............0000000000 000000000000 13A-1 13B. Grass Pickup Unit 60” (Product No. 66101 and 66102) ..............e=.e.ee..- 13B-1 General .........122022000 0000000 00e a nee na 00000 000 000000000000 0000000000 13B-1 = 7 (©) (=) dE ES RES eee aa 000000 13B-1 Disassembly ...........000000 00000 ne 0 se 0000000 0000000000 ea aa 0000000000 13B-1 Inspection ............0000000 0000 sea 0 00000000 eee 0000000 0000 0000000000 13B-2 Reassembly ............00000 0000 nee 0 eee 00e se 00000 0000000000 0000000000 13B-2 m 0) 0 00 eee eee 000000000000 0000000 T 00 13B-3 Repair 222000000000 s eee 00000000 0000010 000000000100 00000000 13B-3 Caster Wheels .............0000000000 0000000 ae 0000000000 000000 0000000000 13B-4 13C. Caster Wheels | OPTIONS SECTION 13A. REPAIR AND SERVICE TOOLS AND MATERIALS Tools required: Standard automotive hand tools, including driving tools, bearing pullers, and seal sleeves. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Non-metallic additive wheel bearing grease (eg. Sunray DX 292 or Enco Fibrox 280). Grease gun grease (eg. Sunray DX 671 or Gulf Supreme No. 0). Other service items: Blind hole bearing puller. 13A-1 OPTIONS SECTION 13B. GRASS PICKUP UNIT 60” (Product No. 66101 and 66102) GENERAL The Grass Pickup Unit is broken down into two groups; blower and hopper asembilies. BLOWER Disassembly Refer to steps in Figure 13B-1 for disassembly proce- Refer to the Operator's Manual for proper set up and dures. operation. Beari ring Cover Mounting \ Plate A SY Housing ! Gear ® | __Cove Box | | Le и | | STEP 2 | _ 2® =. < Bushing Drive | f ; ~~. Pulle | Blower | HX Idier — у 7 RQ | \ Arm ——Bearing Collar Bearing STEP 1 Bearing Idler Pulley Coupling Disc. ве S+—— — Washer Pulley STEP 3 oA Г Gasket ; —~<> | | | J Miter < Gear = \ Bearing rad 7 L 7 Miter Gasket Bearing Gear Sy © | Output Shaft в ED Bearing Retainer N o Bearina Cap a A 9 &+—>Snap O. . Snap S Ring \ input Ring Seal — © Shaft N, | а PS STEP 4 Figure 13B-1. Blower Disassembly 13B-1 OPTIONS SECTION 13B. GRASS PICKUP UNIT 60” (Product No. 66101 and 66102) Inspection Reassembly Inspect all parts for wear or damage. Replace as Refer to steps and instructions in Figure 13B-2 for necessary. reassembly. STEP 1 Gasket ~~ > Miter Gear — Bearing —® Pe Output Shaft Shaft “Miter ; ... Gear Bearing 29 о : Gasket \ | © | Bearing Coupling Retainer Bearing @-—Snap = | ap DD \ Snap ES Ring Input Ring | x U Shaft \ Bushing STEP 2 Seal Se NOTE Seal Fill with 4 oz. Molybdenum Disul- ® Washer fide E.P. Grease. Shaft ~~ Flange Cover e Collar STEP 3 4 In + AN _— Cover 1/2"-5/8" (13-16 mm) Pull up to obtain CAUTION | a1/2"-5/8" gap. Gear backlash is determined by gasket thickness. Use manufacturers original gasket. y Push on and turn collar in direction of shaft rotation. e Зы Bushing $ т Idier — Am e S > — J Tighten setscrew. _—— = | — Strike in direction of Bearing font rotation until idler ‘ТА Pulley STEP 4 Figure 13B-2. 13B-2 OPTIONS SECTION 13B. GRASS PICKUP UNIT 60” (Product No. 66101 and 66102) HOPPER (See Figure 13B-3) Repair Top Back tm Frame Figure 13B-3. Hopper Assembly 13B-3 OPTIONS SECTION 13B. GRASS PICKUP UNIT 60” (Product No. 66101 and 66102) CASTER WHEELS (See Figure 13B-4) Fork Through Bolts Bearing Spacers 13B-4 Figure 13B-4. Caster Wheel OPTIONS SECTION 13C. CASTER WHEELS (ALL) Various caster wheel options are offered for rotary and flail mowers. Refer to the illustration below to determine which is the correct caster wheel installed on your machine. Follow the individual repair sequence for bearing or bushing service. Axle Stop Washer Product No. 66117 . Cotter ad Pin ‘Retaining Pin Bearing Product No. 66118 Pin Bushing Washer — Bushing Product No. 66110 and Flail Retaining Bearing Product No. 66114 Figure 13C-1. Caster Wheel Assemblies 13C-1 SECTION 14 MISCELLANEOUS 14A. Precaution Decal Locations ...............2.02000000000 00000000 000000000000 000 14A-1 Tractor ........eeeeoocorcocococccaanroocroracecra arar erracacecacarecacrerer: 14A-1 Deck .......e.oeoeocoscccaororareracacerceracocre acercar roo racaceacerrarecarecer 14A-3 A ee 14A-4 148. Conversion Charts ...............0204000000 0000 0e ee 00 00 00000 0e 000001100000 0 14B-1 Millimeters to Decimals .................00000000 000000000000 00 000000 00000000 0 14B-1 Decimals to Millimeters, Fractions to Decimals to Millimeters .......:.....00000 14B-2 U.S. to Metric Conversions ..............4.<000000 000000 00000000 00000000 000000 14B-3 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS fr F5 , Pt LL i Pa 4.2. 0.2 >. a , AA Aa E No "A NO Y 06° 2500 N wie) NEN { e ’ \ ES / «а 00 аи fo "4 *» 4 cer NA 1 LA Y - won. . “veg? A er gs: a p° , 2277 „” ele ee TT “ad ety’ vr re =be--" oc... “ye < \ Te , “ ~~ coast’ e . wo.” ve | \ 38 ” 7 CS pe Se 2} Se { TR И Gn GE aga NN ; > + Seo = “° “обвес с 1 Tn Na чо Seal “Seay e ‘. / ce. я ` NS / “Un “dy 3 N 39 S `. Se „об. ` # 155 “ No” x \ TTR, / ... { E N J ec. 1 “ae Se 6 \ - of “== Na ‘ОЙ уу "Pa def Pel US N ` ff aa A ia JD EP 7 Mee cell Tt Yoh / / / [tao no, \ г 225) "Men, e O ze pad" Z .. ( ne ЖЗ) - - - - - - - . - - - - - - - - 2 - - - - - - - - - - - ``. Se - Part No. 2 Diesel Only — 363134 1 PartNo. À A CAUTION 361854 TRACTOR DO NOT USE STARTING 4A CAUTION ASSIST FLUIDS. USE OF STARTING ASSIST FLUIDS IN THE AIR INTAKE 1.KEEP ALL SHIELDS IN PLACE. SYSTEM MAY BE POTENTIALLY EXPLOSIVE OR CAUSE 2.STOP ENGINE TO ADJUST AND Oil. A "RUNAWAY" ENGINE CONDITION. THIS COULD 3 WHEN MECHANISM BECOMES CLOGGED RESULT IN SERIOUS ENGINE DAMAGE AND/OR DISENGAGE POWER AND STOP ENGINE PERSONAL INJURY. J-T363134CA BEFORE CLEANING. 4 KEEP HANDS, FEET AND CLOTHING AWAY FROM POWER-DRIVEN PARTS. 5.00 NOT RIDE ON MACHINE OR ALLOW PASSENGERS UNLESS SEAT IS PROVIDED. 6.READ MANUAL THOROUGHLY BEFORE OPERATING MACHINE. 3 Part No. 364661 A\ WARNING RADIATOR TUBE MAY EXCEED 150°F 14A-1 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS COLD ENGINE STARTING INSTRUCTIONS WITH IGNITION SWITCH IN THE OFF POSITION, PRESS GLOW PLUG SWITCH UNTIL GLOW PLUG INDICATOR GLOWS BRIGHT RED. (APPROXIMATELY 30 SECONDS) RELEASE GLOW PLUG SWITCH AND START ENGINE. HOT ENGINE WARNING DO NOT OPERATE MACHINE WITH TEMPERATURE GAUGE READING ABOVE 220°F. HORN WILL SOUND TO WARN OF OVER HEATED ENGINE. SEE OPERATORS MANUAL FOR INSTRUCTION FOR CLEANING RADIATOR AND CHECKING FLUID LEVEL. DO NOT OPERATE ENGINE WITH HORN SOUNDING. J-T338300CA Part No. 338300 Part No. 336640 A DANGER TO AVOID INJURY: ALWAYS CONNECT THE ‘‘GROUND’’ (BLACK) CABLE LAST AND REMOVE IT FIRST WHENEVER PERFORMING ANY BATTERY MAINTENANCE. DO NOT CONTACT BATTERY TERMINALS OR TOOLS USED TO LOOSEN THE TERMINALS WITH METAL PARTS. AVOID CONTACT WITH BATTERY ACID. KEEP SPARKS AND FLAMES AWAY FROM THE BATTERY. A CAUTION TO INSTALL BATTERY: 1. INSTALL BATTERY WITH TERMINALS TOWARD FRAME CENTER. 2. CLAMP BATTERY HOLDDOWN TO SUPPORT. 3. CONNECT POSITIVE (+) TERMINAL (RED CABLE). 4. CONNECT NEGATIVE (-) TERMINAL (BLACK CABLE). TO REMOVE BATTERY: 1. REVERSE INSTALLATION PROCEDURE LISTED ABOVE. TO JUMP THE BATTERY: 1. CONNECT JUMPER TO POSITIVE (+) TERMINAL ON GOOD BATTERY. CONNECT OTHER END OF POSITIVE JUMPER TO POSITIVE TERMINAL ON THE FLAT BATTERY. CONNECT JUMPER TO NEGATIVE (-) TERMINAL ON GOOD BATTERY. CONNECT OTHER END OF NEGATIVE JUMPER TO FRAME OF VEHICLE WITH FLAT BATTERY. 2. 3. 4. 3-1 336640 CA Part No. 337509 A DANGER TO AVOID POSSIBLE SERIOUS BODILY INJURY: WHEN OPERATING VEHICLE WITHOUT ATTACHMENTS, TURN CORNERS AT A SLOW SPEED TO REDUCE RISK OF VEHICLE TIPPING. WHEN ON SLOPES AND/OR ROUGH TERRAIN OR WHEN MAKING SHARP TURNS RUN AT REDUCED SPEEDS. LOWER ATTACHMENT TO GROUND WHEN DESCENDING SLOPES TO REDUCE RISK OF VEHICLE TIPPING. DO NOT OPERATE MOWER WITH BENT OR MISSING COMPONENTS OR WITHOUT DISCHARGE CHUTE EXTENSION IN PLACE. OBJECTS CAN BE THROWN VERY LONG DISTANCES, STRIKING OTHER PERSONS AND/OR OPERATOR. DO NOT OPERATE BLADES WITH MOWER IN RAISED POSITION. 14A-2 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS DECK | A DANGER DO NOT OPERATE MOWER WITH BENT OR MISSING COMPONENTS.OPERATION WITH BENT COMPONENTS OR WITHOUT THE DISCHARGE CHUTE EXTENSION GREATLY INCREASES THE RISK OF SERIOUS BODILY INJURY DUE TO OBJECTS BEING THROWN VERY LONG DISTANCES AND STRIKING OTHER PERSONS AND/OR THE OPERATOR. Part No. 337857 Part No. 339460 8 KEEP HANDS and FEET AWAY | 14A-3 MISCELLANEOUS SECTION 14A. PRECAUTION DECAL LOCATIONS Serial No. Plate ` ` x * . ets ` > . + a . . Sn ve A . °° e * * . . . . e. . - e - - . . . „* ° > Jae >» FLAIL 1 Part No. A DANGER 337837 DO NOT OPERATE MOWER WITH BENT OR MISSING COMPONENTS.OPERATION WITH BENT COMPONENTS OR WITHOUT THE DISCHARGE CHUTE EXTENSION GREATLY INCREASES THE RISK OF SERIOUS BODILY INJURY DUE TO OBJECTS BEING THROWN VERY LONG DISTANCES AND STRIKING OTHER PERSONS AND/OR THE OPERATOR. Part No. 339460 Part No. 361854 A CAUTION 1.KEEP ALL SHIELDS IN PLACE. 2.STOP ENGINE TO ADJUST AND OIL. 3.WHEN MECHANISM BECOMES CLOGGED DISENGAGE POWER AND STOP ENGINE 2 BEFORE CLEANING. 4XEEP HANDS, FEET AND CLOTHING AWAY FROM POWER-DRIVEN PARTS. S.00 NOT RIDE ON MACHINE OR ALLOW PASSENGERS UNLESS SEAT IS PROVIDED. 6.READ MANUAL THOROUGHLY BEFORE OPERATING MACHINE. KEEP HANDS and FEET AWAY 14A-4 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS MILLIMETERS TO DECIMALS Starrett Metric Tools MILLIMETERS TO DECIMALS Deci- Deci- Deci- Deci- Deci- mm mal mm mal mm mal mm то! mm mal 0.01 .00039 0.41 .01614 0.81 .03189 21 .82677 61 | 2.40157 0.02 .00079 0.42 .01654 0.82 .03228 22 .86614 62 | 2.44094 0.03 .00118 0.43 .01693 0.83 .03268 23 .90551 63 | 2.48031 0.04 .00157 0.44 .01732 0.84 .03307 24 .94488 64 | 2.51969 0.05 .00197 0.45 .01772 0.85 .03346 25 ‚98425 65 | 2.55906 0.06 .00236 0.46 .01811 0.86 .03386 26 | 1.02362 66 | 2.59843 0.07 .00276 0.47 .01850 0.87 .03425 27 | 1.06299 67 | 2.63780 0.08 .00315 0.48 .01890 0.88 .03465 28 | 1.10236 68 | 2.67717 0.09 ‚00354 0.49 ‚01929 0.89 ‚03504 29 | 1.13173 69 | 2.71654 0.10 ‚00394 0.50 ‚01969 0.90 ‚03543 30 | 1.18110 70 | 2.75591 0.11 .00433 0.51 .02008 0.91 .03583 31 | 1.22047 71 | 2.79528 0.12 .00472 0.52 .02047 0.92 .03622 32 | 1.25984 72 | 2.83465 0.13 .00512 0.53 .02087 0.93 .03661 33 | 1.29921 73 | 2.87402 0.14 .00551 0.54 .02126 0.94 .03701 34 | 1.33858 74 | 2.91339 0.15 .00591 0.55 .02165 0.95 .03740 35 | 1.37795 75 | 2.95276 0.16 .00630 0.56 .02205 0.96 .03780 36 | 1.41732 76 | 2.99213 0.17 .00669 0.57 .02244 0.97 .03819 37 | 1.45669 77 | 3.03150 0.18 .00709 0.58 .02283 0.98 .03858 38 | 1.49606 78 | 3.07087 0.19 .00748 0.59 .02323 0.99 .03898 39 | 1.53543 79 | 3.11024 0.20 .00787 0.60 .02362 1.00 ‚03937 40 | 1.57480 80 | 3.14961 0.21 ‚00827 0.61 ‚02402 1 ‚03937 41 | 1.61417 81 | 3.18898 0.22 ‚00866 0.62 ‚02441 2 ‚07874 42 | 1.65354 82 | 3.22835 0.23 ‚00906 0.63 ‚02480 3 „171811 43 | 1.69291 83 | 3.26772 0.24 ‚00945 0.64 ‚02520 4 ‚15748 44 | 1.73228 84 | 3.30709 0.25 .00984 0.65 ‚02559 5 ‚19685 45 | 1.77165 85 | 3.34646 0.26 .01024 0.66 .02598 6 .23622 46 | 1.81102 86 | 3.38583 0.27 .01063 0.67 .02638 7 .27559 47 | 1.85039 87 | 3.42520 0.28 .01102 0.68 .02677 8 31496 48 | 1.88976 88 | 3.46457 0.29 .01142 0.69 .02717 9 .35433 49 | 1.92913 89 | 3.50394 0.30 .01181 0.70 .02756 10 .39370 50 | 1.96850 90 | 3.54331 0.31 .01220 0.71 .02795 11 .43307 51 | 2.00787 91 | 3.58268 0.32 .01260 0.72 ‚02835 12 ‚47244 52 | 2.04724 92 | 3.62205 0.33 ‚01299 0.73 ‚02874 13 ‚51181 53 | 2.08661 93 | 3.66142 0.34 ‚01339 0.74 02913 14 .55118 54 | 2.12598 94 | 3.70079 0.35 01378 0.75 .02953 15 .59055 55 | 2.16535 95 | 3.74016 0.36 .01417 0.76 .02992 16 .62992 56 | 2.20472 96 | 3.77953 0.37 .01457 0.77 .03032 17 .66929 57 | 2.24409 97 | 3.81890 0.38 .01496 0.78 .03071 18 .70866 58 | 2.28346 98 | 3.85827 0.39 .01535 0.79 .03110 19 .74803 59 | 2.32283 99 | 3.89764 0.40 .01575 0.80 .03150 20 .78740 60 | 2.36220 100 | 3.93701 THE L. S. STARRETT COMPANY Athol, Massachusetts 01331, U. S. A. 14B-1 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS DECIMALS TO MILLIMETERS, FRACTIONS TO DECIMALS TO MILLIMETERS Starrett’ Metric Tools DECIMALS TO MILLIMETERS FRACTIONS TO DECIMALS TO MILLIMETERS - Deci- Deci- Frac- Deci- Frac- Deci- mal mm mal mm tion mal mm tion mal mm 0.001 | 0.0254 | 0.500 | 12.7000 1.64 | 0.0156 | 0.3969 | 33/64 | 0.5156 | 13.0969 0-002 00 es 0-250 122080 1:32 | 0.0312 | 0.7938 E 17/32 | 0.5312 | 13.4938 0004 01016 0.530 | 134620 3,64 | 0.0469 | 1.1906 | 35/64 | 0.5469 | 13.8906 0.005 | 0.1270 | 0.540 | 13.7160 0.006 | 0.1524 | 0.550 | 13.9700 1/16 | 0.0625 | 1.5875 | 9/16 | 0.5625 | 14.2875 0.007 | 0.1778 | 0.560 | 14.2240 0.008 | 0.2032 | 0.570 | 14.4780 0.009 0.2286 1 0.580 | 14.7320 5:64 | 0.0781 1.9844 E 37/64 | 0.5781 | 14.6844 0.010 | 0.2540 | 0-590 | 14.9860 3/32 | 0.0938 | 2.3812 | 19/32 | 0.5938 | 15.0812 0.020 | 0.5080 7/64 | 0.1094 | 2.7781 | 39/64 | 0.6094 | 15.4781 0.030 | 0.7620 0.600 | 15.2400 0.030 1 1:3369 1 0.610 | 15.4940 | 1/8 | 01250] 3.1750 | 5/8 | 0.6250 | 15.8750 0.060 1.5240 § 0.620 | 15.7480 0.070 | 1.7780 e Le 2560 9/64 | 0.1406 | 3.5719 E 41/64 | 0.6406 | 16.2719 0.080 | 2.0320 E 0650 | 16.510 | 5/32 | 0.1562 | 3.9688 | 21/32 | 0.6562 | 16.6688 ° ° 0.660 | 16.7640 11/64 | 0.1719 | 4.3656 | 43/64 | 0.6719 | 17.0656 0.100 | 2.5400 0.670 | 17.0180 0.110 | 2.7940 $ 0.680 | 17.2720 0.120 3.0480 0.690 17.5260 3/16 | 0.1875 | 4.7625 | 11/16 | 0.6875 | 17.4625 0.130 | 3.3020 | " О 50 23700 13/64 | 0.2031 | 5.1594 | 45/64 | 0.7031 | 17.8594 0.160 | 4.0640 | 0-700 | 17.7800 7/32 | 0.2188 | 5.5562 | 23/32 | 0.7188 | 18.2562 0.170 | 4.3180 0720 18080 15/64 | 0.2344 | 5.9531 | 47/64 | 0.7344 | 18.6531 0.180 | 4.5720 | * - ° ° 0.740 | 18.7960 1,4 | 0.2500| 6.3500 | 3.4 | 0.7500 | 19.0500 0.200 | 5.0800 | 0.750 | 19.0500 0.210 | 5.3340 | 0.760 | 19.3040 0.220 5.5880 | 0.770 | 19.5580 17/64 | 0.2656 | 6.7469 | 49/64 | 0.7656 | 19.4469 0.230 5.8420 0.780 | 19.8120 9,32 | 0.2812 | 7.1438 | 25/32 | 0.7812 | 19.8438 0.240 | 6.0960 § 0.790 | 20.0660 29 54 1/64 | 0.7969 | 20.24 0.250 | 6.3500 19/64 | 0.2969 | 7.5406 | 51/64 | 0.7969 | 20.2406 0.260 | 6.6040 5 16| 0.3125| 7.9375 | 13.16 | 0.8125 | 20.6375 0.280 | 7.1120 9 | 73660 | 0-810 | 20.5740 0.29 -3660 | 0.820 | 20.8280 | 21/64 | 0.3281 | 8.3344 | 53/64 | 0.8281 | 21.0344 0.300 7.6200 0-830 2179520 11/32 | 0.3438 | 8.7312 E 27/32 | 0.8438 | 21.4312 07320 | 81280 | 0.850 | 215900 | 23/64 | 0.3594 | 9.1281 | 55/64 0.8594 | 21.8281 0.330 8.3820 0.860 | 21.8440 0.340 | 8.6360 | 0.870 | 22.0980 3.8 | 0.3750 | 9.5250 78 | 0.8750 | 22.22 0.350 | 8.8900 | 0.880 | 22.3520 50 ; 1 0.890 | 22.6060 0390 3050 25/64 | 0.3900 | 9.9219 | 57/64 | 0.8906 | 22.6219 0.380 | 9.6520 13,32 | 0.4062 | 10.3188 | 29:32 | 0.9062 | 23.0188 0.390 | 9.9060 | ¿900 | 22.8600 | 27/64 | 0.4219 | 10.7156 | 59 64 | 0.9219 | 23.4156 0.400 | 10.1600 Г 0.910 | 23.1140 0.410 {10.4140 1 0.920 | 23.3680 7 16 | 0.4375 | 11.1125 1 15 16 | 0.9375 123.8125 9.420 | 10.6680 | 0.930 | 23.6220 0.430 | 10.9220 | 0.940 | 23.8760 0.430 11.1760 | 0.950 | 24.1300 | 29.64 | 0.4531 | 11.5094 | 61 64 | 0.9531 | 24.2094 0.450 | 11.4300 0.960 24.3840 15 32 | 0.4688 | 11.9062 | 31 32 | 0.9688 | 24.6062 0.460 | 11.6840 | 0. .6 3031 9844 0.470 | 11:9380 | 0.980 | 24 8920 31 64 | 0.4844 | 12.3031 | 63 64 | 0.98 25.0031 0.480 | 12.1920 | 0.990 | 25.1460 0490 |12:4460 | 1.000 | 25.4000 12 | 0.5000 | 12.7000 1 1.0000 | 25.4000 14B-2 MISCELLANEOUS SECTION 14B. CONVERSION CHARTS U.S. TO METRIC CONVERSIONS To Convert Into Multiply By Linear Miles Kilometers 1.609 Measurement Yards Meters 0.9144 Feet Meters 0.3048 Feet Centimeters 30.48 Inches Meters 0.0254 Inches Centimeters 2.54 Inches Millimeters 25.4 Area Square Miles Square Kilometers 2.59 Square Feet Square Meters 0.0929 Square Inches Square Centimeters 6.452 Acre | Hectare 0.4047 Volume Cubic Yards Cubic Meters 0.7646 Cubic Feet Cubic Meters 0.02832 Cubic Inches Cubic Centimeters 16.39 Weight Tons (Short) Metric Tons 0.9078 Pounds Kilograms 0.4536 Ounces (Avdp.) Grams 28.3495 Pressure Pounds/Sq. In. Kilopascal 6.895 Work Foot-pounds Newton-Meters 1.356 Foot-pounds Kilogram-Meters 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Liquid Volume Quarts Liters 0.9463 Gallons Liters 3.785 Liquid Flow Gallons/Minute Liters/Minute 3.785 - Temperature Fahrenheit Celsius 1. Subtract 32° 14B-3 2. Multiply by 5/9

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