Ransomes 4157082 PGM 22 Technical/Repair Manual
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InCommand™ PGM 22
Technical/Repair Manual
When Performance Matters.
™
PGM 22
Technical/Repair Manual
!
WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain this machine should be trained in its proper use, warned of its dangers and should read the entire manual before attempting to set up, operate, adjust or service the machine.
©2008 Jacobsen, A Textron Company. All rights reserved.
Foreword
General
This manual provides detailed information and procedures to safely repair and maintain the following:
Jacobsen® PGM 22™ walking greens mowers and associated accessory attachments
This manual is intended to introduce and guide the user through the latest factory-approved troubleshooting and repair techniques and practices.
Before you attempt to troubleshoot or make repairs, you must be familiar with the operation of this machine. Refer to the operator’s manual and parts manual for specific information on these topics.
THE INFORMATION CONTAINED IN THIS MANUAL IS
BASED ON MACHINES MANUFACTURED UP TO THE
TIME OF PUBLICATION. JACOBSEN RESERVES THE
RIGHT TO CHANGE ANY OF THIS INFORMATION
WITHOUT NOTICE.
CALIFORNIA
Proposition 65 Warning
!
WARNING
Certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Trademark Acknowledgement
Jacobsen acknowledges the following trademarks for company names or products mentioned within this publication:
Lubriplate
®
is a trademark of Fiske Brothers Refining Co.
Loctite
®
and Permatex
®
are trademarks of Henkel
Corporation.
4157082 First Edition i
FOREWORD
How to Use This Manual
This manual is designed to provide multiple ways to locate and access repair information.
Read each section in entirety before beginning a procedure. Proper understanding of machine operation and components is the key to successful diagnostics and repair.
Make use of special information features with in this manual in order to be better prepared to perform repairs.
Always follow manual procedures and safety guidelines.
Never take shortcuts.
Table of Contents
Major machine components or topics of interest are separated into specific chapters. Each manual lists these chapters in a main Table of Contents.
Chapter Table of Contents
Each chapter begins with a detailed Table of Contents related to the specific machine component or system.
Use the Chapter Table of Contents to find specific component or procedural information.
Index
An alphabetical Index is located at the back of the manual.
Use the Index to find specific components and related procedures.
Required Tools and Materials
Some procedures will require the use of specific tools and/or materials. These tools and/or materials will be listed for reference, prior to beginning a procedure.
Specifications
Near the beginning of each chapter is a specifications listing. This listing contains any specifications contained within the chapter.
Quick Reference Specifications
A list of all machine specifications can be found in
Chapter 2 Specifications and General Information. This is a list of all specifications from each chapter, combined and listed in one place for easy reference.
Warnings and Cautions
Warning and Caution indicators are located throughout the manual at specific points of interest. These notices are given to prevent personal injury, death and/or equipment damage. Always heed these notices, and practice common sense when performing any maintenance or repair procedure.
Notes
Special notes are given in order to draw attention to detailed instructions. These notes are intended to give further important information regarding the machine and/or a step in a procedure.
Troubleshooting
Troubleshooting charts are provided in each chapter to aid in the diagnostic process. Use these suggestions to aid in identifying a potential mechanical or machine adjustment problem.
Copyright 2008 Textron Inc.
“All rights reserved, including the right to reproduce this material or portions thereof in any form.” ii 4157082 First Edition
4157082 First Edition
Table of Contents
Safety
Specifications and
General Information
Engine
Electrical
Power Train
Handle and Controls
Brakes
Cutting Unit
Miscellaneous
Accessories
6
7
4
5
8
9
10
1
2
3 iii
Chapter 1
Safety
1
4157082 First Edition 1-1
1
SAFETY
Page Intentionally Blank
1-2 4157082 First Edition
SAFETY
Introduction
Safety is the most important element of any repair procedure. Knowledge of the procedure to be performed and safe work habits are essential to preventing death, personal injury, or property damage. Use the following statements as a common-sense guide to proper work and tool-use habits.
Prepare for the Job
Preparation is essential to complete a procedure in a safe and efficient manner.
• Wear proper clothing. Loose or baggy clothing could become tangled in moving parts.
• Use eye/face protection. Always use proper eye/face protection to protect your eyes from flying debris or chemical splatters.
• Wear protective footwear. Wear safety shoes
(steel-toe) to protect your feet from falling objects.
• Use gloves when handling parts. Parts may have sharp edges or may be hot.
• Remove jewelry prior to servicing electrical systems.
• Prepare proper tools and equipment. Always use the correct tool for the job. Improper or homemade tools can cause injury or machine damage.
• Prepare needed parts and materials. Gather the needed parts and materials before beginning the procedure.
• Allow machine to cool. Many components can get hot during operation. Be sure to allow enough time for components to cool before beginning service.
• Prepare proper work-space lighting. A well-lit work area can make the job easier.
• Follow procedures and safety warnings. Service procedures are written to be as safe and efficient as possible. Never take short cuts.
• Be prepared for emergencies. Accidents can happen, even under the best conditions. Fire extinguishers and first aid kits should be well maintained and easily accessible.
Safety Notices
Throughout this manual, the following key safety words will be used to alert the reader of potential hazards.
Become familiar with these words and their meaning.
Take all precautions to avoid the hazards described.
!
This safety alert symbol is used to alert you to potential hazards.
!
DANGER
Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
!
!
WARNING
CAUTION
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury and property damage. It may also be used to alert against unsafe practices.
NOTICE
Indicates a potentially hazardous situation which, if not avoided, MAY result in property damage. It may also be used to alert against unsafe practices.
1
4157082 First Edition 1-3
1
0
SAFETY
Safety Label Locations
Become familiar with machine safety labels and locations. The following illustrations show safety label locations on the machine.
1
2
3
5
6
4
Figure 1-1
4
TN0004
7 8
Figure 1-2
7
TN0003
1-4 4157082 First Edition
SAFETY
1
!
WARNING
1. Read operators manual. Do not allow
untrained operators to use machine.
2. Keep shields in place and hardware
securely tightened.
3. Before you clean, adjust or repair this
equipment, disengage all drives, engage
parking brake and stop engine.
4. Keep hands, feet and clothing away
from moving parts.
5. Never carry passengers.
6. Keep bystanders away
361854
2
!
ADVERTENCIA
1. Leer el manual del operador. No permitir
que personas no capacitadas para ello usen
la maquina.
2. Mantener los protectores en su lugar y sus
tornillos debidamente fijados.
3. Antes de limpiar, ajustar o reparar este
equipo, apagar todas los mandos, aplicar
el freno de estacionamiento y apagar el motor.
4. Mantener las manos, los pies y la ropa
alejados de las piezas en movimiento.
5. No conducir como pasajero ni llevar pasajeros
en maquinas sin asiento para ello.
6. Mantener a las demas personas alejadas
durante el functionamiento de la maquina.
7. Si no sabe leer ingles, solicitarle a otra persona
que le lea y explique el contenido de las
etiquetas y del manual de la maquina.
340830
3
!
CAUTION
BE SURE THE TRACTION CLUTCH
LEVER IS IN NEUTRAL BEFORE
STARTING THE ENGINE
3001790
5
!
CAUTION
ALLOW ENGINE
TO COOL FOR 2
MINUTES BEFORE
REFUELING
4
Vehicle Mass:
Model PGM 19 84.0 Kg.
Model PGM 22 85.0 Kg.
Model 518A 95.3 Kg.
Model 522TA 100.7 Kg.
Model 522A 101.2 Kg.
Model 526A 123.4 Kg.
Model TC22 101.1 Kg.
!
WARNING
Keep Bystanders Away. Do
Not Operate Without Guards
In Place.
2811102
6
!
WARNING
TO PREVENT INJURY AND ACCIDENTAL
CLUTCH ENGAGEMENT DO NOT ADJUST
ENGINE SPEED USING THROTTLE LEVER
ON ENGINE. ALWAYS ADJUST ENGINE
SPEED USING THE OPC HANDLE AND
THROTTLE PADDLE.
4146636
7
4127335
8
!
DANGER
To avoid serious bodily injury, stop engine and disengage reels before working on machine or emptying baskets.
3001235
1
4157082 First Edition 1-5
SAFETY
Inspect Safety Labels
Safety decals are critical to the safe operation of the mower. Inspect the mower for any damaged, missing, or unreadable decals. Replace decals as needed before placing the mower back in service.
1
Keep Work Area Clean
A clean, organized, well lit work area is important to promote safe working conditions.
• Keep floor clean of debris and clear of parts and tools.
• Clean up any spilled fuel, oil, and/or chemicals immediately.
• Store all air hoses and electrical cords properly when not in use.
Keep Work Area Well Ventilated
!
WARNING
Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled.
Park Mower Safely
!
WARNING
Before you clean, adjust, or repair this equipment, disengage all drives, engage parking brake and stop engine to prevent injuries.
Whenever performing maintenance other than adjustments that require the engine to be running, remove the spark plug wire and place the wire away from the plug to prevent accidental starting and bodily injury.
1
2
Certain test and adjustment procedures require the engine to be running. Be sure work area is well ventilated; never run the engine in an enclosed area.
Use Proper Eye and Face
Protection
!
WARNING
Always use approved personal protection equipment. Avoid workplace hazards by wearing properly maintained, approved eye and face protection. Failure to use appropriate protection equipment may result in death or serious injury.
TN0014
Figure 1-3
1.
Release the Operator Presence Control (OPC) bail
(2).
2.
Engage the park brake lever (1).
3
4
Always wear eye protection while in a shop environment.
• Safety Glasses: Safety glasses offer a minimum level of protection from flying debris.
• Face Shields: Face shields are often used along with safety glasses to offer a higher level of protection when sparks and flying debris are present.
• Vented Goggles: Goggles offer side protection not offered by safety glasses alone.
• Unvented Goggles: Unvented goggles offer protection from chemical splashes and vapors.
Figure 1-4
3.
Move engine on/off switch (4) to OFF position.
4.
Close fuel shutoff valve (3).
TN0015
1-6 4157082 First Edition
SAFETY
Use Lifting Equipment Safely
!
WARNING
Always check the lifting capacity and condition of hoists, slings, cables, or chains before use.
Using underrated or worn lifting components can result in death or serious injury.
• Always use a lifting device with a lifting capacity greater than the weight of the item being lifted.
• Secure the load to the lifting device using cables, chains, or slings rated to handle the load being lifted.
Fasteners being used to connect lifting devices must be strong enough to handle the load. Also be sure the mounting point of load is strong enough to handle the load.
• When using a lifting device, always connect the load so it is balanced.
• Always use a lifting device on a hard, level surface.
• Lower the lifting device to the lowest point before moving. Move the load slowly.
• Always support the load as soon as possible; never leave a load suspended in mid-air.
5
TN0004
Figure 1-5
5.
Lower and hold the kickstand (5) against the ground, and pull the mower back until the mower rests securely on the kickstand.
Support Machine Securely
!
WARNING
• Support the machine using properly rated jackstands. Never work under a machine supported only by a jack.
• Do not use wood or concrete blocks to support the machine. Failure to properly support the machine may result in death or serious injury.
1
6
TN0017
Figure 1-6
6.
Disengage reel clutch by rotating reel clutch lever (6) until it points down.
4157082 First Edition 1-7
SAFETY
1
Use Compressed Air and Air
Tools Safely
!
WARNING
Always wear approved eye and ear protection while using compressed air. Misuse of compressed air could result in death or serious injury.
• When using air nozzles, air pressure should not exceed 30 psi (206.8 kPa).
• Never direct air nozzles or tools at a person.
• Never point air nozzles directly at skin.
• Compressed air is a useful tool when used in a safe manner.
• Always use eye and ear protection while using compressed air and air tools.
• When using air tools, do not exceed the air pressure rating for the tool.
• When using an impact wrench, always use approved impact sockets. Never use standard sockets on an impact wrench.
• Disconnect the air supply before changing air tool attachments.
• Never point air nozzles or air tools at another person.
• Always maintain air tools properly.
Service Tires Safely
!
WARNING
An inflated tire contains explosive force. Use care when handling wheels and tires.
• Always wear safety glasses or goggles.
• Use proper lifting methods when working with wheels and tires.
• When working on an inflated tire, never position yourself directly over the work area.
• When dismounting or mounting tires, use a wheel holder or tire machine. Use proper tire mounting tools and equipment. Never use screwdrivers or makeshift tools to force a tire on or off a wheel.
• Be sure tire irons and mounting tools are free of grease and oil. Grip them firmly.
• Inspect wheel parts for rust, damage, or distortion.
Never use wheels that are out-of-round, rusted, or cracked.
• Never hammer on wheels with a steel hammer. Use rubber-covered hammers.
• When inflating tires, always use an inflation cage.
Always stand away from the valve stem.
• Use accurate, tested inflation gauges to set air pressures.
1-8 4157082 First Edition
SAFETY
Handle Fuel Safely
Handle fuel with care—it is highly flammable.
!
WARNING
• Never remove the fuel cap from the fuel tank, or add fuel, when the engine is running or while the engine is hot.
• Do not smoke when handling fuel. Never fill or drain the fuel tank indoors.
• Do not spill fuel. Clean spilled fuel immediately.
• Never handle or store fuel containers near an open flame or any device that may create sparks and ignite the fuel or fuel vapors.
• Be sure to reinstall and tighten fuel cap securely.
• Use an approved container; the spout must fit inside the fuel filler neck. Avoid using cans and funnels to transfer fuel.
Store fuel according to local, state, or federal ordinances and recommendations from your fuel supplier.
Never overfill or allow the tank to become empty.
Use clean, fresh fuel.
Do not fill above the fuel filler neck.
Handle Chemical Products
Safely
!
WARNING
Exposure to chemical products could result in serious injury. Handle chemical products with care. Refer to the chemical manufacturer’s
Material Safety Data Sheet (MSDS) for information regarding health hazards, safe handling, and emergency response procedures.
Routine service often requires the use of various chemical products, including lubricants and cleaning solutions. Many of these chemicals are flammable and can pose health risks if not handled properly.
• Never mix chemicals. Mixing chemicals can produce toxic or explosive results.
• Follow the manufacture’s recommendations for safe usage and handling of the product.
• Various materials may pose a health hazard if used incorrectly. A Material Safety Data Sheet (MSDS) contains important information regarding proper handling and health hazards, as well as emergency response procedures. Contact the chemical manufacturer to obtain an MSDS for the chemical product.
1
Store Volatile and Hazardous
Materials Safely
Store volatile materials (gasoline, diesel fuel, oil, etc.) in approved containers that are clearly marked. Containers should be stored in an approved safety cabinet away from possible sources of ignition. Storage areas and cabinets should be well ventilated to prevent the possible build-up of fumes.
Service Electrical Components
Safely
!
WARNING
Always disconnect the negative terminal first and positive terminal last. Connect positive terminal first and negative terminal last. Use care when testing live circuits to prevent arcing. Arcing could result in death or serious injury.
• Disconnect the battery negative (–) cable before removing or installing electrical components. Always connect the battery negative (–) cable last.
• Certain test and adjustment procedures must be performed with the battery connected. Use care to prevent arcing when working on live circuits or components. Arcing can cause component damage and could ignite flammable materials.
4157082 First Edition 1-9
SAFETY
1
Dispose of Waste Materials
Safely
Routine service can produce waste products such as used oil, grease, and used batteries.
If not handled properly, these materials can pose a threat to the environment.
Collect fluids in well-marked, approved storage containers. Some waste fluids can react with certain types of plastics. Make sure the fluid to be stored is compatible with the storage container. Never use food or beverage containers to store waste fluids.
IMPORTANT
Never dispose of waste fluids by pouring on the ground, down sewer drains, or into any body of water.
• Dispose of waste fluids properly at approved local recycling centers. If recycling facilities are not available, contact your local community for the correct disposal procedure for waste fluids.
• Dispose of old batteries properly. Battery electrolyte contains sulfuric acid and other hazardous materials.
Never place an old battery in the trash. Batteries must be disposed of in a manner consistent with EPA and/or local regulations.
1-10 4157082 First Edition
Chapter 2
Specifications and General Information
2
4157082 First Edition 2-1
2
SPECIFICATIONS AND GENERAL INFORMATION
Mower Identification Model Identification Number
63280
Professional Greens Mower (11-blade 22 in. (559 mm) reel) with InCommand™ control system, 4.0 hp gasoline engine (Honda), Operator Presence Control (OPC), grass catcher (optional), brakes, and kickstand.
Serial Number
An identification plate like the one shown, listing the serial number, is attached to the right side frame.
Always provide the serial number of the unit when ordering replacement parts or requesting service information.
Engine Serial Number
1
CHARLOTTE, NC
YEAR OF
PRODUCTION:
63280
A Textron Company
MADE IN U.S.A.
2006
1602
®
Model
Identification
Number
Serial
Number
Figure 2-1
TN0004, 0039
TN0020
Figure 2-2
The engine serial number (1) is stamped into the front of the engine block.
Optional Machine Accessories
This manual is structured to cover all basic machine components and repair. The addition of accessories can affect certain troubleshooting, adjustment, and repair procedures.
If the machine requiring service is equipped with an
accessory kit, see Section 10, “Accessories” for
troubleshooting, removal, repair, and installation procedures.
2-2 4157082 First Edition
Component Location
!
CAUTION
Become familiar with operator controls, machine components, and correct operating procedures before beginning repair procedures.
SPECIFICATIONS AND GENERAL INFORMATION
1 2
3
2
1
4
5
2
3
10
5
3
4
1
2
5
6
9
8 7
Park Brake Lever
E-stop Switch
Clutch Cover
Transport Wheels
(Optional)
Chain Cover
8
9
6
7
Reel Clutch Lever
Engine Oil Dipstick
Roller
Reel
10 Engine On/Off Switch
Figure 2-3: Component Location—Front
TN0003
4
3
4
1
2
7
6
TN0004
Throttle Paddle
Handle
OPC Bail Lever
Fuel Shutoff and Choke
Control
5
6
7
Product Identification Plate
Kickstand
Traction Drum
Figure 2-4: Component Location—Rear
4157082 First Edition 2-3
SPECIFICATIONS AND GENERAL INFORMATION
Specifications
Quick Reference Specifications
Brakes
Park Brake Lever Actuating Force
Park Brake Band—Anchor Pin
Center-to-Center Distance (Park
Brake Released) lb (kg) in. (mm)
2
Cutting Unit
Flat Surface Height at the Front of the
Bedknife (Minimum)
Reel-to-Bedknife Gap
Reel Side-to-Side Clearance (Reel
Bearing Pre-Load) in. (mm) in. (mm) in. (mm)
PGM 22
10 (4.5)
1.50 (38)
PGM 22
1/32 (0.8)
0.001—0.003 (0.025—0.076)
0.040 (1.27)
Accessories
Turf Groomer Drive Belt Eccentric Nut
Locking Screw Torque
Solid Tube Roller Lock Nut Torque
Solid Tube Roller Rotational
Resistance
Transport Tire Air Pressure lb-ft (N•m) lb-ft (N•m) lb-in
(N•m) psi (kPa)
General Specifications
Engine
Manufacturer/Model
Type
Power Rating @ 4000 RPM
Maximum Torque
Operating Speed
Gasoline Specification
Fuel Tank Capacity
Engine Oil Specification
Engine Oil Capacity hp (kW) ft-lb (N•m) rpm gal (l) qt (l)
PGM 22
20 (27)
10—30 (13.5—40.6)
0—1 with no end play (0—0.11 with no end play)
6—8 (41—55)
PGM 22
Honda/GX-120 K1QJG2
4-Cycle
4 (2.98)
5.4 (7.5)
Low Idle: 1700 ± 100
High Idle: 3300 ± 100
Regular Grade Unleaded (86 Octane Minimum)
0.66 (2.5)
SAE 10W-30, API Classification SF or SG
5/8 (0.6)
2-4 4157082 First Edition
Mower
Height-of-Cut Range
High Profile Cut Yield
Low Profile Cut Yield
Tournament Cut Yield
Super Tournament Cut Yield
Cutting Frequency
Reel Diameter
Reel Composition
Bedknife Composition
Reel Clutch
Reel Reduction Ratio
Width of Cut
Weights and Dimensions
Weight (Mass)
(with Grass Catcher, Roller, and
Kickstand) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (cm)
Traction Drive and Differential
Drive Clutch Engagement RPM
Traction Reduction Ratio
Transport Wheels (Optional)
Traction and Reel Drive
Tire Pressure
Differential
Rear Drive Drum Composition
Rear Drive Drum Dimensions
(OD x Length)
Travel Speed @ 3000 RPM rpm psi (kPa) in. (mm) mph (km/h) lb (kg)
SPECIFICATIONS AND GENERAL INFORMATION
PGM 22
5/64—7/16 (2.0—11.1)
5/32 (4.0)
7/64 (2.8)
5/64 (2.0)
1/16 (1.6)
13/64 (5)
5 (127)
Hardened High-Manganese Carbon Steel
Hardened Carbon Steel
Separate Cog-Type
2.25 to 1
22(55.9)
PGM 22
2000
24 : 1
(2) Bi-Directional, Pneumatic, 11 x 4 Goodyear Softrac
Chain Driven
6—8 (41—55)
Full Automotive Type, Housed in Traction Drum
Machined Aluminum Alloy, 2 Sections
7-3/4 x 10.97 (197 x 278)
2.9 (4.7)
PGM 22
187 (85)
2
4157082 First Edition 2-5
SPECIFICATIONS AND GENERAL INFORMATION
Standard Torque Values
NOTICE
All torque values included in these charts are approximate and are for reference only. Use of these torque values is at your sole risk. Jacobsen is not responsible for any loss, claim, or damage arising from the use of these charts.
Extreme caution should always be used when using any torque value.
2
Inch Fastener Torque Values
NOTE
Jacobsen uses Grade 5 plated bolts as standard, unless otherwise noted. When tightening plated bolts, use the value given for lubricated.
AMERICAN NATIONAL STANDARD FASTENERS
#6-32
#8-32
#10-24
#10-32
#12-24
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
SIZE UNITS
in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) in-lb (Nm) ft-lb (Nm) ft-lb (Nm)
GRADE 5
Lubricated
–
–
–
–
–
75 (8.4)
85 (9.6)
157 (17.7)
173 (19.5)
23 (31.1)
26 (35.2)
Dry
20 (2.3)
24 (2.7)
35 (4.0)
40 (4.5)
50 (5.7)
100 (11.3)
115 (13.0)
210 (23.7)
230 (26.0)
31 (42.0)
35 (47.4)
GRADE 8
Lubricated
–
–
–
–
–
107 (12.1)
120 (13.5)
220 (24.8)
245 (27.6)
32 (43.3)
37 (50.1)
Dry
–
30 (3.4)
45 (5.1)
50 (5.7)
65 (7.3)
143 (16.1)
163 (18.4)
305 (34.4)
325 (36.7)
44 (59.6)
50 (67.8)
SIZE UNITS
7/16-14 ft-lb (Nm)
7/16-20 ft-lb (Nm)
1/2-13 ft-lb (Nm)
1/2-20 ft-lb (Nm)
9/16-12 ft-lb (Nm)
9/16-18 ft-lb (Nm)
5/8-11
5/8-18
3/4-10
3/4-16
7/8-14 ft-lb (Nm) ft-lb (Nm) ft-lb (Nm) ft-lb (Nm) ft-lb (Nm)
GRADE 5
Lubricated
37 (50.1)
42 (56.9)
57 (77.2)
64 (86.7)
82 (111)
92 (124)
113 (153)
128 (173)
200 (271)
223 (302)
355 (481)
Dry
50 (67.8)
55 (74.6)
75 (101)
85 (115)
109 (148)
122 (165)
151 (204)
170 (230)
266 (360)
298 404
473 (641)
GRADE 8
Lubricated
53 (71.8)
59 (80.0)
80 (108)
90 (122)
115 (156)
129 (174)
159 (215)
180 (244)
282 (382)
315 (427)
500 (678)
Dry
70 (94.9)
78 (105)
107 (145)
120 (162)
154 (209)
172 (233)
211 (286)
240 (325)
376 (509)
420 (569)
668 (905)
Metric Fastener Torque Values
METRIC FASTENERS
M4
M5
M6
M8
M10
M12
M14
SIZE UNITS
Nm (in-lb)
Nm (in-lb)
Nm (in-lb)
Nm (in-lb)
Nm (ft-lb)
Nm (ft-lb)
Nm (ft-lb)
Lubricated
–
1.80 (16)
3.05 (27)
7.41 (65)
14.7 (11)
25.6 (19)
40.8 (30)
4.6
Dry
–
2.40 (21)
4.07 (36)
9.98 (88)
19.6 (14)
34.1 (25)
54.3 (40)
8.8
10.9
12.9
Lubricated
–
4.63 (41)
7.87 (69)
19.1 (69)
37.8 (29)
66.0 (48)
105 (77)
Dry
–
6.18 (54)
10.5 (93)
25.5 (226)
50.5 (37)
88.0 (65)
140 (103)
Lubricated
–
6.63 (59)
11.3 (102)
27.3 (241)
54.1 (40)
94.5 (70)
150 (110)
Dry
–
8.84 (78)
15.0 (133)
36.5 (323)
72.2 (53)
125 (92)
200 (147)
Lubricated
3.83 (34)
7.75 (68)
13.2 (117)
32.0 (283)
63.3 (46)
110 (81)
175 (129)
Dry
5.11 (45)
10.3 (910
17.6 (156)
42.6 (377)
84.4 (62)
147 (108)
234 (172)
Non-Critical
Fasteners into
Aluminum
2.0 (18)
4.0 (35)
6.8 (60)
17.0 (150)
33.9 (25)
61.0 (45)
94.9 (70)
2-6 4157082 First Edition
SPECIFICATIONS AND GENERAL INFORMATION
Gasoline, Oils and Lubricant
Specifications
Engine Oil
Use only SAE 10W-30 engine oils with API classification
SF or SG.
Refer to the engine manufacturer’s manual for additional information.
Traction/Reel Drive Chain Case Oil
The traction/reel drive chain case requires SAE EP-140 oil to lubricate the drive chains and related components.
Grease
Lubricate fittings with grease that meets or exceeds NLGI
Grade 2 LB specifications. Apply grease with a manual grease gun; fill slowly until grease begins to seep out. Do not use a compressed air grease gun.
Synthetic Lubricants
Synthetic grease is a suitable alternative lubricant, provided it meets or exceeds NLGI Grade 2 LB specifications. Apply synthetic grease with a manual grease gun; fill slowly until grease begins to seep out. Do not use a compressed air grease gun.
Lubricant Storage
Use of clean lubricants is essential to efficient operation of equipment.
• Always store lubricants in approved, clean containers.
• Store containers in an area free from dirt, filings, moisture, and other contaminates.
• Clearly mark containers for easy identification of contents.
• Always dispose of used containers properly.
Avoid Mixing of Lubricants
Avoid mixing different brands or types of oil. Oils are specifically manufactured to meet certain specifications and performance standards.
Mixing different brands or types of oil can reduce the functionality of the lubricant and result in possible equipment damage.
Gasoline
Use clean, fresh, regular grade, unleaded gasoline with a minimum octane rating of 86.
Refer to the engine manufacturer’s manual before using oxygenated (blended) fuel.
Operational Checks
!
WARNING
Never attempt to operate the machine unless you have read the Operator’s Manual and engine manual, and know how to operate all controls correctly.
The operational check procedures are meant to verify the correct operation of the control systems. Before placing the mower back into service, all checks should be performed to ensure that each system is working properly.
2
4157082 First Edition 2-7
SPECIFICATIONS AND GENERAL INFORMATION
Engine Oil Check
!
CAUTION
Maintain proper oil level! Operation of the mower with low oil level will result in engine damage.
2
NOTE
Allow the mower to cool before checking oil level.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
NOTE
The engine must be level before checking the oil level.
3.
Push the mower forward so that the mower is resting on the traction roller.
2
TN0019
Figure 2-6
5.
Check oil level. When the reservoir is properly filled, the oil should be even with the bottom edge (2) of the filler neck.
6.
Add oil as needed. (See “Engine Oil” on page 2-7.)
3
4
1
Figure 2-5
4.
Remove the oil filler cap/dipstick (1).
TN0018
TN0055
Figure 2-7
7.
Inspect the gasket (4) before installing the oil filler cap/dipstick (3).
Traction/Reel Chain Case Oil Check
NOTE
Allow the mower to cool before checking oil the level.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
2-8 4157082 First Edition
SPECIFICATIONS AND GENERAL INFORMATION
NOTE
The mower must be level before checking the oil level.
3.
Push the mower forward so that the mower is resting on the traction roller.
Park Brake Check
See Figure 2-10.
1
1
TN0021
Figure 2-8
4.
Remove the inspection plug (1). When the chain case is properly filled the oil should be up to the level
of the hole. Add oil as needed. (See “Traction/Reel
Drive Chain Case Oil” on page 2-7.)
2
TN0022
Figure 2-9
5.
Remove fill plug (2).
6.
Add oil until oil comes out of the inspection hole.
7.
Install the inspection plug (1) and the fill plug (2).
8.
Install transport wheels (if equipped). (See “Transport
Wheels (Optional)” on page 9-2.)
TN0004
Figure 2-10
1.
Connect a spring scale to the park brake lever (1).
2.
Pull the spring scale to engage the park brake and record the reading.
A properly adjusted park brake will require 10 lb (4.5 kg) of force to engage.
If the park brake does not meet specification, adjust or repair the brake system as needed before returning the mower to service. (See “Park Brake Check and
Adjustment” on page 7-4.)
Engine Stop (E-Stop) Switch Check
See Figures 2-11 and 2-12.
The unit is equipped with an E-stop switch to stop the engine from the operator’s position.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
!
WARNING
Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled.
2.
Start the engine. (Refer to Operator’s Manual.)
2
4157082 First Edition 2-9
SPECIFICATIONS AND GENERAL INFORMATION
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
1
2
TN0082
Figure 2-11
2
TN0015
Figure 2-12
3.
Push the E-stop switch (1)
The engine will stop.
If engine does not stop, use engine on/off switch (2) to stop engine, and repair the system immediately.
Operator Presence Control (OPC)
System Check
!
WARNING
Never operate equipment with the Operator
Presence Control (OPC) system disconnected or malfunctioning. Do not disconnect or bypass any switch.
The OPC system is intended to protect the operator and others from injury by stopping the reel and drive mechanism as soon as the operator releases the OPC bail.
TN0031
Figure 2-13
2.
Disengage the reel clutch lever (1).
!
WARNING
Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled.
3.
Start the engine. (Refer to Operator’s Manual.)
Does the drive mechanism engage before the
OPC bail is engaged?
YES
Stop the engine immediately and repair the system.
2
3
Figure 2-14
TN0082
2-10 4157082 First Edition
SPECIFICATIONS AND GENERAL INFORMATION
4.
Slide OPC bail (2) to the left and engage.
Engine speed will increase, drive mechanism will engage, and wheels will begin to turn.
Does the drive mechanism engage?
NO
Stop the engine immediately and repair the system.
5.
Release the OPC bail.
Bail will disengage, engine speed will return to idle, and drive mechanism will stop.
Does the drive mechanism continue turning after the OPC bail is released?
YES
Stop the engine immediately and repair the system.
6.
Push E-stop switch (3) to stop engine.
2
4157082 First Edition 2-11
2
SPECIFICATIONS AND GENERAL INFORMATION
Page Intentionally Blank
2-12 4157082 First Edition
Chapter 3
Engine
3
4157082 First Edition 3-1
ENGINE
3
Specifications
General Engine Specifications
Engine
Manufacturer/Model
Engine Type
Displacement
Bore x Stroke
Cooling System
Ignition System
PTO Shaft Rotation
Recommended Spark Plug
Spark Plug Gap cu in. (cc) in. (mm) in. (mm)
PGM 22
Honda/GX120 K1QJG2
4-Stroke, Overhead Valve, Single Cylinder
7.3 (118)
2.4 x 1.7 (60 x 42)
Forced Air
Transistorized Magneto
Counterclockwise
BPR6ES (NGK)
W20EPR-U (ND)
0.028—0.031 (0.7—0.8)
3-2 4157082 First Edition
ENGINE
Troubleshooting
This troubleshooting chart will cover basic engine troubleshooting information. A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for further engine troubleshooting information.
Condition
Engine does not start.
Engine is hard to start, runs erratically, stalls, looses power, or stops.
Probable Cause
Choke not set properly.
Fuel tank empty.
Fuel shutoff valve closed.
Engine on/off switch in OFF position.
E-stop switch in OFF position.
Engine problem.
Choke not set properly.
Dirty or incorrect fuel.
Mower does not engage when the OPC bail is engaged.
Loose wire connections.
Air intake clogged.
Spark plug worn, dirty, or improperly gapped.
Vent in fuel filler cap plugged.
Park brake is engaged.
Throttle/clutch cable is not adjusted properly.
Reel clutch is not engaged.
Traction/reel drive clutch faulty.
Problem in power train.
Remedy
Refer to the engine manual for correct choke usage.
Fill fuel tank with fresh, clean gasoline.
Open shutoff valve.
Move engine on/off switch to ON position.
Move E-stop switch to ON position.
Refer to the engine manual.
Refer to the engine manual for correct choke usage.
Drain fuel tank and fill fuel tank with fresh,
clean gasoline. (See “Gasoline” on page 2-7.)
Check wiring connections.
Refer to the engine manual for air cleaner service information.
Refer to the engine manual for spark plug service information.
Clean fuel filler cap.
Release park brake. (Refer to Operator’s
Manual.)
Adjust throttle/clutch cable. (See “Throttle and Clutch Control Cable Adjustment” on page 3-4.)
Engage reel clutch. (Refer to Operator’s
Manual.)
Replace clutch. (See “Engine and Clutch” on page 3-7.)
Repair as needed. (See “Troubleshooting” on page 5-3.)
3
4157082 First Edition 3-3
ENGINE
Checks and Adjustments
Throttle and Clutch Control Cable
Adjustment
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Raise and support mower so traction drum is able to freely rotate when clutch is disengaged.
3
NOTE
If adjusting after installing a new cable, proceed to step 7.
3.
Remove throttle cover. (See “Throttle Cover” on page 3-5.)
4.
Remove air cleaner cover and air cleaner. (Refer to engine manual.)
8.
Pull bail cable (4) until throttle lever (3) moves and engine speed starts to increase. Tighten cable clamp screw (5). Engine speed should be between 1500 and 1800 rpm. Verify that clutch is not engaged.
9.
Set engine maximum speed by pulling throttle against stop. Adjust throttle stop screw (2) until engine speed is between 3200 and 3400 rpm.
10. Stop engine.
7
10
8
5
6
1
2
4
3
9
TN0006
Figure 3-2
11. Move throttle paddle (7) to lowest setting. The low paddle stop should be set so the throttle cable (10) does not flex when at the lowest setting. Adjust low paddle stop screw (9) as needed.
To adjust the stop screw: a.
Loosen jam nut (8).
b.
Turn stop screw (9) clockwise to raise screw, counterclockwise to lower screw.
c.
Tighten jam nut (8).
12
TN0005
Figure 3-1
5.
Loosen throttle lever pivot nut (1) until throttle lever
(3) returns to idle by itself.
6.
Loosen cable clamp screw (5) and cable guide set screw (6).
!
WARNING
Never operate the engine without proper ventilation; exhaust fumes can be fatal if inhaled.
7.
Start engine. (Refer to Operator’s Manual.)
NOTE
When tightening the cable clamp, make sure the clamp is making contact with the cable sheath.
11
Figure 3-3
13
TN0005
3-4 4157082 First Edition
ENGINE
14
1
15
2
16
TN0007
Figure 3-4
12. Slide cable guide (13) down until it touches throttle lever (12). Tighten cable guide set screw (11).
13. Move throttle paddle (14) to highest setting. Engage bail and verify that cable guide (13) does not touch throttle lever (12). Adjust high paddle stop screw (16) as needed.
To adjust the stop screw: a.
Loosen jam nut (15).
b.
Turn stop screw (16) clockwise to raise screw, counterclockwise to lower screw.
c.
Tighten jam nut (15).
14. Install air cleaner and air cleaner cover. (Refer to engine manual.)
15. Install throttle cover. (See “Throttle Cover” on page 3-5.)
Idle Speed Adjustment
Refer to the engine manufacturer’s manual for adjustment information and specifications.
TN0016
Figure 3-5
2.
Remove wing nut (1) and throttle cover (2).
Installation Note
Install throttle cover by reversing the order of removal.
3
Throttle Cable
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove throttle cover. (See “Throttle Cover” on page 3-5.)
3.
Remove air cleaner cover and air cleaner. (Refer to engine manual.)
4.
Remove rear half of handle cover. (See “Handle
Repair
Throttle Cover
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
4157082 First Edition 3-5
ENGINE
8 9
12
13
11
10
3
1
2
3
4
5
TN0007
Figure 3-7
8.
Remove jam nut (12) from throttle cable sheath (10).
9.
Pull throttle cable sheath (10) down and remove it from handlebar top plate (9).
10. Disconnect end of throttle cable (13) from throttle paddle (8).
11. Pull throttle cable (13) and sheath (10) out through front half of handlebar cover (11).
Installation
7
2 3
6
TN0010
Figure 3-6
NOTE
Record position of cable ties before removing to ensure correct installation.
5.
Remove cable ties (1).
6.
Loosen set screw (5) in cable guide (7).
7.
Loosen cable clamp screw (3) and remove throttle cable (4) and sheath (2) from throttle plate (6).
6
5
1
4
TN0007
Figure 3-8
1.
Install jam nut (6) over end of throttle cable (1), but do not thread it onto throttle cable sheath (4).
2.
Route throttle cable (1) with sheath (4) through handlebar cover (5).
3.
Connect end of throttle cable (1) to throttle paddle
(2).
4.
Install throttle cable sheath (4) into slot in handlebar top plate (3). Tighten jam nut (6).
3-6 4157082 First Edition
ENGINE
Engine and Clutch
Removal
See Figures 3-10 through 3-21.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove throttle cover. (See “Throttle Cover” on page 3-5.)
3.
Remove air cleaner cover and air cleaner. (Refer to engine manual.)
7
1
2
8
8
3
15
9
10
7
4
6 5
11
14
12
13
TN0010
Figure 3-9
5.
Loosen throttle lever pivot nut (11) until throttle lever
(13) returns to idle by itself.
6.
Route throttle cable (10) and sheath (8) through cable clamp (15) and cable guide (14). Do not tighten cable clamp screw (9) or cable guide set screw (12) at this time.
7.
Install rear half of handle cover. (See “Handle Cover” on page 6-2.)
8.
Install cable ties (7).
9.
Perform throttle and clutch cable adjustment. (See
“Throttle and Clutch Control Cable Adjustment” on page 3-4.)
TN0005
Figure 3-10
4.
Remove collar (1) and spring (2) from clutch control cable (5).
5.
Loosen cable clamp screw (7) and remove clutch control cable (5) from swivel nut (3) and cable guide
(4).
6.
Loosen cable guide set screw (8) and remove throttle cable (6).
3
4157082 First Edition 3-7
ENGINE
9 16
17 18 19
10
12
11
3
TN0072
Figure 3-11
NOTE
Label all wires before disconnecting to ensure correct installation.
7.
Remove nut (10) and disconnect ground wire (9).
8.
Disconnect engine on/off switch wire (12).
9.
Disconnect engine harness wire (11).
20 21
TN0009
Figure 3-13
NOTE
Use a strap wrench to prevent clutch from turning while removing screws.
11. Remove three socket-head screws (20) and lock washers (21).
12. Remove screw (17), lock washer (18), flat washer
(19), and clamp (16) from engine.
13 14
15
13 14
22 23
~
13 14 13 14
TN0008
Figure 3-12
10. Remove four screws (13) and lock nuts (14), and remove front half of clutch cover (15).
24
TN0073
Figure 3-14
NOTE
Support engine before removing mounting hardware.
13. Remove two screws (22) and lock washers (23) from rear of engine mounting plate (24).
3-8 4157082 First Edition
ENGINE
38
25 26
33
27 28
29
30 31
32
TN0074
Figure 3-15
14. Remove nut (30), lock washer (31), and screw (32).
15. Remove screw (27), lock washer (28), and bracket
(29) from front of engine mounting plate (33).
16. Remove screw (25) and lock washer (26) from front of engine mounting plate (33).
Figure 3-17
18. Remove four spacers (38) from frame.
TN0079
3
34
35
36
39 40
37
TN0080
Figure 3-16
17. Remove engine (34) with mounting plate (37), clutch (35), and cover (36).
41
TN0075
Figure 3-18
NOTE
Use a strap wrench to prevent clutch from turning while removing screw.
19. Remove screw (39) and washer (40) from clutch (41).
4157082 First Edition 3-9
ENGINE
42
49
43
3
TN0076
Figure 3-19
20. Loosen two set screws (42) and remove clutch (43) from engine output shaft.
53
52
44 45
46
50
51
TN0045
Figure 3-21
23. Remove four nuts (53), lock washers (52), carriage bolts (51), and mounting plate (50) from engine (49).
48
44 45
47
TN0077
Figure 3-20
21. Remove key (48) from engine output shaft (46).
22. Remove two screws (44), washers (45), and cover
(47) from engine.
3-10 4157082 First Edition
ENGINE
Installation
See Figures 3-22 through 3-33.
Required Materials
Anti-Seize Compound
Loctite 242 (Blue) Thread Sealant
6 7
8
1
10
6 7
9
TN0077
Figure 3-23
2.
Install rear half of clutch cover (9) on engine using two screws (6) and washers (7).
3.
Install key (10) in output shaft (8).
4.
Apply a thin film of anti-seize compound to output shaft (8).
3
11
5
4
12
2
14
3
TN0045
Figure 3-22
1.
Install mounting plate (2) on engine (1) using four carriage bolts (3), lock washers (4), and nuts (5).
13
TN0078
Figure 3-24
5.
Align slot (12) in clutch with key (11) on output shaft
(14) and install clutch (13) on output shaft (14).
4157082 First Edition 3-11
ENGINE
19
15
3
Figure 3-25
6.
Tighten two set screws (15).
TN0076
Figure 3-27
8.
Install four spacers (19) on frame and install engine/clutch assembly.
TN0079
20 21
22 23
16 17
28
24
18
TN0075
Figure 3-26
NOTE
Use a strap wrench to prevent clutch from turning while installing screw.
7.
Apply Loctite 242 (Blue) to threads of screw (16).
Install screw (16) and washer (17) on clutch (18).
25 26
27
TN0074
Figure 3-28
9.
Secure engine mounting plate (28) to frame using a screw (20) and lock washer (21). Do not tighten hardware at this time.
10. Install bracket (24) onto engine mounting plate (28) using a screw (22) and lock washer (23). Do not tighten hardware at this time.
11. Secure bracket to grass shield using a screw (27), lock washer (25), and nut (26). Do not tighten hardware at this time.
3-12 4157082 First Edition
29 30
39 40
41
39 40
~
ENGINE
39 40 39 40
31
TN0073
Figure 3-29
12. Install two screws (29) and lock washers (30) at rear of engine mounting plate (31). Do not tighten hardware at this time.
TN0008
Figure 3-31
17. Install front half of clutch cover (41) using four screws
(39) and lock nuts (40).
3
42
33
32
34 35 36
43
45
44
37 38
TN0009
Figure 3-30
NOTE
Use a strap wrench to prevent clutch from turning while installing screws.
13. Secure clutch/input shaft to clutch using three socket-head screws (37) and lock washers (38).
14. Rotate engine and clutch shaft five times, using pull start rope.
15. Tighten all engine mounting plate hardware
previously installed in Steps 9 through 12.
16. Secure wiring harness (32) to engine using a clamp
(33), screw (34), lock washer (35), and flat washer
(36).
TN0072
Figure 3-32
18. Connect wire (44) to engine harness.
19. Connect wire (45) to engine on/off switch.
20. Install ground wire (42) to stud and secure with nut
(43).
4157082 First Edition 3-13
ENGINE
47
48
46
56
58
57
50
49
51
3
55 52
53
54
TN0005
Figure 3-33
21. Loosen throttle lever pivot nut (46) until throttle lever
(48) returns to idle by itself.
22. Route throttle cable (57) and sheath (55) through cable clamp (53) and install cable guide (51). Do not tighten cable clamp screw (56) or cable guide set screw (58) at this time.
23. Route clutch control cable (52) and sheath (54) through cable clamp (53), cable guide (51), and swivel nut (50).
24. Install spring (49) and collar (47) on clutch control cable (52). Slide collar (47) until 1/4-inch of cable extends past collar. Tighten collar.
25. Perform throttle and clutch cable adjustment. (See
“Throttle and Clutch Control Cable Adjustment” on page 3-4.)
Engine Service
A separate engine manual, prepared by the engine manufacturer, is supplied with this machine. Refer to the engine manufacturer’s manual for all engine related service.
Proper attention to the engine manufacturer’s directions will ensure maximum service life of the engine.
3-14 4157082 First Edition
Chapter 4
Electrical
4
4157082 First Edition 4-1
ELECTRICAL
Component Location
1
2
3
5
4
4
6
1
2
3
Spark Plug
Flywheel
Flywheel Magnet
4
5
6
Figure 4-1
Ignition Coil
E-Stop Switch
Engine On/Off Switch
TN0003, 0157
4-2 4157082 First Edition
ELECTRICAL
Theory and Diagnostic
Information
Electrical Component Symbols
The following symbols are used in the electrical schematics to represent various electrical components.
Single Pole, Single Throw
(SPST)
Single Pole, Double Throw
(SPDT)
Temperature Switch t˚
86
85 87
30
87A
Relay
Fuse
P
Double Pole, Single Throw
(DPST)
Double Pole, Double Throw
(DPDT)
Pressure Switch
Circuit Breaker
4
M
Electric Motors (may also include “AC” or “DC”)
Alternator
3
G
U
4157082 First Edition
G
Stator
4-3
ELECTRICAL
Solenoid Valve
4
U
Ignition Coil
Regulator
Single-Element Light
PTO Clutch
Spark Plug
Dual-Element Light
4-4 4157082 First Edition
4157082 First Edition
Enclosure
(cabinet, housing, etc.)
Ground (to earth)
Ground (to chassis)
Direct Current (DC)
(as shown on an oscilloscope)
Alternating Current (AC)
(as shown on an oscilloscope)
Resistor
ELECTRICAL
Wires (crossing but not connected)
Wiring Connections
Coil
Battery
Diode
Pin and Socket Connector
4
4-5
4
ELECTRICAL
Electrical Schematic
Blk
X2
S1
E-Stop
Switch
On
Off
X3
Red
X1
S2
Engine
On/Off
Switch
On
Off
Blk
X4
Red
Splice 1
Red
X5
Gry
X6
T1
Ignition
Coil
E1
Spark
Plug
Figure 4-2
4-6 4157082 First Edition
Wiring Harness
X2
S1
E-Stop
Switch
X3
Blk Red
X1
Blk
Red
Splice 1
Red
X4
S2
Engine
On/Off
Switch
Red
X5
Figure 4-3
T1
Ignition
Coil
X6
ELECTRICAL
4
4157082 First Edition 4-7
4
ELECTRICAL
Circuit Operation
Ignition Circuit
Operation
Blk
X2
S1
E-Stop
Switch
On
Off
X3
Red
X1
S2
Engine
On/Off
Switch
On
Off
Blk
X4
Red
Splice 1
Red
X5
Gry
X6
T1
Ignition
Coil
E1
Spark
Plug
Figure 4-4: Ignition Circuit—Run Position
A magnet is mounted on the flywheel. When the flywheel turns, the magnet passes by the ignition coil (T1). The moving magnetic field provided by the magnet induces voltage in the primary windings in the ignition coil. The secondary windings provide high voltage to spark plug
(E1) by stepping up the voltage that is generated in the primary windings.
When the E-stop switch (S1) or the engine on/off switch
(S2) is in the OFF position, the primary windings in the ignition coil are grounded. With the primary windings grounded, voltage induced in windings is shorted to ground and the ignition coil does not produce high voltage. Without high voltage at spark plug (E1), the engine cannot operate.
4-8 4157082 First Edition
ELECTRICAL
Troubleshooting
Symptom: Engine does not run.
Probable Cause
Faulty E-stop switch.
Faulty engine on/off switch.
Faulty ignition coil.
Remedy
Test switch. (See “E-Stop Switch” on page 4-11.)
Test switch. (See “Engine On/Off Switch” on page 4-11.)
Test spark plug for spark. (Refer to engine manual for test procedure.)
Symptom: Engine continues to run with E-stop switch in the OFF position.
Probable Cause
Faulty E-stop switch
Open ground circuit.
Open switch circuit.
Remedy
Test switch. (See “E-Stop Switch” on page 4-11.)
Check black wire between ring terminal ground (X1) and E-stop switch terminal (X2).
Check red wire between E-stop switch terminal (X3) and ignition coil wire terminal (X5).
Symptom: Engine continues to run with engine on/off switch in the OFF position.
Probable Cause
Faulty engine on/off switch
Open ground circuit.
Open switch circuit.
Remedy
Test switch. (See “Engine On/Off Switch” on page 4-11.)
Check ground tab on engine on/off switch. Ground tab must have a clean connection to cover.
Check red wire between engine on/off switch terminal (X4) and ignition coil wire terminal
(X5).
Symptom: Engine continues to run with E-stop and on/off switches in the
OFF position.
Probable Cause
Faulty connections.
Remedy
Check ignition coil wire connector (X5) for good connection.
Check gray wire between connectors (X5 and X6).
4
4157082 First Edition 4-9
ELECTRICAL
Component Testing
Electrical System and Component
Testing
4
General Information
Repair of the electrical system, for the most part, is limited to the replacement of defective components or wiring. Wiring diagrams are provided in this section for troubleshooting and/or testing the electrical system.
Specific testing and replacement information, where applicable, is also provided 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 in the following tests.
NOTES
• Before performing any component or wiring tests, check for corrosion and loose or missing connections.
• If a component (switch, relay, etc.) is removed for testing or replacement, make sure to identify and label all wires so that the component can be installed correctly.
Continuity Test
Required Tools or Equipment
Digital Multimeter, Ohmmeter, or Continuity Tester
1.
Identify and locate the wire or component to be checked using the electrical schematic.
NOTE
Some meters may have a continuity tester setting that uses a buzzer to indicate continuity. See the meter operator’s manual for more information.
2.
If using a multimeter, set to read ohms or set meter to continuity setting.
3.
Disconnect the ends of the wire being tested.
4.
Touch meter leads to the ends of the wire or to the terminals of the component to be tested.
Does meter read less than 0.5 ohms, and/or does the buzzer sound?
YES
The wire is good.
NO
Proceed to step 5.
5.
Use a known good jumper wire of the correct gauge to bypass the wire in question.
6.
Test the function of the circuit.
Does the circuit now operate properly?
YES
Replace the wire.
NO
Continue testing other wires and components in the circuit.
Resistance Test
Required Tools or Equipment
Digital Multimeter or Ohmmeter
1.
Identify and locate the wire or component to be checked using the electrical schematic.
NOTE
On some meters it will be necessary to select an ohms scale. Select an appropriate range for the component being tested. Refer to the specifications listed in the component test procedure.
2.
If using a multimeter, set to read ohms.
3.
Isolate (disconnect) the component to be tested from the circuit to prevent a false reading through the circuit.
4.
Connect the meter leads to the terminals of the component being tested. Check the component test procedure for specifications and additional test conditions.
Does the resistance through the component match the specified value listed in the test procedure?
YES
The component is good.
NO
Replace the component.
4-10 4157082 First Edition
ELECTRICAL
Engine On/Off Switch
Required Tools or Equipment
Digital Multimeter, Ohmmeter, or Continuity Tester
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
TN0139
Figure 4-5
2.
Disconnect engine on/off switch wire (1).
3.
Remove the blower housing from the engine. (Refer to engine manual.)
5.
Move engine on/off switch to the ON position and check for continuity.
Is continuity indicated?
YES
The switch is faulty; replace the switch.
NO
6.
Move engine on/off switch to the OFF position and check for continuity.
Is continuity indicated?
YES
The switch is good.
NO
The switch is faulty; replace the switch.
E-Stop Switch
See Figure 4-7.
Required Tools or Equipment
Digital Multimeter, Ohmmeter, or Continuity Tester
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove the rear half of the handle cover. (See
3.
Remove E-stop switch. (See “Component Removal and Installation” on page 4-12.)
4
1
ON
2
OFF
3
TN0138
Figure 4-6
4.
Connect test leads between engine on/off switch wire
(2) and grounding tab (3).
2
TN0142
Figure 4-7
4.
Connect test leads to the COM C (1) and NC (2) switch terminals (1 and 2).
5.
Move the engine on/off switch to the ON position and check for continuity.
Is continuity indicated?
YES
The switch is faulty; replace the switch.
NO
4157082 First Edition 4-11
ELECTRICAL
6.
Move the engine on/off switch to the OFF position and check for continuity.
Is continuity indicated?
YES
The switch is good.
NO
The switch is faulty; replace the switch.
7.
Install E-stop switch. (See “Component Removal and
8.
Install handle cover. (See “Handle Cover” on page 6-2.)
Engine Components
Refer to the engine manual for testing of engine-related electrical components.
Component Removal and
Installation
4
E-Stop Switch
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove the rear half of the handle cover. (See
1
2
3
4
TN0025
Figure 4-8
NOTE
Record the location of the wires before disconnecting.
3.
Disconnect E-stop switch wires (1 and 2) and remove the E-stop switch (3) from the front half of cover (4).
Installation Note
Install the E-stop switch by reversing the order of removal.
4-12 4157082 First Edition
Chapter 5
Power Train
5
4157082 First Edition 5-1
POWER TRAIN
Component Location
1
2
5
3
9
10
11
4
5
5-2
1
2
3
Traction/Reel Drive Clutch
Traction/Reel Drive Chain
Case
Traction Drum/Differential
Assembly
8
7
6
4
5
Clutch/Input Shaft and
Sprocket
Traction Drive
Sprocket/Planetary Gear
Assembly
6
7
8
9
Chain Guide
Reel to Traction Drive
Chain
Reel Clutch
Reel Sprocket
Figure 5-1: Drive Train Component Location
TN0155, 0004, 0087
10 Chain Guide
11 PTO to Reel Chain
4157082 First Edition
POWER TRAIN
Troubleshooting
Condition
Traction drive does not engage when OPC bail is engaged.
Traction drive pulls to one side
Probable Cause
Park brake engaged.
Clutch (OPC) cable not adjusted properly.
Faulty traction/reel clutch.
Drive chains damaged.
Planetary gear set damaged.
Traction drum differential damaged.
Wheel hub damaged/roll pin missing.
Traction drum differential damaged.
Wheel hub damaged/roll pin missing.
Park brake cable not adjusted properly/not fully releasing.
Traction drum bearing binding, worn or damaged.
Remedy
Release park brake. (Refer to Operator’s
Manual.)
Adjust clutch (OPC) cable. (See “Throttle and Clutch Control Cable Adjustment” on page 3-4.)
Replace traction/reel drive clutch. (See
“Engine and Clutch” on page 3-7.)
Repair/replace drive chain(s). (See “Drive
Repair/replace planetary gear set. (See
“Traction/Reel Drive Chain Case” on page 5-13.)
Repair/replace differential assembly. (See
“Differential Assembly” on page 5-27.)
Repair/replace wheel hub(s). (See “Wheel
Hubs and Bearings” on page 9-3.)
Repair/replace differential assembly. (See
“Differential Assembly” on page 5-27.)
Repair/replace wheel hub(s). (See “Wheel
Hubs and Bearings” on page 9-3.)
Adjust park brake cable. (See “Park Brake
Check and Adjustment” on page 7-4.)
Replace traction drum bearing. (See
“Traction Drive Drum Assembly” on
page 5-23 or “Right Frame” on page 5-17.)
5
4157082 First Edition 5-3
5
POWER TRAIN
Repair
Clutch Control Cable
Removal
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove throttle cover. (See “Throttle Cover” on page 3-5.)
3.
Remove air cleaner cover and air cleaner. (Refer to engine manual.)
4.
Remove OPC bail. (See “Handle and OPC Bail” on page 6-6.)
5.
Remove handle rear cover. (See “Handle Cover” on page 6-2.)
7.
Remove collar (3) and spring (4) from clutch control cable (7).
8.
Loosen cable clamp screw (2) and remove the clutch control cable (7) and sheath (8) from swivel nut (5) and cable guide (6).
9
10
11
TN0083
Figure 5-3
9.
Remove clutch control cable (10) and sheath (9) from tilt plate (11).
Installation
1
2
1
4
3
8
2
7
6
5
4
3
Figure 5-2
TN0010
NOTE
Record the position of cable ties before removing to ensure correct installation.
6.
Remove cable ties (1).
5-4
TN0083
Figure 5-4
1.
Install clutch control cable (1) and sheath (4) into tilt plate (2).
2.
Install OPC bail. (See “Handle and OPC Bail” on page 6-6.)
3.
Route cable through handle cover (3).
4.
Install handle rear cover. (See “Handle Cover” on page 6-2.)
4157082 First Edition
POWER TRAIN
Traction/Reel Drive Chain Case Cover
Removal
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove left-side park brake band. (See “Park Brake
2
5
1
6
14
13
12
11
7
10
8
9
TN0010
Figure 5-5
5.
Loosen throttle lever pivot nut (7) until the throttle lever (9) returns to idle by itself.
6.
Route clutch control cable (13) through cable clamp
(14), cable guide (12) and swivel nut (11).
NOTE
Do not tighten the cable clamp screw (6) or throttle lever pivot nut (7) until the cable has been properly adjusted.
7.
Install spring (10) and collar (8) onto clutch control cable (13). Slide the collar (8) until 1/4-inch of cable extends past the collar. Tighten the collar.
8.
Install cable ties (5).
9.
Adjust throttle and clutch cable. (See “Throttle and
Clutch Control Cable Adjustment” on page 3-4.)
Traction/Reel Drive Clutch
The traction/reel drive clutch is serviced with the engine.
(See “Engine and Clutch” on page 3-7.)
TN0044
Figure 5-6
3.
Loosen nut (2) and turn nut (1) counterclockwise
1/4 turn or more to bring the bedknife into light contact with the reel blades.
3
4
TN0085
Figure 5-7
4.
Using a punch, remove the roll pin (3) from the traction drum shaft (4).
5
4157082 First Edition 5-5
POWER TRAIN
5 6
13 14
7
15 16
12
11
8 9 10
TN0031
Figure 5-8
5
NOTE
Record the location and number of shims used (if any) to ensure correct installation.
5.
Remove the bedknife shoe mounting screw (8), shake-proof cone washer (9) and shim(s) (10) from the frame and bedknife shoe.
6.
Remove screw (5), lock washer (6), retainer (12), and reel clutch lever (7) from chain cover (11).
17
Figure 5-9
15 16
TN0041
NOTES
• Place a suitable container under the cover and drive case to catch oil.
• Dispose of used oil in compliance with all applicable regulations.
7.
Remove three 1/4-20 x 2-1/4” socket-head screws
(13) and washers (14) from cover (17).
8.
Remove five 1/4-20 x 1-1/2” socket-head screws (15) and washers (16) from cover (17).
9.
Remove cover (17).
5-6 4157082 First Edition
POWER TRAIN
Disassembly and Assembly
5
1
2
3
4
6
7
8
9
10
12
11
TN0043
3
4
1
2
Screw (2)
Lock Washer (2)
Cover
Gasket
5
6
7
Required Materials
• Loctite
®
Primer
• Loctite
®
518 Gasket Eliminator
• Loctite
®
242 (Blue) Thread Sealant
Chain Cover
Square-Head Pipe Plug
Gasket
8
9
Bearing
Bearing Housing
10 Oil Seal
11 Brake Mounting Bracket
(Left)
12 Socket-Head Screw (4)
Figure 5-10
Assembly Notes
• Apply Loctite
®
Primer to the front surface of the bearing housing (9) and the rear surface of the brake mounting bracket (11).
Apply a 1/4 inch (6 mm) bead of Loctite
®
518 Gasket
Eliminator to the bearing housing mating surface.
• Apply Loctite
®
242 (Blue) Thread Sealant to the threads of the screws (1).
• Apply Loctite
®
242 (Blue) Thread Sealant to the threads of the socket-head screws (12).
• Replace gaskets (4 and 7).
• Install a new oil seal (10).
5
4157082 First Edition 5-7
POWER TRAIN
Installation
See Figures 5-11 through 5-16.
Required Materials
• Loctite
®
Primer
• Loctite
®
518 Gasket Eliminator
• Loctite
®
242 (Blue) Thread Sealant
• Anti-Seize Compound
1
2
NOTE
Apply Loctite
®
242 (Blue) Thread Sealant to the threads of the socket-head screws (3 and 5) before installation.
4.
Install the cover (7) on the chain case using five
1/4-20 x 1-1/2” socket-head screws (5) and washers
(6).
5.
Install three 1/4-20 x 2-1/4” socket-head screws (3) and washers (4).
9
8
5
TN0042
Figure 5-11
1.
Clean the chain cover (2) and chain case (1) mating surfaces.
2.
Apply Loctite
®
Primer to the cover and chain case mating surfaces.
3.
Apply a 1/4 inch (6 mm) bead of Loctite
®
518 Gasket
Eliminator to the chain case mating surface.
TN0086
Figure 5-13
NOTE
Always replace O-rings before assembly.
6.
Apply lithium grease NLGI Grade 2 to the reel clutch lever shaft (8) and O-ring (9) before installation.
10 11
12
3 4
5 6
17
Figure 5-12
5 6
7
TN0041
13 14 15
16
TN0031
Figure 5-14
7.
Install reel clutch lever (12) in cover (16), using screw
(10), lock washer (11), and retainer (17).
5-8 4157082 First Edition
POWER TRAIN
NOTES
• Apply anti-seize compound to the threads of the bedknife shoe mounting screws before installing.
• Install shims (if any) in the same locations as recorded during removal.
8.
Install the bedknife shoe mounting screw (13), shake proof cone washer (14) and shim(s) (15) in the frame and bedknife shoe.
9.
Install left-side park brake band. (See “Park Brake
Drive Chains
Removal
See Figures 5-17 through 5-23.
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove traction/reel drive case cover. (See
“Traction/Reel Drive Chain Case Cover” on page 5-5.)
18
Figure 5-15
10. Remove the inspection plug (18).
1
TN0021
2
Figure 5-17
3.
Remove reel clutch (2) from reel shaft (1).
TN0046
5
19
3
4
TN0022
Figure 5-16
11. Remove oil fill plug (19).
12. Add oil until oil flows from the inspection hole. (See
“Traction/Reel Drive Chain Case Oil” on page 2-7.)
13. Install the inspection (18) and oil fill (19) plugs.
14. Adjust bedknife. (See “Bedknife-to-Reel Adjustment” on page 8-13.)
4157082 First Edition
6
5
TN0089
Figure 5-18
4.
Remove two keys (4 and 6) from reel shaft (5).
5-9
POWER TRAIN
5.
Remove washer (3) from reel shaft (5).
7 8
9
7 8
13
14
5
7 8
7 8
Figure 5-19
6.
Remove four screws (7) and lock nuts (8) and remove the front half of the clutch cover (9).
TN0090
15
TN0092
Figure 5-21
8.
Remove retaining ring (13) and washer (14) from the traction drum shaft (15).
10 11 12
16
TN0091
Figure 5-20
NOTE
Use a strap wrench to prevent clutch from turning while removing nut.
7.
Remove nut (11) and washer (12) from clutch/input shaft (10).
17
TN0093
Figure 5-22
9.
Remove the PTO-to-reel (16) and reel-to-traction drum shaft (17) chains with sprockets as a unit.
5-10 4157082 First Edition
POWER TRAIN
18
19
~
Figure 5-23
10. Remove key (18) from clutch/input shaft (19).
TN0096
Installation
See Figures 5-24 through 5-32.
10
9
8
7
6
TN0134
Figure 5-26
3.
Install the reel-to-traction chain (8) and sprocket assembly by sliding the drive pinion sprocket (9) onto the traction drum shaft (10) until the reel sprocket (6) is started on the reel shaft (7).
1
12
5
2
11
Figure 5-24
1.
Install key (1) in the clutch/input shaft (2).
3
TN0096
~
5
4
TN0133
Figure 5-25
2.
Assemble the reel-to-traction drum shaft chain (3), drive pinion sprocket (4), and reel sprocket (5).
13
TN0093
Figure 5-27
4.
Install the clutch/input shaft sprocket (12) on the
PTO-to-reel chain (11), and install the chain over the reel sprocket (13).
5.
Slide the both chains and sprockets toward the chain case until the sprockets are fully seated.
4157082 First Edition 5-11
POWER TRAIN
15
14
5
20
21
22
16
TN0092
Figure 5-28
6.
Install washer (15) and retaining ring (14) on the traction drum shaft (16).
23
Figure 5-30
8.
Install washer (20) on reel shaft (22).
9.
Install two keys (21 and 23) on reel shaft (22).
TN0089
17
18 19
TN0091
Figure 5-29
NOTE
Use a strap wrench to prevent clutch from turning while installing nut.
7.
Install nut (18) and washer (19) on the clutch/input shaft (17).
24
Figure 5-31
10. Install reel clutch (24) on reel shaft (25).
25
TN0046
5-12 4157082 First Edition
1
POWER TRAIN
26 27 28
26 27
26 27
26 27
TN0090
Figure 5-32
11. Install the front half of the clutch cover (28) using four screws (26) and lock nuts (27).
12. Install traction/reel chain case cover. (See
“Traction/Reel Drive Chain Case Cover” on page 5-5.)
Traction/Reel Drive Chain Case
Removal
See Figures 5-33 through 5-38.
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove engine. (See “Engine and Clutch” on page 3-7.)
3.
Remove grass shield. (See “Grass Shield” on page 8-17.)
4.
Remove handle assembly. (See “Handle Assembly” on page 6-3.)
5.
Remove drive chains. (See “Drive Chains” on page 5-9.)
Figure 5-33
6.
Remove clutch/input shaft (1).
2
3
4
TN0094
5
TN0095
Figure 5-34
7.
Using a punch, remove pin (3) from the collar (4).
8.
Remove the collar (4) from the reel shaft (5).
9.
Remove bearing (2) from reel shaft (5).
5
4157082 First Edition 5-13
POWER TRAIN
6
12
5
Figure 5-35
10. Remove oil fill plug (6).
7
8 9
TN0099
13
TN0122
Figure 5-37
15. Remove bearing (12) from the traction drum shaft
(13).
14
15
16
17 18
10
11
TN0098
Figure 5-36
11. Rotate the planetary gear assembly (10) until the outer set screw (8) aligns with oil filler hole (7).
12. Remove the outer (8) and inner (9) set screws.
13. Remove the planetary gear set assembly (10).
14. Remove the key (not shown) from the traction drum shaft (11).
22 23 20 21 19
TN0143
Figure 5-38
16. Remove nut (22) and lock washer (23).
17. Remove two screws (17) and lock washers (18).
18. Remove screw (15), lock washer (16), and chain guide (14).
19. Remove screw (20) and lock washer (21).
20. Remove chain case (19).
5-14 4157082 First Edition
Disassembly and Assembly
3
4
5
POWER TRAIN
6
7
8
9
1
2
14
15
17
18
19
14
13
12
11
10
3
4
1
2
5
Bearing
Grease Seal
Truss-Head Screw
Lock Washer
Washer
16
8
9
6
7
Grease Fitting
Chain Case Housing
Filler Plug
Handle Stud (Press-Fit)
10 Internal Gear (Press-Fit)
11 Type 1 Groove Pin (3)
(Press-Fit)
12 Bushing (2) (Press-Fit)
13 Oil Seal
14 Bearing Cone and Cup (2)
Figure 5-39
Assembly Notes
Inspect the internal gear (10). If replacement is required, remove the gear using a slide hammer with hook.
Required Materials
Loctite
®
242 (Blue) Thread Sealant
• Install new oil seals (13 and 15).
• Install a new grease seal (2).
• Apply Loctite
®
242 (Blue) Thread Sealant to the threads of the socket-head screw (17).
15 Oil Seal
16 Chain Guide
17 Socket-Head Screw
18 Lock Washer
19 Washer
TN0101
• If installing a new internal gear:
— Press the gear (10) into the housing.
— Drill three new holes, equally spaced around the circumference of the gear, to install new groove pins (11). The holes should be positioned so that the pins engage both the chain case housing and the internal gear equally. Drill the holes only deep enough to seat the pins. Do not drill completely through the housing, as oil leakage will result.
— Apply lithium grease NLGI Grade 2 to grease fitting (6) after installation is complete.
4157082 First Edition 5-15
5
POWER TRAIN
Installation
See Figures 5-40 through 5-46.
Required Materials
Loctite
®
Primer
Loctite
®
518 Gasket Eliminator
13
14
15
1
2
5
TN0103
Figure 5-40
1.
Clean the chain case (2) and front crossbar (1) mating surfaces.
2.
Apply Loctite
®
Primer to the chain case and front crossbar mating surfaces.
3.
Apply a 1/4 inch (6 mm) bead of Loctite
®
518 Gasket
Eliminator to the drive case mating surface.
16
TN0095
Figure 5-42
9.
Install bearing (13) on the reel shaft (16).
10. Install collar (15) on the reel shaft (16) and secure using a pin (14).
17
3
4 5
6 7
18
TN0122
Figure 5-43
11. Install bearing (17) on the traction drum shaft (18).
11 12 9 10
Figure 5-41
8
TN0143
4.
Install chain case (8) on the front and rear crossbars.
5.
Install two screws (6) and lock washers (7).
6.
Install nut (11) and lock washer (12).
7.
Install screw (9) and lock washer (10).
8.
Install chain guide (3) using screw (4) and lock washer (5).
20
19
TN0102
Figure 5-44
12. Install inner set screw (20) into the planetary gear assembly (19), until the end is flush with the bottom of the threaded hole.
5-16 4157082 First Edition
POWER TRAIN
21
22 23
24
25
TN0098
Figure 5-45
13. Install key (not shown) from the traction drum shaft
(25).
14. Install the planetary gear assembly (24) over the key.
15. Rotate the planetary gear assembly (24) until the inner set screw (22) aligns with oil filler hole (21).
16. Tighten the inner set screw (22).
17. Install the outer set screw (23).
Right Frame
Removal
See Figures 5-47 through 5-55.
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove engine. (See “Engine and Clutch” on page 3-7.)
3.
Remove handle assembly. (See “Handle Assembly” on page 6-3.)
4.
Remove bedknife shoe. (See “Bedknife Shoe” on page 8-18.)
5.
Remove grass shield. (See “Grass Shield” on page 8-17.)
1
5
26
2
TN0109
Figure 5-47
6.
Remove the right-side wheel hub (2) and brake band
(1). (See “Wheel Hubs and Bearings” on page 9-3.)
3
4
TN0094
Figure 5-46
18. Install the clutch/input shaft (26).
19. Install the drive chains. (See “Drive Chains” on page 5-9.)
20. Install the engine. (See “Engine and Clutch” on page 3-7.)
21. Install the grass shield. (See “Grass Shield” on page 8-17.)
22. Install the handle assembly. (See “Handle Assembly” on page 6-3.)
5
5
TN0110
Figure 5-48
7.
Using a punch, remove the roll pin (3) from the transport roller shaft.
4157082 First Edition 5-17
POWER TRAIN
8.
Remove four flat socket-head screws (5) and right brake mounting bracket (4).
6
7
9
10
5
TN0116
Figure 5-49
9.
Remove the bearing housing assembly (6) and gasket (7).
TN0118
Figure 5-51
11. Remove spacer (9) and bearing (10) from the traction drum shaft.
11
12 13
8
~
Figure 5-50
10. Remove nut (8) from the traction drum shaft.
TN0117
12 13 14
TN0111
Figure 5-52
12. Remove four socket-head screws (12), lock washers
(13), reel cover (14), and gasket (11).
5-18 4157082 First Edition
POWER TRAIN
15 16
17
Figure 5-53
TN0112
13. Remove nut (17), washer (15), and spring (16) from the reel shaft.
18
Figure 5-54
14. Remove bearing (18) from the reel shaft.
TN0119
19 20
19 20
23
21 22
TN0113
Figure 5-55
15. Remove nut (21) and lock washer (22).
16. Remove four screws (19) and lock washers (20) from the front and rear crossbars.
17. Remove right side frame (23).
4157082 First Edition 5-19
5
POWER TRAIN
Disassembly and Assembly
See Figure 5-56.
1
2
3
4
5
4
5
8 7
1
2
Grease Fitting
Grease Fitting
3
4
Oil Seal
Bearing Cup and Cone (2)
5
6
Oil Seal
Frame
Figure 5-56
Assembly Note
• Install new oil seals (3 and 5).
• Apply lithium grease NLGI Grade 2 to grease fitting
(1) after assembly is completed.
• Apply Lubriplate
®
grease to grease fitting (2) after assembly.
6
7
8
Handle Stud (Press-Fit)
Bushing (Press-Fit)
TN0120
5-20 4157082 First Edition
POWER TRAIN
Installation
See Figures 5-57 through 5-64.
1 2
1 2
7 8
5
3 4
TN0113
Figure 5-57
1.
Install the right side frame (5) to the front and rear crossbars using four screws (1) and lock washers (2).
2.
Install nut (3) and lock washer (4).
9
Figure 5-59
TN0112
4.
Install spring (8), washer (7), and nut (9) on the reel shaft.
11
10
5
6
TN0119
Figure 5-58
NOTE
Pack bearing with lithium grease NLGI Grade 2 before installation.
3.
Install bearing (6) on reel shaft.
TN0118
Figure 5-60
NOTE
Pack bearing with Lubriplate
®
grease before installation.
5.
Install bearing (11) and spacer (10) on the traction drum shaft.
4157082 First Edition 5-21
POWER TRAIN
16
17
12
18
Figure 5-61
6.
Install nut (12) on the traction drum shaft.
TN0117
18
TN0110
Figure 5-63
8.
Install the right brake mounting bracket (17) using four flat socket-head screws (18).
9.
Install roll pin (16) in the transport drum shaft.
13
5
19
14
15
TN0116
Figure 5-62
7.
Install bearing (15), gasket (14), and bearing housing
(13).
20
TN0109
Figure 5-64
10. Install the right-side wheel hub (20) and brake band
(19). (See “Wheel Hubs and Bearings” on page 9-3.)
11. Install the engine. (See “Engine and Clutch” on page 3-7.)
12. Install the handle assembly. (See “Handle Assembly” on page 6-3.)
13. Install the bedknife shoe. (See “Bedknife Shoe” on page 8-18.)
14. Install the grass shield. (See “Grass Shield” on page 8-17.)
15. Adjust reel bearing pre-load. (See “Reel Bearing
Pre-Load Adjustment” on page 8-15.)
5-22 4157082 First Edition
POWER TRAIN
Traction Drive Drum Assembly
Removal
See Figures 5-65 through 5-68.
1.
Park mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove drive chains. (See “Drive Chains” on page 5-9.)
1
Figure 5-65
3.
Remove the oil fill plug (1).
2
7
TN0099
8
TN0122
Figure 5-67
8.
Remove bearing (7) from the traction drum shaft (8).
9.
Remove the right frame. (See “Right Frame” on page 5-17.)
10
9
5
3 4
TN0121
Figure 5-68
10. Remove the traction drum assembly (9) from the frame assembly (10).
5
6
TN0098
Figure 5-66
4.
Rotate the planetary gear assembly (5) until the set screw (3) aligns with oil filler hole (2).
5.
Remove the outer (3) and inner (4) set screws.
6.
Remove the planetary gear set assembly (5).
7.
Remove the key (not shown) from the traction drum shaft (6).
4157082 First Edition 5-23
POWER TRAIN
Disassembly and Assembly
3
2
5
1
1
2
3
Special Bolt (4 per Drum)
Traction Drum (2)
Differential Assembly
Figure 5-69
Required Materials
Loctite
®
242 (Blue) Thread Sealant
Assembly Note
Apply Loctite
®
242 (Blue) Thread Sealant to the threads of the special bolts (1) before installation.
2
1
TN0135
5-24 4157082 First Edition
POWER TRAIN
Installation
See Figures 5-70 through 5-73.
2
1
7
8
TN0102
Figure 5-72
4.
Install inner set screw (8) into the planetary gear assembly (7), until the end is flush with the bottom of the threaded hole.
9
4
3
10 11
TN0121, 0144
Figure 5-70
1.
Install the traction drum assembly (1) into the frame assembly (2). Position the end with the two threaded sections (3 and 4) toward the right side frame.
2.
Install the right frame. (See “Right Frame” on page 5-17.)
5
12
13
TN0098
Figure 5-73
5.
Install key (not shown) from the traction drum shaft
(13).
6.
Install the planetary gear assembly (12) over the key.
7.
Rotate the planetary gear assembly (12) until the inner set screw (10) aligns with oil filler hole (9).
8.
Tighten the inner set screw (10).
9.
Install the outer set screw (11).
10. Install drive chains. (See “Drive Chains” on page 5-9.)
5
6
TN0122
Figure 5-71
3.
Install bearing (5) on the traction drum shaft (6).
4157082 First Edition 5-25
POWER TRAIN
Traction Drum
Disassembly and Assembly
1
5
3
1
2
4
Grease Fitting
Traction Drum
3
4
Bushing
Grease Seal
Figure 5-74
Assembly Note
Install a new grease seal (4).
2
TN0137
5-26 4157082 First Edition
POWER TRAIN
Differential Assembly
Disassembly and Assembly
7
6
1
2
3
4
5
12
11
5
4
3
14
7
13
1
2
8
3
4
1
2
9
10
Pinion Thrust Washer (2)
Pinion (2)
Bushing (2)
Differential Gear (2)
11
12
7
8
5
6
Thrust Washer (2)
Hex-Head Screw (6)
Grease Fitting (2)
Drum Hub (2)
9 Heavy Lock Washer (6)
10 Hex-Head Screw (6)
11 Bushing (2)
12 Differential Housing (2)
Figure 5-75
Assembly Notes
• Apply lithium grease NLGI Grade 2 to the pinions (2) and differential gears (4) before assembly.
• Apply lithium grease NLGI Grade 2 grease to grease fitting (7) after assembly.
13 Lock Nut (6)
14 Drum Shaft
8
9
10
TN0136
5
4157082 First Edition 5-27
POWER TRAIN
5
Page Intentionally Blank
5-28 4157082 First Edition
Chapter 6
Handle and Controls
6
4157082 First Edition 6-1
HANDLE AND CONTROLS
Adjustments
Handle Height Adjustment
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
2
2
1
TN0024
Figure 6-2
2.
Remove four socket-head screws (2) and remove rear half of cover (1).
2
4
3
6
TN0023
Figure 6-1
2.
Loosen screws (2) on both sides of mower and adjust handle stops (1) until desired handle height is obtained.
3.
Tighten screws (2).
Repair
Handle Cover
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
6
5
TN0025
Figure 6-3
3.
Remove throttle cable (6). (See “Throttle Cable” on page 3-5.)
NOTE
Record location of wires before disconnecting.
4.
Disconnect E-stop switch wires (3 and 4) and remove front half of cover (5).
6-2 4157082 First Edition
Installation
1
2
HANDLE AND CONTROLS
Handle Assembly
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Disconnect throttle cable at engine throttle plate.
(See “Throttle Cable” on page 3-5.)
3.
Disconnect clutch cable at engine throttle plate. (See
“Clutch Control Cable” on page 5-4.)
4.
Disconnect both park brake cables at brake bands.
(See “Park Brake Cable” on page 7-5.)
3
4
TN0025
Figure 6-4
1.
Route throttle cable (4) through hole at top of front half of cover (3).
2.
Connect wires (1 and 2) to E-stop switch.
1
2
3 4 5
6
8
6
5
6
TN0024
Figure 6-5
NOTE
Align park brake cables with openings in covers before tightening cover screws.
3.
Install rear half of cover (5) to front half using four socket-head screws (6).
4.
Install throttle cable. (See “Throttle Cable” on page 3-5.)
5.
Adjust throttle cable. (See “Throttle and Clutch
Control Cable Adjustment” on page 3-4.)
7
TN0032
6
Figure 6-6
NOTE
Label all wires before disconnecting to ensure correct installation.
5.
Remove nut (6) and disconnect ground wire (1).
6.
Disconnect engine on/off switch wire (8).
7.
Disconnect engine harness wire (7).
8.
Remove screw (3), lock washer (4), flat washer (5), and clamp (2) from engine.
4157082 First Edition 6-3
HANDLE AND CONTROLS
10
9
19
20
6
TN0033
Figure 6-7
NOTES
• Support handle assembly before removing mounting hardware.
• Steps 9 through 11 apply to both sides of handle
assembly.
9.
Disconnect torsion spring (10) from handle stop (9).
TN0036
Figure 6-9
12. Remove handle assembly, by pressing in on handle tube (19) until end of tube clears stud (20). Slide other side off other stud.
Installation
See Figures 6-10 through 6-14.
2
1
11
12 13
3
4
16 17 18
14
15
TN0034
Figure 6-8
10. Remove screw (16), lock washer (17), and washer
(18) from handle stop (11).
11. Remove retaining ring (12), washer (13), and torsion spring (15) from stud (14).
TN0062
Figure 6-10
1.
Slide right (1) and left (4) handle stops over handle tubes (2 and 3).
6-4 4157082 First Edition
HANDLE AND CONTROLS
16
5
15
6
TN0036
Figure 6-11
2.
Slide one handle tube (5) onto stud (6). Press other handle tube in until end of tube slips over end of stud.
3.
Support handle assembly.
TN0033
Figure 6-13
6.
Connect torsion spring (16) to handle stop (15).
17
18
19 20 21
7
8 9
24
22
12 13 14
10
11
TN0034
Figure 6-12
NOTES
• Support handle assembly until mounting hardware is installed.
• Steps 4 through 6 apply to both sides of the handle
assembly.
4.
Install torsion spring (11), washer (8), and retaining ring (9) on stud (10).
5.
Secure handle stop (7) to frame using screw (12), lock washer (13), and washer (14).
23
TN0032
Figure 6-14
NOTE
Connect wires to same connector as noted during removal.
7.
Install ground wire (17) to stud using nut (22).
8.
Connect wire (24) to engine on/off switch.
9.
Connect wire (23) to engine harness connector.
10. Install clamp (18) to engine using a screw (19), lock washer (20), and flat washer (21).
11. Connect throttle cable to engine throttle plate. (See
“Throttle Cable” on page 3-5.)
12. Connect clutch cable to engine throttle plate. (See
“Clutch Control Cable” on page 5-4.)
13. Connect both park brake cables to brake bands. (See
“Park Brake Cable” on page 7-5.)
6
4157082 First Edition 6-5
HANDLE AND CONTROLS
14. Adjust throttle and clutch cable. (See “Throttle and
Clutch Control Cable Adjustment” on page 3-4.)
15. Check brake cable adjustment. Adjust as needed.
(See “Park Brake Check and Adjustment” on page 7-4.)
Handle and OPC Bail
Removal
See Figures 6-15 through 6-17.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
5 6
7
TN0064
Figure 6-17
4.
Disconnect end of clutch cable (6) from OPC bail (7) and remove OPC bail from tilt plate (5).
Installation
See Figures 6-18 through 6-20.
1 2
Required Tools and Materials
Lubriplate
®
Grease
1
2
6
TN0059
Figure 6-15
2.
Remove four nuts (1) and socket-head screws (2).
3 4
6
3
4
TN0060
Figure 6-16
3.
Rotate handle (3) up and disconnect throttle cable
(4). Remove handle (3).
5
5
TN0084
Figure 6-18
1.
Apply a thin film of Lubriplate
®
grease to OPC bail grooves (5) of tilt plate (1) and spring on OPC bail
(2).
2.
Install end of clutch cable (3) into slot in OPC bail (4) and install OPC bail into tilt plate (1). Make sure end of spring (2) is flush against edge of opening (6) in tilt plate.
6-6 4157082 First Edition
7 8
HANDLE AND CONTROLS
Throttle Paddle
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove handle cover. (See “Handle and OPC Bail” on page 6-6.)
1
2
Figure 6-19
3.
Connect throttle cable (8) to handle (7)
9
TN0060
10 11
3
4
TN0059
Figure 6-20
4.
Install handle (9) on tilt plate, using four socket-head screws (10) and four nuts (11).
5
TN0063
Figure 6-21
3.
Remove nut (5), socket-head screw (1), throttle paddle (2), and spring washer (3) from handle cover
(4).
6
Installation Note
Install throttle paddle by reversing the order of removal.
4157082 First Edition 6-7
HANDLE AND CONTROLS
Brake Control Lever
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Release park brake.
3.
Remove rear half of handle cover. (See “Handle
Installation
6
1
2 3
1
2
3
4
6
TN0026
Figure 6-22
4.
Remove nut (2), lock washer (3), and screw (1) from brake lever arm (4).
5
4
TN0047
Figure 6-24
1.
Install flanged bearings (2) in handle (1).
2.
Install spring washer (4) over end of brake lever (3), and install lever into flanged bearings (2).
3.
Install brake lever arm (6) onto brake lever shaft, and secure by driving a pin (5) through lever arm and shaft.
7
8 9
5
6
10
10
7
9
8
TN0047
Figure 6-23
5.
Using a punch, drive out pin (9) and remove brake lever arm (10).
6.
Slide brake lever (7) out of handle (5), and remove spring washer (8).
7.
Inspect flanged bearings (6). Replace as needed.
TN0026
Figure 6-25
4.
Install screw (7) on lever arm (10) using a lock washer (8) and nut (9).
5.
Check and adjust park brake as needed. (See “Park
Brake Check and Adjustment” on page 7-4.)
6.
Install rear half of handle cover. (See “Handle Cover” on page 6-2.)
6-8 4157082 First Edition
Chapter 7
Brakes
7
4157082 First Edition 7-1
7
7-2
BRAKES
Specifications
Brakes
Park Brake Lever Actuating Force
Park Brake Band—Anchor Pin
Center-to-Center Distance (Park
Brake Released) lb (kg) in. (mm)
PGM 22
10 (4.5)
1.50 (38)
4157082 First Edition
BRAKES
Troubleshooting
Condition
Park brake does not engage when the lever is engaged.
Park brake does not hold mower.
Excessive brake wear.
Probable Cause
Park brake cables not adjusted properly.
Park brake cables damaged.
Brake bands worn.
Park brake cables not adjusted properly.
Brake bands worn.
Park brake bands contaminated.
Wheel hub damaged/roll pin(s) missing.
Traction drum differential gears damaged.
Park brake cables not adjusted properly/not releasing fully.
Remedy
Adjust the park brake cables. (See “Park
Brake Check and Adjustment” on page 7-4.)
Replace park brake cables. (See “Park
Replace park brake bands. (See “Park
Adjust the park brake cables. (See “Park
Brake Check and Adjustment” on page 7-4.)
Replace park brake bands. (See “Park
Replace park brake bands. (See “Park
Repair/replace wheel hub. (See “Wheel
Hubs and Bearings” on page 9-3.)
Repair/replace differential assembly. (See
“Differential Assembly” on page 5-27.)
Adjust the park brake cables. (See “Park
Brake Check and Adjustment” on page 7-4.)
7
4157082 First Edition 7-3
BRAKES
Checks and Adjustments
Park Brake Check and Adjustment
Check Procedure
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
3.
Disengage park brake.
6.
If the brakes do not meet specifications, proceed to
“Adjustment Procedure.”
Adjustment Procedure
NOTE
Minor adjustments are made at the handle.
1.
Remove the rear half of the handle cover. (See
3
4
1
6
7
TN0012
Figure 7-1
4.
Measure the distance (1) between the center of the park brake band anchor bolts. When correctly adjusted, the distance should be 1.50 in. (38 mm).
Repeat Step 4 to check the brake on the other side of
the mower.
TN0013
Figure 7-3
2.
Loosen jam nuts (3 and 4), turn nuts (5 and 6) to adjust the brake cable, then tighten nuts (3 and 4).
If adjustments cannot be made at the cable, make the adjustment at the brake bands.
2
5
TN0014
Figure 7-2
5.
Attach a scale to the top of the brake lever (2).
Record the force required to engage the park brake.
A properly adjusted brake requires 10 lb (4.5 kg) pull to engage the brake.
7-4
7
Figure 7-4
8
TN0012
4157082 First Edition
BRAKES
3.
Loosen screw (7) and pull cable (8) to obtain desired brake tension. Tighten screw (7).
4.
Repeat “Check Procedure.”
5.
Install the rear half of the handle cover. (See “Handle
6.
Install transport wheels (if equipped). (See “Transport
Wheels (Optional)” on page 9-2.)
Repair
Park Brake Cable
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove the transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
3.
Release the park brake.
4.
Remove the rear half of the handle cover. (See
7
8
4
9 10
3
6
5
TN0012
Figure 7-6
6.
Loosen set screw (5) and remove the brake cable (4) from the lower brake band pin (6) and bracket (3).
7.
Remove the lower brake band pin (6).
1
2
18
17
16
15
11
12
7
TN0027
Figure 7-5
NOTE
Record the position of cable ties before removing to ensure correct installation.
5.
Remove cable ties (1 or 2).
14
13
TN0013
Figure 7-7
8.
Remove nut (9), lock washer (10), and screw (7) from brake lever arm (18).
9.
Remove nut (8) from screw (7) and remove brake cables (11 and 17).
10. Remove jam nut (12 or 16) from brake cable sheath
(13 or 14), and slide brake cable sheath down and remove from bracket (15).
4157082 First Edition 7-5
BRAKES
7
Installation
1
12
11
10
9
2
5
6
3 4
7
8
TN0013
Figure 7-8
1.
Slide brake cable sheath (7 or 8) into bracket (9) and secure with jam nut (6 or 10).
2.
Install screw (1) through cables (5 and 11) and install nut (2).
3.
Install screw (1) on brake lever arm (12) and secure using lock washer (3) and nut (4).
5.
Route the end of the brake cable (20) through the bracket (14), upper brake band pin (15), and the lower brake band pin (19).
6.
Position the brake band so the upper brake band pin
(15) rests against the end of the cable sheath (13).
7.
Move the free end of the brake band until the distance between the center of the park brake band pins (16) is approximately 1.50 in. (38 mm). Tighten set screw (18).
8.
Check brake adjustment. (See “Park Brake Check and Adjustment” on page 7-4.)
Park Brake Band
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
3.
Release the park brake.
1
2
3
13
14
15
16
20
19
17
18
TN0012
Figure 7-9
4.
Install the lower brake band pin (19) into the brake band (17).
6
4
5
Figure 7-10
TN0012
4.
Loosen set screw (5) and remove the brake cable (3) from the lower brake band pin (6) and bracket (2).
5.
Remove the lower brake band pin (6).
6.
Remove wheel hub (1). (See “Wheel Hubs and
7.
Remove brake band (4) from bracket.
7-6 4157082 First Edition
Installation
1
2
4
3
5
8
6
7
Figure 7-11
TN0012
1.
Install park brake band (6) on bracket (3).
2.
Install wheel hub (1). (See “Wheel Hubs and
3.
Install the lower brake band pin (8) into the brake band (6).
4.
Route the end of the brake cable (5) through the bracket (3), upper brake band pin (4), and the lower brake band pin (8).
5.
Position the brake band so the upper brake band pin
(4) rests against the end of the cable sheath (2).
9
7
TN0012
Figure 7-12
6.
Move the free end of the brake band until the distance between the center of the park brake band pins (9) is approximately 1.50 in. (38 mm). Tighten set screw (7).
7.
Check brake adjustment. (See “Park Brake Check and Adjustment” on page 7-4.)
4157082 First Edition
BRAKES
7-7
7
BRAKES
7
7-8
Page Intentionally Blank
4157082 First Edition
Chapter 8
Cutting Unit
8
4157082 First Edition 8-1
8
8-2
CUTTING UNIT
Specifications
Adjustments
Flat Surface Height at the Front of the
Bedknife (Minimum)
Reel-to-Bedknife Gap
Reel Side-to-Side Clearance (Reel
Bearing Pre-Load) in. (mm) in. (mm) in. (mm)
PGM 22
1/32 (0.8)
0.001—0.003 (0.025—0.076)
0.040 (1.27)
4157082 First Edition
Component Location
1
2
6
5
3
4
1
1
2
3
TN0029, 0035
Roller Height Adjuster (2)
Grass Shield
Bedknife Adjuster (2)
4
5
6
Figure 8-1
Bedknife/Shoe Assembly
Front Roller
Reel
CUTTING UNIT
Troubleshooting
Cutting unit troubleshooting is broken down into two areas: Quality of Cut Appearance and Mechanical.
Quality of Cut Appearance Troubleshooting, as the name states, evaluates the mower’s performance by the visual appearance of the cut delivered by the mower.
Undesirable patterns and other conditions noted may be caused by various mechanical, environmental (variations in turf, grass conditions, weather, etc.), or operating conditions.
Mechanical Troubleshooting is related to operational problems that may or may not be related to quality of cut problems (reel drive does not engage, etc.).
Quality of Cut Troubleshooting
Factors that Affect Cut Appearance
In most cases, information provided by the user/customer will provide the basis for the repairs and adjustments that are required; however, it is recommended that a “test cut” be performed to evaluate the mower’s performance before beginning repairs.
An area should be available where “test cuts” can be made. This area should provide known and consistent turf conditions to allow accurate evaluation of the mower’s performance.
Another “test cut” should be performed after the completion of the repairs and/or adjustments to verify the mower’s performance.
Before performing a test cut to diagnose cut appearance and mower performance, the following items should be verified to ensure an accurate “test cut.”
1.
Engine Speed
2.
Reel Bearing Condition and Pre-Load (End Play)
Adjustment
3.
Reel and Bedknife Sharpness
4.
Bedknife Alignment to Reel
5.
Reel to Bedknife Contact
6.
Height of Cut
7.
Bedknife Application (Correct Bedknife)
8.
Roller and Roller Bearing Condition
9.
Reel Speed
10. Traction (Drive) Speed
8
4157082 First Edition 8-3
CUTTING UNIT
Definition of Terms
The following terms are used to describe various cut appearance symptoms.
Washboarding
Washboarding is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is approximately 6—
8 inches (15—20 cm). Color variation (light-to-dark) may also be noticed.
This condition is usually caused by a rocking motion in the cutting unit(s). This condition is found mostly on mowers with multiple (suspended) cutting units, but other causes in walk-behind mowers can produce the same result.
Washboarding may also be caused by variations in the turf.
8
TN0159
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Mowing (ground) speed is too fast.
Grass build-up on roller.
Roller is out of round.
Mowing in the same direction.
Use of a groomer on cleanup pass.
Remedy
Reduce mowing (ground) speed.
Clean the roller and use scrapers or brushes.
Replace front roller. (See “Front Roller—Solid Tube and
Change mowing direction regularly.
Groomers should only be used in a straight line.
8-4 4157082 First Edition
Marcelling
CUTTING UNIT
Marcelling, like washboarding, is a cyclical pattern of varying cutting heights, resulting in a wave-like cut appearance. In most cases, the wave tip-to-tip distance is
2 inches (5 cm) or less.
TN0220
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Mowing (ground) speed is too fast.
HOC (height-of-cut) setting is too low for the machine’s capability.
Engine rpm too low.
Remedy
Reduce mowing (ground) speed.
Confirm proper HOC range for reel/bedknife combination.
Check and adjust engine rpm.
8
4157082 First Edition 8-5
CUTTING UNIT
Step Cutting
Step cutting is grass that is cut taller on one side of the reel than the other. This is usually caused by mechanical wear or an incorrect roller adjustment.
8
TN0221
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
HOC (height-of-cut) settings are different from one side of the reel to the other.
Worn roller bearings.
Reel-to-bedknife contact is different from one side of the cutting unit to the other.
Remedy
Check HOC adjustment. (See “Height-of-Cut Adjustment” on page 8-14.)
Check/replace roller bearings. (See “Front Roller—Solid Tube and
Check reel to bedknife contact. (See “Bedknife-to-Reel Adjustment” on page 8-13.)
8-6 4157082 First Edition
Scalping
CUTTING UNIT
Scalping is areas of grass cut noticeably shorter than the surrounding areas, resulting in a light green or even brown patch. This is usually caused by an excessively low height-of-cut setting and/or uneven turf.
TN0222
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
HOC (height-of-cut) settings are lower than normal.
Turf too uneven for the mower to follow.
Incorrect bedknife for HOC.
Cutting too much grass at one time.
Remedy
Check and adjust the HOC settings. (See “Height-of-Cut
Try a different mowing direction.
Install correct bedlknife for desired HOC. (See “Bedknife” on page 8-17.)
Mow more often.
8
4157082 First Edition 8-7
CUTTING UNIT
Stragglers
Stragglers are scattered blades of uncut or poorly cut grass.
8
TN0223
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Bedknife improperly adjusted.
Dull cutting edges.
Mowing (ground) speed is too fast.
Incorrect roller.
Grass is too tall.
Mowing in the same direction.
Remedy
Adjust bedknife. (See “Bedknife-to-Reel Adjustment” on page 8-13.)
Sharpen reel and bedknife.
Reduce mowing (ground) speed.
Install correct roller for application. (See “Front Roller—Solid Tube and Segmented” on page 10-9.)
Mow more often.
Change mowing direction regularly.
8-8 4157082 First Edition
Streaks
CUTTING UNIT
A streak is a line of uncut grass. This is usually caused by a nicked or bent bedknife.
TN0224
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Damaged bedknife.
Damaged or unevenly worn reel.
Loose or missing bedknife fasteners.
Incorrect roller.
Bedknife is matting the grass down.
Remedy
Replace bedknife. (See “Bedknife” on page 8-17.)
Inspect reel. Replace as needed. (See “Reel Assembly” on page 8-20.)
Check bedknife screws; tighten loose screws. Replace missing screws.
Install correct roller for application. (See “Front Roller—Solid Tube and Segmented” on page 10-9.)
Install correct bedknife for the application. (See “Bedknife” on page 8-17.)
8
4157082 First Edition 8-9
CUTTING UNIT
Windrowing
Windrowing is the deposit of clippings concentrated at one end of the cutting unit, forming a line in the direction of travel.
8
TN0225
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Grass is too tall.
Mowing while turf is damp.
Grass built up on roller.
Improperly adjusted scrapers or brushes.
Remedy
Mow more often.
Mow when turf is dry.
Clean rollers; use roller brushes or scrapers.
Adjust scrapers/brushes.
8-10 4157082 First Edition
Rifling or Tramlining
CUTTING UNIT
Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife.
TN0987
NOTE: One cutting unit width shown. Arrow indicates direction of travel.
Probable Cause
Reel and/or bedknife unevenly worn.
Remedy
8
4157082 First Edition 8-11
8
8-12
CUTTING UNIT
Mechanical Troubleshooting
Cutting Unit
Condition
Reel drive does not engage when
Operator Presence Control (OPC) bail is engaged.
Probable Cause
Throttle/clutch cable is not adjusted properly.
Reel clutch is not engaged.
Traction/reel drive clutch faulty.
PTO-to-reel chain damaged.
Reel clutch damaged.
Remedy
Adjust throttle/clutch cable. (See “Throttle and Clutch Control Cable Adjustment” on page 3-4.)
Engage reel clutch. (Refer to Operator’s
Manual.)
Replace clutch. (See “Engine and Clutch” on page 3-7.)
Replace PTO-to-reel chain. (See “Drive
Replace reel clutch. (See “Traction/Reel
4157082 First Edition
CUTTING UNIT
Checks and Adjustments
Reel and Bedknife Inspection
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
!
CAUTION
To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.
7.
Grass conditions will also affect the adjustment.
a.
Dry, sparse conditions will require a wider gap to prevent heat build-up and damage to the reel and bedknife.
b.
High-quality grass with a good moisture content requires a closer gap (near zero).
Bedknife-to-Reel Adjustment
1.
Inspect reel and bedknife before performing
adjustment. (See “Reel and Bedknife Inspection” on page 8-13.)
2.
Check the reel bearings for end play or radial play. If there is any abnormal movement of the reel, up and down or side to side, adjust or replace components
as needed. (See “Reel Bearing Pre-Load
1/32 in.
(0.8 mm)
Figure 8-2
3.
Inspect the reel blades and bedknife to ensure good sharp edges without bends or nicks.
a.
The cutting edges of the reel blades and bedknife must be sharp, free of burrs, and show no signs of rounding off.
b.
The bedknife and bedknife shoe must be securely tightened. The bedknife must be straight and sharp.
c.
A flat surface of 1/32 in. (0.8 mm) minimum must be maintained on the front face of the bedknife.
Use a standard flat file to dress the bedknife.
4.
If wear or damage is beyond the point where the reel or bedknife can be corrected by backlapping, it must be reground.
5.
Proper reel-to-bedknife adjustment is critical. A gap of 0.001—0.003 in. (0.025—0.076 mm) must be maintained across the entire length of the reel and bedknife.
6.
The reel must be parallel to the bedknife. An improperly adjusted reel will lose its sharp edges prematurely and may result in serious damage to the reel and bedknife.
1
TN0081
Figure 8-3
2.
Start adjustment at the leading edge (1) of the reel, followed by the trailing edge. The leading edge of the reel blade is the end that passes over the bedknife first during normal reel rotation.
2
3
TN0030
Figure 8-4
!
CAUTION
To prevent personal injury and damage to cutting edges, handle the reel with extreme care.
3.
Slide a feeler gauge or shim stock 0.001—0.003 in.
(0.025—0.075 mm) between the reel blade and the bedknife. Do not turn the reel.
4.
Loosen nut (2) and turn nut (3) counterclockwise to bring the bedknife closer to the reel or clockwise to back the bedknife away from the reel.
8
4157082 First Edition 8-13
CUTTING UNIT
5.
Adjust the trailing edge of the reel in the same manner, then recheck the adjustment at the leading edge.
6.
Tighten nut (2). Recheck adjustment.
7.
When the reel and bedknife are properly adjusted, the reel will spin freely and will cut a piece of newspaper along the full length of the reel when the paper is held at 90° to the bedknife.
Backlapping Procedure
Whenever a reel and bedknife have been ground, or a new reel and/or bedknife have been installed, the assembled reel should be backlapped using an electric-powered bench lapper.
Required Tools and Materials
• Lapping Compound (150 Grit)
• Long-Handled Brush
• 3/8-24 Bolt (The length will vary depending on the lapping machine being used. When installed, the bolt must be threaded fully into the reel shaft, yet have enough length to engage the lapping machine.)
8
1.
Check for damage to the bedknife and reel blades.
(See “Reel and Bedknife Inspection” on page 8-13.)
2.
Determine if backlapping or grinding will restore the proper cutting edge.
3.
For optimum performance, use a bedknife grinder to touch up the blade, then reassemble and adjust the
bedknife to the reel. (See “Bedknife-to-Reel
4.
Move fuel shutoff lever to the OFF position to prevent fuel leaking into the combustion chamber. (Refer to engine manufacturer’s manual.)
5.
Disengage reel clutch and tip machine back to rest on the handle. Do not leave the mower tipped back for an extended length of time or oil may migrate into the combustion chamber.
1
TN0031
Figure 8-5
6.
Remove shaft cover (1) and gasket from left side of reel. Assemble a 3/8-24 bolt and lock nut to the end of the shaft and attach to lapping machine.
a.
Apply lapping compound with a long-handled brush along the entire length of the reel (150 grit or finer is recommended).
b.
Continue lapping and at the same time make a fine adjustment on the reel and bedknife until there is a uniform clearance along the full length of the cutting edges.
7.
Carefully and thoroughly remove all lapping compound from reel and bedknife before running the reel in forward direction.
Height-of-Cut Adjustment
Required Tools and Materials
Height-of-Cut Gauge Bar (Jacobsen P/N 158568)
NOTE
Make sure the bedknife is properly adjusted before
adjusting the cutting height. (See “Bedknife-to-Reel
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Tip mower back on traction drum or tires. Do not leave the mower tipped back for an extended length of time or oil may migrate into the combustion chamber.
8-14 4157082 First Edition
1
CUTTING UNIT
Reel Bearing Pre-Load Adjustment
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2
2
1
3 4
~
6
5
4
3
TN0011
Figure 8-6
3.
Loosen nuts (2) on both sides just enough to allow knob (1) to raise the front roller or turf groomer. Raise both sides an equal amount.
4.
Set gauge screw (4) to the desired cutting height (5).
Measure from the gauge bar (6) to the underside of the screw head (4), then tighten wing nut to lock the adjustment.
5.
Place gauge bar between front roller and traction roller, near the outer end of the rollers.
6.
Slide screw head over bedknife (3) and adjust knob
(1) so roller just contacts the gauge bar. Tighten nut
(2).
7.
Repeat steps 5 and 6 on the opposite end of the reel, then tighten nuts (2). Recheck and readjust the cutting height if necessary.
3 4
TN0153
Figure 8-7
2.
Remove four socket-head screws (3), lock washers
(4), reel cover (1), and gasket (2).
5
6
TN0154
Figure 8-8
3.
Tighten nut (5) until the spring (6) is completely collapsed, then back the nut 2—3 turns, or until there is 0.040 in. (1.27 mm) side-to-side movement of the reel.
8
4157082 First Edition 8-15
8
8-16
CUTTING UNIT
7
8
~
9 10
9 10
TN0153
Figure 8-9
4.
Install reel cover (7) and new gasket (8) using four socket-head screws (9) and lock washers (10).
4157082 First Edition
CUTTING UNIT
Repair
Grass Shield
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
Bedknife
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Tip mower back on traction drum or tires. Do not leave the mower tipped back for an extended length of time or oil may migrate into the combustion chamber.
1 2
1
4
3
TN0048
Figure 8-10
2.
Remove nut (1), lock washer (2), and screw (3).
3.
Pull grass shield (4) forward.
Installation Note
Install the grass shield by reversing the order of removal.
2
TN0035
Figure 8-11
3.
Remove 13 flat-head screws (2) and remove the bedknife (1).
Installation Note
Bedknife is installed by reversing order of removal.
8
4157082 First Edition 8-17
CUTTING UNIT
Bedknife Shoe
Removal
See Figures 8-12 through 8-15.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
6
2
TN0030
Figure 8-12
NOTE
Steps 2 through 5 apply to both sides of the mower.
2.
Loosen nut (1) and turn nut (2) counterclockwise
1/4 turn or more to bring the bedknife into light contact with the reel blades.
TN0030
Figure 8-14
4.
Remove nut (6).
5.
Tip mower back on traction drum or tires. Do not leave the mower tipped back for an extended length of time or oil may migrate into the combustion chamber.
7
8
3 4 5
TN0037
Figure 8-13
NOTES
• The right and left bedknife shoe mounting screws are different. Label each during removal to ensure correct installation.
• Record the location and number of shims used
(if any) to ensure correct installation.
3.
Remove the bedknife shoe mounting screw (3), shakeproof cone washer (4), and shim(s) (5) from the frame and bedknife shoe.
8
Figure 8-15
6.
Remove the bedknife shoe assembly (8) and adjustment rod assemblies (7).
TN0156
8-18 4157082 First Edition
Disassembly and Assembly
1
2
3
2
4
1
2
3
2
CUTTING UNIT
Installation
See Figures 8-17 through 8-19.
Required Materials
Anti-Seize Compound
1
5
1
2
3
Nut (4)
Cups (4)
Spring (2)
4
5
Figure 8-16
TN0038
Bedknife Shoe
Bedknife Adjuster Bolt (2)
5
2
Figure 8-17
1.
Install the bedknife shoe assembly (2) with adjustment rod assemblies (1).
TN0156
3
4
8
TN0030
Figure 8-18
NOTE
Steps 2 through 4 apply to both sides of the mower.
2.
Install nut (3).
3.
Turn nut (4) clockwise until the bedknife makes light contact with the reel.
8-19 4157082 First Edition
8
CUTTING UNIT
Reel Assembly
Removal
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove drive chains. (See “Drive Chains” on page 5-9.)
5 6 7
TN0037
Figure 8-19
NOTES
• Apply anti-seize compound to the threads of the bedknife shoe mounting screws before installing.
• Install shims (if any) in the same locations as recorded during removal.
4.
Install the bedknife shoe mounting screw (5), shakeproof cone washer (6), and shim(s) (7) in the frame and bedknife shoe.
5.
Adjust bedknife. (See “Bedknife-to-Reel Adjustment” on page 8-13.)
1
2
3
4
TN0095
Figure 8-20
3.
Using a punch, remove pin (2) from the collar (3).
4.
Remove the collar (3) from the reel shaft (4).
5.
Remove reel bearing (1) from reel shaft (4).
6.
Remove the right frame. (See “Right Frame” on page 5-17.)
5
Figure 8-21
6
TN0121
8-20 4157082 First Edition
CUTTING UNIT
!
CAUTION
To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.
7.
Remove the reel (6) from the frame (5).
Installation
4
5
6
1
2
TN0121
Figure 8-22
!
CAUTION
To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.
1.
Install the reel (2) into the frame (1), positioning the longer end on the reel shaft (3) toward the chain case.
2.
Install the right frame. (See “Right Frame” on page 5-17.)
7
TN0095
Figure 8-23
3.
Install the reel bearing (4) on the left (drive) side of the reel shaft (7).
4.
Install the collar (6) on the reel shaft (7) and secure using a pin (5).
5.
Install the drive chains. (See “Drive Chains” on page 5-9.)
6.
Adjust the reel bearing pre-load. (See “Reel Bearing
Pre-Load Adjustment” on page 8-15.)
8
4157082 First Edition 8-21
CUTTING UNIT
8
8-22
Page Intentionally Blank
4157082 First Edition
Chapter 9
Miscellaneous
9-1
9
4157082 First Edition
MISCELLANEOUS
Specifications
Transport Tires
Transport Tire Air Pressure psi (kPa)
Repair
Transport Wheels (Optional)
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
PGM 22
6—8 (41—55)
3.
To Install Wheels: Set the park brake, pull the retaining clip (2) back and hold. Place the wheel (1) on the hub and turn the wheel backwards until studs
(4) on the rear of wheel line up with holes in the hub
(3). Push the wheel in and release the retaining clip.
Disassembly and Assembly
See Figure 9-3.
2
3
1
1
4
5
6
4
9
2
TN0049
Figure 9-1
2.
To Remove Wheels: Pull retaining clip (2) away from the hub and pull wheel(s) (1) off hub.
4
3
4
1
2
Socket-Head Screw (3)
Spacer
Wheel and Tire Assembly
Flat Washer (6)
7
8
5
6
Figure 9-3
Spring
Spacer (3)
Lock Nut
Latch
8
TN0028
3
7
3
TN0050
Figure 9-2
9-2 4157082 First Edition
Wheel Hubs and Bearings
Removal
NOTE
The hub assemblies are unique to each side and are marked “L” and “R.” Do not exchange them side-for-side.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove the transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
Disassembly
1
2
3
4
MISCELLANEOUS
5
6
1
TN0132
Figure 9-4
3.
Remove lock nut (1) from the transport roller shaft.
4
TN0053
Figure 9-6
1.
Remove washer (1), bushing (2), and clutch sleeve
(3) from hub (5).
2.
Remove seals (4) and bearing (6).
Assembly
1
2
3
2
3
4
TN0054
Figure 9-7
1.
Apply lithium grease NLGI Grade 2 to the wheel bearing rollers (3).
NOTE
The bearing used in the wheel hub is directional and must be installed in the correct direction of rotation.
2.
Install bearing (2) in the hub (1):
Right Wheel Hub: Install the bearing with the word
“lock” and arrow (4) stamped in the face facing the
OUTSIDE of the hub housing.
Left Wheel Hub: Install the bearing with the word
“lock” and arrow (4) stamped in the face facing the
INSIDE of the hub housing.
9
9-3 4157082 First Edition
4
TN0051
Figure 9-5
4.
Remove latching collar (4), bushing (3), and hub assembly (2).
MISCELLANEOUS
5
6
7
8
9
5
6
8
TN0056
Figure 9-8
NOTE
Always use new seals.
3.
Apply a thin film of lithium grease NLGI Grade 2 to the lips of the seals (8).
4.
Using a seal driver, install seals (8) in the wheel hub
(9).
5.
Install clutch sleeve (7) into seals (8) and bearing (2).
6.
Install bushing (6) and washer (5) over the clutch sleeve (7).
Installation
Figure 9-10
2.
Install bushing (5) and latching collar (6).
7
TN0051
1
2
3
9
4
TN0052
Figure 9-9
1.
Align the groove (2) in the hub (3) with the pin (1) in the transport roller shaft (4), and install the hub assembly on the shaft.
TN0132
Figure 9-11
3.
Install a new lock nut (7) on the transport roller shaft.
4.
Install the transport wheels (if equipped). (See
“Transport Wheels (Optional)” on page 9-2.)
Kickstand
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Retract the kickstand and allow the mower to rest on the traction roller or transport wheels.
9-4 4157082 First Edition
1 2
MISCELLANEOUS
Disassembly and Assembly
1
2
3
Figure 9-12
3.
Remove two screws (1) and lock washers (2).
4.
Remove kickstand assembly (3).
TN0065
1
2
4
3
Support Bracket
Support Rod and Foot Rest
3
4
Groove Pin
Spring
Figure 9-14
TN0066
4
5
TN0067
Figure 9-13
Installation Notes
• Install the kickstand by reversing the order of removal.
• Make sure the end of the spring (4) is positioned under the rear crossbar (5).
9
4157082 First Edition 9-5
MISCELLANEOUS
9
9-6
Page Intentionally Blank
4157082 First Edition
Chapter 10
Accessories
10
4157082 First Edition 10-1
ACCESSORIES
Specifications
Adjustments
Turf Groomer Drive Belt Eccentric Nut
Locking Screw Torque lb-ft (N•m)
Assembly
Solid Tube Roller Lock Nut Torque
Solid Tube Roller Rotational
Resistance lb-ft (N•m) lb-in
(N•m)
20 (27)
10—30 (13.5—40.6)
0—1 with No End Play
(0—0.11 with No End Play)
10
10-2 4157082 First Edition
ACCESSORIES
Component Location
Turf Groomer
1
2
3
4
5
3
9
6
11
8
10
NOTE: Clutch knob and belt cover removed for clarity.
8
1
2
3
4
5
Clutch Control Knob
Belt Cover
Turf Groomer Height
Adjuster (2)
Blade Assembly
Roller Assembly
8
9
6
7
Reel Clutch Lever
Driven Assembly
Roller Height Adjuster (2)
Drive Assembly
10 Belt Tensioner Assembly
11 Clutch Assembly
Figure 10-1
7
TN0308, 0309, 00310
10
4157082 First Edition 10-3
10
ACCESSORIES
Troubleshooting
Turf Groomer
Condition
Turf groomer does not engage when clutch is engaged.
Turf groomer does not reach full speed.
Turf is being damaged when turf groomer is engaged.
Premature wear or failure of belt, pulleys, and/or bearings.
Probable Cause
Drive belt not properly tensioned.
Drive belt worn, stretched, or damaged.
Clutch shaft roll pin loose or broken.
Drive shaft roll pin loose or broken.
Clutch spring broken.
Turf groomer height-of-cut set too low.
Turf groomer shaft key broken or missing.
Turf groomer drive pulley set screw loose or missing.
Reel clutch not engaged.
Traction/reel drive clutch faulty.
Front roller not properly aligned with turf groomer blades.
Turf groomer drive belt not properly tensioned.
Turf groomer drive belt worn, stretched, or damaged.
Grooming too frequently.
Turf groomer height-of-cut set too low.
Drive belt is adjusted too tight.
Bearings not lubricated properly.
Remedy
Adjust drive belt tension. (See “Turf
Replace drive belt. (See “Drive Belt” on page 10-17.)
Replace clutch shaft roll pin. (See “Drive
Replace drive shaft roll pin. (See “Drive
Replace clutch pin. (See “Drive Assembly” on page 10-18.)
Adjust height-of-cut. (See “Turf Groomer
Height-of-Cut Adjustment” on page 10-7.)
Replace turf groomer shaft. (See “Turf
Groomer Shaft Assembly” on page 10-27.)
Tighten or replace groomer shaft drive
pulley set screw. (See “Drive Assembly” on page 10-18.)
Engage reel clutch. See Operator’s
Manual.
Replace clutch. (See “Engine and Clutch” on page 3-7.)
Adjust front roller. (See “Front Roller” on page 10-26.)
Adjust belt tension. (See “Turf Groomer
Drive Belt Tension Adjustment” on page 10-6.)
Replace drive belt. (See “Drive Belt” on page 10-17.)
Reduce frequency of grooming.
Adjust turf groomer height-of-cut. (See
Adjust drive belt tension. (See “Turf
Replace damaged or faulty components and lubricate at the intervals indicated in the Operator’s Manual.
10-4 4157082 First Edition
ACCESSORIES
Gear Drive
Condition
Vertical reel/soft touch brush does not engage when clutch is engaged.
Probable Cause
Reel clutch not engaged.
Traction/reel drive clutch faulty.
Shifter shaft roll pin loose or broken.
Premature wear or failure of belt, pulleys, and/or bearings.
Drive gear roll pin loose or broken.
Vertical reel/soft touch brush shaft key broken or missing.
Shifter gear damaged.
Idler gear damaged.
Drive gear damaged.
Bearings not lubricated properly.
Remedy
Engage reel clutch. See Operator’s
Manual.
Replace clutch. (See “Engine and Clutch” on page 3-7.)
Replace shifter shaft roll pin. (See
“Right-Side Gear Drive—Disassembly and Assembly” on page 10-30.)
Replace drive gear roll pin. (See “Drive
Replace clutch pin. (See “Repair—Vertical
Reel and Soft-Touch Brush” on page 10-31.)
Replace shifter gear. (See “Repair—Gear
Replace idler gear. (See “Repair—Gear
Replace drive gear. (See “Repair—Gear
Replace damaged or faulty components and lubricate at the intervals indicated in the Operator’s Manual.
10-5
10
4157082 First Edition
ACCESSORIES
Checks and Adjustments
Turf Groomer Drive Belt Tension
Adjustment
See Figures 10-2 through 10-4.
NOTICE
To prevent permanent damage to the belt, do not over-tighten, twist, fold, or bend the belt.
Over-tightening the belt will cause premature belt failure and abrasive wear of the pulley and bearings. Twisting or bending the belt will damage the belt cord fibers.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
3
10
12
11
TN0309
Figure 10-3
NOTE
Do not over-tighten belt. Be sure idler pulley does not contact small drive pulley.
5.
Loosen screw (11) and turn eccentric nut (12) to tighten drive belt (10).
6.
Hold eccentric nut (12) with a 3/4-in. wrench and tighten screw (11) to 20 lb-ft (27 N•m).
1
14
10
7 8 9
4
5 6
TN0311
Figure 10-2
2.
Remove hex head screws (5) and lock washers (6).
3.
Remove hex head screw (7), lock washer (8), flat washer (9), and clutch control knob (1).
4.
Remove lock nuts (2), flat washers (3), and belt cover
(4).
21
18 19 20
15
16 17
TN0311
Figure 10-4
7.
Install belt cover (15) using flat washers (13) and lock nuts (14).
8.
Install clutch control knob (21) using lock washers
(16) and hex head screws (17).
9.
Install hex head screw (18) with lock washer (19) and flat washer (20).
10-6 4157082 First Edition
ACCESSORIES
Turf Groomer Height-of-Cut
Adjustment
See Figures 10-5 through 10-7.
Required Tools
Height-of-Cut Gauge Bar (Jacobsen P/N 158568)
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Set height-of-cut. (See “Height-of-Cut Adjustment” on page 8-14.)
NOTICE
Do not set the blades at ground level or below. To mow at this level may damage the machine as well as the turf. The turf groomer is designed to be a conditioner, not a vertical mower.
Textron Turf Care and Specialty Products does not recommend setting the groomer blades more than 1/16 in. (2 mm) below the reel cutting height.
3
4
2
1
TN0329
Figure 10-5
3.
Loosen screw (1) on both sides of machine.
4.
Tip mower back on traction drum or tires. Do not leave the mower tipped back for an extended length of time, or oil may migrate into the combustion chamber.
NOTE
Make sure the bedknife is properly adjusted before
adjusting the turf groomer cutting height. (See
“Bedknife-to-Reel Adjustment” on page 8-13.)
6
5
TN0313
Figure 10-6
5.
Place height-of-cut gauge bar (2) across the front and rear rollers at one end of the turf groomer, with the head of screw (3) over bedknife (4).
6.
Loosen wing nut (6) and adjust screw (5) from
0—1/16 in. (0—0.4 mm) shorter than the mower height-of-cut. Tighten wing nut (6) to secure setting.
7.
Turn the turf groomer height-of-cut adjuster to bring one of the groomer blades into contact with screw
(5).
NOTE
The groomer edge must be perpendicular with screw (5) as shown.
8.
Repeat step 7 on the opposite end of the reel. Be sure both ends are adjusted evenly.
10
4157082 First Edition 10-7
ACCESSORIES
7
TN0329
Figure 10-7
9.
Tighten screw (7) on both sides of machine. Recheck the cutting height. Readjust if necessary.
Strip Brush Adjustment
NOTES
• The brush should be raised to clear the turf and securely tightened when not in use.
• Make sure the brush does not come into contact with the reel.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
2
3
5
1/16 in. (1.58 mm)
TN0281
Figure 10-8
4
TN0281
10
2.
Loosen jam nuts (1) and square head bolts (2) on both sides of the mower.
3.
Center the brush assembly (3) between the mounting brackets.
4.
Adjust the brush assembly (3) to the desired depth below the ground line (bottom of rollers, 4 and 5), and tighten square head bolts (2) and jam nuts (1): a.
For best results, position the brush 1/16 in.
(1.58 mm) below the rollers.
b.
The brush should not be adjusted so low that it damages the turf. Check the adjustment in a test area before returning the mower to service.
10-8 4157082 First Edition
ACCESSORIES
Repair—Front Rollers
Front Roller—Solid Tube and
Segmented
Removal
See Figures 10-9 through 10-11.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Retract the kickstand and allow the mower to rest on the traction roller or transport wheels.
3.
Place blocks under the frame to remove weight from the front roller.
9
TN0069
Figure 10-10
6.
Slide the roller assembly (10) toward the opposite side.
7.
Pivot the adjuster bracket (9) down, and remove adjuster bracket (9) and roller (10) as an assembly.
8.
Remove adjusting nut (8).
1
10
8
11
2 3 4
5
6
7
TN0068
Figure 10-9
4.
Loosen jam nuts (6) and square head bolts (7) on both sides of the mower.
5.
Remove nut (2), lock washer (3), flat washer (4), and carriage bolt (1) from adjuster bracket (5).
14
15 16
12
13
TN0070
Figure 10-11
9.
Remove nut (14), lock washer (15), flat washer (16), carriage bolt (12), and adjuster bracket (13).
10. Remove adjusting nut (11).
10
4157082 First Edition 10-9
10
ACCESSORIES
Disassembly—Solid Rollers
See Figure 10-12.
1
2
4
1
2
3
7
6
5
TN0314
Figure 10-13
1.
Remove the shield (1) from one side of each new bearing (2).
8
3
TN0312
Figure 10-12
1.
Remove grease fittings (1 and 5) from the roller shaft
(4).
2.
Support one end of the roller (8), allowing enough free space for seal (6) and bearing (7) to exit the roller (8).
3.
Apply pressure to the other end of the roller shaft (4) until the seal (6) and bearing (7) are clear of the roller
(8).
4.
Repeat steps 2 and 3 to remove the seal (2) and
bearing (3) from the other end of the roller (8).
Assembly—Solid Rollers
See Figures 10-13 through 10-17.
Required Materials
Permatex
®
Anaerobic Sealer (or equivalent)
4
5
TN0315
Figure 10-14
2.
Pack the bearing (5) with a good grade of general-purpose grease before installation.
3.
Install bearing (5) on the roller shaft (4) with the shielded side toward the step (3) on the shaft. Press the bearing on the shaft until it rests against the step.
10-10 4157082 First Edition
ACCESSORIES
13
6
14
7
9
8
15
TN0316
Figure 10-15
4.
Install the roller shaft (9) with bearing (6) into the roller (8) until the bearing is seated against the shoulder (7) in the roller.
10
TN0318
Figure 10-17
NOTE
Always use new grease seals for installation.
7.
Apply a thin film of Permatex
®
Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seal (14). Install grease seals into each end of the roller (15).
8.
Install grease fittings (13) in both ends of the roller shaft.
11
12
TN0317
Figure 10-16
5.
Pack bearing (10) with a good grade of general-purpose grease before installation.
6.
Install bearing (10) over the other end of the roller shaft (11), with the sealed side toward the inside of the roller. Seat the bearing against shoulder (12).
4157082 First Edition 10-11
10
ACCESSORIES
Disassembly—Solid Tube and Grooved
Rollers
See Figure 10-18.
5
2
3
4
1
4.
Inspect the bearings (2 and 9). If replacement is required, use a blind hole bearing puller to remove the bearing cups (1 and 8) from both ends of the roller (7).
5.
Remove grease seals (4 and 11) from the adapter seals (5 and 12).
6
7
8
9
11
10
TN0253
12
Figure 10-18
TN0253
10
NOTE
Solid tube roller shown; grooved roller is similar.
1.
Using a puller, remove the adapter seals (5 and 12) from both ends of the roller assembly.
2.
Remove lock nuts (3 and 10) and bearings (2 and 9) from both ends of the roller assembly.
3.
Remove the roller shaft (6).
10-12 4157082 First Edition
ACCESSORIES
Assembly—Solid Tube and Grooved Rollers
See Figure 10-19.
Required Tools and Materials
Permatex
®
Anaerobic Sealer (or equivalent)
1
2
3
4
6
5
NOTE
Bearings and bearing cups should always be replaced as a set.
2.
If removed, press new bearing cups (1 and 8) in the roller (7).
3.
Pack the bearings (2 and 9) with NLGI Grade 2 lithium grease before installation.
4.
Install the roller (7) and bearings (2 and 9) on the roller shaft (6). Center the roller on the shaft, and install lock nuts (3 and 10). Tighten lock nuts to
10—30 lb-ft (13.5—40.6 N•m) to seat the bearings.
5.
Check the rotational resistance of the roller on the shaft. The resistance should be 0—1 lb-in.
(0—0.11 N•m) with no end play. Adjust the lock nuts as needed.
6.
Apply a thin film of Permatex
®
Anaerobic Sealant (or equivalent) to the outside diameter of the adapter seals (5 and 12). Install (press) the adapter seals
(5 and 12) in the roller (7).
7
8
9
TN0253
12
Figure 10-19
11
10
TN0253
NOTE
Always use new grease seals for installation.
1.
Apply a thin film of Permatex
®
Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seals (4 and 11), and install the grease seals in the adapter seals (5 and 12).
4157082 First Edition 10-13
10
ACCESSORIES
Disassembly—Grooved Disc Roller
See Figure 10-20.
1
2
3
4
Assembly—Grooved Disc Roller
See Figure 10-21.
1
2
3
4
5 5
4 4
6
TN0254
7
8
TN0254
Figure 10-20
10
1.
Remove grease fittings (1 and 8) from the roller shaft
(4).
2.
Support one end of the roller (5), allowing enough free space for seal (2) and bearing (3) to exit the roller (5).
3.
Apply pressure to the other end of the roller shaft (4) until the seal (2) and bearing (3) are clear of the roller
(5).
4.
Repeat steps 2 and 3 to remove the seal (7) and
bearing (6) from the other end of the roller (5).
6
7
TN0254
8
TN0254
Figure 10-21
1.
Install bearing (3) in the roller (5).
2.
Install the roller shaft (4) into the roller (5) and bearing (3).
3.
Install bearing (6) into the roller (5).
NOTE
Always use new grease seals for installation.
4.
Install new grease seals (2 and 7) in the roller (5).
5.
Install both grease fittings (1 and 8) in the roller shaft
(4).
6.
Apply a good grade of general-purpose grease to both grease fittings (1 and 8). Apply grease slowly to prevent damaging the grease seals.
10-14 4157082 First Edition
ACCESSORIES
Disassembly—Grooved Segmented Roller
See Figures 10-22 and 10-23.
1
2
11
12
13
14
3
4
5
6
TN0252
16
15
TN0252
Figure 10-23
NOTE
All three roller segment assemblies are disassembled in the same way.
5.
Remove grease seals (11 and 15), ball bearings
(12 and 16) and spacer (13) from the roller segment
(14).
Assembly—Grooved Segmented Roller
See Figures 10-24 and 10-25.
7
8
TN0251
9
10
TN0251
Figure 10-22
1.
Remove hex-jam, nylon-insert nut (10) from the roller shaft (2) while holding the nut (1) at the other end of the shaft.
2.
Remove short spacer (9) and roller segment assembly (8).
3.
Remove long spacers (5 and 7) and roller segment assemblies (4 and 6).
4.
Remove short spacer (3) from roller shaft (2).
1
TN0252
2
3
4
5
6
TN0252
Figure 10-24
NOTES
• All three roller segments are assembled in the same way.
• Always use new grease seals for installation.
1.
Install ball bearing (2) and a new grease seal (1) in one end of the roller segment (4).
10
4157082 First Edition 10-15
ACCESSORIES
2.
Apply lithium grease NLGI Grade 2 to the inside of the spacer (3), and install the spacer (3) into the roller segment (4).
3.
Install a ball bearing (5) and grease seal (6) in the other end of the roller segment (4).
4.
Apply lithium grease NLGI Grade 2 to the lips of the grease seals (1 and 5).
.
Installation
See Figures 10-26 through 10-28.
1.
Apply lithium grease NLGI Grade 2 to the height adjustment channels on both sides of the mower.
1
7
8
4 5
6
2
9
10
11
3
TN0070
Figure 10-26
2.
Install adjusting nut (1)
3.
Install adjuster bracket (3) using carriage bolt (2), flat washer (6), lock washer (5), and nut (4).
12
7
13
14
TN0251
15
16
TN0251
Figure 10-25
10
5.
Apply a thin film of lithium grease NLGI Grade 2 to the inside diameter of the short spacer (9), and install the spacer on the roller shaft (8) with the bevel facing away from the nut (7).
6.
Install the roller segment assemblies (10, 12, and 14) on the roller shaft (8), placing a long spacer (11 and
13) between each of the roller segments.
7.
Apply a thin film of lithium grease NLGI Grade 2 to the inside diameter of the short spacer (15) on the roller shaft (8).
8.
Install hex-jam, nylon-insert nut (16) on the roller shaft (8).
9
8
TN0069
Figure 10-27
4.
Install adjusting nut (7).
5.
Slide the roller assembly (9) and adjuster bracket (8) toward the opposite side.
6.
Pivot the adjuster bracket (8) up and install to adjusting nut (7).
10-16 4157082 First Edition
10
ACCESSORIES
Repair—Turf Groomer
Drive Belt
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
14 15
16
2 3
1
13
11
12
TN0068
Figure 10-28
7.
Install carriage bolt (10) through adjuster bracket (13) and secure with flat washer (16), lock washer (15), and nut (14).
8.
Center roller assembly between adjuster brackets and tighten square head bolt (11) and jam nut (12) on both sides of machine.
9.
Check height-of-cut. (See “Height-of-Cut Adjustment” on page 8-14.)
4
7 8 5 6
TN0311
Figure 10-29
2.
Remove hex head screws (5) and lock washers (6).
3.
Remove hex head screw (7), lock washer (8), and clutch control knob (1).
4.
Remove lock nuts (2), flat washers (3), and belt cover
(4).
11
12
13
9 10
14
TN0333
Figure 10-30
5.
Remove hex head screw (9) and lock washer (10).
6.
Remove eccentric adjuster nut (11), idler pulley (12), and spacer (13).
7.
Remove belt (14).
10
Installation Notes
• Install belt by reversing the order of removal.
• Adjust belt tension. (See “Turf Groomer Drive Belt
Tension Adjustment” on page 10-6.)
10-17 4157082 First Edition
ACCESSORIES
Drive Assembly
Removal
See Figures 10-31 through 10-34.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
15 16 17
21
18 19
2 3
1
4
7
8
5 6
TN0311
Figure 10-31
2.
Remove hex head screws (5) and lock washers (6).
3.
Remove hex head screw (7), lock washer (8), and clutch control knob (1).
4.
Remove lock nuts (2), flat washers (3), and belt cover
(4).
20
TN0334
Figure 10-33
8.
Remove set screw (21) and drive pulley (20).
9.
Loosen groomer shaft set screw (18) and roller shaft set screw (19).
10. Remove hex head screw (15), spacer (16), and lock nut (17).
22
11
12 13
Figure 10-34
11. Remove drive assembly (22) from machine.
TN0335
9 10
14
TN0333
Figure 10-32
10
5.
Remove hex head screw (9) and lock washer (10).
6.
Remove eccentric adjuster nut (11), idler pulley (12), and spacer (13).
7.
Remove drive belt (14).
10-18 4157082 First Edition
ACCESSORIES
4157082 First Edition
Page Intentionally Blank
10-19
10
10
ACCESSORIES
Disassembly and Assembly
See Figure 10-35.
3
4
5
6
7
8
9
10
11
12
13
15
14
16
29
17
18
28
26
25
35
30
36
2
39
1
38
37
40
31
33
32
34
41
47
48
46
45 44
43
42
49
64
50
61
63
62
51
60
59
52
24
27
19
20
21
22
23
53
54
55
56
57
58
Figure 10-35
TN0336
10-20 4157082 First Edition
3
4
5
1
2
1/4” Lock Washer
1/4-20 x 2” Hex Head Screw
3/8-24 x 1/2” Hex Head Screw
3/8” Lock Washer
3/8” Flat Washer
6
7
8
9
Clutch Control Plate
3/8-24 x 1” Hex Head Screw
3/8” Lock Washer
Spacer Knob
10 Washer
11 Spring
12 Drive Hub
13 Hub
14 3/16 x 1-1/4” Roll Pin
15 16-Groove Pulley
16 Bearing
17 Snap Ring
18 5/32 x 3/4” Groove Pin
19 1/8” Grease Fitting
20 Height Adjustment Nut
21 5/16” Hex Nut
22 5/16” Lock Washer
23 Strap
24 3/32 x 1-3/4” Cotter Pin
25 3/16 x 1” Roll Pin
26 Shaft
27 Spacer
28 Gasket
29 Hub
30 Hub Seal
31 1/4” Lock Washer
32 1/4-20 x 3/4” Socket Head Screw
Assembly Notes
• Install new gasket (28).
• Apply lithium grease NLGI Grade 2 to stud (63) during assembly.
• Apply lithium grease NLGI Grade 2 to grease fitting
(19) after assembly.
• Torque hex head screw (47) to 20 lb-ft (27 N•m).
33 5/16” Lock Nut
34 14-20 x 3/4” Socket Head Screw
35 Right-Side Roller Bracket
36 Right-Side Mower Bracket
37 Special Washer
38 3/8” Lock Washer
39 3/8-16 x 1” Hex Head Screw
40 Spacer
41 1/4-20 x 5/8” Socket Head Screw
42 Snap Ring
43 Bearing
44 15-Groove Pulley
45 Eccentric Adjuster Nut
46 3/8” Lock Washer
47 3/8-16 x 1-1/2” Hex Head Screw
48 1/4-20 x 1/4” Set Screw
49 10-Groove Pulley
50 Belt
51 1/4” Flat Washer
52 1/4” Lock Nut
53 Belt Cover
54 1/4” Lock Nut
55 1/4” Lock Washer
56 5/16-18 x 2-1/4” Hex Head Screw
57 Adjustment Bracket Pivot
58 Height Adjustment Bracket
59 Spacer
60 5/16” Lock Nut
61 Spacer
62 Adjustment Bracket Pivot
63 Stud
64 Roller Adjustment Knob
ACCESSORIES
10-21
10
4157082 First Edition
ACCESSORIES
Installation
See Figures 10-36 through 10-39.
1
3.
Tighten turf groomer shaft set screw (5) and roller shaft set screw (6).
4.
Place a straightedge (10) across the face of clutch pulley (9) and drive pulley (7). Make sure both pulleys are properly aligned.
5.
Once properly aligned, secure drive pulley (7) with set screw (8).
11
12 13
TN0335
Figure 10-36
1.
Align turf groomer and roller shafts with corresponding brackets and slide drive assembly (1) onto machine.
9
10
2 3 4
8
7
9
7
5 6
10
TN0334, 0342
Figure 10-37
2.
Install hex head screw (2), spacer (3), and lock nut
(4).
15 16
14
TN0333
Figure 10-38
NOTICE
To prevent permanent damage to the belt, do not over-tighten, twist, fold, or bend the belt.
Over-tightening the belt will cause premature belt failure and abrasive wear of the pulley and bearings. Twisting or bending the belt will damage the belt cord fibers.
6.
Install drive belt (14).
7.
Install spacer (13), idler pulley (12), and eccentric adjuster nut (11).
8.
Install hex head screw (15) with lock washer (16). Do not tighten at this time.
9.
Turn eccentric adjuster nut (11) by hand to adjust drive belt (14) tension.
NOTE
Do not over-tighten drive belt. Be sure idler pulley does not contact drive pulley.
10. Use a 3/4-in. open-end wrench to hold eccentric adjuster nut (11) while tightening hex head screw
(15) to 20 lb-ft (27 N•m).
10-22 4157082 First Edition
ACCESSORIES
18 19
17
7
20
23
24
21
22
TN0311
Figure 10-39
11. Install belt cover (20) using flat washers (18) and lock nuts (19).
12. Install clutch control knob (17) using lock washers
(21) and hex head screws (22).
13. Install hex head screw (23) with lock washer (24).
14. Set height-of-cut. (See “Height-of-Cut Adjustment” on page 8-14.)
15. Set turf groomer height-of-cut. (See “Turf Groomer
Height-of-Cut Adjustment” on page 10-7.)
Driven Assembly
Removal
See Figures 10-40 through 10-41.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
Figure 10-41
5.
Remove driven assembly (7) from machine.
TN0330
2 3
1
4 5 6
TN0329
Figure 10-40
2.
Loosen turf groomer and roller shaft set screws (1).
3.
Remove hex head screw (2) and lock washer (3).
4.
Remove hex head screw (4), lock washer (5), and spacer (6).
4157082 First Edition 10-23
10
ACCESSORIES
Disassembly and Assembly
1
2
7
13
9
12
14
15
16
17
18
19
20
6
8
10
11
3
5
4
23
24
25
22
26
45
44
28
29
30
31
21
32
27
46 47 46
51
33
43
48
49 50
52
42
41
40
39
38
37
36
35
34
1
4
5
2
3
5/16-18 x 1-1/2” Hex Head
Screw
5/16” Lock Washer
Strap
8
9
6
7
5/16” Flat Washer
5/16” Lock Washer
5/16” Lock Nut
Gasket
Spacer
Pivot
10 Spacer
11 5/16-18 Hex Nut
12 #8 Lock Washer
13 #8-32 x 3/8” Hex Head Screw
14 Plate
15 1/4” Flat Washer
16 1/4” Lock Washer
17 1/4-20 x 1/2” Hex Head Screw
18 1/2” Lock Washer
19 1/2-13 x 4” Hex Head Screw
20 Height Adjuster Knob
21 5/16” Flat Washer
22 Stud
23 Bar
24 5/16” Flat Washer
25 5/16-18 x 1-1/2” Hex Head
Screw
26 1/4-20 x 3/4” Hex Head Screw
27 5/16” Lock Nut
28 Left-Side Roller Bracket
Figure 10-42
29 1/4-20 x 5/8” Socket-Head
Screw
30 Left-Side Mower Bracket
31 5/16” Flat Washer
32 Adjustment Pivot Bracket
33 Height Adjustment Bracket
34 Adjustment Pivot Bracket
35 Spacer
36 5/16” Lock Washer
37 5/16-18 x 1-1/4” Hex Head
Screw
38 5/16” Lock Nut
39 5/16” Lock Nut
40 Stud
41 Height Adjuster Knob
10
Installation Notes
• Apply a small amount of NLGI Grade 2 grease to studs (22 and 40) before installing height adjuster knobs (20 and 41).
• Install new gasket (7).
• Apply NLGI Grade 2 grease to height adjuster knob grease fitting after assembly is complete.
TN0331
42 3/8-16 x 1” Hex Head Screw
43 3/8” Lock Washer
44 Special Washer
45 Pin
46 Cup Washer
47 Spring
48 Clamp
49 1/4” Lock Washer
50 1/4-20 x 3/4” Socket-Head
Screw
51 O-Ring
52 Shifter Shaft
10-24 4157082 First Edition
Installation
1
ACCESSORIES
Front Roller and Turf Groomer
NOTE
The front roller and turf groomer shaft must be removed and installed together.
Removal and Installation
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Remove drive assembly. (See “Drive Assembly” on page 10-18.)
3
TN0330
Figure 10-43
1.
Install driven assembly (1).
3 4
2
2
5 6 7
TN0329
Figure 10-44
2.
Install spacer (5), lock washer (6), and hex head screw (7).
3.
Install lock washer (3) and hex head screw (4).
4.
Tighten turf groomer and roller shaft set screws (2).
5.
Adjust mower height-of-cut. (See “Height-of-Cut
6.
Adjust turf groomer height-of-cut. (See “Turf Groomer
Height-of-Cut Adjustment” on page 10-7.)
1
Figure 10-45
3.
Loosen set screws (1).
4.
Remove roller (2) and turf groomer (3) as an assembly.
TN0329
Installation Note
Install front roller and turf groomer by reversing the order of removal.
10
4157082 First Edition 10-25
ACCESSORIES
Front Roller
Disassembly and Assembly
See Figure 10-46.
1
2
3
1
2
4
5
TN0328, 0337
10
1.
Measure and record the distance between the face of the locking collar and the bearing face (4).
2.
Loosen locking collar (2) and remove bearing assembly (1).
3.
Repeat steps 1 and 2 to remove the other bearing
assembly.
Figure 10-46
Assembly Notes
• Assemble roller (3) by reversing the order of disassembly.
• Install the bearing assemblies to the same distance as noted during removal.
• Apply NLGI Grade 2 grease to grease fitting (5) after assembly is completed.
10-26 4157082 First Edition
Turf Groomer Shaft Assembly
Disassembly
See Figures 10-47 through 10-50.
!
CAUTION
To prevent personal injury and damage to cutting edges, handle the vertical mower shaft assembly with extreme care.
6
7
ACCESSORIES
8
9
8
9
8
10
1
TN0340
Figure 10-49
3.
Remove the locking collar (6), two spacers (7), blades (8), and spacers (9) from shaft (10).
13
12
14
TN0338
Figure 10-47
1.
Measure and record the distance between the face of the locking collar and the bearing face (1) on both ends of the shaft assembly.
11
3
4
2
5
TN0339
Figure 10-48
2.
Loosen set screw (5) in locking collar (4) and remove bearing shaft assembly (2) and key (3) from both ends of the shaft.
TN0341
Figure 10-50
4.
Remove two spacers (11) from the shaft (12).
5.
Loosen the set screw (14) and remove the locking collar (13) from the shaft (12).
10
4157082 First Edition 10-27
10
ACCESSORIES
Assembly
See Figures 10-51 through 10-53.
3
13
12
2
11
4
14
1
15
TN0341
Figure 10-51
1.
Install locking collar (3) flush with the end of shaft (2).
Tighten set screw (4).
2.
Install two spacers (1) on shaft (2).
5
6
7
8
7
8
7
9
16
TN0339, 0338
Figure 10-53
5.
Install key (12) in bearing shaft assembly (11). Install shaft assembly (11) into the roller. Position the shaft assembly so the distance between the face of the locking collar and the bearing face (15) is the same as noted during disassembly.
6.
Tighten the set screw (14) in the locking collar (13).
7.
Repeat steps 5 and 6 to install the bearing shaft
assembly in the other end of the shaft.
8.
Apply NLGI Grade 2 grease to the grease fitting (16) on both ends of the roller assembly.
10
TN0340
Figure 10-52
3.
Install blades (7) and spacers (8) on shaft (9).
4.
Install two spacers (6) and locking collar (5) on shaft
(9). Do not tighten set screw (10) at this time.
10-28 4157082 First Edition
ACCESSORIES
Repair—Gear Drive
Left-Side Gear Drive—Disassembly and Assembly
See Figure 10-54.
6
3
1
2
4
5
32 31
30
29
28
7
8
10
9
11
12
13
15
14
16
17
18 27
25
26
24
23
22
21
19
20
TN0343
7
8
5
6
3
4
1
2
5/16-18 x 1-1/2” Carriage Bolt
5/16-18 x 1-1/2” Hex Bolt
Roller Adjuster
Stud
Left-Side Roller Bracket Extension
Left-Side Frame
1/4” Lock Washer
1/4-20 Hex Nut
9 1/4-20 x 4-1/8” Stud
10 Stud
11 Height Adjuster
12 1/4-20 Hex Nut
13 1/4” Lock Washer
14 1/4-20 Hex Nut
15 Adjuster Pivot Bracket
16 1/4” Flat Washer
17 1/4” Lock Nut
18 Locking Nut
19 Pivot Ring
20 1/4-20 x 1/2 Socket Head Screw (4)
21 5/16-18 x 1” Hex Bolt
22 Bearing Housing
23 Pivot Plate
24 5/16” Lock Washer
Figure 10-54
Assembly Notes
• Apply lithium grease NLGI Grade 2 to the channel of roller bracket extension (5) before installing roller.
• Apply lithium grease NLGI Grade 2 to studs (4 and
10) before installing adjusters.
25 5/16-18 Nut
26 Pivot Mounting Plate
27 Spacer
28 Left-Side Locking Stud
29 5/16-18 Nut
30 5/16” Lock Washer
31 5/16-18 Nut
32 5/16” Lock Washer
10
4157082 First Edition 10-29
ACCESSORIES
Right-Side Gear Drive—Disassembly and Assembly
Required Materials
Sunray DX-671or Gulf Supreme #0 Grease
2
1
3
4
10
5
6
9
12
8
17
14
13
15
7
11
48
30
21
22
23
24
25
26
27
28
29
20
19
42
41
18
16
47
43
45
44
46
31
32
40
39
33
37
38
34
36
35
TN0345
7
8
5
6
3
4
1
2
Knob
5/16-18 x1-3/4” Hex Bolt
5/16” Lock Washer
Gear Box Cover
Ball
Gear Box Gasket
Set Screw
Spring
9 3/8” Flat Washer
10 3/8” Lock Washer
11 Shifter Shaft
12 3/16 x 1-1/4” Roll Pin
13 Internal Retaining Ring
14 Bearing
15 19-Tooth Shifter Gear
16 External Retaining Ring
17 Locking Nut
18 1/4-20 x5/8” Socket-Head Screw
19 Spacer
20 Stud
21 Height Adjusting Nut
22 Adjuster Pivot Bracket
23 Gear Box Housing
24 5/16” Flat Washer
25 5/16-18 Hex Nut
26 24 Tooth Drive Gear
27 3/32 x 1-3/4” Cotter Pin
28 3/16 x 1-1/4” Roll Pin
29 Right-Side Locking Stud
30 Grease Fitting
31 Right-Side Frame
32 Stud
33 Roller Adjuster
34 5/16-18 x 1-1/2” Hex Bolt
35 5/16-18 x 1-1/2” Carriage Bolt
36 Right-Side Roller Bracket
Extension
Figure 10-55
10
Assembly Notes
• Apply Sunray DX-671 or Gulf Supreme #0 grease around gears and bearings, then fill gear box approximately 1/3 full before installing cover.
• Install new gear box gasket (6) during assembly.
37 5/16” Lock Washer
38 5/16-18 Hex Nut
39 5/16” Lock Washer
40 5/16-18 Hex Nut
41 3/8-16 Hex Nut
42 3/8” Lock Washer
43 Washer
44 Bearing
45 18-Tooth Idler Gear
46 Spacer
47 Bearing
48 Shoulder Bolt
• Apply lithium grease NLGI Grade 2 to the channel of roller bracket extension (36) before installing roller.
• Apply lithium grease NLGI Grade 2 to studs (20 and
32) before installing adjusters.
• Apply lithium grease NLGI Grade 2 to grease fitting
(30) after assembly.
10-30 4157082 First Edition
ACCESSORIES
Repair—Vertical Reel and
Soft-Touch Brush
Vertical Reel—Disassembly
See Figures 10-56 through 10-59.
!
CAUTION
To prevent personal injury and damage to cutting edges, handle the blade assembly with extreme care.
11
12
13
14
1
2
TN0321
Figure 10-58
5.
Remove two spacers (11) from blade roller shaft (14).
6.
Remove 39 blades (12) and 36 spacers (13) from blade roller shaft (14).
18
17
16
3
6
5
4
TN0319
Figure 10-56
1.
Remove screw (6), lock washer (5), and flat washer
(4).
2.
Remove gear (1) and key (2) from blade roller shaft
(3).
8
9
15
19
TN0322
Figure 10-59
7.
Remove bearing (18) from blade roller shaft (15).
8.
Measure and record the distance from the end of the shaft to the face of the jam nut.
9.
Loosen set screw (19) and remove jam nut (17) from blade roller shaft (15).
10. Remove two spacers (16) from blade roller shaft (15).
7
10
10
TN0320
Figure 10-57
3.
Remove bearing (7) from blade roller shaft (8).
4.
Loosen set screw (9) and remove jam nut (10) from blade roller shaft (8).
4157082 First Edition 10-31
ACCESSORIES
Vertical Reel—Assembly
See Figures 10-60 through 10-64.
1
2
3
NOTE
The blades must be installed so that the indexing holes are rotated 60° from the hole in the previous blade.
Clockwise or counterclockwise rotation is acceptable, as long as the direction of rotation remains the same.
5.
Install first blade (7), noting the position of the indexing hole (10).
6.
Install a spacer (6) between the blades.
7.
Continue installing blades (7) and spacers (6). Rotate each blade 60° from the previous blade, using the index holes as reference.
4
5
13
TN0323
Figure 10-60
1.
Install jam nut (2) on blade roller shaft (1), the same distance from the end of the shaft as noted during removal.
2.
Tighten set screw (4).
3.
Press bearing (3) onto blade roller shaft (1) until bearing is seated against the shoulder (5) on the shaft.
8
9
11
12
14
TN0325
Figure 10-62
8.
Install two spacers (12) and jam nut (14) on blade roller shaft (13). Tighten set screw (11).
7
6
10
16
60° First Blade to Second Blade
15
7
60° Second Blade to Third Blade
10
Figure 10-61
4.
Install two spacers (8) on blade roller shaft (9).
TN0324
17
TN0326
Figure 10-63
9.
Press bearing (15) on blade roller shaft (16) until the bearing is seated against the shoulder (17) of the shaft.
10-32 4157082 First Edition
19
18
20
22
21
23
TN0319
Figure 10-64
10. Install key (19) and gear (18) on blade roller shaft
(20). Secure the gear using screw (23), lock washer
(22), and flat washer (21).
ACCESSORIES
10-33
10
4157082 First Edition
ACCESSORIES
Soft-Touch Brush—Disassembly and
Assembly
See Figure 10-65.
2
1
3
4
1
2
8
5
7
6
10
TN0327
3
4
1
2
Shaft
Bearing (2) (Press Fit)
Brush Assembly
Key
7
8
5
6
Figure 10-65
Gear
Washer
Lock Washer
Screw
Disassembly Note
• Use a knife-edge puller to remove bearing (2) from shaft (1).
Assembly Note
• Bearing (2) is press fit. Use a press to install bearing
(2) onto shaft (1).
10-34 4157082 First Edition
Repair—Miscellaneous
Strip Brush
Removal and Installation
See Figure 10-66.
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
1
2
3
5
4
TN0307
Figure 10-66
2.
Loosen jam nut (3) on both sides of the mower.
3.
Remove square head bolt (4), jam nut (3), and washers (2) from roller bracket (1) on both sides of the mower.
4.
Remove brush (5).
Installation Notes
• Install the strip brush by reversing the order of removal.
• Do not tighten the mounting hardware until the strip
brush is properly adjusted. (See “Strip Brush
4157082 First Edition
ACCESSORIES
10-35
10
ACCESSORIES
Scraper Blade Assembly
Disassembly and Assembly
6
5
7
8
1
2
3
4
9
10
12
11
13
14
TN0344
10
1.
Park the mower safely. (See “Park Mower Safely” on page 1-6.)
2.
Retract the kickstand and allow the mower to rest on the traction roller or transport wheels.
3.
Place blocks under the frame to remove weight from the front roller.
4.
Loosen lock nuts and square head screws (10 and
13.)
5.
Remove nut (1), lock washer (2), flat washer (3), and carriage bolt (12).
6.
Remove nut (7), lock washer (6), flat washer (5), and carriage bolt (8).
7.
Slide roller brackets (9 and 14) toward center of roller
(11).
Figure 10-67
8.
Remove roller (11), scraper (4), and roller brackets (9 and 14) from machine as an assembly.
9.
Remove roller bracket (9) from roller (11) and scraper
(4).
10. Remove scraper (4).
Installation Notes
• Install the scraper by reversing the order of removal.
• Apply lithium grease NLGI Grade 2 to the outer face of roller brackets (9 and 14) before assembly.
• Set height-of-cut. (See “Height-of-Cut Adjustment” on page 8-14.)
10-36 4157082 First Edition
A
Accessories
Checks and Adjustments . . . . . . . . . . . . . . . 10-6
Component Location . . . . . . . . . . . . . . . . . . 10-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 10-4
Adjustment
Clutch Control Cable . . . . . . . . . . . . . . . . . . . 3-4
Engine Idle Speed . . . . . . . . . . . . . . . . . . . . . 3-5
Handle Height . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Height-of-Cut . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Reel Bearing Pre-Load . . . . . . . . . . . . . . . . 8-15
Strip Brush . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Turf Groomer Belt . . . . . . . . . . . . . . . . . . . . 10-6
Adjustment Bedknife-to-Reel . . . . . . . . . . . . . 8-13
Air Tools, Safety . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
B
Bedknife
Removal and Installation . . . . . . . . . . . . . . . 8-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Bedknife Shoe
Disassembly and Assembly . . . . . . . . . . . . . 8-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Brake Control Lever
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Brakes
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 7-3
C
Check and Adjustments
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Turf Groomer Height-of-Cut Adjustment . . . 10-7
INDEX
Checks and Adjustments
Accessories . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Backlapping Procedure . . . . . . . . . . . . . . . . 8-14
Bedknife-to-Reel Adjustment . . . . . . . . . . . 8-13
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Height-of-Cut Adjustment . . . . . . . . . . . . . . 8-14
Park Brake Cable . . . . . . . . . . . . . . . . . . . . . 7-4
Reel and Bedknife Inspection . . . . . . . . . . . 8-13
Reel Bearing Pre-Load Adjustment . . . . . . 8-15
Strip Brush Adjustment . . . . . . . . . . . . . . . . 10-8
Turf Groomer Belt Tension Adjustment . . . 10-6
Chemical Products, Safe Handling . . . . . . . . . 1-9
Circuit Operation
Electrical, Schematic . . . . . . . . . . . . . . . . . . 4-8
Clutch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Clutch Control Cable
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Component Location . . . . . . . . . . . . . . . . . . . . 2-3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Turf Groomer . . . . . . . . . . . . . . . . . . . . . . . 10-3
Component Removal and Installation
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Component Symbols
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Component Testing
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Compressed Air, Safety . . . . . . . . . . . . . . . . . . 1-8
Cutting Unit
Component Location . . . . . . . . . . . . . . . . . . . 8-3
Mechanical Troubleshooting . . . . . . . . . . . . 8-12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8-3
D
Diagnostic Information
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Differential Assembly
Disassembly and Assembly . . . . . . . . . . . . 5-27
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
IX
IX-1 4157082 First Edition
INDEX
Drive Chains
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
E
Electrical
Circuit Operation, Schematic . . . . . . . . . . . . . 4-8
Component Location . . . . . . . . . . . . . . . . . . . 4-2
Component Removal and Installation . . . . . 4-12
Component Symbols . . . . . . . . . . . . . . . . . . . 4-3
Component Testing . . . . . . . . . . . . . . . . . . . 4-10
Engine Components . . . . . . . . . . . . . . . . . . . 4-12
Engine On/Off Switch Test . . . . . . . . . . . . . . 4-11
E-Stop Switch, Removal and Installation . . . 4-12
E-Stop Switch,Test . . . . . . . . . . . . . . . . . . . . 4-11
Resistance Test . . . . . . . . . . . . . . . . . . . . . . 4-10
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Theory and Diagnostic Information . . . . . . . . 4-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 4-9
Electrical Components, Safety . . . . . . . . . . . . . 1-9
Engine
General Specifications . . . . . . . . . . . . . . . . . . 3-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine Components
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Engine Idle Speed
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . 2-8
Engine On/Off Switch
Electrical, Test . . . . . . . . . . . . . . . . . . . . . . . 4-11
E-Stop Switch
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Removal and Installation . . . . . . . . . . . . . . . 4-12
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
F
IX
Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Front Roller
Disassembly and Assembly . . . . . . . . . . . . 10-26
IX-2
Front Roller and Turf Groomer
Removal and Installation . . . . . . . . . . . . . . 10-25
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Front Roller Repair . . . . . . . . . . . . . . . . . . . . . 10-9
Front Roller-Solid Tube and Segmented
Disassembly-Solid Rollers . . . . . . . . . . . . . 10-10
Disassembly-Solid Tube
and Grooved Rollers . . . . . . . . . . . . . . 10-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Fuel, Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
G
Gasoline Requirements . . . . . . . . . . . . . . . . . . . 2-7
Gear Drive
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 10-5
Gear Drive, Left-Side
Disassembly and Assembly . . . . . . . . . . . 10-29
Gear Drive, Right-Side
Disassembly and Assembly . . . . . . . . . . . 10-30
Grass Shield
Removal and Installation . . . . . . . . . . . . . . . 8-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Grooved Disc Roller
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-14
Grooved Segmented Roller
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-15
H
Handle
Height Adjustment . . . . . . . . . . . . . . . . . . . . . 6-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Handle Assembly
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Handle Cover
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Harness, Wiring
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4157082 First Edition
I
Hazardous Materials Storage . . . . . . . . . . . . . . 1-9
Height-of-Cut
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Idle Speed, Engine
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
INDEX
Operational Checks
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
E-Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Traction/Reel Chain Case Oil . . . . . . . . . . . . 2-8
Operator Presence Control
Optional Machine Accessories . . . . . . . . . . . . 2-2
J
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
K
Kickstand
Disassembly and Assembly . . . . . . . . . . . . . . 9-5
Removal and Installation . . . . . . . . . . . . . . . . 9-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
L
Lubricants
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . 2-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Traction/Reel Drive Chain Case Oil . . . . . . . . 2-7
P
Park Brake
Checks and Adjustments . . . . . . . . . . . . . . . 7-4
Park Brake Band
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Park Brake Cable
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Parking Mower . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Power Train
Component Location . . . . . . . . . . . . . . . . . . . 5-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-3
Product Identification
Engine Serial Number . . . . . . . . . . . . . . . . . . 2-2
Model Identification Number . . . . . . . . . . . . . 2-2
Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Mower Serial Number . . . . . . . . . . . . . . . . . . 2-2
M
Mechanical Troubleshooting
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Miscellaneous Accessories
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Q
Quality of Cut
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 8-3
O
OPC
Operational Check . . . . . . . . . . . . . . . . . . . . 2-10
OPC Bail
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
4157082 First Edition
R
Reel and Bedknife
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Reel Assembly
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
IX
IX-3
IX
INDEX
Reel Bearing
Pre-Load Adjustment . . . . . . . . . . . . . . . . . . 8-15
Repair
Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Bedknife Shoe . . . . . . . . . . . . . . . . . . . . . . . 8-18
Brake Control Lever . . . . . . . . . . . . . . . . . . . . 6-8
Clutch Control Cable . . . . . . . . . . . . . . . . . . . 5-4
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Differential Assembly . . . . . . . . . . . . . . . . . . 5-27
Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Engine Service . . . . . . . . . . . . . . . . . . . . . . . 3-14
Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Front Roller and Turf Groomer . . . . . . . . . . 10-25
Front Roller-Solid Tube and Segmented . . . 10-9
Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Grass Shield . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Handle Assembly . . . . . . . . . . . . . . . . . . . . . . 6-3
Handle Cover . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Kickstand . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Miscellaneous Accessories . . . . . . . . . . . . 10-35
OPC Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Park Brake Band . . . . . . . . . . . . . . . . . . . . . . 7-6
Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . 7-5
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Reel Assembly . . . . . . . . . . . . . . . . . . . . . . . 8-20
Right Frame . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Scraper Blade Assembly . . . . . . . . . . . . . . 10-36
Strip Brush . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Throttle Cover . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Throttle Paddle . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Traction Drive Drum Assembly . . . . . . . . . . . 5-23
Traction Drum . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Traction/Reel Drive Chain Case . . . . . . . . . . 5-13
Traction/Reel Drive Clutch . . . . . . . . . . . . . . . 5-5
Transport Wheels (Optional) . . . . . . . . . . . . . 9-2
Turf Groomer . . . . . . . . . . . . . . . . . . . . . . . 10-17
Turf Groomer Drive Assembly . . . . . . . . . . 10-18
Turf Groomer Drive Belt . . . . . . . . . . . . . . . 10-17
Turf Groomer Driven Assembly . . . . . . . . . 10-23
Turf Groomer Shaft Assembly . . . . . . . . . . 10-27
Vertical Reel and Soft-Touch Brush . . . . . . 10-31
Wheel Hubs and Bearings . . . . . . . . . . . . . . . 9-3
Resistance Test
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Right Frame
Disassembly and Assembly . . . . . . . . . . . . . 5-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
IX-4
S
Safety
Chemical Products Handling . . . . . . . . . . . . . 1-9
Compressed Air and Air Tools . . . . . . . . . . . 1-8
Electrical Components . . . . . . . . . . . . . . . . . 1-9
Eye and Face Protection . . . . . . . . . . . . . . . . 1-6
Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lifting Equipment . . . . . . . . . . . . . . . . . . . . . . 1-7
Machine Support . . . . . . . . . . . . . . . . . . . . . . 1-7
Parking Mower . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tire Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Volatile and Hazardous Materials Storage . . 1-9
Waste Material Disposal . . . . . . . . . . . . . . . 1-10
Work Area Cleanliness . . . . . . . . . . . . . . . . . 1-6
Work Area Ventilation . . . . . . . . . . . . . . . . . . 1-6
Safety Labels
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Schematic
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Scraper Blade Assembly
Disassembly and Assembly . . . . . . . . . . . 10-36
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Service
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Soft-Touch Brush
Disassembly and Assembly . . . . . . . . . . . 10-34
Solid Rollers
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-10
Solid Tube and Grooved Rollers
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-12
Specifications
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Gasoline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Quick Reference Specifications . . . . . . . . . . 2-4
Traction Drive and Differential . . . . . . . . . . . . 2-4
Weights and Dimensions . . . . . . . . . . . . . . . . 2-4
Strip Brush
Removal and Installation . . . . . . . . . . . . . . 10-35
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
4157082 First Edition
T
Throttle Cable
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Throttle Cover
Removal and Installation . . . . . . . . . . . . . . . . 3-5
Throttle Paddle
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Tires, Service Safety . . . . . . . . . . . . . . . . . . . . . 1-8
Torque Values (Standard)
Inch Fastener Torque Values . . . . . . . . . . . . . 2-6
Metric Fastener Torque Values . . . . . . . . . . . 2-6
Traction Drive Drum Assembly
Disassembly and Assembly . . . . . . . . . . . . . 5-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Traction Drum
Disassembly and Assembly . . . . . . . . . . . . . 5-26
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Traction/Reel Chain Case Oil
Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Traction/Reel Drive Chain Case
Disassembly and Assembly . . . . . . . . . . . . . 5-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Traction/Reel Drive Clutch
Disassembly and Assembly . . . . . . . . . . . . . . 5-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Transport Wheels (Optional)
Disassembly and Assembly . . . . . . . . . . . . . . 9-2
Removal and Installation . . . . . . . . . . . . . . . . 9-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Troubleshooting
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Gear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Quality of Cut . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Turf Groomer . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Turf Groomer
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 10-4
4157082 First Edition
INDEX
Turf Groomer Drive Assembly
Disassembly and Assembly . . . . . . . . . . . 10-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Turf Groomer Drive Belt
Removal and Installation . . . . . . . . . . . . . 10-17
Turf Groomer Driven Assembly
Disassembly and Assembly . . . . . . . . . . . 10-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Turf Groomer Repair . . . . . . . . . . . . . . . . . . . 10-17
Turf Groomer Shaft Assembly
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . 10-27
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
V
Vertical Reel and Soft-Touch Brush
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Volatile Materials Storage . . . . . . . . . . . . . . . . . 1-9
W
Waste Materials
Safe Disposal . . . . . . . . . . . . . . . . . . . . . . . 1-10
Wheel Hubs and Bearings
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Wiring Harness
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Work Area
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
IX-5
IX
INDEX
IX
IX-6 4157082 First Edition
Jacobsen, A Textron Company
11108 Quality Drive, Charlotte, NC 28273 www.Jacobsen.com
800-848-1636
Equipment from Jacobsen is built to exacting standards ensured by ISO 9001 and ISO 14001 registration at all of our manufacturing locations.
A worldwide dealer network and factory trained technicians backed by Jacobsen Parts Xpress provide reliable, high-quality product support.

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