HR-5111™

Rotary Mower
Technical/Repair Manual
69116
 When Performance Matters.™

HR-5111™
Rotary Mower
Technical/Repair Manual
69116

!
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.

©2009 Jacobsen, A Textron Company. All rights reserved.

 Foreword

General California
This manual provides detailed information and Proposition 65 Warning
procedures to safely repair and maintain the following:
Jacobsen HR-5111 rotary mowers and associated
accessory attachments
! WARNING
Certain vehicle components contain or emit
This manual is intended to introduce and guide the user
chemicals known to the State of California to
through the latest factory-approved troubleshooting and
cause cancer and birth defects or other
repair techniques and practices.
reproductive harm.
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 Trademark Acknowledgement
information on these topics.
Jacobsen acknowledges the following trademarks for
THE INFORMATION CONTAINED IN THIS MANUAL IS
company names or products mentioned within this
BASED ON MACHINES MANUFACTURED UP TO THE
publication:
TIME OF PUBLICATION. JACOBSEN RESERVES THE
RIGHT TO CHANGE ANY OF THIS INFORMATION Lubriplate® is a trademark of Fiske Brothers Refining Co.
WITHOUT NOTICE. Loctite® and Permatex® are trademarks of Henkel
Corporation.

4203780 First Edition 3

FOREWORD

How to Use This Manual Quick Reference Specifications

This manual is designed to provide multiple ways to A list of all machine specifications can be found in
locate and access repair information. Chapter 2 Specifications and General Information. This is
a list of all specifications from each chapter, combined
Read each section in entirety before beginning a
and listed in one place for easy reference.
procedure. Proper understanding of machine operation
and components is the key to successful diagnostics and
repair. Warnings and Cautions
Make use of special information features with in this Warning and Caution indicators are located throughout
manual in order to be better prepared to perform repairs. the manual at specific points of interest. These notices
Always follow manual procedures and safety guidelines. are given to prevent personal injury, death and/or
Never take shortcuts. equipment damage. Always heed these notices, and
practice common sense when performing any
Table of Contents maintenance or repair procedure.

Major machine components or topics of interest are

separated into specific chapters. Each manual lists these Notes
chapters in a main Table of Contents. Special notes are given in order to draw attention to
detailed instructions. These notes are intended to give
Chapter Table of Contents further important information regarding the machine
and/or a step in a procedure.
Each chapter begins with a detailed Table of Contents
related to the specific machine component or system.
Troubleshooting
Use the Chapter Table of Contents to find specific
component or procedural information. 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
Index adjustment problem.
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.

Copyright 2009, Jacobsen, a Textron Company

“All rights reserved, including the right to reproduce this material or portions thereof in any form.”

4 4203780 First Edition

 Table of Contents

Safety 1
Specifications and
General Information 2
Engine 3
Electrical 4
Hydrostatic Power Train 5
Hydraulics 6
Steering 7
Cutting Units 8
Accessories and Miscellaneous
Repair 9

4203780 First Edition 5

 Chapter 1

Safety

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1
Prepare for the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Inspect Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Keep Work Area Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Keep Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Park Mower Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Support Machine Securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Use Compressed Air and Air Tools Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Handle Fuel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Service Hydraulic System Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Service Cooling System Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Service Electrical Components Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

4203780 First Edition 1-1

 SAFETY

Introduction Safety Notices

Safety is the most important element of any repair Throughout this manual, the following key safety words
procedure. Knowledge of the procedure to be performed will be used to alert the reader of potential hazards.
and safe work habits are essential to preventing death, Become familiar with these words and their meaning.
personal injury, or property damage. Use the following Take all precautions to avoid the hazards described.
statements as a common-sense guide to proper work

!
and tool-use habits.
1 Prepare for the Job
This safety alert symbol is used to
alert you to potential hazards.

Preparation is essential to complete a procedure in a

safe and efficient manner.
• Wear proper clothing. Loose or baggy clothing could ! DANGER
become tangled in moving parts. Indicates an imminently hazardous situation
• Use eye/face protection. Always use proper eye/face which, if not avoided, WILL result in death or
protection to protect your eyes from flying debris or serious injury.
chemical splatters.
• Wear protective footwear. Wear safety shoes
(steel-toe) to protect your feet from falling objects. ! WARNING
• Use gloves when handling parts. Parts may have
sharp edges or may be hot. Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious
• Remove jewelry prior to servicing electrical systems. injury.
• 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
! CAUTION
needed parts and materials before beginning the Indicates a potentially hazardous situation which,
procedure. if not avoided, MAY result in minor or moderate
• Allow machine to cool. Many components can get hot injury and property damage. It may also be used
during operation. Be sure to allow enough time for to alert against unsafe practices.
components to cool before beginning service.
• Prepare proper work-space lighting. A well-lit work
area can make the job easier. NOTICE
• Follow procedures and safety warnings. Service
Indicates a potentially hazardous situation which,
procedures are written to be as safe and efficient as
if not avoided, MAY result in property damage. It
possible. Never take shortcuts.
may also be used to alert against unsafe
• Be prepared for emergencies. Accidents can happen, practices.
even under the best conditions. Fire extinguishers
and first aid kits should be well maintained and easily
accessible. Safety Label Locations
Become familiar with machine safety labels and
locations. The following illustrations show safety label
locations on the machine.
See Figure 1-1.

1-2 4203780 First Edition

 SAFETY

1
3

6 7
5 8
9
10
17
16

15
11

14 12
13

TN1767, TN1770
Figure 1-1

4203780 First Edition 1-3

 SAFETY

1 2

1 3

4 5

6
7

1-4 4203780 First Edition

 SAFETY

10 11

1
12
13

14

15

16 17

4203780 First Edition 1-5

 SAFETY

Inspect Safety Labels Park Mower Safely

Safety decals are critical to the safe operation of the See Figure 1-2.
mower. Inspect the mower for any damaged, missing, or
unreadable decals. Replace decals as needed before ! WARNING
placing the mower back in service.
Before cleaning, adjusting, or repairing this
equipment, disengage all drives, engage park

1 Keep Work Area Clean

A clean, organized, well-lit work area is important to
brake, and stop engine to prevent injuries.
When performing maintenance other than
promote safe working conditions. adjustments that require the engine to be
running, disconnect the battery negative cables
• Keep floor clean of debris and clear of parts and
to prevent accidental starting and bodily injury.
tools.
• Clean up any spilled fuel, oil, and/or chemicals
immediately. 1. Park the mower on a solid, level surface.
• Store all air hoses and electrical cords properly when
not in use. 2
1
Keep Work Area Well Ventilated

! WARNING
3

Never operate the engine without proper

ventilation; exhaust fumes can be fatal if inhaled.

Certain test and adjustment procedures require the

engine to be running. Be sure work area is well
TN1990
ventilated; never run the engine in an enclosed area.
Figure 1-2

Use Proper Eye and Face 2. Disengage front and wing deck enable switches (3).
3. Disengage PTO switch (2).
Protection
4. Lower the cutting units by moving joysticks (1)
forward.
! WARNING 5. Engage the park brake.
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.
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 TN1906
offered by safety glasses alone. Figure 1-3
• Unvented Goggles: Unvented goggles offer 6. Move key switch (4) to OFF position, and remove key.
protection from chemical splashes and vapors.

1-6 4203780 First Edition

 SAFETY

Use Lifting Equipment Safely Use Compressed Air and Air

Tools Safely
! WARNING
Always check the lifting capacity and condition of ! WARNING
hoists, slings, cables, or chains before use. Always wear approved eye and ear protection
Using underrated or worn lifting components can while using compressed air. Misuse of
result in death or serious injury. compressed air could result in death or serious
injury.
1
• Always use a lifting device with a lifting capacity • When using air nozzles, air pressure should
greater than the weight of the item being lifted. not exceed 30 psi (206.8 kPa).
• Secure the load to the lifting device using cables, • Never direct air nozzles or tools at a person.
chains, or slings rated to handle the load being lifted.
• Never point air nozzles directly at skin.
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 • Compressed air is a useful tool when used in a safe
the load. manner.
• When using a lifting device, always connect the load • Always use eye and ear protection while using
so it is balanced. compressed air and air tools.
• Always use a lifting device on a hard, level surface. • When using air tools, do not exceed the air pressure
• Lower the lifting device to the lowest point before rating for the tool.
moving. Move the load slowly. • When using an impact wrench, always use approved
• Always support the load as soon as possible; never impact sockets. Never use standard sockets on an
leave a load suspended in mid-air. impact wrench.
• Disconnect the air supply before changing air tool
attachments.
Support Machine Securely • Never point air nozzles or air tools at another person.
• Always maintain air tools properly.
! 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.

4203780 First Edition 1-7

 SAFETY

Service Tires Safely Handle Fuel Safely

Handle fuel with care—it is highly flammable.
! WARNING
An inflated tire contains explosive force. Use care
! WARNING
when handling wheels and tires. • Never remove the fuel cap from the fuel tank,
or add fuel, when the engine is running or

1 • Always wear safety glasses or goggles.

• Use proper lifting methods when working with wheels
while the engine is hot.
• Do not smoke when handling fuel. Never fill
or drain the fuel tank indoors.
and tires.
• Do not spill fuel. Clean spilled fuel
• When working on an inflated tire, never position
immediately.
yourself directly over the work area.
• Never handle or store fuel containers near an
• When dismounting or mounting tires, use a wheel
open flame or any device that may create
holder or tire machine. Use proper tire mounting tools
sparks and ignite the fuel or fuel vapors.
and equipment. Never use screwdrivers or makeshift
tools to force a tire on or off a wheel. • Be sure to reinstall and tighten fuel cap
securely.
• Be sure tire irons and mounting tools are free of
grease and oil. Grip them firmly. • Use an approved container; the spout must fit
inside the fuel filler neck. Avoid using cans
• Inspect wheel parts for rust, damage, or distortion.
and funnels to transfer fuel.
Never use wheels that are out-of-round, rusted, or
cracked.
• Never hammer on wheels with a steel hammer. Use Store fuel according to local, state, or federal ordinances
rubber-covered hammers. and recommendations from your fuel supplier.
• When inflating tires, always use an inflation cage. Never overfill or allow the tank to become empty.
Always stand away from the valve stem. Use clean, fresh fuel.
• Use accurate, tested inflation gauges to set air Do not fill above the fuel filler neck.
pressures.

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.

1-8 4203780 First Edition

 SAFETY

Handle Chemical Products Service Hydraulic System Safely

Safely
! WARNING
! WARNING The hydraulic system is under pressure, and the
Exposure to chemical products could result in oil may be hot!
serious injury. Handle chemical products with • Always allow the machine to cool completely
care. Refer to the chemical manufacturer’s
Material Safety Data Sheet (MSDS) for information
before performing service.
• Always relieve pressure in the hydraulic
1
regarding health hazards, safe handling, and system before performing service.
emergency response procedures. • Always use appropriate safety equipment and
clothing to protect exposed skin and eyes
Routine service often requires the use of various from high-pressure oil.
chemical products, including lubricants and cleaning • Tighten all connections to proper
solutions. Many of these chemicals are flammable and specifications before applying pressure.
can pose health risks if not handled properly. • Never use bare hands to check for leaks! Oil
• Never mix chemicals. Mixing chemicals can produce under pressure can penetrate the skin, and
toxic or explosive results. can cause gangrene within a few hours if not
• Follow the manufacture’s recommendations for safe properly removed. Use a piece of cardboard
usage and handling of the product. to check for leaks.
• Various materials may pose a health hazard if used Failure to follow appropriate safety precautions
incorrectly. A Material Safety Data Sheet (MSDS) may result in death or serious injury.
contains important information regarding proper
handling and health hazards, as well as emergency Always dispose of used hydraulic oil properly. (See
response procedures. Contact the chemical “Dispose of Waste Materials Safely” on page 1-10.)
manufacturer to obtain an MSDS for the chemical
product.
Service Cooling System Safely

! WARNING
Engine coolant is hot and under pressure! Allow
the cooling system to cool completely before
performing service.
Rotate the filler cap 1/2-turn counterclockwise
and allow pressure to vent before removing filler
cap.
Failure to follow appropriate safety precautions
may result in death or serious injury.

! WARNING
Contact with anti-freeze can damage your skin.
Use gloves when working with anti-freeze. If you
come in contact with anti-freeze, wash it off
immediately.

Always dispose of used engine coolant properly. (See

“Dispose of Waste Materials Safely” on page 1-10.)

4203780 First Edition 1-9

 SAFETY

Service Electrical Components

Safely

! WARNING
Always disconnect the negative terminal first and
positive terminal last. Connect positive terminal
1 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.

Dispose of Waste Materials

Safely
Routine service can produce waste products such as
used oil, coolant grease, and used batteries.
If not handled properly, these materials can pose a threat
to the environment.
Collect fluids in well-marked, approved storage
containers. 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 4203780 First Edition

 Chapter 2

Specifications and General Information

Mower Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Optional Machine Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3
2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Quick Reference Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Standard Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Inch Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Metric Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

4203781 First Edition 2-1

 SPECIFICATIONS AND GENERAL INFORMATION

Mower Identification Serial Number

See Figures 2-1 through 2-5. An identification plate (1) listing the serial number (3) is
attached to the frame of the tractor and is located just
ahead of the rear axle on the right side. Always provide
the serial number of the unit when ordering replacement
parts or requesting service information. A label attached
to the base of the operator’s seat (2) indicates the mower
weight (4) and engine power output (5).
2

2 6

TN1767
Figure 2-1

TN1858
Figure 2-4

3
7

TN1855
Figure 2-2

TN1859
Figure 2-5

4
5

TN1857
Figure 2-3

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 SPECIFICATIONS AND GENERAL INFORMATION

Engine Serial Number Optional Machine Accessories

The engine serial number (6) is located on a plate This manual is structured to cover all basic machine
attached to the top of the rocker arm cover which also components and repair. The addition of accessories can
includes the engine model number and the engine code affect certain troubleshooting, adjustment, and repair
number. There is also an engine data tag (7) attached to procedures.
the top of the rocker arm cover and information that can
be found on the plate includes: valve adjustment
specifications, injector timing information, engine idle Component Location
speed and engine displacement. See Figures 2-6 and 2-7.

! CAUTION
Become familiar with operator controls, machine
components, and correct operating procedures
2
before beginning repair procedures.

1
3
2
10
4

9
7

8
TN1767
1 Seat 6 Left Cutting Unit
2 Control Panel 7 Center Cutting Unit
3 Steering Wheel 8 Right Cutting Unit
4 Traction Pedal 9 Fuel Tank
5 Brake Pedal 10 Hood
Figure 2-6: Component Location—Right Side

4203781 First Edition 2-3

 SPECIFICATIONS AND GENERAL INFORMATION

2
6

5 4

TN1770
1 OPS 4 4WD Valve
2 Hydraulic Oil Tank 5 Front Differential
3 Rear Wheel Motor (2) 6 Battery
Figure 2-7: Component Location—Left Side

2-4 4203781 First Edition

 SPECIFICATIONS AND GENERAL INFORMATION

Specifications
Quick Reference Specifications
Electrical

Test and Adjustment Specifications

Resistance Across Solenoid Coil—Front Mow ohms 7.1 ± 10%
Solenoid Coil at 68° F
Resistance Across Solenoid Coil—Right Mow ohms 7.1 ± 10%
Solenoid Coil at 68° F
Resistance Across Solenoid Coil—
Left Mow Solenoid Coil at 68° F
ohms 7.1 ± 10% 2
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
4WD Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
Diff Lock Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
4WD Rev Solenoid Coil at 68° F
Fuel Level Sender Resistance Between Terminals at ohms 32 ± 10%
Full Position
Fuel Level Sender Resistance Between Terminals at ohms 256 ± 10%
Empty Position
Resistance Across Fuel Shutoff Pull-In Coil at 68° F ohms 0.5 ± 10%
Resistance Across Fuel Shutoff Hold-In Coil at 68° F ohms 15 ± 10%
Resistance Across Cruise Control Magnet at 68° F ohms 4.2 ± 10%
Mow Solenoids Nut Torque lb-ft (N·m) 5—7 (6.8—9.5)
4WD Solenoids Nut Torque lb-ft (N·m) 4—5 (5.4—6.8)

Hydrostatic Power Train

Test and Adjustment Specifications

Traction Pump Flow gpm (Lpm) 35 (132) at 2850 rpm
Charge Pump Flow gpm (Lpm) 10.5 (40) at 2850 rpm
Forward System Relief Pressure psi (bar) 3625 (250) at 2850 rpm
Reverse System Relief Pressure psi (bar) 3625 (250) at 2850 rpm
Charge Pressure psi (bar) 275—285 (19—20) @2850 rpm
Hydrostatic Leakage Percentage Ranges 0—10% = Good
11—20% = Marginal
21% and Beyond = Bad

4203781 First Edition 2-5

 SPECIFICATIONS AND GENERAL INFORMATION

Repair Specifications
Front Axle Motor—Shaft Seal Installation Depth in. (mm) 7/32 (5.5)
Front Axle Motor—Backplate Assembly Screw Torque lb-ft (N·m) 15—18 (20—24)
Differential Lock Assembly—Fork Screw Torque lb-ft (N·m) 19 (26)
Differential Lock Assembly—Housing Screw Torque lb-ft (N·m) 37 (51)
Input Bevel Pinion Assembly—Housing Screw Torque lb-ft (N·m) 37 (51)
Drive Axle Reducer Assembly—Axle Shaft-to-Brake lb-ft (N·m) 29 (40)
Disk Screw Torque
Drive Axle Reducer Assembly— lb-ft (N·m) 37 (51)
Housing-to-Differential Gear Case Screw Torque
2 Drive Axle Reducer Assembly—Brake
Caliper-to-Housing Screw Torque
lb-ft (N·m) 37 (51)

Differential Assembly—Ring Gear-to-Differential lb-ft (N·m) 37 (51)

Screw Torque
Differential Assembly—Housing Screw Torque lb-ft (N·m) 37 (51)
Rear Wheel Motor—Valve Housing Screw Torque lb-ft (N·m) 36—37 (49—50)
Rear Wheel Motor Hub Nut Torque lb-ft (N·m) 175—200 (237—271)

Hydraulics

Test and Adjustment Specifications

Front Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Left Wing Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Right Wing Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Lift/Steer Pump Flow gpm (Lpm) 7.9 (30) at 2800 rpm
Hydraulic Leakage Percentage Ranges 0—10% = Good
11—20% = Marginal
21% and Beyond = Bad
Lift System Relief Valve Pressure Setting psi (bar) 1500 (103)
Steer System Relief Valve Pressure Setting psi (bar) 1500 (103)
Front Cutting Unit Deck Valve System Relief Valve psi (bar) 2700—3300 (186—228)
Pressure Setting
Left Wing Cutting Unit Deck Valve System Relief Valve psi (bar) 2700—3300 (186—228)
Pressure Setting
Right Wing Cutting Unit Deck Valve System Relief psi (bar) 2700—3300 (186—228)
Valve Pressure Setting
Cutting Unit Motor Case Drain Rate Less than 1 pint (0.47 L) per minute at
2000 psi (138 bar)

2-6 4203781 First Edition

 SPECIFICATIONS AND GENERAL INFORMATION

Repair Specifications
Gear Pump—Rear Cover-to-Pump Body Bolt Torque lb-ft (N·m) 20 (27)
Mow Solenoid Valve Torque lb-ft (N·m) 24—26 (32.5—35.3)
Mow Solenoid Valve Nut Torque lb-ft (N·m) 5—7 (6.8—9.5)
Blade Brake Relief Valve Torque lb-ft (N·m) 33—37 (44.7—50.2)
Deck Valve System Relief Valve Torque lb-ft (N·m) 24—26 (32.5—35.3)
Hydraulic Oil Tank Capacity gal (L) 17 (64.3)
Front Lift Cylinder Rod Nut Torque lb-ft (N·m) 50 (68)
Wing Lift Cylinder Rod Nut Torque lb-ft (N·m) 95 (129)

Steering 2
Test and Adjustment Specifications
Steering System Leakage Test—Cylinder Leakage pt (L) Zero—Nominal Amount
Rear Axle Alignment Toe-In Measurement in. (mm) 0.0625 (1.6)
Rear Axle Spindle Arm-to-Axle Stop Measurement in. (mm) 0.030—0.060 (0.76—1.5)

Repair Specifications
Steering Wheel Nut lb-ft (N·m) 28—30 (38—41)
Steering Valve Rotor-to-Stator Clearance in. (mm) 0.003 (0.08)
Steering Valve Metering Assembly Screw Torque lb-in. (N·m) 11—13 (1.2—1.5)
Steering Valve Port Cover-to-Port Manifold Nut Torque lb-ft (N·m) 18—22 (24—30)
Steering Cylinder Ball Joint-to- Steering Arm Torque lb-ft (N·m) 40 (54)
Tie Rod Ball Joint-to-Steering Arm Torque lb-ft (N·m) 30 (41)

Cutting Units

Repair Specifications
Blade Retaining Screw lb-ft (N·m) 75 (100)
Adapter Screws lb-ft (N·m) 35–40 (47–54)

Accessories and Miscellaneous

OPS Mounting Hardware

Mounting Hardware Torque lb-ft (N·m) 135—165 (183—224)

Fuel Tank
Capacity gal (L) 20 (75.7)

Front Tires
Size 26 x 12.00-12
Type 6-Ply
Air Pressure psi (bar) 16—20 (0.55—0.69)
Mounting Bolt Torque lb-ft (N·m) 100—120 (135—162)

4203781 First Edition 2-7

 SPECIFICATIONS AND GENERAL INFORMATION

Rear Tires
Size 23 x 10.50-12
Type 4-Ply
Air Pressure psi (bar) 8—10 (55—69)
Mounting Bolt Torque lb-ft (N·m) 40—50 (54—68)

Mower Speed
Transport—2WD mph (km/h) 0—15 (0—24)
Transport—4WD mph (km/h) 0—8.4 (0—13.5)

2 Mowing
Reverse
mph (km/h)
mph (km/h)
0—7.5 (0—12)
0—6 (0—9.7)

Brakes
Brake Pedal Free Travel in. (mm) 0.125 (3)
Park Brake Lever Force lb (kg) 36—42 (16—19)
Brake Caliper Nut Torque lb-ft (N·m) 37 (51)

Traction Pedal
Traction Pedal Mounting Bracket Nut Torque lb-ft (N·m) 25 (34)
Traction Pedal Ball Joint Nut Torque lb-ft (N·m) 50 (68)

Engine
Manufacturer/Model Kubota® Tier 2/V2203-DI-B
Engine Type 4-stroke, diesel
Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45)
Number of Cylinders/Configuration 4, in-line
Displacement cu in. (cc) 131.1 (2148)
Bore x Stroke in. (mm) 3.43 x 3.64 (87 x 92.4)
Power Output hp (kW) 49 (36.5) @ 2500 rpm
Firing Order 1-3-4-2
Compression Ratio 19-1
Injection Timing (Before T.D.C.) degrees 18°
Cooling System liquid cooled
Cooling System Capacity qt (L) 8 (7.6)
Idle Speed 850-900 rpm
Maximum Speed (No Load) 3050 rpm
Oil Sump Capacity qt (L) 10 (9.5)
Alternator 12 volt, 45 amp
Dry Weight lb (kg) 397 (180)

2-8 4203781 First Edition

 SPECIFICATIONS AND GENERAL INFORMATION

Weights and Dimensions

Overall Weight lb (kg) 3780 (1718)
Width of Cut in. (mm) 134 (3404)
Overall Width in. (mm) 139 (3531)
Overall Height with OPS in. (mm) 81 (2057)
Overall Height with OPS & Canopy in. (mm) 89 (2260)
Overall Length in. (mm) 144 (3658)

4203781 First Edition 2-9

 SPECIFICATIONS AND GENERAL INFORMATION

Standard Torque Values

NOTICE NOTE
Jacobsen uses Grade 5 plated bolts as standard, unless
All torque values included in these charts are
otherwise noted. When tightening plated bolts, use the
approximate and are for reference only. Use of
value given for lubricated.
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
AMERICAN NATIONAL STANDARD FASTENERS

SIZE UNITS GRADE 5 GRADE 8 SIZE UNITS GRADE 5 GRADE 8

Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
#6-32 in-lb (Nm) – 20 (2.3) – – 7/16-14 ft-lb (Nm) 37 (50.1) 50 (67.8) 53 (71.8) 70 (94.9)
#8-32 in-lb (Nm) – 24 (2.7) – 30 (3.4) 7/16-20 ft-lb (Nm) 42 (56.9) 55 (74.6) 59 (80.0) 78 (105)
#10-24 in-lb (Nm) – 35 (4.0) – 45 (5.1) 1/2-13 ft-lb (Nm) 57 (77.2) 75 (101) 80 (108) 107 (145)
#10-32 in-lb (Nm) – 40 (4.5) – 50 (5.7) 1/2-20 ft-lb (Nm) 64 (86.7) 85 (115) 90 (122) 120 (162)
#12-24 in-lb (Nm) – 50 (5.7) – 65 (7.3) 9/16-12 ft-lb (Nm) 82 (111) 109 (148) 115 (156) 154 (209)
1/4-20 in-lb (Nm) 75 (8.4) 100 (11.3) 107 (12.1) 143 (16.1) 9/16-18 ft-lb (Nm) 92 (124) 122 (165) 129 (174) 172 (233)
1/4-28 in-lb (Nm) 85 (9.6) 115 (13.0) 120 (13.5) 163 (18.4) 5/8-11 ft-lb (Nm) 113 (153) 151 (204) 159 (215) 211 (286)
5/16-18 in-lb (Nm) 157 (17.7) 210 (23.7) 220 (24.8) 305 (34.4) 5/8-18 ft-lb (Nm) 128 (173) 170 (230) 180 (244) 240 (325)
5/16-24 in-lb (Nm) 173 (19.5) 230 (26.0) 245 (27.6) 325 (36.7) 3/4-10 ft-lb (Nm) 200 (271) 266 (360) 282 (382) 376 (509)
3/8-16 ft-lb (Nm) 23 (31.1) 31 (42.0) 32 (43.3) 44 (59.6) 3/4-16 ft-lb (Nm) 223 (302) 298 404 315 (427) 420 (569)
3/8-24 ft-lb (Nm) 26 (35.2) 35 (47.4) 37 (50.1) 50 (67.8) 7/8-14 ft-lb (Nm) 355 (481) 473 (641) 500 (678) 668 (905)

Metric Fastener Torque Values

METRIC FASTENERS
Non-Critical
Fasteners
4.6 8.8 10.9 12.9
into
SIZE UNITS Aluminum
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry

M4 Nm (in-lb) – – – – – – 3.83 (34) 5.11 (45) 2.0 (18)

M5 Nm (in-lb) 1.80 (16) 2.40 (21) 4.63 (41) 6.18 (54) 6.63 (59) 8.84 (78) 7.75 (68) 10.3 (910 4.0 (35)
M6 Nm (in-lb) 3.05 (27) 4.07 (36) 7.87 (69) 10.5 (93) 11.3 (102) 15.0 (133) 13.2 (117) 17.6 (156) 6.8 (60)
M8 Nm (in-lb) 7.41 (65) 9.98 (88) 19.1 (69) 25.5 (226) 27.3 (241) 36.5 (323) 32.0 (283) 42.6 (377) 17.0 (150)
M10 Nm (ft-lb) 14.7 (11) 19.6 (14) 37.8 (29) 50.5 (37) 54.1 (40) 72.2 (53) 63.3 (46) 84.4 (62) 33.9 (25)
M12 Nm (ft-lb) 25.6 (19) 34.1 (25) 66.0 (48) 88.0 (65) 94.5 (70) 125 (92) 110 (81) 147 (108) 61.0 (45)
M14 Nm (ft-lb) 40.8 (30) 54.3 (40) 105 (77) 140 (103) 150 (110) 200 (147) 175 (129) 234 (172) 94.9 (70)

2-10 4203781 First Edition

 SPECIFICATIONS AND GENERAL INFORMATION

Page Intentionally Blank

4203781 First Edition 2-11

 SPECIFICATIONS AND GENERAL INFORMATION

2-12 4203781 First Edition

 Chapter 3

Engine

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Kubota V2203-DI-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Solenoid Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-6
3-6
3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Radiator/Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Throttle Cable and Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

4203780 First Edition 3-1

 ENGINE

Specifications
General Engine Specifications

Engine
Manufacturer/Model Kubota® Tier 2/V2203-DI-B
Engine Type 4-stroke, diesel
Fuel Requirement No. 2-D diesel fuel (Cetane Rating-45)
Number of Cylinders/Configuration 4, in-line
Displacement cu in. (cc) 131.1 (2148)
Bore x Stroke in. (mm) 3.43 x 3.64 (87 x 92.4)
Power Output hp (kW) 49 (36.5) @ 2500 rpm
Firing Order 1-3-4-2

3 Compression Ratio
Injection Timing (Before T.D.C.)
19:1
18°
Cooling System liquid cooled
Cooling System Capacity qt (L) 8 (7.6)
Idle Speed 850–900 rpm
Maximum Speed (No Load) 3050 rpm
Oil Sump Capacity qt (L) 10 (9.5)
Alternator 12 volt, 45 amp
Dry Weight lb (kg) 397 (180)

Repair Specifications

Specification
Hydrostatic Pump Drive Plate Screw lb-ft (N·m) 37 (51)

3-2 4203780 First Edition

 ENGINE

Component Location
Kubota V2203-DI-B
See Figures 3-1 and 3-2.

1 5
2 3 4
6

3
10
11 9

8 7

12

TN2003, TN2036
1 Hydraulic Oil Cooler 7 Oil Pressure Sending Unit
2 Radiator 8 Starter Motor
3 Thermostat 9 Alternator
4 Air Cleaner Assembly 10 Fan Drive Belt
5 Coolant Overflow Reservoir 11 Engine Temperature Sensor
6 Hydraulic Oil Filters 12 Fuel Pump
Figure 3-1: Component Location—Right Side

4203780 First Edition 3-3

 ENGINE

8 5

7
TN2004, TN2005
1 Hydraulic Tank 5 Oil Filler Cap
2 Air Cleaner Service Switch 6 Oil Filter
3 Radiator Cap 7 Fuel Filter
4 Throttle Cable 8 Fuel Shutoff Solenoid
Figure 3-2: Component Location—Left Side

3-4 4203780 First Edition

 ENGINE

Checks and Adjustments 6. Move throttle lever to slow idle position.

Throttle Cable
13
Adjustment 10 11 12
See Figures 3-3 through 3-5.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

18 17 15

1 16
2 1 14

Figure 3-5
TN2011 3
1 3
7. Loosen clamp nuts (18) and position cable in clamp
4 so that governor throttle lever (15) contacts the idle
1
TN1990 screw (14). Tighten nuts (18).
Figure 3-3 8. Push throttle lever to full open position and check to
2. Remove four knobs (2) and eight screws (1), and see that governor throttle lever (15) contacts the high
slide the console cover boot (4) back. Lift instrument speed stop (13).
panel (3) up and turn counterclockwise to clear the 9. Verify the engine rpm (idle 750–800 rpm and high
lever handles. speed 2800 ± 50 rpm) at engine crankshaft using a
photo tach.
10. Adjust ball joint (12) to obtain full governor throttle
5 lever movement by backing off nut (10) and washer
(11) and removing nut (16) and washer (17).
7 Disconnect ball joint from governor lever arm and
6 turn clockwise or counterclockwise as needed to
adjust.
11. Assemble ball joint to governor throttle lever and
tighten hardware securely.
12. Install the instrument panel by reversing the order of
removal.
9

TN2008
Figure 3-4
3. Place throttle lever (5) in slow idle position and check
throttle cable (6) and ball joint (7) for wear.
4. Check throttle for ease of movement and adjust
throttle tension with throttle tension adjuster (8).
5. Be sure throttle lock nuts (9) are tightened.

4203780 First Edition 3-5

 ENGINE

Fuel Solenoid Rod Purging the Fuel System

Adjustment Adjustment
See Figure 3-6. See Figure 3-7.

!
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) CAUTION
2. Raise the hood. Do not purge fuel system when engine is hot.

NOTE
Whenever the fuel filter or fuel lines are removed, the fuel
tank is completely emptied, or the engine has not been
5 6 used for an extended time, purge the system of air.
1. Park the mower safely. (See “Park Mower Safely” on
1 3 page 1-6.)
3 2 4
2. Raise the hood.

NOTE
Be sure the fuel tank is filled with clean, fresh diesel fuel
8 7 before performing a purge of the fuel system.
9
TN2012
Figure 3-6 1

NOTE 2
The fuel solenoid (1) will not activate without the parking
brake engaged and PTO switch disengaged. Turn key to
start position only long enough to activate solenoid. Do
not start engine without operator in seat.
3. Measure fuel solenoid rod (3) at points (8 and 9).
4. The distance at point (8) should be 4.30 in.
(110.50 mm), and the distance at point (9) should be
4.70 in. (119.40 mm).
5. Loosen nuts (2 and 4) and disconnect solenoid clevis 3
(7) from fuel solenoid bracket (6). Turn solenoid
clevis either clockwise to decrease distance or
counterclockwise to increase distance. Tighten nuts
(2 and 4) and measure distance again. Connect
solenoid clevis to fuel solenoid bracket. TN1994
6. A distance of 0.03125–0.0625 in. (0.8–1.8 mm) must Figure 3-7
be maintained between fuel solenoid bracket (6) and
3. Loosen the air vent screw (3) at the top of the filter by
casting boss (5) when the ignition key is in the off
turning it counterclockwise two turns. Place a
position.
suitable container under the filter to catch the fuel
that will flow from the screw hole.
4. Turn the ignition switch to the on position to allow the
fuel pump to operate.
5. When the bubbles disappear from fuel coming out of
the air vent screw hole, tighten air vent screw and
turn ignition switch to the off position.
6. Open the air vent plug (2) on the fuel injection pump.

3-6 4203780 First Edition

 ENGINE

7. Turn the ignition switch to the on position to allow the Repair

fuel pump to operate.
8. Close the air vent plug when bubbles disappear from
the fuel flow and turn the ignition switch to the off
Fan Belt
position.
Removal and Installation
! WARNING See Figures 3-8 and 3-9.

The engine may start during this process. Be NOTE

careful of injury due to moving components. If Inspect and adjust the new engine belt after the first 50
the engine starts, continue purging the remaining hours of operation. Check and adjust annually thereafter.
fuel injector lines. 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
9. Loosen the high pressure fuel injector line nuts at the 2. Raise the hood.
four fuel injectors (1), one at a time while, cranking 3. Disconnect the battery negative (–) cable at the
the engine. battery.
10. When the bubbles disappear, tighten the fuel injector
line nut and repeat the process for the remaining
3
injectors.
11. When all the fuel injector lines have been purged and 1
the engine is running, listen to the engine. If the
engine is misfiring, repeat steps 9 and 10 for all the 2
3
fuel injector lines.

TN2013
Figure 3-8
4. Loosen screws (2 and 4) and push the alternator (3)
toward the engine to loosen the belt (1).

4203780 First Edition 3-7

 ENGINE

Air Cleaner Assembly

Removal and Installation
6 3 See Figures 3-10 and 3-11.

! CAUTION
• Do not open the air cleaner assembly for
inspection or cleaning. Unnecessary removal
of the filter increases the risk of injecting dust
and other impurities into the engine.
• Removal and service of the filter element is
required when the air service indicator light
1
comes on during normal operation.
5 • Do not remove air filter with engine running.

3 Figure 3-9
TN1113
NOTES
5. Remove the fan belt (1) from the alternator (3), • The air cleaner on this engine is a dry type; never
coolant pump (6), and crankshaft pulley (5). apply oil to it.
• It is recommended to remove and clean the dust cap
Installation Note daily (in dusty conditions).
Install the fan drive belt by reversing the order of removal. 1. Park the mower safely. (See “Park Mower Safely” on
6. Adjust the belt tension by loosening the alternator page 1-6.)
mounting screws (2 and 4) and pulling the alternator
(3) against the belt (1) until the proper tension is
achieved.
7. Measure the belt tension at the midpoint between 1
pulleys. Adjust the alternator belt to 0.28 to 0.35 in. 2
(7 to 9 mm) with a deflection of 22 lb.
See the engine manufacturer’s manual for further
information.

TN2002
Figure 3-10
2. Remove the retaining clamp (3) and ring fastener (2),
and remove the air cleaner dust cap (1).
3. Using damp, lint-free cloths, thoroughly clean the
inside of the dust cap.

3-8 4203780 First Edition

 ENGINE

5
4
4
3
5

2 6
7
1

Figure 3-12
TN1996 3
4. Remove the muffler clamp and hardware (2) from the
TN2001 exhaust pipe (1).
Figure 3-11 5. Remove four nuts (4), isolation mounts (5), screws
4. Remove the wing nut and gasket (4), and slide the (7), and eight flat washers (3). Remove the muffler
element (5) out of the assembly. (8) from the two muffler brackets (6) and exhaust
pipe (1).
Installation Notes
• Install air cleaner in the reverse order of removal.
• If a new element is installed, use a new gasket (4).
10
Muffler 9

Removal, Inspection, and Installation

See Figures 3-12 and 3-13.

! CAUTION
Do not attempt to service the exhaust system
when the engine is hot. Serious personal injury
can occur.
11
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
3. Raise the hood.
TN2010
Figure 3-13
6. Remove the four bolts (9) securing the exhaust pipe
(11) to the exhaust manifold (10).
7. Inspect the exhaust system for cracks, holes, and
distortion. Replace exhaust gaskets and exhaust
clamps.

4203780 First Edition 3-9

 ENGINE

Installation Notes
• Install the muffler in the reverse order of removal.
• Install new gaskets during installation.

Exhaust Manifold
Removal and Installation
See Figure 3-14.

! CAUTION
Do not attempt to service the exhaust system
when the engine is hot. Serious personal injury
can occur.

3 1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Allow the engine to cool completely.
3. Raise the hood.
4. Remove the muffler. (See “Muffler” on page 3-9.)

3
1
2

TN2014
Figure 3-14
5. Remove eight nuts (1) and lock washers (2).
6. Tilt exhaust manifold (3) upward and remove from
engine.

Installation Notes
• Clean the gasket surfaces.
• Install the exhaust manifold by reversing the order of
removal.
• Use new gaskets during installation.

3-10 4203780 First Edition

 ENGINE

Radiator/Hydraulic Oil Cooler

Removal and Installation
See Figure 3-15.

14 15
11 12 13
10
7
16
8 17
5 9 18
6 11

5 11
12 18
17
12
3
12
4 19
20
8
3 22 21
2 26
1
23

24

25

TN1998
1 Screw (4) 10 Radiator 19 Wing Nut (2)
2 Lock Washer (4) 11 Nut (8) 20 Shoulder Bolt (2)
3 Flat Washer (4) 12 Lock Washer (10) 21 Hydraulic Oil Cooler Pivot Plate
4 Radiator Shroud 13 Radiator Support Bracket (2) 22 Petcock
5 Seal (2) 14 Hydraulic Oil Cooler 23 Weather Strip
6 Base Seal 15 Carriage Bolt (2) 24 Screw (2)
7 Hose Clamp 16 Lock Nut (2) 25 Screw (6)
8 Upper Radiator Hose 17 Flat Washer (4) 26 Lower Radiator Hose
9 Engine Temperature Sensor 18 Hydraulic Oil Cooler Spacer (4)
Figure 3-15

4203780 First Edition 3-11

 ENGINE

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Lower mowing decks to ground.
3. Allow the engine to cool completely.
4. Raise the hood.

Hydraulic Oil Cooler Removal

See Figures 3-16 and 3-17.

NOTE
Label all hoses before removing to ensure correct 10 11
installation.
1. Cycle the lift levers to relieve system of any hydraulic
pressure.

3 1
2 12 13

3 TN2015
Figure 3-17
5. While supporting the hydraulic oil cooler, remove the
two lock nuts (10), flat washers (11), and hydraulic oil
4 cooler spacers (12).
6. Remove the hydraulic oil cooler (13).
5 6 7
Installation Note
Install the hydraulic oil cooler by reversing the order of
8 9 removal.

Radiator Removal
See Figures 3-18 through 3-20.

NOTES
TN2006
• It is not necessary to remove the hydraulic oil cooler
Figure 3-16 to remove the radiator.
2. Disconnect hose (2) from fitting (1). Cap and plug • Loosen wing nuts securing hydraulic oil cooler in
hose and fitting. place and tilt out of the way.
3. Disconnect hose (3) from fitting (4). Cap and plug
hose and fitting. ! WARNING
4. Remove the two wing nuts (8), lock washers (9), flat
Never remove the radiator cap when the coolant
washers (5), hydraulic oil cooler spacers (6), and
is hot. The engine must be shut down and cooled
screws (7).
before the radiator cap is removed. Very hot
coolant will be sprayed from the radiator if the
cap is loosened before the engine has cooled.
Serious personal injury can occur.

1. Drain cooling system, 8 qt (7.6 L).

a. Open access door at bottom of radiator.
b. Open petcock, remove radiator cap, and drain
coolant into a clean container.

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 ENGINE

7. Disconnect engine temperature sensor lead from

NOTE engine temperature sensor (11).
Label all hoses before removing to ensure correct 8. Loosen two clamps (13) and remove lower radiator
installation. hose (12).

1 3 4 5
2
6

14 17 18 19
15
16

20
7

8
3
TN2016
Figure 3-20
TN2009
Figure 3-18 9. Remove the two shoulder bolts (14), lock washers
(15), and nuts (16).
2. Loosen two hose clamps (1) and remove air intake
10. While supporting the radiator, remove the two screws
hose (2).
(17), lock washers (18), and nuts (19).
3. Disconnect overflow hose (8) from radiator and
11. Carefully remove the radiator (20).
secure out of the way.
4. Remove four screws (3), flat washers (4), and lock Radiator Installation
washers (5) that secure the base seal (6) and fan 1. Install the radiator by reversing the order of removal.
shroud (7) in place.
2. Inspect the weather strip and seal around the
5. Remove base seal and move fan shroud back over radiator and replace if worn or damaged.
fan.
3. With the lower radiator hose removed from radiator,
flush the inside of the radiator with fresh water.

9 10 ! CAUTION
Always use a mixture of antifreeze and fresh
water in the engine cooling system. Normally a
50/50 coolant mixture will provide freeze
protection to 37°F (3°C) and boil-over protection
11 in an efficient cooling system.

4. Fill the radiator with a 50/50 mixture of good quality

ethylene glycol-base antifreeze and clean fresh
water.
12 5. Install the radiator cap and start the engine following
13 the instructions in the “Safety and Operation Manual.”

TN2017
Figure 3-19
6. Loosen two clamps (9) and remove upper radiator
hose (10).

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 ENGINE

Installation Notes
! CAUTION • Install the thermostat by reversing the order of
removal.
Allow the engine coolant to completely cool
before removing the radiator cap. Hot coolant • Clean gasket surface.
sprayed from the cap can cause serious personal • Use a new gasket during installation.
injury. • Fill the radiator with a 50/50 mixture of good quality
ethylene glycol-base antifreeze and clean fresh
6. When the engine reaches normal operating water.
temperature, check and fill the coolant reservoir to
the hot full level. Throttle Cable and Control Lever
Thermostat Removal and Installation
See Figures 3-22 through 3-25.
Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on
See Figure 3-21. page 1-6.)
3 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
3. Raise the hood. 1 1
2
! WARNING
Never remove the radiator cap when the coolant
is hot. The engine must be shut down and cooled
before the radiator cap is removed. Very hot 1 3
coolant will be sprayed from the radiator if the
cap is loosened before the engine has cooled. 4
1
Serious personal injury can occur. TN1990
Figure 3-22
4. Drain the cooling system, 8 qt (7.6 L). 2. Remove four knobs (2) and eight screws (1), and
slide the console cover boot (4) back. Lift instrument
panel (3) up and turn counterclockwise to clear the
1 lever handles.

4 7

5 6
9

TN2018
Figure 3-21 10
5. Loosen hose clamp (1) and remove hose (2). TN2000
6. Remove two screws (4). Figure 3-23
7. Remove thermostat housing (3), gasket, and 3. Remove nut (5) and lock washer (6).
thermostat.

3-14 4203780 First Edition

 ENGINE

4. Disconnect and remove ball joint (10) from throttle Installation Notes
lever control (7) and throttle cable (9). • Install the throttle cable and control lever by reversing
5. Remove nut (8) and slide throttle cable through the order of removal.
frame. • When replacing a worn or broken throttle cable, route
the same as the old cable.
11 • Secure using existing cable clamps.
12 • After replacing, follow the adjustment procedure.
13 (See “Throttle Cable” on page 3-5.)
16
15 Fuel Filter
Removal and Installation
15 See Figures 3-26 and 3-27.
14 17
18 ! CAUTION
Diesel fuel is highly flammable. Handle with care.
Use an approved container with a spout that will
3
fit inside the fuel filler neck. Avoid using
unapproved containers to transport fuel. Keep all
19 fuel containers clean and closed when not in use.
20
19
TN1999
1. Park the mower safely. (See “Park Mower Safely” on
Figure 3-24 page 1-6.)
6. Remove lock nut (11), washer (12), and compression 2. Allow the engine to cool completely before servicing.
spring (13). 3. Disconnect the battery negative (–) cable at the
7. Remove nuts (19), lock washer (20), and screw (14). battery.
8. Remove throttle control lever (16), and disassemble
friction discs (15), throttle plate (17), and screw (18)
from lever.

28 22
21
23

26 27 25
24
TN1788
Figure 3-26
4. Turn the fuel outlet hose shutoff valve (1) clockwise
TN2011 until valve bottoms lightly. Valve is located on the
Figure 3-25 bottom of the fuel tank.
5. Thoroughly clean the fuel filter cover and area
9. Remove nut (24) and washer (25) to disconnect the
surrounding the fuel filter.
ball joint (22) from the governor throttle lever (23).
10. Remove clamp nuts (26), washers (27), and clamp
(28). Remove throttle cable assembly.

4203780 First Edition 3-15

 ENGINE

Fuel Pump
Removal and Installation
See Figure 3-28.

! CAUTION
Diesel fuel is highly flammable. Handle with care.
Use an approved container with a spout that will
fit inside the fuel filler neck. Avoid using
unapproved containers to transport fuel. Keep all
fuel containers clean and closed when not in use.

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
5
2. Disconnect the battery negative (–) cable at the
3 3
4
battery.
3. Turn the fuel outlet hose shutoff valve clockwise until
valve bottoms lightly. Valve is located on the bottom
2 of the fuel tank.

1
TN1993 2
Figure 3-27
3
6. Turn the cover (2) counterclockwise to remove it.
7. Remove the filter element (3). Drain excess fuel into
an appropriate container.
8. Remove O-rings (4). 5
6
! CAUTION
Dispose of fuel properly. Contact the local
environmental department for instructions on 4
disposing of unwanted fuel products.
TN2019
9. Clean the inside and outside of the filter head (5). Figure 3-28
10. Lightly lubricate the filter seal with clean oil and 4. Disconnect the positive lead (1) from the wiring
install. Tighten the cover hand tight plus one-half harness connector.
turn.
5. Loosen the two clamps to the inlet fuel hose (2) and
11. Open the fuel outlet hose shutoff valve on the bottom outlet fuel hose (4).
of the fuel tank.
6. Disconnect inlet and outlet fuel hoses from fuel pump
12. Purge air from the fuel system after installing the new (3). Use a suitable container to catch the fuel that will
filter. (See “Purging the Fuel System” on page 3-6.) flow from the fuel hoses. Cap the hoses.
and the engine manufacturer’s manual for further
instructions. 7. Remove two nuts (6) and ground lead (5).
8. Remove fuel pump.

Installation Note
Install the fuel pump by reversing the order of removal.

3-16 4203780 First Edition

 ENGINE

Engine 11. Remove two nuts (7), two lock washers (6), four
washers (5), and two screws (4) to remove fuel filter
Removal and Installation assembly.
See Figures 3-29 through 3-34.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely before
attempting to service the engine. 13
3. Disconnect the negative (–) battery cable first, then 8 9 10
disconnect the positive (+) cable. Remove the battery 11
hold-down clamp and battery. 12

NOTE
Label all wires before disconnecting to ensure correct
installation.
4. Tag and disconnect the wiring harness at the starter,
oil sender, engine coolant temp switch, and 15
14
TN2012
3
alternator. Remove the harness hold-down clamps.
Move the wiring harness away from the engine. Figure 3-30
5. Remove the muffler and exhaust assembly. (See 12. Disconnect solenoid clevis (14) from fuel solenoid
“Muffler” on page 3-9.) bracket (13).
6. Remove the radiator. (See “Radiator/Hydraulic Oil 13. Tag and disconnect fuel solenoid (8) wiring harness
Cooler” on page 3-11.) connector from the wiring harness.
7. Remove 4WD valve. (See “4WD Valve” on 14. Remove two nuts (12), two lock washers (11), four
page 5-53.) washers (10), and two screws (9).
8. Turn the fuel outlet hose shutoff valve clockwise until 15. Remove fuel solenoid assembly from fuel solenoid
valve bottoms lightly. Valve is located on the bottom bracket (15).
of the fuel tank.
16. Disconnect and remove fuel solenoid bracket from
engine.
1

2 23 17
16
18

3 21 22 20
19
4
5

53 6 7
TN2011

TN2020 Figure 3-31

Figure 3-29 17. Remove nut (19) and washer (20) to disconnect the
ball joint (17) from the governor throttle lever (18).
9. Disconnect and remove fuel hose (1) from inlet of
fuel filter (3) and from fuel pump. 18. Remove clamp nuts (21), washers (22), and clamp
(23). Remove throttle cable assembly.
10. Disconnect and remove fuel hose (2) from outlet of
fuel filter and from injection pump.

4203780 First Edition 3-17

 ENGINE

25 26 27
24
28

29

38
31 30
27
32 33
34

3 35
39
40

37
36

TN1997
Figure 3-33
22. Remove six screws (40) and lock washers (39) to
disconnect the hydrostatic pump drive plate (38) from
the engine.

TN2026
Figure 3-32
19. Loosen clamps (27) and remove air intake hose (28)
and hose (29). Cover intake manifold opening.
20. Remove two nuts (25), washers (24), and screws
(30) to remove air filter assembly from air cleaner
support (31).
21. Remove four nuts (34), lock washers (33), flat
washers (32), and screws (37), and remove clamp
(36) and mounting bracket clamp (35) to remove air
cleaner support from the frame.

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 ENGINE

! WARNING
Prevent personal injury. Use a properly rated
lifting device. Always be sure the load is
balanced before lifting.

41 43

42

45

TN1995
Figure 3-34
23. Using an engine hoist, support the engine (43) and 25. Place the engine on a suitable stand or workbench
remove the four engine mounting bolts (41) and flat that will support the full weight in a safe manner while
washers (42). preventing damage to the engine.
24. Check for any connected wires and components and
carefully remove the engine from the machine.

4203780 First Edition 3-19

 ENGINE

NOTE
Engine Service
A separate engine manual, prepared by the engine
If the engine is being replaced, some components must
manufacturer, is supplied with this machine. Refer to the
be removed and installed on the new engine. See the
engine manufacturer’s manual for all engine-related
“Parts & Maintenance Manual” for additional information
service.
and illustrations.
Proper attention to the engine manufacturer’s manual
Installation Notes directions will ensure maximum service life of the engine.
• Inspect engine mounts and replace if necessary.
• Install the engine by reversing the order of removal.
• Tighten the hydrostatic pump drive plate screws to 37
lb-ft (51 N·m).
• If necessary, remove components from the engine
and install the components on the new engine.
• Use new gaskets when installing the exhaust system.

3 • Fill the radiator with a 50/50 mixture of ethylene

glycol-base antifreeze and clean fresh water.
• Replace the engine oil filter and fill engine with oil.
• Purge air from the fuel system. See the engine
manufacturer’s manual for further instructions.

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 Chapter 4

Electrical

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Test and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Theory and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electrical Component Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Electrical Schematic Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Theory of Operation and Sub-Circuit Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Power Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Power Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Glow Plug Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Glow Plug Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27
4-28
4-29
4
Run Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Run Circuit Schematic—On Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Run Circuit Schematic—Off Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Charging Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Charging Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Mow Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Mow Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Four Wheel Drive Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Four Wheel Drive Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Four Wheel Drive Reverse Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Cruise Control—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Cruise Control Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Cruise Control Disable Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Work Lights Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Work Lights Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Instrumentation Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Instrumentation Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Horn/Test Circuit—Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Horn/Test Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

4203780 First Edition 4-1

 ELECTRICAL

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Four Wheel Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Cruise Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Work Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Instrumentation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Horn and Audible Alert Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Electrical System and Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Circuit Breakers Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Thermal Circuit Breakers Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Time Delay Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Key Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Horn/Test Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

4 Seat Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Limit Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-76
4-76
4-77
PTO Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Front Mow Enable Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Wing Mow Enable and Light Switches Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Cruise Control Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4WD Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Micro Switches Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Diff Lock Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Fuel Level Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Solenoids Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Fuel Shutoff Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Diodes Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

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 ELECTRICAL

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Battery and Battery Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Thermal Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Brake Pedal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Horn/Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Glow Plug Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Engine Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Right and Left Wing Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Front Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Rocker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Reverse Kick-Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99
Diff Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
4
Air Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Return Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Hyd Oil Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101
Charge Filter Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Engine Coolant Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Low Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Mow Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
4WD Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
Glow Plug Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
Cruise Control Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Volt Meter, Hour Meter, and Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113

4203780 First Edition 4-3

 ELECTRICAL

Specifications
Test and Adjustment Specifications
Specification
Resistance Across Solenoid Coil— ohms 7.1 ± 10%
Front Mow Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 7.1 ± 10%
Right Mow Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 7.1 ± 10%
Left Mow Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
4WD Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
Diff Lock Solenoid Coil at 68° F
Resistance Across Solenoid Coil— ohms 8.8 ± 10%
4WD Rev Solenoid Coil at 68° F
Fuel Level Sender Resistance ohms 32 ± 10%

4 Between Terminals at Full Position

Fuel Level Sender Resistance
Between Terminals at Empty Position
ohms 256 ± 10%

Resistance Across Fuel Shutoff Pull-In ohms 0.5 ± 10%

Coil at 68° F
Resistance Across Fuel Shutoff ohms 15 ± 10%
Hold-In Coil at 68° F
Resistance Across Cruise Control ohms 4.2 ± 10%
Magnet at 68° F
Mow Solenoids Nut Torque lb-ft (N·m) 5—7 (6.8—9.5)
4WD Solenoids Nut Torque lb-ft (N·m) 4—5 (5.4—6.8)

4-4 4203780 First Edition

 ELECTRICAL

Theory and Diagnostic

Information
Electrical Component Symbols
The following symbols are used in the electrical
schematics to represent various electrical components.

Switches1
Single Pole, Single Throw Double Pole, Single Throw
(SPST) (DPST)

Single Pole, Double Throw Double Pole, Double Throw

(SPDT) (DPDT)

Proximity Switch 4
Blk Wht

N.O. (+)

1 The sample switch symbols shown are just a few of the many switch configurations. Switches are
designated by the number of “poles” (circuits controlled) and “throws” (actuator positions). Unless otherwise
specified, switches are shown in the “Normally Open” (N.O.) position.

Switching Devices
Temperature Switch Pressure Switch

t˚ P

Relay
86 30

85 87 87A

Circuit Protection Devices

Fuse Circuit Breaker

4203780 First Edition 4-5

 ELECTRICAL

Motors and Generating Devices

Electric Motors (may also Stator
include “AC” or “DC.”)
M G

Alternator
G
3
U

Actuating Devices
Solenoid Valve PTO Clutch

4
Engine-Related Devices
Ignition Coil Spark Plug

Regulator Fuel Shutoff Solenoid

Pull-In Hold-In

Lights
Single-Element Light Dual-Element Light

4-6 4203780 First Edition

 ELECTRICAL

Miscellaneous Symbols
Enclosure Wires (crossing but not
(cabinet, housing, etc.) connected)

Ground (to earth) Wiring Connections

Ground (to chassis) Coil

Direct Current (DC) Battery

(as shown on an oscilloscope)
4
Alternating Current (AC) Diode
(as shown on an oscilloscope)

Resistor Pin and Socket Connector

4203780 First Edition 4-7

 ELECTRICAL

Electrical Schematic Component Identification

Electrical components shown in the main schematic are identified with an alpha-numeric callout. All electrical
components shown in the electrical schematic are listed below.
• B1—Engine Temperature Sensor (See Figure 4-4.) • K4—Time Delay Relay (See Figure 4-2.)
• B2—Engine Speed Sensor (See Figure 4-5.) • K5—Cruise Cancel Relay (See Figure 4-4.)
• B3—Fuel Level Sensor (See Figure 4-5.) • K6—Cruise Relay (See Figure 4-4.)
• B4—Air Filter Pressure Switch (See Figure 4-6.) • K7—Horn Relay (See Figure 4-4.)
• B5—Return Filter Pressure Switch (See Figure 4-6.) • K8—Right Wing Relay (See Figure 4-2.)
• B6—Hyd Oil Temp Switch (See Figure 4-6.) • K9—Left Wing Relay (See Figure 4-2.)
• B7—Charge Filter Pressure Switch (See Figure 4-6.) • M1—Starter Motor (See Figure 4-1.)
• B8—Low Charge Pressure Switch (See Figure 4-6.) • M2—Fuel Pump (See Figure 4-3.)
• B9—Engine Coolant Temp Switch (See Figure 4-6.) • R1—Glow Plugs (See Figure 4-1.)
• B10—Engine Oil Pressure Switch (See Figure 4-6.) • S1—Key Switch (See Figure 4-1.)
• E1—Right Turn Indicator (See Figure 4-5.) • S2—Glow Plug Switch (See Figure 4-1.)
• E2—Glow Plug Light (See Figure 4-5.) • S3—PTO Switch (See Figure 4-2.)
• E3—Air Filter Service Light (See Figure 4-6.) • S4—Park Brake Switch (See Figure 4-2.)
• E4—Return Filter Service Light (See Figure 4-6.) • S5—Seat Switch (See Figure 4-2.)
4 • E5—Hyd Oil Temp Light (See Figure 4-6.)
• E6—Charge Filter Service Light (See Figure 4-6.)
• S6—Right Wing Proximity Switch (See Figure 4-2.)
• S7—Left Wing Proximity Switch (See Figure 4-2.)
• E7—Low Charge Pressure Light (See Figure 4-6.) • S8—Front Limit Switch (See Figure 4-3.)
• E8—Engine Coolant Temp Light (See Figure 4-6.) • S9—Front Mow Enable Switch (See Figure 4-3.)
• E9—Engine Oil Pressure Light (See Figure 4-6.) • S10—Wing Mow Enable Switch (See Figure 4-3.)
• E10—Left Turn Indicator (See Figure 4-5.) • S11—4WD Switch (See Figure 4-3.)
• E11— Tail Light (See Figure 4-7.) • S12—Reverse Kick-Out Switch (See Figure 4-3.)
• E12— Work Light (See Figure 4-7.) • S13—Diff Lock Switch (See Figure 4-3.)
• E13— Work Light (See Figure 4-7.) • S14—Brake Pedal Switch (See Figure 4-4.)
• F1—50A Circuit Breaker (See Figure 4-1.) • S15—Cruise Switch (See Figure 4-4.)
• F2—30A Circuit Breaker (See Figure 4-1.) • S16—Horn/Test Switch (See Figure 4-6.)
• F3—50A Circuit Breaker (See Figure 4-1.) • S17—Light Switch (See Figure 4-7.)
• F4—10A Circuit Breaker (See Figure 4-1.) • V1—Engine Coolant Temp Light Diode
• F5—10A Circuit Breaker (See Figure 4-2.) (See Figure 4-6.)
• F6—10A Circuit Breaker (See Figure 4-3.) • V2—Horn Relay Diode (See Figure 4-6.)
• F7—30A Circuit Breaker (See Figure 4-7.) • V3—Air Filter Service Light Diode (See Figure 4-6.)
• G1—12V Battery (See Figure 4-1.) • V4—Return Filter Service Light Diode
(See Figure 4-6.)
• G2—Alternator (See Figure 4-1.)
• V5—Hyd Oil Temp Light Diode (See Figure 4-6.)
• H1—Horn (See Figure 4-4.)
• V6—Horn Relay Diode (See Figure 4-6.)
• H2—Volt Meter (See Figure 4-4.)
• V7—Charge Filter Service Light Diode
• H3—Engine Temperature Gauge (See Figure 4-4.)
(See Figure 4-6.)
• H4—Tachometer (See Figure 4-5.)
• V8—Cruise Control Magnet Diode (See Figure 4-4.)
• H5—Hour Meter (See Figure 4-5.)
• Y1—Fuel Shutoff Solenoid (See Figure 4-1.)
• H6—Fuel Gauge (See Figure 4-5.)
• Y2—Front Mow Solenoid (See Figure 4-3.)
• J4—Cab/Canopy Connector (See Figure 4-7.)
• Y3—Right Mow Solenoid (See Figure 4-3.)
• K1—Glow Plug Solenoid (See Figure 4-1.)
• Y4—Left Mow Solenoid (See Figure 4-3.)
• K2—Accessory Relay (See Figure 4-1.)
• Y5—4WD Solenoid (See Figure 4-3.)
• K3—Fuel Pull-In Relay (See Figure 4-1.)

4-8 4203780 First Edition

 ELECTRICAL

• Y6—4WD Rev Solenoid (See Figure 4-3.)

• Y7—Diff Lock Solenoid (See Figure 4-3.)
• Y8—Cruise Control Magnet (See Figure 4-4.)

4203780 First Edition 4-9

 ELECTRICAL

Electrical Schematic
See Figures 4-1 through 4-7.

Org Org
Brn/Red Brn/Red
Org
Pur Pur
Red Red
Yel Yel

Off
Run
Start
Org

Brn/Red B
F4
I Pnk/Blu 10A
Circuit
S1 Breaker
S Pur/wht
Key Pur Red
Switch K2
A Wht/

4
Accessory Red
X Y Relay
Red 87

30 Pnk/Blu
Tan 87 S2
Pnk/Blu
86 85 Blk Glow
Plug
K3 30 86
Switch
Fuel
Pull-In
Relay 87 87 85 Off
Wht/ On
Red Red/ Wht Blk Red
Wht Red Grn/Wht Grn
IG
F2 G Grn/Wht
B
Org 30A Red 3
Circuit Red
U
Breaker Wht
G2
Y1 Alternator Red Grn/
Pull-In Hold-In Wht
Org
Fuel
F1 Shutoff K1
50A Solenoid Glow
Circuit Plug
Breaker Solenoid
Red Red Red Blk
Brn
Pur/
wht F3
Brn 50A
Circuit Brn Red
Red
Breaker
Brn

M1
Red R1
Starter M
(+) G1 Glow
Motor
12V Plugs
(-) Battery
Grn/Wht
Blk Red

TN1745
Figure 4-1

4-10 4203780 First Edition

 ELECTRICAL

Electrical Schematic
Continued

Org
Brn/Red
Org Org
Pur Pur
Red S4
Yel F5 Org S3 Park
10A PTO Brake
Circuit Switch Switch
Breaker
Red/ Off Off
Brn On On

F Org/Brn Brn/Red
E

Brn
A Red/Wht Red/Wht
Red B
C Red/Lt Blu
Pur
Red/Yel

S5

4
Seat Off
Switch On
Pur Wht/Brn

Wht/Brn
Brn

S6
+12V Enable K4
Right
Time
1 Sec. Wing
Off Delay Delay
Proximity
Output Gnd Relay
Switch
Yel Blk Wht/Blk 2 Blk Wht 1 Red/Blu Red/Yel

N.O.
Red/Wht

S7
Left
86 30 K8 Wing
Right Proximity
Wing Switch
85 87 87 Relay
Wht/Blk 2 Blk Wht 1 Red/Blu Red/Lt Blu
Blk Pnk
N.O.
Red/Wht

86 30 K9
Left
Wing
85 87 87 Relay
Blk Pnk

Pnk

Pnk Pnk

Grn/Wht Grn/Wht

Red Red

TN1746
Figure 4-2

4203780 First Edition 4-11

 ELECTRICAL

Electrical Schematic
Continued

Org Org
Pur Wht
Org Red
Pur F6 Pur
10A
Circuit S12
S8 Reverse
Front Breaker Wht
Kick Out
Limit Red
Switch
Switch
S11
Reverse
Off 4WD
Pnk Forward
On
Switch

On
Red/Wht Brn/Red Off
Grn
Mom. ON
Y5
Blu
S9 Pnk 4WD
Pur Solenoid
Front
Blk
Mow

4 Enable
Switch Wht
Grn

S13 Grn
Off Diff Y6
Off Lock 4WD Rev
On Switch Solenoid
Blk
Brn/Red Off
Wht
On

Wht Grn
Wht Y2
Front Grn
Mow Y7
Blk Solenoid Pnk Diff
S10 Lock
Wing Blk Solenoid
Mow M
Enable M2
Switch Fuel
Pump Blk

Off
Off
On

66A Pnk
Lt Grn

66A Pnk
Org

Lt Grn
Org
Y3 Y4
Pnk
Right Left
Mow Mow
Pnk Solenoid Blk Blk Solenoid

Grn/Wht Grn/Wht

Red Red

TN1747
Figure 4-3

4-12 4203780 First Edition

 ELECTRICAL

Electrical Schematic
Continued

Org Org
Wht Wht
Red Wht/Grn Wht/Grn
Wht/Grn Wht/Grn
K7 Wht
H1 Org
Horn Horn
Relay Blk Org Org

Red 87
Org Org
30
+12V
87
Lt Blu/Red Wht/Grn
+12V H3
Lt Blu/Red 86 85 Wht/Grn Engine
H2
Volt Temperature
Meter Gauge
Gnd
Gnd Signal

S14 Blk Blk Lt B1

Brake Grn
Blk Engine
Pedal
Switch

Off
Temperature
Sensor
Blk
4
On

Lt Blu/Red Wht Blk Blk

S15
Cruise
Control
Switch K6
Cruise
Disable
Relay
Wht Off Wht 87
Enable
30
Wht/Red
Wht 87
Wht/Grn Wht/Grn Gry/ Gry/
86 85 Blk Red Red
Mom. Sw.

K5
Cruise Y8
V8 Cruise
Cancel
Relay Control
Gry/
Red Magnet
Wht/Grn 87A 5B Gry/
Blk Blk
30

87 Blk
Wht/Red Blk Blk

86 85
5B
Blk

Grn/Wht Grn/Wht

Red Red

TN1748
Figure 4-4

4203780 First Edition 4-13

 ELECTRICAL

Electrical Schematic
Continued

Wht Wht
Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org Org

Org Org Org Org Org Org

+12V +12V

+12V
H4 H5 H6
Tachometer Hour Fuel
Meter Gauge
Gnd
Gnd Signal Gnd Signal

Blk Blk Brn

B2 Blk Tan B3
Blk Blk
Fuel

4 Blk
Brn
Engine
Speed
Sensor Blk
Level
Sensor

Blk Blk

Lt Blu

Grn/Wht Lt Grn

E2 E10 E1
Glow Left Right
Plug Turn Turn
Light Indicator Indicator

Blk Blk Blk Blk Blk

Lt Blu
Grn/Wht Lt Grn

Red Red

TN1749
Figure 4-5

4-14 4203780 First Edition

 ELECTRICAL

Electrical Schematic
Continued

Wht Wht

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org

Org Org Org Org Org Org Wht/ Org Org

Grn
E4 E5 E6
E3 V6
Return Hyd Charge
Air Filter Grn\
Filter Oil Wht Filter
Blu/ Tan Service Gry/
Wht Service Temp Wht
Service
Light Grn\
Light Light
Light Wht

Blu/ Tan Gry/

Wht Grn\ Wht
Wht
B4 B5 B7
Air Return B6 Charge
P Filter P Filter Hyd P Filter

Blu/
Wht Blk
Pressure
Switch
Tan Blk
Pressure
Switch
Grn\
t˚ Oil
Temp
Switch
Gry/
Pressure
Switch 4
Wht Wht
V3 V4
V5 V7
Wht/ Wht/
Blk Blk Wht/ Wht/
Blk Blk

Org Wht/ Org Org Org Org

S16 Grn
Horn/Test E9 E8 E7
V2
Switch Engine Engine Low
Grn
Off
Oil Coolant Charge
Blu Pressure Temp Gry/ Pressure
On Red
Light Light Light
Grn

B10 B9 B8
Blk
Engine Engine Low
P Oil t˚ Coolant P Charge
Pressure Temp Pressure
Switch Switch Switch
Blk Grn Blk

V1
Wht/
Blk

Lt Blu Lt Blu

Lt Grn Lt Grn

Red Red

TN1750
Figure 4-6

4203780 First Edition 4-15

 ELECTRICAL

Electrical Schematic
Continued

Wht Wht

S17
Light Optional
Red Red Switch Work Lights
F7
30A Road
Circuit Off
Breaker Work
Org/
Blu Tan/Red
Tan/Red
Org/Blu
Wht
Wht

Gry Wht Wht Wht Tan/

Red
Org/Blu
Gry
E12 E13 E11

4 Work
Light
Work
Light
Tail
Light

Blk Blk Blk Blk Blk

Gry 6
Wht 4
Red Red 8

Org/Blu Org/Blu 5 J4
Cab/Canopy
Lt Grn 1
Option
Lt Blu 3 Connector
Tan/Red 2

Wht 7

Lt Blu Lt Blu

Lt Grn Lt Grn

Red

TN1751
Figure 4-7

4-16 4203780 First Edition

 ELECTRICAL

Page Intentionally Blank

4203780 First Edition 4-17

 ELECTRICAL

Theory of Operation and Switched power is provided from 10-amp circuit breaker
(F6) to the following:
Sub-Circuit Schematics • 4WD switch
• Diff lock switch
Power Circuit—Theory of Operation • Fuel pump
Unswitched Power Circuit • Horn relay terminals 30 and 86
Unswitched power is available from the battery positive • Brake pedal switch
terminal to the starter motor battery terminal and then • Cab/Canopy option connector (J4) terminal 4
from the starter motor battery terminal to 50-amp circuit With switched power provided to the fuel pump, the fuel
breaker (F1) battery terminal. Unswitched power is pump starts to operate.
available through the 50-amp circuit breaker (F1) to
Switched power is also provided from 10-amp circuit
30-amp circuit breaker (F2) input terminal and from
breaker (F4) to the following:
circuit breaker (F2) input terminal to 10-amp circuit
breaker (F5). • Volt meter
Unswitched power is available from 30-amp circuit • Engine temperature gauge
breaker (F2) output terminal to the following: • Tachometer
• Fuel pull-in relay terminal 30 • Hour meter
• Accessory relay terminal 30 • Fuel gauge
Unswitched power is provided from 10-amp circuit • Air filter service light
4 breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.
• Return filter service light
• Hyd oil temp light
Unswitched power is also available from the battery • Charge filter service light
positive terminal to the battery terminal of 50-amp circuit
breaker (F3). From circuit breaker (F3) unswitched power • Low charge pressure light
is available to glow plug solenoid battery terminal and to • Engine coolant temp light
30-amp circuit breaker (F7). Circuit breaker (F3) also • Engine oil pressure light
provides protection to the alternator battery terminal. With switched power provided to the gauges and hour
meter, the gauges start to operate and the hour meter
Interlock Circuit
starts logging hours.
The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is
provided with 12 volts:
• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Switched Power Circuit

When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to the following components:
• Alternator terminal I
• Fuel shutoff solenoid hold-in coil
• PTO switch terminal B
• Seat switch
• 10-amp circuit breaker (F4)
• 10-amp circuit breaker (F6)

4-18 4203780 First Edition

 ELECTRICAL

Power Circuit Schematic

See Figures 4-8 through 4-14.

Org Org
Brn/Red Brn/Red
Org
Unswitched Power Circuit
Pur Pur
Switched Power Circuit
Red Red
Interlock Circuit
Yel Yel
Ground Circuit

Off
Run
Start
Org

Brn/Red B
F4
I Pnk/Blu 10A
Circuit
S1 Breaker
S Pur/wht
Key Pur Red
Switch K2
A Wht/

4
Accessory Red
X Y Relay
Red 87

30 Pnk/Blu
Tan 87 S2
Pnk/Blu
86 85 Blk Glow
Plug
K3 30 86
Switch
Fuel
Pull-In
Relay 87 87 85 Off
Wht/ On
Red Red/ Wht Blk Red
Wht Red Grn/Wht Grn
IG
F2 G Grn/Wht
B
Org 30A Red 3
Circuit Red
U
Breaker Wht
G2
Y1 Alternator Red Grn/
Pull-In Hold-In Wht
Org
Fuel
F1 Shutoff K1
50A Solenoid Glow
Circuit Plug
Breaker Solenoid
Red Red Red Blk
Brn
Pur/
wht F3
Brn 50A
Circuit Brn Red
Red
Breaker
Brn

M1
Red R1
Starter M
(+) G1 Glow
Motor
12V Plugs
(-) Battery
Grn/Wht
Blk Red

TN1752
Figure 4-8

4203780 First Edition 4-19

 ELECTRICAL

Power Circuit Schematic

Continued

Org
Brn/Red
Org Org
Pur Pur
Red S4
Yel F5 Org S3 Park
10A PTO Brake
Circuit Switch Switch
Breaker
Red/ Off Off
Brn On On

F Org/Brn Brn/Red
E

Brn
A Red/Wht Red/Wht
Red B
C Red/Lt Blu
Pur
Red/Yel

S5

4
Seat Off
Switch On
Pur Wht/Brn

Wht/Brn
Brn

S6
+12V Enable K4
Right
Time
1 Sec. Wing
Off Delay Delay
Proximity
Output Gnd Relay
Switch
Yel Blk Wht/Blk 2 Blk Wht 1 Red/Blu Red/Yel

N.O.
Red/Wht

S7
Left
86 30 K8 Wing
Right Proximity
Wing Switch
85 87 87 Relay
Wht/Blk 2 Blk Wht 1 Red/Blu Red/Lt Blu
Blk Pnk
N.O.
Red/Wht

86 30 K9
Left
Wing
85 87 87 Relay
Blk Pnk
Unswitched Power Circuit
Pnk
Switched Power Circuit
Interlock Circuit
Pnk Pnk
Ground Circuit

Grn/Wht Grn/Wht

Red Red

TN1753
Figure 4-9

4-20 4203780 First Edition

 ELECTRICAL

Power Circuit Schematic

Continued

Org Org
Pur Wht
Org Red
Pur F6 Pur
10A
Circuit S12
S8 Reverse
Front Breaker Wht
Kick-Out
Limit Red
Switch
Switch
S11
Reverse
Off 4WD
Pnk Forward
On
Switch

On
Red/Wht Brn/Red Off
Grn
Mom. ON
Y5
Blu
Pnk 4WD
Pur Solenoid
Blk

Wht
Grn

S13 Grn
4
Off Diff Y6
Off Lock 4WD Rev
On Switch Solenoid
Blk
Brn/Red Off
Wht
On

Wht Grn
Wht Y2
Front Grn
Mow Y7
Blk Solenoid Pnk Diff
S10 Lock
Wing Blk Solenoid
Mow M
Enable M2
Switch Fuel
Pump Blk

Off
Off
On

66A Pnk
Lt Grn

66A Pnk
Org

Lt Grn
Org
Y3 Y4
Pnk
Right Left Unswitched Power Circuit
Mow Mow
Switched Power Circuit
Pnk Solenoid Blk Blk Solenoid
Ground Circuit

Grn/Wht Grn/Wht

Red Red

TN1754
Figure 4-10

4203780 First Edition 4-21

 ELECTRICAL

Power Circuit Schematic

Continued

Org Org
Wht Wht
Red Wht/Grn Wht/Grn
Wht/Grn Wht/Grn
K7 Wht
H1 Org
Horn Horn
Relay Blk Org Org

Red 87
Org Org
30
+12V
87
Lt Blu/Red Wht/Grn
+12V H3
Lt Blu/Red 86 85 Wht/Grn Engine
H2
Volt Temperature
Meter Gauge
Gnd
Gnd Signal

S14 Blk Blk Lt B1

Brake Grn
Blk Engine

4 Pedal
Switch

Off
Temperature
Sensor
Blk

On

Lt Blu/Red Wht Blk Blk

S15
Cruise
Control
Switch K6
Cruise
Disable
Relay
Wht Off Wht 87
Enable
30
Wht/Red
Wht 87
Wht/Grn Wht/Grn Gry/ Gry/
86 85 Blk Red Red
Mom. Sw.

K5
Cruise Y8
V8 Cruise
Cancel
Relay Control
Gry/
Red Magnet
Wht/Grn 87A 5B Gry/
Blk Blk
30

87 Blk
Wht/Red Blk Blk
Unswitched Power Circuit
86 85
Switched Power Circuit 5B
Blk
Ground Circuit

Grn/Wht Grn/Wht

Red Red

TN1755
Figure 4-11

4-22 4203780 First Edition

 ELECTRICAL

Power Circuit Schematic

Continued

Wht Wht
Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org Org

Org Org Org Org Org Org

+12V +12V

+12V
H4 H5 H6
Tachometer Hour Fuel
Meter Gauge
Gnd
Gnd Signal Gnd Signal

Blk Blk Brn

B2 Blk Tan B3
Blk Blk
Fuel

Blk
Brn
Engine
Speed
Sensor Blk
Level
Sensor 4
Blk Blk

Lt Blu

Grn/Wht Lt Grn

E2 E10 E1
Glow Left Right
Plug Turn Turn
Light Indicator Indicator

Blk Blk Blk Blk Blk

Unswitched Power Circuit

Switched Power Circuit
Ground Circuit
Lt Blu
Grn/Wht Lt Grn

Red Red

TN1756
Figure 4-12

4203780 First Edition 4-23

 ELECTRICAL

Power Circuit Schematic

Continued

Wht Wht

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org

Org Org Org Org Org Org Wht/ Org Org

Grn
E4 E5 E6
E3 V6
Return Hyd Charge
Air Filter Grn\
Filter Oil Wht Filter
Blu/ Tan Service Gry/
Wht Service Temp Wht
Service
Light Grn\
Light Light
Light Wht

Blu/ Tan Gry/

Wht Grn\ Wht
Wht
B4 B5 B7
Air Return B6 Charge
P Filter P Filter Hyd P Filter

4 Blu/
Wht Blk
Pressure
Switch
Tan Blk
Pressure
Switch
Grn\
t˚ Oil
Temp
Switch
Gry/
Pressure
Switch

Wht Wht
V3 V4
V5 V7
Wht/ Wht/
Blk Blk Wht/ Wht/
Blk Blk

Org Wht/ Org Org Org Org

S16 Grn
Horn/Test E9 E8 E7
V2
Switch Engine Engine Low
Grn
Off
Oil Coolant Charge
Blu Pressure Temp Gry/ Pressure
On Red
Light Light Light
Grn

B10 B9 B8
Blk
Engine Engine Low
P Oil t˚ Coolant P Charge
Pressure Temp Pressure
Switch Switch Switch
Blk Grn Blk

V1
Wht/
Blk
Unswitched Power Circuit
Switched Power Circuit
Ground Circuit
Lt Blu Lt Blu

Lt Grn Lt Grn

Red Red

TN1757
Figure 4-13

4-24 4203780 First Edition

 ELECTRICAL

Power Circuit Schematic

Continued

Wht Wht

S17
Light Optional
Red Red Switch Work Lights
F7
30A Road
Circuit Off
Breaker Work
Org/
Blu Tan/Red
Tan/Red
Org/Blu
Wht
Wht

Gry Wht Wht Wht Tan/

Red
Org/Blu
Gry
E12 E13 E11
Work
Light
Work
Light
Tail
Light 4
Blk Blk Blk Blk Blk

Gry 6
Wht 4
Red Red 8

Org/Blu Org/Blu 5 J4
Cab/Canopy
Lt Grn 1
Option
Lt Blu 3 Connector
Tan/Red 2

Wht 7

Unswitched Power Circuit

Switched Power Circuit
Ground Circuit
Lt Blu Lt Blu

Lt Grn Lt Grn

Red

TN1758
Figure 4-14

4203780 First Edition 4-25

 ELECTRICAL

Glow Plug Circuit—Theory of

Operation
Unswitched Power Circuit
Unswitched power is available from the battery positive
terminal to the starter motor battery terminal and then
from the starter motor battery terminal to 50-amp circuit
breaker (F1) battery terminal. Unswitched power is
available through the 50-amp circuit breaker (F1) to
10-amp circuit breaker (F5).
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E.
Unswitched power is also available from the battery
positive terminal to the battery terminal of 50-amp circuit
breaker (F3). Circuit breaker (F3) provides unswitched
power to glow plug relay battery terminal.

Interlock Circuit
The interlock circuit provides 12 volts to the key switch.

4 The following must occur before the key switch is

provided with 12 volts:
• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Glow Plug Circuit

Key switch terminal B provides voltage to the glow plug
switch. When the glow plug switch is held in the on
position, voltage is provided to the glow plug solenoid
positive terminal, energizing the solenoid. With the
solenoid energized, voltage is provided through 50-amp
circuit breaker (F3) and the glow plug solenoid contacts
to the glow plugs, heating the glow plugs. Voltage is also
provided from the glow plug switch to the glow plug light,
turning on the light.

4-26 4203780 First Edition

 ELECTRICAL

Glow Plug Circuit Schematic

See Figure 4-15.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
Switch Switch
Breaker
Red/
S1 Brn Off Off
Key On On
Switch
F Org/Brn Brn/Red
E
Off
Run A
B
Start C

Brn/Red B
I

4
S
S2
A Glow
Plug
X Y Switch

Off
On

Grn Grn/Wht

Grn/Wht

Grn/
Wht
E2
Unswitched Power Circuit Glow
Plug
Org Switched Power Circuit
Blk Light
Glow Plug Circuit
Interlock Circuit
Ground Circuit Red Grn/
Org Wht

F1 K1
50A Glow
Circuit Plug
Breaker Solenoid
Red Red Blk
Brn M1
Starter F3
Motor 50A
Brn
Circuit Brn
Red
Breaker
Brn

Red R1
(+) G1 M Glow
12V Plugs
(-) Battery

Blk

TN1763
Figure 4-15

4203780 First Edition 4-27

 ELECTRICAL

Start Circuit—Theory of Operation Key switch terminal S also provides voltage to fuel pull-in
relay terminal 86, energizing the relay. With the relay
Unswitched Power Circuit energized, voltage is provided to the fuel shutoff solenoid
pull-in coil, energizing the coil. With the pull-in coil
Unswitched power is available from the battery positive
energized, the solenoid plunger retracts. When the
terminal to the starter motor battery terminal and then
solenoid plunger is fully retracted, an internal switch
from the starter motor battery terminal to 50-amp circuit
opens the pull-in coil circuit. This prevents extended
breaker (F1) battery terminal. Unswitched power is
activation of the high-current pull-in coil. The hold-in coil
available through the 50-amp circuit breaker (F1) to
keeps the solenoid plunger in the retracted position until
30-amp circuit breaker (F2) input terminal and from
it is de-energized. With the solenoid plunger retracted,
circuit breaker (F2) input terminal to 10-amp circuit
fuel is allowed to flow, and as the starter motor cranks the
breaker (F5).
engine, the engine starts operating.
Unswitched power is available from 30-amp circuit
breaker (F2) output terminal to accessory relay terminal
30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E.

Interlock Circuit
The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is

4 provided with 12 volts:

• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Switched Power Circuit

When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to fuel shutoff hold-in coil and to 10-amp
circuit breaker (F6).
Switched power is provided from 10-amp circuit breaker
(F6) to the fuel pump. With switched power provided to
the fuel pump, the fuel pump starts to operate.

Start Circuit
When the key switch is turned to the start position,
voltage is provided from key switch terminal S to the
starter motor solenoid, energizing the solenoid. With the
starter solenoid energized, voltage is provided from the
starter solenoid contacts to the starter motor, engaging
the motor.

4-28 4203780 First Edition

 ELECTRICAL

Start Circuit Schematic

See Figure 4-16.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run E

Start
A
B
Brn/Red B C
I Pnk/Blu

S Pur/wht

K2 S11
A
Pur 4WD

4
Accessory F6
X Y Relay 10A Switch
Circuit
Red 87 Pur
Breaker On
30 Pnk/Blu Off
Mom. ON
Tan 87
Pnk/Blu
Blk Pnk
86 85
K3 30 86
Fuel
Pull-In
Relay 87 87 85 Wht
Red Red/ Wht Blk Wht/ S13
Wht Red Diff
Lock
Wht/
F2 Red
Switch
Org 30A Red Red
Circuit IG Off
Breaker Wht
G On

3 Wht
Y1 Pull-In Hold-In U
Org
Fuel
F1 Shutoff G2
50A Solenoid Alternator Pnk
Circuit
Breaker
M
Brn M2
Pur/
wht
Fuel
Brn
Pump Blk

Red

Red
M1 Unswitched Power Circuit Start Circuit
Starter M Switched Power Circuit Fuel Pull-In Circuit
(+) G1
Motor
12V Interlock Circuit
(-) Battery
Ground Circuit
Blk

TN1800
Figure 4-16

4203780 First Edition 4-29

 ELECTRICAL

Run Circuit—Theory of Operation Run Circuit—Off Seat

Before leaving the seat, the PTO switch must be in the off
Unswitched Power Circuit position and the park brake switch in the on position. With
Unswitched power is available from the battery positive the PTO switch in the off position and park brake switch
terminal to the starter motor battery terminal and then in the on position, voltage is provided from the park brake
from the starter motor battery terminal to 50-amp circuit switch to key switch terminal B.
breaker (F1) battery terminal. Unswitched power is With voltage provided to key switch terminal B, key switch
available through the 50-amp circuit breaker (F1) to terminal I continues to energize the accessory relay. The
30-amp circuit breaker (F2) input terminal and from accessory relay continues to provide voltage to the fuel
circuit breaker (F2) input terminal to 10-amp circuit shutoff hold-in coil, keeping the fuel shutoff solenoid
breaker (F5). plunger retracted. With the solenoid plunger retracted,
Unswitched power is available from 30-amp circuit fuel continues to flow to the engine. Voltage is also
breaker (F2) output terminal to the following: provided from the accessory relay to the fuel pump and
the pump continues to operate.
• Fuel pull-in relay terminal 30
• Accessory relay terminal 30
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.

Run Circuit—On Seat

4 The seat switch and time delay relay allow the engine to
continue to operate when the park brake is released or
when the PTO switch is in the on position.
When the operator is on the seat, the seat switch
contacts close. With the seat switch contacts closed,
voltage is provided to time delay relay enable terminal,
energizing the relay. With the relay energized, voltage is
provided to key switch terminal A from time delay relay
output terminal.
With voltage provided to key switch terminal A, key switch
terminal I continues to energize the accessory relay. The
accessory relay continues to provide voltage to the fuel
shutoff hold-in coil, keeping the fuel shutoff solenoid
plunger retracted. With the solenoid plunger retracted,
fuel continues to flow to the engine. Voltage is also
provided from the accessory relay to the fuel pump and
the pump continues to operate.
If the operator leaves the seat with the park brake in the
released position or with the PTO switch in the on
position, the time delay relay de-energizes after a 1
second delay. The time delay is to compensate for seat
bounce when operating the machine over rough terrain.
With the time delay relay de-energized, the accessory
relay de-energizes, and then the fuel shutoff solenoid
hold-in coil de-energizes, shutting off the engine.

4-30 4203780 First Edition

 ELECTRICAL

Run Circuit Schematic—On Seat

See Figure 4-17.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

Yel K2 S11
A
Red Pur 4WD

4
Accessory F6
X Y Relay 10A Switch
Circuit
Red 87 Pur
Breaker On
30 Pnk/Blu Off
Mom. ON
87
Pnk/Blu
S5 86 85 Blk Pnk
Seat
Switch

Off
Wht
On
Red S13
Pur Wht/Brn Diff
Lock
F2 Switch
Org 30A Wht/Brn
Circuit Brn Off
Breaker On
+12V Enable K4
Time Wht
1 Sec.
Org Off Delay Delay
F1 Output Gnd Relay
50A Wht/
Yel Blk Red Pnk
Circuit Y1
Breaker Fuel
IG M2
Shutoff Red M
G Fuel
Brn Solenoid
Pump
3
Pull-In Hold-In U Blk
Brn
Red G2
Alternator

Red
M1
M Starter
(+) G1
Motor Unswitched Power Circuit
12V
(-) Battery Switched Power Circuit

Blk Interlock Circuit

Ground Circuit
TN1804
Figure 4-17

4203780 First Edition 4-31

 ELECTRICAL

Run Circuit Schematic—Off Seat

See Figure 4-18.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

Yel K2 S11
A
Red Pur 4WD

4
Accessory F6
X Y Relay 10A Switch
Circuit
Red 87 Pur
Breaker On
30 Pnk/Blu Off
Mom. ON
87
Pnk/Blu
S5 86 85 Blk Pnk
Seat
Switch

Off
Wht
On
Red S13
Pur Wht/Brn Diff
Lock
F2 Switch
Org 30A Wht/Brn
Circuit Brn Off
Breaker On
+12V Enable K4
Time Wht
1 Sec.
Org Off Delay Delay
F1 Output Gnd Relay
50A Wht/
Yel Blk Red Pnk
Circuit Y1
Breaker Fuel
IG M2
Shutoff Red M
G Fuel
Brn Solenoid
Pump
3
Pull-In Hold-In U Blk
Brn
Red G2
Alternator

Red
M1
M Starter
(+) G1
Motor Unswitched Power Circuit
12V
(-) Battery Switched Power Circuit

Blk Interlock Circuit

Ground Circuit
TN1803
Figure 4-18

4-32 4203780 First Edition

 ELECTRICAL

Page Intentionally Blank

4203780 First Edition 4-33

 ELECTRICAL

Charging Circuit—Theory of
Operation
Unswitched Power Circuit
Unswitched power is available from the battery positive
terminal to the starter motor battery terminal and then
from the starter motor battery terminal to 50-amp circuit
breaker (F1) battery terminal. Unswitched power is
available through the 50-amp circuit breaker (F1) to
30-amp circuit breaker (F2) input terminal and from
circuit breaker (F2) input terminal to 10-amp circuit
breaker (F5).
Unswitched power is available from circuit breaker (F2)
output terminal to accessory relay terminal 30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E.
Unswitched power is also available from the battery
positive terminal to the battery terminal of 50-amp circuit
breaker (F3). Circuit breaker (F3) provides protection to

4 the alternator battery terminal.

Interlock Circuit
The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is
provided with 12 volts:
• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Charging Circuit
When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to the alternator field terminal, exciting
the alternator. With the alternator field terminal excited,
the alternator produces three-phase alternating current
(AC). The AC current is rectified by internal diodes and
direct current (DC) is available to the internal voltage
regulator.
When the battery voltage is low, current flows from the
voltage regulator to the battery, charging the battery.
When the battery is fully charged, the regulator stops
providing current to the battery.

4-34 4203780 First Edition

 ELECTRICAL

Charging Circuit Schematic

See Figure 4-19.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run E

Start
A
B
Brn/Red B C
I Pnk/Blu

A
K2
Accessory
X Y

Red
Relay
87
4
30 Pnk/Blu
87
Pnk/Blu
86 85 Blk

Red

Wht/
F2 Red
Org 30A
Circuit IG
Breaker G
3
Org
U
F1 G2
50A Alternator
Circuit
Breaker
Red
Brn

F3
Brn 50A
Circuit Brn
Red
Breaker
Brn
Unswitched Power Circuit
Switched Power Circuit
Red
M1
Starter Charging Circuit
(+) G1 M
Motor Interlock Circuit
12V
(-) Battery Ground Circuit

Blk

TN1762
Figure 4-19

4203780 First Edition 4-35

 ELECTRICAL

Mow Circuit—Theory of Operation NOTE

Unswitched Power Circuit The proximity switch is a solid state switch and will have
approximately a 2 to 3 volt drop across the switch when
Unswitched power is available from the battery positive
activated.
terminal to the starter motor battery terminal and then
from the starter motor battery terminal to 50-amp circuit When the front deck is lowered, the front limit switch is
breaker (F1) battery terminal. Unswitched power is turned to the on position. With the switch in the on
available through the 50-amp circuit breaker (F1) to position, voltage is provided to the front mow enable
30-amp circuit breaker (F2) input terminal and from switch. When the front mow enable switch is placed in the
circuit breaker (F2) input terminal to 10-amp circuit on position, voltage is provided to the front mow solenoid,
breaker (F5). energizing the solenoid.
Unswitched power is available from 30-amp circuit
breaker (F2) output terminal to accessory relay terminal
30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.

Switched Power Circuit

When the key switch is turned to the run position, voltage

4 is provided from key switch terminal I to accessory relay

terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to PTO switch terminal B and from
terminal B to the seat switch.

Interlock Circuit
The operator must be on the seat before releasing the
park brake or placing the PTO switch in the on position.
(See “Run Circuit—Theory of Operation” on page 4-30.)

Mow Circuit
When the PTO switch is placed in the on position, voltage
is provided to the following:
Front limit switch
• Right wing proximity switch
• Right wing relay terminal 30
• Left wing proximity switch
• Left wing relay terminal 30
When the right wing is lowered, the linkage is brought
near the magnetic target zone of the neutral proximity
switch, activating the switch. With the switch activated,
voltage is provided from the proximity switch to right wing
relay terminal 86, energizing the relay. With the relay
energized, voltage is provided to wing mow enable
switch. When the wing mow enable switch is placed in
the on position, voltage is provided to the right mow
solenoid, energizing the solenoid.
The left wing circuit operates the same as the right wing
circuit.

4-36 4203780 First Edition

 ELECTRICAL

Mow Circuit Schematic

See Figures 4-20 and 4-21.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A Red/Wht Red/Wht
Pur B
Red
B C Red/Lt Blu Red/Lt Blu
Pnk/Blu
I Red/Yel Red/Yel

Red
S

A Yel K2

4
Accessory
X Y Relay
Red 87 Red

30
S5
87
Seat Pnk/Blu
Switch 86 85 Blk

Off
On

Pur Wht/Brn
Red

Wht/Brn
Brn
F2
Org 30A
+12V Enable K4
Circuit
Time
Breaker 1 Sec.
Off Delay Delay
Output Gnd Relay
Org
Yel Blk
F1
50A
Circuit
Breaker

Brn

Brn
Red

Red
M1
M Starter Unswitched Power Circuit
(+) G1
Motor Switched Power Circuit
12V
(-) Battery Interlock Circuit

Blk Ground Circuit

TN1806
Figure 4-20

4203780 First Edition 4-37

 ELECTRICAL

Mow Circuit Schematic

Continued

S8
Front
Limit
Switch

Off
On

Red/Wht Red/Wht Red/Wht Brn/Red

Red/Lt Blu Red/Lt Blu
Red/Yel Red/Yel

S6
Right
Wing

4 Wht/Blk 2 Blk
Proximity
Switch
Wht 1 Red/Blu Red/Yel

N.O.
S9
Red/Wht Front
Mow
S7 Enable
Left Switch
86 30 K8 Wing
Right Proximity Off
Wing Switch Off
85 87 87 Relay On
Wht/Blk 2 Blk Wht 1 Red/Blu Red/Lt Blu
Blk Pnk
N.O.
Red/Wht Brn/Red
Wht

86 30 K9
Wht
Left
S10
Wing Y2
85 87 87
Wing
Relay Front
Mow Off Blk Mow
Blk Pnk Enable Off
Switch Solenoid
On

Pnk
Lt Grn

Pnk Pnk
Org

Lt Grn
Org
Y3 Y4
Right Left
Mow Mow
Solenoid Blk Blk Solenoid
Right Mow Circuit
Left Mow Circuit
Front Mow Circuit
Ground Circuit

TN1807
Figure 4-21

4-38 4203780 First Edition

 ELECTRICAL

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4203780 First Edition 4-39

 ELECTRICAL

Four Wheel Drive Circuit—Theory of Four Wheel Drive Reverse Circuit

Operation When the 4WD switch is held in the momentary on
position, voltage is provided to the 4WD and 4WD rev
Unswitched Power Circuit solenoids, energizing the solenoids.
Unswitched power is available from the battery positive
terminal to the starter motor battery terminal and then
from the starter motor battery terminal to 50-amp circuit
breaker (F1) battery terminal. Unswitched power is
available through the 50-amp circuit breaker (F1) to
30-amp circuit breaker (F2) input terminal and from
circuit breaker (F2) input terminal to 10-amp circuit
breaker (F5).
Unswitched power is available from 30-amp circuit
breaker (F2) output terminal to accessory relay terminal
30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.

Switched Power Circuit

4 When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to PTO switch terminal B and from
terminal B to the seat switch.
Accessory relay terminal 87 also provides switched
power to 10-amp circuit breaker (F6). Circuit breaker (F6)
provides voltage to 4WD switch and then to the diff lock
switch.

Interlock Circuit
The operator must be on the seat before releasing the
park brake or placing the PTO switch in the on position.
(See “Run Circuit—Theory of Operation” on page 4-30.)

Four Wheel Drive Circuit

When the 4WD switch is placed in the on position,
voltage is provided to the reverse kick-out switch. When
the traction pedal is in the forward position, the reverse
kick-out switch is placed in the forward position, voltage is
provided to the 4WD solenoid, energizing the solenoid. If
the traction pedal is in the reverse position, the reverse
kick-out switch is placed in the reverse position, opening
the circuit to the 4WD solenoid.

Diff Lock Circuit

When the diff lock switch is in the on position, voltage is
provided to the diff lock solenoid, energizing the solenoid.

4-40 4203780 First Edition

 ELECTRICAL

Four Wheel Drive Circuit Schematic

See Figure 4-22.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

Unswitched Power Circuit

S
Switched Power Circuit
Red
A Yel K2 4WD Circuit

4
Accessory
X Diff Lock Circuit
Y Relay
Interlock Circuit
Red 87 Pur
Ground Circuit
30 Pur
87
F6
Pnk/Blu 10A
86 85 Circuit S12
Blk Breaker Reverse
Pnk Kick Out
S5 S11 Switch
Seat 4WD
Switch Switch On Reverse
Red
Off Forward
Off Mom. ON

On Blu
F2 Pnk
30A Pur Wht/Brn Pur
Org
Circuit Grn
Breaker
Wht/Brn Y5
Brn Wht 4WD
Grn
Org Solenoid Blk
F1 +12V Enable K4
Time Y6
50A 1 Sec.
Delay 4WD Rev Blk
Circuit Off Delay
Relay Solenoid S13
Breaker Output Gnd
Diff
Brn Yel Blk Lock
Switch
Brn
Off
Red
On

Wht
Red
G1 M1 Grn
(+)
12V M Starter Y7
(-) Battery Motor Diff
Lock
Blk
Solenoid Blk

TN1809
Figure 4-22

4203780 First Edition 4-41

 ELECTRICAL

Four Wheel Drive Reverse Circuit Schematic

See Figure 4-23.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

Unswitched Power Circuit

S
Switched Power Circuit
Red
A Yel K2 4WD Circuit

4
Accessory
X Reverse Circuit
Y Relay
Interlock Circuit
Red 87 Pur
Ground Circuit
30 Pur
87
F6
Pnk/Blu 10A
86 85 Circuit S12
Blk Breaker Reverse
Pnk Kick Out
S5 S11 Switch
Seat 4WD
Switch Switch On Reverse
Red
Off Forward
Off Mom. ON

On Blu
F2 Pnk
30A Pur Wht/Brn Pur
Org
Circuit Grn
Breaker
Wht/Brn Y5
Brn Wht 4WD
Grn
Org Solenoid Blk
F1 +12V Enable K4
Time Y6
50A 1 Sec.
Delay 4WD Rev Blk
Circuit Off Delay
Relay Solenoid S13
Breaker Output Gnd
Diff
Brn Yel Blk Lock
Switch
Brn
Off
Red
On

Wht
Red
G1 M1 Grn
(+)
12V M Starter Y7
(-) Battery Motor Diff
Lock
Blk
Solenoid Blk

TN1810
Figure 4-23

4-42 4203780 First Edition

 ELECTRICAL

Page Intentionally Blank

4203780 First Edition 4-43

 ELECTRICAL

Cruise Control—Theory of Operation • Cruise control switch is momentarily placed in the

disable position.
Unswitched Power Circuit When the cruise control switch is placed in the disable
Unswitched power is available from the battery positive position, voltage is provided to cruise cancel relay
terminal to the starter motor battery terminal and then terminal 86, energizing the relay. With the cruise cancel
from the starter motor battery terminal to 50-amp circuit relay energized, voltage is interrupted to the cruise
breaker (F1) battery terminal. Unswitched power is control switch and to cruise relay terminal 86,
available through the 50-amp circuit breaker (F1) to de-energizing the relay. With the cruise relay
30-amp circuit breaker (F2) input terminal and from de-energized, the cruise control circuit is turned off.
circuit breaker (F2) input terminal to 10-amp circuit Diode (V8) conducts to ground the reverse voltage
breaker (F5). generated when the cruise control magnet de-activates.
Unswitched power is available from 30-amp circuit
breaker (F2) output terminal to accessory relay terminal
30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.

Switched Power Circuit

When the key switch is turned to the run position, voltage

4 is provided from key switch terminal I to accessory relay

terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to PTO switch terminal B and from
terminal B to the seat switch.
Accessory relay terminal 87 also provides switched
power to 10-amp circuit breaker (F6). Circuit breaker (F6)
provides voltage to horn relay terminal 30 and from horn
relay terminal 86 to the brake pedal switch.

Interlock Circuit
The operator must be on the seat before releasing the
park brake. (See “Run Circuit—Theory of Operation” on
page 4-30.)

Cruise Control Circuit

When the brake pedal switch is in the on position, voltage
is provided to the cruise control switch and then to cruise
control relay terminal 30.
When the cruise control switch is momentarily placed in
the enable position, voltage is provided to cruise relay
terminal 86, energizing the relay. With the relay
energized, voltage is provided from cruise relay terminal
87 to the cruise control magnet, activating the magnet. At
the same time voltage is also provided from cruise relay
terminal 87 to cruise cancel relay terminal 87A. Now the
cruise cancel relay terminal 30 provides voltage back to
the cruise control switch, and then to cruise relay terminal
86, keeping the relay energized.
The cruise relay will continue to activate the cruise
control magnet until the following occurs:
• Brake pedal is depressed, placing the brake pedal
switch in the off position.

4-44 4203780 First Edition

 ELECTRICAL

Cruise Control Circuit Schematic

See Figures 4-24 and 4-25.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
Switch Switch
Breaker
Red/
Off Off
S1 Brn
Key On On
Switch Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

S
Red
A Yel K2

4
Accessory
X Y Relay
Red 87 Pur
30 Pur
F6
87 K7
Pnk/Blu 10A
Horn
86 85 Circuit
Blk Relay
Breaker
Red
87
S5
30
Seat
Switch 87
Lt Blu/Red
Red
Lt Blu/Red 86 85
Off
On
F2
Org 30A Pur Wht/Brn
Circuit Lt Blu/Red
Breaker
Wht/Brn
Brn
Org
F1 +12V Enable K4
50A 1 Sec.
Time
Circuit Off Delay Delay
Breaker Output Gnd Relay
Unswitched Power Circuit
Brn Yel Blk Switched Power Circuit
Interlock Circuit
Brn Ground Circuit
Red

Red
G1 M1
(+)
12V M Starter
(-) Battery Motor

Blk

TN1811
Figure 4-24

4203780 First Edition 4-45

 ELECTRICAL

Cruise Control Circuit Schematic

Continued

S14
Brake

4 Pedal
Switch

Off
On

Lt Blu/Red Wht

S15
Cruise
Control
Switch K6
Cruise
Disable
Relay
Lt Blu/Red Wht Off Wht 87
Enable
30
Wht/Red
Wht 87
Wht/Grn Wht/Grn Gry/ Gry/
86 85 Blk Red Red
Mom. Sw.

K5
Unswitched Power Circuit Cruise Y8
V8 Cruise
Switched Power Circuit Cancel
Relay Control
Gry/
Cruise Control Circuit Red Magnet
Wht/Grn 87A 5B Gry/
Diff Lock Circuit
Blk Blk
30
Interlock Circuit
87 Blk
Ground Circuit
Wht/Red Blk Blk

86 85
5B
Blk

TN1812
Figure 4-25

4-46 4203780 First Edition

 ELECTRICAL

Cruise Control Disable Circuit Schematic

See Figures 4-26 and 4-27.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
Switch Switch
Breaker
Red/
Off Off
S1 Brn
Key On On
Switch Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I

S
Red
A Yel K2

4
Accessory
X Y Relay
Red 87 Pur
30 Pur
F6
87 K7
Pnk/Blu 10A
Horn
86 85 Circuit
Blk Relay
Breaker
Red
87
S5
30
Seat
Switch 87
Lt Blu/Red
Red
Lt Blu/Red 86 85
Off
On
F2
Org 30A Pur Wht/Brn
Circuit Lt Blu/Red
Breaker
Wht/Brn
Brn
Org
F1 +12V Enable K4
50A 1 Sec.
Time
Circuit Off Delay Delay
Breaker Output Gnd Relay

Brn Yel Blk

Brn
Red Unswitched Power Circuit
Switched Power Circuit
Red Interlock Circuit
G1 M1
(+) Ground Circuit
12V M Starter
(-) Battery Motor

Blk

TN1813
Figure 4-26

4203780 First Edition 4-47

 ELECTRICAL

Cruise Control Disable Circuit Schematic

Continued

S14
Brake

4 Pedal
Switch

Off
On

Lt Blu/Red Wht

S15
Cruise
Control
Switch K6
Cruise
Disable Relay
Lt Blu/Red Wht Off
Wht 87
Enable
30
Wht/Red
Wht 87
Wht/Grn Wht/Grn Gry/ Gry/
86 85 Blk Red Red
Mom. Sw.

K5
Cruise Y8
V8 Cruise
Cancel
Unswitched Power Circuit Relay Control
Gry/
Red Magnet
Switched Power Circuit Wht/Grn 87A 5B Gry/
Cruise Control Circuit Blk Blk
30
Cruise Control Disable Circuit 87 Blk

Interlock Circuit Wht/Red Blk Blk

Ground Circuit 86 85
5B
Blk

TN1814
Figure 4-27

4-48 4203780 First Edition

 ELECTRICAL

Page Intentionally Blank

4203780 First Edition 4-49

 ELECTRICAL

Work Lights Circuit—Theory of Operation

Unswitched Power Circuit Light Circuit
Unswitched power is available from the battery positive When the light switch is placed in the work position,
terminal to the starter motor battery terminal and then voltage is provided to the work lights, turning on the
from the starter motor battery terminal to 50-amp circuit lights. Voltage is also provided from the light switch to
breaker (F1) battery terminal. Unswitched power is cab/canopy connector (J4) terminal 7.
available through the 50-amp circuit breaker (F1) to When the light switch is placed in the road position,
30-amp circuit breaker (F2) input terminal and from voltage is provided to the tail light, turning on the light.
circuit breaker (F2) input terminal to 10-amp circuit Voltage is also provided from the light switch to
breaker (F5). cab/canopy connector (J4) terminals 2 and 6.
Unswitched power is available from 30-amp circuit
breaker (F2) output terminal to accessory relay terminal
30.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.
Unswitched power is also available from the starter motor
battery terminal to 50-amp circuit breaker (F3). Circuit
breaker (F3) provides unswitched power to 30-amp
4 circuit breaker (F7) and to cab/canopy connector (J4)
terminal 8. Unswitched power is provided from circuit
breaker (F7) to the light switch and to cab/canopy
connector (J4) terminal 5.

Interlock Circuit
The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is
provided with 12 volts:
• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Switched Power Circuit

When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to 10-amp circuit breaker (F6).
Switched power is provided from 10-amp circuit breaker
(F6) to cab/canopy connector (J4) terminal 4.

4-50 4203780 First Edition

 ELECTRICAL

Work Lights Circuit Schematic

See Figures 4-28 and 4-29.

Org Org
Brn/Red Brn/Red Wht

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I
F6 Wht

S 10A
Circuit
A Yel K2 Breaker
Red

4
Accessory Pur
X Y Relay
Red 87 Pur
30

87
Pnk/Blu
86 85 Blk

S5
Seat
Switch
Red
Red
Off
On

F2 Pur Wht/Brn
Org 30A
Circuit
Breaker Wht/Brn
Brn

Org K4
+12V Enable
F1 1 Sec.
Time
50A Off Delay Delay
Circuit Output Gnd Relay
Breaker
Yel Blk
Red
Brn

F3
Brn 50A
Circuit Brn
Red
Breaker
Brn

Red
M1
M Starter
(+) G1
Motor Unswitched Power Circuit
12V
(-) Battery Switched Power Circuit

Blk Interlock Circuit

Ground Circuit
TN1835
Figure 4-28

4203780 First Edition 4-51

 ELECTRICAL

Work Lights Circuit Schematic

Continued

Wht Wht

S17
Light Optional
Red Red Switch Work Lights
F7
30A Road
Circuit Off
Breaker Work
Org/
Blu Tan/Red
Tan/Red
Org/Blu
Wht

Wht

Gry Wht Wht Wht Tan/

Red
Org/Blu
Gry
E12 E13 E11

4 Work
Light
Work
Light
Tail
Light

Blk Blk Blk Blk Blk

Red

Gry 6
Wht 4
Red Red 8

Org/Blu Org/Blu 5 J4
Cab/Canopy
Lt Grn Lt Grn 1
Option
Lt Blu Lt Blu 3 Connector
Tan/Red 2

Wht 7
E2 E10 E1
Glow Left Right
Plug Turn Turn
Light Indicator Indicator

Blk Blk Blk Blk Blk

Unswitched Power Circuit
Switched Power Circuit
To Ground Circuit
Fuel Level
Gauge Ground
Terminal
(See Power Circuit)

TN1836
Figure 4-29

4-52 4203780 First Edition

 ELECTRICAL

Instrumentation Circuit—Theory of Engine Temperature Gauge

Operation The engine temperature sensor resistance changes in
relationship to the engine coolant temperature. As the
Unswitched Power Circuit engine temperature sensor is heated, the resistance of
the sensor changes from a high resistance to a low
Unswitched power is available from the battery positive
resistance. The amount of resistance in the circuit
terminal to the starter motor battery terminal and then
controls the amount of current flowing through the engine
from the starter motor battery terminal to 50-amp circuit
temperature gauge. The amount of current flowing
breaker (F1) battery terminal. Unswitched power is
through the circuit is indicated by the gauge as a
available through the 50-amp circuit breaker (F1) to
temperature measurement.
30-amp circuit breaker (F2) input terminal and from
circuit breaker (F2) input terminal to 10-amp circuit Tachometer
breaker (F5).
The engine speed sensor provides a signal relative to the
Unswitched power is available from 30-amp circuit speed of the engine to the tachometer. The tachometer
breaker (F2) output terminal to accessory relay terminal indicates the speed of the engine on the gauge in rpms.
30.
Unswitched power is provided from 10-amp circuit Hour Meter
breaker (F5) to PTO switch terminal E and then from The hour meter starts logging hours when switched
terminal E to time delay relay +12V terminal. power is provided by the accessory relay.
Interlock Circuit Fuel Gauge
The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is
The float attached to the fuel level sender moves as the
fuel level changes to various levels. The resistance of the
4
provided with 12 volts: fuel level sender changes in relationship to the position of
• PTO switch in the off position the float. As the resistance changes, the amount of
• Park brake switch in the on position current flowing through the circuit changes and the
amount of current flowing is indicated by the fuel gauge.
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the Air Filter Service Light
park brake switch to key switch terminal B.
When the air filter pressure switch is closed, a ground is
Switched Power Circuit provided to the air filter service light, turning on the light.
When the key switch is turned to the run position, voltage Return Filter Service Light
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay When the return filter pressure switch is closed, a ground
energized, switched power is provided from accessory is provided to the return filter service light, turning on the
relay terminal 87 to 10-amp circuit breaker (F6) and light.
10-amp circuit breaker (F4).
Hyd Oil Temp Light
Switched power is provided from 10-amp circuit breaker
When the hyd temp switch is closed, a ground is provided
(F6) to horn relay terminals 30 and 86.
to the hyd temp light, turning on the light.
Switched power is provided from 10-amp circuit breaker
Ground is also provided from the hyd temp switch
(F4) to the gauges and the indicator lights.
through diode (V6) to horn relay terminal 85, energizing
Volt Meter the relay. With the relay energized, voltage is provided
from horn relay terminal 87 to the horn, turning on the
Voltage is provided from 10-amp circuit breaker (F4) to
horn.
the volt meter. The volt meter indicates the condition of
the battery. Charge Filter Service Light
When the charge filter pressure switch is closed, a
ground is provided to the charge filter service light,
turning on the light.

4203780 First Edition 4-53

 ELECTRICAL

Low Charge Pressure Light

When the low charge pressure switch is closed, a ground
is provided to the low charge light, turning on the light.

Engine Coolant Temp Light

When the engine coolant temp switch is closed, a ground
is provided to the engine coolant temp light, turning on
the light.
Ground is also provided from the hyd temp switch
through diode (V2) to horn relay terminal 85, energizing
the relay. With the relay energized, voltage is provided
from horn relay terminal 87 to the horn, turning on the
horn.

Engine Oil Pressure Light

When the engine oil pressure is below 7 psi (0.483 bar),
the engine oil pressure switch contacts close. With the
switch contacts closed, a ground is provided to the
engine oil pressure light, turning on the light.

4-54 4203780 First Edition

 ELECTRICAL

Instrumentation Circuit Schematic

See Figures 4-30 through 4-32.

Org Org
Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I
Red
S
Red Red
Yel K2 F6
A
10A

4
Accessory
X Y Relay Circuit
Pur Breaker
Red 87 Pur

30 Pnk/Blu

87
Pnk/Blu Pnk/
86 85 Blu F4
Blk 10A
Circuit
S5 Org Breaker
Seat
Org
Switch
Red

Off
On
F2
Org 30A Pur Wht/Brn
Circuit
Breaker
Wht/Brn
Brn
Org
F1 +12V Enable K4
50A 1 Sec.
Time
Circuit Off Delay Delay
Breaker Output Gnd Relay

Brn Yel Blk

Brn
Red

Red
G1 M1
(+)
12V M Starter Unswitched Power Circuit
(-) Battery Motor
Switched Power Circuit

Blk Interlock Circuit

Ground Circuit

TN1822
Figure 4-30

4203780 First Edition 4-55

 ELECTRICAL

Instrumentation Circuit Schematic

Continued

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn
K7 Wht
H1 Org
Horn Horn
Relay Blk

Red 87

30

87
Lt Blu/Red Wht/Grn
86 85 Wht/Grn

Red

Org

Org Org Org Org Org Org Org Org

Org Org
+12V +12V +12V

+12V H3 +12V
H2 Engine H4 H5 H6
Volt Temperature Tachometer Hour Fuel
Meter Gauge Meter Gauge
Gnd Gnd
Gnd Signal Gnd Signal Gnd Signal

Blk Blk Lt B1 Blk Blk Brn Blk Tan B3

Blk
Grn
Engine B2 Blk Blk
Engine Fuel
Temperature Level
Sensor Speed
Sensor Blk Sensor
Brn

Blk Blk

Switched Power Circuit

Engine Temperature Circuit
Oil Pressure Circuit
Fuel Level Circuit
Ground Circuit
TN1823
Figure 4-31

4-56 4203780 First Edition

 ELECTRICAL

Instrumentation Circuit Schematic

Continued

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org

Org Org Org Org Org Org Wht/ Org Org

Grn
E4 E5 E6
E3 V6
Return Hyd Charge
Air Filter Grn\
Filter Oil Wht Filter
Blu/ Tan Service Gry/
Wht Service Temp Wht
Service
Light Grn\
Light Light
Light Wht

Blu/ Tan Gry/

Wht Grn\ Wht
Wht
B4 B5 B7
Air Return B6 Charge
P Filter P Filter Hyd P Filter

Blu/
Wht Blk
Pressure
Switch
Tan Blk
Pressure
Switch
Grn\
t˚ Oil
Temp
Switch
Gry/
Pressure
Switch 4
Wht Wht
V3 V4
V5 V7
Wht/ Wht/
Blk Blk Wht/ Wht/
Blk Blk

Org Wht/ Org Org Org Org

S16 Grn
Horn/Test E9 E8 E7
V2
Switch Engine Engine Low
Grn
Off
Oil Coolant Charge
Blu Pressure Temp Gry/ Pressure
On Red
Light Light Light
Grn

B10 B9 B8
Blk
Engine Engine Low
P Oil t˚ Coolant P Charge
Pressure Temp Pressure
Switch Switch Switch
Blk Grn Blk

V1
Wht/
Blk

Switched Power Circuit Air Filter Circuit Charge Filter Circuit Low Charge Pressure Circuit
Ground Circuit Return Filter Circuit Engine Oil Pressure Circuit
Hyd Oil Temp Engine Coolant Temp Circuit

TN1824
Figure 4-32

4203780 First Edition 4-57

 ELECTRICAL

Horn/Test Circuit—Theory of When the horn/test switch is in the on position, a ground

is provided through diode (V3) to the air filter service
Operation light, turning on the light. Ground is also provided through
diode (V4) to the return filter service light, turning on the
Unswitched Power Circuit light. Ground is also provided through diode (V5) to the
Unswitched power is available from the battery positive hyd oil temp light, turning on the light. Ground is also
terminal to the starter motor battery terminal and then provided through diode (V7) to the charge filter service
from the starter motor battery terminal to 50-amp circuit light, turning on the light. Ground is also provided through
breaker (F1) battery terminal. Unswitched power is diode (V1) to the engine coolant temp light, turning on the
available through the 50-amp circuit breaker (F1) to light.
30-amp circuit breaker (F2) input terminal and from With the horn/test switch in the on position, two ground
circuit breaker (F2) input terminal to 10-amp circuit paths are provided to the horn relay. Ground is provided
breaker (F5). through diodes (V1 and V2) and diodes (V5 and V6) to
Unswitched power is available from 30-amp circuit horn relay terminal 85, energizing the relay. With the
breaker (F2) output terminal to accessory relay terminal relay energized, voltage is provided from horn relay
30. terminal 87 to the horn, turning on the horn.
Unswitched power is provided from 10-amp circuit
breaker (F5) to PTO switch terminal E and then from
terminal E to time delay relay +12V terminal.

Interlock Circuit
4 The interlock circuit provides 12 volts to the key switch.
The following must occur before the key switch is
provided with 12 volts:
• PTO switch in the off position
• Park brake switch in the on position
With the PTO switch in the off position and park brake
switch in the on position, voltage is provided from the
park brake switch to key switch terminal B.

Switched Power Circuit

When the key switch is turned to the run position, voltage
is provided from key switch terminal I to accessory relay
terminal 86, energizing the relay. With the relay
energized, switched power is provided from accessory
relay terminal 87 to 10-amp circuit breaker (F6) and
10-amp circuit breaker (F4).
Switched power is provided from 10-amp circuit breaker
(F6) to horn relay terminals 30 and 86.
Switched power is provided from 10-amp circuit breaker
(F4) to the gauges and the indicator lights.

Horn/Test Circuit
When the horn/test switch is pressed, the horn sounds
and the following indicator lights turn on:
• Air filter service light
• Return filter service light
• Hyd oil temp light
• Charge filter service light
• Engine coolant temp light

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Horn/Test Circuit Schematic

See Figures 4-33 through 4-35.

Org Org

Brn/Red Brn/Red

Org S4
F5
S3 Park
10A
PTO Brake
Circuit
S1 Switch Switch
Breaker
Key
Red/
Switch Brn Off Off
On On
Off
F Org/Brn Brn/Red
Run Brn E

Start
Brn/ A
Pur B
Red
B C
Pnk/Blu
I
Red
S
Red Red
Yel K2 F6

4
A
Accessory 10A
X Y Relay Circuit
Pur Breaker
Red 87 Pur

30 Pnk/Blu

87
Pnk/Blu Pnk/
86 85 Blu F4
Blk 10A
Circuit
S5 Org Breaker
Seat
Org
Switch
Red

Off
On
F2
Org 30A Pur Wht/Brn
Circuit
Breaker
Wht/Brn
Brn
Org
F1 +12V Enable K4
50A 1 Sec.
Time
Circuit Off Delay Delay
Breaker Output Gnd Relay

Brn Yel Blk

Brn
Red

Red
G1 M1
(+) Unswitched Power Circuit
12V M Starter
(-) Battery Motor Switched Power Circuit
Interlock Circuit
Blk
Ground Circuit

TN1825
Figure 4-33

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 ELECTRICAL

Horn/Test Circuit Schematic

Continued

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn
K7 Wht
H1 Org
Horn Horn
Relay Blk

Red 87

30

87
Lt Blu/Red Wht/Grn
86 85 Wht/Grn

Red

Org

Org Org Org Org Org Org Org Org

Org Org
+12V +12V +12V

+12V H3 +12V
H2 Engine H4 H5 H6
Volt Temperature Tachometer Hour Fuel
Meter Gauge Meter Gauge
Gnd Gnd
Gnd Signal Gnd Signal Gnd Signal

Blk Blk Lt B1 Blk Blk Brn Blk Tan B3

Blk
Grn
Engine B2 Blk Blk
Engine Fuel
Temperature Level
Sensor Speed
Sensor Blk Sensor
Brn

Blk

Switched Power Circuit Horn Circuit

Ground Circuit Test Circuit

TN1826
Figure 4-34

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Horn/Test Circuit Schematic

Continued

Wht/Grn Wht/Grn
Wht/Grn Wht/Grn

Org

Org Org Org Org Org Org Wht/ Org Org

Grn
E4 E5 E6
E3 V6
Return Hyd Charge
Air Filter Grn\
Filter Oil Wht Filter
Blu/ Tan Service Gry/
Wht Service Temp Wht
Service
Light Grn\
Light Light
Light Wht

Blu/ Tan Gry/

Wht Grn\ Wht
Wht
B4 B5 B7
Air Return B6 Charge
P Filter P Filter Hyd P Filter

Blu/
Wht Blk
Pressure
Switch
Tan Blk
Pressure
Switch
Grn\
t˚ Oil
Temp
Switch
Gry/
Pressure
Switch 4
Wht Wht
V3 V4
V5 V7
Wht/ Wht/
Blk Blk Wht/ Wht/
Blk Blk

Org Wht/ Org Org Org Org

S16 Grn
Horn/Test E9 E8 E7
V2
Switch Engine Engine Low
Grn
Off
Oil Coolant Charge
Blu Pressure Temp Gry/ Pressure
On Red
Light Light Light
Grn

B10 B9 B8
Blk
Engine Engine Low
P Oil t˚ Coolant P Charge
Pressure Temp Pressure
Switch Switch Switch
Blk Grn Blk

V1
Wht/
Blk

Switched Power Circuit

Test Circuit
Ground Circuit

TN1827
Figure 4-35

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Troubleshooting
Glow Plug Circuit
Symptom: Glow plugs do not get hot.

Probable Cause Remedy

Faulty circuit breaker. Test 50A circuit breaker F3. (See “Thermal Circuit Breakers Test” on page 4-73.)
Faulty power circuit. Check continuity between 50A circuit breaker F3 and glow plug solenoid terminal.
Continuity must be indicated.
Faulty glow plug switch. Test glow plug switch. (See “Glow Plug Switch Test” on page 4-76.)
Faulty glow plug switch circuit. Check continuity between the glow plug switch and glow plug solenoid. Continuity must
be indicated.
Open glow plug solenoid ground circuit. Check continuity between glow plug solenoid terminal and ground. Continuity must be
indicated.
Faulty glow plug solenoid output circuit. With the glow plug switch in the ON position, measure voltage between glow plug output
terminal and ground. Voltage must be approximately 12 VDC.
Faulty glow plug solenoid. Replace glow plug solenoid.
Faulty connection at glow plug terminal Clean and tighten ring terminal connector.

4
strip.

Start Circuit
Symptom: Starter motor solenoid does not engage.

Probable Cause Remedy

Faulty 50A circuit breaker. Test 50A circuit breaker F1. (See “Thermal Circuit Breakers Test” on page 4-73.)
Tripped 30A circuit breaker. Reset 30A circuit breaker F2.
Park brake lever is in the released position. Place the park brake lever in the locked position.
PTO switch is in the ON position. Place the PTO switch in the OFF position.
Faulty park brake switch. Test park brake switch. (See “Micro Switches Test” on page 4-82.)
Faulty PTO Switch. Test PTO switch. (See “PTO Switch Test” on page 4-77.)
Faulty accessory relay. Test accessory relay. (See “Relays Test” on page 4-74.)
Faulty key switch. Test key switch. (See “Key Switch Test” on page 4-75.)
Faulty key switch circuit. Measure continuity between the key switch and starter solenoid. Continuity must be
indicated.

Symptom: Engine does not run.

Probable Cause Remedy

Faulty fuel shutoff solenoid. Test fuel shutoff solenoid. (See “Fuel Shutoff Solenoid Test” on page 4-84.)
Faulty fuel pull-in relay. Test fuel pull-in relay. (See “Relays Test” on page 4-74.)
Faulty park brake switch. Test park brake switch. (See “Micro Switches Test” on page 4-82.)
Faulty key switch. Test key switch. (See “Key Switch Test” on page 4-75.)
Faulty key switch circuit. Measure continuity between the key switch and starter solenoid. Continuity must be
indicated.

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Run Circuit
Symptom: Engine stops running when the park brake is released.

Probable Cause Remedy

Faulty seat switch. Test seat switch. (See “Seat Switch Test” on page 4-76.)
Faulty time delay relay. Test time delay relay. (See “Time Delay Relay Test” on page 4-74.)

Charging Circuit
Symptom: Battery not charging.

Probable Cause Remedy

Faulty alternator output circuit. Make sure alternator output cable and battery positive (+) cable terminals are clean and
tight.
Check continuity between starter battery terminal and battery positive (+) terminal.
Continuity must be indicated.
Faulty battery ground circuit. Make sure battery negative (–) cable terminals are clean and tight.
Check continuity between battery negative (–) terminal and ground. Continuity must be

Faulty battery.
indicated.
Check specific gravity of the individual battery cells. 4
Mow Circuit
Symptom: Front, right, and left mow solenoids do not energize.

Probable Cause Remedy

Faulty PTO switch. Test PTO switch. (See “PTO Switch Test” on page 4-77.)

Symptom: Front mow solenoid does not energize.

Probable Cause Remedy

Faulty front limit switch. Test front limit switch. (See “Front Limit Switch Test” on page 4-77.)
Faulty front mow enable switch. Test front mow enable switch. (See “Front Mow Enable Switch Test” on page 4-78.)
Faulty front mow solenoid. Test front mow solenoid. (See “Mow Solenoids” on page 4-105.)
Faulty wire harness. Measure continuity between the PTO switch and front limit switch. Continuity must be
indicated.
Measure continuity between the front limit switch and front mow enable switch. Continuity
must be indicated.
Measure continuity between the front mow enable switch and the front mow solenoid.
Continuity must be indicated.
Measure continuity between ground and the front mow solenoid ground terminal.
Continuity must be indicated.

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Symptom: Right mow solenoid does not energize.

Probable Cause Remedy

Faulty right wing proximity switch. With the right wing in the lowered position, check the proximity switch LED indicator. If the
LED does not turn on, substitute the proximity switch with a known good switch.
Faulty right wing relay. Test right wing relay. (See “Relays Test” on page 4-74.)
Faulty wing mow enable switch. Test wing mow enable switch. (See “Wing Mow Enable and Light Switches Test” on
page 4-79.)
Faulty right mow solenoid. Test right mow solenoid. (See “Solenoids Test” on page 4-83.)
Faulty wire harness. Measure continuity between the PTO switch and the right wing proximity switch.
Continuity must be indicated.
Measure continuity between the PTO switch and right wing relay terminal 30. Continuity
must be indicated.
Measure continuity between the right wing proximity switch and right wing relay terminal
86. Continuity must be indicated.
Measure continuity between ground and right wing relay terminal 85. Continuity must be
indicated.
Measure continuity between right wing relay terminal 87 and the wing mow enable switch.
Continuity must be indicated.
Measure continuity between the wing mow enable switch and the right mow solenoid.

4 Continuity must be indicated.

Measure continuity between ground and the right mow solenoid ground terminal.
Continuity must be indicated.

Symptom: Left mow solenoid does not energize.

Probable Cause Remedy

Faulty left wing proximity switch. With the left wing in the lowered position, check the proximity switch LED indicator. If the
LED does not turn on, substitute the proximity switch with a known good switch.
Faulty left wing relay. Test left wing relay. (See “Relays Test” on page 4-74.)
Faulty wing mow enable switch. Test wing mow enable switch. (See “Wing Mow Enable and Light Switches Test” on
page 4-79.)
Faulty left mow solenoid. Test left mow solenoid. (See “Solenoids Test” on page 4-83.)
Faulty wire harness. Measure continuity between the PTO switch and the left wing proximity switch. Continuity
must be indicated.
Measure continuity between the PTO switch and left wing relay terminal 30. Continuity
must be indicated.
Measure continuity between the left wing proximity switch and left wing relay terminal 86.
Continuity must be indicated.
Measure continuity between ground and left wing relay terminal 85. Continuity must be
indicated.
Measure continuity between left wing relay terminal 87 and the wing mow enable switch.
Continuity must be indicated.
Measure continuity between the wing mow enable switch and the left mow solenoid.
Continuity must be indicated.
Measure continuity between ground and the left mow solenoid ground terminal.
Continuity must be indicated.

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Four Wheel Drive Circuit

Symptom: Four wheel drive solenoid does not energize.

Probable Cause Remedy

Tripped 10-amp circuit breaker (F6). Reset circuit breaker.
Faulty 4WD switch. Test 4WD switch. (See “4WD Switch Test” on page 4-81.)
Faulty reverse kick-out switch. Test reverse kick-out switch. (See “Micro Switches Test” on page 4-82.)
Faulty 4WD solenoid. Test 4WD solenoid. (See “Solenoids Test” on page 4-83.)
Faulty wire harness. Measure continuity between 10-amp circuit breaker (F6) and the 4WD switch. Continuity
must be indicated.
Measure continuity between the 4WD switch and the reverse kick-out switch (blu wire).
Continuity must be indicated.
Measure continuity between the reverse kick-out switch and the 4WD solenoid (grn wire).
Continuity must be indicated.
Measure continuity between ground and the 4WD solenoid ground terminal. Continuity
must be indicated.

Symptom: Four wheel drive solenoid does not energize when the 4WD switch is in reverse
position.

Probable Cause Remedy

4
Faulty 4WD switch. Test 4WD switch. (See “4WD Switch Test” on page 4-81.)
Faulty wire harness. Measure continuity between the 4WD switch and the reverse kick-out switch (pur wire).
Continuity must be indicated.

Symptom: Four wheel drive rev solenoid does not energize when the 4WD switch is in
reverse position.

Probable Cause Remedy

Faulty 4WD switch. Test 4WD switch. (See “4WD Switch Test” on page 4-81.)
Faulty 4WD rev solenoid. Test 4WD rev solenoid. (See “Solenoids Test” on page 4-83.)
Faulty wire harness. Measure continuity between the 4WD switch and the 4WD rev solenoid. Continuity must
be indicated.
Measure continuity between ground and the 4WD rev solenoid ground terminal.
Continuity must be indicated.

Symptom: Diff lock solenoid does not energize.

Probable Cause Remedy

Faulty diff lock switch. Test diff lock switch. (See “Diff Lock Switch Test” on page 4-82.)
Faulty diff lock solenoid. Test diff lock solenoid. (See “Solenoids Test” on page 4-83.)
Faulty wire harness. Measure continuity between the 4WD switch and the diff lock switch. Continuity must be
indicated.
Measure continuity between the diff lock switch and the diff lock solenoid. Continuity must
be indicated.
Measure continuity between ground and the diff lock solenoid ground terminal. Continuity
must be indicated.

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Cruise Control Circuit

Symptom: Cruise control magnet does not energize.

Probable Cause Remedy

Tripped 10-amp circuit breaker (F6). Reset circuit breaker.
Faulty brake pedal switch. Test brake pedal switch. (See “Micro Switches Test” on page 4-82.)
Faulty cruise control switch. Test cruise control switch. (See “Cruise Control Switch Test” on page 4-80.)
Faulty cruise relay. Test cruise relay. (See “Relays Test” on page 4-74.)
Faulty cruise cancel relay. Test cruise cancel relay. (See “Relays Test” on page 4-74.)
Faulty wire harness. Measure continuity between 10-amp circuit breaker (F6) and the horn relay. Continuity
must be indicated.
Measure continuity between the horn relay and the brake pedal switch. Continuity must
be indicated.
Measure continuity between the brake pedal switch and the cruise control switch.
Continuity must be indicated.
Measure continuity between the cruise control switch and cruise relay terminal 30 (wht
wire). Continuity must be indicated.
Measure continuity between the cruise control switch and cruise relay terminal 86
(wht/grn wire). Continuity must be indicated.

4 Measure continuity between the cruise control switch and cruise cancel relay terminal 30
(wht/grn wire). Continuity must be indicated.
Measure continuity between the cruise control switch and cruise cancel relay terminal 86
(wht/red wire). Continuity must be indicated.
Measure continuity between cruise relay terminal 87 and cruise cancel relay terminal
87A. Continuity must be indicated.
Measure continuity between cruise relay terminal 87 and the cruise control magnet.
Continuity must be indicated.
Measure continuity between ground and the cruise control magnet ground terminal.
Continuity must be indicated.

Work Light Circuit

Symptom: Work lights do not turn on.

Probable Cause Remedy

Tripped circuit breaker (F7). Reset breaker.
Faulty light switch. Test light switch. (See “Wing Mow Enable and Light Switches Test” on page 4-79.)

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Instrumentation Circuit
Horn/Test Circuit
When the horn/test switch is pressed, the horn sounds and the following indicator lights turn on:
• Air filter service light
• Return filter service light
• Hyd oil temp light
• Charge filter service light
• Engine coolant temp light
The low charge pressure and oil pressure lights remain on because the engine is not operating. If any of the lights fail
to turn on, check the light bulbs.

Symptom: Engine oil pressure light does not turn on.

Probable Cause Remedy

Faulty engine oil pressure switch. With the key switch in the OFF position, check continuity between engine oil pressure
switch and ground. Continuity must be indicated. If continuity is not indicated, replace
engine oil pressure switch.
Faulty engine oil pressure light switched With the key switch in the run position (engine off), measure voltage between engine oil
power circuit.
Faulty engine oil pressure switch circuit.
pressure light org wire terminal and ground. Voltage must be approximately 12 VDC.
Check continuity between engine oil pressure switch terminal and engine oil pressure
light terminal (blu wire). Continuity must be indicated.
4
Symptom: Engine oil pressure light stays on with engine running.

Probable Cause Remedy

Low engine oil pressure. Check engine oil pressure.
Faulty engine oil pressure switch. If engine oil pressure tests good, replace engine oil pressure switch.

Symptom: Glow plug wait light does not come on.

Probable Cause Remedy

Faulty light. Check light bulb.
Faulty light circuit. Check continuity between the glow plug switch and glow plug light. Continuity must be
indicated.
Faulty ground circuit. Check continuity between ground and glow plug light ground terminal. Continuity must be
indicated.

Symptom: Charge filter pressure light does not turn on with a blocked filter.

Probable Cause Remedy

Faulty charge filter pressure light switched With the key switch in the run position (engine off), measure voltage between hydraulic
power circuit. filter pressure light org terminal and ground. Voltage must be approximately 12 VDC.
Faulty wiring. Connect a jumper wire to charge filter pressure switch gry/wht wire terminal and ground.
With the key switch in the run position, check the charge filter service light. If the light
does not turn on, check continuity between charge filter pressure switch gry/wht wire
terminal and charge filter service light. Continuity must be indicated.
Faulty charge filter pressure switch. Replace charge filter pressure switch.

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Symptom: Charge filter pressure light is on with the key switch in the run
position (engine off).

Probable Cause Remedy

Faulty charge filter pressure switch. Replace charge filter pressure switch.

Symptom: Charge filter pressure light is on with the key switch in the run
position (engine on).

Probable Cause Remedy

Blocked hydraulic filter. Replace hydraulic filter.
Faulty charge filter pressure switch. Replace charge filter pressure switch.

Symptom: Engine temperature gauge indicates a temperature when the engine is cold.

Probable Cause Remedy

Faulty engine temperature sensor. Replace engine temperature sensor.
Faulty ground circuit. Check continuity between the engine temperature gauge and ground. Continuity must be

4 indicated.

Symptom: Engine temperature gauge does not indicate a temperature.

Probable Cause Remedy

Faulty engine temperature sensor. With a jumper wire, connect the engine temperature sensor to ground. With the key
switch in the run position, check the gauge. If the gauge is indicating full scale, replace
the engine temperature sensor.
Faulty engine temperature circuit. Check continuity between engine temperature gauge lt grn wire terminal and the engine
temperature sensor terminal. Continuity must be indicated.
Faulty switched power circuit. With the key switch in the On position, measure voltage between engine temperature
gauge org terminal and ground. Voltage must be approximately 12 VDC.
Faulty ground circuit. Check continuity between engine temperature gauge blk wire terminal and ground.
Continuity must be indicated.
Faulty engine temperature gauge. Replace the engine temperature gauge.

Symptom: Engine coolant temp light does not turn on.

Probable Cause Remedy

Faulty engine coolant temp switch. With a jumper wire, connect the engine coolant temp switch terminal to ground. With the
key switch in the run position, check the engine coolant temp light. If the light turns on,
replace the engine coolant temp switch.
Faulty wiring. Check continuity between engine coolant temp switch grn wire terminal and the engine
coolant temp light. Continuity must be indicated.

Symptom: Engine coolant temp light turns on when engine is cold.

Probable Cause Remedy

Faulty engine coolant temp switch. Disconnect the engine coolant temp switch terminal. With the key switch in the run
position, check the engine coolant temp light. If the light turns off, replace the engine
coolant temp switch.
Faulty wiring. Check ground short on engine coolant temp switch grn wire.

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Symptom: Air filter service light does not turn on.

Probable Cause Remedy

Faulty ground circuit. Check continuity between air filter pressure switch blk wire terminal and ground.
Continuity must be indicated.
Faulty air filter pressure switch. With a jumper wire, connect the air filter pressure switch blu/wht wire terminal to ground.
With the key switch in the run position, check the air filter service light. If the light turns
on, replace the air filter pressure switch.
Faulty wiring. Check continuity between air filter pressure switch blu/wht wire terminal and the air filter
service light. Continuity must be indicated.

Symptom: Return filter service light does not turn on.

Probable Cause Remedy

Faulty ground circuit. Check continuity between return filter pressure switch blk wire terminal and ground.
Continuity must be indicated.
Faulty air filter pressure switch. With a jumper wire, connect the return filter pressure switch tan wire terminal to ground.
With the key switch in the run position, check the return filter service light. If the light
turns on, replace the air pressure switch.
Faulty wiring. Check continuity between return filter pressure switch tan wire terminal and the return
filter service light. Continuity must be indicated.

Symptom: Low charge pressure light does not turn on.

4
Probable Cause Remedy
Faulty low charge pressure switch. With the key switch in the OFF position, check continuity between low charge pressure
switch and ground. Continuity must be indicated. If continuity is not indicated, replace
low charge pressure switch.
Faulty low charge pressure light switched With the key switch in the run position (engine off), measure voltage between engine oil
power circuit. pressure light org wire terminal and ground. Voltage must be approximately 12 VDC.
Faulty low charge pressure switch circuit. Check continuity between low charge pressure switch terminal and low charge pressure
light terminal (gry/red wire). Continuity must be indicated.

Symptom: Low charge pressure light stays on with engine running.

Probable Cause Remedy

Low charge pressure. Check charge pressure.
Faulty low charge pressure switch. If charge pressure tests good, replace low charge pressure switch.

Symptom: Hyd oil temp light does not turn on.

Probable Cause Remedy

Faulty hyd oil temp switch. With a jumper wire, connect the hyd oil temp switch terminal to ground. With the key
switch in the run position, check the hyd oil temp light. If the light turns on, replace the
hyd oil temp switch.
Faulty wiring. Check continuity between hyd oil temp switch grn/wht wire terminal and the hyd oil temp
light. Continuity must be indicated.

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Symptom: Tachometer does not indicate engine speed.

Probable Cause Remedy

Faulty engine speed sensor. Substitute the engine speed sensor with a known good sensor.
Faulty switched power circuit. With the key switch in the ON position, measure voltage between tachometer org terminal
and ground. Voltage must be approximately 12 VDC.
Faulty ground circuit. Check continuity between tachometer blk wire terminal and ground. Check continuity
between engine speed sensor blk wire terminal and ground. Continuity must be
indicated.
Faulty wiring. Check continuity between tachometer brn wire terminal and the engine speed sensor.
Continuity must be indicated.

Symptom: Fuel gauge does not indicate fuel level.

Probable Cause Remedy

Faulty fuel level sensor. With a jumper wire, connect the fuel level sensor brn wire terminal to ground. With the key
switch in the run position, check the gauge. If the gauge is indicating full scale, replace
the fuel level sensor.
Faulty fuel level circuit. Check continuity between fuel gauge brn wire terminal and the fuel level sensor terminal.
Continuity must be indicated.

4 Faulty switched power circuit.

Faulty ground circuit.

With the key switch in the ON position, measure voltage between engine temperature
gauge org terminal and ground. Voltage must be approximately 12 VDC.
Check continuity between fuel gauge blk wire terminal and ground. Continuity must be
indicated.

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Horn and Audible Alert Circuit

Symptom: Horn does not sound when horn switch is pressed.

Probable Cause Remedy

Faulty horn switch. With the key switch in the run position, press the horn switch. If the horn does not sound,
test horn switch.
Faulty horn. Connect a test light between horn terminals (pnk/blk and blk wires). With the key switch in
the run position, press the horn switch. If the test light turns on and the horn does not
sound, replace the horn.
Faulty horn relay. Test horn relay. (See “Relays Test” on page 4-74.)
Faulty ground circuit. Check continuity between horn blk wire terminal and ground. Continuity must be
indicated.

Symptom: Horn does not sound when engine coolant temp light turns on.

Probable Cause Remedy

Faulty diode. Test diode (V2). (See “Diodes Test” on page 4-85.)

Symptom: Horn does not sound when hyd oil temp light turns on.

Probable Cause Remedy

4
Faulty diode. Test diode (V6).(See “Diodes Test” on page 4-85.)

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Component Testing 6. Test the function of the circuit.

Does the circuit now operate properly?
Electrical System and Component YES Replace the wire.
Testing NO Continue testing other wires and
components in the circuit.
General Information
Resistance Test
Repair of the electrical system, for the most part, is
limited to the replacement of defective components or
Required Tools or Equipment
wiring. When replacing either electrical components or
wiring, be sure to apply dielectric grease (Jacobsen PN Digital Multimeter or Ohmmeter
365422) to all connector terminals to prevent corrosion.
Wiring diagrams are provided in this section for
1. Identify and locate the wire or component to be
troubleshooting and/or testing the electrical system.
checked using the electrical schematic.
Specific testing and replacement information, where
applicable, is also provided in this section.
NOTE
In addition to testing a suspected faulty component, it
may be necessary to check for shorts or breaks in the On some meters it will be necessary to select an ohms
wiring to the component. A common method of testing scale. Select an appropriate range for the component
wires or circuits is to perform a continuity check as being tested. Refer to the specifications listed in the
component test procedure.
4 described in the following tests.

NOTE
2. If using a multimeter, set to read ohms.
3. Isolate (disconnect) the component to be tested from
Before performing any component or wiring tests, check the circuit to prevent a false reading through the
for corrosion and loose or missing connections. circuit.
If a component (switch, relay, etc.) is removed for testing 4. Connect the meter leads to the terminals of the
or replacement, make sure to identify and label all wires component being tested. Check the component test
so that the component can be installed correctly. procedure for specifications and additional test
conditions.
Continuity Test
Does the resistance through the component
match the specified value listed in the test
Required Tools or Equipment
procedure?
Digital Multimeter, Ohmmeter, or Continuity Tester YES The component is good.
NO Replace the component.
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 ohm 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.

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Circuit Breakers Test Thermal Circuit Breakers Test

See Figure 4-36. See Figure 4-37.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester

1. Park the mower safely. (See “Park Mower Safely” on

1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
page 1-6.)
2. Remove circuit breaker. (See “Circuit Breakers” on
2. Allow engine to cool completely.
page 4-87.)
3. Set the multimeter to 20 volts DC.
4. Connect the black test lead to the negative
(–) battery terminal.
1 2

1
2 3

4
4
1
2
TN2041
Figure 4-36

NOTE TN1960
Be sure circuit breaker is reset prior to testing. Figure 4-37
3. Connect test leads to terminals (1 and 2).
4. Check for continuity. Glow Plug and Work Lights 50-Amp Thermal Circuit
Breaker Test
Is continuity indicated?
5. Connect the red test lead to each of the circuit
YES Circuit breaker is good. breaker terminals (1 and 2).
NO Circuit breaker is faulty; replace circuit
Is battery voltage indicated?
breaker.
YES Circuit breaker is good.
NO Circuit breaker is faulty; replace circuit
breaker.

Main 50-Amp Thermal Circuit Breaker Test

6. Connect the red test lead to each of the circuit
breaker terminals (3 and 4).
Is battery voltage indicated?
YES Circuit breaker is good.
NO Circuit breaker is faulty; replace circuit
breaker.

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Relays Test Time Delay Relay Test

See Figure 4-38. See Figure 4-39.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter

1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove relay. (See “Relays” on page 4-88.) 2. Remove relay. (See “Time Delay Relay” on
page 4-89.)

2 3
1 4
1 2
2 3 34
5 4
5

4
TN2058
TN1531
Figure 4-39
Figure 4-38
3. Connect one test lead to terminal (1).
3. Connect one test lead to terminal (1).
4. Connect the other test lead to terminal (2) and check
4. Connect the other test lead to terminal (3) and check for continuity.
for continuity.
Is continuity indicated?
Is continuity indicated?
YES The relay is faulty; replace the relay.
YES Proceed to step 5.
NO Proceed to step 5.
NO The relay is faulty; replace the relay.
5. Connect +12 volts to terminals (2 and 3), and
5. Connect one test lead to terminal (1). connect ground to terminal (4).
6. Connect the other test lead to terminal (4). 6. Measure voltage between terminals (1 and 4).
7. Connect a 12-volt DC power source to terminals (2
and 5). Is approximately 12 volts indicated?
8. Check for continuity across terminals (4 and 1). YES The relay is good.
NO The relay is faulty; replace the relay.
Is continuity indicated?
YES The relay is good. NOTE
NO The relay is faulty; replace the relay. 12 volts will remain indicated for approximately one
second after power is removed from relay.

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Key Switch Test Horn/Test Switch Test

See Figure 4-40. See Figure 4-41.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester

1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove key switch. (See “Key Switch” on 2. Remove horn/test switch. (See “Horn/Test Switch” on
page 4-90.) page 4-92.)

1
1

2
I
X 3

Y A
B
S
4
2

3
TN1968
4
TN1892
Figure 4-41
Figure 4-40 3. Connect test leads to the switch terminals (2 and 3).
4. Check for continuity.
3. Turn key switch to the run position.
Is continuity indicated?
4. Check continuity between terminals (1, 3, and 4).
YES The switch is faulty; replace the switch.
Is continuity indicated? NO Proceed to step 5.
YES Proceed to step 5. 5. Depress and hold the plunger (1).
NO The key switch is faulty. 6. Check for continuity.
5. Turn the key switch to the start position. Check
Is continuity indicated?
continuity between terminals (1, 2, and 3).
YES The switch is good.
Is continuity indicated?
NO The switch is faulty; replace the switch.
YES The key switch is good.
NO The key switch is faulty; replace the switch.

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 ELECTRICAL

Seat Switch Test Glow Plug Switch Test

See Figure 4-42. See Figure 4-43.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester

1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove glow plug switch. (See “Glow Plug Switch”
on page 4-93.)

2
1

4 1
2

3
TN1887
Figure 4-42 TN1919
Figure 4-43
2. Connect test leads to the switch terminals (1 and 2).
3. Check for continuity. 3. Connect test leads to terminals (1 and 3).
4. With the switch lever (2) in the OFF position, check
Is continuity indicated? for continuity.
YES The switch is faulty; replace the switch.
Is continuity indicated?
NO Proceed to step 4.
YES The switch is faulty; replace the glow plug
4. Depress the seat switch. switch.
Is continuity indicated? NO Proceed to step 5.
YES The switch is good. 5. With the switch lever (2) held in the On position,
NO The switch is faulty; replace the switch. check for continuity.
Is continuity indicated?
YES The switch is good.
NO The switch is faulty; replace the glow plug
switch.

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Front Limit Switch Test PTO Switch Test

See Figure 4-44. See Figure 4-45.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester

1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove front limit switch. (See “Front Limit Switch” 2. Remove PTO switch. (See “PTO Switch” on
on page 4-97.) page 4-96.)

1
3
2 1
2 2
3
5
4
4 3
TN1982 TN1969
Figure 4-44 Figure 4-45
3. Connect test leads to terminals (2 and 3). 3. Place the switch in the OFF (locked) position.
4. Check for continuity. 4. Connect test leads to the switch terminals (1 and 2).
Is continuity indicated? 5. Check for continuity.
YES Proceed to step 5. Is continuity indicated?
NO The switch is faulty; replace the switch. YES Proceed to step 6.
5. Lift and hold the actuator arm (1) in the OFF position. NO The switch is faulty; replace the switch.
6. Check for continuity. 6. Place the switch in the ON position.
Is continuity indicated? 7. Check for continuity.
YES The switch is faulty; replace the switch. Is continuity indicated?
NO The switch is good. YES The switch is faulty; replace the switch.
NO Proceed to step 8.
8. Connect test leads to the switch terminals (3 and 4).
9. Check for continuity.
Is continuity indicated?
YES The switch is faulty; replace the switch.
NO Proceed to step 10.
10. Place the switch in the OFF (locked) position.

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 ELECTRICAL

11. Check for continuity. 5. Check for continuity.

Is continuity indicated? Is continuity indicated?
YES Proceed to step 12. YES The switch is faulty; replace the switch.
NO The switch is faulty; replace the switch. NO Proceed to step 6.
12. Connect test leads to the switch terminals (4 and 5). 6. Place the switch in the (2) position.
13. Check for continuity. 7. Check for continuity.
Is continuity indicated? Is continuity indicated?
YES The switch is faulty; replace the switch. YES Proceed to step 8.
NO Proceed to step 14. NO The switch is faulty; replace the switch.
14. Place the switch in the ON position. 8. Place the switch in the (1) position.
15. Check for continuity. 9. Check for continuity.
Is continuity indicated? Is continuity indicated?
YES The switch is good. YES The switch is faulty; replace the switch.
NO The switch is faulty; replace the switch. NO Proceed to step 10.
10. Connect test leads to the switch terminals (3 and 4).
Front Mow Enable Switch Test 11. Check for continuity.

4 See Figure 4-46.

Required Tools or Equipment

Is continuity indicated?
YES Proceed to step 12.
NO The switch is faulty; replace the switch.
Digital Multimeter, Ohmmeter, or Continuity Tester 12. Place the switch in the OFF (middle) position.
13. Check for continuity.
1. Park the mower safely. (See “Park Mower Safely” on
Is continuity indicated?
page 1-6.)
YES The switch is faulty; replace the switch.
2. Remove front mow enable switch. (See “Rocker
Switches” on page 4-98.) NO Proceed to step 14.
14. Place the switch in the (2) position.
15. Check for continuity.
1
Is continuity indicated?
2 YES The switch is faulty; replace the switch.
NO The switch is good.

3
TN1965
Figure 4-46
3. Place the switch in the OFF (middle) position.
4. Connect test leads to the switch terminals (4 and 5).

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Wing Mow Enable and Light Switches 9. Check for continuity.

Test Is continuity indicated?
See Figure 4-47. YES The switch is faulty; replace the switch.
NO Proceed to step 10.
Required Tools or Equipment 10. Connect test leads to the switch terminals (2 and 3).
11. Check for continuity.
Digital Multimeter, Ohmmeter, or Continuity Tester
Is continuity indicated?
1. Park the mower safely. (See “Park Mower Safely” on YES Proceed to step 12.
page 1-6.) NO The switch is faulty; replace the switch.
12. Place the switch in the OFF (middle) position.
NOTES
13. Check for continuity.
This procedure applies to the following switches:
• Wing Mow Enable Switch Is continuity indicated?
• Light Switch YES The switch is faulty; replace the switch.
2. Remove switch. (See “Rocker Switches” on NO Proceed to step 14.
page 4-98.) 14. Place the switch in the (5) position.
15. Check for continuity.

2
4 Is continuity indicated?
YES The switch is faulty; replace the switch. 4
1 5 NO Proceed to step 16.
3 16. Connect test leads to the switch terminals (6 and 7).
17. Check for continuity.
8
Is continuity indicated?
YES The switch is faulty; replace the switch.
NO Proceed to step 18.
18. Place the switch in the (4) position.
19. Check for continuity.
7 Is continuity indicated?
6 YES Proceed to step 20.
TN1966
Figure 4-47 NO The switch is faulty; replace the switch.
3. Place the switch in the OFF (middle) position. 20. Place the switch in the OFF (middle) position.
4. Connect test leads to the switch terminals (1 and 2). 21. Check for continuity.
5. Check for continuity. Is continuity indicated?
Is continuity indicated? YES The switch is faulty; replace the switch.
YES The switch is faulty; replace the switch. NO Proceed to step 22.
NO Proceed to step 6. 22. Connect test leads to the switch terminals (7 and 8).
6. Place the switch in the (5) position. 23. Check for continuity.
7. Check for continuity. Is continuity indicated?
Is continuity indicated? YES The switch is faulty; replace the switch.
YES Proceed to step 8. NO Proceed to step 24.
NO The switch is faulty; replace the switch. 24. Place the switch in the (5) position.
8. Place the switch in the (4) position.

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 ELECTRICAL

25. Check for continuity. 7. Check for continuity.

Is continuity indicated? Is continuity indicated?
YES Proceed to step 26. YES Proceed to step 8.
NO The switch is faulty; replace the switch. NO The switch is faulty; replace the switch.
26. Place the switch in the (4) position. 8. Place and hold the switch in the (1) position.
27. Check for continuity. 9. Check for continuity.
Is continuity indicated? Is continuity indicated?
YES The switch is faulty; replace the switch. YES The switch is faulty; replace the switch.
NO The switch is good. NO Proceed to step 10.
10. Connect test leads to the switch terminals (3 and 4).
Cruise Control Switch Test 11. Place and hold the switch in the (1) position.
See Figure 4-48. 12. Check for continuity.
YES Proceed to step 13.
Required Tools or Equipment NO The switch is faulty; replace the switch.
Digital Multimeter, Ohmmeter, or Continuity Tester 13. Place the switch in the OFF (middle) position.
14. Check for continuity.
1. Park the mower safely. (See “Park Mower Safely” on
4 page 1-6.)
2. Remove cruise control switch. (See “Rocker
Is continuity indicated?
YES
NO
The switch is faulty; replace the switch.
Proceed to step 15.
Switches” on page 4-98.)
15. Place the switch in the (2) position.
16. Check for continuity.
1
Is continuity indicated?
YES The switch is faulty; replace the switch.
2
NO The switch is good.

3
TN1965
Figure 4-48
3. Place the switch in the OFF (middle) position.
4. Connect test leads to the switch terminals (4 and 5).
5. Check for continuity.
Is continuity indicated?
YES The switch is faulty; replace the switch.
NO Proceed to step 6.
6. Place the switch in the (2) position.

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4WD Switch Test 12. Check for continuity.

See Figure 4-49. Is continuity indicated?

YES Proceed to step 13.
Required Tools or Equipment NO The switch is faulty; replace the switch.
Digital Multimeter, Ohmmeter, or Continuity Tester 13. Place the switch in the OFF (middle) position.
14. Check for continuity.
1. Park the mower safely. (See “Park Mower Safely” on Is continuity indicated?
page 1-6.) YES The switch is faulty; replace the switch.
2. Remove 4WD switch. (See “Rocker Switches” on NO Proceed to step 15.
page 4-98.)
15. Place the switch in the (4) position.
16. Check for continuity.

3 Is continuity indicated?
YES The switch is faulty; replace the switch.
4 NO Proceed to step 17.
2
1 17. Connect test leads to the switch terminals (1 and 6).
18. Place the switch in the (4) position.
19. Check for continuity.
Is continuity indicated? 4
YES Proceed to step 20.
NO The switch is faulty; replace the switch.
20. Place and hold the switch to the OFF (middle)
6 position.
5
21. Check for continuity.
TN1967
Figure 4-49 Is continuity indicated?
YES The switch is faulty; replace the switch.
3. Place the switch in the OFF (middle) position.
NO Proceed to step 22.
4. Connect test leads to the switch terminals (2 and 6).
22. Place and hold the switch in the (3) position.
5. Check for continuity.
23. Check for continuity.
Is continuity indicated?
Is continuity indicated?
YES The switch is faulty; replace the switch.
YES The switch is faulty; replace the switch.
NO Proceed to step 6.
NO The switch is good.
6. Place the switch in the (4) position.
7. Check for continuity.
Is continuity indicated?
YES The switch is faulty; replace the switch.
NO Proceed to step 8.
8. Place and hold the switch in the (3) position.
9. Check for continuity.
Is continuity indicated?
YES Proceed to step 10.
NO The switch is faulty; replace the switch.
10. Connect test leads to the switch terminals (5 and 6).
11. Place and hold the switch in the (3) position.

4203780 First Edition 4-81

 ELECTRICAL

Micro Switches Test Diff Lock Switch Test

See Figure 4-50. See Figure 4-51.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter, Ohmmeter, or Continuity Tester Digital Multimeter, Ohmmeter, or Continuity Tester

1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove diff lock switch. (See “Diff Lock Switch” on
NOTES page 4-100.)
This procedure applies to the following micro switches:
• Park Brake Switch
• Brake Pedal Switch
1
• Reverse Kick-Out Switch
2 3 4
2. Remove switch. (See “Park Brake Switch” on
page 4-91, “Brake Pedal Switch” on page 4-91 and
“Reverse Kick-Out Switch” on page 4-99.)

4
3
2
1

TN1861
Figure 4-51
3. Connect test leads to terminals (2 and 4).
4. Check for continuity.
Is continuity indicated?
TN1894 YES The switch is faulty; replace the diff lock
Figure 4-50 switch.
3. Connect test leads to the switch terminals (2 and 3). NO Proceed to step 5.
4. Check for continuity. 5. Depress and hold the plunger (1).
6. Check for continuity.
Is continuity indicated?
YES The switch is faulty; replace the switch. Is continuity indicated?
NO Proceed to step 5. YES Proceed to step 7.
5. Depress the switch lever (1). NO The switch is faulty; replace the diff lock
switch.
6. Check for continuity.
7. Connect test leads to terminals (3 and 4).
Is continuity indicated?
8. Depress and hold the plunger.
YES The switch is good.
9. Check for continuity.
NO The switch is faulty; replace the switch.
Is continuity indicated?
YES The switch is faulty; replace the diff lock
switch.
NO Proceed to step 10.

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 ELECTRICAL

10. Release the plunger to the extended position. 5. Move the float (2) to the full position and read the
11. Check for continuity. resistance value.

Is continuity indicated? Is the resistance value approximately 32 ohms?

YES The diff lock switch is good. YES Proceed to step 6.
NO The switch is faulty; replace the switch. NO The sensor is faulty; replace fuel level
sensor.
Fuel Level Sensor Test 6. Move the float (2) to the empty position and read the
resistance value.
See Figure 4-52.
Is the resistance value approximately 256 ohms?
Required Tools or Equipment YES The sensor is good.
NO The sensor is faulty; replace fuel level
Digital Multimeter, Ohmmeter, or Continuity Tester sensor.

1. Park the mower safely. (See “Park Mower Safely” on Solenoids Test
page 1-6.)
See Figure 4-53.
2. Remove fuel level sensor. (See “Fuel Level Sensor”
on page 4-113.)
Required Tools or Equipment

Digital Multimeter or Ohmmeter

1. Park the mower safely. (See “Park Mower Safely” on

4
page 1-6.)
2
NOTE
This procedure applies to the following solenoids:
• Front Mow Solenoid
• Right Mow Solenoid
• Left Mow Solenoid
• 4WD Solenoid
• 4WD Rev Solenoid
1
• Diff Lock Solenoid
2. Remove solenoid. (See “Mow Solenoids” on
page 4-105 and “4WD Solenoids” on page 4-106.)

1
3
TN1889
Figure 4-52

NOTE
Float shown in the full position.
3. Connect the test leads to sensor bracket (1) and 2
sensor terminal (3).
4. Set the meter to read ohms.
TN1595
Figure 4-53

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 ELECTRICAL

NOTE
Fuel Shutoff Solenoid Test
See Figure 4-54.
On some meters it will be necessary to select a range for
the solenoid being tested.
Required Tools or Equipment
3. Using a multimeter or ohmmeter, measure the
resistance between terminals (1 and 2). Refer to the Digital Multimeter, Ohmmeter, or Continuity Tester
specifications listed for the specific solenoid
resistance.
1. Park the mower safely.
• Front Mow Solenoid Coil—7.1 ohms ± 10% at 68° F
• Right Mow Solenoid Coil—7.1 ohms ± 10% at 68° F
• Left Mow Solenoid Coil—7.1 ohms ± 10% at 68° F
• 4WD Solenoid Coil—8.8 ohms ± 10% at 68° F 1 2 3
• 4WD Rev Solenoid Coil—8.8 ohms ± 10% at 68 ° F
• Diff Lock Solenoid Coil—8.8 ohms ± 10% at 68° F
Does the resistance through the component
match the specified value listed?
YES The solenoid is good.
NO The solenoid is faulty; replace the solenoid.

4
TN1875
Figure 4-54
2. Connect the black test lead to the fuel shutoff
solenoid black wire terminal (1).
3. Connect the red test lead to the fuel shutoff solenoid
white wire terminal (2).
4. Using a multimeter or ohmmeter, measure the
resistance between terminals (1 and 2).
Is the resistance value approximately 0.5 ohms?
YES Proceed to step 5
NO The fuel shutoff solenoid is faulty; replace
the solenoid.

5. Connect the red test lead to the fuel shutoff solenoid

red wire terminal (3).
6. Measure the resistance between terminals (1 and 3).
Is the resistance value approximately 15 ohms?
YES The fuel shutoff solenoid is good.
NO The fuel shutoff solenoid is faulty; replace
the solenoid.

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Diodes Test Fuel Pump Test

See Figure 4-55. See Figure 4-56.

Required Tools or Equipment Required Tools or Equipment

Digital Multimeter Jumper wire

1. Park the mower safely. 1. Park the mower safely. (See “Park Mower Safely” on
2. Remove diode. (See “Diodes” on page 4-109.) page 1-6.)
2. Allow engine to cool completely.

1
2

4
1
2

TN2024 TN2019
Figure 4-55 Figure 4-56
3. Set the digital multimeter to the diode check setting.
4. Connect the test leads to terminals (1 and 2) and
NOTE
record the reading. Label all wires before disconnecting to ensure correct
5. Reverse the test leads and record the reading. installation.
3. Disconnect harness connector (1).
Does the meter read approximately 0.5 volts in
one direction, and an open circuit when the leads 4. Using a jumper wire, connect the battery positive
are reversed? terminal to fuel pump connector (2).
YES The diode is good. Does the fuel pump operate?
NO The diode is faulty; replace the diode. YES The fuel pump is good.
NO The fuel pump is faulty; replace the fuel
pump.

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Repair 7. Lower battery (14) and battery tray (13) with floor
jack.
8. Remove nut (9), lock washer (10), flat washer (11),
Battery and Battery Tray and screw (12). Remove battery and battery tray.
Removal and Installation
NOTICE
See Figures 4-57.
Never place used batteries in the garbage.
! WARNING Dispose of used batteries in accordance with all
applicable regulations.
• Battery posts, terminals, and related
accessories contain lead and lead
compounds. Wash your hands after handling.
NOTES
• Always wear eye protection when servicing
battery. • Install the battery and battery tray by reversing the
order of removal.
• Route battery cables between the battery and battery
1. Park the mower safely. (See “Park Mower Safely” on
tray to avoid pinch points.
page 1-6.)

Alternator
2 3
4 1
4
Removal and Installation
See Figure 4-58.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise the hood.
14 3. Disconnect the negative (–) battery cable at the
13 battery.

9 10 11 12
5 6 7 8
1

TN1896 2
Figure 4-57 9
2. Raise cutting deck and engage the deck latch. 8 7 6
3. Support battery tray (13) with floor jack.

! WARNING
Always disconnect the negative terminal first and
positive terminal last. Connect positive terminal
first and negative terminal last. Use care when 5 4 3
TN1782
testing live circuits to prevent arcing. Arcing
Figure 4-58
could result in death or serious injury.

NOTE
4. Remove screw (3) and disconnect the negative (–)
battery cable (4). Label all wires before disconnecting to ensure correct
installation.
5. Remove screw (2), and disconnect the positive (+)
battery cable (1). 4. Disconnect wire connectors (1 and 2).
6. Remove four nuts (5), lock washers (6), flat washers 5. Loosen screw (8) and push the alternator (3) toward
(7), and screws (8). the engine.

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 ELECTRICAL

6. Remove fan drive belt (9) from alternator pulley. Circuit Breakers
7. Support the alternator (3).
8. Remove screw (8), lock washer (7), and flat washer Removal and Installation
(6). See Figures 4-60 and 4-61.
9. Remove screw (5) and nut (4). 1. Park the mower safely. (See “Park Mower Safely” on
10. Remove alternator (3). page 1-6.)
2. Disconnect the negative (–) battery cable at the
Installation Notes battery.
• Install the alternator by reversing the order of 3. Remove instrument panel. (See “Instrument Panel”
removal. on page 4-110.)
• Adjust fan belt tension. (Refer to “Safety, Operation &
Maintenance Manual”.)

Starter Motor 1

Removal and Installation

See Figure 4-59.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the
4
battery. TN1990
Figure 4-60
4. Remove nut (1).
1 2

3
4 2
7
5
3
6
TN2025
Figure 4-59 4
TN2030
NOTE Figure 4-61
Label all wires before disconnecting to ensure correct
installation. NOTE
4. Disconnect wire connectors (4, 5, 6, and 7) from the Label all wires before disconnecting to ensure correct
starter motor (1). installation.
5. Support the starter motor (1). 5. Disconnect wire connectors (3 and 4).
6. Remove screw (3) and nut (2). 6. Remove circuit breaker (2).
7. Remove starter motor.
Installation Note
Installation Note 7. Install the circuit breaker by reversing the order of
Install the starter motor by reversing the order of removal. removal.

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Thermal Circuit Breakers Main 50-Amp Thermal Circuit Breaker

Removal and Installation

See Figures 4-62 and 4-63.
1. Park the mower safely. (See “Park Mower Safely” on 7
8 9
page 1-6.) 6
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the
battery.

Glow Plug and Work Lights 50-amp Thermal Circuit 10

Breaker

2
3 4
1 TN1960
Figure 4-63
6. Remove nuts (7 and 8) and disconnect wires (10).

4 5
7. Remove screws and nuts (6 and 9) and the thermal
breaker.

Installation Note
Install thermal circuit breakers by reversing the order of
removal.

Relays
TN1960
Figure 4-62 See Figure 4-64.

NOTE
Label all wires before disconnecting to ensure correct 1 2
installation.
4. Remove nuts (2 and 3) and disconnect wires (5).
5. Remove screws and nuts (1 and 4) and the thermal 3
breaker. 8
4
5
7
6
TN2021
Figure 4-64

NOTE
Seat removed for picture clarity.
This procedure applies to the following relays:
• Left Wing Relay (1)
• Right Wing Relay (2)
• Cruise Cancel Relay (3)
• Cruise Relay (4)
• Fuel Pull-In Relay (5)

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 ELECTRICAL

• Horn Relay (6) Time Delay Relay

• Accessory Relay (7)
Removal and Installation
NOTE See Figure 4-66.
For time delay relay, (See “Time Delay Relay” on 1. Park the mower safely. (See “Park Mower Safely” on
page 4-89.) page 1-6.)
Removal and Installation 2. Disconnect the negative (–) battery cable at the
battery.
See Figures 4-64 and 4-65.
3. Remove instrument panel. (See “Instrument Panel”
1. Park the mower safely. (See “Park Mower Safely” on on page 4-110.)
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
3. Raise the seat.
3 4 5

1 2
6
7 8 9

9
10 4
TN2031
Figure 4-66
TN1990
Figure 4-65 NOTE
4. Remove four screws (9) and cover (10). Label all wires before disconnecting to ensure correct
5. Pull relay straight up and out of the relay base (8). installation.
4. Cut cable tie (2).
Installation Note 5. Disconnect wire connector (1).
Install the relay by reversing the order of removal. 6. Remove nut (7), lock washer (8), and ground wire
terminal (9).
7. Remove two nuts (3), lock washers (4), and screws
(5).
8. Remove time delay relay (6).

Installation Notes
• Install the time delay relay by reversing the order of
removal.
• Use new cable tie to secure wire connector.

4203780 First Edition 4-89

 ELECTRICAL

Key Switch
Removal and Installation
See Figures 4-67 through 4-70.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery. 4

TN1905

1 Figure 4-69
5. Remove key switch cover (4).

4
TN1903
Figure 4-67
3. Remove right cover screws (1).

2 TN1906
Figure 4-70
6. Remove retaining nut (5) from the key switch.
7. Remove key switch from the bottom of the steering
3 console.

TN1904 Installation Note

Figure 4-68 Install the key switch by reversing the order of removal.
4. Remove left cover screws (2) and pull down cover
(3).

4-90 4203780 First Edition

 ELECTRICAL

Park Brake Switch Brake Pedal Switch

Removal and Installation Removal and Installation
See Figure 4-71. See Figure 4-72.
1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Disconnect the negative (–) battery cable at the 2. Disconnect the negative (–) battery cable at the
battery. battery.

2 1
1 2
3

3 4 5 6
4
5
TN1913
4 Figure 4-72

TN1992
NOTE
Figure 4-71
Label all wires before disconnecting to ensure correct
installation.
NOTE
3. Disconnect wire connector (2).
Label all wires before disconnecting to ensure correct
4. Remove two nuts (3), lock washers (4), flat washers
installation.
(5) and screws (6).
3. Disconnect the wire connector.
5. Remove brake pedal switch (1).
4. Remove two nuts (4), lock washers (5), flat washers
(3) and screws (2). Installation Notes
5. Remove park brake switch (1). • Install the brake pedal switch by reversing the order
of removal.
Installation Note
• Make sure switch is properly aligned to brake switch
Install the park brake switch by reversing the order of activator plate.
removal.
• Adjust switch so that the brake pedal moves
approximately 0.5 in. (12.7 mm) before disengaging
switch and cruise control.

4203780 First Edition 4-91

 ELECTRICAL

Horn/Test Switch Installation Notes

• Adjust jam nut (4) for proper switch height if
Removal and Installation necessary.
See Figures 4-73 and 4-74. • Install horn switch by reversing the order of removal.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) Seat Switch
2. Disconnect the battery negative (–) cable at the
battery. Removal and Installation
3. Remove instrument panel. (See “Instrument Panel” See Figures 4-75 through 4-77.
on page 4-110.) 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.

1 2

4 1 3

4
7
TN1936 6 4 5
Figure 4-73

5
TN1987
Figure 4-75
3. Tilt seat back (1) to forward position.
4. Cut cable ties (5).

NOTE
Label all wires before disconnecting to ensure correct
2 installation.
3
5. Disconnect wire connector (6).
6. Remove two screws (3).
4 7. Disengage lower seat back tabs (4) from seat back
support (2).
TN1937
8. Push bottom of seat back (1) forward; lift and remove
Figure 4-74 seat back.
4. Remove bezel nut (1). 9. Lift rear of seat (7); slide forward and remove seat.

NOTE
Label all wires before disconnecting to ensure correct
installation.
5. Disconnect wire terminals (2).
6. Remove horn/test switch (3).

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Glow Plug Switch

Removal and Installation
See Figures 4-78 through 4-81.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
8 2. Disconnect the negative (–) battery cable at the
battery.

TN1988
Figure 4-76
10. Cut cable ties (8).

10 1
9
11
4
TN1903
Figure 4-78
12
3. Remove right cover screws (1).

TN1989
Figure 4-77
11. Disengage switch cover tabs (12) and remove switch
cover (9).
12. Raise end of switch actuator (10) and remove seat
switch (11).
2
Installation Notes
• Install the seat switch by reversing the order of
removal.
• Use new cable ties to secure wire harness and wire
3
connector.
TN1904
Figure 4-79
4. Remove left cover screws (2) and pull down cover
(3).

4203780 First Edition 4-93

 ELECTRICAL

Engine Temperature Gauge

Removal and Installation
See Figures 4-82 through 4-84.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
4
2. Disconnect the negative (–) battery cable at the
battery.

TN1917
Figure 4-80 1
5. Remove boot with retaining nut (4).

4
TN1903
Figure 4-82
3. Remove right cover screws (1).
5

TN1918
2
Figure 4-81
6. Remove retaining nut (5) from the glow plug switch.
7. Remove glow plug switch from the bottom of the
steering console. 3

Installation Note TN1904

Install the glow plug switch by reversing the order of Figure 4-83
removal.
4. Remove left cover screws (2) and pull down cover
(3).

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 ELECTRICAL

• Charge Filter Service Light (8)

• Low Charge Pressure Light (4)
4 • Engine Coolant Temp Light (7)
• Engine Oil Pressure Light (5)
5 6 • Left Turn Indicator (6)

8 Removal and Installation

See Figures 4-86 through 4-88.
1. Park the mower safely. (See “Park Mower Safely” on
7 page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
TN2033
Figure 4-84
5. Remove nuts (5), lock washers (6), and bracket (8).

NOTE
Label all wires before disconnecting to ensure correct
installation.
6. Disconnect wire terminals (7).
7. Remove engine temperature gauge (4).
11
4
Installation Note
TN1903
Install the engine temperature gauge by reversing the
order of removal. Figure 4-86
3. Remove right cover screws (11).
Indicator Lights
See Figure 4-85.

1 2 3 4 5

12

10 9 8 7 6 13

TN1904

TN2034 Figure 4-87

Figure 4-85 4. Remove left cover screws (12) and pull down cover
(13).
This procedure applies to the following indicator lights:
• Right Turn Indicator (1)
• Glow Plug Light (10)
• Air Filter Service Light (2)
• Return Filter Service Light (9)
• Hyd Oil Temp Light (3)

4203780 First Edition 4-95

 ELECTRICAL

14 15

6
4 5
8

TN2034
TN1937
Figure 4-88
Figure 4-90
5. Rotate indicator light holder (15) 1/8 turn
counterclockwise to disengage from socket (14). NOTE
6. Pull indicator light from indicator light holder.
Label all wires before disconnecting to ensure correct
installation.
4 Installation Note
Install the indicator light by reversing the order of
removal.
4. Disconnect wire connector (4).
5. Remove toggle boot (2) from PTO switch (5).
6. Remove two nuts (1), upper panel plug (3), lower
panel plug (6), and PTO switch.
PTO Switch
Installation Notes
Removal and Installation
• Install PTO switch by reversing the order of removal.
See Figures 4-89 and 4-90.
• See Figure 4-91.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the battery negative (–) cable at the
battery.
3. Remove instrument panel. (See “Instrument Panel”
on page 4-110.)

3 2
TN1969
Figure 4-91
• Arrow indicates rear of mower.
• Make sure PTO switch is installed as shown in
Figure 4-91.

TN1936
Figure 4-89

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 ELECTRICAL

Right and Left Wing Proximity 2. Disconnect the negative (–) battery cable at the
battery.
Switches
Removal and Installation
See Figure 4-92.
1. Park the mower safely. (See “Park Mower Safely” on 1 2
page 1-6.)
2. Disconnect the negative (–) battery cable at the 3
battery.

3
TN1977
1 2
Figure 4-93
3. Remove two screws (3).
4. Remove cover (1) and gasket (2).

5
4
5
4
4

TN1976 6
Figure 4-92 12

NOTE 11
Right wing proximity switch shown; left wing is similar. 9 10 7 8
3. Cut cable tie (5).

NOTE TN1981
Figure 4-94
Label all wires before disconnecting to ensure correct
installation. 5. Remove two screws (7), lock washers (8), and
4. Disconnect wire connector (4). spacer (4).
5. Remove two screws (1) and flat washers (2).
NOTE
6. Remove proximity switch (3).
Label all wires before disconnecting to ensure correct
Installation Notes installation.
• Install the proximity switch by reversing the order of 6. Disconnect wires (9 and10).
removal. 7. Remove nut (5), wire harness (6), and switch (12).
• Use new cable tie to secure wire connector.
Installation Notes
• Install the front limit switch by reversing the order of
Front Limit Switch removal.
Removal and Installation • Adjust actuator arm (11) so that switch is engaged
when front lift arms are raised.
See Figures 4-93 and 4-94.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

4203780 First Edition 4-97

 ELECTRICAL

Rocker Switches
See Figure 4-95.

1
6
5 2
8 7

4 TN1937
3 Figure 4-96

NOTE
Label all wires before disconnecting to ensure correct
TN1936

4 Figure 4-95
This procedure applies to the following switches:
installation.
4. Disconnect wire connector (8).
5. Spread panel plug tab (6) on each side of rocker
• Front Mow Enable Switch (4) switch (7) and pull rocker switch to remove.
• Wing Mow Enable Switch (5)
Installation Notes
• Cruise Control Switch (3)
• Install rocker switch by reversing the order of
• 4WD (Four Wheel Drive) Switch (2)
removal.
• Light Switch (1)
• See Figures 4-97 through 4-99.
Removal and Installation
See Figure 4-96.

NOTE
Front mow enable switch shown.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the battery negative (–) cable at the
battery.
3. Remove instrument panel. (See “Instrument Panel”
on page 4-110.)

TN1965
Figure 4-97
• Arrow indicates rear of mower.
• Make sure front mow enable switch and cruise
control switch are installed as shown in Figure 4-97.

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Reverse Kick-Out Switch

Removal and Installation
See Figure 4-100.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.

1 2 3 4
TN1966
Figure 4-98 5
• Arrow indicates rear of mower.
• Make sure wing mow enable switch and light switch
are installed as shown in Figure 4-98.
6 4
TN1915
Figure 4-100

NOTE
Remove floorboard plug to access switch.

NOTE
Label all wires before disconnecting to ensure correct
installation.
3. Disconnect wire connector (5).
4. Remove two nuts (1), lock washers (2), flat washers
(3) and screws (4).
TN1967
5. Remove reverse kick-out switch (6).
Figure 4-99
• Arrow indicates rear of mower. Installation Notes
• Make sure 4WD switch is installed as shown in • Install the reverse kick-out switch by reversing the
Figure 4-99. order of removal.
• Adjust the reverse kick-out switch. (See “Reverse
Kick-Out Switch Initial Adjustment” on page 5-30.)

4203780 First Edition 4-99

 ELECTRICAL

Diff Lock Switch Air Filter Pressure Switch

Removal and Installation Removal and Installation
See Figure 4-101. See Figure 4-102.
1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Disconnect the negative (–) battery cable at the 2. Raise the hood.
battery. 3. Disconnect the negative (–) battery cable at the
battery.

2
5 6 7 2
3
4
1
3
4
TN1850
Figure 4-101 TN2027
Figure 4-102
NOTE
Label all wires before disconnecting to ensure correct NOTE
installation.
Label all wires before disconnecting to ensure correct
3. Disconnect wire connector (3). installation.
4. Remove four nuts (5), lock washers (6), and screws 4. Disconnect wire connectors (1 and 2).
(7) from mounting plate (4).
5. Remove air filter pressure switch (3).
5. Remove diff lock switch (1) and switch cover (2).
Installation Note
Installation Note
Install the air filter pressure switch by reversing the order
Install the diff lock switch by reversing the order of of removal.
removal.

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 ELECTRICAL

Return Filter Pressure Switch 4. Disconnect connectors (2) from the return filter
pressure switch (1).
Removal and Installation 5. Remove return filter pressure switch (1).
See Figure 4-103.
Installation Notes
! WARNING
Required Materials
The hydraulic system is under pressure, and the
oil may be hot! Telfon® Tape
• Always allow the machine to cool completely
before performing service. • Install the return filter pressure switch by reversing
• Always relieve pressure in the hydraulic the order of removal.
system before performing service. • Apply Teflon tape to the threads of the return filter
• Always use appropriate safety equipment and pressure switch before installing.
clothing to protect exposed skin and eyes
from high-pressure oil. Hyd Oil Temp Switch
• Tighten all connections to proper
specifications before applying pressure. Removal and Installation
• Never use bare hands to check for leaks! Oil See Figure 4-104.
under pressure can penetrate the skin and
can cause gangrene within a few hours if not
properly removed. Use a piece of cardboard
! WARNING
The hydraulic system is under pressure, and the
4
to check for leaks.
oil may be hot!
Failure to follow appropriate safety precautions
may result in death or serious injury. • Always allow the machine to cool completely
before performing service.
• Always relieve pressure in the hydraulic
1. Park the mower safely. (See “Park Mower Safely” on system before performing service.
page 1-6.)
• Always use appropriate safety equipment and
2. Raise the hood. clothing to protect exposed skin and eyes
3. Disconnect the negative (–) battery cable at the from high-pressure oil.
battery. • Tighten all connections to proper
specifications before applying pressure.
• Never use bare hands to check for leaks! Oil
under pressure can penetrate the skin and
can cause gangrene within a few hours if not
properly removed. Use a piece of cardboard
to check for leaks.
1
Failure to follow appropriate safety precautions
2 may result in death or serious injury.

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the
battery.
TN1940 4. Drain hydraulic oil. (See “Hydraulic Oil Tank—Drain
Figure 4-103 Procedure” on page 6-58.)

NOTE
Label all wires before disconnecting to ensure correct
installation.

4203780 First Edition 4-101

 ELECTRICAL

Charge Filter Pressure Switch

Removal and Installation
See Figure 4-105.
1
! WARNING
2 The hydraulic system is under pressure, and the
oil may be hot!
• Always allow the machine to cool completely
before performing service.
• Always relieve pressure in the hydraulic
system before performing service.
• Always use appropriate safety equipment and
clothing to protect exposed skin and eyes
TN2028
from high-pressure oil.
Figure 4-104
• Tighten all connections to proper
specifications before applying pressure.
NOTE • Never use bare hands to check for leaks! Oil
Label all wires before disconnecting to ensure correct under pressure can penetrate the skin and
4 installation.
5. Disconnect wire connector (2).
can cause gangrene within a few hours if not
properly removed. Use a piece of cardboard
6. Remove hyd oil temp switch (1). to check for leaks.
Failure to follow appropriate safety precautions
Installation Notes may result in death or serious injury.
• Install the hyd oil temp switch by reversing the order
of removal. 1. Park the mower safely. (See “Park Mower Safely” on
• Replace hydraulic oil return filter. (See “Hydraulic Oil page 1-6.)
Return Filter” on page 6-67.) 2. Raise the hood.
• Replace charge pressure filter. (See “Charge 3. Disconnect the negative (–) battery cable at the
Pressure Filter” on page 6-68.) battery.
• Refill hydraulic tank. (Refer to “Safety, Operation, and
Maintenance Manual” for oil specifications.)
• Start engine. Check hydraulic system for leaks.
Repair as necessary.
• Check hydraulic oil level and add if necessary.

TN1938
Figure 4-105
4. Remove nut (1) and disconnect wire (2) from the
charge filter pressure switch (3).
5. Remove charge filter pressure switch (3).

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 ELECTRICAL

Installation Notes Installation Notes

Required Materials Required Materials

Telfon® Tape Telfon® Tape

• Install the charge filter pressure switch by reversing • Install the engine oil pressure switch by reversing the
the order of removal. order of removal.
• Apply Teflon tape to the threads of the charge filter • Apply Teflon tape to the threads of the oil pressure
pressure switch before installing. switch before installing.

Engine Oil Pressure Switch Engine Temperature Sensor

Removal and Installation Removal and Installation
See Figure 4-106. See Figure 4-107.

! CAUTION ! WARNING
Engine components will become hot during Engine coolant is hot and under pressure! Allow
operation. Allow engine components to cool the cooling system to cool completely before
before performing service. performing service.
Rotate the filler cap 1/2 turn counterclockwise
and allow pressure to vent before removing filler
4
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) cap.
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the 1. Park the mower safely. (See “Park Mower Safely” on
battery. page 1-6.)
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the
battery.

1 2
1 2

TN1908
Figure 4-106

NOTE TN1909

Label all wires before disconnecting to ensure correct Figure 4-107

installation.
4. Remove screw (3) and disconnect wire (2) from the NOTE
engine oil pressure switch (1). Label all wires before disconnecting to ensure correct
5. Remove engine oil pressure switch. installation.

4203780 First Edition 4-103

 ELECTRICAL

4. Remove nut (2) and disconnect wire (3) from the

engine temperature sensor (1). NOTE
5. Remove engine temperature sensor (1). Label all wires before disconnecting to ensure correct
installation.
Installation Notes 4. Remove nut (2) and disconnect wire (3) from the
engine coolant temp switch (1).
Required Materials 5. Remove engine coolant temp switch (1).
Telfon® Tape
Installation Notes

• Install the engine temperature sensor by reversing Required Materials

the order of removal.
• Apply Teflon tape to the threads of the engine Telfon® Tape
temperature sensor before installing.
• Install the engine coolant temp switch by reversing
Engine Coolant Temp Switch the order of removal.
• Apply Teflon tape to the threads of the engine coolant
Removal and Installation temp switch before installing.
See Figure 4-108.
Low Charge Pressure Switch
4 ! WARNING
Engine coolant is hot and under pressure! Allow
Removal and Installation
the cooling system to cool completely before See Figure 4-109.

!
performing service.
WARNING
Rotate the filler cap 1/2 turn counterclockwise
and allow pressure to vent before removing filler The hydraulic system is under pressure, and the
cap. oil may be hot!
• Always allow the machine to cool completely
1. Park the mower safely. (See “Park Mower Safely” on before performing service.
page 1-6.) • Always relieve pressure in the hydraulic
2. Raise the hood. system before performing service.
3. Disconnect the negative (–) battery cable at the • Always use appropriate safety equipment and
battery. clothing to protect exposed skin and eyes
from high-pressure oil.
• Tighten all connections to proper
specifications before applying pressure.
• Never use bare hands to check for leaks! Oil
1 under pressure can penetrate the skin and
2 can cause gangrene within a few hours if not
properly removed. Use a piece of cardboard
3 to check for leaks.
Failure to follow appropriate safety precautions
may result in death or serious injury.

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
TN1914
Figure 4-108

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 ELECTRICAL

1
2
3

TN1868
TN1921
Figure 4-111: Right Mow Solenoid
Figure 4-109

NOTES
• The low charge pressure switch is installed on the
control valve.
• Label all wires before disconnecting to ensure correct
4
installation.
3. Remove cover (1).
4. Disconnect wire connector (3).
5. Remove low charge pressure switch (2).

Installation Notes 3
• Install the low charge pressure switch by reversing
the order of removal.
• Install cover (1). TN1744
Figure 4-112: Front Mow Solenoid
Mow Solenoids This procedure applies to the following solenoids:
See Figures 4-110 through 4-112. • Left Mow Solenoid (1)
• Right Mow Solenoid (2)
• Front Mow Solenoid (3)
The left mow solenoid is located on the left deck valve.
The right mow solenoid is located on the right deck valve
The front mow solenoid is located on the front deck valve.

1
TN1860
Figure 4-110: Left Mow Solenoid

4203780 First Edition 4-105

 ELECTRICAL

Removal and Installation 4WD Solenoids

See Figure 4-113. See Figures 4-114 and 4-115.
NOTE
The left mow solenoid is shown; all solenoids are
removed and installed the same way.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
3. Locate correct deck valve.

2
1 TN1921
Figure 4-114: 4WD Solenoid and Diff Lock Solenoid

4
7 4
5
3
6
TN1860
Figure 4-113

NOTE
Label connectors before disconnecting to ensure correct
installation.
4. Disconnect connector (4) from solenoid (6).
5. Remove nut (5) and solenoid (6) from the valve (7). TN1929
Figure 4-115: 4WD Rev Solenoid
Installation Notes This procedure applies to the following solenoids:
• Clean cartridge of any debris or surface rust and • 4WD Solenoid (1)
apply dielectric grease (Jacobsen PN 365422) to
• Diff Lock Solenoid (2)
cartridge before installation.
• 4WD Reverse Solenoid (3)
• Install the solenoid by reversing the order of removal.
The 4WD solenoid is located on the control valve.
• Tighten nut (5) to 5—7 lb-ft (6.8—9.5 N·m).
The diff lock solenoid is located on the control valve.
The 4WD reverse solenoid is located on the 4WD valve.

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Removal and Installation Glow Plug Solenoid

See Figure 4-116.
Removal and Installation
NOTE See Figure 4-117.
The diff lock solenoid is shown; all solenoids are removed 1. Park the mower safely. (See “Park Mower Safely” on
and installed the same way. page 1-6.)
1. Park the mower safely. (See “Park Mower Safely” on 2. Raise the hood.
page 1-6.)
3. Disconnect the negative (–) battery cable at the
2. Disconnect the negative (–) battery cable at the battery.
battery.
3. Locate correct valve.

6 2
5 7

4
3

5 4
4

TN1931
8 Figure 4-117
7 6
TN1921
Figure 4-116 NOTE
Label all wires before disconnecting to ensure correct
NOTE installation.
The control valve has a cover that blocks the solenoids, 4. Remove nuts (2 and 4) and disconnect wires (3).
4WD valve does not. The picture above shows the control 5. Remove nuts (5 and 6) and disconnect wires (7).
valve with the cover hinged up. 6. Remove screws (1) and glow plug solenoid.
4. Remove cover (4).
Installation Note
NOTE Install the glow plug solenoid by reversing the order of
Label connectors before disconnecting to ensure correct removal.
installation.
5. Disconnect connector (8) from solenoid (7).
6. Remove nut (6), and remove the solenoid (7) from
the valve (5).

Installation Notes
• Clean cartridge of any debris or surface rust and
apply dielectric grease (Jacobsen PN 365422) to
cartridge before installation.
• Install the solenoid by reversing the order of removal.
• Tighten nut (6) to 4—5 lb-ft (5.4—6.8 N·m).

4203780 First Edition 4-107

 ELECTRICAL

Fuel Shutoff Solenoid

Removal and Installation 1
See Figure 4-118.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise the hood.
3. Disconnect the negative (–) battery cable at the
battery. 2

TN2038

2 3 Figure 4-119

NOTE
Label all wires before disconnecting to ensure correct
4 installation.
4. Disconnect wire connectors (1 and 2).

TN1971
Figure 4-118

NOTE
Label all wires before disconnecting to ensure correct
installation.
4. Disconnect the solenoid electrical connector (1). 4
5. Remove two nuts (2) and washers (3).
6. Remove solenoid. 3
Installation Note
Install the fuel shutoff solenoid by reversing the order of
removal. TN2037
Figure 4-120
Cruise Control Magnet
NOTE
Removal and Installation Make marks on machine to ensure correct bracket
See Figures 4-119 through 4-121. installation. Correctly installing bracket will position cruise
1. Park the mower safely. (See “Park Mower Safely” on control magnet.
page 1-6.) 5. Remove bracket (4) with cruise control magnet (3)
2. Disconnect the negative (–) battery cable at the attached.
battery.
3. Raise the seat.

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 ELECTRICAL

5. Remove screws (2), lock washers (3), flat washers

(4), and trim (8).
6. Remove screws (5), lock washers (6), and flat
washers (7).

1
4

TN2042
Figure 4-121
9 10

6. Remove cruise control magnet (3) from bracket (4).

TN2023
Installation Note
Install the cruise control magnet by reversing the order of
removal.
Figure 4-123
7. Tilt console wall (1) inward to allow access to diode
(9).
4
Diodes NOTE
Removal and Installation Label all wires before disconnecting to ensure correct
installation.
See Figures 4-122 and 4-123.
8. Remove diode (9) from diode holder (10).
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) Installation Note
2. Disconnect the negative (–) battery cable at the Install the diode by reversing the order of removal.
battery.
3. Remove seat. (See “Seat and Seat Platform” on
page 9-13.)
4. Remove instrument panel. (See “Instrument Panel”
on page 4-110.)

2 3 4
8
5 6 7

TN2022
Figure 4-122

4203780 First Edition 4-109

 ELECTRICAL

Instrument Panel 10. Lift and move the instrument panel aside or service
components as needed.
Removal and Installation
Installation Notes
See Figure 4-124.
• Anti-seize must be applied to screw threads when
NOTE installing instrument panel.
If servicing individual components, it is not necessary to • Install the instrument panel by reversing the order of
completely remove the instrument panel. In most cases, removal.
the instrument panel can be moved aside for access to
components. Engine Speed Sensor
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) Removal and Installation
2. Remove horn/test switch. (See “Horn/Test Switch” on See Figure 4-125.
page 4-92.) 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
NOTE
2. Raise the hood.
Label all wires before disconnecting to ensure correct
3. Disconnect the negative (–) battery cable at the
installation.
battery.
3. Disconnect the negative (–) battery cable at the

4 battery.
4. If removing the instrument panel, disconnect the
positive (+) battery cables from the battery.
2

1 2 3
4 1

12 1 2 3
5
11
8 9 10 1 2 3 TN1972
Figure 4-125

7 6
1 2 3
NOTE
TN1990 Label all wires before disconnecting to ensure correct
Figure 4-124 installation.
4. Disconnect the engine speed sensor connectors (2).
NOTE 5. Remove engine speed sensor (1).
If moving the instrument panel aside, use caution to
prevent stretching or kinking of the wires. Installation Note
5. Remove four threaded knobs (4). Install the engine speed sensor by reversing the order of
6. Remove six screws (1), lock washers (2), and flat removal.
washers (3).
7. Remove two screws (8), lock washers (9), and flat
washers (10).
8. Slide steering console cover (11) away from
instrument panel (7).
9. Lift the instrument panel (7) to clear the edge of the
console wall (6) and rotate the instrument panel to
diagonally align the four levers (12) with the four slots
(5) in the instrument panel.

4-110 4203780 First Edition

 ELECTRICAL

Volt Meter, Hour Meter, and Fuel 4 5 6

Gauge 4 5 6
See Figure 4-126.

7
7 7

5 6
2
4 TN2030
Figure 4-127
4. Remove nuts (5), lock washers (6), and bracket (4).

NOTE
Figure 4-126
TN2030
Label all wires before disconnecting to ensure correct
installation.
4
This procedure applies to the following gauges:
5. Disconnect wire terminals (7).
• Volt Meter (1)
6. Remove gauge.
• Fuel Gauge (2)
• Hour Meter (3) Installation Note
Install the gauge by reversing the order of removal.
Removal and Installation
See Figure 4-127.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
3. Remove instrument panel. (See “Instrument Panel”
on page 4-110.)

4203780 First Edition 4-111

 ELECTRICAL

Tachometer Installation Note

Install the tachometer by reversing the order of removal.
Removal and Installation
See Figures 4-128 and 4-129. Horn
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) Removal and Installation
2. Disconnect the negative (–) battery cable at the See Figure 4-130.
battery. 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the battery negative (–) cable at the
1 battery.
3. Raise the seat.

2 3

4
4 1 2 3
4 Figure 4-128
TN1990

3. Remove four screws (2), lock washers (3), and

5
tachometer cover (1) from instrument panel (4).

TN2040
5 6 7 Figure 4-130

NOTE
Label all wires before disconnecting to ensure correct
9 installation.
4. Disconnect wire connectors (4).
5. Remove screw (1), lock washer (2), and flat washer
8 (3).
6. Remove horn (5).

Installation Notes
• Install the horn by reversing the order of removal.
TN2029 • Horn must not touch any adjacent parts.
Figure 4-129
4. Remove two nuts (6), lock washers (7), and bracket
(9).

NOTE
Label all wires before disconnecting to ensure correct
installation.
5. Disconnect wire terminals (8).
6. Remove tachometer (5).

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 ELECTRICAL

Fuel Level Sensor Installation Note

Install the fuel level sensor by reversing the order of
Removal and Installation removal.
See Figures 4-131 and 4-132.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.
3. Drain fuel until level is below fuel level sensor mount
opening.

4
TN2055
Figure 4-131
4. Remove fuel level sensor cover (1).

2
3

TN1833
Figure 4-132

NOTE
Label all wires before disconnecting to ensure correct
installation.
5. Disconnect fuel level sensor wire harness (3).
6. Remove five screws (4).
7. Remove fuel level sensor (2).

4203780 First Edition 4-113

 ELECTRICAL

4-114 4203780 First Edition

 Chapter 5

Hydrostatic Power Train

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Portable In-Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Theory of Operation and Sub-Circuit Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Traction Circuit Neutral Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Traction Circuit—Neutral Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Traction Circuit—Forward 2WD Schematic and Theory of Operation . . . . . . . . . . . . . . . . . 5-11
Traction Circuit—Forward 2WD, Differential Locked Schematic . . . . . . . . . . . . . . . . . . . . . 5-12
Traction Circuit—Reverse 2WD Schematic and Theory of Operation . . . . . . . . . . . . . . . . 5-15
Traction Circuit—Reverse 2WD, Differential Unlocked Schematic . . . . . . . . . . . . . . . . . . . 5-16
Traction Circuit—Forward 4WD Schematic and Theory of Operation . . . . . . . . . . . . . . . . . 5-19
Traction Circuit—Forward 4WD, Differential Locked Schematic . . . . . . . . . . . . . . . . . . . . . 5-20
Traction Circuit—Reverse 4WD Schematic and Theory of Operation . . . . . . . . . . . . . . . . 5-23
Traction Circuit—Reverse 4WD, Differential Unlocked Schematic . . . . . . . . . . . . . . . . . . . 5-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Traction Linkage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Weight Transfer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Field Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Charge Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Traction System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Instrument Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Instrument Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Charge Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Charge Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Traction System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Traction Pump Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Front Axle Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

4203780 First Edition 5-1

 HYDROSTATIC POWER TRAIN

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Front Axle U-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Traction Pump U-Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Traction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
4WD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Front Axle Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Front (Drive) Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Differential Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
Input Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Drive Axle Reducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Rear Wheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Traction Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

5-2 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Specifications
Test and Adjustment Specifications

Specification
Traction Pump Flow gpm (Lpm) 35 (132) at 2850 rpm
Charge Pump Flow gpm (Lpm) 10.5 (40) at 2850 rpm
Forward System Relief Pressure psi (bar) 3625 (250) at 2850 rpm
Reverse System Relief Pressure psi (bar) 3625 (250) at 2850 rpm
Charge Pressure psi (bar) 275—285 (19—20) @2850 rpm
Hydrostatic Leakage Percentage 0—10% = Good
Ranges 11—20% = Marginal
21% and Beyond = Bad

Repair Specifications

Specification
Front Axle Motor—Shaft Seal in. (mm) 7/32 (5.5)
Installation Depth
Front Axle Motor—Backplate lb-ft (N·m) 15—18 (20—24)
Assembly Screw Torque
Differential Lock Assembly—Fork
Screw Torque
lb-ft (N·m) 19 (26)
5
Differential Lock Assembly—Housing lb-ft (N·m) 37 (51)
Screw Torque
Input Bevel Pinion Assembly— lb-ft (N·m) 37 (51)
Housing Screw Torque
Drive Axle Reducer Assembly—Axle lb-ft (N·m) 29 (40)
Shaft-to-Brake Disk Screw Torque
Drive Axle Reducer Assembly— lb-ft (N·m) 37 (51)
Housing-to-Differential Gear Case
Screw Torque
Drive Axle Reducer Assembly— lb-ft (N·m) 37 (51)
Brake Caliper-to-Housing Screw
Torque
Differential Assembly—Ring lb-ft (N·m) 37 (51)
Gear-to-Differential Screw Torque
Differential Assembly—Housing lb-ft (N·m) 37 (51)
Screw Torque
Rear Wheel Motor—Valve Housing lb-ft (N·m) 36—37 (49—50)
Screw Torque
Rear Wheel Motor Hub Nut Torque lb-ft (N·m) 175—200 (237—271)

4203780 First Edition 5-3

 HYDROSTATIC POWER TRAIN

Portable In-Line Filter

See Figure 5-1.

TN1367
Figure 5-1
When hydraulic components fail internally, debris from
the failed component can spread throughout the
hydraulic system, causing additional damage.
This situation can be magnified when dealing with a
closed loop traction system where oil is not filtered. In the
event of a traction system component failure, It is
recommended that all traction system components be
disassembled and cleaned, or filtered using a portable
in-line filter available through your Jacobsen Dealer. The
5 portable in-line filter should also be used when testing
hydraulic systems or after replacing a failed component.

IMPORTANT
Always install the in-line filter so oil flows through
the filter before entering a component. Once filtering
has begun, never reverse the flow of oil, or debris will
re-enter the system.

5-4 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Component Location
See Figures 5-2 and 5-3.

1 5

2
3 4

TN1768, TN1970, TN1893

1 Hydrostatic Pump 3 Front Axle Motor 5 4WD Valve
2 Gear Pump 4 Front Axle U-Joint 6 Front Axle
Figure 5-2: Component Location—Left Side

4203780 First Edition 5-5

 HYDROSTATIC POWER TRAIN

4 3

3 2

TN1769, TN1921
1 Control Valve 2 Right Rear Wheel Motor 3 Left Rear Wheel Motor
Figure 5-3: Component Location—Right Side

5-6 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Theory of Operation and

Sub-Circuit Schematics
Traction Circuit Neutral Schematic
and Theory of Operation
System Conditions:
• Engine running
• Park brake released
• Traction pedal in NEUTRAL position

Charge Pressure Circuit

The traction pump and gear pump are both driven by the
engine. Section 1 of the gear pump provides operating
pressure oil for the steering and lift systems, and charge
pressure oil for the traction pump.
Oil is drawn from the hydraulic tank through a 100-mesh
screen, and enters the gear pump, supplying oil to all four
pump sections. Operating-pressure oil from section 1 of
the gear pump is routed to port “P” of the control valve,
flows through the 4.5-gpm priority valve, and out port
“ST” to the steering valve.
The oil flows through the steering valve to the charge
filter. The charge filter uses a 10-micron filter to remove
debris from the oil. In the event of the charge filter
becoming plugged, a 25-psi pressure switch will activate
5
the “Charge Filter” light on the control panel, and a
bypass valve will open to provide oil to the traction pump
and other systems. Charge-pressure oil is then routed to
port “C” of the 4WD valve, port “F” of the control valve,
and the traction pump.
The control valve also incorporates a charge pressure
switch that will activate the “Charge Pressure” light on the
control panel if the charge oil pressure drops below
125 psi. The control valve also includes a charge relief
valve that will open to dump oil to the hydraulic tank when
the charge pressure reaches 250 psi.

Traction Pump Circuit

With the traction pedal in the NEUTRAL position, the
swash plate is in a neutral position; therefore, oil simply
flows through the traction pump without an increase in
pressure. Charge pressure oil flows to the relief valves,
front axle motor, and ports “A” and “B” of the 4WD valve.
Since oil pressure is equal on both sides of the front and
rear drive motors, no movement occurs.

4203780 First Edition 5-7

 HYDROSTATIC POWER TRAIN

Traction Circuit—Neutral Schematic

See Figures 5-4 and 5-5.

A
2
1 2 3 4 3500 psi
Check
Valve
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 RPM

Check
Valve 3500 psi
B
3

Hydrostatic Traction Pump

4
5

10 Micron

25 psi
Switch

5
25 psi
Crack
Bypass
Charge
Filter

Tank Fill Cap

Assembly
IN Steering
Valve Body
RT
40 Micron Check
Filter Valve

Relief Valve 6.6 ci

1450 psi
Suction
LT
Strainer
Steering
560 Micron
Strainer
Cylinder

OUT

Steering Unit

6
Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Charge Pressure Oil

TN1730

1 Operating Pressure Oil to Control Valve 3 Charge Pressure Oil from Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
(Port P) and 4WD Valve (Port B) F)
2 Charge Pressure Oil to Front Axle Motor 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port A) (Port ST)
Figure 5-4

5-8 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Neutral Schematic Continued

A
4WD Valve
2
Secondary 4WD
AD Shuttle Valve
Front
2.48 ci Axle
Motor BD

3
4WD Reverse
Solenoid

4 C B L2 R2 4WD R1 L1

Right
Wheel
Motor

11.9
ci

Differential Lock

Charge Pressure
Light Switch Left
11.9
ci 5
Wheel
125 psi N.C. Motor

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P

ST 4WD

Differential
LD
Lock Solenoid 4WD Solenoid

Control Valve Tank

Check
Valve

Hydraulic
6 7 Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Free Flowing or Drain Oil Return Oil
TN1731
1 Operating Pressure Oil to Control Valve 4 Case Drain Oil to Front Axle Motor 7 Charge Pressure Oil to Lift Valve
(Port P)
2 Charge Pressure Oil to Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
and 4WD Valve (Port A) F) and 4WD Valve (Port C)
3 Charge Pressure Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port B) (Port ST)
Figure 5-5

4203780 First Edition 5-9

 HYDROSTATIC POWER TRAIN

5 Page Intentionally Blank

5-10 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 2WD Charge-pressure oil is also supplied to port “C” of the
4WD valve. With the 2WD/4WD switch in the 2WD
Schematic and Theory of Operation position, oil flows through the 4WD reverse solenoid and
System Conditions: secondary 4WD shuttle valves, applying equal pressure
• Engine running to both sides of the right and left rear wheel motors. This
provides no driving force to the rear wheel motors, but
• Park brake released
allows the motors to rotate freely as the mower travels
• Traction pedal in FORWARD position forward.
• 2WD/4WD switch in 2WD position
• Differential lock pedal in LOCKED position
Circuit Relief
(differential lock mode only) The traction circuit is protected by a relief valve. The relief
valve will open if the pressure rises to 3500 psi, allowing
Charge Pressure Circuit oil to dump to the charge side of the circuit.
The traction pump and gear pump are both driven by the
engine. One section of the gear pump provides operating
Differential Lock
pressure oil for the steering and lift systems, and charge Charge-pressure oil is supplied to port “F” of the control
pressure oil for the traction pump. valve, and is routed to the pilot line of the charge relief
valve, charge pressure switch, and the differential lock
Oil is drawn from the hydraulic tank through a 100-mesh
solenoid. When the differential lock pedal is depressed,
screen, and enters the gear pump, supplying oil to all four
the solenoid engages, shifting the valve. This allows
pump sections. Operating-pressure oil from section 1 of
charge-pressure oil to flow to the differential lock cylinder,
the gear pump is routed to port “P” of the control valve,
engaging the differential lock mechanism on the front
flows through the 4.5-gpm priority valve, and out port
axle.
“ST” to the steering valve.
Oil flows through the steering valve to the charge filter.
The charge filter uses a 10-micron filter to remove debris
from the oil. In the event of the charge filter becoming
plugged, a 25-psi pressure switch will activate the
5
“Charge Filter” light on the control panel, and a bypass
valve will open to provide oil to the traction pump and
other systems. Charge-pressure oil is then routed to port
“C” of the 4WD valve, port “F” of the control valve, and
the traction pump.
The control valve also incorporates a charge pressure
switch that will activate the “Charge Pressure” light on the
control panel if the charge oil pressure drops below 125
psi. The control valve also includes a charge relief valve
that will open to dump oil to the hydraulic tank when the
charge pressure reaches 250 psi.

Traction Drive Circuit

When the traction pedal is moved to FORWARD position,
the swash plate is moved, stroking the pump. This
change of the swash plate angle produces an increase of
oil pressure on one side of the pump. Oil at operating
pressure is then routed against the check valve and relief
valve (3500 psi), and exits the traction pump at Port “A.”
The oil is then routed to the front axle drive motor, driving
the motor. Oil exiting the front axle motor is returned to
the traction pump to replenish the intake side of the
pump.

4203780 First Edition 5-11

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 2WD,

Differential Locked Schematic
See Figures 5-6 and 5-7.

A
2
1 2 3 4 3500 psi
Check
Valve
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 RPM

Check
Valve 3500 psi
B
3

Hydrostatic Traction Pump

4
5

10 Micron

25 psi
Switch

5
25 psi
Crack
Bypass
Charge
Filter

Tank Fill Cap

Assembly
IN Steering
Valve Body
RT
Check
40 Micron Valve
Filter

Relief Valve 6.6 ci

1450 psi

Suction
LT
Strainer
Steering
560 Micron
Strainer
Cylinder

OUT

Steering Unit

Hydraulic Oil Tank

6
Inlet or Drain Oil Operating Pressure Oil Charge Pressure Oil
TN1722
1 Operating Pressure Oil to Control Valve 3 Charge Pressure Oil from Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
(Port P) and 4WD Valve (Port B) F)
2 Operating Pressure Oil to Front Axle Motor 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port A) (Port ST)
Figure 5-6

5-12 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 2WD Differential Locked Schematic Continued

A
2 4WD Valve
Secondary 4WD
AD Shuttle Valve
Front
2.48 ci Axle
Motor BD

3
4WD Reverse
Solenoid

4 C B L2 R2 4WD R1 L1

Right
Wheel
Motor

11.9
ci

Differential Lock

Charge Pressure
Light Switch
11.9
ci

Left
5
Wheel
125 psi N.C. Motor

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P

ST
4WD

Differential
LD
Lock Solenoid 4WD Solenoid

Control Valve
Tank Check Valve

Hydraulic
6 7 Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Free Flowing or Drain Oil Return Oil
TN1723
1 Operating Pressure Oil to Control Valve 4 Case Drain Oil from Front Axle Motor 7 Charge Pressure Oil to Lift Valve
(Port P)
2 Operating Pressure Oil to Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
and 4WD Valve (Port A) F)
3 Charge Pressure Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port B) (Port ST)
Figure 5-7

4203780 First Edition 5-13

 HYDROSTATIC POWER TRAIN

5 Page Intentionally Blank

5-14 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 2WD Operating-pressure oil is also supplied to port “B” of the
4WD valve. With the 2WD/4WD switch in the 2WD
Schematic and Theory of Operation position, oil flows through the 4WD reverse solenoid and
System Conditions: secondary 4WD shuttle valves, applying equal pressure
• Engine running to both sides of the right and left rear wheel motors. This
provides no driving force to the rear wheel motors, but
• Park brake released
allows the motors to rotate freely as the mower travels in
• Traction pedal in REVERSE position reverse.
• 2WD/4WD switch in 2WD position
• Differential lock pedal in UNLOCKED position
Circuit Relief
The traction circuit is protected by a relief valve. The relief
Charge Pressure Circuit valve will open if the pressure rises to 3500 psi, allowing
The traction pump and gear pump are both driven by the oil to dump to the charge side of the circuit.
engine. One section of the gear pump provides operating
pressure oil for the steering and lift systems, and charge
pressure oil for the traction pump.
Oil is drawn from the hydraulic tank through a 100-mesh
screen, and enters the gear pump, supplying oil to all four
pump sections. Operating-pressure oil from section 1 of
the gear pump is routed to port “P” of the control valve,
flows through the 4.5-gpm priority valve, and out port
“ST” to the steering valve.
Oil flows through the steering valve to the charge filter.
The charge filter uses a 10-micron filter to remove debris
from the oil. In the event of the charge filter becoming
plugged, a 25-psi pressure switch will activate the
“Charge Filter” light on the control panel, and a bypass
valve will open to provide oil to the traction pump and
5
other systems. Charge-pressure oil is then routed to port
“C” of the 4WD valve, port “F” of the control valve, and
the traction pump.
The control valve also incorporates a charge pressure
switch that will activate the “Charge Pressure” light on the
control panel if the charge oil pressure drops below 125
psi. The control valve also includes a charge relief valve
that will open to dump oil to the hydraulic tank when the
charge pressure reaches 250 psi.

Traction Drive Circuit

When the traction pedal is moved to REVERSE position,
the swash plate is moved, stroking the pump. This
change of the swash plate angle produces an increase of
oil flow on one side of the pump. Oil at operating pressure
is then routed against the check valve and the relief valve
(3500 psi), and exits the traction pump at port “B.” The oil
is then routed to the front axle drive motor, driving the
motor. Oil exiting the front axle motor is returned to the
traction pump to replenish the intake side of the pump.

4203780 First Edition 5-15

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 2WD,

Differential Unlocked Schematic
See Figures 5-8 and 5-9.

A
2
1 2 3 4 3500 psi
Check
Valve
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 RPM

Check
Valve 3500 psi
B
3

Hydrostatic Traction Pump

4
5

10 Micron

25 psi
Switch

5 25 psi
Crack
Bypass
Charge
Filter

Tank Fill Cap

Assembly
IN Steering
Valve Body
RT
40 Micron Check
Filter Valve

6.6 ci
Relief Valve
1450 psi
Suction
Strainer LT

Steering
560 Micron
Strainer Cylinder

OUT

Steering Unit

6
Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Charge Pressure Oil

TN1724
1 Operating Pressure Oil to Control Valve 3 Operating Pressure Oil to Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
(Port P) and 4WD Valve (Port B) F)
2 Charge Pressure Oil from Front Axle Motor 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port A) (Port ST)
Figure 5-8

5-16 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 2WD,

Differential Unlocked Schematic Continued

4WD Valve A
2
Secondary 4WD
AD Shuttle Valve
Front
2.48 ci Axle
Motor BD 4WD
Reverse
Solenoid

4 L2 R2 R1
C B 4WD L1

Right
Wheel
Motor

11.9
ci

Differential Lock

Charge Pressure
11.9
ci 5
Light Switch Left
Wheel
125 psi N.C. Motor

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P

ST 4WD

Differential
LD Lock Solenoid
4WD Solenoid

Control Valve
Tank Check Valve

6 7 Hydraulic
Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Free Flowing or Drain Oil Return Oil
TN1725
1 Operating Pressure Oil to Control Valve 4 Case Drain Oil from Front Axle Motor 7 Charge Pressure Oil to Lift Valve
(Port P)
2 Charge Pressure Oil from Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
and 4WD Valve (Port A) F)
3 Operating Pressure Oil to Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port B) (Port ST)
Figure 5-9

4203780 First Edition 5-17

 HYDROSTATIC POWER TRAIN

5 Page Intentionally Blank

5-18 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 4WD When the 2WD/4WD switch is placed in the 4WD
position, the 4WD solenoid in the control valve shifts,
Schematic and Theory of Operation allowing oil to flow through the valve. Oil is then routed to
System Conditions: the pilot line of the secondary 4WD shuttle valve in the
• Engine running 4WD valve, causing the valve to shift. Operating-pressure
oil from port “A” flows through the 4WD shuttle valve
• Park brake released
through ports “R1” (right motor) and “L1” (left motor) to
• Traction pedal in FORWARD position the right and left rear wheel motors, driving the rear
• 2WD/4WD switch in 4WD position wheels.
• Differential lock pedal in LOCKED position Oil exiting the rear wheel motors enters the 4WD valve at
(differential lock mode only) ports “R2” (right motor) and “L2” (left motor), and flows
through the 4WD reverse solenoid valve, exiting the 4WD
Charge Pressure Circuit valve at port “C.” A check valve will also open, allowing oil
The traction pump and gear pump are both driven by the to exit the 4WD valve at port “B.” Oil exiting the rear wheel
engine. One section of the gear pump provides operating motors is returned to the traction pump to replenish the
pressure oil for the steering and lift systems, and charge intake side of the pump.
pressure oil for the traction pump.
Circuit Relief
Oil is drawn from the hydraulic tank through a 100-mesh
screen, and enters the gear pump, supplying oil to all four The traction circuit is protected by a relief valve. The relief
pump sections. Operating-pressure oil from section 1 of valve will open if the pressure rises to 3500 psi, allowing
the gear pump is routed to port “P” of the control valve, oil to dump to the charge side of the circuit.
flows through the 4.5-gpm priority valve, and out port
“ST” to the steering valve.
Differential Lock
Charge-pressure oil is supplied to port “P” of the control
Oil flows through the steering valve to the charge filter.
valve by section 1 of the gear pump, and is routed to the
The charge filter uses a 10-micron filter to remove debris
from the oil. In the event of the charge filter becoming
plugged, a 25-psi pressure switch will activate the
pilot line of the charge relief valve and the differential lock
valve. When the differential lock pedal is depressed, the
solenoid engages, shifting the valve. This allows
5
“Charge Filter” light on the control panel, and a bypass
charge-pressure oil to flow to the differential lock cylinder,
valve will open to provide oil to the traction pump and
engaging the differential lock.
other systems. Charge-pressure oil is then routed to
ports “B” and “C” of the 4WD valve, port “F” of the control
valve, and the traction pump.
The control valve also incorporates a charge pressure
switch that will activate the “Charge Pressure” light on the
control panel if the charge oil pressure drops below 125
psi. The control valve also includes a charge relief valve
that will open to dump oil to the hydraulic tank when the
charge pressure reaches 250 psi.

Traction Drive Circuit

When the traction pedal is moved to FORWARD position,
the swash plate is moved, stroking the pump. This
change of the swash plate angle produces an increase of
oil flow on one side of the pump. Oil at operating pressure
is then routed against the check valve and relief valve
(3500 psi), and exits the traction pump through port “A.”
Oil is then routed to the front axle drive motor, driving the
motor. Operating-pressure oil is also routed to port “A” of
the 4WD valve. Oil exiting the front axle motor is returned
to the traction pump to replenish the intake side of the
pump.

4203780 First Edition 5-19

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 4WD,

Differential Locked Schematic
See Figures 5-10 and 5-11.

A
2
1 2 3 4 3500 psi
Check
Valve
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 RPM

Check
Valve 3500 psi
B
3

Hydrostatic Traction Pump

4
5

10 Micron

25 psi
Switch

5 25 psi
Crack
Bypass
Charge
Filter

Tank Fill Cap

Assembly
IN Steering
Valve Body
RT
40 Micron Check
Filter Valve

Relief Valve 6.6 ci

1450 psi
Suction
LT
Strainer
Steering
560 Micron
Strainer
Cylinder

OUT

Steering Unit

6
Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Charge Pressure Oil TN1726
1 Operating Pressure Oil to Control Valve 3 Charge Pressure Oil from Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
(Port P) and 4WD Valve (Port B) F)
2 Operating Pressure Oil to Front Axle Motor 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port A) (Port ST)
Figure 5-10

5-20 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Forward 4WD, Differential

Locked Schematic Continued

4WD Valve A
2
Secondary 4WD
AD Shuttle Valve
Front
2.48 ci Axle
Motor BD

3
4WD Reverse
Solenoid

4 C B L2 R2 4WD R1 L1

Right
Wheel
Motor

11.9
ci

Differential Lock

Charge Pressure
Light Switch Left
11.9
ci
5
Wheel
125 psi N.C. Motor

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P

ST 4WD

Differential
LD Lock Solenoid
4WD Solenoid

Control Valve
Tank Check Valve

Hydraulic
6 7 Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Free Flowing or Drain Oil Return Oil
TN1727
1 Operating Pressure Oil to Control Valve 4 Case Drain Oil from Front Axle Motor 7 Charge Pressure Oil to Lift Valve
(Port P)
2 Operating Pressure Oil to Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
and 4WD Valve (Port A) F)
3 Charge Pressure Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port B) (Port ST)
Figure 5-11

4203780 First Edition 5-21

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5 Page Intentionally Blank

5-22 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 4WD When the 2WD/4WD switch is held in the momentary
4WD reverse position, the 4WD reverse solenoid shifts,
Schematic and Theory of Operation allowing operating-pressure oil to flow through the valve
System Conditions: to ports “R2” (right motor) and “L2” (left motor) driving the
• Engine running rear wheels.
• Park brake released The 4WD solenoid in the control valve also shifts,
allowing oil to flow to the pilot line of the secondary 4WD
• Traction pedal in REVERSE position
shuttle valve, causing the valve to shift.
• 2WD/4WD switch held in the momentary 4WD
With the secondary 4WD shuttle valve shifted, oil exiting
position
the rear wheel motors enters the 4WD valve at ports “R1”
• Differential lock pedal in UNLOCKED position (right motor) and “L1” (left motor), and flows through the
secondary 4WD shuttle valve, exiting the 4WD valve at
Charge Pressure Circuit port “A.” Oil exiting the rear wheel motors is returned to
The traction pump and gear pump are both driven by the the traction pump to replenish the intake side of the
engine. One section of the gear pump provides operating pump.
pressure oil for the steering and lift systems, and charge
pressure oil for the traction pump. Circuit Relief
Oil is drawn from the hydraulic tank through a 100-mesh The traction circuit is protected by a relief valve. The relief
screen, and enters the gear pump, supplying oil to all four valve will open if the pressure rises to 3500 psi, allowing
pump sections. Operating-pressure oil from section 1 of oil to dump to the charge side of the circuit.
the gear pump is routed to port “P” of the control valve,
flows through the 4.5-gpm priority valve, and out port
“ST” to the steering valve.
Oil flows through the steering valve to the charge filter.
The charge filter uses a 10-micron filter to remove debris
from the oil. In the event of the charge filter becoming
plugged, a 25-psi pressure switch will activate the
5
“Charge Filter” light on the control panel, and a bypass
valve will open to provide oil to the traction pump and
other systems. Charge-pressure oil is then routed to port
“C” of the 4WD valve, port “F” of the control valve, and
the traction pump.
The control valve also incorporates a charge pressure
switch that will activate the “Charge Pressure” light on the
control panel if the charge oil pressure drops below 125
psi. The control valve also includes a charge relief valve
that will open to dump oil to the hydraulic tank when the
charge pressure reaches 250 psi.

Traction Drive Circuit

When the traction pedal is moved to REVERSE position,
the swash plate is moved, stroking the pump. This
change of the swash plate angle produces an increase of
oil flow on one side of the pump. Oil at operating pressure
is then routed against the check valve and relief valve
(3500 psi), and exits the traction pump through port “B.”
The oil is then routed to the front axle drive motor, driving
the motor. Operating-pressure oil is also routed to port
“B” of the 4WD valve. Oil exiting the front axle motor is
returned to the traction pump to replenish the intake side
of the pump.

4203780 First Edition 5-23

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 4WD,

Differential Unlocked Schematic
See Figures 5-12 and 5-13.
1

A
2
1 2 3 4 3500 psi
Check
Valve
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 RPM

Check
Valve 3500 psi
B
3

Hydrostatic Traction Pump

4
5

10 Micron

25 psi
Switch

5
25 psi
Crack
Bypass
Charge
Filter

Tank Fill Cap

Assembly
IN
Steering Valve
RT
40 Micron Check
Filter Valve

6.6 ci
Relief Valve
1450 psi
Suction
LT
Strainer
Steering
560 Micron
Strainer
Cylinder

OUT

Steering Unit

6
Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Charge Pressure Oil

TN1728
1 Operating Pressure Oil to Control Valve 3 Operating Pressure Oil to Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
(Port P) and 4WD Valve (Port B) F)
2 Charge Pressure Oil from Front Axle Motor 4 Case Drain Oil from Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port A) (Port ST)
Figure 5-12

5-24 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Traction Circuit—Reverse 4WD,

Differential Unlocked Schematic Continued

4WD Valve A
2
Secondary 4WD
AD Shuttle Valve
Front
2.48 ci Axle
Motor BD 4WD
Reverse
Solenoid

4 C B L2 R2 4WD R1 L1

Right
Wheel
Motor

11.9
ci

Differential Lock

Charge Pressure
Left
11.9
ci 5
Light Switch
Wheel
125 psi N.C. Motor

SD DL SW CP F T
Charge Pressure
Relief Valve 250 psi
Priority Valve
4.5 gpm
P

ST 4WD

Differential
LD Lock Solenoid 4WD Solenoid

Control Valve
Tank Check Valve

Hydraulic
6 7 Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Free Flowing or Drain Oil Return Oil
TN1729
1 Operating Pressure Oil to Control Valve 4 Case Drain Oil from Front Axle Motor 7 Charge Pressure Oil to Lift Valve
(Port P)
2 Charge Pressure Oil from Front Axle Motor 5 Charge Pressure Oil to Control Valve (Port
and 4WD Valve (Port A) F)
3 Operating Pressure Oil to Front Axle Motor 6 Charge Pressure Oil from Control Valve
and 4WD Valve (Port B) (Port ST)
Figure 5-13

4203780 First Edition 5-25

 HYDROSTATIC POWER TRAIN

Troubleshooting
Mower Will Not Move Forward or Reverse

Probable Cause Remedy

Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and
Maintenance Manual” for the correct oil specifications.)
Tow valve open. Close tow valve. (Refer to “Safety, Operation, and Maintenance
Manual.”)
Low charge pressure. Test charge pressure relief valve setting. (See “Charge Pressure
Test” on page 5-34.) Repair or replace charge pressure relief
valve as needed. (See “Control Valve” on page 5-55.)
Gear pump damaged. Test and repair. (See “Charge Pressure Test” on page 5-34.)
Front axle motor worn or damaged. Test motor. (See “Front Axle Motor Test” on page 5-42.) Repair or
replace motor as needed. (See “Front Axle Motor” on
page 5-58.)
Traction pump worn or damaged. Test pump. (See “Traction Pump Tests” on page 5-40.) Repair or
replace pump as needed. (See “Traction Pump” on page 5-50.)
Damaged traction linkage. Repair traction linkage. (See “Traction Pedal” on page 9-9 and
“Traction Linkage” on page 5-81.)
Front axle assembly worn or damaged. Repair front axle. (See “Front (Drive) Axle Assembly” on
page 5-60.)

Mower Will Not Reach Full Speed

5 Probable Cause
Hydraulic oil not at correct level in reservoir.
Remedy
Fill reservoir to correct level. (Refer to “Safety, Operation, and
Maintenance Manual” for the correct oil specifications.)
Tow valve open. Close tow valve. (Refer to “Safety, Operation, and Maintenance
Manual.”)
Air in hydraulic system (air bubbles in hydraulic oil). Check suction line for air leaks. Repair as needed. Operate
various hydraulic systems until hydraulic system is free of air.
Traction linkage not properly adjusted. Adjust traction linkage. (See “Traction Linkage Adjustments” on
page 5-29.)
Low charge pressure. Test charge pressure relief valve setting. (See “Charge Pressure
Test” on page 5-34.) Repair or replace charge pressure relief
valve as needed. (See “Control Valve” on page 5-55.)
Gear pump worn or damaged. Test gear pump. (See “Charge Pressure Test” on page 5-34.)
Repair or replace gear pump as needed. (See “Gear Pump” on
page 6-58.)
Taction pump worn or damaged. Test pump. (See “Traction Pump Tests” on page 5-40.) Repair or
replace pump as needed. (See “Traction Pump” on page 5-50.)
Front axle motor worn or damaged. Test motor. (See “Front Axle Motor Test” on page 5-42.) Repair or
replace motor as needed. (See “Front Axle Motor” on
page 5-58.)

Mower Moves When Traction Pedal Is in Neutral

Probable Cause Remedy

Traction linkage not properly adjusted. Adjust traction linkage. (See “Traction Linkage Adjustments” on
page 5-29.)

5-26 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Hydrostatic System Operating Hot

Probable Cause Remedy

Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and
Maintenance Manual” for the correct oil specifications.)
Tow valve open. Close tow valve. (Refer to “Safety, Operation, and Maintenance
Manual.”)
Oil cooler has dirt or debris in fins. Clean oil cooler fins of dirt and debris.
Incorrect charge pressure relief setting. Test charge pressure relief valve setting. (See “Charge Pressure
Test” on page 5-34.) Repair or replace charge pressure relief
valve as needed. (See “Control Valve” on page 5-55.)
Slippage in pump or motor. Perform instrument tests. (See “Instrument Test Overview” on
page 5-34.)
Faulty relief valve. Test and repair. (See “Traction Pump Tests” on page 5-40.)

Excessive Traction Pump Noise

Probable Cause Remedy

Hydraulic oil not at correct level in reservoir. Fill reservoir to correct level. (Refer to “Safety, Operation, and
Maintenance Manual” for the correct oil specifications.)
Hydraulic oil cold. Warm hydraulic oil to operating temperature.
Air in hydraulic system (air bubbles in hydraulic oil). Check suction line for air leaks. Repair as needed. Operate
various hydraulic systems until hydraulic system is free of air.
Traction pump worn or damaged. Repair or replace pump as needed. (See “Traction Pump” on

Differential Lock Will Not Engage

page 5-50.)
5
Probable Cause Remedy
Differential lock solenoid does not engage when differential lock Problem in electrical circuit. (See Electrical section,
switch is depressed. Troubleshooting—“Four Wheel Drive Circuit Schematic” on
page 4-41.)
Differential lock valve in control valve assembly sticking. Repair or replace differential lock valve. (See “Control Valve” on
page 5-55.)
Low charge pressure. Test charge pressure relief valve setting. (See “Charge Pressure
Test” on page 5-34.) Repair or replace charge pressure relief
valve as needed. (See “Control Valve” on page 5-55.)
Differential lock assembly damaged. Repair differential lock assembly. (See “Differential Lock
Assembly” on page 5-64.)

Differential Lock Will Not Disengage

Probable Cause Remedy

Differential lock solenoid does not disengage when differential Problem in electrical circuit. (See Electrical section,
lock switch is released. Troubleshooting—“Four Wheel Drive Circuit Schematic” on
page 4-41.)
Differential lock valve in control valve assembly sticking. Repair or replace differential lock valve. (See “Control Valve” on
page 5-55.)

4203780 First Edition 5-27

 HYDROSTATIC POWER TRAIN

4WD Will Not Engage

Probable Cause Remedy

4WD solenoid in control valve does not engage when 4WD switch Problem in electrical circuit. (See Electrical section,
is placed in ON position. Troubleshooting—“Four Wheel Drive Circuit Schematic” on
page 4-41.)
4WD valve in control valve assembly sticking. Repair or replace 4WD valve. (See “Control Valve” on page 5-55.)
Secondary 4WD shuttle valve in 4WD valve assembly sticking. Repair or replace 4WD shuttle valve. (See “4WD Valve” on
page 5-53.)
Low charge pressure. Test charge pump. (See “Charge Pressure Test” on page 5-34.)

4WD Will Not Disengage

Probable Cause Remedy

4WD solenoid in control valve does not disengage when 4WD Problem in electrical circuit. (See Electrical section,
switch is placed in OFF position, or the traction pedal is moved to Troubleshooting—“Four Wheel Drive Circuit Schematic” on
the reverse position. page 4-41.)
4WD valve in control valve assembly sticking. Repair or replace 4WD valve. (See “Control Valve” on page 5-55.)
Secondary 4WD shuttle valve in 4WD valve assembly sticking. Repair or replace 4WD shuttle valve. (See “4WD Valve” on
page 5-53.)

5-28 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Tests and Adjustments

Traction Linkage Adjustments
See Figures 5-14 through 5-19.

Traction Pedal Neutral Adjustment

1 2
3

TN1985
Figure 5-14

NOTE ! WARNING
If the mower creeps in either direction while the engine is
running and the traction pedal is in the NEUTRAL
Use extreme caution while performing the
5
following adjustment, as the drive wheels will be
position, the hydro linkage may need adjustment.
off the ground and the engine will be running.
1. Park the mower safely. (See “Park Mower Safely” on Serious personal injury can result if clothing or
page 1-6.) limbs become entangled in moving parts.

! WARNING
8. Loosen the jam nut (1) on the traction pump
• Support the machine using properly rated centering cylinder (3), and turn the adjustment nut (2)
jackstands. Never work under a machine moving the threaded rod in or out as required to stop
supported only by a jack. the wheels from turning.
• Do not use wood or concrete blocks to 9. Stop the engine.
support the machine. Failure to properly 10. Hold the adjustment nut (2) and tighten the jam nut
support the machine may result in death or (1).
serious injury. 11. Start the engine and check the adjustment.
12. Proceed to “Reverse Kick-Out Switch Initial
2. Raise the mower so that all four wheels are off the Adjustment” on page 5-30.
ground. Place jackstands under the frame to support
the mower.
3. Disengage the parking brake.
4. Bypass the seat switch.
5. Place the 4WD switch in the ON position.
6. Apply a small amount of oil to the pedal linkage pivot
points before adjusting, to ensure free movement of
the linkage.
7. Start the engine and set the throttle in the fast idle
position.

4203780 First Edition 5-29

 HYDROSTATIC POWER TRAIN

Reverse Kick-Out Switch Initial Adjustment

4
Required Tools or Equipment 5

Digital Multimeter, Ohmmeter, or Continuity Tester 3

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
6
2. Disconnect the negative (–) battery cable at the
battery.

TN2140
Figure 5-16
2 4. Loosen nuts (3 and 6).
1
5. Position switch bracket (4), and reverse kick-out
switch (5) to achieve continuity when the traction
pedal is in the neutral position and the 4WD switch is
in the ON position and no continuity when the traction
pedal is in the reverse position.
6. Tighten nuts (1 and 4) and install floorboard plug.

5 Figure 5-15
TN1915
7. Proceed to “Reverse Kick-Out Switch Adjustment” on
page 5-31.

NOTES
• Remove floorboard plug to access reverse kick-out
switch (1).
• Label all wires before disconnecting to ensure correct
installation.
3. Disconnect wire connector (2) and connect test leads
to the reverse kick-out switch terminals.
The reverse kick-out switch should indicate continuity
when the traction pedal is in the forward or neutral
position. The reverse kick-out switch should not indicate
continuity when the traction pedal is in the reverse
position.
If adjustment is required, proceed to step 4. If no
adjustment is required, proceed to “Reverse Kick-Out
Switch Adjustment” on page 5-31.

5-30 4203780 First Edition

 HYDROSTATIC POWER TRAIN

Reverse Kick-Out Switch Adjustment

IMPORTANT
The traction linkage must be adjusted in proper
sequence. Do not perform this procedure until the
traction pedal neutral adjustment has been 4
performed. (See “Traction Pedal Neutral Adjustment”
on page 5-29.)
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise the operator’s seat platform to access the 5
hydro control rod and lock nut. TN1991
Figure 5-17
! WARNING 10. Loosen lock nut (5).
• Support the machine using properly rated 11. Turn rod (4) counterclockwise to decrease the delay
jackstands. Never work under a machine at which the rear wheels engage.
supported only by a jack. 12. Tighten lock nut (5).
• Do not use wood or concrete blocks to 13. Repeat steps 6 through 8 to check the four-wheel
support the machine. Failure to properly drive (rear wheel) engagement delay.
support the machine may result in death or 14. Start the engine and set the throttle in the fast idle
serious injury. position.
15. Place the 4WD switch in the ON position.
3. Raise the mower so that all four wheels are off the
ground. Place jackstands under the frame to support
the mower.
NOTE
Four-wheel drive (rear wheels) will not engage unless the
5
4. Disengage the parking brake. 4WD switch is held in the momentary position.
5. Bypass the seat switch. 16. Slowly push the traction pedal to engage reverse
drive while observing the front and rear tires. The
! WARNING front tires should start to turn, but the rear wheels
should not engage.
Carbon monoxide in the exhaust fumes can be
17. Remove the jackstands and lower the mower to the
fatal when inhaled. Any adjustments or repairs
ground.
performed with the engine running must be made
with ample ventilation. 18. Proceed to “Speed Limit Adjustment” on page 5-31.

Speed Limit Adjustment

6. Start the engine and set the throttle in the fast idle
position. IMPORTANT
7. Place the 4WD switch in the ON position. The traction linkage must be adjusted in proper
8. Slowly push the traction pedal to engage the forward sequence. Do not perform this procedure until the
drive while observing the front and rear tires. The traction pedal neutral adjustment and reverse
front tires and rear tires should start to rotate at the kick-out switch adjustments have been performed.
same time. (See “Traction Pedal Neutral Adjustment” on
9. Stop the engine. page 5-29 and “Reverse Kick-Out Switch Initial
Adjustment” on page 5-30.)
If adjustment is required, proceed to step 10.
If no adjustment is required, proceed to “Speed Limit Reverse
Adjustment” on page 5-31. The reverse pedal travel can be adjusted by changing the
length of the traction pedal rod:
• Shortening the rod will increase the reverse speed.
• Lengthening the rod will decrease the reverse speed.

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1. Move the traction pedal (14) to the maximum forward

position. If the pedal touches the stop stud (13)
before reaching the maximum forward position,
adjust the stop stud position.
2. Loosen jam nut (16) and lock nut (15).
3. Adjust (turn) the stop stud (13) in (clockwise).
6 4. Move the traction pedal (14) to the maximum forward
position and hold.
10 5. Adjust (turn) the stop stud (13) counterclockwise,
11 until it touches the traction pedal (14), then one
additional turn.
12 9 8 7 TN1986
6. Tighten jam nut (16) and lock nut (15).
Figure 5-18
1. Loosen lock nut (8). Weight Transfer Adjustment
2. Remove the nut (10), lock washer (11), and flat See Figure 5-20.
washer (12) from the ball joint (9), and disconnect the
The adjustable weight transfer valve can be used to
ball joint from the throttle pedal lever (6).
maintain 0—50 psi (0—3.45 bar) of upward force on the
3. Adjust the overall length of the traction pedal rod (7), cutting unit lift cylinders. Increased upward pressure on
by turning the ball joint (9), in to shorten, or out to the cutting unit cylinders will transfer additional weight to
lengthen as needed. the machine drive wheels, improving traction, and
4. Tighten lock nut (8). reducing the chance of wheel spin.
5. Connect the traction pedal rod ball joint (9) to the
NOTE
throttle pedal lever (6) using flat washer (12), lock

5 washer (11), and nut (10).

6. Start the engine and check the reverse speed.
Adjustments (clockwise or counterclockwise) are referred
to while facing the adjustment knob and instructional
decal as shown below.
7. Stop the engine.
8. Repeat steps 1 through 7 as needed until the correct
adjustment is obtained.
9. When the desired reverse speed adjustment is
obtained, proceed to “Forward” adjustment.

Forward
The forward limit is adjusted by changing the height of 1 2
the stop stud under the traction pedal.

14
13

16
TN1759
Figure 5-20
15 1. Loosen adjustment lock (2).
2. Rotate adjustment knob (1) counterclockwise to
decrease upward force on the cutting unit lift
cylinders. This will increase the weight of the decks
TN1986 on the ground.
Figure 5-19

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NOTE
Adjusting weight transfer knob completely clockwise may
cause decks not to lower.
3. Rotate adjustment knob (1) clockwise to increase
upward force on cutting unit lift cylinders. This will
improve machine traction and reduce wheel spin.
4. Tighten adjustment lock (2).
1
5. Test mow with the machine to verify desired
adjustment. Re-adjust as needed.

Field Test Procedures

When a hydraulic system failure occurs, some simple TN1761
effective tests can be performed prior to using a test Figure 5-21
instrument. The results of these tests can lead you to the
suspected component failure. More extensive test 3. Install wheel restraints (1) to all four wheels.
procedures, using test instruments, are presented later in 4. Lower the cutting units and move throttle lever to full
this section. (See “Instrument Test Procedures” on throttle. Slowly push the traction pedal forward.
page 5-34.) Does the engine labor or stall?
YES The traction pump and front axle motor are
Preliminary Checks not faulty. Continue to step 5.
Perform the following checks prior to beginning any tests. NO A fault exists in the hydrostatic drive circuit,
including the traction pump or front axle
1. Check the hydraulic oil reservoir for proper fluid level,
the presence of air or water, and unusual odor.
2. Check all lines and fittings for leaks. Tighten as
motor. Proceed to instrument test. (See
“Instrument Test Procedures” on page 5-34.)
5
needed. 5. Operate hydraulic system until oil temperature is at
120—150° F (49—65° C).
3. Eliminate all mechanical issues prior to starting
hydraulic tests. 6. Set park brake.
7. Verify wheel restraints are installed to all four wheels.
Charge Pump Test 8. Lower the cutting units and move throttle lever to full
throttle.
The charge pump supplies oil for charging the traction
circuit and traction pump. 9. Engage 4WD switch in the forward position and
slowly push the traction pedal forward.
If faults exist in the charge pump, proceed with an
instrument test for the charge pump. (See “Charge Does the engine labor or stall?
Pressure Test” on page 5-34.) YES The hydrostatic drive train circuit is good.
NO The hydrostatic drive circuit is faulty.
Traction System Test Additional testing is required. Proceed to
See Figure 5-21. instrument test. (See “Instrument Test
Procedures” on page 5-34.)
NOTE
Be sure tow valve is closed before beginning traction
system test.
1. Operate hydraulic system until oil temperature is at
120—150° F (49—65° C).
2. Set park brake.

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Instrument Test Procedures Calculations:

System Test
Instrument Test Overview No Load Flow = 15 gpm
The following tests are specifically designed to approach Loaded Flow = 9.4 gpm
hydraulic testing on a system level. Each component 15 – 9.4 / 15 x 100 = Total System Leakage 37%
within the system represents a portion of the total system
leakage. An internal leakage percentage for each Traction Pump Test
component will be calculated and recorded, enabling the
No Load Flow = 15 gpm
technician to view the system performance issue more
completely. The test results will help the technician to Loaded Flow = 14 gpm
decide which repairs will best remedy the performance 15 – 14 / 15 x 100 = Traction Pump Leakage 6.7%
issue experienced by the machine user.
Front Axle Motor Test
The internal leakage percentage ranges are as follows: Loaded Flow from traction pump test = 14 gpm
0—10% = Good Loaded Flow from front axle motor test = 9.4 gpm
11—20% = Marginal 14 – 9.4 / 14 x 100 = Front Axle Motor Leakage 32.9%
21% and Beyond = Bad
Charge Pressure Test
Example: Traction System Performance Complaint
See Figures 5-22 and 5-23.
The machine operator reports the machine struggles to
climb hills. ! WARNING
A charge pressure test must first be performed to rule out
a charge pump issue. Next, the traction system is tested The hydraulic system is under pressure, and the

5 as outlined, and the calculated system leakage is 37%; a

result which requires the testing of individual
components. This result can also be interpreted as the
oil will be hot.
• Always relieve pressure in the hydraulic
system before performing service.
system is 63% efficient. • Failure to follow appropriate safety
The remaining components in question are the traction precautions may result in death or serious
pump and the front axle motor. Following the procedures injury.
as outlined, test each individual component, then
calculate and record leakage percentages.
The results from this test reveal leakage of 6.7% in the Required Tools and Materials
traction pump and 32.9% in the front axle motor.
• Pressure Gauge 500 psi (35 bar)
Although both the components lend to the overall system
leakage, only the front axle motor, which is in the bad • Test Hose 500 psi (35 bar)
range, would be considered for repair/replacement. • -8 ORFS Quick Coupler

Formulas:
1. Operate hydraulic system until oil temperature is at
Front Axle Motor, Rear Wheel Motors, Secondary 120—150° F (49—65° C).
4WD Shuttle Valve, and 4WD Reverse Solenoid Valve 2. Park the mower safely. (See “Park Mower Safely” on
Loaded Flow from previous component – Loaded Flow page 1-6.)
from current component / Loaded Flow from previous
component x 100 = Leak Percentage

System and Traction Pump

No Load Flow – Loaded Flow / No Load Flow x 100 =
Leak Percentage

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Charge Pump Test

See Figures 5-24 through 5-26.
2
1 ! WARNING
The hydraulic system is under pressure, and the
oil will be hot.
• Always relieve pressure in the hydraulic
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
TN1921 injury.
Figure 5-22
3. Remove cover (1) to expose control valve.
Required Tools and Materials

• Flow Meter
3
• -10 ORFS Test Hose 2000 psi (138 bar)

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Raise the seat.

TN1275 5
Figure 5-23
2
4. Connect test hose and pressure gauge (3) to “SD”
test port (2). 1
5. Set park brake.

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
6. Start engine and run at full throttle (2800 rpm ± 50).
7. Record pressure reading.
8. Stop the engine. TN1862
Figure 5-24
Is charge pressure 240—250psi (16—17 bar)?
YES Charge pressure relief valve is good. 3. Disconnect hose (1) from fitting (2).
Proceed to step 9.
NO Charge pump or charge pressure relief valve
is at fault. Inspect, repair, or replace charge
pressure relief valve. Inspect, repair, or
replace charge pump as needed.
9. Disconnect and remove test equipment. Install all
hoses and fittings as noted prior to removal.
10. Install and connect all components as noted prior to
test.
11. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for
correct oil specifications.)

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3 ! CAUTION
Do not exceed 1500 psi (103 bar) as this test does
not utilize system relief.

9. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (4) until a reading of 750 psi (52 bar)
or one half of the relief valve rating is reached. Warm
4 oil to 120—150° F (49—65° C).
10. Open flow meter valve (4) completely. Read and
5 record the charge pump no load flow.
TN1359
11. Slowly close flow meter valve (4) until pressure
Figure 5-25 reaches 1125 psi (78 bar). Read and record the
4. Connect flow meter inlet test hose (5) to fitting (2). charge pump loaded flow.
5. Connect flow meter outlet test hose (3) to hose (1). 12. Open flow meter valve (4) and stop engine.
6. Open flow meter valve (4) completely. 13. Calculate charge pump leakage.
(Step 10 – Step 11 / Step 10 x 100 = Leak
Percentage)
Is charge pump leakage 10% or less?
YES The charge pump is good. Proceed to
step 14.
NO Proceed to next question.

5 Is charge pump leakage 11% to 20%?

YES The charge pump is marginal. Additional
testing is required.
NO Proceed to next question.
Is charge pump leakage 21% or more?
YES Repair or replace charge pump. (See “Gear
Pump” on page 6-58.)
14. Disconnect and remove test equipment. Install all
hoses and fittings as noted prior to removal.
15. Install and connect all components as noted prior to
test.
16. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for
correct oil specifications.)

TN2121
Figure 5-26: Charge Pump Test
7. Set park brake.

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
8. Start engine and run at full throttle (2800 rpm ± 50).

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Traction System Test

See Figures 5-27 through 5-32.

IMPORTANT
• This test works together with the wheel motors
test to isolate a problem within the hydrostatic
power train.
• Performing this test will isolate the traction pump
and front axle motor from the rest of the
hydrostatic system. Secondly, this test will
isolate the secondary 4WD shuttle valve, right
rear wheel motor, left rear wheel motor, and 4WD 1
reverse solenoid valve from the rest of the
hydrostatic system.

! WARNING
The hydraulic system is under pressure, and the
TN1329
oil will be hot.
• Always relieve pressure in the hydraulic Figure 5-27
system before performing service. 3. Install wheel restraint (1) to all four wheels.
• Failure to follow appropriate safety 4. Disconnect traction pump control rod from pump
precautions may result in death or serious control arm.
injury.

Required Tools and Materials 2

5
• Flow Meter
• -12 ORFS Test Hose 4000 psi (276 bar)
• -10 ORFS Blocking Disks
• Flow Lock Tool
• Wheel Restraints

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove the seat and seat platform. (See “Seat and
Seat Platform” on page 9-13.)
TN1364
Figure 5-28
5. Install flow lock tool (2) and secure to pump control
arm.
6. Close tow valve completely by turning clockwise.

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16. Adjust flow lock tool (2) to allow pump to produce 15

gpm (57 Lpm) in the forward direction.
17. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (7) until a reading of 1750 psi (121
bar) or one half of the relief valve rating is reached.
3 Warm oil to 120—150° F (49—65° C); open valve
4 fully after operating temperature is reached.
5 6 18. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.
19. Engage 4WD switch in the forward position.
20. Read and record no load flow.
21. Slowly close flow meter valve (7) until pressure
reaches 2625 psi (181 bar). Read and record loaded
flow.
TN2069 22. Open flow meter valve (7), stop engine, and set park
Figure 5-29 brake. Return flow lock tool back to neutral position.
7. Disconnect hoses (4 and 5). 23. Calculate traction system leakage.
(Step 20 – Step 21 / Step 20 x 100 = Leakage
Percentage)
Is traction system leakage 10% or less?
YES The traction system is good. Continue to
7 step 34.

5 NO Proceed to next question.

Is traction system leakage 11% to 20%?
YES The traction system is marginal. Continue to
step 24.
10 9 NO Proceed to next question.

11 8 Is traction system leakage 21% or more?

TN1357
YES The traction system is faulty. Continue to
step 24.
Figure 5-30
8. Connect test hose (11) of flow meter inlet to hose (5). 2WD System Test
9. Connect test hose (10) of flow meter inlet to fitting
(6).
12
10. Connect test hose (8) of flow meter outlet to hose (4).
11. Connect test hose (9) of flow meter outlet to fitting
(3).
12. Open flow meter valve (7) completely before starting
engine.
13. Set park brake. 13
14. Bypass seat switch.

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results. TN2069
15. Start engine, release park brake, and run at full Figure 5-31
throttle (2800 rpm ± 50).
24. Install blocking disks at locations (12 and 13) to block
oil from 4WD valve.

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25. Disengage 4WD switch. 31. Slowly close flow meter valve (7) until pressure
reaches 2625 psi (181 bar). Read and record loaded
flow.
32. Open flow meter valve (7), stop engine, and set park
brake. Return flow lock tool back to neutral position.
33. Calculate traction system leakage.
(Step 30 – Step 31 / Step 30 x 100 = Leakage
Percentage)
Is 2WD traction system leakage 10% or less?
YES The pump and front axle motor are good.
The 4WD system is faulty. (See “Front Axle
Motor Test” on page 5-42.)
NO Proceed to next question.
Is 2WD traction system leakage 11% to 20%?
YES Test individual components in the traction
system.
NO Proceed to next question.
Is 2WD traction system leakage 21% or more?
YES Test individual components in traction
system for leakage.
34. Disconnect and remove test equipment. Install all
hoses and fittings as noted prior to removal.
35. Install and connect all components as noted prior to
test. 5
36. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for oil
specifications.)

TN2089
Figure 5-32: 2WD Traction System Test—Blocking
Disks at 4WD Valve, All Wheels Restrained

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
26. Start engine, release park brake, and run at full
throttle (2800 rpm ± 50).
27. Adjust flow lock tool (2) to allow pump to produce 15
gpm (57 Lpm) in the forward direction.
28. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (7) until a reading of 1750 psi (121
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
29. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.
30. Read and record no load flow.

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Traction Pump Tests

See Figures 5-33 through 5-35.

! WARNING
The hydraulic system is under pressure, and the
oil will be hot.
• Always relieve pressure in the hydraulic
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -12 ORFS Test Hose 4000 psi (276 bar)
• -12 ORFS Blocking Disks
• Flow Lock Tool

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform traction system
5 test leaving flow meter, flow lock tool, and wheel
restraints connected/installed as outlined. (See
“Traction System Test” on page 5-37.)

TN2090
Figure 5-34: Traction Pump Test—Blocking Disks
Between Flow Meter and Front Axle Motor, All
Wheels Restrained
2
1 3 NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
7. Start engine, release park brake, and run at full
5 4 throttle (2800 rpm ± 50).

TN1357
Figure 5-33
3. Install blocking disks at locations (1 and 3).
4. Open flow meter valve (2) completely before starting
6
engine.
5. Set park brake.
6. Bypass the seat switch.

TN1364
Figure 5-35

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8. Adjust flow lock tool (6) to allow pump to produce 15 18. Use the flow meter to warm the hydraulic oil. Turn the
gpm (57 Lpm) in the forward direction. flow meter valve (2) until a reading of 1750 psi (121
9. Use the flow meter to warm the hydraulic oil. Turn the bar) or one half of the relief valve rating is reached.
flow meter valve (2) until a reading of 1750 psi (121 Warm oil to 120—150° F (49—65° C).
bar) or one half of the relief valve rating is reached. 19. Continue to close flow meter valve (2) until zero flow
Warm oil to 120—150° F (49—65° C); open valve is obtained. Record forward system relief valve
fully after operating temperature is reached. pressure.
10. After warming the hydraulic oil, verify flow lock tool is 20. Open flow meter valve (2), stop engine, and set park
adjusted to allow pump to produce 15 gpm (57 Lpm) brake. Return flow lock tool back to neutral position.
in the forward direction.
Is forward system relief pressure 3500 psi (241
11. Read and record no load flow. bar)?
12. Slowly close flow meter valve (2) until pressure YES Forward system relief valve is good. Proceed
reaches 2625 psi (181 bar). Read and record loaded to step 27.
flow.
NO Replace forward system relief valve. (See
13. Open flow meter valve (2), stop engine, and set park “Traction Pump” on page 5-50.)
brake. Return flow lock tool back to neutral position.
14. Calculate traction pump leakage. Reverse System Relief Valve Test
(Step 11 – Step 12 / Step 11 x 100 = Leak 21. To test reverse system relief valve, reverse hoses
Percentage) (4 and 5) at flow meter.
Is traction pump leakage 10% or less? 22. Open flow meter valve (2) completely before starting
YES The traction pump is good. Proceed to engine.
step 15.
NOTE
NO Proceed to next question.
Is traction pump leakage 11% to 20%?
YES The traction pump is marginal. Additional
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
23. Start engine, release park brake, and run at full
5
testing is required. Continue to step 15. throttle (2800 rpm ± 50).
NO Proceed to next question. 24. Adjust flow lock tool (6) to 15 gpm (57 Lpm) in
Is traction pump leakage 21% or more? reverse direction.
YES Repair or replace traction pump. (See 25. Close flow meter valve (2) until zero flow is obtained
“Traction Pump” on page 5-50.) and record reverse system relief valve pressure.
26. Open flow meter valve (2), stop engine, and set park
! CAUTION brake. Return flow lock tool back to neutral position.

Do not exceed 3550 psi (245 bar) when testing Is reverse system relief pressure 3500 psi (241
system relief valves or equipment damage may bar)?
occur. YES Reverse system relief valve is good. Proceed
to step 27.
Forward System Relief Valve Test NO Replace reverse system relief valve. (See
“Traction Pump” on page 5-50.)
15. Open flow meter valve (2) completely before starting
engine. 27. If no further testing is required, disconnect and
remove test equipment. Install all hoses and fittings
NOTE as noted prior to removal.
Verify engine rpm is within specification (2800 rpm ± 50) 28. Install and connect all components as noted prior to
to ensure accurate hydraulic test results. test.
16. Start engine, release park brake, and run at full 29. Check hydraulic oil level. Add oil as needed. (Refer to
throttle (2800 rpm ± 50). “Safety, Operation, and Maintenance Manual” for oil
specifications.)
17. Adjust flow lock tool (6) to allow pump to produce 15
gpm (57 Lpm) in the forward direction.

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Front Axle Motor Test IMPORTANT

See Figures 5-36 through 5-43.
• If performing this test after performing the
IMPORTANT traction system test, and the test results have
proven the pump and front axle motor to be
• This test works together with the 2WD traction good, proceed to step 15.
system test to isolate a problem within the
hydrostatic power train. • If performing this test to determine which
component in system is at fault (front axle motor,

!
secondary 4WD shuttle valve, right rear wheel
WARNING motor, left rear wheel motor, or 4WD reverse
The hydraulic system is under pressure, and the solenoid valve) continue to step 5.
oil will be hot. 5. Set park brake.
• Always relieve pressure in the hydraulic 6. Bypass seat switch.
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -12 ORFS Test Hose 4000 psi (276 bar)
• -12 ORFS and -10 ORFS Blocking Disks

5 • Flow Lock Tool

• Wheel Restraints

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform traction system
test leaving flow meter, flow lock tool, blocking disks,
and wheel restraints connected as outlined. (See
“Traction System Test” on page 5-37.)

1 2

TN2089
Figure 5-37: Front Axle Motor Test—Blocking Disks
4 3 at 4WD Valve, All Wheels Restrained

TN1357
NOTE
Figure 5-36 Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
3. Remove the blocking disks from locations (1 and 2).
7. Start engine, release park brake, and run at full
4. Swap hoses 3 and 4 back to original position after throttle (2800 rpm ± 50).
performing reverse relief test.

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TN1364
Figure 5-38
TN2069
8. Adjust flow lock tool (5) to allow pump to produce 15 Figure 5-39
gpm (57 Lpm) in the forward direction.
14. Remove blocking disks from locations (6 and 7).
9. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1750 psi (121 bar) Secondary 4WD Shuttle Valve Test
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
10. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.
11. Slowly close flow meter valve until pressure reaches
2625 psi (181 bar). Read and record loaded flow.
12. Open flow meter valve, stop engine, and set park
5
brake. Return flow lock tool back to neutral position.
13. Calculate front axle motor leakage.
(Step 12 of traction pump test – Step 11 / Step 12 of
traction pump test x 100 = Leak Percentage) 8 9

Is front axle motor leakage 10% or less?

YES The front axle motor is good. Proceed to TN1970
step 14. Figure 5-40
NO Proceed to next question. 15. Install blocking disks at “L1” and “R1” locations (8
Is front axle motor leakage 11% to 20%? and 9) of 4WD valve.
YES The front axle motor is marginal. Additional 16. Open flow meter valve completely before starting
testing is required. Continue to step 14. engine.
NO Proceed to next question. 17. Set park brake.

Is front axle motor leakage 21% or more?

YES Repair or replace front axle motor. (See
“Front Axle Motor” on page 5-58.)

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25. Calculate secondary 4WD shuttle valve leakage.

(Step 11 – Step 23 / Step 11 x 100 = Leak
Percentage)
Is secondary 4WD shuttle valve leakage 10% or
less?
YES The secondary 4WD shuttle valve is good.
Proceed to step 26.
NO Proceed to next question.
Is secondary 4WD shuttle valve leakage 11% to
20%?
YES The secondary 4WD shuttle valve is
marginal. Repair or replace secondary 4WD
shuttle valve as needed. (See “4WD Valve”
on page 5-53.) Continue to step 26.
NO Proceed to next question.
Is secondary 4WD shuttle valve leakage 21% or
more?
YES Repair or replace secondary 4WD shuttle
valve. (See “4WD Valve” on page 5-53.)
Continue to step 26.
26. Remove blocking disk from “L1” location (2) of 4WD
Valve.

5
TN2091
Figure 5-41: Secondary 4WD Shuttle Valve Test—
Blocking Disks at Rear Wheel Motor Inlets

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
18. Start engine, release park brake, and run at full
throttle (2800 rpm ± 50).
19. Adjust flow lock tool (1) to allow pump to produce 15
gpm (57 Lpm) in the forward direction.
20. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1750 psi (121 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
21. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.
22. Engage 4WD switch in the forward position.
23. Slowly close flow meter valve until pressure reaches
2625 psi (181 bar). Read and record loaded flow.
24. Open flow meter valve, stop engine, and set park
brake. Return flow lock tool back to neutral position.

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Left Rear Wheel Motor Test 32. Engage 4WD switch in the forward position.
27. Open flow meter valve completely before starting 33. Slowly close flow meter valve until pressure reaches
engine. 2625 psi (181 bar). Read and record loaded flow.
34. Open flow meter valve, stop engine, and set park
brake. Return flow lock tool back to neutral position.
35. Calculate left rear wheel motor leakage.
(Step 23 – Step 33 / Step 23 x 100 = Leak
Percentage)
Is left rear wheel motor leakage 10% or less?
YES The left rear wheel motor is good. Proceed to
step 36.
NO Proceed to next question.
Is left rear wheel motor leakage 11% to 20%?
YES The left rear wheel motor is marginal. Repair
or replace left rear wheel motor as
necessary. Continue to step 36.
NO Proceed to next question.
Is left rear wheel motor leakage 21% or more?
YES Repair or replace left rear wheel motor. (See
“Rear Wheel Motor” on page 5-77.)
36. Remove blocking disk from “R1” location (3).

TN2093
Figure 5-42: Left Rear Wheel Motor Test—Blocking
Disk at Right Rear Wheel Motor, All Wheels
Restrained

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
28. Start engine, release park brake, and run at full
throttle (2800 rpm ± 50).
29. Adjust flow lock tool (1) to allow pump to produce 15
gpm (57 Lpm) in the forward direction.
30. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1750 psi (121 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
31. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.

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 HYDROSTATIC POWER TRAIN

Right Rear Wheel Motor Test 42. Engage 4WD switch in the forward position.
37. Open flow meter valve completely before starting 43. Slowly close flow meter valve until pressure reaches
engine. 2625 psi (181 bar). Read and record loaded flow.
44. Open flow meter valve, stop engine, and set park
brake. Return flow lock tool back to neutral position.
45. Calculate right rear wheel motor leakage.
(Step 33 – Step 43 / Step 33 x 100 = Leak
Percentage)
Is right rear wheel motor leakage 10% or less?
YES The right rear wheel motor is good. Proceed
to step 46.
NO Proceed to next question.
Is right rear wheel motor leakage 11% to 20%?
YES The right rear wheel motor is marginal.
Repair or replace right rear wheel motor as
necessary. Continue to step 46.
NO Proceed to next question.
Is right rear wheel motor leakage 21% or more?
YES Repair or replace right rear wheel motor.
(See “Rear Wheel Motor” on page 5-77.)
Continue to step 46.
46. Disconnect and remove test equipment. Install all

5 hoses and fittings as noted prior to removal.

47. Install and connect all components as noted prior to
test.
48. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for oil
specifications.)

TN2092
Figure 5-43: Right Rear Wheel Motor Test—Blocking
Disk at Left Rear Wheel Motor, Rear Wheels
Restrained

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
38. Start engine, release park brake, and run at full
throttle (2800 rpm ± 50).
39. Adjust flow lock tool (1) to allow pump to produce 15
gpm (57 Lpm) in the forward direction.
40. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1750 psi (121 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
41. After warming the hydraulic oil, verify flow lock tool is
adjusted to allow pump to produce 15 gpm (57 Lpm)
in the forward direction.

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 HYDROSTATIC POWER TRAIN

Repair
Front Axle U-Joint
Removal and Installation
See Figure 5-44.

2 5
3

TN1984
Figure 5-44
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove park brake. (See “Park Brake” on
page 9-11.)
3. Remove front axle motor (2). (See “Front Axle Motor”
on page 5-58.)
4. Disconnect front axle U-joint (1) from front axle (3).
5. Remove front axle U-joint (1).

Installation Notes
• Install the drive shaft by reversing the order of
removal.
• Adjust park brake. (See “Park Brake Adjustment” on
page 9-4.)

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 HYDROSTATIC POWER TRAIN

Traction Pump U-Joint

Removal and Installation
See Figure 5-45.

2
1

2
3

12
11 1
10 2
9 1
4
2

5 8
7

6
5

6
5

6
TN2032

Figure 5-45

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 HYDROSTATIC POWER TRAIN

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove the 4WD valve. (See “4WD Valve” on
page 5-53.)

NOTE
It may be necessary to rotate the flywheel to access all of
the pump drive flange screws.
3. Remove six screws (10) and lock washers (11) from
pump drive flange (12) and flywheel (3).

! WARNING
Prevent personal injury. Use a properly rated
lifting device. Always be sure the load is
balanced before lifting.

4. Attach a suitable lifting device to the engine.

\

NOTE
It may be necessary to unbolt the muffler down pipe from
the exhaust manifold flange to allow engine movement.
5. Remove the four engine mount screws (1), washers
(2), nuts (6), and lock washers (5), and carefully
move the engine to the rear of the mower as far as
possible. 5
6. Slide the U-joint off the traction pump input shaft, and
remove the U-joint/pump drive flange assembly from
the mower.
7. Remove four nuts (7), lock washers (8), and screws
(4), and remove the U-joint (9) from the pump drive
flange (12).
Installation Notes
• Install traction pump U-joint by reversing the order of
removal.
• Replace hydraulic oil filter.
• Refill hydraulic oil tank. (Refer to “Safety, Operation,
and Maintenance Manual” for oil specifications.)
• Start engine. Check hydraulic system for leaks.
Repair as necessary.
• Check hydraulic oil level and add if necessary.

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 HYDROSTATIC POWER TRAIN

Traction Pump
16 17
Removal and Installation 18
15
See Figures 5-46 and 5-47.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove seat and seat platform. (See “Seat and Seat
Platform” on page 9-13.)
3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank—
Drain Procedure” on page 6-58.)
23 19
4. Remove gear pump. (See “Gear Pump” on 20 21
page 6-58.)

22
3

1
4
TN2035
2
Figure 5-47
14 5
11. Remove two screws (16) and lockwashers (17).
Remove top block (15) and traction arm (23) from the
pump control shaft.
5 12
6
! WARNING
13 Prevent personal injury. Use a properly rated
7 lifting device. Always be sure the load is
balanced before lifting.
8

12. Attach a suitable lifting device to the traction pump

11 10 (18).
9 TN2039 13. Remove two nuts (19), lock washers (20), and bolts
(21).
Figure 5-46
14. Move the traction pump (18) toward the front of the
5. Thoroughly clean the pump, especially the area machine until the input shaft clears the front U-joint.
surrounding the hydraulic hoses and fittings. Remove the traction pump from the frame (22).

NOTES Installation Notes

• Label all hydraulic hoses before disconnecting to • Install the hydrostatic pump by reversing the order of
ensure correct installation. removal.
• Close all openings with caps or plugs to prevent • Lubricate all O-rings prior to assembly.
contamination.
• Make sure new O-rings are in place before installing
6. Disconnect hoses (1 and 14) from tee fitting (2). hoses on fittings.
7. Disconnect hoses (3 and 5) from tee fitting (4). • Pressure filter the hydraulic system. (See “Portable
8. Disconnect hoses (7 and 8) from tee fitting (6). In-Line Filter” on page 5-4.)
9. Disconnect hose (9) from tee fitting (10). • Fill the hydraulic oil tank. (Refer to “Safety, Operation,
10. Disconnect hoses (11 and 12) from tee fitting (13). and Maintenance Manual” for the correct oil
specifications.)
• Start engine. Check for leaks and repair as
necessary.

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 HYDROSTATIC POWER TRAIN

Disassembly, Inspection, and Assembly

See Figure 5-48.

12
13
15 16 17
14
18

1 2 11
3 19
4
5
6 10
7
9
8 14
13
20 12
21

22 5
7
5
23
24
1
25 26

27
28
29
28
27
30
32 31
TN1895
1 Screw (4) 9 Rotating Assembly 17 O-Ring 25 Housing
2 Trunnion Cover 10 Valve Plate 18 Coupler 26 Drive Shaft
3 Inner Race 11 Gasket 19 Screw, Bottom (2) 27 Retaining Ring (2)
4 O-Ring 12 Plug (2) 20 Backplate 28 Thrust Race (2)
5 Washer (2) 13 Spring (2) 21 Dowel Pin (2) 29 Thrust Bearing
6 O-Ring Cover 14 Relief Valve (2) 22 Key, Trunnion 30 Washer
7 Needle Bearing (2) 15 Tow Valve 23 Shaft Seal, Viton 31 Shaft Seal, Viton
8 Cam Plate 16 Screw, Top (2) 24 Cover 32 Retaining Ring
Figure 5-48

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 HYDROSTATIC POWER TRAIN

NOTICE
• It is important that motor parts are marked
and placed in assembly order to aid in
assembly.
• It is important that all pump parts are
absolutely clean, as contamination can result
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
after cleaning, as lint may clog passages. Dry
parts using compressed air.

IMPORTANT
Do not disassemble the rotating assembly (9). If parts
are worn or damaged, replace the entire rotating
assembly.
1. Disassemble traction pump as shown in Figure 5-48
on page 5-51.
2. Place parts in assembly order on a clean work area
as they are removed.

Inspection Notes

5 • Keeping parts in assembly order, clean and air dry

each item for inspection.
• Inspect for worn or defective parts.
• Look for metal chips or slivers during cleaning (an
indication of damage to pump or other hydraulic
component).
• Inspect all parts for cracks, nicks, burrs, and
excessive wear. Inspect for scoring, galling, and
scratches on surfaces. Replace parts as necessary.

Assembly Notes

Required Materials

Overhaul Seal and Gasket Kit (Jacobsen PN 557446)

• Assemble the pump by reversing the order of

disassembly.
• Lubricate all O-rings prior to assembly.
• Install new O-rings and seals. Use clean grease to
keep seals in position.

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4WD Valve Installation Notes

• Install the 4WD valve by reversing the order of
Removal and Installation removal.
See Figure 5-49. • Lubricate all O-rings prior to assembly.
1. Park the mower safely. (See “Park Mower Safely” on • Make sure new O-rings are in place before installing
page 1-6.) hoses on fittings.
2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— • Replace hydraulic oil filter and charge pressure filter.
Drain Procedure” on page 6-58.) • Refill hydraulic oil tank. (Refer to “Safety, Operation,
and Maintenance Manual” for oil specifications.)
NOTE • Start engine. Check hydraulic system for leaks.
The 4WD valve is located on the bottom center of Repair as necessary.
machine. • Check hydraulic oil level and add if necessary.
3. Thoroughly clean the valve, especially the area
surrounding the hydraulic hoses, tubes, and fittings. Disassembly, Inspection, and Assembly
See Figures 5-50 and 5-51.
1 2 NOTE
Repair of the control valve is limited to replacing valves
3 and cartridges or replacing O-rings.
4

5 5
6
6 7 8 9
3
4
7 5
2
1
10
14 13 11
12 TN1929
Figure 5-49 8
4. Disconnect bracket (10).

NOTE
Label connector before disconnecting to ensure correct 9
installation. 10
11
5. Disconnect electrical connector (2).
TN1974

NOTES Figure 5-50

• Label all hydraulic hoses and tubes before
disconnecting to aid in installation. NOTE
• Close all openings with caps or plugs to prevent Record the location and orientation of the all fittings
contamination. before removing to ensure correct installation.
6. Disconnect hydraulic hoses (1, 3, 4, 5, 11, 12, and 1. Remove straight adapter (1) from port “B.”
14). 2. Remove 90° adapter (2) from port “R1.”
7. Support the 4WD valve (13). 3. Remove straight adapter (3) from port “R2.”
8. Remove mounting screws (6), washers (7), lock 4. Remove 90° adapter (4) from port “4WD.”
washers (8), and nuts (9). 5. Remove dust cover (7), diagnostic port adapter (6),
9. Remove the 4WD valve (13). and 90° adapter (5) from port “AD.”

4203780 First Edition 5-53

 HYDROSTATIC POWER TRAIN

6. Remove straight adapter (8) from port “L2.” 14. Remove O-rings (19 and 20) and backup ring (18)
7. Remove straight adapter (9) from port “L1.” from check valve (21).
8. Remove 90° adapter (10) from port “C.” 15. Remove secondary 4WD shuttle valve (23) from
valve block (26).
9. Remove 45° adapter (11) from port “A.”
16. Remove O-rings (22 and 24) and backup rings (25)
from secondary 4WD shuttle valve (23).
12
NOTICE
13
• It is important that all component parts are
absolutely clean, as contamination can result
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
14 after cleaning, as lint may clog passages. Dry
parts using compressed air.

15
17. Clean all parts using clean solvent, and dry using
compressed air.
18. Inspect all parts for wear or damage. Replace parts
as needed.
17 16
Assembly Notes
18
19 NOTICE
20
5 21 • It is important that all component parts are
absolutely clean, as contamination can result
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
22 after cleaning, as lint may clog passages. Dry
parts using compressed air.
26
Required Materials
25
• Seal Kit, Check Valve (Jacobsen PN 5003581)
24 • Seal Kit, Spool Valve (Jacobsen PN 5003581)
• Seal Kit, Solenoid Valve (Jacobsen PN 5003578)
23 TN1978
Figure 5-51 • Assemble the 4WD valve by reversing the order of
disassembly.
NOTE • Lubricate all O-rings prior to assembly.
Record the location of the all cartridges before removing
to ensure correct installation.
10. Remove nut (12) and solenoid coil (13) from 4WD
reverse valve (14).
11. Remove 4WD reverse valve (14) from valve block
(26).
12. Remove O-rings (15 and 17) and backup rings (16)
from valve (14).
13. Remove check valve (21) from valve block (26).

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Control Valve Installation Notes

• Install the control valve by reversing the order of
Removal and Installation removal.
See Figure 5-52. • Lubricate all O-rings prior to assembly.
1. Park the mower safely. (See “Park Mower Safely” on • Make sure new O-rings are in place before installing
page 1-6.) hoses on fittings.
2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— • Replace hydraulic oil filter and charge pressure filter.
Drain Procedure” on page 6-58.) • Refill hydraulic tank. (Refer to “Safety, Operation, and
Maintenance Manual” for oil specifications.)
1 2 3 • Start engine. Check hydraulic system for leaks.
4 5 6 7 Repair as necessary.
8 • Check hydraulic oil level and add if necessary.

9 Disassembly, Inspection, and Assembly

See Figures 5-53 and 5-54.
16 10
NOTE
4 5 6 7 11
Repair of the control valve is limited to replacing
cartridges or replacing O-rings on each cartridge.
15
14 12 1 2
13 TN1921
3
Figure 5-52 4
5
5
NOTE
The control valve is located on the right side of machine. 7
3. Remove cover (1). 8
4. Thoroughly clean the valve, especially the area 18 6
surrounding the hydraulic hoses, tubes, and fittings.
17
NOTE
9
Label connectors before disconnecting to ensure correct
installation.
5. Disconnect electrical connectors (9, 12, and 13). 16
10
15
NOTES
• Label all hydraulic hoses and tubes before
disconnecting to aid in installation.
14 13 12 11
• Close all openings with caps or plugs to prevent TN1973
contamination. Figure 5-53
6. Disconnect hydraulic hoses (2, 11, 14, and 15).
7. Disconnect hydraulic tubes (3, 10, and 16). NOTE
8. Support the control valve (8). Record the location and orientation of all fittings before
9. Remove mounting screws (4), washers (5), lock removing to ensure correct installation.
washers (6), and nuts (7). 1. Remove dust cover (1), diagnostic port adapter (2),
10. Remove the control valve (8). and 90° adapter (3) from port “LD.”
2. Remove straight adapter (4) from port “ST.”
3. Remove straight adapter (5) from port “P.”
4. Remove 90° adapter (6) from port “L.”

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 HYDROSTATIC POWER TRAIN

26
25 27
28
29
24
23 30
22

21 31
20 32
19
37 33
36 34

35
38
39

40

PT1975 41
42
5 Figure 5-54
TN1975

5. Remove dust cover (7), diagnostic port adapter (8), 18. Remove O-rings (31 and 32) and backup rings (36)
and 90° adapter (9) from port “CD.” from 4WD valve (33).
6. Remove 45° adapter (10) from port “F.” 19. Remove nut (42) and solenoid coil (41) from
7. Remove 90° adapter (11) from port “T.” differential lock valve (40).
8. Remove 90° adapter (13) from port “4WD.” 20. Remove differential lock valve (40) from the control
valve (25).
9. Remove 90° adapter (14) from port “DL.”
21. Remove O-rings (37 and 39) and backup rings (38)
10. Remove dust cover (17), diagnostic port adapter
from differential lock valve (40).
(16), and 90° adapter (15) from port “SD.”
11. Remove charge pressure switch (18) from control
valve (12).
NOTICE
• It is important that all component parts are
NOTE absolutely clean, as contamination can result
Record the location of the all cartridges before removing in serious damage and/or improper operation.
to ensure correct installation. • Never use shop towels or rags to dry parts
12. Remove plug (19) and charge pressure relief valve after cleaning, as lint may clog passages. Dry
(21) from the control valve block (25). parts using compressed air.
13. Remove O-rings (20, 22, and 24) and backup ring
(23) from charge pressure relief valve (21). 22. Clean all parts using clean solvent, and dry using
14. Remove priority valve (30) from the control valve compressed air.
block (25). 23. Inspect all parts for wear or damage. Replace parts
15. Remove O-rings (26, 28, and 29) and backup rings as needed.
(27) from priority valve (30).
16. Remove nut (35) and solenoid coil (34) from 4WD
valve (33).
17. Remove 4WD valve (33) from the control valve (25).

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Assembly Notes

NOTICE
• It is important that all component parts are
absolutely clean, as contamination can result
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
after cleaning, as lint may clog passages. Dry
parts using compressed air.

Required Materials

• Seal Kit, Relief Valve (Jacobsen PN 555861)

• Seal Kit, Priority Valve (Jacobsen PN 556856)
• Seal Kit, Solenoid Valve—Differential Lock
(Jacobsen PN 556858)
• Seal Kit, Solenoid Valve—4WD
(Jacobsen PN 556858)

• Assemble the control valve by reversing the order of

disassembly.
• Lubricate all O-rings prior to assembly.

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 HYDROSTATIC POWER TRAIN

Front Axle Motor

Removal and Installation
See Figure 5-55.

2
3
4
5
6
1

8
17 9
16
15

5 10

14 13 12 11 TN1983

Figure 5-55
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) NOTE
Record the location and orientation of all fittings before
NOTES removing to ensure correct installation.
• Label all hydraulic hoses before disconnecting to 9. Remove two 90° adapters (5 and 6) from front axle
ensure correct installation. motor (9).
• Plug hydraulic hoses after disconnecting to prevent 10. Remove straight adapter (2) from front axle motor
the loss of hydraulic oil. (9).
2. Disconnect case drain hose (3) from straight adapter
(2). Installation Notes
3. Disconnect hose (4) from 90° adapter (5). • Install the front axle motor by reversing the order of
removal.
4. Disconnect hose (7) from 90° adapter (6).
• Pressure filter traction system upon start-up if metal
5. Loosen nut (15) on front axle U-joint bolt (13).
debris is found in system oil or motor. (See “Portable
6. Support the front axle motor (9) using a suitable In-Line Filter” on page 5-4.)
lifting device.
• Check hydraulic oil level. Add oil as needed. (Refer to
7. Remove two nuts (12 and 16), lock washers “Safety, Operation, and Maintenance Manual” for the
(11 and 17), and screws (1 and 8). correct oil specifications.)
8. Remove front axle motor (9) from frame (10) and
front axle U-joint (14).

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 HYDROSTATIC POWER TRAIN

Disassembly, Inspection, and Assembly

See Figure 5-56.

13
12

11

10
9

7
6

4
5
4

1
2
3
5
14 TN1902
TN1902

1 Retaining Ring 5 Thrust Bearing 9 Cam Plate Insert 13 Screw (6)

2 Shaft Seal 6 Key 10 Rotating Assembly 14 Thrust Race (2)
3 Washer 7 Drive Shaft 11 O-Ring
4 Retaining Ring (2) 8 Housing 12 Backplate Assembly
Figure 5-56

NOTICE NOTES
• The drive shaft (7) is press-fit into a bearing in the
• It is important that motor parts are marked
housing (8). Do not remove the shaft unless the
and placed in assembly order to aid in
bearing or drive shaft is worn or damaged.
assembly.
• If the drive shaft (7) must be removed, press the drive
• It is important that all motor parts are
shaft out from the inside of the housing (8).
absolutely clean, as contamination can result
in serious damage and/or improper operation. • If bearing replacement is required, the entire housing
(8) must be replaced.
• Never use shop towels or rags to dry parts
after cleaning, as lint may clog passages. Dry 1. Disassemble front wheel motor as shown.
parts using compressed air. 2. Place parts in assembly order on a clean work area
as they are removed.

IMPORTANT
Do not disassemble the rotating assembly (10). If
parts are worn or damaged, replace the entire
rotating assembly.

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 HYDROSTATIC POWER TRAIN

Inspection Notes Front (Drive) Axle Assembly

• Keeping parts in assembly order, clean and air dry
each item for inspection. Removal and Installation
• Inspect for worn or defective parts. See Figures 5-57 through 5-67.
1. Park the mower safely. (See “Park Mower Safely” on
NOTE page 1-6.)
Do not lap the piston shoes, piston block, or backplate 2. Remove the front mower deck. (See “Front Deck” on
surfaces. page 8-19.)
• Inspect pistons and shoes. The pistons should be 3. Remove floorboard. (See “Floorboard” on
snug, and the shoes should be flat and display no page 9-16.)
signs of flaking.
• Inspect piston block. Make sure the flat surface is
free of score marks.
• Inspect the flat surface of the backplate. It should be
free of score marks and metal build-up.
• Look for metal chips or slivers during cleaning (an
indication of damage to pump or other hydraulic
component).
• Inspect all parts for cracks, nicks, burrs, and
excessive wear. Inspect for scoring, galling, and
scratches on surfaces. Replace parts as necessary.

Assembly Notes

5 NOTICE
• It is important that all motor parts are
absolutely clean, as contamination can result
1
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
after cleaning, as lint may clog passages. Dry
parts using compressed air. 2 TN2045

Figure 5-57
Required Materials
NOTE
Seal Kit (Jacobsen PN 557432)
Label all connectors before disconnecting to ensure
correct installation.
• Assemble the front wheel motor by reversing the
4. Disconnect wire harness connector (2) from the front
order of disassembly.
mower deck valve solenoid (1).
• Lubricate all O-rings prior to assembly.
• Press shaft seal (2) into the housing until the seal is
approximately 7/32 inch (5.5 mm) below the surface
of the housing.
• Install cam plate insert (9), making sure the lettering
is facing toward the housing (8).
• Tighten backplate assembly screws (13) 15—18 lb-ft
(20—24 N·m).
• Pressure filter traction system upon start-up if metal
debris is found in system oil or motor. (See “Portable
In-Line Filter” on page 5-4.)

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14
3 4 5

15 16 17 18

4 5

TN2044
19
Figure 5-58
TN2050
5. Remove two screws (4) and lock washers (5), and Figure 5-60
remove front limit switch (6) and spacer (3).
10. Remove two nuts (15), lock washers (16), and
screws (17), and four flat washers (18) from console
7 support (14) and right side front lift arm support (19).
8

9
5
13 20

10
12

11
TN2043 21
Figure 5-59
TN2046
6. Disconnect the reverse sensing switch wire harness
Figure 5-61
connector (8) from the wire harness connector (9).
7. Disconnect the brake pedal switch wire harness 11. Disconnect the brake line (20) at tee fitting (21).
connector (13) from the wire harness connector (12).
8. Cut cable ties (10) as needed.
9. Move the lift arm limit switch and harness (7) and
wire harnesses (11) aside.

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 HYDROSTATIC POWER TRAIN

22

36
37

38 39 40

23
29

27 28 24 25
41
26 TN2051
TN2047
Figure 5-62 Figure 5-64

NOTES
• Label all hydraulic hoses before disconnecting to
ensure correct installation.
• Plug hydraulic hoses after disconnecting to prevent
the loss of hydraulic oil.
5 12. Disconnect hydraulic line (22) from gear pump.
13. Remove nut (24), lock washer (25), screw (27), and
42
flat washer (28) from traction linkage (23) and
traction bell crank (26).
14. Disconnect hydraulic hose (29).

30
31 32 33 43
44
TN2052
35
31 32 33 Figure 5-65

NOTE
Perform steps 18 through 21 for both lift cylinders.
18. Support both front lift arms.
19. Remove screw (38), lock washer (39), and retaining
pin (40).
34 20. Remove pin (37) from the front lift cylinder (36) and
front lift arm support (41).
TN2048
21. Remove cotter pin (42) and lift cylinder pin (44), and
Figure 5-63 lower the lift cylinder (43) to the floor.
15. Disconnect hydraulic line (35).
16. Disconnect hydraulic hose (34) at tee fitting.
17. Remove four screws (31), lock washers (32), and flat
washers (33), and remove the platform support (30).

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48 67
66
49
50
47
51 52
46 53
45 54

65
56 67
63 57 55
64 58 66
59
68
60
TN2056
61
Figure 5-67
30. Remove four screws (67) and lock washers (66), and
remove front axle assembly (68) from the frame.

Installation Notes
62
• Install the front axle by reversing the order of
TN2054 removal.
Figure 5-66 • Bleed the brake system. (See “Bleed Brake System”

! WARNING
on page 9-5.)
• Pressure filter traction system upon start-up if metal
5
debris is found in system oil. (See “Portable In-Line
• Support the machine using properly rated Filter” on page 5-4.)
jackstands. Never work under a machine
supported only by a jack. • Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for the
• Do not use wood or concrete blocks to correct oil specifications.)
support the machine. Failure to properly
support the machine may result in death or
serious injury.

22. Raise the mower so wheels are off the ground. Place
jackstands under the frame to support the mower.
23. Support the axle assembly using a suitable lifting
device.
24. Remove two nuts (51), lock washers (50), and
screws (63), and four flat washers (49 and 64).
25. Remove two screws (45), lock washers (46) and flat
washers (65), and remove scraper (47).
26. Remove right lift arm support (48) from frame.
27. Remove two nuts (55), lock washers (54), and
screws (60), and four flat washers (53 and 61).
28. Remove two screws (58), lock washers (57) and flat
washers (56), and remove scraper (59).
29. Remove left lift arm support (52) from frame.

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 HYDROSTATIC POWER TRAIN

Differential Lock Assembly Assembly Notes

Disassembly, Inspection, and Assembly NOTICE

See Figure 5-68. • It is important that all parts are absolutely
clean, as contamination can result in serious
damage and/or improper operation.
1
2 • Never use shop towels or rags to dry parts
5
3 after cleaning, as lint may clog passages. Dry
4 parts using compressed air.

Required Materials

Loctite® 242 (Blue)

• Assemble the differential lock assembly by reversing

the order of disassembly.
6
• Lubricate all O-rings prior to assembly.
7 • Apply Loctite 242 (Blue) to fork screw (7) before
8 assembly, and tighten to 19 lb-ft (26 N·m).
• Apply Loctite 242 (Blue) to housing screws (5) before
assembly, and tighten to 37 lb-ft (51 N·m).

TN1907

1 Cylinder 5 Screw (4)

2 O-Ring 6 Housing
3 Piston 7 Screw
4 Spring 8 Fork
Figure 5-68

NOTE
If it is necessary to replace the differential lock collar, see
“Differential Assembly” on page 5-73.
1. Disassemble differential lock assembly as shown.
2. Place parts in assembly order on a clean work area
as they are removed.

Inspection Notes
• Keeping parts in assembly order, clean and air dry
each item for inspection.
• Inspect for worn or defective parts.
• Inspect all parts for cracks, nicks, burrs, and
excessive wear. Inspect for scoring, galling, and
scratches on surfaces. Replace parts as necessary.

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Input Bevel Pinion Assembly

Disassembly and Inspection
See Figure 5-69.

4 5
3
2
1

6
7

8
9
10
11

12

13
5

14

15

TN1911

1 Screw (4) 5 Nut, Elastic Stop 9 Collapsible Spacer 13 O-Ring

2 Bearing Cup, Outer 6 Seal, Outer 10 Bearing Cup, Inner 14 Shim (As Required)
3 Bearing Cone, Outer 7 O-Ring 11 Bearing Cone, Inner 15 Axle Assembly
4 Spacer 8 Pinion Housing 12 Pinion Shaft
Figure 5-69

4203780 First Edition 5-65

 HYDROSTATIC POWER TRAIN

NOTES
• Do not remove the input bevel pinion assembly from
the axle assembly before removing the elastic stop
nut (5).
• Once the elastic stop nut (5) has been loosened, a
new collapsible spacer (9) must be installed.
1. Remove elastic stop nut (5).

NOTE
If the original pinion shaft is to be used, remove the shims
(14), and mark them for assembly. If the shims are
damaged, record the thickness of the shims removed and
use an equal thickness of shims for assembly.
2. Remove four screws (1) and remove the input bevel
pinion assembly (2—12), O-ring (13), and shims (14)
from the axle assembly (15).
3. Support the pinion housing (8) and inner bearing
cone (11). Press the pinion shaft (12) from the
bearing cones (3 and 11).
4. Remove bearing cones (3 and 11) and cups
(2 and 10) and collapsible spacer (9) from pinion
housing (8).
5. Remove seal (6), spacer (4), and O-ring (7) from
5 pinion housing (8).

Inspection Notes
• Keeping parts in assembly order, clean and air dry
each item for inspection.
• Inspect for worn or defective parts.
• Inspect all parts for cracks, nicks, burrs, and
excessive wear. Inspect for scoring, galling, and
scratches on surfaces. Replace parts as necessary.

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Assembly
See Figures 5-70 and 5-71.

4 5
3
2
1

6
7

8
9
10
11

12

13

14

15

TN1911

1 Screw (4) 5 Nut, Elastic Stop 9 Collapsible Spacer 13 O-Ring

2 Bearing Cup, Outer 6 Seal, Outer 10 Bearing Cup, Inner 14 Shim (As Required)
3 Bearing Cone, Outer 7 O-Ring 11 Bearing Cone, Inner 15 Axle Assembly
4 Spacer 8 Pinion Housing 12 Pinion Shaft
Figure 5-70

4203780 First Edition 5-67

 HYDROSTATIC POWER TRAIN

Required Materials NOTE

Loctite® 242 (Blue) Lubricate all O-rings prior to assembly.
10. Install O-ring (13) on pinion housing (8).

NOTE IMPORTANT
Always replace the bearing cones and cups as a set. • If the original pinion shaft was reused, proceed to
1. Support the inner race of the inner bearing cone (11). step 11.
Press the pinion shaft (12) into the bearing cone with • If a new matched input bevel pinion and ring gear
the bearing taper facing away from the pinion gear. was installed, proceed to “Input Bevel Pinion and
2. Press the bearing cups (2 and 10) in the pinion Ring Gear Clearance Adjustment” on page 5-75.
housing (8) with the taper facing outward. 11. Install the input bevel pinion assembly (2—12) and
3. Install the bearing gear and pinion shaft (12) and shims (14) on the axle assembly (15). Use the same
inner bearing cone (11) assembly in the pinion thickness of shims as recorded during disassembly.
housing (8). 12. Apply Loctite 242 (Blue) to screws (1) before
4. Install the collapsible spacer (9) on pinion shaft (12). assembly. Install screws and tighten to 37 lb-ft
Position the sleeve against the bearing inner race. (51 N·m).

IMPORTANT
Do not collapse the collapsible spacer when
installing the outer bearing cone. If collapsed at this
time, a new spacer must be installed.
5. Install the outer bearing cone (3) over the bearing

5 gear and pinion shaft (12). Applying pressure to the

bearing inner race only, press the bearing into the
housing until it just contacts the collapsible spacer
(9).

NOTE
Lubricate all O-rings prior to assembly.
6. Install O-ring (7) in spacer (4). Install spacer in the
housing, positioning the O-ring against the outer
bearing cone (3).
7. Install, but do not tighten, the elastic stop nut (5).

16

TN1912
Figure 5-71
8. While applying slow and steadily increasing pressure
on the torque wrench, tighten the elastic stop nut (16)
until a break-away torque of 4.5—6.3 lb-in.
(0.5—0.7 N·m) is obtained.
9. Install the seal (6) in the pinion housing (8).

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Drive Axle Reducer Assembly 5. Remove two dowel sleeves (3) from the differential
housing (10).
Removal
NOTE
See Figure 5-72.
The bearings are press-fit in the differential housing.
Remove the bearings only if replacement is required.
6. Remove the drive axle (1) and wheel axle (9)
bearings from the differential housing (10).

1
2
3

11
10 4
9

3
5

6
8 7
TN1920
5
1 Bearing, Drive Axle 7 Nut (2)
2 Reducer Shaft 8 Brake Caliper Assembly
3 Dowel Sleeve (2) 9 Bearing, Wheel Axle
4 Screw (2) 10 Differential Housing
5 Drive Axle Reducer Assembly, Left 11 Screw (2)
6 Screw (2)
Figure 5-72

NOTES
• Left side shown.
• Step 1 applies to the right side only.
1. Remove the differential lock assembly. (See
“Differential Lock Assembly” on page 5-64.)
2. Place a suitable container under the reduction
assembly to catch oil.
3. Remove two nuts (7) and screws (11), and remove
the brake caliper assembly (8).

NOTES
• Remove the reducer shaft (2) only as needed.
• When removing the right reducer shaft, the
differential lock collar will slide off the reducer shaft.
4. Remove four screws (4 and 6), and remove the
reducer assembly (5) from the differential
housing (10).

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 HYDROSTATIC POWER TRAIN

Disassembly and Inspection

See Figure 5-73.

1
2

14
13
12 4

11 5
6 7

8
9

10

TN1786
1 Ball Bearing (2 per side) 5 Retaining Ring 9 Wheel Bolt (5 per side) 13 Washer
2 Reducer Shaft 6 Seal 10 Flat Head Screw (5 per side) 14 Gear, Reducer
3 Housing, Reducer 7 Brake Disk 11 Spacer, Tube
4 Ball Bearing 8 Drive Axle 12 Retaining Ring
Figure 5-73
Inspection Notes
NOTES • Keeping parts in assembly order, clean and air dry
• Left side shown. each item for inspection.
• Remove wheel bolts (9) only if replacement is • Inspect for worn or defective parts.
required.
• Inspect all parts for cracks, nicks, burrs, and
1. Disassemble drive axle reducer as shown. excessive wear. Inspect for scoring, galling, and
2. Place parts in assembly order on a clean work area scratches on surfaces. Replace parts as necessary.
as they are removed.

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 HYDROSTATIC POWER TRAIN

Installation
5
See Figures 5-74 through 5-79.
6
Required Materials

Loctite® Ultra-Blue Gasket Material

7
8
9
1

TN1923
Figure 5-75

4 7. Press ball bearings (5 and 7) into the reducer

3
housing (6).
TN1924
8. Install retaining ring (8) and seal (9) into the reducer
Figure 5-74 housing (6).

NOTE
If the axle shafts were not removed, proceed to step 7.
10 5
1. Press the wheel axle bearing (3) into the differential
housing (4).
2. Support the inner race of the drive axle bearing (1),
and press the reducer shaft (2) into the bearing.
11
IMPORTANT
Steps 3 through 5 apply to the right side only. If
installing the left side axle, proceed to step 6.
3. Remove the differential lock assembly. (See
“Differential Lock Assembly” on page 5-64.) 12
4. Press the reducer shaft (2)/bearing (1) assembly into
the differential housing (4), sliding the reducer shaft
through the differential lock collar. TN1925

5. Install the differential lock assembly. (See Figure 5-76

“Differential Lock Assembly” on page 5-64.) 9. Install drive axle (11) to brake disk (10) using five flat
6. Press the reducer shaft (2)/bearing (1) assembly into head screws (12). Tighten screws to 29 lb-ft
the differential housing (4). (40 N·m).

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 HYDROSTATIC POWER TRAIN

13

20
14
22
23
21
29
24
28

22
TN1926

Figure 5-77
10. Press the drive axle/brake disk assembly (14) into
the reducer housing (13). 25

27 26
15 TN1928
Figure 5-79
16
5 17
18
12. Clean the mating surfaces (20 and 21) of the
differential housing (28) and reducer housing (23).
Make sure the surfaces are dry. Apply Loctite Ultra
Blue gasket material in a continuous bead around the
mating surface, making sure to go around each hole.
13. Install the dowel sleeves (22) in the holes as shown.
14. Install the reducer housing (23) on the differential
19 housing (28) using four screws (24 and 25). Tighten
screws to 37 lb-ft (51 N·m).
15. Install the brake caliper assembly (27) using two
screws (29) and nuts (26). Tighten nuts to 37 lb-ft
(51 N·m).
TN1927

Figure 5-78
11. Install spacer (18), retaining ring (17), washer (16),
and gear (15) on drive axle (19).

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 HYDROSTATIC POWER TRAIN

Differential Assembly
Disassembly and Inspection
See Figure 5-80.

3 4

5
10 6
2 7
8
9

4
5
11

12

13

9
8
7
6

14
15
16
TN1787

1 Differential Housing, Right 5 Differential Lock Collar 9 Ball Bearing (2) 13 Differential
2 Screw (8) 6 Shim (As Required) 10 Plug (2) 14 Differential Housing, Left
3 Breather 7 Shim (As Required) 11 Hex Head Bolt (8) 15 Seal
4 Dowel Sleeve (2) 8 Shim (As Required) 12 Ring Gear 16 Drain Plug
Figure 5-80

4203780 First Edition 5-73

 HYDROSTATIC POWER TRAIN

1. Remove both drive axle reducer assemblies. (See

“Drive Axle Reducer Assembly” on page 5-69.) 1 2
2. Remove the input bevel pinon assembly. (See “Input
Bevel Pinion Assembly” on page 5-65.)

NOTES 3
Remove the breather (3), plugs (10), drain plug (16), and 4
seal (15) only if replacement is required.
3. Disassemble the differential assembly as shown.
4. Place parts in assembly order on a clean work area 1
as they are removed.

NOTICE
• It is important that parts are marked and TN1932
placed in assembly order to aid in assembly. Figure 5-81
• It is important that all parts are absolutely 1. Assemble the differential (3) and ring gear (2) using
clean, as contamination can result in serious eight hex head bolts (4). Apply Loctite 242 to hex
damage and/or improper operation. head bolts (4) before assembly. Install hex head bolts
• Never use shop towels or rags to dry parts and tighten to 37 lb-ft (51 N·m).
after cleaning, as lint may clog passages. Dry 2. Press ball bearings (1) onto the differential assembly.
parts using compressed air.

Inspection Notes 5 6

5 • Keeping parts in assembly order, clean and air dry

each item for inspection. 7
• If replacing the ring gear, the pinion shaft must also
be replaced. These parts are a matched set.
• Inspect for worn or defective parts.
• Inspect all parts for cracks, nicks, burrs, and
excessive wear. Inspect for scoring, galling, and
scratches on surfaces. Replace parts as necessary.

Assembly 8
See Figures 5-81 through 5-83. 9
TN1933

Required Materials Figure 5-82

• Loctite® Primer 3. Install the differential assembly (6) in the left

differential housing (9). Do not install shims at this
• Loctite® 518 Gasket Eliminator
time. Make sure the differential assembly is fully
seated in the bearing bore.

NOTE
Do not apply Loctite to the input bevel pinion housing
bolts at this time.
4. Install input bevel pinion assembly (8). (See
“Assembly” on page 5-67.)
5. Using a dial indicator (5) against the pinion tooth,
check the gear backlash.
6. Subtract 0.008 in. (0.2 mm) from the measurement
obtained. Build a shim pack equal to the final
dimension.

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 HYDROSTATIC POWER TRAIN

7. Remove the input bevel pinion assembly (8) and 15. Apply Loctite 242 to eight screws (11) before
differential assembly (6). assembly. Install screws and tighten to 37 lb-ft
8. Place the shim pack in the bearing bore of the left (51 N·m).
differential housing (9). 16. Install plugs (16), drain plug (19) and seal (18)
9. Install the input bevel pinion assembly (8) and (if removed).
differential assembly (6). Apply Loctite 242 to input 17. Install breather (12) (If removed).
bevel pinion housing screws (7) before assembly. 18. Install both drive axle reducer assemblies. (See
Install screws and tighten to 37 lb-ft (51 N·m). “Drive Axle Reducer Assembly” on page 5-69.)
10. Determine the shim thickness needed for the right
differential housing. (See “Determine Shim Input Bevel Pinion and Ring Gear Clearance
Thickness” on page 5-76.) Adjustment
See Figure 5-84.
11
10
2
1
13
12 3

14
16
15
11
4
5
13 5
TN1916
Figure 5-84
1. Install the input bevel pinion assembly (4) in the
differential housing (5). Do not install shim pack at
this time.
2. Install and tighten screws (3) to 37 lb-ft (51 N·m).
17
3. Install special tool (1) in the bearing bore of the
differential housing (5).
18
4. Measure the distance (2) between the face of the
19 pinion gear and the surface of the special tool (1).
TN1958
5. Subtract the measurement obtained in step 4 from
Figure 5-83 0.689 in. (17.5 mm).
11. Install the differential lock collar (14) and shim pack 6. Remove the input bevel pinion assembly (4) from the
(15) (as previously determined) in the right differential housing (5).
differential housing (10). 7. Build a shim pack to equal the final dimension
12. Apply Loctite Primer to the mating surfaces of the obtained in step 5.
right (10) and left (17) differential housings. 8. Install the input bevel pinion assembly (4) and shim
13. Apply Loctite Gasket Eliminator 518 in a continuous pack on the differential housing (5).
bead around the mating surfaces of the right (10) and 9. Apply Loctite 242 to screws (3) before assembly.
left (17) differential housings, making sure to go Install screws and tighten to 37 lb-ft (51 N·m).
around each hole. 10. Remove special tool (1).
14. Install two dowel sleeves (13) in the locations shown, 11. Proceed to “Assembly” on page 5-74.
and assemble the right (10) and left (17) differential
housings.

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 HYDROSTATIC POWER TRAIN

Determine Shim Thickness Method “B”

There are two possible methods for determining the See Figure 5-87.
thickness of shims needed for the right differential
housing. Review each procedure to determine which
method best fits your application.
1
Method “A”
See Figures 5-85 and 5-86. 2
3

1 2 3

4
TN1939
Figure 5-87
1. Build a temporary shim pack (2) equal to 0.030 in.
(0.76 mm), and place it on the bearing bore of the
TN1934
right differential housing (1).
Figure 5-85 2. Place the right differential housing (1) on the left

5 1. Measure the distance (1) from the side of the

differential bearing (2) to the housing flange surface
(3).
differential housing (4).

NOTICE
Tightening the differential housing bolts at this
4 5 6 time could result in damage to the differential
housings or other components.

3. Install the differential housing bolts evenly to hand

tight.
4. Using a feeler gauge, measure the gap (3) between
the housings.
5. Add 0.004 in. (0.1 mm) to the dimension obtained in
step 3, then subtract the total from 0.030 in.
TN1935
(0.76 mm). This is the thickness of the shim pack
needed.
Figure 5-86
6. Separate the differential housings.
2. Measure the distance (6) from the right differential 7. Remove the temporary shim pack (2).
housing flange (4) to the bottom of the bearing bore
8. Continue assembly of the differential housings, step
(5).
11 of “Assembly” on page 5-74.
3. Subtract distance (1) from distance (6). From the
answer, add 0.004 in. (0.1 mm). This is the thickness
of the shim pack needed.
4. Continue assembly of the differential housings, step
11 of “Assembly” on page 5-74.

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 HYDROSTATIC POWER TRAIN

Rear Wheel Motor

Removal and Installation 9
See Figures 5-88 through 5-91.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove rear wheel. (See “Rear Wheels” on
page 9-17.)

10
1

14

13
12
11
TN1963
Figure 5-90

3 2 7. Remove cotter pin (10).

TN1970
Figure 5-88 ! CAUTION

NOTES
The wheel hub may move unexpectedly when
using a puller. To prevent injury and/or property
damage, do not remove the castle nut until the
5
• Label all hydraulic hoses before disconnecting to
ensure correct installation. wheel hub has been loosened from the wheel
motor shaft.
• Plug hydraulic hoses after disconnecting to prevent
the loss of hydraulic oil.
3. Disconnect hoses (1 and 3) at the 4WD valve (2). 8. Loosen, but do not remove, the castle nut (11).
9. Loosen the wheel hub (13) from the motor shaft (14)
using a puller.
4
10. Remove the castle nut (11), washer (12), and wheel
hub (13) from motor shaft (14).
5 11. Remove key (9) from motor shaft (14).

6
7 TN1962
Figure 5-89
4. Disconnect hoses (5 and 6) from wheel motor (7).
5. Disconnect hose (4) from fitting (8).
6. Remove fitting (8) from wheel motor (7).

4203780 First Edition 5-77

 HYDROSTATIC POWER TRAIN

15

19 16
17

18

TN1964
Figure 5-91
12. Remove four screws (17) and lock washers (16).
13. Remove guard (18) and wheel motor (15) from motor
mount (19).

5 Installation Notes

Required Materials

Anti-Seize Compound

• Install the rear wheel motor by reversing the order of

removal.
• Apply anti-seize compound to the motor shaft
threads (14). Be careful not to apply anti-seize
compound to the motor shaft.
• Tighten castle nut (11) to 175—200 lb-ft
(237—271 N·m).
• Install a new cotter pin (10) in castle nut (11) and
motor shaft (14).
• Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for the
correct oil specifications.)

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 HYDROSTATIC POWER TRAIN

Disassembly, Inspection, and Assembly

See Figures 5-92 and 5-93.

11 12
10

9
3
8
7
6
5 3
4
2 3

17
16
19 5
18
15
13 14 TN1779
1 Seal, Exclusion 6 Shaft and Bearing Kit 11 Valve Drive 16 Pin (2)
2 Bearing Housing 7 Seal 12 Valve Plate 17 Spring (2)
3 O-Ring (4) 8 Wear Plate 13 Valve 18 Port Manifold Cover
4 Back-Up Ring 9 Drive 14 Balance Ring 19 Screw (4)
5 Shaft Seal 10 Geroler 15 Outer Face Seal
Figure 5-92

NOTE
When removing the port manifold cover (18) do not lose
the two pins (16) and springs (17) between the balance
ring (14) and the port manifold cover (18).
1. Disassemble rear wheel motor as shown.
2. Place parts in assembly order on a clean work area
as they are removed.

4203780 First Edition 5-79

 HYDROSTATIC POWER TRAIN

Rear Wheel Motor Timing

NOTICE
• It is important that motor parts are marked
3 4
and placed in assembly order to aid in
assembly.
• It is important that all motor parts are
2
absolutely clean, as contamination can result 1
in serious damage and/or improper operation.
• Never use shop towels or rags to dry parts
after cleaning, as lint may clog passages. Dry
parts using compressed air.
5
Inspection Notes 6
• Keeping parts in assembly order, clean and air dry
each item for inspection.
• Inspect for worn or defective parts. 7
8 TN1541
• Look for metal chips or slivers during cleaning (an
indication of damage to pump or other hydraulic Figure 5-93: Correct Motor Timing
component). 1. Locate the largest open pocket (8) in geroler (1).
• Inspect all parts for cracks, nicks, burrs, and Mark the location of the pocket on the outside edge
excessive wear. Inspect for scoring, galling, and of geroler.
scratches on surfaces. Replace parts as necessary. 2. Align the case drain hole (7) in the geroler with the
case drain hole in the bearing housing. Install the
5 Assembly Notes geroler on the bearing housing. Retain the rollers in
the outer geroler ring if they are loose.
NOTICE 3. Install the valve drive (2) in geroler (1).
• It is important that all component parts are 4. Lubricate the seal and install it in the valve plate (3).
absolutely clean, as contamination can result 5. Align the case drain hole (6) in the valve plate (3)
in serious damage and/or improper operation. with the case drain hole (7) in the geroler (1). Install
• Never use shop towels or rags to dry parts the valve plate (3) with the seal side toward the
after cleaning, as lint may clog passages. Dry geroler.
parts using compressed air. 6. Locate the slot in the valve plate (3) that is in line with
the largest open pocket (8) of geroler.
7. Locate any side valve opening (5) through to the face
Required Materials of the valve. Line up the opening with the open slot of
the valve plate that is in line with the largest open
• Seal Kit (Jacobsen PN 5003385)
pocket of geroler. Rotate valve (4) clockwise 1/2
• Shaft and Bearing Kit (Jacobsen PN 5003384) spline tooth to engage with the valve drive.

• Assemble the rear wheel motor by reversing the

order of disassembly.
• Lubricate all O-rings prior to assembly.
• Time the motor correctly. (See “Rear Wheel Motor
Timing” on page 5-80.)
• Tighten valve housing screws (19) to 36—37 lb-ft
(49—50 N·m).
• Pressure filter traction system upon start-up if metal
debris is found in system oil or motor. (See “Portable
In-Line Filter” on page 5-4.)

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 HYDROSTATIC POWER TRAIN

Traction Linkage
Disassembly and Assembly
See Figure 5-94.
2 3

1
4

6 5
7
8

40 9
39 10
38 11
36 12
13
37
36 11
3
17 12
35
28 18 4
29 14 3
34
19 20
3
14 16
1 15
5
3
2 21
23 22
33 23
2
32 24

7
31

2
2 26
27
28
30 29 25
3
4 TN1980
1 Lock Nut (2) 11 Pin, Magnet Support (2) 21 Block, Top (2) 31 Screw
2 Flat Washer (8) 12 Spring (2) 22 Rubber Mount, Traction Arm 32 Traction Arm
3 Lock Washer, Heavy (7) 13 Bracket, Cruise Control Magnet 23 Washer (2) 33 Bushing (2)
4 Nut (3) 14 Flat Washer (3) 24 Rod End 34 Screw
5 Screw 15 Screw (2) 25 Traction Pump 35 Tube, Traction Return
6 Bracket, Traction Return 16 Traction Damper 26 Lock Nut, Center 36 Washer (4)
7 Nut (3) 17 Screw 27 Rod, Traction Pump Adjusting 37 Spring, Compression
8 Lock Washer, Heavy (2) 18 Screw 28 Jam Nut (4) 38 Screw, Special
9 Screw (2) 19 Spacer, Traction Control 29 Rod End (2) 39 Stop, Rear Pivot
10 Magnet, Cruise Control 20 Screw (2) 30 Traction Bell Crank 40 Frame
Figure 5-94

4203780 First Edition 5-81

 HYDROSTATIC POWER TRAIN

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove seat and seat platform. (See “Seat and Seat
Platform” on page 9-13.)
3. Disassemble traction linkage as shown in
Figure 5-94 on page 5-81.

NOTES
When removing rod ends (24 and 29) from traction pump
adjusting rod (27), record the number of turns needed to
remove the rod ends to ensure correct assembly.
4. Place parts in assembly order on a clean work area
as they are removed.

Assembly Notes

• Assemble the traction linkage by reversing the order

of disassembly.
• Install rod ends (24 and 29) on traction pump
adjusting rod (27), using the same number of turns
as recorded during removal.
• Adjust traction linkage. (See “Traction Linkage
Adjustments” on page 5-29.)

5-82 4203780 First Edition

 Chapter 6

Hydraulics

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Test and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Theory of Operation and Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Steering Circuit Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Steering Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Raise Circuit Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Raise Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Lower Circuit Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Lower Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Mower Deck Float Circuit Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . 6-18
Mower Deck Float Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Mow Circuit (ON) Schematic and Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Mow Circuit (ON) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Mow Circuit (OFF) Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Mow Circuit (OFF) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Field Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Lift Cylinders Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wing Lift Cylinders Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-24
6-24
6-25
6
Power Steering Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Cutting Unit System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

4203780 First Edition 6-1

 HYDRAULICS

Instrument Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Instrument Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Front Cutting Unit Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Front Cutting Unit Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Front Cutting Unit Deck Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Adjust Front Cutting Unit Deck Valve System Relief Valve Pressure . . . . . . . . . . . . . . . . . 6-33
Front Cutting Unit Motors Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Right Wing Cutting Unit Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Right Wing Cutting Unit Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Right Wing Cutting Unit Deck Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Adjust Right Wing Cutting Unit Deck Valve System Relief Valve Pressure . . . . . . . . . . . . . 6-42
Right Wing Cutting Unit Motors Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Left Wing Cutting Unit Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Left Wing Cutting Unit Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Left Wing Cutting Unit Deck Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Adjust Left Wing Cutting Unit Deck Valve System Relief Valve Pressure . . . . . . . . . . . . . . 6-51
Left Wing Cutting Unit Motors Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Lift/Steer System Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Lift/Steer Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Hydraulic Oil Tank—Drain Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Deck Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61
Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Right Deck Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64
Left Deck Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Front Deck Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Hydraulic Oil Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
6 Charge Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-68
6-69
Wing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77
Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77

6-2 4203780 First Edition

 HYDRAULICS

Specifications
Test and Adjustment Specifications

Specifications
Front Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Left Wing Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Right Wing Cutting Unit Pump Flow gpm (Lpm) 13 (49.2) at 2800 rpm
Lift/Steer Pump Flow gpm (Lpm) 7.9 (30) at 2800 rpm
Hydraulic Leakage Percentage Ranges 0—10% = Good
11—20% = Marginal
21% and Beyond = Bad
Lift System Relief Valve Pressure psi (bar) 1500 (103)
Setting
Steer System Relief Valve Pressure psi (bar) 1500 (103)
Setting
Front Cutting Unit Deck Valve System psi (bar) 2700—3300 (186—228)
Relief Valve Pressure Setting
Left Wing Cutting Unit Deck Valve psi (bar) 2700—3300 (186—228)
System Relief Valve Pressure Setting
Right Wing Cutting Unit Deck Valve psi (bar) 2700—3300 (186—228)
System Relief Valve Pressure Setting
Cutting Unit Motor Case Drain Rate Less than 1 pint (0.47 L) per minute at 2000 psi
(138 bar)

Repair Specifications

Specifications
6
Gear Pump—Rear Cover-to-Pump Body lb-ft (N·m) 20 (27)
Bolt Torque
Mow Solenoid Valve Torque lb-ft (N·m) 24—26 (32.5—35.3)
Mow Solenoid Valve Nut Torque lb-ft (N·m) 5—7 (6.8—9.5)
Blade Brake Relief Valve Torque lb-ft (N·m) 33—37 (44.7—50.2)
Deck Valve System Relief Valve Torque lb-ft (N·m) 24—26 (32.5—35.3)
Hydraulic Oil Tank Capacity gal (L) 17 (64.3)
Front Lift Cylinder Rod Nut Torque lb-ft (N·m) 50 (68)
Wing Lift Cylinder Rod Nut Torque lb-ft (N·m) 95 (129)

4203780 First Edition 6-3

 HYDRAULICS

Component Location
See Figures 6-1 and 6-2.

1 2

5
6 4
3
7

6
8

10 11 12
9
TN1768, TN1780, TN1893
1 Right Deck Valve 6 Gear Pump 11 Left Wing Lift Cylinder
2 Hydraulic Oil Cooler 7 Left Deck Valve 12 Left Wing Cutting Unit Motor (2)
3 Hydraulic Oil Tank 8 Front Lift Cylinder (2)
4 Charge Pressure Filter 9 Front Cutting Unit Motor (3)
5 Hydraulic Oil Return Filter 10 Front Deck Valve
Figure 6-1: Component Location—Left Side

6-4 4203780 First Edition

 HYDRAULICS

1
13
2

14

4 3
15

TN1769

6
13 Lift Valve 14 Right Wing Cutting Unit Motor (2) 15 Right Wing Lift Cylinder
Figure 6-2: Component Location—Right Side

4203780 First Edition 6-5

 HYDRAULICS

Hydraulic Schematic
See Figures 6-3 through 6-7.

1
2

3
4

A
5
1 2 3 4
Check
Valve 3500 psi
Gear Pump 0.65 ci 1.08 ci 1.08 ci 1.08 ci 2.48 ci 2800 ±50 rpm

Check
Valve 3500 psi
B
6

Hydrostatic Traction Pump

6 10 Micron

25 psi
Switch
Charge
25 psi
Filter
Crack
Bypass
Suction
Screen
100 Mesh

Tank Fill Cap 9

Assembly

10

40 Micron Oil
Filter Cooler

10 Micron
560 Micron
Strainer
25 psi
Switch 11
25 psi
Crack
Return Bypass

Filter

Hydraulic Oil Tank TN1732

Figure 6-3

6-6 4203780 First Edition

 HYDRAULICS

Hydraulic Schematic
Continued

1
2 2

3 3
4 4

Front
2.48 ci Axle A
4WD Valve
Motor
Secondary 4WD
AD
Shuttle Valve

6
BD 4WD
Reverse
Solenoid

8 C B L2 R2 4WD R1 L1

Right
Differential Lock Wheel
Motor
Charge Pressure
Light Switch

6
11.9
ci
125 psi N.C.

11.9
SD DL SW CP F ci

Left
Wheel
Charge Pressure Motor
9 Relief Valve 250 psi

Priority Valve
4.5 gpm T
10 P

ST 4WD

LD Differential
Lock Solenoid 4WD Solenoid

L
12
Control Valve
11 13
14
9
10
11
TN1733
Figure 6-4

4203780 First Edition 6-7

 HYDRAULICS

Hydraulic Schematic
Continued

2 2

3 3
4 4

Steering Valve
IN
Check RT
Valve

Relief Valve 6.6 ci

1450 psi

LT

Steering
Cylinder

6 Steering Unit OUT

12
13
14 12
9 13
10 10
11 11
TN1734

Figure 6-5

6-8 4203780 First Edition

 HYDRAULICS

Hydraulic Schematic
Continued

2 2

3 3
4 4

IN OUT
Lift Valve
Relief Valve
1500 psi

Left Lift Valve Front Lift Valve Right Lift Valve 50 psi

Weight
Transfer
Valve
300 psi 300 psi 300 psi

B
Detent Valve
A D
Detent Valve
C F
Detent Valve
E
6

0.060" Orifice 0.060" Orifice 0.060" Orifice 0.060" Orifice

Left Wing Front Left Front Right Right Wing

Cylinder Cylinder Cylinder Cylinder

12
13 12
10 10
11 11
TN1735

Figure 6-6

4203780 First Edition 6-9

 HYDRAULICS

Hydraulic Schematic
Continued

3
4
A P

CW Outside
Right Wing 1.04 ci D
Motor
0.67"

Right Deck
Solenoid Valve
CCW Inside Valve
Relief Valve
Right Wing 1.04 ci 3000 psi
Motor
0.67"
B T

Blade Brake Relief

630 psi

A P

CW Inside
Left Wing 1.04 ci D
Motor 0.67"

Left Deck
Solenoid
Valve
CCW Outside Valve Relief Valve
Left Wing 1.04 ci 3000 psi
Motor 0.67"

6 B

Blade Brake Relief

630 psi
T

A P

CCW Left
1.04 ci D
Front Motor
0.67"
Front Deck
Solenoid Valve
Valve
Relief Valve
CW Center 1.04 ci
3000 psi
Front Motor
0.67"
B T

Blade Brake Relief

630 psi

CW Right
1.04 ci
Front Motor
0.67"

Tank Check Valve

12
10
11
TN1736

Figure 6-7

6-10 4203780 First Edition

 HYDRAULICS

Page Intentionally Blank

4203780 First Edition 6-11

 HYDRAULICS

Theory of Operation and

Diagnostic Information
Steering Circuit Schematic and
Theory of Operation
System Conditions:
• Engine running
• Steering wheel turned to the right or left (right turn
shown)

Oil Supply to Steering Valve

Hydraulic oil is drawn from the hydraulic oil tank by
section 1 of the gear pump assembly. Before entering the
gear pump assembly, the inlet oil is filtered by a
100-mesh screen to remove any debris.
Operating-pressure oil from section 1 of the four-section
gear pump is routed to port “P” of the control valve, flows
through the 4.5-gpm priority valve and out port “ST” to
the steering valve.
The priority valve will supply oil flow to the steering valve
before allowing oil flow to the lift valve, to ensure
maximum steering control at any engine rpm range.

Steering Circuit
Operating-pressure oil enters the steering unit at “IN”
port, and is routed to the pilot line of the 1450-psi relief
valve, against the check valve, and to the steering valve.

6 With the steering wheel turned to the right, the steering

valve is moved, allowing oil to flow through the valve to
the gerotor metering section. Oil is then routed through
port “RT” of the steering unit to the steering cylinder,
moving the rear wheels in the desired direction.
Oil from the opposite end of the steering cylinder flows
back into the steering unit through port “LT” and back
through the steering valve, exiting through the steering
unit “OUT” port. Oil exiting the steering unit then flows
through the charge filter, and supplies charge-pressure
oil to the traction pump and other systems.

6-12 4203780 First Edition

 HYDRAULICS

Steering Circuit Schematic

See Figure 6-8.

Steering
Valve

IN
1
RT

Check
Valve

6.6 ci
Relief Valve
1450 psi

LT

Steering
Cylinder

OUT

Steering Unit

Hydraulic
Oil Cooler 2

Operating Pressure Oil Charge Pressure Oil 6

TN1716
1 Operating Pressure Oil from Control Valve (Port ST) 2 Charge Pressure Oil to Charge Filter
Figure 6-8

4203780 First Edition 6-13

 HYDRAULICS

Raise Circuit Schematic and Theory

of Operation
System Conditions:
• Engine running at fast idle
• Right, left, and/or front lift/lower lever(s) in RAISE
position

NOTE
The cutting unit motors will automatically shut off as the
cutting units are raised. (See “Mow Circuit (OFF) Theory
of Operation” for more information.)

Oil Supply to the Lift Valve

Hydraulic oil is drawn from the hydraulic oil tank by
section 1 of the gear pump assembly. Before entering the
gear pump assembly, the inlet oil is filtered by a
100-mesh screen to remove any debris.
Operating-pressure oil from section 1 of the gear pump is
routed to port “P” of the control valve and flows through
the 4.5-gpm priority valve. The four-section gear pump
will need to produce a flow rate of 4.5 gpm before the
priority valve opens to supply oil to the lift valve.
The priority valve will supply oil flow to the steering valve
before allowing oil flow to the lift valve, to ensure
maximum steering control at any engine rpm range.

Raise Circuit
Operating-pressure oil supplied by section 1 of the gear
6 pump enters the lift valve body at the “IN” port, and is
routed to the relief valve (1500 psi) and lift valve spools.
The oil flows through the lift valve, and is routed to the
pilot line of the detent valves, causing the valves to shift.
The oil then flows through the check valve and 0.60 fitting
orifice to the piston side of the lift cylinders, lifting the
cutting units.
Oil from the other end of the lift cylinders flows back to
the hydraulic tank.

Circuit Relief
The lift system is protected by the 1500-psi relief valve. If
the pressure on the pilot line of the relief valve reaches
1500 psi, the valve will open, dumping
operating-pressure oil through the “OUT” port of the lift
valve body, through the weight transfer valve to the
hydraulic tank.

6-14 4203780 First Edition

 HYDRAULICS

Raise Circuit Schematic

See Figure 6-9.

Differential Lock

Charge Pressure
Light Switch
165 psi N.C.

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P
1

ST 4WD
2
Differential
LD Lock Solenoid 4WD Solenoid

Control Valve

Lift Valve
IN OUT
Relief Valve
1500 psi

Left Lift Valve Front Lift Valve Right Lift Valve

50 psi
6
Weight
Transfer
Valve

300 psi 300 psi 300 psi

Detent Valve Detent Valve Detent Valve

B A D C F E

0.060" Orifice 0.060" Orifice 0.060" Orifice 0.060" Orifice

Left Wing Front Left Front Right Right Wing

Cylinder Cylinder Cylinder Cylinder

Hydraulic Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Return Oil
TN1719

1 Operating Pressure Oil from Section 1 of Gear Pump 2 Charge Pressure Oil to Charge Filter
Figure 6-9

4203780 First Edition 6-15

 HYDRAULICS

Lower Circuit Schematic and Theory

of Operation
System Conditions:
• Engine running
• Right, left, and/or front lift/lower lever(s) in LOWER
position

Oil Supply to Lift Valves

Hydraulic oil is drawn from the hydraulic oil tank by
section 1 of the gear pump assembly. Before entering the
gear pump assembly, the inlet oil is filtered by a
100-mesh screen to remove any debris.
Operating-pressure oil from section 1 of the gear pump is
routed to port “P” of the control valve and flows through
the 4.5-gpm priority valve. The four-section gear pump
will need to produce a flow rate of 4.5 gpm before the
priority valve opens to supply oil to the lift valve.
The priority valve will supply oil flow to the steering valve
before allowing oil flow to the lift valve, to ensure
maximum steering control at any engine rpm range.

Lower Circuit
Operating-pressure oil enters the lift valve body at the
“IN” port, and flows to the relief valve (1500 psi) and to
each of the spool valves. With the lift/lower levers in the
LOWER position, operating-pressure oil flows through
the spools. Oil is directed to the detent load check spools.
The spools are shifted, and open the ports to allow

6 trapped oil in the cylinder circuit to flow to the lift spools.

Gravity pulls the cutting units down, pulling against the lift
cylinders. Oil from the piston end of the lift cylinders flows
into the lift valve body at port “B,” through the detent
valves and lift valves. The oil exits the lift valve body
through the “OUT” port, through the weight transfer valve
to the hydraulic tank.

Circuit Relief
The lift system is protected by the 1500-psi relief valve. If
the pressure on the pilot line of the relief valve reaches
1500 psi, the valve will open, dumping
operating-pressure oil through the “OUT” port of the lift
valve body, through the weight transfer valve to the
hydraulic tank.

6-16 4203780 First Edition

 HYDRAULICS

Lower Circuit Schematic

See Figure 6-10.

Differential Lock

Charge Pressure
Light Switch
165 psi N.C.

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P
1
4WD
ST
2
Differential
LD Lock Solenoid 4WD Solenoid

L
Control Valve

Lift Valve
IN OUT
Relief Valve
1500 psi

Left Spool Valve Front Spool Valve Right Spool Valve

50 psi
6
Weight
Transfer
Valve

300 psi 300 psi 300 psi

Detent Valve Detent Valve Detent Valve

B A D C F E

0.060" Orifice 0.060" Orifice 0.060" Orifice 0.060" Orifice

Left Wing Front Left Front Right Right Wing

Cylinder Cylinder Cylinder Cylinder

Hydraulic Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Return Oil
TN1717
1 Operating Pressure Oil from Section 1 of Gear Pump 2 Charge Pressure Oil to Steering Unit
Figure 6-10

4203780 First Edition 6-17

 HYDRAULICS

Mower Deck Float Circuit Schematic

and Theory of Operation
System Conditions:
• Engine running
• Right, left, and/or front cutting units lowered to the
ground
• Right, left, and/or front cutting units lift/lower lever(s)
in NEUTRAL position

Oil Supply to Lift Valves

Hydraulic oil is drawn from the hydraulic oil tank by
section 1 of the gear pump assembly. Before entering the
gear pump assembly, the inlet oil is filtered by a
100-mesh screen to remove any debris.
Operating-pressure oil from section 1 of the gear pump is
routed to port “P” of the control valve and flows through
the 4.5-gpm priority valve. The four-section gear pump
will need to produce a flow rate of 4.5 gpm before the
priority valve opens to supply oil to the lift valve.
The priority valve will supply oil flow to the steering valve
before allowing oil flow to the lift valve, to ensure
maximum steering control at any engine rpm range.

Float Circuit
With the cutting units lowered, and the lift/lower levers in
the NEUTRAL position, oil from the lift cylinders can flow
freely in both directions through the detent and spool
valves.
6 As the cutting units move along the ground, they rise and
fall with the contour of the ground. As cutting units rise,
oil from the piston end of the cylinders flows back into the
lift valve block. As the cutting units drop to follow the
ground contour, oil flows back into the lift cylinder. As the
cutting units drop, operating-pressure oil flows through
the valves to supply make-up oil to the piston end of the
lift cylinders. Operating-pressure oil flows to the weight
transfer valve, opening the valve and allowing the excess
oil to dump to the hydraulic tank.
Slight upward pressure (up to 50 psi) is maintained
against the lift cylinders. This is accomplished with an
adjustable weight transfer valve located in the hydraulic
return line between the lift valve body and the hydraulic
tank. This valve can be adjusted to increase or decrease
the amount of cutting unit weight being transferred to the
ground, thus increasing or decreasing weight transfer to
the machine’s drive wheels.
This allows the machine to retain traction while allowing
the cutting units to adapt to variations in ground contour.

6-18 4203780 First Edition

 HYDRAULICS

Mower Deck Float Circuit Schematic

See Figure 6-11.

Differential Lock

Charge Pressure
Light Switch
165 psi N.C.

SD DL SW CP F Charge Pressure T
Relief Valve 250 psi
Priority Valve
4.5 gpm
P
1
4WD
ST
2
Differential
LD Lock Solenoid 4WD Solenoid

L
Control Valve

Lift Valve
IN OUT
Relief Valve
1500 psi

Left Spool Valve Front Spool Valve Right Spool Valve 50 psi
6
Weight
Transfer
Valve

300 psi 300 psi 300 psi

Detent Valve Detent Valve Detent Valve

B A D C F E

0.060" Orifice 0.060" Orifice 0.060" Orifice 0.060" Orifice

Left Wing Front Left Front Right Right Wing

Cylinder Cylinder Cylinder Cylinder

Hydraulic Oil Tank

Operating Pressure Oil Charge Pressure Oil Metered Oil Return Oil
TN1718
1 Operating Pressure Oil from Section 1 of Gear Pump 2 Charge Pressure Oil to Steering Unit
Figure 6-11

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 HYDRAULICS

Mow Circuit (ON) Schematic and Oil Return

Theory of Operation Oil returning from the motors enters the valve body at
port “B,” and flows through the pilot-operated brake valve,
System Conditions: exiting the valve body at port “T” and is returned to the
• Engine running hydraulic tank:
• Cutting units lowered Right Wing Deck: The oil from this motor is routed
• Mow switch(es) in ON position directly to the hydraulic tank.
• Park brake released Front Deck and Left Wing Deck: The oil from these
decks is routed through the oil cooler and through a
NOTES 10-micron filter to remove debris from the oil. In the
event of the return filter becoming plugged, a 25-psi
• See “Mow Circuit—Theory of Operation” on
pressure switch will activate the “Return Filter” light
page 4-36 for the electrical operation of this circuit.
on the control panel and return filter will be
• The function of each deck valve is the same, except bypassed.
where noted.
Oil that leaks through the motors drains back to the
Oil Supply to Deck Valves hydraulic tank through the case drain hoses. A check
valve located in the return line at the bottom of the
Oil is drawn from the hydraulic tank through a 100-mesh hydraulic tank prevents oil from back-feeding into the oil
screen, and enters the gear pump, supplying oil to all four return lines in the event of a hose failure.
pump sections. Sections 2 (front deck), 3 (left wing deck),
and 4 (right wing deck), supply operating-pressure oil to
port “P” of the corresponding cutting unit deck valves.

Mow Circuit
Operating pressure oil flows to the relief valve (3000 psi),
solenoid valve, and the brake valve pilot port (630 psi).
With the mow switch(es) in the ON position, the solenoid
valve shifts, applying pressure against the check valve,
stopping oil flow through the solenoid valve.

6 Operating-pressure oil increases and opens the brake

valve (630 psi). Operating-pressure oil flows out of the
valve body through port “A,” driving the motors.

Circuit Relief
The mow circuit is protected by a pilot-operated relief
valve. The relief valve will open if the oil pressure in the
circuit reaches 3000 psi, allowing oil to bypass the circuit
and return directly to the hydraulic tank.

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 HYDRAULICS

Mow Circuit (ON) Schematic

See Figure 6-12.

2
3
A P

CW Outside
Right Wing 1.04 ci D
Motor 0.67"

Right Deck
Solenoid
Valve
CCW Inside Valve
Relief Valve
Right Wing 1.04 ci 3000 psi
Motor B
0.67"

T
Blade Brake Relief
630 psi

A P

CW Inside
Left Wing 1.04 ci D
Motor 0.67"

Left Deck
Solenoid Valve
CCW Outside Valve
Relief Valve
Left Wing 1.04 ci 3000 psi
Motor
0.67" B

Blade Brake Relief

630 psi
T 6
A P

CCW Left
1.04 ci
Front Motor D
0.67"

Front Deck
Solenoid Valve
Valve
Relief Valve
CW Center 3000 psi
Front Motor 1.04 ci
B
0.67"
T

Blade Brake Relief

630 psi

CW Right
Front Motor 1.04 ci 4
0.67" Tank Check Valve

Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Return Oil TN1721

1 Operating Pressure Oil from Gear Pump (Section 2) 3 Operating Pressure Oil from Gear Pump (Section 4)
2 Operating Pressure Oil from Gear Pump (Section 3) 4 Return Oil to Oil Cooler and Return Filter
Figure 6-12

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 HYDRAULICS

Mow Circuit (OFF) Theory of

Operation
System Conditions:
• Engine running
• Cutting units lowered
• Mow switches in OFF position
• Park brake released

NOTE
See “Mow Circuit—Theory of Operation” on page 4-36
for the electrical operation of this circuit.

Oil Supply to Deck Valves

Oil is drawn from the hydraulic tank through a 100-mesh
screen, and enters the gear pump, supplying oil to all four
pump sections. Sections 2 (front deck), 3 (left wing deck),
and 4 (right wing deck) supply operating-pressure oil to
port “P” of the corresponding cutting unit deck valves.

Motor Shutdown/Blade Braking

Operating pressure oil flows to the relief valve (3000 psi)
and the solenoid valve. With the mow switch(es) in the
OFF position, the solenoid valves are de-engerized,
opening the valves. Oil can then flow through the valves,
returning to the hydraulic tank. With the oil pressure/flow
diverted to the hydraulic tank, the blade brake check
valves close (630 psi), preventing oil flow through the

6 motors.
The blade brake check valves have a second pilot line on
the motor side. As oil flow is stopped to the motors, the
motors will act a pumps as they rotate during shutdown.
This pilot line allows the valve to close slowly, acting as a
cutting unit motor brake. This prevents a sudden
shutdown of the motors.

Circuit Relief
The mow circuit is protected by a pilot-operated relief
valve. The relief valve will open if the oil pressure in the
circuit reaches 300 psi, allowing oil to bypass the circuit
and return directly to the hydraulic tank.

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 HYDRAULICS

Mow Circuit (OFF) Schematic

See Figure 6-13.

2
3
A P

CW Outside
Right Wing 1.04 ci D
Motor 0.67"

Right Deck
Valve
Solenoid
CCW Inside Valve Relief Valve
Right Wing 1.04 ci 3000 psi
Motor B
0.67"

Blade Brake Relief

630 psi

A P

CW Inside
Left Wing 1.04 ci D
Motor 0.67"

Left Deck
Solenoid Valve
CCW Outside Valve
Relief Valve
Left Wing 1.04 ci 3000 psi
Motor
0.67" B

Blade Brake Relief

630 psi
T
6
A P

CCW Left
1.04 ci
Front Motor D
0.67"

Front Deck
Solenoid Valve
Valve
Relief Valve
CW Center 3000 psi
Front Motor 1.04 ci
B
0.67"
T
Blade Brake Relief
630 psi

CW Right
Front Motor 1.04 ci 4
0.67" Tank Check Valve

Hydraulic Oil Tank

Inlet or Drain Oil Operating Pressure Oil Return Oil TN1720

1 Operating Pressure Oil from Gear Pump (Section 2) 3 Operating Pressure Oil from Gear Pump (Section 4)
2 Operating Pressure Oil from Gear Pump (Section 3) 4 Return Oil to Oil Cooler and Return Filter
Figure 6-13

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 HYDRAULICS

Field Test Procedures 8. Remove support from front cutting unit.

After 15 minutes, does cutting unit drift down?
Front Lift Cylinders Leakage Test YES Cylinder is bypassing oil. Replace lift
cylinder. (See “Front Lift Cylinders” on
See Figure 6-14.
page 6-69.)
! WARNING NO Repeat the test for all of the lift cylinders. If
all cylinders pass test, the problem may be in
The hydraulic system is under pressure, and the the lift valve. Proceed to step 9.
oil will be hot. 9. Support front cutting unit.
• Always relieve pressure in the hydraulic 10. Connect hose (2) to lift cylinder fitting (1).
system before performing service.
11. Start the engine and lower cutting units.
• Failure to follow appropriate safety
12. Stop the engine.
precautions may result in death or serious
injury.

1. Start engine. Operate hydraulic system until oil

temperature is at 120—150° F (49—65° C).
2. Raise front cutting unit.
3. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
4. Support front cutting unit.
.

6 1

2
TN2057
Figure 6-14

NOTE
Figure 6-14 shows left front lift cylinder. Procedure is
similar for right front lift cylinder.
5. Disconnect hose (2) from lift cylinder piston end
fitting (1).
6. Install plug in hose (2).
7. Install cap on lift cylinder fitting (1).

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 HYDRAULICS

Wing Lift Cylinders Leakage Test 8. Remove support from wing cutting unit.

See Figure 6-15. After 15 minutes, does cutting unit drift down?
YES Cylinder is bypassing oil. Replace lift
! WARNING cylinder. (See “Wing Lift Cylinders” on
page 6-73.)
The hydraulic system is under pressure, and the
oil will be hot. NO Repeat the test for all of the lift cylinders. If
all cylinders pass test, the problem may be in
• Always relieve pressure in the hydraulic
the lift valve. Proceed to step 9.
system before performing service.
9. Support wing cutting unit.
• Failure to follow appropriate safety
precautions may result in death or serious 10. Connect hose (2) to lift cylinder fitting (1).
injury. 11. Start the engine and lower cutting units.
12. Stop the engine.
1. Start engine. Operate hydraulic system until oil
temperature is at 120—150° F (49—65° C).
2. Raise the wing cutting unit one foot off the ground.
3. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
4. Support the wing cutting unit to be tested.
.

1
2 6
TN1797
Figure 6-15

NOTE
Figure 6-15 shows left wing lift cylinder. Procedure is
similar for right wing lift cylinder.
5. Disconnect hose (2) from lift cylinder piston end
fitting (1).
6. Install plug in hose (2).
7. Install cap on lift cylinder fitting (1).

4203780 First Edition 6-25

 HYDRAULICS

Power Steering Circuit Test NOTES

The purpose of this test is to determine if the steering
• Perform test on only one cutting unit motor at a time.
cylinder and the steering valve are operating properly.
• The case drain on a hydraulic motor is used to return
NOTE lubrication or bypassed hydraulic oil back to the
Before performing this test, check the steering system for hydraulic tank.
mechanical binding or damage that may affect the 1. Operate the machine until hydraulic oil reaches
steering. operating temperature, 120—150° F (49—65° C).
1. Operate the machine until hydraulic oil reaches 2. Stop the engine and remove the key.
operating temperature, 120—150° F (49—65° C). 3. Bypass the seat switch.
2. With the engine running, turn the steering wheel all 4. Remove the case drain hose from the cutting unit
the way to the right and then all the way to the left. motor. Immediately plug the hose.
Does the steering wheel continue to turn after full 5. Position a drain pan with a minimum capacity of 1
left or right movement of the steering cylinder? gallon (3.8 L) near the cutting unit motor.
YES Proceed to step 3. 6. Install a separate hose on the case drain fitting and
NO Steering system is not faulty. place the free end in the container. Secure the hose
to prevent spills.
3. Stop the engine and remove both hydraulic hoses
from the steering cylinder; plug the hoses and cap
the cylinder ports. ! WARNING
4. Start the engine and turn the steering wheel all the Safely block cutting unit from rotating using a
way to the right and then all the way to the left. Only a suitable device or tool. Failure to follow
little movement should be evident. appropriate safety precaution may result in death
or serious injury.
Is the steering wheel hard to turn or does not
turn?
YES Steering cylinder is faulty; repair or replace 7. Install suitable blocking device or tool in cutting unit,
as needed. (See “Steering Cylinder” on preventing cutting unit from turning.
page 7-21.) 8. Set the park brake and start the engine.
6 With steady pressure in one direction, does
steering wheel make one complete revolution in
9. Place the PTO switch in the ON position.
10. Place the mow enable switch in the ON position for
30 seconds? 15 seconds.
YES Steering valve is faulty; repair or replace as 11. Stop the engine and remove the ignition key.
needed. (See “Steering Valve” on page 7-8.) 12. Measure the amount of oil that flowed from the case
drain. The amount x 4 = amount per minute.
Cutting Unit System Test Is the oil captured from the case drain within a
The cutting unit system consists of three circuits: the front half pint per minute?
cutting unit circuit, the left wing cutting unit circuit, and YES The motor shaft and/or bearings are not
the right wing cutting unit circuit. The front cutting unit faulty; proceed with an instrument test. (See
circuit consists of the front cutting unit pump, front deck “Instrument Test Procedure” on page 6-27.)
valve, right front cutting unit motor, center front cutting
unit motor, and left front cutting unit motor. The left wing Is the oil captured from the case drain more than
cutting unit circuit consists of the left wing cutting unit 1 pint per minute?
pump, left deck valve, left wing inside cutting unit motor, YES The motor may be faulty; repair or replace as
and left wing outside cutting unit motor. The right wing needed. (See “Deck Motors” on page 6-61.)
cutting unit circuit consists of the right wing cutting unit 13. Disconnect and remove test equipment. Install all
pump, right deck valve, right wing inside cutting unit hoses, fittings, and components as noted prior to
motor, and right wing outside cutting unit motor. This test removal.
determines if one of the cutting unit motors is faulty. An
instrument test must be performed to isolate the
performance of the cutting unit pumps and deck valves.

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Instrument Test Procedure Circuit and Rear Cutting Unit Pump

No Load Flow – Loaded Flow / No Load Flow x 100 =
Leak Percentage
Instrument Test Overview
The following tests are specifically designed to approach Calculations:
hydraulic testing on a system level. Each component
within the system represents a portion of the total system Circuit Test
leakage. An internal leakage percentage for each No Load Flow = 10 gpm
component will be calculated and recorded, enabling the Loaded Flow = 6.5 gpm
technician to view the system performance issue more
10 – 6.5 / 10 x 100 = Total Circuit Leakage 35%
completely. The test results will help the technician to
determine which repairs will best remedy the Front Cutting Unit Pump Test
performance issue experienced by the machine user.
No Load Flow = 10 gpm
Loaded Flow = 9.5 gpm
The internal leakage percentage ranges are as follows:
10 – 9.5 / 10 x 100 = Front Cutting Unit Pump Leakage
0—10% = Good 5%
11—20% = Marginal
21% and Beyond = Bad Front Deck Valve Test
Loaded Flow from front cutting unit pump test = 9.5 gpm
Example: Cutting Unit System Performance Loaded Flow from front deck valve test = 9 gpm
Complaint
10 – 9 / 9.5 x 100 = Front Deck Valve Leakage 10.5%
The machine operator reports the mower is not cutting
correctly. Left Front Cutting Unit Motor Test
Troubleshooting must first be performed to rule out a Loaded Flow from front deck valve test = 9 gpm
cutting unit adjustment issue. Once the issue is known to Loaded Flow from right front cutting unit motor test = 7.2
be component related, the entire cutting unit system is gpm
tested as outlined. The calculated system leakage is
9 – 7.2 / 9 x 100 = Right Front Cutting Unit Motor
35%, a result that requires the testing of individual
Leakage 20%
components. This result can also be interpreted as the
system is 65% efficient.
The remaining components in question are as follows:
Center Front Cutting Unit Motor Test 6
Loaded Flow from left front cutting unit motor test = 7.2
front cutting unit pump, front deck valve, right front cutting
gpm
unit motor, center front cutting unit motor, and left front
cutting unit motor. Following the procedures as outlined, Loaded Flow from center front cutting unit motor test =
test each individual component, then calculate and 6.8 gpm
record leakage percentages. 7.2 – 6.8 / 7.2 x 100 = Center Front Cutting Unit Motor
The results from this test reveal leakage of 5% in the front Leakage 5.6%
cutting unit pump, 10.5% in the front deck valve, 20% in
Right Front Cutting Unit Motor Test
the right front cutting unit motor, 5.6% in the center front
cutting unit motor, and 4.4% in the left front cutting unit Loaded Flow from center front cutting unit motor test =
motor. Although all the components lend to the overall 6.8 gpm
circuit leakage, only the right front cutting unit motor, Loaded Flow from right front cutting unit motor test =
which is at the extreme end of the marginal range, would 6.5 gpm
be considered for repair/replacement. 6.8 – 6.5 / 6.8 x 100 = Left Front Cutting Unit Motor
Leakage = 4.4%
Formulas:

Cutting Unit Motor and Deck Valve

Loaded Flow from previous component – Loaded Flow
from current component / Loaded Flow from previous
component x 100 = Leak Percentage

4203780 First Edition 6-27

 HYDRAULICS

Front Cutting Unit Circuit Test

See Figures 6-16 through 6-18.

IMPORTANT
• This test works together with the front cutting 3
units motors test to isolate a problem with the
front cutting unit circuit.
• Performing this test will isolate the front cutting
unit pump, deck valve, and right front cutting unit
motor from the rest of the front cutting unit
circuit. 4

! WARNING 6 5
TN1363
The hydraulic system is under pressure, and the
Figure 6-17
oil will be hot.
• Always relieve pressure in the hydraulic 4. Install tee fitting (5) to fitting (2).
system before performing service. 5. Connect test hose (6) of flow meter inlet and
• Failure to follow appropriate safety hydraulic line (1) to tee fitting (5).
precautions may result in death or serious
injury. NOTE
Make sure hose end is under oil level in hydraulic tank to
prevent aeration of oil.
Required Tools and Materials 6. Secure flow meter outlet hose (3) to the hydraulic
tank fillneck.
• Flow Meter
• -10 ORFS Test Hose 3600 psi (248 bar)
• -10 ORFS Tee Fitting
! WARNING

6 • Blocking Device or Tool Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
1. Park the mower safely. (See “Park Mower Safely” on or serious injury.
page 1-6.)
2. Remove the seat and seat platform. (See “Seat and
7. Install suitable blocking device or tool in left motor of
Seat Platform” on page 9-13.)
front cutting unit, preventing the motor from turning.
Open flow meter valve (4) completely.
1
2

TN2047
Figure 6-16
3. Disconnect hydraulic line (1) from fitting (2).

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 HYDRAULICS

16. Calculate front cutting units circuit leakage.

(Step 13 – Step 14 / Step 13 x 100 = Leak
Percentage)
Is front cutting units circuit leakage 10% or less?
YES The front cutting units circuit is good.
Proceed to “Front Cutting Unit Motors Test”
on page 6-34.
NO Proceed to next question.
Is front cutting units circuit leakage 11% to 20%?
YES The front cutting units circuit is marginal.
Additional testing is required. Proceed to
“Front Cutting Unit Pump Test” on page 6-29.
NO Proceed to next question.
Is front cutting units circuit leakage 21% or
more?
YES Test individual components in front cutting
unit circuit for leakage. Proceed to “Front
Cutting Unit Pump Test” on page 6-29.

Front Cutting Unit Pump Test

See Figures 6-19 through 6-21.

! WARNING
The hydraulic system is under pressure, and the
oil will be hot.
• Always relieve pressure in the hydraulic
Figure 6-18: Front Cutting Unit Circuit Test—Left
Front Cutting Unit Motor Blocked
TN2071
system before performing service.
• Failure to follow appropriate safety
6
precautions may result in death or serious
8. Set park brake. injury.
9. Bypass seat switch.

NOTE Required Tools and Materials

Verify engine rpm is within specification (2800 rpm ± 50) • Flow Meter
to ensure accurate hydraulic test results.
• -10 ORFS Test Hose 3600 psi (248 bar)
10. Start engine and run at full throttle (2800 rpm ± 50).
• -10 ORFS Tee Fitting
11. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (4) until a reading of 1500 psi (103 • -10 ORFS Blocking Disk
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve 1. Park the mower safely. (See “Park Mower Safely” on
fully after operating temperature is reached. page 1-6.)
12. Enable front mower deck switch and engage PTO 2. Before performing this test, perform front cutting unit
switch. circuit test, leaving flow meter connected as outlined.
13. Read and record the front cutting unit circuit no load
flow.
14. Slowly close flow meter valve (4) until pressure
reaches 2250 psi (155 bar). Read and record the
front cutting unit circuit loaded flow.
15. Open flow meter valve (4), disengage switches, and
stop engine.

4203780 First Edition 6-29

 HYDRAULICS

TN2047
Figure 6-19

6 3
TN1363
Figure 6-21: Front Cutting Unit Pump Test—Blocking
Disk Between Pump and Deck Valve
TN2072

Figure 6-20
5. Set park brake.
3. Install blocking disk between hydraulic line (1) and
tee fitting (3). 6. Bypass seat switch.
4. Open flow meter valve (2) completely.
NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
7. Start engine and run at full throttle (2800 rpm ± 50).
8. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1500 psi (103 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
9. Enable front mower deck switch and engage PTO
switch.

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 HYDRAULICS

1. Park the mower safely. (See “Park Mower Safely” on

! CAUTION page 1-6.)

Do not exceed 3350 psi (231 bar) when testing 2. Before performing this test, perform front cutting unit
pump or equipment damage may occur. circuit test, leaving flow meter connected as outlined.

10. Slowly close flow meter valve (2) until pressure

1
reaches 2250 psi (155 bar). Read and record the
front cutting unit pump loaded flow.
11. Open flow meter valve (2), disengage switches, and
stop engine.
12. Calculate front cutting unit pump leakage.
(Step 13 of previous test – Step 10 / Step 13 of
previous test x 100 = Leak Percentage)
Is front cutting unit pump leakage 10% or less?
YES The front cutting unit pump is good. Proceed
to “Front Cutting Unit Deck Valve Test” on
page 6-31. TN1838
NO Proceed to next question. Figure 6-22
Is front cutting unit pump leakage 11% to 20%? 3. Install blocking disk at fitting (1) on left front cutting
YES The front cutting unit pump is marginal. unit motor, blocking oil flow from entering left front
Additional testing is required. Proceed to cutting unit motor.
“Front Cutting Unit Deck Valve Test” on
page 6-31.
NO Proceed to next question.
Is front cutting unit pump leakage 21% or more?
YES Repair or replace front cutting unit pump.
(See “Gear Pump” on page 6-58.) Then
proceed to “Front Cutting Unit Deck Valve
6
Test” on page 6-31.

Front Cutting Unit Deck Valve Test

See Figures 6-22 through 6-24. 2

! WARNING
TN1363
The hydraulic system is under pressure, and the
oil will be hot. Figure 6-23
• Always relieve pressure in the hydraulic 4. Open flow meter valve (2) completely.
system before performing service. 5. Bypass seat switch and set park brake.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (248 bar)
• -10 ORFS Tee Fitting
• -10 ORFS Blocking Disk

4203780 First Edition 6-31

 HYDRAULICS

11. Calculate front cutting unit deck valve leakage.

(Step 10 of previous test – Step 9 / Step 10 of
previous test x 100 = Leak Percentage)
Is front cutting unit deck valve leakage 10% or
less?
YES The front cutting unit deck valve is good.
Proceed to step 12.
NO Proceed to next question.
Is front cutting unit deck valve leakage 11% to
20%?
YES The front cutting unit deck valve is marginal.
Additional testing is required. Proceed to
step 12.
NO Proceed to next question.
Is front cutting unit deck valve leakage 21% or
more?
YES Repair or replace deck valve. (See “Front
Deck Valve” on page 6-66.) Then proceed to
step 12.

! CAUTION
Do not exceed 3350 psi (231 bar) when testing
system relief valve or equipment damage may
occur.

NOTE
6 Figure 6-24: Front Cutting Unit Deck Valve Test—
Blocking Disk at Left Front Cutting Unit Motor
TN2073
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
12. Start engine and run at full throttle (2800 rpm ± 50).
NOTE 13. Enable front mower deck switch and engage PTO
Verify engine rpm is within specification (2800 rpm ± 50) switch.
to ensure accurate hydraulic test results. 14. Continue to close flow meter valve (2) until zero flow
6. Start engine and run at full throttle (2800 rpm ± 50). is obtained. Record cutting unit deck valve system
relief valve pressure.
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (2) until a reading of 1500 psi (103 15. Open flow meter valve (2), disengage switches, stop
bar) or one half of the relief valve rating is reached. engine.
Warm oil to 120—150° F (49—65° C); open valve Is cutting unit deck valve system relief valve
fully after operating temperature is reached. pressure 2700 psi (186 bar) to 3300 psi (228 bar)?
8. Enable front mower deck switch and engage PTO YES Cutting unit deck valve system relief valve is
switch. good. Proceed to “Front Cutting Unit Motors
9. Slowly close flow meter valve (2) until pressure Test” on page 6-34.
reaches 2250 psi (155 bar). Read and record the NO Adjust cutting unit deck valve system relief
front cutting unit deck valve loaded flow. valve pressure. (See “Adjust Front Cutting
10. Open flow meter valve (2), disengage switches, and Unit Deck Valve System Relief Valve
stop engine. Pressure” on page 6-33.)

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 HYDRAULICS

Adjust Front Cutting Unit Deck Valve 4. Rotate screw (2) to adjust the relief valve pressure
setting.
System Relief Valve Pressure
To increase the pressure setting: Turn the screw
See Figure 6-25. in (clockwise).

! WARNING
To decrease the pressure setting: Turn the screw
out (counterclockwise).
The hydraulic system is under pressure, and the 5. Tighten nut (1).
oil will be hot.
Could relief valve be adjusted to 2700 psi (186
• Always relieve pressure in the hydraulic bar) to 3300 psi (228 bar)?
system before performing service.
YES Front cutting unit deck valve system relief
• Failure to follow appropriate safety valve is good. Proceed to “Front Cutting Unit
precautions may result in death or serious Motors Test” on page 6-34.
injury.
NO Repair or replace front cutting unit deck valve
system relief valve. (See “Front Deck Valve”
on page 6-66.)
Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (248 bar)
• -10 ORFS Tee Fitting
• -10 ORFS Blocking Disk

NOTE
This adjustment should be done in conjunction with front
cutting unit deck valve test.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Perform front cutting unit deck valve test. (See “Front
Cutting Unit Deck Valve Test” on page 6-31.)
6

TN2059
Figure 6-25
3. Loosen nut (1).

4203780 First Edition 6-33

 HYDRAULICS

Front Cutting Unit Motors Test

See Figures 6-26 through 6-29.

IMPORTANT
• This test works together with the front cutting
units circuit test to isolate a problem with the
front cutting units circuit.
• Performing this test will isolate the front cutting
unit motors from the rest of the front cutting unit
circuit.
1
! WARNING
The hydraulic system is under pressure, and the TN1363
oil will be hot.
Figure 6-26
• Always relieve pressure in the hydraulic
system before performing service. 5. Open flow meter valve (1) completely.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (248 bar)
• -10 ORFS Tee Fitting
• Blocking Device or Tool

6 1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform front cutting unit
deck valve test, leaving flow meter connected as
outlined.
3. Bypass seat switch and set park brake.

! WARNING
Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
or serious injury.

4. Install suitable blocking device or tool in left front

cutting unit motor, preventing left front cutting unit
motor from turning.
TN2071
Figure 6-27: Front Cutting Unit Motors Test—Left
Cutting Unit Motor Blocked

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.

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 HYDRAULICS

6. Start engine and run at full throttle (2800 rpm ± 50).

7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
8. Enable front mower deck switch and engage PTO
switch.
9. Slowly close flow meter valve (1) until pressure
reaches 2250 psi (155 bar). Read and record the
front cutting unit right motor loaded flow.
10. Open flow meter valve (1), disengage switches, and
stop engine.
11. Calculate front cutting unit right motor leakage.
(Step 9 of front cutting unit deck valve tests – Step 9 /
Step 9 of front cutting unit deck valve tests x 100 =
Leak Percentage)
Is front cutting unit left motor leakage 10% or
less?
YES The front cutting unit left motor is good.
Proceed to step 12.
NO Proceed to next question.
Is front cutting unit left motor leakage 11% to
20%?
YES The front cutting unit left motor is marginal.
Additional testing is required. Proceed to
step 12.
NO Proceed to next question.
Is front cutting unit left motor leakage 21% or
Figure 6-28: Front Cutting Unit Motors Test—Center
Cutting Unit Motor Blocked
TN2074
6
more?
YES Repair or replace front cutting unit left motor. 15. Bypass seat switch and set park brake.
(See “Deck Motors” on page 6-61.) Then
proceed to step 12. NOTE
12. Remove device or tool from front cutting unit left Verify engine rpm is within specification (2800 rpm ± 50)
motor. to ensure accurate hydraulic test results.
16. Start engine and run at full throttle (2800 rpm ± 50).
! WARNING 17. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
Safely block cutting unit from rotating using a bar) or one half of the relief valve rating is reached.
suitable device or tool. Failure to follow Warm oil to 120—150° F (49—65° C); open valve
appropriate safety precaution may result in death fully after operating temperature is reached.
or serious injury.
18. Enable front mower deck switch and engage PTO
switch.
13. Install suitable blocking device or tool in front cutting 19. Slowly close flow meter valve (1) until pressure
unit center motor, preventing front cutting unit center reaches 2250 psi (155 bar). Read and record the
motor from turning. front cutting unit center motor loaded flow.
14. Open flow meter valve (1) completely. 20. Open flow meter valve (1), disengage switches, and
stop engine.

4203780 First Edition 6-35

 HYDRAULICS

21. Calculate front cutting unit center motor leakage.

(Step 9 – Step 19 / Step 9 x 100 = Leak Percentage)
Is front cutting unit center motor leakage 10% or
less?
YES The front cutting unit center motor is good.
Proceed to step 22.
NO Proceed to next question.
Is front cutting unit center motor leakage 11% to
20%?
YES The front cutting unit center motor is
marginal. Additional testing is required.
Proceed to step 22.
NO Proceed to next question.
Is front cutting unit center motor leakage 21% or
more?
YES Repair or replace front cutting unit center
motor. (See “Deck Motors” on page 6-61.)
Then proceed to step 22.
22. Remove device or tool from front cutting unit center
motor.

! WARNING
Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
or serious injury.

6 23. Install suitable blocking device or tool in front cutting Figure 6-29: Front Cutting Unit Motors Test—Right
Cutting Unit Motor Blocked
TN2075

unit right motor, preventing front cutting unit right

motor from turning. 25. Bypass seat switch and set park brake.
24. Open flow meter valve (1) completely.
NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
26. Start engine and run at full throttle (2800 rpm ± 50).
27. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
28. Enable front mower deck switch and engage PTO
switch.
29. Slowly close flow meter valve (1) until pressure
reaches 2250 psi (155 bar). Read and record the
front cutting unit right motor loaded flow.
30. Open flow meter valve (1), disengage switches, and
stop engine.

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 HYDRAULICS

31. Calculate front cutting unit right motor leakage. Right Wing Cutting Unit Circuit Test
(Step 19 – Step 29 / Step 19 x 100 = Leak
Percentage) See Figures 6-30 through 6-32.

Is front cutting unit right motor leakage 10% or IMPORTANT

less? • This test works together with the right cutting
YES The front cutting unit right motor is good. unit motors test to isolate a problem with the
Proceed to step 32. right cutting unit circuit.
NO Proceed to next question. • Performing this test will isolate the right wing
cutting unit pump, deck valve, and right wing
Is front cutting unit right motor leakage 11% to
cutting unit outside motor from the rest of the
20%?
right wing cutting unit circuit.
YES The front cutting unit right motor is marginal.
Determine component(s) with greatest
leakage and repair or replace as necessary. ! WARNING
NO Proceed to next question. The hydraulic system is under pressure, and the
oil will be hot.
Is front cutting unit right motor leakage 21% or
more? • Always relieve pressure in the hydraulic
system before performing service.
YES Repair or replace front cutting unit right
motor. (See “Deck Motors” on page 6-61.) • Failure to follow appropriate safety
precautions may result in death or serious
32. Remove device or tool from front cutting unit right
injury.
motor.
33. Disconnect and remove test equipment. Install all
hoses, lines, and fittings as noted prior to removal. Required Tools and Materials
34. Install and connect all components as noted prior to
test. • Flow Meter
35. Check hydraulic oil level. Add oil as needed. (Refer to • -10 ORFS Test Hose 3600 psi (248 bar)
“Safety, Operation, and Maintenance Manual” for • -10 ORFS Tee Fitting
correct oil specifications.) • Blocking Device or Tool
6
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove the seat and seat platform. (See “Seat and
Seat Platform” on page 9-13.)

1 2

TN2047
Figure 6-30
3. Disconnect hose (1) from fitting (2).

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 HYDRAULICS

6 5
TN1363
Figure 6-31
4. Install tee fitting (5) to fitting (2).
5. Connect test hose (6) of flow meter inlet and hose (1)
to tee fitting (5).

NOTE
Make sure hose end is under oil level in hydraulic tank to
prevent aeration of oil.
6. Secure flow meter outlet hose (3) to the hydraulic
tank fillneck.

! WARNING

6 Safely block cutting unit from rotating using a

suitable device or tool. Failure to follow
appropriate safety precaution may result in death
Figure 6-32: Right Wing Cutting Unit Circuit Test—
Outside Cutting Unit Motor Blocked
TN2077

or serious injury.
9. Bypass seat switch and set park brake.
7. Install suitable blocking device or tool in right wing
outside cutting unit motor, preventing right wing
NOTE
cutting unit motor from turning. Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
8. Open flow meter valve (4) completely.
10. Start engine and run at full throttle (2800 rpm ± 50).
11. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (4) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
12. Enable wing mower deck switch and engage PTO
switch.
13. Read and record the right wing cutting unit pump no
load flow.
14. Slowly close flow meter valve (4) until pressure
reaches 2250 psi (155 bar). Read and record the
right wing cutting unit circuit loaded flow.
15. Open flow meter valve (4), disengage switches, and
stop engine.

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16. Calculate right wing cutting unit circuit leakage.

(Step 13 – Step 14 / Step 13 x 100 = Leak
Percentage)
Is right wing cutting unit circuit leakage 10% or
less?
YES The right wing cutting unit circuit is good. 1
Proceed to “Right Wing Cutting Unit Motors
Test” on page 6-43.
NO Proceed to next question.
Is right wing cutting unit circuit leakage 11% to
20%?
YES The right wing cutting unit circuit is marginal.
Additional testing is required. Proceed to
“Right Wing Cutting Unit Pump Test” on
page 6-39.
TN2047
NO Proceed to next question.
Figure 6-33
Is right wing cutting unit circuit leakage 21% or
more?
YES Test individual components in right wing
cutting unit circuit for leakage. Proceed to
“Right Wing Cutting Unit Pump Test” on
page 6-39.

Right Wing Cutting Unit Pump Test

See Figures 6-33 through 6-35.

! WARNING
The hydraulic system is under pressure, and the
oil will be hot.
2 6
• Always relieve pressure in the hydraulic 3
TN1363
system before performing service.
Figure 6-34
• Failure to follow appropriate safety
precautions may result in death or serious 3. Install blocking disk between hose (1) and tee fitting
injury. (3).
4. Open flow meter valve (2) completely.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (207 bar)
• -10 ORFS Tee Fitting
• -10 ORFS Blocking Disk

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform right wing cutting
unit circuit test, leaving flow meter connected as
outlined.

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 HYDRAULICS

9. Slowly close flow meter valve (2) until pressure

reaches 2250 psi (155 bar). Read and record the
right wing cutting unit pump loaded flow.
10. Open flow meter valve (2), disengage switches, and
stop engine.
11. Calculate right wing cutting unit pump leakage.
(Step 13 of previous test – Step 9 / Step 13 of
previous test x 100 = Leak Percentage)
Is right wing cutting unit pump leakage 10% or
less?
YES The right wing cutting unit pump is good.
Proceed to “Right Wing Cutting Unit Deck
Valve Test” on page 6-40.
NO Proceed to next question.
Is right wing cutting unit pump leakage 11% to
20%?
YES The right wing cutting unit pump is marginal.
Additional testing is required. Proceed to
“Right Wing Cutting Unit Deck Valve Test” on
page 6-40.
NO Proceed to next question.
Is right wing cutting unit pump leakage 21% or
more?
YES Repair or replace right wing cutting unit
pump. (See “Gear Pump” on page 6-58.)
Then proceed to “Right Wing Cutting Unit
Deck Valve Test” on page 6-40.

6 Figure 6-35: Right Wing Cutting Unit Pump Test—

Blocking Disk Between Pump and Deck Valve
TN2078

Right Wing Cutting Unit Deck Valve

Test
5. Bypass seat switch and set park brake.
See Figures 6-36 through 6-38.
NOTE
Verify engine rpm is within specification (2800 rpm ± 50) ! WARNING
to ensure accurate hydraulic test results. The hydraulic system is under pressure, and the
6. Start engine and run at full throttle (2800 rpm ± 50). oil will be hot.
7. Use the flow meter to warm the hydraulic oil. Turn the • Always relieve pressure in the hydraulic
flow meter valve until a reading of 1500 psi (103 bar) system before performing service.
or one half of the relief valve rating is reached. Warm • Failure to follow appropriate safety
oil to 120—150° F (49—65° C); open valve fully after precautions may result in death or serious
operating temperature is reached. injury.

! CAUTION
Required Tools and Materials
Do not exceed 3350 psi (231 bar) when testing
pump or equipment damage may occur. • Flow Meter
• -10 ORFS Test Hose 3000 psi (207 bar)
8. Enable wing mower deck switch and engage PTO • -10 ORFS Tee Fitting
switch. • -10 ORFS Blocking Disk

6-40 4203780 First Edition

 HYDRAULICS

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform right wing cutting
unit pump test, leaving flow meter connected as
outlined.

TN2062
Figure 6-36
3. Install blocking disk at fitting (1) on right wing cutting
unit outside motor, blocking oil flow from entering
right wing cutting unit outside motor.

Figure 6-38: Right Wing Cutting Unit Deck Valve

Test—Blocking Disk at Outside Cutting Unit Motor
TN2079
6
5. Bypass seat switch and set park brake.

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
6. Start engine and run at full throttle (2800 rpm ± 50).
2
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (2) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
TN1363
Warm oil to 120—150° F (49—65° C); open valve
Figure 6-37 fully after operating temperature is reached.
4. Open flow meter valve (2) completely. 8. Enable wing mower deck switch and engage PTO
switch.
9. Slowly close flow meter valve (2) until pressure
reaches 2250 psi (155 bar). Read and record the
right wing cutting unit pump loaded flow.
10. Open flow meter valve (2), disengage switches, and
stop engine.

4203780 First Edition 6-41

 HYDRAULICS

11. Calculate right wing cutting unit deck valve leakage. Adjust Right Wing Cutting Unit Deck
(Step 9 of previous test – Step 9 / Step 9 of previous
test x 100 = Leak Percentage) Valve System Relief Valve Pressure
See Figure 6-39.
Is right wing cutting unit deck valve leakage 10%
or less?
YES The right wing cutting unit deck valve is
! WARNING
good. Proceed to step 12. The hydraulic system is under pressure, and the
NO Proceed to next question. oil will be hot.
• Always relieve pressure in the hydraulic
Is right wing cutting unit deck valve leakage 11%
system before performing service.
to 20%?
• Failure to follow appropriate safety
YES The right wing cutting unit deck valve is
precautions may result in death or serious
marginal. Additional testing is required.
injury.
Proceed to step 12.
NO Proceed to next question.
Is right wing cutting unit deck valve leakage 21% Required Tools and Materials
or more?
• Flow Meter
YES Repair or replace right wing cutting unit deck
valve. (See “Right Deck Valve” on • -10 ORFS Test Hose 3600 psi (248 bar)
page 6-64.) Then proceed to step 12. • -10 ORFS Tee Fitting
• -10 ORFS Blocking Disk
! CAUTION
Do not exceed 3350 psi (231 bar) when testing
system relief valve or equipment damage may
NOTE
occur. This adjustment should be done in conjunction with right
cutting unit circuit valve tests.
12. Start engine and run at full throttle (2800 rpm ± 50). 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
6 13. Enable wing mower deck switch and engage PTO
switch. 2. Perform right wing cutting unit deck valve test. (See
“Right Wing Cutting Unit Deck Valve Test” on
14. Continue to close flow meter valve (2) until zero flow page 6-40.)
is obtained. Record cutting unit system relief valve
pressure.
15. Open flow meter valve (2), disengage switches, and
stop engine.
1
Is right wing cutting unit deck valve system relief
valve pressure 2700 psi (186 bar) to 3300 psi (228 2
bar)?
YES Right wing cutting unit deck valve system
relief valve is good. Proceed to “Right Wing
Cutting Unit Motors Test” on page 6-43.
NO Adjust right wing cutting unit deck valve
system relief pressure. (See “Adjust Right
Wing Cutting Unit Deck Valve System Relief
Valve Pressure” on page 6-42.) Then
proceed to “Right Wing Cutting Unit Motors
Test” on page 6-43.
TN2060
Figure 6-39
3. Loosen nut (1).

6-42 4203780 First Edition

 HYDRAULICS

4. Rotate screw (2) to adjust the relief valve pressure 2. Before performing this test, perform right wing cutting
setting. unit deck valve test, leaving flow meter connected as
To increase the pressure setting: Turn the screw outlined.
in (clockwise). 3. Bypass seat switch and set park brake.
To decrease the pressure setting: Turn the screw
out (counterclockwise). ! WARNING
5. Tighten nut (1). Safely block cutting unit from rotating using a
Could right wing cutting unit deck valve system suitable device or tool. Failure to follow
relief valve be adjusted to 2700 psi (186 bar) to appropriate safety precaution may result in death
3300 psi (228 bar)? or serious injury.
YES Right wing cutting unit deck valve system
relief valve is good. Proceed to “Right Wing 4. Install suitable blocking device or tool in right wing
Cutting Unit Motors Test” on page 6-43. cutting unit outside motor, preventing right wing
NO Repair or replace right wing cutting unit deck cutting unit outside motor from turning.
valve system relief valve. (See “Right Deck
Valve” on page 6-64.) Then proceed to
“Right Wing Cutting Unit Motors Test” on
page 6-43.

Right Wing Cutting Unit Motors Test

See Figures 6-40 through 6-42.

IMPORTANT
• This test works together with the right wing
cutting unit circuit test to isolate a problem with
the right wing cutting units motors. 1
• Performing this test will isolate the right wing
cutting unit motors from the rest of the right wing
cutting units circuit.
Figure 6-40
TN1363 6
! WARNING 5. Open flow meter valve (1) completely.
The hydraulic system is under pressure, and the
oil will be hot.
• Always relieve pressure in the hydraulic
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (255 bar)
• -10 ORFS Tee Fitting
• Blocking Device or Tool

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)

4203780 First Edition 6-43

 HYDRAULICS

test x 100 = Leak Percentage)

Is right wing cutting unit outside motor leakage
10% or less?
YES The right wing cutting unit outside motor is
good. Proceed to step 12.
NO Proceed to next question.
Is right wing cutting unit outside motor leakage
11% to 20%?
YES The right wing cutting unit outside motor is
marginal. Additional testing is required.
Proceed to step 12.
NO Proceed to next question.
Is right wing cutting unit outside motor leakage
21% or more?
YES Repair or replace right wing cutting unit
outside motor. (See “Deck Motors” on
page 6-61.) Then proceed to step 12.
12. Remove device or tool from right wing cutting unit
outside motor.
13. Bypass seat switch and set park brake.

! WARNING
Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
or serious injury.

6 Figure 6-41: Right Wing Cutting Unit Motors Test—

Outside Cutting Unit Motor Blocked
TN2077

14. Install suitable blocking device or tool in right wing

cutting unit inside motor, preventing right wing cutting
unit inside motor from turning.
NOTE 15. Open flow meter valve (1) completely.
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
6. Start engine and run at full throttle (2800 rpm ± 50).
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
8. Enable wing mower deck switch and engage PTO
switch.
9. Slowly close flow meter valve (1) until pressure
reaches 2250 psi (155 bar). Read and record the
right wing cutting unit outside motor loaded flow.
10. Open flow meter valve (1), disengage switches, and
stop engine.
11. Calculate right wing cutting unit outside motor
leakage.
(Step 9 of right wing cutting unit deck valve test –
Step 9 / Step 9 of right wing cutting unit deck valve

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 HYDRAULICS

21. Calculate right wing cutting unit inside motor

leakage.
(Step 9 – Step 19 / Step 9 x 100 = Leak Percentage)
Is right wing cutting unit inside motor leakage
10% or less?
YES The right wing cutting unit inside motor is
good. Proceed to step 22.
NO Proceed to next question.
Is right wing cutting unit inside motor leakage
11% to 20%?
YES The right wing cutting unit inside motor is
marginal. Determine component(s) with
greatest leakage and repair or replace as
necessary.
NO Proceed to next question.
Is right wing cutting unit inside motor leakage
21% or more?
YES Repair or replace right wing cutting unit
inside motor. (See “Deck Motors” on
page 6-61.)
22. Remove device or tool from right wing cutting unit
inside motor.
23. Disconnect and remove test equipment. Install all
hoses and fittings as noted prior to removal.
24. Install and connect all components as noted prior to
test.

Figure 6-42: Right Wing Cutting Unit Motors Test—

Inside Cutting Unit Motor Blocked
TN2080 25. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for
correct oil specifications.)
6
NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
16. Start engine and run at full throttle (2800 rpm ± 50).
17. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
18. Enable wing mower deck switch and engage PTO
switch.
19. Slowly close flow meter valve (1) until pressure
reaches 2250 psi (155 bar). Read and record the
right wing cutting unit inside motor loaded flow.
20. Open flow meter valve (1), disengage switches, and
stop engine.

4203780 First Edition 6-45

 HYDRAULICS

Left Wing Cutting Unit Circuit Test

See Figures 6-43 through 6-45.

IMPORTANT
• This test works together with the left cutting unit 3
motors test to isolate a problem with the left
cutting unit circuit.
• Performing this test will isolate the left wing
cutting unit pump, deck valve, and left wing
cutting unit inside motor from the rest of the left
wing cutting unit circuit. 4

! WARNING 6 5
TN1363
The hydraulic system is under pressure, and the
Figure 6-44
oil will be hot.
• Always relieve pressure in the hydraulic 4. Install tee fitting (5) to fitting (2).
system before performing service. 5. Connect test hose (6) of flow meter inlet and hose (1)
• Failure to follow appropriate safety to tee fitting (5).
precautions may result in death or serious
injury. NOTE
Make sure hose end is under oil level in hydraulic tank to
prevent aeration of oil.
Required Tools and Materials 6. Secure flow meter outlet hose (3) to the hydraulic
tank fillneck.
• Flow Meter
• -10 ORFS Test Hose 3600 psi (248 bar)
• -10 ORFS Tee Fitting
! WARNING

6 • Blocking Device or Tool Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
1. Park the mower safely. (See “Park Mower Safely” on or serious injury.
page 1-6.)
2. Remove the seat and seat platform. (See “Seat and
7. Install suitable blocking device or tool in left wing
Seat Platform” on page 9-13.)
cutting unit inside motor, preventing left wing cutting
unit inside motor from turning.
8. Open flow meter valve (4) completely.

TN2047
Figure 6-43
3. Disconnect hose (1) from fitting (2).

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 HYDRAULICS

16. Calculate left wing cutting unit circuit leakage.

(Step 13 – Step 14 / Step 13 x 100 = Leak
Percentage)
Is left wing cutting unit circuit leakage 10% or
less?
YES The left wing cutting unit circuit is good.
Proceed to “Left Wing Cutting Unit Motors
Test” on page 6-52.
NO Proceed to next question.
Is left wing cutting unit circuit leakage 11% to
20%?
YES The left wing cutting unit circuit is marginal.
Additional testing is required. Proceed to
“Left Wing Cutting Unit Pump Test” on
page 6-47.
NO Proceed to next question.
Is left wing cutting unit circuit leakage 21% or
more?
YES Test individual components in left wing
cutting unit circuit for leakage. Proceed to
“Left Wing Cutting Unit Pump Test” on
page 6-47.

Left Wing Cutting Unit Pump Test

See Figures 6-46 through 6-48.

! WARNING
Figure 6-45: Left Wing Cutting Unit Circuit Test—
Inside Cutting Unit Motor Blocked
TN2077
The hydraulic system is under pressure, and the
oil will be hot.
6
9. Bypass seat switch and set park brake. • Always relieve pressure in the hydraulic
system before performing service.
NOTE • Failure to follow appropriate safety
Verify engine rpm is within specification (2800 rpm ± 50) precautions may result in death or serious
to ensure accurate hydraulic test results. injury.
10. Start engine and run at full throttle (2800 rpm ± 50).
11. Use the flow meter to warm the hydraulic oil. Turn the
Required Tools and Materials
flow meter valve (4) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached. • Flow Meter
Warm oil to 120—150° F (49—65° C); open valve • -10 ORFS Test Hose 3600 psi (207 bar)
fully after operating temperature is reached.
• -10 ORFS Tee Fitting
12. Enable wing mower deck switch and engage PTO
switch. • -10 ORFS Blocking Disk
13. Read and record the left wing cutting unit circuit no
load flow. 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
14. Slowly close flow meter valve (4) until pressure
reaches 2250 psi (155 bar). Read and record the left 2. Before performing this test, perform left wing cutting
wing cutting unit circuit loaded flow. unit circuit test, leaving flow meter connected as
outlined.
15. Open flow meter valve (4), disengage switches, and
stop engine.

4203780 First Edition 6-47

 HYDRAULICS

TN2047
Figure 6-46

6 2
Figure 6-48: Left Wing Cutting Unit Pump Test—
Blocking Disk Between Pump and Deck Valve
TN2078

3
TN1363 5. Bypass seat switch and set park brake.
Figure 6-47
NOTE
3. Install blocking disk between hose (1) and tee fitting
Verify engine rpm is within specification (2800 rpm ± 50)
(3).
to ensure accurate hydraulic test results.
4. Open flow meter valve (2) completely.
6. Start engine and run at full throttle (2800 rpm ± 50).
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve until a reading of 1500 psi (103 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C); open valve fully after
operating temperature is reached.
8. Enable wing mower deck switch and engage PTO
switch.

6-48 4203780 First Edition

 HYDRAULICS

Left Wing Cutting Unit Deck Valve

! CAUTION
Test
Do not exceed 3350 psi (231 bar) when testing
See Figures 6-49 through 6-51.
pump or equipment damage may occur.
! WARNING
9. Slowly close flow meter valve (2) until pressure
The hydraulic system is under pressure, and the
reaches 2250 psi (155 bar). Read and record the left
oil will be hot.
wing cutting unit pump loaded flow.
• Always relieve pressure in the hydraulic
10. Open flow meter valve (2), disengage switches, and
system before performing service.
stop engine.
• Failure to follow appropriate safety
11. Calculate left cutting unit pump leakage.
precautions may result in death or serious
(Step 13 of previous test – Step 9 / Step 13 of
injury.
previous test x 100 = Leak Percentage)
Is left wing cutting unit pump leakage 10% or
less? Required Tools and Materials
YES The left wing cutting unit pump is good.
Proceed to “Left Wing Cutting Unit Deck • Flow Meter
Valve Test” on page 6-49. • -10 ORFS Test Hose 3000 psi (207 bar)
NO Proceed to next question. • -10 ORFS Tee Fitting
Is left wing cutting unit pump leakage 11% to • -10 ORFS Blocking Disk
20%?
YES The left wing cutting unit pump is marginal. 1. Park the mower safely. (See “Park Mower Safely” on
Additional testing is required. Proceed to page 1-6.)
“Left Wing Cutting Unit Deck Valve Test” on 2. Before performing this test, perform left wing cutting
page 6-49. unit pump test, leaving flow meter connected as
NO Proceed to next question. outlined.

Is left wing cutting unit pump leakage 21% or

more? 6
YES Repair or replace left wing cutting unit pump. 1
(See “Gear Pump” on page 6-58.) Then
proceed to “Left Wing Cutting Unit Deck
Valve Test” on page 6-49.

TN2063
Figure 6-49
3. Install blocking disk at fitting (1) on left wing inside
cutting unit motor, blocking oil flow from entering left
wing inside cutting unit motor.

4203780 First Edition 6-49

 HYDRAULICS

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
6. Start engine and run at full throttle (2800 rpm ± 50).
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (2) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
2 8. Enable wing mower deck switch and engage PTO
switch.
9. Slowly close flow meter valve (2) until pressure
TN1363 reaches 2250 psi (155 bar). Read and record the left
Figure 6-50 wing cutting unit pump loaded flow.
10. Open flow meter valve (2), disengage switches, and
4. Open flow meter valve (2) completely.
stop engine.
11. Calculate left wing cutting unit deck valve leakage.
(Step 9 of previous test – Step 9 / Step 9 of previous
test x 100 = Leak Percentage)
Is left wing cutting unit deck valve leakage 10%
or less?
YES The left wing cutting unit deck valve is good.
Proceed to step 12.
NO Proceed to next question.
Is left wing cutting unit deck valve leakage 11% to
20%?

6 YES The left wing cutting unit deck valve is

marginal. Additional testing is required.
Proceed to step 12.
NO Proceed to next question.
Is left wing cutting unit deck valve leakage 21%
or more?
YES Repair or replace left wing cutting unit deck
valve. (See “Left Deck Valve” on page 6-65.)
Then proceed to step 12.

! CAUTION
Do not exceed 3350 psi (231 bar) when testing
system relief valve or equipment damage may
occur.

12. Start engine and run at full throttle (2800 rpm ± 50).
TN2079 13. Enable wing mower deck switch and engage PTO
Figure 6-51: Left Wing Cutting Unit Deck Valve switch.
Test—Blocking Disk at Inside Cutting Unit Motor 14. Continue to close flow meter valve (2) until zero flow
5. Bypass seat switch and set park brake. is obtained. Record left wing cutting unit deck valve
system relief valve pressure.

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 HYDRAULICS

15. Open flow meter valve (2), disengage switches, and

stop engine.
1
Is left wing cutting unit deck valve system relief
valve pressure 2700 psi (186 bar) to 3300 psi (228 2
bar)?
YES Left wing cutting unit deck valve system relief
valve is good. Proceed to “Left Wing Cutting
Unit Motors Test” on page 6-52
NO Adjust left wing cutting unit deck valve
system relief valve pressure. (See “Lift/Steer
System Relief Valve Pressure Test” on
page 6-54.)

Adjust Left Wing Cutting Unit Deck

Valve System Relief Valve Pressure TN2061

See Figure 6-52. Figure 6-52

!
3. Loosen nut (1).
WARNING 4. Rotate screw (2) to adjust the relief valve pressure
The hydraulic system is under pressure, and the setting.
oil will be hot. To increase the pressure setting: Turn the screw
• Always relieve pressure in the hydraulic in (clockwise).
system before performing service. To decrease the pressure setting: Turn the screw
• Failure to follow appropriate safety out (counterclockwise).
precautions may result in death or serious 5. Tighten nut (1).
injury.
Could relief valve be adjusted to 2700 psi (186
bar) to 3300 psi (228 bar)?

• Flow Meter
Required Tools and Materials YES Left wing cutting unit deck valve system relief
valve is good. Proceed to “Left Wing Cutting 6
Unit Motors Test” on page 6-52.
• -10 ORFS Test Hose 3600 psi (248 bar) NO Repair or replace left wing cutting unit deck
• -10 ORFS Tee Fitting valve system relief valve. (See “Left Deck
Valve” on page 6-65.) Then proceed to “Left
• -10 ORFS Blocking Disk
Wing Cutting Unit Motors Test” on
page 6-52.
NOTE
This adjustment should be done in conjunction with left
wing cutting unit deck valve test.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Perform left wing cutting unit deck valve test. (See
“Left Wing Cutting Unit Deck Valve Test” on
page 6-49.)

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 HYDRAULICS

Left Wing Cutting Unit Motors Test

See Figures 6-53 through 6-55.

IMPORTANT
• This test works together with the left wing cutting
unit circuit test to isolate a problem with the left
wing cutting unit motors.
• Performing this test will isolate the left wing
cutting unit motors from the rest of the left wing
cutting units circuit.
1
! WARNING
The hydraulic system is under pressure, and the TN1363
oil will be hot. Figure 6-53
• Always relieve pressure in the hydraulic
5. Open flow meter valve (1) completely.
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
injury.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 3600 psi (255 bar)
• -10 ORFS Tee Fitting
• Blocking Device or Tool

6 1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Before performing this test, perform left wing cutting
unit deck valve test, leaving flow meter connected as
outlined.
3. Bypass seat switch and set park brake.

! WARNING
Safely block cutting unit from rotating using a
suitable device or tool. Failure to follow
appropriate safety precaution may result in death
or serious injury.

4. Install suitable blocking device or tool in left wing

cutting unit inside motor, preventing left wing cutting
unit inside motor from turning. TN2077
Figure 6-54: Left Wing Cutting Unit Motors Test—
Inside Cutting Unit Motor Blocked

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 HYDRAULICS

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
6. Start engine and run at full throttle (2800 rpm ± 50).
7. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (1) until a reading of 1500 psi (103
bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
fully after operating temperature is reached.
8. Enable wing mower deck switch and engage PTO
switch.
9. Slowly close flow meter valve (1) until pressure
reaches 2250 psi (155 bar). Read and record the left
wing cutting unit inside motor loaded flow.
10. Open flow meter valve (1), disengage switches, and
stop engine.
11. Calculate left wing cutting unit inside motor leakage.
(Step 9 of left wing cutting unit deck valve test –
Step 9 / Step 9 of left wing cutting unit deck valve test
x 100 = Leak Percentage)
Is left wing cutting unit inside motor leakage 10%
or less?
YES The left wing cutting unit inside motor is
good. Proceed to step 12.
NO Proceed to next question.
Is left wing cutting unit inside motor leakage 11%
to 20%?
YES The left wing cutting unit inside motor is Figure 6-55: Left Wing Cutting Unit Motors Test—
Outside Cutting Unit Motor Blocked
TN2080
6
marginal. Additional testing is required.
Proceed to step 12. 15. Bypass seat switch and set park brake.
NO Proceed to next question.
Is left wing cutting unit inside motor leakage 21%
NOTE
or more? Verify engine rpm is within specification (2800 rpm ± 50)
YES Repair or replace left wing cutting unit inside to ensure accurate hydraulic test results.
motor. (See “Deck Motors” on page 6-61.) 16. Start engine and run at full throttle (2850 rpm ± 50).
Then proceed to step 12. 17. Use the flow meter to warm the hydraulic oil. Turn the
12. Remove device or tool from left wing cutting unit flow meter valve (1) until a reading of 1500 psi (103
inside motor. bar) or one half of the relief valve rating is reached.
Warm oil to 120—150° F (49—65° C); open valve
! WARNING fully after operating temperature is reached.
18. Enable wing mower deck switch and engage PTO
Safely block cutting unit from rotating using a switch.
suitable device or tool. Failure to follow
19. Slowly close flow meter valve (1) until pressure
appropriate safety precaution may result in death
reaches 2250 psi (155 bar). Read and record the left
or serious injury.
cutting unit outside motor loaded flow.
20. Open flow meter valve (1), disengage switches, and
13. Install suitable blocking device or tool in left cutting stop engine.
unit outside motor, preventing left cutting unit outside
motor from turning.
14. Open flow meter valve (1) completely.

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 HYDRAULICS

21. Calculate left outside cutting unit motor leakage. Lift/Steer System Relief Valve
(Step 9 – Step 19 / Step 9 x 100 = Leak Percentage)
Pressure Test
Is left outside cutting unit motor leakage 10% or
See Figures 6-56 and 6-57.
less?
YES The left outside cutting unit motor is good. NOTE
Proceed to step 22. Before performing this test perform field test procedures.
NO Proceed to next question. (See “Field Test Procedures” on page 6-24.)
Is left outside cutting unit motor leakage 11% to
20%? ! WARNING
YES The left outside cutting unit motor is The hydraulic system is under pressure, and the
marginal. Determine component(s) with oil will be hot.
greatest leakage and repair or replace
component(s) as necessary. • Always relieve pressure in the hydraulic
system before performing service.
NO Proceed to next question.
• Failure to follow appropriate safety
Is left outside cutting unit motor leakage 21% or precautions may result in death or serious
more? injury.
YES Repair or replace left outside cutting unit
motor. (See “Deck Motors” on page 6-61.)
22. Remove device or tool from left cutting unit outside Required Tools and Materials
motor.
• Pressure Gauge 5000 psi (345 bar)
23. Disconnect and remove test equipment. Install all
• -10 ORFS Test Hose 5000 psi (345 bar)
hoses and fittings as noted prior to removal.
• -10 ORFS Tee Fitting
24. Install and connect all components as noted prior to
test.
1. Operate hydraulic system until oil temperature is at
25. Check hydraulic oil level. Add oil as needed. (Refer to
120—150° F (49—65° C).
“Safety, Operation, and Maintenance Manual” for
2. Park the mower safely. (See “Park Mower Safely” on
6 correct oil specifications.)
page 1-6.)
3. Raise the seat.

2
1

TN1862
Figure 6-56

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 HYDRAULICS

! CAUTION
3 Do not run mower steer system relief valve over
relief longer than 10 seconds or damage may
occur to hydraulic system.

12. Turn the steering wheel fully right against stop.

13. Record pressure reading.
14. Stop engine.
Is steer system relief pressure 1450 psi (100
bar)?
YES Steer system relief valve is good. Proceed to
TN1275 step 15.
Figure 6-57 NO Test lift/steer pump. (See “Lift/Steer Pump
4. Install tee fitting between fitting (2) and hose (1). Test” on page 6-56.) Test steer cylinder. (See
5. Connect test hose from tee fitting to pressure gauge “Steering Leakage Test” on page 7-7.)
(3). Repair or replace steering valve. (See
“Steering Valve” on page 7-8.)
6. Set park brake.
15. Disconnect and remove test equipment. Install all
NOTE hoses and fittings as noted prior to removal.
16. Install and connect all components as noted prior to
Verify engine rpm is within specification (2800 rpm ± 50)
test.
to ensure accurate hydraulic test results.
17. Check hydraulic oil level. Add oil as needed. (Refer to
7. Start engine and run at full throttle (2800 rpm ± 50).
“Safety, Operation, and Maintenance Manual” for

!
correct oil specifications.)
CAUTION
Do not run mower lift system relief valve over
relief longer than 10 seconds or damage may
occur to hydraulic system.
6
8. Raise the front deck and hold lever in the raise
position.
9. Record pressure reading.
10. Stop engine.
Is lift system relief pressure 1500 psi (103 bar)?
YES Lift system relief valve is good. Proceed to
step 12.
NO Test lift/steer pump. (See “Lift/Steer Pump
Test” on page 6-56.) Test lift cylinders. (See
“Front Lift Cylinders Leakage Test” on
page 6-24.) Replace lift system relief valve.
(See “Lift Valve” on page 6-62.)

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
11. Start engine and run at full throttle (2800 rpm ± 50).

4203780 First Edition 6-55

 HYDRAULICS

Lift/Steer Pump Test

3
See Figures 6-58 and 6-59.

NOTE
Before performing this test perform field test procedures.
(See “Field Test Procedures” on page 6-24.)

! WARNING
The hydraulic system is under pressure, and the 4
oil will be hot.
5
• Always relieve pressure in the hydraulic TN1359
system before performing service.
Figure 6-59
• Failure to follow appropriate safety
precautions may result in death or serious 4. Connect flow meter inlet test hose (5) to fitting (2).
injury. 5. Connect flow meter outlet test hose (3) to hose (1).
6. Open flow meter valve (4) completely.

Required Tools and Materials

• Flow Meter
• -10 ORFS Test Hose 2000 psi (138 bar)

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Raise the seat.

6
2
1

TN1862
Figure 6-58
3. Disconnect hose (1) from fitting (2).
TN2121
Figure 6-60: Lift Steer Pump Test
7. Set park brake.

NOTE
Verify engine rpm is within specification (2800 rpm ± 50)
to ensure accurate hydraulic test results.
8. Start engine and run at full throttle (2800 rpm ± 50).

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 HYDRAULICS

! CAUTION
Do not exceed 1500 psi (103 bar) as this test does
not utilize system relief.

9. Use the flow meter to warm the hydraulic oil. Turn the
flow meter valve (4) until a reading of 750 psi (52 bar)
or one half of the relief valve rating is reached. Warm
oil to 120—150° F (49—65° C).
10. Open flow meter valve (4) completely. Read and
record the lift/steer pump no load flow.
11. Slowly close flow meter valve (4) until pressure
reaches 1125 psi (78 bar). Read and record the
lift/steer pump loaded flow.
12. Open flow meter valve (4) and stop engine.
13. Calculate lift/steer pump leakage.
(Step 10 – Step 11 / Step 10 x 100 = Leak
Percentage)
Is lift/steer pump leakage 10% or less?
YES The lift/steer pump is good. Proceed to
step 14.
NO Proceed to next question.
Is lift/steer pump leakage 11% to 20%?
YES The lift/steer pump is marginal. Additional
testing is required. (See “Field Test
Procedures” on page 6-24.)
NO Proceed to next question.
Is lift/steer pump leakage 21% or more?
6
YES Repair or replace lift/steer pump. (See “Gear
Pump” on page 6-58.)
14. Disconnect and remove test equipment. Install all
hoses and fittings as noted prior to removal.
15. Install and connect all components as noted prior to
test.
16. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for
correct oil specifications.)

4203780 First Edition 6-57

 HYDRAULICS

Repair Installation Notes

• Ensure new O-ring is in place before installing hose
on fitting.
Hydraulic Oil Tank—Drain Procedure
• Connect hose (1).
See Figure 6-61.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
1. Park the mower safely. (See “Park Mower Safely” on Return Filter” on page 6-67.)
page 1-6.)
• Replace charge pressure filter. (See “Charge
2. Block both sides of rear wheels using suitable wheel Pressure Filter” on page 6-68.)
blocks.
• Refill hydraulic tank. (Refer to “Safety, Operation, and
3. Raise and support front of mower with jackstands. Maintenance Manual” for oil specifications.)
• Start engine. Check hydraulic system for leaks.
Repair as necessary.
Check hydraulic oil level and add if necessary.

Gear Pump
Removal and Installation
See Figures 6-62 and 6-63.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove the seat and mount plate. (See “Seat and
1 2
Seat Platform” on page 9-13.)
3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank—
TN2053 Drain Procedure” on page 6-58.)
Figure 6-61

NOTES
6 • Label all hydraulic hoses and tubes before
disconnecting to aid in installation. 1
2

• Close all openings with caps or plugs to prevent

contamination. 7
• Have a #8 cap available to seal the 90° control valve
fitting.
• The hydraulic oil tank capacity is 17 gallons (64.3
liters). Use appropriate containers when draining
hydraulic oil.
4. Place a suitable container underneath control valve 5 4
6 3
(2) and hose (1).
TN1862
5. Disconnect hose (1) and plug the 90° control valve Figure 6-62
fitting.
6. Loosen the hydraulic oil tank cap to provide a vent for
NOTES
draining oil.
• Label all hydraulic hoses and tubes before
disconnecting to aid in installation.
• Close all openings with caps or plugs to prevent
contamination.
4. Disconnect hoses (1 and 2).
5. Disconnect hoses (3, 5, and 6).
6. Disconnect tube (4).
7. Support gear pump (7).

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 HYDRAULICS

10
11

13 12

TN1865
Figure 6-63
8. Remove gear pump strap (8).
9. Remove two screws (13) and lock washers (12).
10. Remove gear pump (7).
11. Remove gasket (11), flange adapter (10), and O-ring
(9).
Installation Notes
• Install gear pump by reversing the order of removal.
• Make sure new O-rings are in place before installing
hoses on fittings.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
6
Return Filter” on page 6-67.)
• Replace charge pressure filter. (See “Charge
Pressure Filter” on page 6-68.)
• Refill hydraulic tank. (Refer to “Safety, Operation, and
Maintenance Manual” for oil specifications.)
• Install seat and mounting plate.
• Start engine. Check hydraulic system for leaks.
Repair as necessary.
• Check hydraulic oil level and add if necessary.

4203780 First Edition 6-59

 HYDRAULICS

Disassembly, Inspection, and Assembly

See Figures 6-64 and 6-65.

8
7 4
6
4 5
3
2
1
11
1
10 7 4

6
4 5
1 2

4
7
10 1
6 10
3

6 1
11 11
1
3 5

7 1

4 12
2
4
2

4
10
3
14 1
13

TN1816
1 Seal Ring (8) 5 Coupling (3) 9 Screw (8) 13 Front Cover/Flange
2 Pre-Load Seal (4) 6 Gear Set (3) 10 Dowel Pin (8) 14 Shaft Seal
3 Load Seal (4) 7 Gear Plate (4) 11 Body (3)
4 Wear Plate (8) 8 Rear Cover Assembly 12 Gear Set (Drive Shaft)
Figure 6-64

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 HYDRAULICS

Disassembly Notes Assembly Notes

• Do not disassemble pump for repair unless test
procedures indicate internal leakage. NOTICE
• Never pry components apart. Use a soft face It is important that all component parts are
hammer, and gently tap housing and shaft to absolutely clean, as contamination can result in
separate pump bodies. serious damage and/or improper operation.
• Scribe or mark the pump bodies and end covers Never use shop towels or rags to dry parts after
before disassembly to aid in assembly. cleaning, as lint may clog passages. Dry parts
Recommended method of marking body sections is using compressed air.
to use a fine point metal punch, making one
indentation for section #1, two indentations for
section #2, etc. Required Materials

Seal Kit (Jacobsen PN 2721419)

• Assemble the gear pump by reversing the order of

disassembly.
• Use a new seal kit during assembly.
• Apply a coat of clean hydraulic oil to all parts to ease
assembly.
• Assemble pump one section at a time, building up
from flange section.
• Remove alignment mark from gear sets after gears
TN1384 have been installed with teeth in proper mesh.
Figure 6-65 • Rotate drive shaft by hand after assembling each
1. After removing bolts, disassemble pump, one section section to make sure there is no binding between
at a time. Before removing gear set, mark a line parts; do not force.
across meshing teeth to ensure that gears are • Use extreme care when installing shaft seal. Seal
reassembled in the same position.
2. Place parts in assembly order, on a clean work area
must seat squarely in seal bore. Use caution not to
damage seal when installing cover over pump shaft.
6
as they are removed. • Install retaining bolts finger-tight and rotate drive
3. Discard seals as they are removed. shaft to make sure it turns freely. Tighten bolts evenly
in steps to a final torque of 20 lb-ft (27 N·m) and
check rotation of pump drive shaft.
NOTICE
• Lubricate pump through ports with clean hydraulic oil
It is important that all components are absolutely prior to installing.
clean, as contamination can result in serious
damage and/or improper operation.
Deck Motors
Never use shop towels or rags to dry parts after
cleaning, as lint may clog passages. Dry parts Removal and Installation
using compressed air.
NOTE
4. Clean all parts using clean solvent and dry using See Chapter 8—Cutting Units for deck motor service
compressed air. information. (See “Deck Motor” on page 8-16.)
5. Inspect all parts for wear or damage. Replace the
gear pump as a unit if any parts other than seals
require replacement.

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 HYDRAULICS

Lift Valve Installation Notes

• Install the lift valve by reversing the order of removal.
Removal and Installation • Make sure new O-rings are in place before installing
See Figure 6-66. hoses on fittings.
1. Park the mower safely. (See “Park Mower Safely” on • Replace hydraulic oil return filter. (See “Hydraulic Oil
page 1-6.) Return Filter” on page 6-67.)
2. Remove fuel tank. (See “Fuel Tank” on page 9-7.) • Refill hydraulic tank. (Refer to “Safety, Operation, and
3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Maintenance Manual” for oil specifications.)
Drain Procedure” on page 6-58.) • Start engine. Check hydraulic system for leaks.
Repair as necessary.
• Check hydraulic oil level and add if necessary.
1

8
2
7
6 1
5 3

TN1837
Figure 6-66

6 NOTE
Label connectors before disconnecting to ensure correct
installation.
4. Disconnect electrical connectors (3).

NOTES
• Label hydraulic hoses to aid in installation.
• Close all openings with caps or plugs to prevent
contamination.
5. Disconnect hydraulic tube (4).
6. Disconnect hydraulic hoses (5—8).
7. Support lift valve (2).
8. Remove nuts, lock washers, and mounting screws
(1).
9. Remove lift valve (2).

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 HYDRAULICS

Disassembly, Inspection, and Assembly

See Figure 6-67.

8
9

7
5
4
10
3
2 11
1 6 14 13
12

26
25
28
24 27
23
6
21 22
18 20
16
17
15

19

TN1834
1 Plug (3) 8 Plug (3) 15 Cap (3) 22 Spool (3)
2 O-Ring (3) 9 Plug (3) 16 Retaining Ring (3) 23 Detent Plunger (3)
3 Spring (3) 10 Plug 17 Spacer (3) 24 Detent Spring (3)
4 Poppet (3) 11 Shim (3) 18 Spring (3) 25 O-Ring (3)
5 Seat (3) 12 Spring 19 Washer (3) 26 Plug (3)
6 Plunger 13 Poppet 20 Bushing (3) 27 O-Ring (6)
7 Plunger (2) 14 Seat 21 O-Ring (6) 28 Wiper Seal (3)
Figure 6-67

4203780 First Edition 6-63

 HYDRAULICS

1. Remove all fittings from the lift valve.

1 2
2. Remove, inspect, and replace lift valve components
as needed.
3. Clean all parts using clean solvent, and dry using
compressed air.
4. Inspect all parts for wear or damage. Replace parts 7 8 9
as needed.
Assembly Notes 6
NOTICE 3
It is important that all component parts are
absolutely clean, as contamination can result in 5 4
serious damage and/or improper operation. TN1868
Never use shop towels or rags to dry parts after Figure 6-68
cleaning, as lint may clog passages. Dry parts
using compressed air. NOTE
Label connector before disconnecting to ensure correct
installation.
Required Materials
4. Disconnect electrical connector (3) from solenoid.
• Seal Kit (Jacobsen PN 558010)
• Detent Kit (Jacobsen PN 5001612) NOTES
• Label all hydraulic hoses and tubes before
• Assemble the lift valve by reversing the order of disconnecting to aid in installation.
disassembly. • Close all openings with caps or plugs to prevent
• Use a new seal kit during assembly. contamination.
• Lubricate all O-rings prior to assembly. 5. Disconnect hydraulic hoses (1, 2, 4, and 5).

6 Right Deck Valve

6. Support the deck valve (6).
7. Remove mounting screws (7), washers (8), and nuts
(9).
Removal and Installation 8. Remove the deck valve (6).
See Figure 6-68. Installation Notes
1. Park the mower safely. (See “Park Mower Safely” on • Install the deck valve by reversing the order of
page 1-6.) removal.
2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— • Make sure new O-rings are in place before installing
Drain Procedure” on page 6-58.) hoses on fittings.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
NOTE Return Filter” on page 6-67.)
The right deck valve is located behind the front cross • Refill hydraulic tank. (Refer to “Safety, Operation, and
member. Maintenance Manual” for oil specifications.)
3. Thoroughly clean the valve, especially the area • Start engine. Check hydraulic system for leaks.
surrounding the hydraulic hoses, tubes, and fittings. Repair as necessary.
• Check hydraulic oil level and add if necessary.

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Left Deck Valve Installation Notes

• Install the deck valve by reversing the order of
Removal and Installation removal.
See Figure 6-69. • Make sure new O-rings are in place before installing
1. Park the mower safely. (See “Park Mower Safely” on hoses on fittings.
page 1-6.) • Replace hydraulic oil return filter. (See “Hydraulic Oil
2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Return Filter” on page 6-67.)
Drain Procedure” on page 6-58.) • Refill hydraulic tank. (Refer to “Safety, Operation, and
Maintenance Manual” for oil specifications.)
NOTE • Start engine. Check hydraulic system for leaks.
The left deck valve is located in front of front cross Repair as necessary.
member. • Check hydraulic oil level and add if necessary.
3. Thoroughly clean the valve, especially the area
surrounding the hydraulic hoses, tubes, and fittings.

2
3
1
4 5 6

10 7
9 6
4 5 6
8 TN1860
Figure 6-69

NOTE
Label connector before disconnecting to ensure correct
installation.
4. Disconnect electrical connector (7) from solenoid.

NOTES
• Label all hydraulic hoses and tubes before
disconnecting to aid in installation.
• Close all openings with caps or plugs to prevent
contamination.
5. Disconnect hydraulic hoses (1—3).
6. Disconnect hydraulic hoses (8 and 9).
7. Support the deck valve (10).
8. Remove mounting screws (4), washers (5), and nuts
(6).
9. Remove the deck valve (10).

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 HYDRAULICS

Front Deck Valve Installation Notes

• Install the deck valve by reversing the order of
Removal and Installation removal.
See Figure 6-70. • Make sure new O-rings are in place before installing
1. Park the mower safely. (See “Park Mower Safely” on hoses on fittings.
page 1-6.) • Replace hydraulic oil return filter. (See “Hydraulic Oil
2. Drain hydraulic oil tank. (See “Hydraulic Oil Tank— Return Filter” on page 6-67.)
Drain Procedure” on page 6-58.) • Refill hydraulic tank. (Refer to “Safety, Operation, and
3. Thoroughly clean the valve, especially the area Maintenance Manual” for oil specifications.)
surrounding the hydraulic hoses, tubes, and fittings. • Start engine. Check hydraulic system for leaks.
Repair as necessary.
• Check hydraulic oil level and add if necessary.

3
Disassembly, Inspection, and Assembly
2
See Figure 6-71.
1
NOTE
Note orientation and position of all hydraulic hose and
4 tube fittings.
9 1. Remove all hydraulic hose and tube fittings from the
deck valve.

7 6 5 8 7 6 5

6 TN1744
Figure 6-70

NOTE
Label connector before disconnecting to ensure correct
installation.
4. Disconnect electrical connector (8) from solenoid.

NOTES
• Label all hydraulic hoses and tubes before
disconnecting to aid in installation.
• Close all openings with caps or plugs to prevent
contamination.
5. Disconnect hydraulic hoses (1, 3, and 4).
6. Disconnect hydraulic tube (9).
7. Support the deck valve (2).
8. Remove the mounting screws (5), washers (6), and
nuts (7).
9. Remove the deck valve (2).

6-66 4203780 First Edition

 HYDRAULICS

Assembly Notes
2
NOTICE
It is important that all component parts are
absolutely clean, as contamination can result in
1 serious damage and/or improper operation.
Never use shop towels or rags to dry parts after
cleaning, as lint may clog passages. Dry parts
using compressed air.

Required Materials

• Seal Kit, Solenoid Valve (Jacobsen PN 5003579)

• Seal Kit, Relief Valve (Jacobsen PN 5003554)
• Seal Kit, Relief Valve (Jacobsen PN 5003579)

• Assemble the deck valve by reversing the order of

disassembly.
3
• Lubricate all O-rings prior to assembly.
• Tighten relief valve (2) to 33—37 lb-ft (44.7—
5
50.2 N·m).
• Tighten relief valve (5) to 24—26 lb-ft (32.5—
35.3 N·m).
4 • Tighten solenoid valve to 24-26 lb—ft (32.5—
35.3 N·m).
TN1760
• Tighten solenoid valve nut to 5—7 lb-ft (6.8—
1 Deck Valve Block 4 Mow Solenoid Coil
2
3
Relief Valve
Mow Solenoid Valve
5 Relief Valve

Figure 6-71
9.5 N·m).

Hydraulic Oil Return Filter

6
2. Clean all parts using clean solvent and dry using
compressed air.
Removal and Installation
3. Inspect all parts for wear or damage. Replace parts See Figure 6-72.
as needed. 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise engine hood.
3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank—
Drain Procedure” on page 6-58.)

4203780 First Edition 6-67

 HYDRAULICS

22 3 4 2 3 4
1
5
1

7
7
6 6

TN1765
Figure 6-72
TN1764
4. Disconnect electrical connectors (1). Figure 6-73

NOTES 4. Disconnect electrical connector (7).

• Label all hydraulic hoses and tubes to aid in NOTES
installation.
• Label all hydraulic hoses and tubes to aid in
• Close all openings with caps or plugs to prevent
installation.
contamination.
• Close all openings with caps or plugs to prevent
5. Disconnect hydraulic hoses (5 and 7).
contamination.
6. Support the oil filter assembly (6).
5. Disconnect hydraulic hose (1).
7. Remove two screws (2) and lock washers (3) and
6. Disconnect hydraulic tube (5).
four flat washers (4).
6 8. Remove oil filter assembly (6).
Installation Notes
7. Support the oil filter assembly (6).
8. Remove four screws (2), lock washers (3), and flat
washers (4).
• Install oil filter assembly by reversing the order of
9. Remove oil filter assembly (6).
removal.
Installation Notes
• Replace hydraulic oil filter.
• Install oil filter assembly by reversing the order of
• Refill hydraulic tank. (Refer to “Safety, Operation, and
removal.
Maintenance Manual” for oil specifications.)
• Replace hydraulic oil return filter. (See “Hydraulic Oil
• Start engine. Check hydraulic system for leaks.
Return Filter” on page 6-67.)
Repair as necessary.
• Refill hydraulic tank. (Refer to “Safety, Operation, and
• Check hydraulic oil level and add if necessary.
Maintenance Manual” for oil specifications.)
• Start engine. Check hydraulic system for leaks.
Charge Pressure Filter Repair as necessary.
• Check hydraulic oil level and add if necessary.
Removal and Installation
See Figure 6-73.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise engine hood.
3. Drain hydraulic oil tank. (See “Hydraulic Oil Tank—
Drain Procedure” on page 6-58.)

6-68 4203780 First Edition

 HYDRAULICS

Front Lift Cylinders Installation Notes

• Install lift cylinder by reversing the order of removal.
Removal and Installation • Make sure new O-rings are in place before installing
See Figure 6-74. hoses on fittings.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
! CAUTION Return Filter” on page 6-67.)
Care must be taken to avoid damaging the • Refill hydraulic tank. (Refer to “Safety, Operation, and
surface of the cylinder rod during removal and Maintenance Manual” for oil specifications.)
installation. • Start engine. Check hydraulic system for leaks.
Repair as necessary.
1. Lower cutting units. • Check hydraulic oil level and add if necessary.
2. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

4
3
Figure 6-74
TN1766
6
NOTES
• Label all hydraulic hoses before disconnecting to
ensure correct installation.
• All of the lift cylinders have an orifice installed
between the hose and the cylinder head end fitting.
Note the location of the orifice and recover the orifice
when removing the hydraulic hoses.
• Close all openings with caps or plugs to prevent
contamination.
3. Disconnect hydraulic hoses (3).
4. Support lift cylinder (1).
5. Remove pins (2 and 4).
6. Remove lift cylinder (1).

4203780 First Edition 6-69

 HYDRAULICS

Disassembly, Inspection, and Assembly

See Figures 6-75 and 6-76.

NOTE
The machine was built with two types of cylinders, either
a threaded gland or snap ring gland. Determine which
type of cylinder was used and disassemble as needed.

1 3

4
5

8
9
7
10
12
6 14
13 11

12 11 10 8 4
14 7 5

9 6
TN1839, TN1841
1 Grease Fitting (2) 5 Seal 9 O-Ring 13 Piston
2 Barrel 6 Rod Guide 10 Backup Ring 14 Nut
3 Rod 7 Backup Ring 11 O-Ring
4 Rod Wiper 8 O-Ring 12 Backup Ring
Figure 6-75: Threaded Gland

6-70 4203780 First Edition

 HYDRAULICS

4
5
9
3
2 8
7

1 12 10
14 11
16 13
15

4 7 8
15 11
5 10

14

TN1840

6
3 6 12

TN1840, TN1842
1 Grease Fitting (2) 5 Piston 9 Rod 13 Rod Seal
2 Barrel 6 O-Ring (2) 10 Lock Ring 14 Rod Guide
3 Nut 7 Backup Washer 11 Lock Ring 15 O-Ring
4 Seal Ring 8 Spacer 12 Wiper 16 O-Ring
Figure 6-76: Snap Ring Gland

4203780 First Edition 6-71

 HYDRAULICS

Disassembly Notes Assembly Notes

NOTICE NOTICE
During repair of the cylinder, use extreme care It is important that all component parts are
not to damage the barrel, piston, rod, and sealing absolutely clean, as contamination can result in
surfaces of the cylinder. serious damage and/or improper operation.
It is important that all component parts are Never use shop towels or rags to dry parts after
absolutely clean, as contamination can result in cleaning, as lint may clog passages. Dry parts
serious damage and/or improper operation. using compressed air.
Never use shop towels or rags to dry parts after
cleaning, as lint may clog passages. Dry parts
using compressed air. Required Materials

Seal Kit (Jacobsen PN 4137138)

• Drain oil from lift cylinder.
• Remove fittings from lift cylinder. • Use a new seal kit during assembly.
• Remove rod guide from the barrel. • Lubricate O-rings, seal, and rod wiper with clean
• Remove nut. hydraulic oil before assembly.
• Remove piston and rod guide from the rod. • Assemble the lift cylinder by reversing the order of
• Remove O-rings, backup rings, seals, and rod wiper disassembly.
from piston and rod guide. • Torque nut to 50 lb-ft (68 N·m).
• Clean all parts using clean solvent, and dry using
compressed air.
• Inspect all parts for excessive wear, cracks, broken
parts, and scoring of the cylinder barrel, piston, and
rod.
• Replace parts as needed.

6-72 4203780 First Edition

 HYDRAULICS

Wing Lift Cylinders Installation Notes

• Install lift cylinder by reversing the order of removal.
Removal and Installation • Make sure new O-rings are in place before installing
See Figure 6-77. hoses on fittings.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
! CAUTION Return Filter” on page 6-67.)
Care must be taken to avoid damaging the • Refill hydraulic tank. (Refer to “Safety, Operation, and
surface of the cylinder rod during removal and Maintenance Manual” for oil specifications.)
installation. • Start engine. Check hydraulic system for leaks.
Repair as necessary.
1. Lower cutting units. • Check hydraulic oil level and add if necessary.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

2 3 4 5
1
TN1797
Figure 6-77
6
NOTES
• Label all hydraulic hoses before disconnecting to
ensure correct installation.
• All of the lift cylinders have an orifice installed
between the hose and the cylinder head end fitting.
Note the location of the orifice and recover the orifice
when removing the hydraulic hoses.
• Close all openings with caps or plugs to prevent
contamination.
2. Disconnect hydraulic hoses (3 and 5).
3. Support lift cylinder (2).
4. Remove pins (1 and 4).
5. Remove lift cylinder (2).

4203780 First Edition 6-73

 HYDRAULICS

Disassembly, Inspection, and Assembly

See Figures 6-78 and 6-79.

NOTE
The machine was built with two types of cylinders, either
a threaded gland or snap ring gland. Determine which
type of cylinder was used and disassemble as needed.

1 3

4
5

8
9
7
10
12
6 14
13 11

12 11 10 8 4
14 7 5

9 6
TN1839, TN1841
1 Grease Fitting (2) 5 Seal 9 O-Ring 13 Piston
2 Barrel 6 Rod Guide 10 Backup Ring 14 Nut
3 Rod 7 Backup Ring 11 O-Ring
4 Rod Wiper 8 O-Ring 12 Backup Ring
Figure 6-78: Threaded Gland

6-74 4203780 First Edition

 HYDRAULICS

4
5
9
3
2 8
7

1 12 10
14 11
16 13
15

4 7 8
15 11
5 10

14

TN1840

6
3 6 12

TN1840, TN1842
1 Grease Fitting (2) 5 Piston 9 Rod 13 Rod Seal
2 Barrel 6 O-Ring (2) 10 Lock Ring 14 Rod Guide
3 Nut 7 Backup Washer 11 Lock Ring 15 O-Ring
4 Seal Ring 8 Spacer 12 Wiper 16 O-Ring
Figure 6-79: Snap Ring Gland

4203780 First Edition 6-75

 HYDRAULICS

Disassembly Notes Assembly Notes

NOTICE NOTICE
During repair of the cylinder, use extreme care It is important that all component parts are
not to damage the barrel, piston, rod, and sealing absolutely clean, as contamination can result in
surfaces of the cylinder. serious damage and/or improper operation.
It is important that all component parts are Never use shop towels or rags to dry parts after
absolutely clean, as contamination can result in cleaning, as lint may clog passages. Dry parts
serious damage and/or improper operation. using compressed air.
Never use shop towels or rags to dry parts after
cleaning, as lint may clog passages. Dry parts
using compressed air. Required Materials

Seal Kit (Jacobsen PN 4138589)

• Drain oil from lift cylinder.
• Remove fittings from lift cylinder. • Use a new seal kit during assembly.
• Remove rod guide from the barrel. • Lubricate O-rings, seal, and rod wiper with clean
• Remove nut. hydraulic oil before assembly.
• Remove piston and rod guide from the rod. • Assemble the lift cylinder by reversing the order of
• Remove O-rings, backup rings, seals, and rod wiper disassembly.
from piston and rod guide. • Torque nut to 95 lb-ft (129 N·m).
• Clean all parts using clean solvent, and dry using
compressed air.
• Inspect all parts for excessive wear, cracks, broken
parts, and scoring of the cylinder barrel, piston, and
rod.
• Replace parts as needed.

6-76 4203780 First Edition

 HYDRAULICS

Hydraulic Oil Cooler 7. Disconnect hoses (7 and 8) from hydraulic oil tank.

Removal and Installation

11
NOTE 10
The hydraulic oil cooler is in close proximity to the 12
radiator and uses the engine cooling fan to cool the
hydraulic oil. Removal and installation of the
radiator/hydraulic oil cooler is described in Chapter 3—
Engine. (See “Radiator/Hydraulic Oil Cooler” on
page 3-11.) 9
13
Hydraulic Oil Tank
Removal and Installation
See Figures 6-80 through 6-82.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) TN1879
2. Disconnect the negative (–) battery cable from the Figure 6-81
battery.
8. Remove charge pressure filter (12). (See “Charge
3. Remove the seat and mount plate. (See “Seat and Pressure Filter” on page 6-68.)
Seat Platform” on page 9-13.)
9. Disconnect electrical connector (11).
4. Drain hydraulic oil tank. (See “Hydraulic Oil Tank—
10. Disconnect hydraulic hoses (9 and 13).
Drain Procedure” on page 6-58.)
11. Disconnect return filter bracket (10) from tank
support.
3
1 2 4 5 7 8 NOTE
Leave return filter and recovery bottle attached to return
filter bracket.
6
12. Lay return filter bracket (10) aside to gain access to
6 hydraulic oil tank.

TN1874
Figure 6-80

NOTES
• Label all hydraulic hoses and tubes before
disconnecting to aid in installation.
• Close all openings with caps or plugs to prevent
contamination.
5. Disconnect hoses (1 through 5) from hydraulic oil
tank.
6. Disconnect electrical connector (6).

4203780 First Edition 6-77

 HYDRAULICS

14 15

17

6 16

TN1885
Figure 6-82
13. Remove charge pressure filter bracket (14).
14. Remove tank straps (17).
15. Support the hydraulic oil tank (16).
16. Remove hydraulic oil tank back supports (15).
17. Remove the hydraulic oil tank (16).

6-78 4203780 First Edition

 HYDRAULICS

Installation Notes
• Install hydraulic oil tank by reversing the order of
removal.

! CAUTION
When connecting fittings to the tank, be sure to
hold the tank fitting with the proper wrench. If the
proper wrench is not used, the fitting in the tank
might break loose from the tank and cause it to
leak.

• Make sure new O-rings are in place before installing

hoses on fittings.
• Replace hydraulic oil return filter. (See “Hydraulic Oil
Return Filter” on page 6-67.)
• Refill hydraulic oil tank. (Refer to “Safety, Operation,
and Maintenance Manual” for oil specifications.)
• Start engine. Check hydraulic oil tank for leaks and
repair as necessary.
• Check hydraulic oil level and add if necessary.

4203780 First Edition 6-79

 HYDRAULICS

Page Intentionally Blank

6-80 4203780 First Edition

 Chapter 7

Steering

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Steering Linkage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Steering Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Steering Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Steering Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Tie Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

4203780 First Edition 7-1

 STEERING

Specifications
Test and Adjustment Specifications
Steering System Leakage Test— pt (L) Zero—Nominal Amount
Cylinder Leakage
Rear Axle Alignment Toe-In in. (mm) 0.0625 (1.6)
Measurement
Rear Axle Spindle Arm-to-Axle Stop in. (mm) 0.030—0.060 (0.76—1.5)
Measurement

Repair Specifications
Steering Wheel Nut lb-ft (N·m) 28—30 (38—41)
Steering Valve Rotor-to-Stator in. (mm) 0.003 (0.08)
Clearance
Steering Valve Metering Assembly lb-in. (N·m) 11—13 (1.2—1.5)
Screw Torque
Steering Valve Port Cover-to-Port lb-ft (N·m) 18—22 (24—30)
Manifold Nut Torque
Steering Cylinder Ball Joint-to- lb-ft (N·m) 40 (54)
Steering Arm Torque
Tie Rod Ball Joint-to-Steering Arm lb-ft (N·m) 30 (41)
Torque

7-2 4203780 First Edition

 STEERING

Component Location
See Figure 7-1.

2
1

4
5

TN1767, 1856
1 Tie Rod 3 Steering Cylinder 5 Steering Wheel
2 Steering Axle 4 Tilt Lever 6 Steering Valve
7 Steering Console
Figure 7-1

4203780 First Edition 7-3

 STEERING

Tests and Adjustments Turning Radius (Equal Angle) Adjustment

IMPORTANT
Steering Linkage Adjustments
The steering linkage must be adjusted in proper
See Figures 7-2 through 7-7. sequence. Do not perform this procedure until the tie
rod adjustment has been performed. (See “Tie Rod
IMPORTANT Adjustment” on page 7-4.)
The following adjustments must be performed in
1. Check the turning radius by driving the mower in a
sequence to ensure correct steering linkage
circle in both a hard right and a hard left turn.
adjustment.
2. Measure the diameters of the tire track circles. Adjust
Tie Rod Adjustment steering cylinder rod ball joints as needed until equal
angles are achieved.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) 3. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Turn the wheels to the straight-ahead position.
4. Turn the wheels to the straight-ahead position.
5. Check that ball joints are threaded equally into both
1 ends of steering cylinder.

4 3 2 1
5
TN1771

Figure 7-2

7 3. Measure the distance between the center lines of the

tires at the front (1) and rear (5) of the tires. The
measurement (toe-in) at the front of the tires should 4 3
2
TN1798
be a maximum of 0.0625 in. (1.6 mm) less than the
distance at the rear of the tires. If the toe-in does not Figure 7-3
meet specifications, adjust as follows:
a. Loosen the tie rod clamp bolts/nuts (2 and 4) on
both sides of the tie rod (3).
b. Turn the tie rod (3) as needed to obtain proper
toe-in (1).
c. Retighten the tie rod clamp bolts/nuts (2 and 4).
d. Proceed to “Turning Radius (Equal Angle)
Adjustment.”

7
1

5
6 TN1799
Figure 7-4

7-4 4203780 First Edition

 STEERING

6. Remove cotter pins (4 and 5) and castle nuts

(3 and 6), and lift steering cylinder (1) from frame
bracket (2) and steering arm (7).

1
8
2

4
9
12
3

11
TN1877
Figure 7-6: Steering Stop Bolt—Right Side

10
TN1828 6
Figure 7-5 5
7. Loosen clamp bolts/nuts (8 and 9) on both sides of
steering cylinder (11).
8. Adjust (turn) ball joints (10 and 12) in or out equally
as needed.
9. Install the steering cylinder, and check the turning
7
radius in both directions.
8
10. Repeat steps 2 through 9 as needed until the turning
radius is equal in both directions.
11. Proceed to “Steering Stop Bolt Adjustment.”

Steering Stop Bolt Adjustment Figure 7-7: Steering Stop Bolt—Left Side
TN1878
7
3. Loosen both jam nuts (4 and 7), and turn both stop
IMPORTANT bolts (2 and 5) completely against the mounting
The steering linkage must be adjusted in proper brackets (1 and 6).
sequence. Do not perform this procedure until the tie 4. Fully retract the steering cylinder (right turn). Turn the
rod and turning radius (equal angle) adjustments left side stop bolt (5) until there is a 0.030—0.060 in.
have been performed. (See “Tie Rod Adjustment” on (0.76—1.5 mm) gap between the bolt and the
page 7-4 and “Turning Radius (Equal Angle) steering arm (8). Tighten the jam nut (7).
Adjustment” on page 7-4.) 5. Fully extend the steering cylinder (left turn). Turn the
1. Park the mower safely. (See “Park Mower Safely” on left side stop bolt (2) until there is a 0.030—0.060 in.
page 1-6.) (0.76—1.5 mm) gap between the bolt and the
2. Turn the wheels to the straight-ahead position. steering arm (3). Tighten the jam nut (4).

4203780 First Edition 7-5

 STEERING

Steering Relief Valve Pressure Test

See Figures 7-8 and 7-9.
3
! WARNING
• The hydraulic system is under pressure, and
the oil will be hot.
• Always relieve pressure in the hydraulic
system before performing service.
• Failure to follow appropriate safety
precautions may result in death or serious
TN1275
injury.
Figure 7-9
6. Connect test hose from tee fitting to 5000 psi (345
Required Tools and Materials bar) test gauge (3).
7. Disconnect and cap both steering cylinder hydraulic
• Pressure Gauge 0—5000 psi (0—345 bar)
hoses.
• Test Hose
8. Operate hydraulic system until oil temperature is at
• Tee Fitting 120-—150° F (49—65° C).

1. Park the mower safely. (See “Park Mower Safely” on NOTICE

page 1-6.)
2. Remove seat and seat platform. (See “Seat and Seat Do not run mower lift/steer system relief valve
Platform” on page 9-13.) over relief longer than 10 seconds or damage to
hydraulic system may occur.

9. Start engine and run at full throttle (2850 ± 50 rpm).

10. Turn steering wheel fully right against stop.
11. Record pressure reading.
Is lift/steer system relief pressure 1450 psi
(100 bar)?
YES Lift/steer system relief valve is good.
7 NO
Proceed to step 14.
Proceed to next step.
12. Raise the decks and hold the joystick in the raise
position.
13. Record pressure reading.
1
Is lift/steer system relief pressure 1500 psi
(103 bar) reached?
YES Relief valve is good. Replace steering valve.
2
(See “Steering Valve” on page 7-8.)
TN1862
NO Relief valve is faulty. Repair or replace relief
Figure 7-8
valve.
3. Disconnect hose (2) from fitting (1). 14. Stop engine.
4. Install tee fitting to fitting (1). 15. Disconnect and remove test equipment. Install all
5. Connect hose (2) to tee fitting. hoses and fittings as noted prior to removal.
16. Check hydraulic oil level. Add oil as needed. (Refer to
“Safety, Operation, and Maintenance Manual” for
correct oil specifications.)

7-6 4203780 First Edition

 STEERING

Steering Leakage Test

See Figure 7-10.
! WARNING
1. Operate hydraulic system until oil temperature is at Do not turn steering wheel to the right.
120—150° F (49—65° C). Failure to follow appropriate safety precautions
2. Turn steering wheel fully left against stop. may result in death or serious injury.
3. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) 6. With engine off, turn steering wheel fully left against
stop.
! WARNING 7. Check for oil leakage in the drain pan.
Is steering cylinder leakage a nominal amount of
The hydraulic system is under pressure, and the
oil or less?
oil will be hot.
YES Go to step 10.
• Always relieve pressure in the hydraulic
system before performing service. NO Repair or replace steering cylinder. (See
“Steering Cylinder” on page 7-21.)
• Failure to follow appropriate safety
precautions may result in death or serious 8. Disconnect and plug hose (1).
injury. 9. Start the engine and set engine speed to full throttle
(2850 ± 50 rpm).
10. Turn the steering wheel fully left, then fully right.
2 3 Does the steering wheel continue to turn past
stop with little or no resistance?
1 YES Steering valve is faulty. Replace steering
valve. (See “Steering Valve” on page 7-8.)
NO Steering valve is good. Test complete.

TN1798
Figure 7-10
4. Disconnect hose (2) from steering cylinder fitting (3).
Plug hose.
5. Position a suitable container under steering cylinder
fitting (3).

4203780 First Edition 7-7

 STEERING

Repair Steering Valve

Removal and Installation
Steering Wheel
See Figures 7-12 through 7-17.
Removal and Installation 1. Park the mower safely. (See “Park Mower Safely” on
See Figure 7-11. page 1-6.)
1. Park the mower safely. (See “Park Mower Safely” on 2. Remove the steering wheel. (See “Steering Wheel”
page 1-6.) on page 7-8.)

NOTE
1 If available, use a portable hydraulic filtering unit to
remove the hydraulic oil from the hydraulic tank. Place
the filtering unit suction hose in the tank and pump the oil
into a clean and sealable container.
2

1
4

5 2

7 3

4 TN1738
TN1737
Figure 7-12
Figure 7-11
3. Remove (unscrew) knob (1) from tilt lever (2).
2. Remove (unsnap) the cap (1) from the steering
4. Loosen jam nuts (4).
wheel (4).
5. Tilt the steering console (3) forward.
3. Remove nut (2) and internal-tooth lock washer (3).
6. Remove (unscrew) tilt lever (2) from console (3).
4. Remove the steering wheel (4) from the steering
column (6).
5. Remove two washers (5) from the steering column
(6).

Installation Notes
• Install the steering wheel by reversing the order of
removal.
• Tighten the steering wheel nut (3) to 28—30 lb-ft
(38—41 N·m).

7-8 4203780 First Edition

 STEERING

10
9
6

12
11
TN1742

Figure 7-13
TN1740
7. Remove two screws (5) from console cover (6). Figure 7-15

NOTES
• Label all hydraulic hoses and record their locations to
ensure correct installation.
7 • Plug hydraulic hoses after disconnecting to prevent
loss of hydraulic oil.
9. Disconnect hydraulic hose (9) from steering valve
port “LT.”
10. Disconnect hydraulic hose (10) from steering valve
port “RT.”
11. Disconnect hydraulic hose (11) from steering valve
port “OUT.”
12. Disconnect hydraulic hose (12) from steering valve
port “IN.”
7
8

TN1739
Figure 7-14
8. Remove two screws (7) from console cover (8), and
move console cover aside.

4203780 First Edition 7-9

 STEERING

Installation Notes
• Install the steering valve by reversing the order of
removal.
• When installing the tilt lever (19), screw the lever in
until tight, and then back the lever off to the position
shown. Hold the lever and tighten the jam nuts (20).
13
• Check hydraulic oil level. Add oil as needed.
14 • Start the machine and check for hydraulic leaks and
cylinder operation. Repair as necessary.

16 17 18

15

TN1741
Figure 7-16
13. Support the steering valve (15).
14. Remove four nuts (16), lock washers (17), and flat
washers (18). Remove the operator assist handle
bracket (13).
15. Remove steering valve (15) from console (14).

19

20
TN1743
Figure 7-17

7-10 4203780 First Edition

 STEERING

Steering Valve Service Fixture

IMPORTANT
See Figures 7-18 and 7-19.
Scribe a line from the top to the bottom of the
steering valve assembly, not including the steering
Required Tools or Equipment
tube. Use the scribed line for reference when
Steering Valve Service Fixture assembling the valve sections.

TN1435

Figure 7-18

NOTICE
Do not clamp the steering valve assembly directly
into a vise. Clamping the steering valve directly
into a vise may damage or distort the steering
valve.

1 7
2

3
TN1437
Figure 7-19
1. Place the steering valve service fixture (2) securely in
a vise.
2. Place the steering valve (1) into the service fixture
(2), input shaft down.
3. Secure the steering valve to the service fixture using
four nuts (3).

4203780 First Edition 7-11

 STEERING

Disassembly
See Figure 7-20.
3 4
2
6
1
5
7 8
9
18
10
8
17 11 12
15
8 19 13

8 14
20 16

21
22 15
23
24
25
31 26
27
28
29
32 30

33
34

7 35 36
37

38 42
43
39
44
40
41 TN1796

1 Nut 12 Adapter, Straight (2) 23 Commutator 34 Upper Cover Plate

2 Port Cover 13 Isolation Manifold 24 Alignment Pin (5) 35 Gasket
3 Adapter, Straight (2) 14 Drive Link 25 Drive Link Spacer 36 Retaining Ring
4 Relief Valve Assembly 15 Alignment Pin (4) 26 Rotor 37 Retaining Plate
5 O-Ring 16 Spring (3) 27 Stator 38 Input Shaft
6 Ball, 9/32 inch 17 Spring (3) 28 Drive Plate 39 Retaining Ring
7 Port Manifold 18 Seal Ring 29 Spacer, Thrust Bearing 40 Upper Cover and Jacket Assembly
8 Seal Ring (4) 19 Metering Ring 30 Thrust Bearing 41 Special Bolt (4)
9 Valve Ring 20 Socket-Head Cap Screw (11) 31 Commutator Seal 42 Bearing
10 Valve Plate 21 Commutator Cover 32 Face Seal 43 Cover, Bearing Seal
11 Hex Drive 22 Commutator Ring 33 Seal Spacer 44 Push-On Nut (4)
Figure 7-20

7-12 4203780 First Edition

 STEERING

12. Remove drive link spacer (25), rotor (26), and stator
! CAUTION (27) from drive plate (28).
13. Remove face seal (32) and seal spacer (33).
Wear eye protection when assembling and
disassembling the steering valve. Springs and 14. Remove thrust bearing (30) and spacer (29).
other objects may be propelled into the air 15. Remove upper cover plate (34) and retaining ring
causing eye injury. (36).
16. Remove the special bolts (41).
17. Remove the input shaft (38) out of upper cover and
NOTE jacket assembly (40).
Before attempting repairs or disassembly of any hydraulic 18. Remove retaining ring (39), bearing (42), and
components, thoroughly clean the components and work bearing cover seal (43).
area. A clean work area is essential to satisfactory
operation of repaired hydraulic components.
1. Remove straight adapters (3) from port cover (2).
2. Remove straight adapters (12) from isolation
manifold (13).
3. Remove four nuts (1), port cover (2), and
check ball (6).
4. Remove relief valve assembly (4) from port cover (2).
5. Carefully remove the port manifold (7). Be prepared
to catch the three springs (17). Remove the springs.
6. Remove the valve ring (9), valve plate springs (16),
and valve plate (10).
7. Remove hex drive (11) and isolation manifold (13).

NOTE
Secure the alignments pins (15) to prevent loss.
8. Remove drive link (14) and metering ring (19).
9. Remove the metering package (20—28) and
commutator seal (31). The metering package is
serviced as an assembly kit. Refer to the Parts &
Maintenance Manual.
7
NOTE
The metering package should be disassembled for
inspection purposes only. Proceed with step 10 for
disassembly and inspection procedures. If you are not
disassembling the metering package, proceed to step 13.

10. Remove socket-head cap screws (20), commutator

cover (21), commutator ring (22), and commutator
(23).
11. Remove the five alignment pins (24).

4203780 First Edition 7-13

 STEERING

Inspection
See Figures 7-21 and 7-22.
3 4
2
6
1
5
7 8
9
18
10
8
17 11 12
15
8 19 13

8 14
20 16

21
22 15
23
24
25
31 26
27
28
29
32 30

33
34

7 35 36
37

38 42
43
39
44
40

41 TN1796
1 Nut 12 Adapter, Straight (2) 23 Commutator 34 Upper Cover Plate
2 Port Cover 13 Isolation Manifold 24 Alignment Pin (5) 35 Gasket
3 Adapter, Straight (2) 14 Drive Link 25 Drive Link Spacer 36 Retaining Ring
4 Relief Valve Assembly 15 Alignment Pin (4) 26 Rotor 37 Retaining Plate
5 O-Ring 16 Spring (3) 27 Stator 38 Input Shaft
6 Ball, 9/32 inch 17 Spring (3) 28 Drive Plate 39 Retaining Ring
7 Port Manifold 18 Seal Ring 29 Spacer, Thrust Bearing 40 Upper Cover and Jacket Assembly
8 Seal Ring (4) 19 Metering Ring 30 Thrust Bearing 41 Special Bolt (4)
9 Valve Ring 20 Socket-Head Cap Screw (11) 31 Commutator Seal 42 Bearing
10 Valve Plate 21 Commutator Cover 32 Face Seal 43 Cover, Bearing Seal
11 Hex Drive 22 Commutator Ring 33 Seal Spacer 44 Push-On Nut (4)
Figure 7-21

7-14 4203780 First Edition

 STEERING

Assembly
IMPORTANT
See Figures 7-23 through 7-26.
Always replace springs as a set.
1. Inspect the springs (16 and 17) for bent, broken, or Service Part Kits
distorted coils.
2. Inspect the finished ground surfaces of all the Seal Kit (Jacobsen PN 557738)
components. Metering Assembly Kit (Jacobsen PN 1004867-01)
Spring Kit (Jacobsen PN 502924)
3. Inspect the slot edges and surface for nicks, scoring,
Jacket Tube Kit (Jacobsen PN 4119120)
and rounding edges.
Needle Roller Kit (Jacobsen PN 502925)
NOTE
The valve ring (9) and valve plate (10) are a matched set
and are not serviceable.
4. Inspect the hex drive (11) for wear.
5. Inspect the isolation manifold (13) for nicks,
scratches, and scoring. A polished wear pattern due
to valve plate rotation is normal.
6. Inspect the drive link (14) for wear and damage.
7. Inspect the thrust bearing (30) for dents, spalling,
and missing rollers.
8. Discard all seals and seal rings.
9. Inspect the commutator cover (21) and drive plate
(28) for wear and damage. A polished wear pattern is
normal.

45 46

47
7

48
TN1881

Figure 7-22
10. Inspect the rotor (46) and stator (47) fit for wear and
damage.
11. Install rotor in stator and center the rotor lobe (48)
across from a lobe to be measured (45). Measure
rotor (46) and stator (47) fit for maximum trip
clearance of 0.003 in. (0.08 mm).

4203780 First Edition 7-15

 STEERING

3 4
2
6
1
5
7 8
9
18
10
8
17 11 12
15
8 19 13

8 14
20 16

21
22 15
23
24
25
31 26
27
28
29
32 30

32
34
35 36
37
7 38 42
43
39
44
40

41 TN1796
1 Nut 12 Adapter, Straight (2) 23 Commutator 34 Upper Cover Plate
2 Port Cover 13 Isolation Manifold 24 Alignment Pin (5) 35 Gasket
3 Adapter, Straight (2) 14 Drive Link 25 Drive Link Spacer 36 Retaining Ring
4 Relief Valve Assembly 15 Alignment Pin (4) 26 Rotor 37 Retaining Plate
5 O-Ring 16 Spring (3) 27 Stator 38 Input Shaft
6 Ball, 9/32 inch 17 Spring (3) 28 Drive Plate 39 Retaining Ring
7 Port Manifold 18 Seal Ring 29 Spacer, Thrust Bearing 40 Upper Cover and Jacket Assembly
8 Seal Ring (4) 19 Metering Ring 30 Thrust Bearing 41 Special Bolt (4)
9 Valve Ring 20 Socket-Head Cap Screw (11) 31 Commutator Seal 42 Bearing
10 Valve Plate 21 Commutator Cover 32 Face Seal 43 Cover, Bearing Seal
11 Hex Drive 22 Commutator Ring 33 Seal Spacer 44 Push-On Nut (4)
Figure 7-23

7-16 4203780 First Edition

 STEERING

NOTE NOTE
In the following assembly steps, it is important to align the Make sure the alignment pins (49) are pressed below the
components for proper operation of the steering valve. surface of the commutator (48).
Use the scribed line for reference when assembling the 11. Align the five pin holes in the commutator (48) with
valve sections. the holes in the rotor (51), and install the five
1. Install a new bearing (42), retaining ring (39), and alignment pins (49).
bearing cover seal (43) in the upper cover and jacket 12. Install the commutator ring (47) and commutator
assembly (40). Crimp the tube end in two places, 90° cover (46), flat surface down with ring screw
apart. recesses, stator screw slots, and cover screw holes
2. Place the upper cover and jacket assembly (40) and aligned. Install the 11 socket-head cap screws (45).
special bolts (41) in the service fixture.
3. Install the retaining ring (36) on the input shaft (38), NOTE
and install into upper cover and jacket assembly (40). Do not tighten the cap screws.
4. Install the upper cover plate (34) and gasket (35). 13. Place the metering ring (19) on a hard, flat surface.
5. Assemble the seal spacer (33) and face seal (32). 14. Place the assembled metering package in the center
6. Grease the upper cover plate (34), and install the of the metering ring (19) with the commutator cover
assembled seal, backup ring, and seal spacer. down.
15. Place a 0.007 in. (0.18 mm) shim stock, 0.5 in.
NOTE (13 mm) wide by 1.5 in. (38 mm) long, in three
If the metering package was disassembled, proceed with places, equal distance apart, between the metering
step 7. If the metering package was not disassembled or ring and metering package.
a new one is being installed, proceed with step 19.

45
46
47
48
49
50
51
52
53
7
TN1438
Figure 7-25: Metering Package Torque Sequence
TN1882 16. Tighten the cap screws (45) twice in sequence to
11—13 lb-in. (1.2—1.5 N·m).
Figure 7-24
17. Remove the metering package and shims. Place the
7. Place the drive plate (53) on a flat, lint-free surface. drive link (14) large tang into the rotor. Turn the
8. Place the stator (52) on the drive plate (53) and metering package by hand to make sure there is no
insert the rotor (51) into the stator. binding.
9. Apply a small amount of grease to the drive link
spacer (50) and install in the rotor (51). NOTE
10. Place the commutator (48) on top of the rotor (51) The metering package should rotate inside the stator. If
with the aligning pin holes facing up. Place a few binding occurs, disassemble the metering package,
drops of oil in each recess of the commutator (48). correct the cause, and repeat the assembly process.
18. Place the metering ring (19) on top of the upper
cover plate (34) with the alignment pin holes up.

4203780 First Edition 7-17

 STEERING

19. Lubricate and install the thrust bearing spacer (29) Steering Console
and thrust bearing (30) into the metering ring (19).
20. Place the metering package (20—28) into the Removal and Installation
metering ring (19), engaging the drive slot with the See See Figures 7-27 through 7-34.
steering shaft.
1. Park the mower safely. (See “Park Mower Safely” on
21. Install the commutator seal (31), seal ring (8), and page 1-6.)
drive link (14).
2. Remove the steering wheel. (See “Steering Wheel”
22. Place the isolation manifold (13) on the metering ring on page 7-8.)
(19) with the alignment pin holes up. Install the
alignment pins (15) into the metering ring (19).
23. Install alignment pins (15) into the isolation manifold
(13). 1
24. Install the three springs (16) into the isolation
manifold (13) and install the valve ring (9).
25. Install the valve plate (10) as shown (closed cylinder
up) in the valve ring (9), aligning the spring slots with
the springs. Install the seal ring (18).

4 1 5 2 3 4

TN1886
Figure 7-27
3. Remove two screws (2), lock washers (3), and flat
washers (4) from console cover assembly (5) and
console wall (1).

2 3 6

7 Figure 7-26
TN1884

26. Place the three springs (17) in the port manifold (7).
27. Carefully place the port manifold (7), springs down,
onto the valve ring (9). 7
28. Install the O-ring (5) and seal ring (18) on the port
cover (2).
29. Install the relief valve assembly (4) in the port cover
(2).
30. Install the port manifold (7).
31. Install the nuts (1). Tighten the lock nuts gradually in
sequence to 18—22 lb-ft (24—30 N·m).
32. Install straight adapters (3) in the port cover (2). 8
33. Install straight adapters (12) in the isolation manifold
(13). 9 TN1738
Figure 7-28
4. Remove (unscrew) knob (6) from tilt lever (7).

7-18 4203780 First Edition

 STEERING

5. Loosen jam nuts (9).

6. Tilt the steering console (8) forward.
14
7. Remove (unscrew) the tilt lever (7) from console (8).

15

11

18 17 16
TN1888

Figure 7-31
10
NOTE
Label all wiring connectors and record their locations to
ensure correct installation.
10. Disconnect console harness connector (18) from
TN1742 wiring harness.
Figure 7-29
NOTES
8. Remove two screws (10) from console cover (11). • Label all hydraulic hoses and record their locations to
ensure correct installation.
• Plug hydraulic hoses after disconnecting to prevent
loss of hydraulic oil.
11. Disconnect hydraulic hose (14) from steering valve
12 port “LT.”
12. Disconnect hydraulic hose (15) from steering valve
port “RT.”
13. Disconnect hydraulic hose (16) from steering valve
port “OUT.”
14. Disconnect hydraulic hose (17) from steering valve
7
port “IN.”

13

TN1739
Figure 7-30
9. Remove two screws (12) from console cover (13),
and move the console cover aside.

4203780 First Edition 7-19

 STEERING

20
25
24

19

26
27

23

21

22
21 28

22 TN1890
Figure 7-32
15. Remove two nuts (22), lock washers (21), and
screws (20). Remove indictor light module (23) from
console (19).

31 29

7 30
TN1891
Figure 7-33
16. Support the console (25).
17. Remove nut (27), lock washer (26), and bolt (24).
Remove the console (25) from the support (29).
18. Remove the console cover assembly (28) from the
support (29).
19. Inspect the bushing (31). Replace as needed.

Installation Notes
• Install the steering console by reversing the order of
removal.
• Apply grease to grease fitting (30).

7-20 4203780 First Edition

 STEERING

Steering Cylinder
32 Removal and Installation
See Figures 7-35 through 7-37.

Required Tools or Equipment

Ball Joint Removal Tool

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Thoroughly clean the area surrounding the steering
cylinder, especially the hydraulic hose fittings.

33
TN1743
Figure 7-34
• When installing the tilt lever (32), screw the lever in
until tight, and then back the lever off to the position
shown. Hold the lever and tighten the jam nuts (33).
• Check hydraulic oil level. Add oil as needed.
• Start the machine and check for hydraulic leaks and 5
cylinder operation. Repair as necessary.

4
7
TN1798
Figure 7-35

NOTES
• Label all hydraulic hoses and record their locations to
ensure correct installation.
• Plug hydraulic hoses after disconnecting to prevent
loss of hydraulic oil.
3. Disconnect hydraulic hoses (1 and 2) from steering
cylinder (5).
4. Support the steering cylinder (5).
5. Remove cotter pin (4) and castle nut (3) from
steering cylinder (5).

4203780 First Edition 7-21

 STEERING

9. Remove ball joints (10 and 13) and clamps (14 and
16) from steering cylinder (15).
10. Inspect ball joints. Replace as needed.

Installation Notes
• Install the steering cylinder by reversing the order of
removal.
• Using information recorded during disassembly,
install ball joints into tie rod with the correct number
6 of turns.
7 • Before installing the steering cylinder assembly,
verify that the ball joint tapers and the mating tapered
8 surfaces in the steering arm and rear axle are free of
9 TN1799 burrs, dirt, and debris. DO NOT apply lubricant of any
kind to these surfaces.
Figure 7-36
• Tighten castle nuts (3 and 9) to 40 lb-ft (54 N·m).
6. Remove cotter pin (8) and castle nut (9) from Adjust (tighten) nuts as needed to align the slots with
steering cylinder (7). the hole in the rod ends.
7. Using a ball joint removal tool, remove the ball joint • Always install new cotter pins (4 and 8).
from the steering arm. Remove the steering cylinder
• Check hydraulic oil level. Add oil as needed.
(7) from the steering arm (6) and rear axle.
• Start the machine and check for hydraulic leaks and
cylinder operation. Repair as necessary.
10 11 12 • Check steering toe-in adjustment. (See “Tie Rod
Adjustment” on page 7-4.)

16
13

7 15

14
TN1802

Figure 7-37

NOTES
• Record the location and orientation of the fittings
(11 and 12) before removing to ensure correct
installation.
• Record the orientation of the clamps (14 and 16)
before removing to ensure correct installation.
• Record the orientation of the ball joints (10 and 13)
before removing to ensure correct installation.
• Record the number of turns required to remove each
ball joint.
8. Remove fittings (11 and 12) from steering cylinder
(15).

7-22 4203780 First Edition

 STEERING

Disassembly, Inspection, and Assembly

See Figure 7-38.

4
3
2
6

15

14
13
12
11
10

8
9
7
7 TN1790
1 Barrel 5 Backup Ring (2) 9 Rod Seal 13 Snap Ring (Small)
2 Nut 6 O-Ring 10 Rod Wiper 14 O-Ring
3 Seal Ring 7 O-Ring 11 Snap Ring (Large) 15 Rod
4 Piston 8 Rod Guide 12 Rod Guide
Figure 7-38
1. Remove the small snap ring (13) and rod guide (12).
2. Remove the large snap ring (11). ! WARNING
3. Remove the piston and rod assembly (2 through 15) Use appropriate eye protection when using
from barrel (1). compressed air for cleaning or drying purposes.
4. Remove nut (2), piston assembly (3 through 6), and Compressed air can cause serious personal
guide assembly (7 through 10) from rod (15). injury. Use safety reduction valves to reduce the
5. Remove seal ring (3), O-ring (6), and backup rings air pressure to a safe level before use.
(5) from piston (4).
6. Remove O-ring (7), rod seal (9), and rod wiper (10)
from rod guide (12).
7. Remove O-ring (14) from rod (15).

4203780 First Edition 7-23

 STEERING

NOTICE
It is important that all components are absolutely
clean, as contamination can result in serious 1
damage and/or improper operation.
Never use shop towels or rags to dry parts after
cleaning, as lint may clog passages. Dry parts 5
using compressed air.

8. Clean all parts using clean solvent, and dry using

compressed air.
9. Inspect all parts for excessive wear, cracks, broken 6
parts, and damaged threads.
10. Inspect the barrel for dents, score lines, or grooves 7
inside. TN1818
Figure 7-40
Assembly Notes
2. Support the tie rod assembly (1).
Required Materials 3. Remove cotter pins (3 and 7) and castle nuts
(4 and 6) from both steering arms (2 and 5), and
Seal Kit (Jacobsen PN 4137139) remove the tie rod assembly (1).

• Assemble the steering cylinder by reversing the order Installation Notes

of disassembly. • Install the tie rod by reversing the order of removal.
• Lubricate all parts with clean hydraulic oil before • Before installing the tie rod assembly, verify that the
assembly. ball joint tapers and the mating tapered surfaces in
• Always install new seals and O-rings for assembly; the steering arms are free of burrs, dirt, and debris.
used parts may leak. DO NOT apply lubricant of any kind to these
surfaces.
Tie Rod Assembly • Verify that the tie rod clamps do not make contact
with anything when steering in either direction.
Removal and Installation Reposition the clamps as needed.

7 See Figures 7-39 and 7-40.

1. Park the mower safely. (See “Park Mower Safely” on
• Tighten castle nuts (4 and 6) to 30 lb-ft (41 N·m).
Adjust (tighten) nuts as needed to align the slots with
the hole in the rod ends.
page 1-6.)
• Always install new cotter pins (3 and 7).
• Adjust tie rod. (See “Tie Rod Adjustment” on
1 page 7-4.)

3 2 TN1817

Figure 7-39

7-24 4203780 First Edition

 STEERING

Disassembly, Inspection, and Assembly

See Figure 7-41.

2
3

14 5

9 13

6
7
8

12
11

10
9

1 Castle Nut 5 Tie Rod 9 Grease Fitting (2) 13 Hex-Head Bolt

TN1819
7
2 Lock Washer 6 Lock Washer 10 Threaded Ball Joint, Left 14 Threaded Ball Joint, Right
3 Nut 7 Nut 11 Tie Rod Clamp
4 Tie Rod Clamp 8 Castle Nut 12 Hex-Head Bolt
Figure 7-41

Disassembly Note
Record the number of turns required to remove ball joints
from tie rod.

Assembly Notes
• Assemble the tie rod assembly by reversing the order
of disassembly.
• Using information recorded during disassembly,
install ball joints into tie rod with the correct number
of turns.
• Apply grease to grease fittings (9).

4203780 First Edition 7-25

 STEERING

Rear Axle
Removal and Installation
See Figure 7-42.

9 10
8

6
5
11

3 3
3
2
1

7
12
15

14
13

TN1829
1 Cotter Pin 5 Hose, Left 9 Lock Washer 13 Steering Axle Assembly
2 Castle Nut 6 Hex-Head Bolt 10 Nut 14 Hose, Right
3 Thrust Washer (3) 7 Frame Bracket (Rear) 11 Pivot, Steering Axle 15 Steering Cylinder
4 Frame Bracket (Front) 8 Flat Washer 12 Grease Fitting
Figure 7-42

7-26 4203780 First Edition

 STEERING

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove the rear wheel motors. (See “Rear Wheel
Motor” on page 5-77.)

NOTES
• Label all hydraulic hoses and record their locations to
ensure correct installation.
• Plug hydraulic hoses after disconnecting to prevent
loss of hydraulic oil.
3. Disconnect hydraulic hoses (5 and 14) from steering
cylinder (15).
4. Support the rear axle assembly using an appropriate
lifting device.
5. Remove nut (10), lock washer (9), flat washer (8),
and bolt (6) from steering axle pivot (11) and rear
frame bracket (7).
6. Remove cotter pin (1) and castle nut (2), and remove
steering axle pivot (11) and thrust washers (3) from
steering axle assembly (13) and frame brackets
(4 and 7).
7. Remove steering axle assembly (13) from mower.

Installation Notes
• Install the rear axle assembly by reversing the order
of removal.
• Tighten the axle pivot castle nut (2) until axle pivot
tube is snug, but can still pivot. Adjust nut as needed
to align the slots with the hole in the axle pivot.
• Always install new cotter pin (1).
• Apply grease to grease fitting (12).
• Check hydraulic oil level. Add oil as needed.
• Start the machine and check for hydraulic leaks and
cylinder operation. Repair as necessary.
7
• Check steering toe-in adjustment. (See “Tie Rod
Adjustment” on page 7-4.)

4203780 First Edition 7-27

 STEERING

Disassembly, Inspection, and Assembly

See Figure 7-43.

6
3 5
7
8

2
6 4 6
7 4
9

6
16 7
10
3
15
19 5 8
17
18 7
20
6
18 12
7 12
16 9
6
11 15

10

12
13
14
11

13 12
TN1777
1 Tie Rod Assembly 6 Thrust Washer (6) 11 Castle Nut (2) 16 Hex Bolt (6)
2 Roll Pin (2) 7 Bushing, Mount Pivot (4) 12 Cotter Pin (4) 17 Axle
3 Socket-Head Screw (2) 8 Grease Fitting (2) 13 Motor Mount (2) 18 Castle Nut (2)
4 Hex Nut (2) 9 Thrust Bearing (2) 14 Steering Arm, Left 19 Steering Cylinder
5 Bushing, Axle Pivot (2) 10 Thrust Washer (2) 15 Lock Washer (6) 20 Steering Arm, Right
Figure 7-43

7-28 4203780 First Edition

 STEERING

Disassembly Notes
• Before disassembly, clean and remove all dirt and
grass from rear axle assembly.
• Inspect all bushings, thrust washers, and bearings for
damage or wear.
• Inspect steering cylinder for leaks or dents to the
barrel and rod.
• Inspect all ball joints for wear or torn dust seals.

Assembly Notes

Required Materials

Loctite® 242 (Blue)

• Replace any bushings, bearings, and ball joints that

are damaged or have excessive wear.
• Replace or repair steering cylinder if dented or
leaking.
• Never reuse cotter pins; use new cotter pins of
correct size.
• Install thrust washers (6) as needed to remove
excess gap from the underside of axle tube and
motor mount.
• Apply Loctite® 242 (Blue) to steering arm bolts (16)
before installation.
• Before installing the steering cylinder assembly,
verify that the ball joint tapers and the mating tapered
surfaces in the steering arm and rear axle are free of
burrs, dirt, and debris. DO NOT apply lubricant of any
kind to these surfaces.
• Tighten castle nuts (18) to 40 lb-ft (54 N·m). Adjust
(tighten) nuts as needed to align the slots with the
hole in the rod ends. 7
• Before installing the tie rod assembly, verify that the
ball joint tapers and the mating tapered surfaces in
the steering arms are free of burrs, dirt, and debris.
DO NOT apply lubricant of any kind to these
surfaces.
• Verify that the tie rod clamps do not make contact
with anything when steering in either direction.
Reposition the clamps as needed.
• Tighten castle nuts (4 and 11) to 30 lb-ft (41 N·m).
Adjust (tighten) nuts as needed to align the slots with
the hole in the rod ends.
• Apply grease to grease fittings (8).

4203780 First Edition 7-29

 STEERING

Page Intentionally Blank

7-30 4203780 First Edition

 Chapter 8

Cutting Units

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Tests and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Deck Leveling Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Deck Rake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Final Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Mechanical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Quality of Cut Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Front Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
Wing Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Wing Deck Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Swivel Caster Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Fixed Caster Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Anti-Scalp Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

4203780 First Edition 8-1

 CUTTING UNITS

Specifications
Repair Specifications

Specifications
Blade Retaining Screw lb-ft (N·m) 75 (100)
Adapter Screws lb-ft (N·m) 35–40 (47–54)

8-2 4203780 First Edition

 CUTTING UNITS

Component Location
See Figure 8-1.

5 6
4
2
1
7

9
11 10 8
14 13
12
TN1768

8
1 Swivel Caster Wheel Assembly (6) 5 Inner Wing Caster Arm (2) 10 Fixed Caster Wheel Assembly (2)
2 Deck Motor (7) 6 Wing Lift Arm (2) 11 Anti-Scalp Wheel (4)
3 Right Wing Deck Assembly 7 Outer Wing Caster Arm (2) 12 Front Deck Assembly
4 Front Deck Lift/Push Arms 8 Left Wing Deck Assembly 13 Front Caster Arm (2)
9 Height-of-Cut Spacers 14 Anti-Scalp Wheel
Figure 8-1: Component Location

4203780 First Edition 8-3

 CUTTING UNITS

Tests and Adjustments Deck Rake Adjustment

Front Deck
Deck Leveling Adjustment
See Figures 8-3 and 8-4.
See Figure 8-2.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Set all tire pressures for machine and caster wheels.
Set front machine tires at 20 psi, rear machine tires
1
at 10 psi, and casters at 23 psi.

1
1

1
1
TN1872
Figure 8-2
3. With all decks lifted slightly off the ground, loosen all
the caster wheel arms where bolted to the deck shell
brackets (1). Position the arms so the top of the arm
is parallel with the top of the mounting bracket on the
deck. The caster arms should be level and parallel to
the deck shell as shown. This will bring the decks
close to the actual height-of-cut range. Tighten all
caster wheel arms in this leveled position.

8 Figure 8-3
TN1883

NOTE
Each swiveling caster wheel is assembled with at least
two 1/8 inch flat washers (1) along with the 1/2 inch
height-of-cut spacers (2) used to set the cutting height.
1. Make sure that 1/8 inch flat washers (1) are installed
above the caster wheel arms.
2. Install only the proper number of 1/2 inch spacers (2)
for desired height-of-cut setting.
3. With front deck down on the ground and front casters
swiveled in the forward travel position, place a level
on the center of the front deck.

8-4 4203780 First Edition

 CUTTING UNITS

Wing Decks
See Figure 8-5.

TN1880
Figure 8-4
4. Lift the rear of front deck until level, and then lift an
additional 1/8 inch to 1/4 inch.
5. Insert shims (3) on lift arms and secure in place.
6. Front deck rake is now set.

NOTES
• Using too many shims or getting the rear of the deck
too high will affect the cutting height.
• The number of shims may vary between left and right
push arms.

TN1883
Figure 8-5

NOTE 8
Each swiveling caster wheel is assembled with at least
two 1/8 inch flat washers (1) along with the 1/2 inch
height-of-cut spacers (2).
1. Install two 1/8 inch flat washers (1) along with
height-of-cut spacers (2) on the rear caster wheel
yokes to lift the rear of the deck 1/4 inch.

For example, for 2 inch height-of-cut, use two 1/2

inch spacers on front casters. Use two 1/2 inch
spacers plus two 1/8 inch flat washers on rear
casters to achieve the proper rake. This will properly
set the wing decks.

4203780 First Edition 8-5

 CUTTING UNITS

Final Adjustments
1. Make a sample cut with front deck and wing decks. If
front deck is cutting at the same height as wing
decks, unit is ready.
2. If front deck is cutting lower, add 1/8 inch flat washer
to front caster height-of-cut spacer. Add 1/8 inch
shim to lift arm to maintain proper deck rake.
3. If front deck is cutting higher, you may have to loosen
the caster wheel arms and lower the deck to the next
position. Retighten caster arms, again removing
shims from lift arms to maintain proper deck rake.
4. Once the deck is cutting properly, an operator should
only have to move the 1/2 inch height-of-cut spacers
to change the height of cut, and the deck rake will
follow throughout the range.

8-6 4203780 First Edition

 CUTTING UNITS

Troubleshooting
Mechanical Troubleshooting

Condition Probable Cause Remedy

Drive motors do not reach full speed. Engine speed is insufficient, not set to Check engine speed. (Refer to “Safety,
specification. Operation, and Maintenance Manual.”)
Rotary drive motors and/or hydraulic Check hydraulic system performance.
system performance is reduced. (See “Instrument Test Procedure” on
page 6-27.)
Drive motors do not engage. Operator not in seat. Operator must be in seat before engaging
mower.
Seat switch is faulty. Test seat switch. (See “Seat Switch Test”
on page 4-76.)
PTO switch is not engaged. Engage PTO switch. (Refer to “Safety,
Operation, and Maintenance Manual.”)
PTO switch is faulty. Test PTO switch. (See “PTO Switch Test”
on page 4-77.)
Wing mow enable switch not engaged. Engage wing mow enable switch. (Refer to
“Safety, Operation, and Maintenance
Manual.”)
Wing mow enable switch is faulty. Test wing mow enable switch. (See “Wing
Mow Enable and Light Switches Test”
on page 4-79.)
Front mow enable switch not engaged. Engage front mow enable switch. (Refer to
“Safety, Operation, and Maintenance
Manual.”)
Front mow enable switch is faulty. Test front mow enable switch. (See “Front
Mow Enable Switch Test” on
page 4-78.)
Front, right, or left mow solenoid is faulty. Test mow solenoids. (See “Solenoids Test”
on page 4-83.) (See “Mow Circuit
Schematic” on page 4-37.)
Right or left wing proximity switch is faulty. Test right and left wing proximity switches.
(See “Mow Circuit” on page 4-63.)
Front limit switch is faulty. Test front limit switch. (See “Front Limit
Switch Test” on page 4-77.)
Low hydraulic oil level. Check hydraulic oil level.

8
Park brake is on or park brake switch is Test park brake switch. (See “Micro
faulty. Switches Test” on page 4-82.)
Engine overheats. Check engine cooling system and coolant
level.
Hydraulic oil filter restriction. Test hydraulic oil pressure switch. (See
“Instrumentation Circuit Schematic” on
page 4-55.)
Cutting unit does not lower completely to Cutting unit movement is restricted. Check/remove cutting unit restriction.
ground. Weight transfer knob is out of adjustment. Adjust weight transfer knob. (Refer to
“Safety, Operation, and Maintenance
Manual.”)
Raise/lower circuit is faulty. Test raise/lower circuit. (See “Run Circuit
Schematic—Off Seat” on page 4-32.)
Cutting unit does not rise off ground. Engine rpm too slow. Increase engine rpm.
Hydraulic system performance is reduced. Check hydraulic system performance.
(See “Instrument Test Procedure” on
page 6-27.)

4203780 First Edition 8-7

 CUTTING UNITS

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. Tire Pressure (Machine and Caster Tires)
2. Mowing (Ground) Speed
3. Blade Sharpness
4. Height-of-Cut (HOC)
5. Deck Level
6. Deck Rake
7. Blade Speed

8-8 4203780 First Edition

 CUTTING UNITS

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 in. (15—20 cm). Color variation (light-to-dark) may
also be noticed.
This condition is usually caused by a rocking motion in
the cutting unit(s). This condition is found mostly on
mowers with multiple (suspended) cutting units.
Washboarding may also be caused by variations in the
turf.

TN0159
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Mowing (ground) speed is too fast. Reduce mowing (ground) speed.

Improper tire pressure. Set front machine tires at 20 psi, rear machine tires at 10 psi, and
caster tires at 23 psi.

Mowing in the same direction. Change mowing direction regularly.

Incorrect weight transfer adjustment, cutting units have too much Use weight transfer knob to transfer weight on or off cutting units.
or too little weight on them. (See “Weight Transfer Adjustment” on page 5-32.)

Insufficient engine speed, not set to specification. Check/adjust engine speed. (Refer to “Safety, Operation, and
Maintenance Manual.”)

8
Hydraulic system and/or rotary drive motor performance is Check hydraulic system performance (pump output, motor
reduced. operation, valve operation, relief valve settings, etc.). (See
“Instrument Test Procedure” on page 6-27.)

4203780 First Edition 8-9

 CUTTING UNITS

Step Cutting
Mow

Step cutting occurs when grass is cut taller on one side of

a cutting unit than on the other, or on one side of the
mower than on the other. This is usually caused by
mechanical wear or an incorrect roller or deck caster
adjustment.

TN0221
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Improper tire pressure. Set front machine tires at 20 psi, rear machine tires at 10 psi, and
caster tires at 23 psi.

HOC (height-of-cut) settings or spacers are different from one Check HOC adjustment of cutting units.
side of a cutting unit to the other, or from one cutting unit to
another.

Front deck and wing deck are not level. Level decks. (See “Deck Leveling Adjustment” on page 8-4.)

Worn deck caster wheels or deck swivel caster wheels. Check/replace caster wheels. (See “Fixed Caster Wheels” on
page 8-28.) Check/replace deck swivel caster wheels. (See
“Swivel Caster Wheels” on page 8-27.)

Uneven caster wheel arms. Level caster wheel arms. (See “Deck Leveling Adjustment” on
page 8-4.)

Cutting unit movement is restricted. Check/remove cutting unit movement restriction.

8
Variations in turf density. Change mowing direction.

Incorrect weight transfer adjustment, cutting units have too much Use weight transfer knob to transfer weight on or off cutting units.
or too little weight on them. (See “Weight Transfer Adjustment” on page 5-32.)

Mower frame is bent. Repair or replace as needed.

8-10 4203780 First Edition

 CUTTING UNITS

Scalping

Scalping is a condition in which areas of grass are cut

noticeably shorter than the surrounding areas, resulting in
a light green or even brown patch. This is usually caused
by an excessively low height-of-cut setting and/or uneven
turf.

TN0222
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Improper tire pressure. Set front machine tires at 20 psi, rear machine tires at 10 psi, and
caster tires at 23 psi.

HOC (height-of-cut) settings are lower than normal. Check and adjust the HOC settings. (See “Deck Leveling
Adjustment” on page 8-4.)

Front deck and wing deck are not level. Level decks. (See “Deck Leveling Adjustment” on page 8-4.)

Incorrect deck rake. Set proper deck rake. (See “Deck Rake Adjustment” on page 8-4.)

Broken or worn anti-scalp-wheels. Replace anti-scalp-wheels. (See “Anti-Scalp Wheels” on

page 8-29.)

Turf too uneven for the mower to follow. Change mowing direction.

Cutting too much grass at one time. Mow more often.

Mowing (ground) speed is too fast. Reduce mowing (ground) speed.

4203780 First Edition 8-11

 CUTTING UNITS

Stragglers

Stragglers are scattered blades of uncut or poorly cut

grass.

TN0223
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Dull cutting blade(s). Replace or sharpen blade(s). (Refer to “Safety, Operation, and
Maintenance Manual.”)

Mowing (ground) speed is too fast. Reduce mowing (ground) speed.

Grass is too tall. Mow more often.

Mowing in the same direction. Change mowing direction regularly.

8-12 4203780 First Edition

 CUTTING UNITS

Streaks

A streak is a line of uncut grass. This is usually caused by

a damaged blade.

TN0224
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Damaged blade(s). Replace blade(s). (See “Blade” on page 8-18.)

Turning too aggressively. Cutting units don’t overlap during turns Turn less aggressively to allow cutting units to overlap. Change
or on side hills. mowing direction or pattern on side hills.

Tire mats down grass before it is cut. Change mowing direction often. Also check tire pressure.

Wet grass is matted down before it is cut. Cut when grass is dry.

4203780 First Edition 8-13

 CUTTING UNITS

Windrowing

Windrowing is the deposit of clippings concentrated at

one end of cutting unit(s) or between cutting units,
forming line(s) in the direction of travel.

TN0225
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Grass is too tall. Mow more often.

Mowing while grass is wet. Mow when grass is dry.

Mowing (ground) speed is too fast. Reduce mowing (ground) speed.

Grass collecting on mower or deck frame. Clear cutting unit(s) discharge deflector.

8-14 4203780 First Edition

 CUTTING UNITS

Mismatched Cutting Units

Mismatched cutting units cause a pattern of varying

cutting heights, resulting in a stepped cut appearance,
usually due to a different HOC (height-of-cut) adjustment
from one cutting unit to another.

TN1278
NOTE: Arrow indicates direction of travel.

Probable Cause Remedy

Improper tire pressure. Set front machine tires at 20 psi, rear machine tires at 10 psi, and
caster tires at 23 psi.

HOC inconsistent from one cutting unit to another. Check/adjust HOC on cutting units to same height. (Refer to
“Safety, Operation, and Maintenance Manual.”)

Check condition of deck and/or frame. Repair or replace as needed.

Difference in rotary cutting unit speeds. Check operation of rotary cutting motor(s) and repair/replace as
necessary. (See “Cutting Unit System Test” on page 6-26.)

Tire mats down grass before it is cut. Change mowing direction often. Also check tire pressure.

Difference in mower ride height, side to side. Check/adjust for even mower weight distribution. (Refer to “Safety,
Operation, and Maintenance Manual.”)

4203780 First Edition 8-15

 CUTTING UNITS

Repair Installation Notes

• Install the deck motor by reversing the order of
removal.
Deck Motor
• Install the motor on the deck, making sure that it is in
Removal and Installation proper orientation with the marks made on removal.

See Figure 8-6. • Inspect O-rings on fittings before installation.

1. Park the mower safely. (See “Park Mower Safely” on • Replace O-rings if damaged or missing.
page 1-6.) • Replace hydraulic oil filter.
2. Remove cutter blade. (See “Blade” on page 8-18.) • Check hydraulic oil level. Add oil as needed. (Refer to
3. Thoroughly clean the exterior of the motor, especially “Safety, Operation, and Maintenance Manual” for oil
the area surrounding the hydraulic hoses and fittings, specifications.)
with a suitable solvent. • Start engine and check motor operation. Check for
leaks and repair as necessary.

1 2

8 3 4 5 6
7
TN1820
Figure 8-6

NOTES
• Front center deck motor shown; all others are similar.
• Record the orientation and location of hydraulic
hoses to motor to ensure correct installation.
• Mark the orientation and location of deck motor to
ensure correct installation.

8 • Close all openings with caps or plugs to prevent

contamination.
4. Remove hydraulic hoses (1, 2, and 7). Close all
openings using caps and plugs.
5. Remove the six nuts (3), lock washers (4), flat
washers (5), and carriage bolts (6) from the deck
motor (8).
6. Remove deck motor (8) from cutting unit.

8-16 4203780 First Edition

 CUTTING UNITS

Disassembly and Assembly

See Figure 8-7.

1 7

2
8
3
4

7
5
9

10

3 4 11
12
2 13
14
6 15
16

TN1821
1 Cover 5 Motor Body 9 Shaft Key 13 Small Snap Ring
2 Backing Seal (2) 6 Spindle 10 Bearing 14 Washer
3 Bushing Seal (2) 7 Flanged Bushing (2) 11 O-Ring 15 Large Snap Ring
4 O-Ring (2) 8 Spindle Shaft

1. Park the mower safely. (See “Park Mower Safely” on

12
Figure 8-7
Seal 16 Motor Shaft Guard
8
page 1-6.) ! CAUTION
2. Thoroughly clean the exterior of the motor, especially
Never pry components apart. Use a soft faced
the area surrounding the hydraulic hoses and fittings,
hammer, and gently tap housing and shaft to
with a suitable solvent.
separate pump body.
3. Remove deck motor. (See “Deck Motor” on
page 8-16.)
4. After removing screws, disassemble motor.
5. Place parts in assembly order on a clean work area
as they are removed.

4203780 First Edition 8-17

 CUTTING UNITS

Blade
NOTICE
It is important that all motor parts are absolutely Removal and Installation
clean, as contamination can result in serious See Figure 8-8.
damage and/or improper operation. 1. Park the mower safely. (See “Park Mower Safely” on
Never use shop towels or rags to dry parts after page 1-6.)
cleaning, as lint may clog passages. Dry parts 2. Raise and support the cutting units. (Refer to “Safety,
using compressed air. Operation, and Maintenance Manual.”)
3. Disconnect the negative (–) battery cable at the
6. Clean all parts using clean solvent, and dry using battery.
compressed air.
7. Inspect all parts for wear or damage. Replace the
motor as a unit if any parts other than seals require
replacement. 6
Inspect for metal chips or slivers during cleaning (an 5
indication of damage to motor or other hydraulic
components).
4
Assembly Notes
2 3
NOTICE
1 7
It is important that all motor parts are absolutely
clean, as contamination can result in serious 8
damage and/or improper operation. 9
Never use shop towels or rags to dry parts after 7 TN1830
cleaning, as lint may clog passages. Dry parts Figure 8-8
using compressed air.

! CAUTION
Required Materials Blades are extremely sharp and can cause severe
injury.
Seal Kit (Jacobsen P/N 557519)

• Assemble the deck motor by reversing the order of 4. Remove blade screw (8), lock washer (9), blade (1),
disassembly. and key (6) from hydraulic motor spindle (5).
• Apply a coat of clean hydraulic oil to all parts to aid 5. Remove two adapter screws (7), lock washers (2),

8 assembly.
• Use extreme care when installing shaft seal; it must
nuts (3), and blade adapter (4) from blade (1). Repair
or replace blade as necessary.
seat squarely in seal bore. Use clean grease that
Installation Notes
meets or exceeds NLGI Grade 2 LB specifications on
shaft and seal. Use caution when inserting shaft into • Install blade by reversing the order of removal.
seal to avoid cutting or damage to seal during • Tighten adapter screws (4) to 35–40 lb-ft (47–54
assembly. N·m).
• Install screws finger-tight and rotate drive shaft to • Tighten blade screw (5) to 75 lb-ft (100 N·m).
make sure it turns freely. Tighten screws evenly in
steps to a final torque of 30 lb-ft (40 N·m).

8-18 4203780 First Edition

 CUTTING UNITS

Front Deck
Removal and Installation
See Figure 8-9.
1. Lower front deck to the ground, and park the mower
safely. (See “Park Mower Safely” on page 1-6.)

1 2

3
1 2 3

TN1838
Figure 8-9
2. Remove deck motors. (See “Deck Motor” on
page 8-16.)
3. Remove torsion clip (1), clevis pin (2), and bushing
(3).
4. Remove height-of-cut adjustment pins (4).
5. Roll the cutting unit forward, away from machine.
Repair as needed.

Installation Notes
• Install the front deck by reversing the order of
removal.
• Check front deck level adjustment. (See “Deck
Leveling Adjustment” on page 8-4.)
• Check front deck rake adjustment. (See “Deck Rake
Adjustment” on page 8-4.)
8

4203780 First Edition 8-19

 CUTTING UNITS

Disassembly and Assembly

See Figure 8-10.

4
2
3 9
1
8
5 10
9
3 6 7 10
11
1 8
34 12
33 11
8
32 9
11
11
31
11
13
30 14
15

18
28 24 16
27 26 18 9
17
29 25 8
28 7
9 19
8 23
20
19 5 21

20
22
5
21
8 1 Bushing (2) 8 Lock Washer (5) 15
22
Flat Washer 22 Screw (3) 29
TN1899
Anti-Scalp Wheel
2 Screw 9 Nut (5) 16 Screw 23 Screw 30 Shaft
3 Flat Washer (2) 10 Motor (3) 17 Lock Nut 24 Plate 31 Lock Washer
4 Caster Arm 11 Decal (5) 18 Key (3) 25 Carriage Bolt 32 Nut
5 Lock Washer (3) 12 Rubber Stop 19 Adapter (3) 26 Screw 33 Front Deck
6 Nut 13 Anti-Scalp Wheel 20 Blade (3) 27 Cotter Pin 34 Grease Fitting
7 Flat Washer (2) 14 Spacer 21 Screw (2) 28 Bushing (2)
Figure 8-10

Disassembly Note
Inspect all moving parts for wear or damage. Replace as
necessary.

8-20 4203780 First Edition

 CUTTING UNITS

Assembly Notes Installation Notes

• Assemble front deck in reverse order of disassembly. • Install front lift arms by reversing the order of
• Lubricate grease fittings with grease that meets or removal.
exceeds NLGI Grade 2 LB specifications. Apply • Inspect parts for wear or damage, and replace as
grease with a manual grease gun and fill slowly until necessary.
grease begins to seep out. Do not use compressed • Lubricate grease fittings with grease that meets or
air gun. exceeds NLGI Grade 2 LB specifications. Apply
• Always use new cotter pins. grease with a manual grease gun and fill slowly until
• Torque blade retaining screw to 75 lb-ft (100 N·m). grease begins to seep out. Do not use compressed
air gun.
• Torque adapter screw to 35–40 lb-ft (47–54 N·m).

Front Lift Arms

Removal and Installation
See See Figure 8-11.

NOTE
Right side shown; left side is similar.
1. Lower front deck to the ground, and park the mower
safely. (See “Park Mower Safely” on page 1-6.)
2. Remove front deck. (See “Front Deck” on page 8-19.)

1 2 3 4

6 8
TN1766
Figure 8-11
3. Remove screw (2), lock washer (3), and retaining pin
(4).
4. Support the lift arm (1) and remove shaft (5).
5. Remove cotter pin (6).
6. Support the lift arm (1) and remove shaft (7).
7. Remove lift arm (1).

4203780 First Edition 8-21

 CUTTING UNITS
Disassembly and Assembly
See Figure 8-12.

1 2
3

28 32 2 7
6
5
29 31
27 4

3 2 1
26
25 30
24
12
23 8 9
15 14 10
22
15

15 14 11
21 12 13
9
20
8
15
14
19

16
19
17
16
18
8 1
2
Screw (2)
Lock Washer (3)
8
9
Nut (2)
Lock Washer (2)
15
16
Bushing (4)
Flat Washer (2)
22
23
Shim
Bumper
29
30
Lock Washer
Screw
TN1897

3 Pin (2) 10 Washer 17 Lift Cylinder 24 Screw 31 Shaft

4 Screw 11 Bracket 18 Grease Fitting 25 Actuator Arm 32 Pin
5 Bracket 12 Flat Washer (2) 19 Lift Arm (2) 26 Switch
6 Flat Washer 13 Screw 20 Cotter Pin 27 Spacer
7 Nut 14 Grease Fitting (3) 21 Pin 28 Connector
Figure 8-12

Disassembly Note
Inspect all parts for wear or damage. Replace as
necessary.

8-22 4203780 First Edition

 CUTTING UNITS

Assembly Notes
• Assemble front lift arms in reverse order of
disassembly.
3
• Always use new cotter pins.
4
• Lubricate grease fittings with grease that meets or
exceeds NLGI Grade 2 LB specifications. Apply
grease with a manual grease gun and fill slowly until 2
grease begins to seep out. Do not use compressed
air gun.
5
Wing Decks
Removal and Installation
See Figures 8-13 and 8-14.

NOTE 6 7 8
Right wing deck shown; left is similar.
TN1847
1. Lower wing decks to the ground, and park the mower
Figure 8-14
safely. (See “Park Mower Safely” on page 1-6.)
4. Remove screw (6), lock washer (7), nut (8), and lock
pin (2).

NOTE
The deck pivot pin contains two shim washers (not
shown) at both ends of the pin between the mounting
1 brackets (4) and pivot casting (3). Be sure to note the
shim locations to ensure proper assembly.
5. Slide deck pivot pin (5) out of pivot casting (3) and
deck mounting brackets (4). Remove shim washers
and retain for use during installation.
6. Start engine and lift the deck arm. Stop engine and
roll the deck away from the machine.

Installation Notes
• Install the wing deck by reversing the order of
removal.

TN1845
• Apply grease that meets or exceeds NLGI Grade 2
LB specifications to deck pivot pin before installation. 8
Figure 8-13 • Lubricate grease fittings with grease that meets or
exceeds NLGI Grade 2 LB specifications. Apply
2. Remove deck motors. (See “Deck Motor” on grease with a manual grease gun and fill slowly until
page 8-16.) grease begins to seep out. Do not use compressed
3. Disconnect lift chain clevis (1). air gun.

4203780 First Edition 8-23

 CUTTING UNITS

Disassembly and Assembly

See Figure 8-15.

NOTE
Right wing deck shown; left is similar.

3
4
2
1 7 1

4 2
5 6
19 33 3 1
32
4
7 20 4
30
31 14
29 8 5
9
28 6
10
11
12

27 13

20
14

19
11
15
11
26
25 18
19 20

8 20
18
19

21
17 16

21
23
22
5
22 5
23 24 24
TN1900
1 Bushing (3) 8 Screw 15 Lock Nut 22 Blade (2) 29 Spacer
2 Caster Arm (2) 9 Flat Washer 16 Bumper 23 Screw (2) 30 Flat Washer
3 Screw (2) 10 Reflector 17 Carriage Bolt 24 Screw (2) 31 Screw
4 Flat Washer (4) 11 Decal (3) 18 Key (2) 25 Carriage Bolt 32 Wing Deck
5 Lock Washer (4) 12 Lock Washer 19 Nut (4) 26 Lock Nut 33 Motor (2)
6 Nut (2) 13 Nut 20 Lock Washer (4) 27 Rubber Stop
7 Grease Fitting (2) 14 Flat Washer (2) 21 Adapter (2) 28 Anti-Scalp Wheel
Figure 8-15

8-24 4203780 First Edition

 CUTTING UNITS

Disassembly Note
Inspect all moving parts for wear or damage. Replace as 5
necessary.

Assembly Notes 12 13
• Assemble wing deck in reverse order of disassembly.
9 10 11
• Tighten adapter screws (23) to 35–40 lb-ft (47–54
N·m).
6
• Tighten blade screw (24) to 75 lb-ft (100 N·m). 12 13 16
• Lubricate grease fittings with grease that meets or
exceeds NLGI Grade 2 LB specifications. Apply
grease with a manual grease gun and fill slowly until
14 14
grease begins to seep out. Do not use compressed
air gun. 15
TN1961
Wing Deck Lift Arms Figure 8-17

Removal and Installation 6. Remove screw (9), washer (10), nut (11), and pin
(16) allowing the lift cylinder (15) to drop down.
See Figures 8-16 and 8-17.
7. Support lift arm (5) and remove four screws (12), four
1. Lower wing decks to the ground, and park the mower washers (13), and two blocks (14).
safely. (See “Park Mower Safely” on page 1-6.)
8. Remove the lift arm.
2. Remove wing deck. (See “Wing Decks” on
page 8-23.) Installation Notes
• Install the wing deck lift arms by reversing the order
of removal.
• Lubricate grease fittings with grease that meets or
1 2 3 exceeds NLGI Grade 2 LB specifications. Apply
grease with a manual grease gun and fill slowly until
grease begins to seep out. Do not use compressed
air gun.
4
5
8 7 6

TN1959
Figure 8-16
3. Remove screw (8), collar (7), and nut (6).
8
4. Remove pivot (1) from the lift arm (5) along with two
spacers (2) and two washers (3).
5. Remove bracket (4).

4203780 First Edition 8-25

 CUTTING UNITS

Disassembly and Assembly

See Figure 8-18.

NOTE
Right wing deck lift arm shown; left is similar.

4 5
7 8 9
1 10
11 6 11
3
2 14
13
1 15
12
32

16
34 11
33 31
9
35 18
20 19
21
22
8
36 17
10
32

31
30
23 24 25 26

29
28

8 25
20 27

26
TN1843
1 Spacer (2) 10 Washer (4) 19 Pin 28 Block
2 Washer 11 Lock Nut (3) 20 Flat Washer (2) 29 Lock Washer
3 Washer 12 Shim 21 Screw 30 Screw
4 Wing Deck Lift Arm 13 Magnet 22 Shaft 31 Rubber Stop (2)
5 Nut (2) 14 Flat Washer 23 Pin 32 Grease Fitting (3)
6 Lock Washer 15 Lock Washer 24 Pin 33 Screw
7 Flat Washer 16 Screw 25 Lock Washer (2) 34 Collar
8 Grease Fitting (2) 17 Lift Cylinder 26 Screw (2) 35 Flat Washer
9 Bushing (2) 18 Grease Fitting 27 Bracket 36 Pivot
Figure 8-18

8-26 4203780 First Edition

 CUTTING UNITS

Disassembly Note 7. Inspect yoke (1) along with the flat washers (3),
Inspect all moving parts for wear or damage. Replace caster wheel spacers (4), and height-of-cut spacers
parts as necessary. (5) for wear or damage. Replace as necessary.
8. Inspect caster arm (7) for wear or damage, and
Assembly Notes replace as necessary.
• Assemble wing deck lift arm in reverse order of
disassembly. Installation Notes
• Lubricate grease fittings with grease that meets or • Install the swivel caster wheels by reversing the order
exceeds NLGI Grade 2 LB specifications. Apply of removal.
grease with a manual grease gun and fill slowly until • Lubricate grease fittings with grease that meets or
grease begins to seep out. Do not use compressed exceeds NLGI Grade 2 LB specifications. Apply
air gun. grease with a manual grease gun and fill slowly until
grease begins to seep out. Do not use compressed
Swivel Caster Wheels air gun.

Removal and Installation

See Figure 8-19.

NOTE
Note position and order of flat washers and height-of-cut
spacers for proper installation.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise and support cutting deck using jackstands.

1 2

3 4

7 6
8

TN1846
Figure 8-19
3. Support caster wheel assembly (6).
4. Remove lock pin (2).
5. Slide the top flat washers (3), caster wheel spacer
(4), and height-of-cut spacers (5) off yoke (1).
6. Remove caster wheel assembly (6), bottom
height-of-cut spacers (5), and caster wheel spacer
(4), from bottom of caster arm (7).

4203780 First Edition 8-27

 CUTTING UNITS

Disassembly and Assembly Disassembly Notes

See Figure 8-20. • Note position and order of flat washers and
height-of-cut spacers for proper assembly.
• Inspect all moving parts for wear or damage.
1 Replace as necessary.

2 Assembly Notes
• Assemble caster wheel in reverse order of
3 disassembly.
• Lubricate grease fitting with grease that meets or
exceeds NLGI Grade 2 LB specifications. Apply
grease with a manual grease gun and fill slowly until
4 grease begins to seep out. Do not use compressed
air gun.
• Set caster tire pressure to 23 psi.
3
Fixed Caster Wheels
Removal and Installation
See Figure 8-21.
1. Park the mower safely. (See “Park Mower Safely” on
3
page 1-6.)
2. Raise and support cutting deck using jackstands.

6
7
16
8
9

12 1 2 3
11 6 5 4
TN1854

8 13 Figure 8-21
3. Remove screw (1), lock washer (2), and nut (3).
10
4. Remove cotter pin (4).
11 5. Remove shaft pin (5) and caster wheel (6).
12
6. Inspect caster wheel (6) along with bearings,
13 bushings, washers, and pin for wear or damage.
15 Replace as necessary.
14
TN1843
Installation Notes
1 Lock Pin 7 Lock Washer 12 Bushings
2 Flat Washer s 8 Cotter Pin 13 Washers • Inspect cotter pin for damage before installation.
3 Caster Wheel Spacers 9 Screw 14 Valve Stem • Install the fixed caster wheel by reversing the order of
4 Height-of-Cut Spacers 10 Wheel and 15 Tire
Bearing removal.
5 Yoke 11 Rollers 16 Shaft
6 Nut
Figure 8-20

8-28 4203780 First Edition

 CUTTING UNITS

Disassembly and Assembly Anti-Scalp Wheels

See Figure 8-22.
Removal and Installation
See Figure 8-23.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
1 2. Raise and support cutting deck using jackstands.
2

1 2 3

8 9 4
4 11 10
7
5 8 7 6 5
6
TN1863
Figure 8-23
3. Remove screw (1), lock washer (2), and nut (3).
4. Remove cotter pin (9).
6
7 5. Remove shaft (10) and anti-scalp wheel (11).
8 6. Remove screw (5), washer (6), spacer (7), and nut
(8) to remove anti-scalp wheel (4).
11 9 7. Inspect anti-scalp wheels for wear or damage.
10 TN1844 Replace as necessary.
1 Screw 7 Bushing (2)
2 Cotter Pin 8 Flat Washer (2) Installation Notes
3 Shaft 9 Wheel and Bearing • Inspect cotter pin for damage before installation.
4 Lock Washer 10 Valve Stem
• Install anti-scalp wheels by reversing the order of
5 Nut 11 Tire
6 Bearing Roller (2) removal.
Figure 8-22

Disassembly Note
Inspect all moving parts for wear or damage. Replace as
8
necessary.

Assembly Notes
• Assemble fixed caster wheel in reverse order of
disassembly.
• Lubricate grease fitting with grease that meets or
exceeds NLGI Grade 2 LB specifications. Apply
grease with a manual grease gun and fill slowly until
grease begins to seep out. Do not use compressed
air gun.
• Set caster tire pressure to 23 psi.

4203780 First Edition 8-29

 CUTTING UNITS

Disassembly and Assembly

See Figure 8-24.

12
11
1 2
10

6 3
5 4
8 7

TN1864
1 Anti-Scalp Wheel (2) 7 Cotter Pin
2 Spacer (2) 8 Bushings
3 Flat Washer (2) 9 Anti-Scalp Wheel
4 Screw (2) 10 Shaft
5 Lock Nut (2) 11 Nut
6 Screw 12 Lock Washer
Figure 8-24

Disassembly Note
Inspect all parts for wear or damage. Replace as
necessary.

Assembly Notes
• Inspect cotter pin for damage before assembly.
• Assemble anti-scalp wheel in reverse order of
disassembly.

8-30 4203780 First Edition

 Chapter 9

Accessories and Miscellaneous Repair

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Park Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Bleed Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
OPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Seat and Seat Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Work Light Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

4203780 First Edition 9-1

 ACCESSORIES AND MISCELLANEOUS REPAIR

Specifications
OPS Mounting Hardware
Mounting Hardware Torque lb-ft (N·m) 135—165 (183—224)

Fuel Tank
Capacity gal (L) 20 (75.7)

Front Tires
Size 26 x 12.00-12
Type 6-Ply
Air Pressure psi (bar) 16—20 (0.55—0.69)
Mounting Bolt Torque lb-ft (N·m) 100—120 (135—162)

Rear Tires
Size 23 x 10.50-12
Type 4-Ply
Air Pressure psi (bar) 8—10 (55—69)
Mounting Bolt Torque lb-ft (N·m) 40—50 (54—68)

Mower Speed
Transport—2WD mph (km/h) 0—15 (0—24)
Transport—4WD mph (km/h) 0—8.4 (0—13.5)
Mowing mph (km/h) 0—7.5 (0—12)
Reverse mph (km/h) 0—6 (0—9.7)

Brakes
Brake Pedal Free Travel in. (mm) 0.125 (3)
Park Brake Lever Force lb (kg) 36—42 (16—19)
Brake Caliper Nut Torque lb-ft (N·m) 37 (51)

Traction Pedal
Traction Pedal Mounting Bracket lb-ft (N·m) 25 (34)

9 Nut Torque
Traction Pedal Ball Joint Nut Torque lb-ft (N·m) 50 (68)

9-2 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Component Location
See Figure 9-1.

8 9 1

2
7
3
10

6
5

TN1768, TN1849
1 OPS (Operator Protective Structure) 6 Front Wheel (2)
2 Seat and Seat Platform 7 Differential Lock Switch
3 Hood 8 Brake Pedal
4 Park Brake 9 Traction Pedal
5 Rear Wheel (2) 10 Fuel Tank
Figure 9-1
9

4203780 First Edition 9-3

 ACCESSORIES AND MISCELLANEOUS REPAIR

Checks and Adjustments Brake Pedal Adjustment

See Figure 9-3.
Park Brake Adjustment 1. Park the mower safely. (See “Park Mower Safely” on
See Figure 9-2. page 1-6.)
1. Park the mower safely. (See “Park Mower Safely” on S

page 1-6.)
2. Check linkages, cables, and pivot points to ensure 1
they are operating smoothly. Check brake pads for
2
wear.

TN1870
1 Figure 9-3
2. Loosen nuts (2).
3. Turn ball joint (1) to adjust pedal travel.

NOTES
• Adjust ball joint so brake pedal has a minimum of
0.125 in. (3 mm) free travel before plunger touches
piston in the master cylinder.
• Turn ball joint in (clockwise) to decrease pedal travel.
• Turn ball joint out (counterclockwise) to increase
TN1873
pedal travel.
Figure 9-2
4. Tighten nuts.
3. To set brake force: Place brake lever in the
disengaged position. Sit in the operator’s seat and
turn knob (1) clockwise to increase force. Using a
scale to measure the amount of force, apply and
release brake every quarter turn until a force of 36—
42 lb (16—19 kg) is achieved at the base of the
adjustment knob. If a scale is not available for
measuring, place tractor in 2WD mode and adjust

9 brake until motor cannot overcome the park brake.

NOTES
• If the knob on the park brake has been turned to its
maximum extent, new brake pads are required.
• Brake pads must be replaced when worn to the point
that they touch each other above the brake disc.

9-4 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Bleed Brake System Repair

See Figure 9-4.
1. Park the mower safely. (See “Park Mower Safely” on Canopy
page 1-6.)
2. Fill master cylinder with approved brake fluid. See Removal and Installation
operator’s manual for brake fluid recommendations. See Figures 9-5 and 9-6.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

TN1774
Figure 9-5
TN1869 2. Support the canopy (1) using a suitable lifting device.
Figure 9-4
3. Slowly pump the brake pedal several times and hold
1
brake pedal down.
4. Slowly open one of the caliper bleed screws (1) to
release air.

NOTE
Check brake fluid level periodically during bleeding to
maintain brake fluid level above half of the master
cylinder reservoir capacity.
5. Close caliper bleed screw.
6. Release brake pedal slowly.
7. Repeat steps 2 through 5 until all the air has been 2
bled from the brake line. 2 3 4 5
3 4 5
8. Repeat steps 2 through steps 7 for the other caliper TN1775
bleed screw.
Figure 9-6
9. Repeat steps 2 through steps 8 for the opposite
brake caliper assembly. 3. Loosen the nuts on the two front screws (2). 9
10. Fill the master cylinder with approved brake fluid. 4. Remove the rear nuts (3), screws (4), and washers
(5).
5. Remove the canopy (1).

Installation Notes
• Center the canopy before tightening the mounting
hardware.
• Install the canopy by reversing the order of removal.

4203780 First Edition 9-5

 ACCESSORIES AND MISCELLANEOUS REPAIR

OPS 6. Repeat steps 4 and 5 for other side of mower.

7. Lift OPS (6) and slide toward rear of mower until OPS
Removal and Installation clears the end of the mower.
See Figures 9-7 and 9-8.
Installation Notes
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) • Install OPS by reversing the order of removal.
2. Remove canopy (if equipped). (See “Canopy” on • Tighten OPS mounting bolts to 135—165 lb-ft
page 9-5.) (183—224 N·m).

Hood
Removal and Installation
See Figure 9-9.
1 2 3
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

4
1 2 1 2

TN1808 3 3
Figure 9-7 4
4

6
TN1776
Figure 9-9
7 8 9
2. Open and support hood using a suitable lifting
device.
3. Remove cotter pins (1) and washers (2) from pivot
rod (4).
4. Slide hood to one side until pivot (3) clears the end of
the pivot rod (4). With one side disengaged, slide
hood to the other side until the other pivot clears the
pivot rod. Remove hood from mower.

9 Figure 9-8
TN1778
Installation Notes
3. Support the OPS (6) using a suitable lifting device. • Support the hood with a suitable lifting device to aid
in installation.
IMPORTANT • Install hood by reversing the order of removal.
Decks must be down during removal procedure.
4. To allow access to the OPS mounting bolts, remove
bolt (1), nut (2), washer (3), and pin (4) to lower the
end of the wing lift cylinder (5).
5. Remove the four OPS mounting bolts (7), nuts (8),
and washers (9).

9-6 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Fuel Tank
Removal and Installation
See Figures 9-10 through 9-13.
4 5
! CAUTION
Diesel fuel is highly flammable. Do not drain fuel
indoors. Heaters can ignite fuel vapors. Use
extreme caution when draining fuel.
6

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove instrument panel. (See “Instrument Panel” TN1832
on page 4-110.)
Figure 9-11
3. Disconnect the negative (–) battery cable at the
battery. 8. Tag and disconnect fuel return (4) and fuel vent (5)
lines. Plug lines and cap fittings to prevent leakage
and contamination.
9. Remove fuel level sensor cover (6).

1
2
3 8
7

TN1788

Figure 9-10 TN1833

Figure 9-12
NOTE 10. Tag and disconnect the fuel level sensor wire
Fuel tank capacity is 20 gal (75.7 L). Have suitable harness (8) from the fuel level sensor (7).
container(s) available that can hold up to 25 gal (95 L) of
fuel.
4. Place a suitable container underneath the fuel tank
drain valve (2) and open the valve. Loosen the fuel
cap to provide a vent for draining fuel.
9
5. When fuel tank is completely empty, close tank drain
valve and tighten fuel cap.
6. Close fuel outlet hose shutoff valve (1). (Turn
clockwise until valve bottoms lightly.)
7. Tag and disconnect fuel outlet (3). Plug line and cap
fitting to prevent leakage and contamination.

4203780 First Edition 9-7

 ACCESSORIES AND MISCELLANEOUS REPAIR

10

11

10

11

TN1789
Figure 9-13
11. Support the fuel tank (9) and remove the two
mounting screws (11) and washers (10).
12. Remove the fuel tank from the mower.

Required Materials

Anti-Seize Compound

Installation Notes
• Apply anti-seize to the fuel tank screws (11).
• Install the fuel tank by reversing the order of removal.
• Use only clean diesel fuel of the correct type (#2
9 diesel) from a clean, sealed container.
• If fuel was contaminated, install a new fuel filter at
this time. (See “Fuel Filter” on page 3-15.)
• Bleed fuel system.

9-8 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Traction Pedal
Disassembly and Assembly
See Figure 9-14.

1
2
3
33 4
5
6
15
1 14
7
16
32 13
8 17
12
9
18
11
14
10
13 31 30 29
12 28

17

28 16
27 26
25
19
11
24
21
23
22
20

TN1815
9
1 Bushing (2) 12 Flat Washer (2) 23 Nut (2)
2 Traction Pedal 13 Lock Washer (2) 24 Lock Washer (2)
3 Nut (2) 14 Nut (2) 25 Switch Bracket
4 Lock Washer (2) 15 Cotter Pin 26 Lock Washer (2)
5 Flat Washer (2) 16 Flat Washer (2) 27 Nut (2)
6 Traction Pedal Mounting Bracket 17 Bushing (2) 28 Ball Joint (2)
7 Traction Pedal Pivot Rod 18 Traction Bell Crank 29 Traction Pedal Adjusting Rod
8 Cotter Pin 19 Carriage Bolt (2) 30 Jam Nut
9 Screw 20 Screw (2) 31 Screw (2)
10 Grease Fitting 21 Flat Washer (2) 32 Flange Nut (2)
11 Flat Washer (3) 22 Reverse Kick Out Switch 33 Pedal Limiting Stud
Figure 9-14

4203780 First Edition 9-9

 ACCESSORIES AND MISCELLANEOUS REPAIR

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.)
2. Remove nut (14), lock washer (13), and flat washer
(12) from ball joint (28).
3. Remove two nuts (3), lock washers (4), flat washers
(5), and two screws (31) from traction pedal mounting
bracket (6).
4. Lift traction pedal (2) and traction pedal mounting
bracket out and away from machine.
5. Remove screw (9) from traction pedal mounting
bracket, and remove cotter pin (8) from traction pedal
pivot rod (7).
6. Remove traction pedal pivot rod from traction pedal,
and remove two bushings (1) from each side of the
traction pedal. Inspect traction pedal pivot rod and
bushings for wear; replace as necessary.
7. Remove nut (14), lock washer (13), and flat washer
(12) from ball joint (28). Separate ball joint from
traction bell crank (18) and remove traction pedal
adjusting rod (29). Inspect ball joints for binding or
excess free play; replace as necessary.
8. Unplug reverse kick out switch (22), and remove two
nuts (23), lock washers (24), and flat washers (11) to
remove reverse kick out switch with switch bracket
(25).
9. Remove two nuts (27), lock washers (26), flat
washers (21), and screws (20) to remove reverse kick
out switch from switch bracket.
10. Separate traction pump adjusting rod linkage from
the back of the bell crank.
11. Remove cotter pin (15), two flat washers (16), two
bushings (17), and bell crank (18) from frame
assembly. Inspect the two bushings for wear; replace
as necessary.

Disassembly Note
Clean and inspect all moving parts, checking for wear,
damage, and binding parts.

Assembly Notes
• Assemble in reverse order of disassembly.
9 • Apply grease to all pivot points and grease fittings.
• Use new cotter pins during assembly.
• Tighten traction pedal mounting bracket nuts to 25
lb-ft (34 N·m).
• Tighten the ball joint nuts to 50 lb-ft (68 N·m).
• Adjust mowing speed with pedal stop (33).
• Check reverse kick out switch (22) adjustment. (See
“Reverse Kick-Out Switch” on page 4-99.)

9-10 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Park Brake
Disassembly and Assembly
See Figures 9-15 and 9-16.

1 2
4
3 5
8
9
5 8
4 9
10
11
7
6 15
12 13 14 16
29 17
40 28

39 18
38
19 20
30 27 10
26
18 25 24

18 31 23
21
31 32 22
32 33
33 34
35 35
37
36 36

35
36

TN1792
1
2
3
Screw (2)
Flat Washer (2)
Release Spring Bracket
11
12
13
Right Side Brake Switch Bracket
Park Brake Pin
Lock nut
21
22
23
Screw (2)
Nut (2)
Lock Washer (2)
31
32
33
Flat Washer (2)
Park Brake Cable Pulley (2)
Spacer (2)
9
4 Brake Shim (2) 14 Park Brake Switch Actuator 24 Screw (3) 34 Rear Cable Guide Pulley Bracket
5 Park Brake Caliper 15 Screw (2) 25 Spacer (5) 35 Lock Washer (4)
6 Park Brake Release Spring 16 Flat Washer (2) 26 Park Brake Lever 36 Nut (4)
7 Park Brake Caliper Bracket 17 Park Brake Switch 27 Park Brake Handle 37 Front Cable Guide Pulley Bracket
8 Nut (5) 18 Screw (3) 28 Nut (2) 38 Clevis Pin
9 Lock Washer (5) 19 Cotter Pin 29 Lock Washer (2) 39 Park Brake Cable
10 Flat Washer (4) 20 Left Side Brake Switch Bracket 30 Screw (2) 40 Cotter Pin
Figure 9-15

4203780 First Edition 9-11

 ACCESSORIES AND MISCELLANEOUS REPAIR

1. Park the mower safely. (See “Park Mower Safely” on

page 1-6.) 9
2. Place wheel chocks in front of and behind front 8
wheels. 7
3. Remove the battery. (See “Battery and Battery Tray” 6
5 10
on page 4-86.)
4
4. Place brake lever in the disengaged position.
3
5. Disconnect spring (6) from release spring bracket (3) 2
to relieve tension. 1
6. Remove cotter pin (40) and clevis pin (38).
7. Disconnect wiring harness lead to park brake switch
(17).
8. Remove three nuts (8), lock washers (9), screws
(24), and spacers (25). TN1793
9. Raise park brake handle (27) to the engaged position 1 Lock nut (2) 5 Brake Cam 9 Screw (2)
and lower park brake lever (26) down and out of Lever
machine. 2 V-Plate 6 Stud Plate 10 Rib Plate
with Lining with Lining
10. Remove cotter pin (19) and park brake pin (12) to 3 Brake Shim(2) 7 Brake Return
remove park brake cable (39). Inspect park brake Spring (2)
4 Park Brake 8 Brake
cable for wear or fraying; replace as necessary. Caliper Bracket Spacer (2)
11. Remove two nuts (22), lock washers (23), screws Figure 9-16
(15), and flat washers (16) to remove the park brake
switch (17). 18. Remove the two nuts (41), V-plate (42), and two
brake shim (4).
12. Remove the lock nut (13) and screw (18) to remove
the park brake switch actuator (14). 19. Remove the rib plate (48), stud plate (44), two
springs (45), two spacers (46), two bolts (47), and
13. Remove two nuts (8), two lock washers (9), four flat brake cam lever (43) as an assembly.
washers (10), and two screws (21) to remove the left
side brake switch bracket (20) and right side brake 20. Remove the bolts from the two plates, and remove
switch bracket (11). the springs and spacers. Inspect caliper assembly for
wear; replace as necessary.
14. Remove two nuts (36), lock washers (35), and
screws (30) to remove the front cable guide pulley Disassembly Note
bracket (37) and the rear cable guide pulley bracket
(34). Clean and inspect all moving parts, checking for wear,
damage, and binding parts.
15. Remove the nut (36), lock washer (35), spacer (33),
park brake cable pulley (32), flat washer (31), and Installation Notes
screw (18) from the rear cable guide pulley bracket.
Inspect the park brake cable pulley and spacer for • Assemble the park brake by reversing the order of
wear; replace as necessary. disassembly.

16. Remove the nut (36), lock washer (35), spacer (33), • Carefully route park brake switch wire harness to
park brake cable pulley (32), flat washer (31), and avoid damage from pinched wires.

9 screw (18) from the front cable guide pulley bracket.

Inspect the park brake cable pulley and spacer for
wear; replace as necessary.
• Adjust park brake. (See “Park Brake Adjustment” on
page 9-4.)

17. With a marking pen, make a reference mark of the

location of the park brake caliper bracket (7) to the
frame. Remove the two nuts (28), lock washers (29),
flat washers (2), and screws (1) to remove the
release spring bracket (3) and the park brake caliper
bracket with the park brake caliper (5) as an
assembly.

9-12 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Seat and Seat Platform Installation Notes

• Install the seat and seat platform by reversing the
Removal and Installation order of removal.
See Figures 9-17 and 9-18. • Carefully route and secure seat switch wire harness
1. Park the mower safely. (See “Park Mower Safely” on to avoid damage from pinched wires.
page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.

3
1

TN1801
Figure 9-17
3. Rotate seat (1) upward and lock in place by engaging
rod (2).
4. Block front wheels and disengage park brake (3) to
allow clearance for seat removal.

4 5

6
9
TN1772
Figure 9-18
5. Tag and disconnect the operator’s seat switch wire
harness connector (5).
6. Using a suitable lifting device, slide seat to the left
side of the mower to disengage the two pins (4) from
the two hinges (6), and remove seat and seat
platform from the mower.

4203780 First Edition 9-13

 ACCESSORIES AND MISCELLANEOUS REPAIR

Disassembly and Assembly

See Figures 9-19 and 9-20.

5 3 4
6 8
9
7 10
33 11
12

32 13
14
15
31

16
30 17

29

18
19
28 20
21
27
22
26
25
23

9 24
TN1773
1 Seat 9 Nut 17 Trim Seal 25 Foam, Front
2 Screw 10 Lock Washer 18 Rod 26 Nut
3 Armrest, Left-Hand 11 Flat Washer 19 Roll Pin 27 Lock Washer
4 Armrest, Right-Hand 12 Seat Suspension, Mini 20 Knob 28 Flat Washer
5 Seat Switch 13 Spacer 21 Seat Pan 29 Trim Seal
6 Lock Washer 14 Flat Washer 22 Foam, Top 30 Spring
7 Screw 15 Carriage Bolt 23 Foam, Left Side 31 Roll Pin
8 Seat Switch Wire Harness 16 Latching Adjuster 24 Weather Strip 32 Slave Adjuster
33 Screw
Figure 9-19

9-14 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

1
2

1 5
8
7
6

9
9
13

12
10
11
TN1805
1 Push Nut (4) 6 Spring Hanger 11 Nut
2 Pivot Shaft (2) 7 Lock nut 12 Spring Kit
3 Knob 8 Spring (2) 13 Screw
4 Flat Washer 9 Bearing (4)
5 Bumper (2) 10 Lock Washer
Figure 9-20: Mini Seat Suspension

4203780 First Edition 9-15

 ACCESSORIES AND MISCELLANEOUS REPAIR

Floorboard
Removal and Installation
See Figures 9-21 through 9-23.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove seat and seat platform. (See “Seat and Seat
Platform” on page 9-13.)
3. Remove instrument panel. (See “Instrument Panel”
6
on page 4-110.)
4. Remove fuel tank. (See “Fuel Tank” on page 9-7.)
5. Remove traction pedal. (See “Traction Pedal” on
page 9-9.)
6. Remove brake pedal. (See “Brake Pedal” on
page 9-19.)
7. Remove park brake. (See “Park Brake” on TN1852
page 9-11.)
Figure 9-22
8. Remove diff lock switch. (See “Diff Lock Switch” on
page 4-100.) 11. Remove two screws (6).
9. Remove work light kit (if equipped). (See “Work Light
Kit” on page 9-17.)

8 9 10 11
7
2

1 12
3 4 5

TN1851
Figure 9-23
12. Remove two screws (7).
13. Remove nuts (8), lock washers (9), flat washers (10),
and screws (11).

9 14. Using suitable lifting device, raise and slide the

floorboard (12) forward to remove from mower.
TN1853
Figure 9-21 Installation Note
Install the floorboard by reversing the order of removal.
10. Remove bolts (3), lock washers (4), and flat washers
(5). Remove bracket (1) from console (2).

9-16 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Work Light Kit Rear Wheels

Removal and Installation Removal and Installation
See Figure 9-24. See Figure 9-25.
1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Disconnect the negative (–) battery cable at the
battery.

1 2 1

3
2

4
7 6
5
TN1910 TN1794
Figure 9-24 Figure 9-25
3. Remove grommet (3) from floorboard (7). 2. Loosen, but do not remove, wheel-to-hub lug bolts
4. Cut cable tie (4). (2).
5. Tag and disconnect work light wire connector (2) and 3. Raise and support rear of mower with jackstands.
pass through floorboard. 4. Remove wheel-to-hub lug bolts (2).
6. Remove lock nut (5) and flat washer (6) from work 5. Remove wheel (1) and inspect tread area for tears or
light (1). other damage.
7. Remove work light. 6. Replace tire if damage is excessive.

Installation Notes
Required Materials
• Install work light by reversing the order of removal.
• Use new cable tie to secure work light wire harness Anti-Seize Compound
connector.
• Adjust the work lights to project the desired distance Installation Notes
in front of the mower. • Inspect and clean any rust from hub (3) or wheel
mounting area. Apply anti-seize compound to lug
bolts.
• Install wheel by reversing the order of removal.
9
• Torque wheel-to-hub lug bolts to 40—50 lb-ft (54—68
N·m).
• Set tire pressure to 8—10 psi (0.55—0.69 bar).

4203780 First Edition 9-17

 ACCESSORIES AND MISCELLANEOUS REPAIR

Front Wheels
Removal and Installation
See Figure 9-26.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Block both sides of rear wheels using suitable wheel
blocks.

3
4

TN1795
Figure 9-26
3. Loosen, but do not remove, lug nuts (3).
4. Raise and support front of mower with jackstands.
5. Remove lug nuts (3).
6. Remove wheel (2) and inspect tread area for tears or
other damage.
7. Replace tire if damage is excessive.

Required Materials

Anti-Seize Compound

9 Installation Notes
• Inspect and clean any rust from hub (4) or wheel
mounting area. Apply anti-seize compound to wheel
studs (1).
• Install wheel by reversing the order of removal.
• Torque lug nuts to 100—120 lb-ft (135—162 N·m).
• Set tire pressure to 16—20 psi (1.1—1.4 bar).

9-18 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Brake Pedal
Disassembly and Assembly
See Figure 9-27.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)

2 3

18
4
17 5
16
15

14
13
12

11 6
7
10
8
9

TN1866
1 Screw 6 External Tooth Washer 11 Brake Pedal 16 Lock Washer

9
2 Woodruff Key 7 Brake Switch Activator Plate 12 Lock Washer 17 Brake Hub
3 Set Screw 8 Carriage Bolt 13 Brake Pedal Pad 18 Flat Washer (2)
4 Pedal Pin Nut 9 Nut 14 Pedal Pin
5 Grease Fitting 10 Lock nut 15 Nut
Figure 9-27
• Lubricate grease fitting with grease that meets or
NOTES exceeds NLGI Grade 2 LB specifications. Apply
• Using the lower hole on brake pedal (11), install grease with a manual grease gun and fill slowly until
brake switch activator plate (7) so that the external grease begins to seep out. Do not use compressed
tooth washer (6) is fully collapsed and the edges of air gun.
the brake switch activator plate align with the brake
lever.
• Clean grease fitting (5) before and after lubricating.

4203780 First Edition 9-19

 ACCESSORIES AND MISCELLANEOUS REPAIR

Brake Master Cylinder Brake Caliper

Removal and Installation Removal and Installation
See Figures 9-28 and 9-29. See Figure 9-30.
1. Park the mower safely. (See “Park Mower Safely” on 1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.) page 1-6.)
2. Remove front wheels. (See “Front Wheels” on
page 9-18.)

1
1 2
3

2 4

TN1871
Figure 9-28
2
2. Disconnect brake line (1) from master cylinder (2).
Plug brake master cylinder and cap brake line fitting
to prevent leakage and contamination.
TN1869
Figure 9-30
3. Disconnect brake line (3) from caliper (1). Plug brake
caliper and cap brake line fitting to prevent leakage
and contamination.
4. Remove nuts (2) and screws (4).
5. Remove brake caliper.
3 4 5 6
Installation Notes
• Install the brake caliper by reversing the order of
6 7 8 removal.
• Tighten the brake caliper nuts to 37 lb-ft (51 N·m).
• Bleed the brake system. (See “Bleed Brake System”
on page 9-5.)
TN1870
Figure 9-29
9 3. Remove nut (3), lock washer (4), two flat washers (5),
and screw (6).
4. Remove three nuts (6), lock washers (7), and screws
(8).
5. Remove master cylinder (2).

Installation Notes
• Install the master cylinder by reversing the order of
removal.
• Bleed the brake system. (See “Bleed Brake System”
on page 9-5.)

9-20 4203780 First Edition

 ACCESSORIES AND MISCELLANEOUS REPAIR

Disassembly and Assembly

See Figure 9-31.

2
3
3
1

3 2
2

6
5

TN1867
1 Brake Caliper 4 Brake Pad Set
2 Caliper Seal Repair Kit 5 Caliper Bleed Screw
3 Pad Retaining Pin and Spring Kit 6 Bleed Screw Cap
Figure 9-31

NOTE
Inspect and clean any rust from pad retaining pins (3).
Apply anti-seize compound to pad retaining pins and
ensure pad retaining pins slide freely.

4203780 First Edition 9-21

 ACCESSORIES AND MISCELLANEOUS REPAIR

Page Intentionally Blank

9-22 4203780 First Edition

 INDEX

Numerics B
4WD Rev Solenoid Battery
Removal and Installation . . . . . . . . . . . . . . 4-107 Removal and Installation . . . . . . . . . . . . . . 4-85
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Blade
4WD Solenoid Removal and Installation . . . . . . . . . . . . . . 3-18
Removal and Installation . . . . . . . . . . . . . . 4-107 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
Brake Caliper
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Disassembly and Assembly . . . . . . . . . . . . 4-21
4WD Switch Removal and Installation . . . . . . . . . . . . . . 4-20
Removal and Installation . . . . . . . . . . . . . . . 4-98 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Brake Master Cylinder
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Removal and Installation . . . . . . . . . . . . . . 4-20
4WD Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Disassembly, Inspection, and Assembly . . . 5-53
Brake Pedal
Removal and Installation . . . . . . . . . . . . . . . 5-53
Disassembly and Assembly . . . . . . . . . . . . 4-19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Brake Pedal Switch
Removal and Installation . . . . . . . . . . . . . . 4-91
A Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Accessories and Miscellaneous Repair
Checks and Adjustments . . . . . . . . . . . . . . . . 4-4
Component Location . . . . . . . . . . . . . . . . . . . 4-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 C
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Canopy
Actuating Devices
Removal and Installation . . . . . . . . . . . . . . . 4-5
Component Symbols . . . . . . . . . . . . . . . . . . . 4-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Air Cleaner Assembly
Charge Filter Pressure Switch
Removal and Installation . . . . . . . . . . . . . . . . 3-8
Removal and Installation . . . . . . . . . . . . . 4-102
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
Air Filter Pressure Switch
Charging Circuit
Removal and Installation . . . . . . . . . . . . . . 4-100
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Theory of Operation . . . . . . . . . . . . . . . . . . 4-34
Air Tools Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-63
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Checks and Adjustments
Alternator Accessories and Miscellaneous Repair . . . . 4-4
Removal and Installation . . . . . . . . . . . . . . . 4-86 Bleed Brake System . . . . . . . . . . . . . . . . . . . 4-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Brake Pedal Adjustment . . . . . . . . . . . . . . . . 4-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Anti-Scalp Wheels
Fuel Solenoid Rod . . . . . . . . . . . . . . . . . . . . 3-6
Disassembly and Assembly . . . . . . . . . . . . . 3-30
Park Brake Adjustment . . . . . . . . . . . . . . . . . 4-4
Removal and Installation . . . . . . . . . . . . . . . 3-29
Purging the Fuel System . . . . . . . . . . . . . . . 3-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Chemical Products
Safe Handling . . . . . . . . . . . . . . . . . . . . . . . . 1-9

IX
4203780 First Edition IX-1
 INDEX

Circuit Breakers Cruise Control Switch

Removal and Installation . . . . . . . . . . . . . . . 4-87 Removal and Installation . . . . . . . . . . . . . . . 4-98
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Circuit Protection Devices Cutting Units
Component Symbols . . . . . . . . . . . . . . . . . . . 4-5 Component Location . . . . . . . . . . . . . . . . . . . 3-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Component Identification
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical Schematic . . . . . . . . . . . . . . . . . . . . 4-8
Tests and Adjustments . . . . . . . . . . . . . . . . . 3-4
Component Location Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydrostatic Power Train . . . . . . . . . . . . . . . . . 5-5
D
Kubota V2203-DI-B . . . . . . . . . . . . . . . . . . . . 3-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Deck Leveling Adjustment
Tests and Adjustments . . . . . . . . . . . . . . . . . 3-4
Component Symbols
Actuating Devices . . . . . . . . . . . . . . . . . . . . . . 4-6 Deck Motor
Circuit Protection Devices . . . . . . . . . . . . . . . 4-5 Disassembly and Assembly . . . . . . . . . . . . 3-17
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Removal and Installation . . . . . . . . . . . . . . . 3-16
Engine-Related Devices . . . . . . . . . . . . . . . . . 4-6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Deck Motors
Miscellaneous Symbols . . . . . . . . . . . . . . . . . 4-7 Removal and Installation . . . . . . . . . . . . . . . 6-61
Motors and Generating Devices . . . . . . . . . . . 4-6
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Deck Rake Adjustment
Switching Devices . . . . . . . . . . . . . . . . . . . . . 4-5 Front Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Tests and Adjustments . . . . . . . . . . . . . . . . . 3-4
Component Testing Wing Decks . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Deck Valve
Compressed Air Disassembly, Inspection, and Assembly . . . 6-66
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Definition of Terms
Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 Mismatched Cutting Units . . . . . . . . . . . . . . 3-15
Control Valve Quality of Cut Troubleshooting . . . . . . . . . . . 3-9
Disassembly, Inspection, and Assembly . . . 5-55 Scalping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Removal and Installation . . . . . . . . . . . . . . . 5-55 Step Cutting . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Stragglers . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cooling System Washboarding . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Service System Safely . . . . . . . . . . . . . . . . . . 1-9 Windrowing . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Cruise Control Diagnostic Information
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Theory of Operation . . . . . . . . . . . . . . . . . . . 4-44
Diff Lock Solenoid
Cruise Control Circuit Removal and Installation . . . . . . . . . . . . . . 4-107
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-66 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
Cruise Control Disable Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Diff Lock Switch
Cruise Control Magnet Removal and Installation . . . . . . . . . . . . . . 4-100
Removal and Installation . . . . . . . . . . . . . . 4-108 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Differential Assembly
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Disassembly and Inspection . . . . . . . . . . . . 5-73
IX Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

IX-2 4203780 First Edition

 INDEX

Differential Lock Assembly Engine Temperature Gauge

Disassembly, Inspection, and Assembly . . . 5-64 Removal and Installation . . . . . . . . . . . . . . 4-94
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94
Diodes Engine Temperature Sensor
Removal and Installation . . . . . . . . . . . . . . 4-109 Removal and Installation . . . . . . . . . . . . . 4-103
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Engine-Related Devices
Drive Axle Reducer Assembly Component Symbols . . . . . . . . . . . . . . . . . . 4-6
Disassembly and Inspection . . . . . . . . . . . . 5-70
Exhaust Manifold
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Removal and Installation . . . . . . . . . . . . . . 3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

E F
Fan Belt
Electrical
Removal and Installation . . . . . . . . . . . . . . . 3-7
Component Symbols . . . . . . . . . . . . . . . . . . . 4-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Component Testing . . . . . . . . . . . . . . . . . . . 4-72
Continuity Test . . . . . . . . . . . . . . . . . . . . . . . 4-72 Field Test Procedures
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Charge Pump Test . . . . . . . . . . . . . . . . . . . 5-33
Resistance Test . . . . . . . . . . . . . . . . . . . . . . 4-72 Front Lift Cylinder Leakage Test . . . . . . . . . 6-24
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Hydrostatic Power Train . . . . . . . . . . . . . . . 5-33
Theory and Diagnostic Information . . . . . . . . 4-5 Power Steering Circuit Test . . . . . . . . . . . . 6-26
Theory of Operation and Sub Circuit Schematics Preliminary Checks . . . . . . . . . . . . . . . . . . . 5-33
4-18 Traction System Test . . . . . . . . . . . . . . . . . 5-33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-62 Wing Lift Cylinder Leakage Test . . . . . . . . . 6-25
Electrical Components Final Adjustments
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Tests and Adjustments . . . . . . . . . . . . . . . . . 3-6
Electrical Schematic Fixed Caster Wheels
Component Identification . . . . . . . . . . . . . . . . 4-8 Disassembly and Assembly . . . . . . . . . . . . 3-29
Removal and Installation . . . . . . . . . . . . . . 3-28
Engine
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Checks and Adjustments . . . . . . . . . . . . . . . . 3-5
Component Location . . . . . . . . . . . . . . . . . . . 3-3 Floorboard
General Specifications . . . . . . . . . . . . . . . . . . 3-2 Removal and Installation . . . . . . . . . . . . . . 4-16
Removal and Installation . . . . . . . . . . . . . . . 3-17 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Repair . . . . . . . . . . . . . . . . . . . . . . . . . 3-7, 3-17
Four Wheel Drive Circuit
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Engine Coolant Temp Switch Theory of Operation . . . . . . . . . . . . . . . . . . 4-40
Removal and Installation . . . . . . . . . . . . . . 4-104 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Four Wheel Drive Reverse Circuit
Engine Oil Pressure Switch Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Removal and Installation . . . . . . . . . . . . . . 4-103
Front Axle
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
Removal and Installation . . . . . . . . . . . . . . 5-60
Engine Service Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Front Axle Motor
Engine Speed Sensor Disassembly, Inspection, and Assembly . . 5-59
Removal and Installation . . . . . . . . . . . . . . 4-110 Removal and Installation . . . . . . . . . . . . . . 5-58
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

IX
4203780 First Edition IX-3
 INDEX

Front Axle U-Joint Fuel Shutoff Solenoid

Removal and Installation . . . . . . . . . . . . . . . 5-47 Removal and Installation . . . . . . . . . . . . . . 4-108
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Front Deck
Deck Rake Adjustment . . . . . . . . . . . . . . . . . . 3-4 Fuel Solenoid Rod
Disassembly and Assembly . . . . . . . . . . . . . 3-20 Checks and Adjustments . . . . . . . . . . . . . . . . 3-6
Removal and Installation . . . . . . . . . . . . . . . 3-19
Fuel Tank
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Removal and Installation . . . . . . . . . . . . . . . . 4-7
Front Deck Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal and Installation . . . . . . . . . . . . . . . 6-66
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
Front Lift Arms G
Disassembly and Assembly . . . . . . . . . . . . . 3-22
Removal and Installation . . . . . . . . . . . . . . . 3-21 Gear Pump
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Disassembly, Inspection, and Assembly . . . 6-60
Front Lift Cylinders Removal and Installation . . . . . . . . . . . . . . . 6-58
Disassembly, Inspection, and Assembly . . . 6-70 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Removal and Installation . . . . . . . . . . . . . . . 6-69 Glow Plug Circuit
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-69 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Front Limit Switch Theory of Operation . . . . . . . . . . . . . . . . . . 4-26
Removal and Installation . . . . . . . . . . . . . . . 4-97 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-62
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Glow Plug Solenoid
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Removal and Installation . . . . . . . . . . . . . . 4-107
Front Mow Enable Switch Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
Removal and Installation . . . . . . . . . . . . . . . 4-98 Glow Plug Switch
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Removal and Installation . . . . . . . . . . . . . . . 4-93
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Front Mow Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Removal and Installation . . . . . . . . . . . . . . 4-106
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 H
Front Wheels
Removal and Installation . . . . . . . . . . . . . . . 4-18 Hazardous Materials Storage . . . . . . . . . . . . . . 1-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Hood
Fuel Removal and Installation . . . . . . . . . . . . . . . . 4-6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Fuel Filter Horn

Removal and Installation . . . . . . . . . . . . . . . 3-15 Removal and Installation . . . . . . . . . . . . . . 4-112
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112

Fuel Gage Horn and Audible Alert Circuit

Removal and Installation . . . . . . . . . . . . . . 4-111 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-71
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Horn/Test Circuit
Fuel Level Sensor Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Removal and Installation . . . . . . . . . . . . . . 4-113 Theory of Operation . . . . . . . . . . . . . . . . . . 4-58
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113 Horn/Test Switch
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82 Removal and Installation . . . . . . . . . . . . . . . 4-91
Fuel Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Removal and Installation . . . . . . . . . . . . . . . 3-16 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

IX Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85

IX-4 4203780 First Edition

 INDEX

Hour Meter I
Removal and Installation . . . . . . . . . . . . . . 4-111
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Indicator Lights
Hyd Oil Temp Switch Removal and Installation . . . . . . . . . . . . . . 4-95
Removal and Installation . . . . . . . . . . . . . . 4-101 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101 Input Bevel Pinion Assembly
Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Portable In-Line Filter . . . . . . . . . . . . . . . . . . . 5-4 Disassembly and Inspection . . . . . . . . . . . . 5-65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Hydraulic Charge Pressure Filter
Removal and Installation . . . . . . . . . . . . . . . 6-68 Instrument Panel
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-68 Removal and Installation . . . . . . . . . . . . . 4-110
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110
Hydraulic Oil Cooler
Removal and Installation . . . . . . . . . . 3-12, 6-77 Instrument Test Procedure
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-77 Front Cutting Unit Circuit . . . . . . . . . . . . . . 6-28
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Hydraulic Oil Return Filter Instrument Test Overview . . . . . . . . . . . . . . 6-27
Removal and Installation . . . . . . . . . . . . . . . 6-67
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67 Instrument Test Procedures
Charge Pressure Test . . . . . . . . . . . . . . . . . 5-34
Hydraulic Oil Tank Front Cutting Unit Motors Test . . . . . . . . . . 6-34
Drain Procedure . . . . . . . . . . . . . . . . . . . . . . 6-58 Hydrostatic Power Train . . . . . . . . . . . . . . . 5-34
Removal and Installation . . . . . . . . . . . . . . . 6-77 Instrument Test Overview . . . . . . . . . . . . . . 5-34
Hydraulic Schematic Left Wing Cutting Unit Circuit Test . . . . . . . 6-46
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Left Wing Cutting Unit Deck Valve Test . . . 6-49
Left Wing Cutting Unit Motors Test . . . . . . . 6-52
Hydraulic System Left Wing Cutting Unit Pump Test . . . . . . . 6-47
Service System Safely . . . . . . . . . . . . . . . . . . 1-9 Lift/Steer Pump Test . . . . . . . . . . . . . . 5-35, 6-56
Hydraulics Lift/Steer System Relief Valve Pressure Test 6-54
Component Location . . . . . . . . . . . . . . . . . . . 6-4 Right Wing Cutting Unit Circuit Test . . . . . . 6-37
Field Test Procedures . . . . . . . . . . . . . . . . . 6-24 Right Wing Cutting Unit Deck Valve Tests . 6-40
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 6-6 Right Wing Cutting Unit Motors Test . . . . . 6-43
Instrument Test Procedure . . . . . . . . . . . . . 6-27 Right Wing Cutting Unit Pump Test . . . . . . 6-39
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Traction Pump Tests . . . . . . . . . . . . . . . . . . 5-40
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Traction System Test . . . . . . . . . . . . . . . . . 5-37
Wheel Motors Test . . . . . . . . . . . . . . . . . . . 5-42
Hydrostatic Power Train
Component Location . . . . . . . . . . . . . . . . . . . 5-5 Instrumentation Circuit
Field Test Procedures . . . . . . . . . . . . . . . . . 5-33 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Instrument Test Procedures . . . . . . . . . . . . . 5-34 Theory of Operation . . . . . . . . . . . . . . . . . . 4-53
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 Troubleshooting . . . . . . . . . . . . . . . . . . . . . 4-67
Reverse Kick-Out Switch Adjustment . . . . . 5-31
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Speed Limit Adjustment . . . . . . . . . . . . . . . . 5-31 K
Tests and Adjustments . . . . . . . . . . . . . . . . 5-29
Theory of Operation and Sub-Circuit Schematics
Key Switch
5-7
Removal and Installation . . . . . . . . . . . . . . 4-89
Traction Linkage Adjustments . . . . . . . . . . . 5-29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Traction Pedal Neutral Adjustment . . . . . . . 5-29
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-26

IX
4203780 First Edition IX-5
 INDEX

L Muffler
Removal, Inspection, and Installation . . . . . . 3-9
Left Deck Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal and Installation . . . . . . . . . . . . . . . 6-65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-65
Left Mow Solenoid O
Removal and Installation . . . . . . . . . . . . . . 4-106
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105 OPS
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 Removal and Installation . . . . . . . . . . . . . . . . 4-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Left Wing Proximity Switch
Removal and Installation . . . . . . . . . . . . . . . 4-97
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
P
Lift Valve
Disassembly, Inspection, and Assembly . . . 6-63
Park Brake
Removal and Installation . . . . . . . . . . . . . . . 6-62
Disassembly and Assembly . . . . . . . . . . . . 4-11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Lifting Equipment, Safety . . . . . . . . . . . . . . . . . . 1-7
Park Brake Switch
Light Switch Removal and Installation . . . . . . . . . . . . . . . 4-90
Removal and Installation . . . . . . . . . . . . . . . 4-98 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Parking Mower
Lights Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Component Symbols . . . . . . . . . . . . . . . . . . . 4-6
Portable In-Line Hydraulic Filter . . . . . . . . . . . 5-4
Low Charge Pressure Switch
Power Circuit
Removal and Installation . . . . . . . . . . . . . . 4-104
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104
Theory of Operation . . . . . . . . . . . . . . . . . . 4-18
Prepare for the Job
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
M
PTO Switch
Mechanical Troubleshooting Removal and Installation . . . . . . . . . . . . . . . 4-96
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Micro Switches
Removal and Installation . . . . . 4-90, 4-91, 4-99
Repair . . . . . . . . . . . . . . . . . . . . 4-90, 4-91, 4-99
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81 Q
Miscellaneous Symbols
Quality of Cut Troubleshooting
Component Symbols . . . . . . . . . . . . . . . . . . . 4-7
Definition of Terms . . . . . . . . . . . . . . . . . . . . 3-9
Motors and Generating Devices Factors That Affect Cut Appearance . . . . . . . 3-8
Component Symbols . . . . . . . . . . . . . . . . . . . 4-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 3-8
Mow Circuit Quick Reference Specifications
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37 Accessories and Miscellaneous . . . . . . . . . . 2-7
Theory of Operation . . . . . . . . . . . . . . . . . . . 4-36 Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-63 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Mower Identification
Hydrostatic Power Train . . . . . . . . . . . . . . . . 2-5
Engine Serial Number . . . . . . . . . . . . . . . . . . 2-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Optional Machine Accessories . . . . . . . . . . . . 2-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . 2-2

IX Specifications and General Information . . . . . 2-2

IX-6 4203780 First Edition

 INDEX

R
Radiator
Removal and Installation . . . . . . . . . . . . . . . 3-12
Radiator/Hydraulic Oil Cooler
Removal and Installation . . . . . . . . . . . . . . . 3-11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Rear Axle
Disassembly, Inspection, and Assembly . . . 2-28
Removal and Installation . . . . . . . . . . . . . . . 2-26
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Rear Wheel Motor
Disassembly, Inspection, and Assembly . . . 5-79
Motor Timing, Assembly . . . . . . . . . . . . . . . 5-80
Removal and Installation . . . . . . . . . . . . . . . 5-77
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Rear Wheels
Removal and Installation . . . . . . . . . . . . . . . 4-17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Relays
Removal and Installation . . . . . . . . . . . . . . . 4-88
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74

IX
4203780 First Edition IX-7
 INDEX

Repair Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

4WD Rev Solenoid . . . . . . . . . . . . . . . . . . . 4-106 Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . 4-108
4WD Solenoid . . . . . . . . . . . . . . . . . . . . . . 4-106 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4WD Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
4WD Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53 Glow Plug Solenoid . . . . . . . . . . . . . . . . . . 4-107
Accessories and Miscellaneous Repair . . . . . 4-5 Glow Plug Switch . . . . . . . . . . . . . . . . . . . . 4-93
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . 3-8 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Air Filter Pressure Switch . . . . . . . . . . . . . . 4-100 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Horn/Test Switch . . . . . . . . . . . . . . . . . . . . . 4-91
Anti-Scalp Wheels . . . . . . . . . . . . . . . . . . . . 3-29 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . 4-111
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Hyd Oil Temp Switch . . . . . . . . . . . . . . . . . 4-101
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Hydraulic Charge Pressure Filter . . . . . . . . 6-68
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . 6-77
Brake Master Cylinder . . . . . . . . . . . . . . . . . 4-20 Hydraulic Oil Return Filter . . . . . . . . . . . . . . 6-67
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58
Brake Pedal Switch . . . . . . . . . . . . . . . . . . . 4-91 Hydrostatic Power Train . . . . . . . . . . . . . . . 5-47
Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Indicator Lights . . . . . . . . . . . . . . . . . . . . . . 4-95
Charge Filter Pressure Switch . . . . . . . . . . 4-102 Input Bevel Pinion Assembly . . . . . . . . . . . . 5-65
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . 4-87 Instrument Panel . . . . . . . . . . . . . . . . . . . . 4-110
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . 5-55 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Cruise Control Magnet . . . . . . . . . . . . . . . . 4-108 Left Deck Valve . . . . . . . . . . . . . . . . . . . . . . 6-65
Cruise Control Switch . . . . . . . . . . . . . . . . . . 4-97 Left Mow Solenoid . . . . . . . . . . . . . . . . . . . 4-105
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Left Wing Proximity Switch . . . . . . . . . . . . . 4-97
Deck Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
Diff Lock Solenoid . . . . . . . . . . . . . . . . . . . 4-106 Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Diff Lock Switch . . . . . . . . . . . . . . . . . . . . . 4-100 Low Charge Pressure Switch . . . . . . . . . . 4-104
Differential Assembly . . . . . . . . . . . . . . . . . . 5-73 Micro Switches . . . . . . . . . . . . . 4-90, 4-91, 4-99
Differential Lock Assembly . . . . . . . . . . . . . . 5-64 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109 OPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Drive Axle Reducer Assembly . . . . . . . . . . . 5-69 Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Park Brake Switch . . . . . . . . . . . . . . . . . . . . 4-90
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3-7, 3-17 PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-96
Engine Coolant Temp Switch . . . . . . . . . . . 4-104 Radiator/Hydraulic Oil Cooler . . . . . . . . . . . 3-11
Engine Oil Pressure Switch . . . . . . . . . . . . 4-103 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Engine Service . . . . . . . . . . . . . . . . . . . . . . . 3-20 Rear Wheel Motor . . . . . . . . . . . . . . . . . . . . 5-77
Engine Speed Sensor . . . . . . . . . . . . . . . . 4-110 Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Engine Temperature Gauge . . . . . . . . . . . . . 4-94 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Engine Temperature Sensor . . . . . . . . . . . 4-103 Return Filter Pressure Switch . . . . . . . . . . 4-101
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . 3-10 Reverse Kick-Out Switch . . . . . . . . . . . . . . . 4-99
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Right Deck Valve . . . . . . . . . . . . . . . . . . . . . 6-64
Fixed Caster Wheels . . . . . . . . . . . . . . . . . . 3-28 Right Mow Solenoid . . . . . . . . . . . . . . . . . 4-105
Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Right Wing Proximity Switch . . . . . . . . . . . . 4-97
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Rocker Switches . . . . . . . . . . . . . . . . . . . . . 4-97
Front Axle Motor . . . . . . . . . . . . . . . . . . . . . . 5-58 Seat and Seat Platform . . . . . . . . . . . . . . . . 4-13
Front Axle U-Joint . . . . . . . . . . . . . . . . . . . . . 5-47 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Front Deck . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Front Deck Valve . . . . . . . . . . . . . . . . . . . . . 6-66 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Front Lift Arms . . . . . . . . . . . . . . . . . . . . . . . 3-21 Steering Console . . . . . . . . . . . . . . . . . . . . . 2-18
Front Lift Cylinders . . . . . . . . . . . . . . . . . . . . 6-69 Steering Cylinder . . . . . . . . . . . . . . . . . . . . . 2-21
Front Limit Switch . . . . . . . . . . . . . . . . . . . . . 4-97 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Front Mow Enable Switch . . . . . . . . . . . . . . . 4-97 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . 2-8
Front Mow Solenoid . . . . . . . . . . . . . . . . . . 4-105 Swivel Caster Wheels . . . . . . . . . . . . . . . . . 3-27
Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Thermal Circuit Breakers . . . . . . . . . . . . . . . 4-87
Fuel Gage . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

IX Fuel Level Sensor . . . . . . . . . . . . . . . . . . . 4-113 Throttle Cable and Control Lever . . . . . . . . 3-14

IX-8 4203780 First Edition

 INDEX

Time Delay Relay . . . . . . . . . . . . . . . . . . . . . 4-89 S

Traction Linkage . . . . . . . . . . . . . . . . . . . . . 5-81
Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Safety
Traction Pump . . . . . . . . . . . . . . . . . . . . . . . 5-50 Chemical Products Handling . . . . . . . . . . . . 1-9
Traction Pump U-Joint . . . . . . . . . . . . . . . . . 5-48 Compressed Air and Air Tools . . . . . . . . . . . 1-7
Volt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111 Cooling System Safety . . . . . . . . . . . . . . . . . 1-9
Wing Deck Lift Arms . . . . . . . . . . . . . . . . . . 3-25 Electrical Components . . . . . . . . . . . . . . . . 1-10
Wing Decks . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Fuel Handling . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Wing Lift Cylinders . . . . . . . . . . . . . . . . . . . . 6-73 Hydraulic System Service . . . . . . . . . . . . . . . 1-9
Wing Mow Enable Switch . . . . . . . . . . . . . . 4-97 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Work Light Kit . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Keep Work Area Clean . . . . . . . . . . . . . . . . . 1-6
Resistance Test Keep Work Area Well Ventilated . . . . . . . . . 1-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 Lifting Equipment . . . . . . . . . . . . . . . . . . . . . 1-7
Machine Support . . . . . . . . . . . . . . . . . . . . . . 1-7
Return Filter Pressure Switch Park Mower Safely . . . . . . . . . . . . . . . . . . . . 1-6
Removal and Installation . . . . . . . . . . . . . . 4-101 Parking Mower . . . . . . . . . . . . . . . . . . . . . . . 1-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101 Prepare for the Job . . . . . . . . . . . . . . . . . . . . 1-2
Reverse Kick-Out Switch Safety Label Locations . . . . . . . . . . . . . . . . . 1-2
Removal and Installation . . . . . . . . . . . . . . . 4-99 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99 Support Machine Securely . . . . . . . . . . . . . . 1-7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81 Tire Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Use Compressed Air and Air Tools Safely . . 1-7
Reverse Kick-Out Switch Adjustment . . . . . . 5-31 Use Lifting Equipment Safely . . . . . . . . . . . . 1-7
Right Deck Valve Use Proper Eye and Face Protection . . . . . . 1-6
Removal and Installation . . . . . . . . . . . . . . . 6-64 Volatile and Hazardous Materials Storage . . 1-8
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64 Waste Material Disposal . . . . . . . . . . . . . . . 1-10
Work Area Cleanliness . . . . . . . . . . . . . . . . . 1-6
Right Mow Solenoid
Removal and Installation . . . . . . . . . . . . . . 4-106 Safety Label Locations
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105 Inspect Safety Labels . . . . . . . . . . . . . . . . . . 1-6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Right Wing Proximity Switch Safety Labels

Removal and Installation . . . . . . . . . . . . . . . 4-97 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Rocker Switches Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Removal and Installation . . . . . . . . . . . . . . . 4-98 Schematic
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97 Charging Circuit . . . . . . . . . . . . . . . . . . . . . 4-35
Test . . . . . . . . . . . . . . . . . . . . . . 4-77, 4-78, 4-80 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . 4-45
Run Circuit Cruise Control Disable . . . . . . . . . . . . . . . . 4-47
Theory of Operation . . . . . . . . . . . . . . . . . . . 4-30 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-63 Four Wheel Drive Circuit . . . . . . . . . . . . . . . 4-41
Four Wheel Drive Reverse Circuit . . . . . . . 4-42
Run Circuit–Off Seat Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . 4-27
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Horn/Test Circuit . . . . . . . . . . . . . . . . . . . . . 4-59
Run Circuit–On Seat Instrumentation Circuit . . . . . . . . . . . . . . . . 4-55
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Power Circuit . . . . . . . . . . . . . . . . . . . . . . . 4-19
Run Circuit–Off Seat . . . . . . . . . . . . . . . . . . 4-32
Run Circuit–On Seat . . . . . . . . . . . . . . . . . . 4-31
Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Work Light Circuit . . . . . . . . . . . . . . . . . . . . 4-51

IX
4203780 First Edition IX-9
 INDEX

Schematic, Hydraulic Steering Cylinder

Traction Circuit—Forward 2WD . . . . . . . . . . 5-12 Disassembly, Inspection, and Assembly . . . 2-23
Traction Circuit—Forward 4WD . . . . . . . . . . 5-20 Removal and Installation . . . . . . . . . . . . . . . 2-21
Traction Circuit—Neutral . . . . . . . . . . . . . . . . 5-8 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Traction Circuit—Reverse 2WD . . . . . . . . . . 5-16
Steering Leakage Test
Traction Circuit—Reverse 4WD . . . . . . . . . . 5-24
Test and Adjustments . . . . . . . . . . . . . . . . . . 2-7
Seat and Seat Platform
Steering Linkage Adjustments
Disassembly and Assembly . . . . . . . . . . . . . 4-14
Steering Stop Bolt Adjustment . . . . . . . . . . . 2-5
Removal and Installation . . . . . . . . . . . . . . . 4-13
Tests and Adjustments . . . . . . . . . . . . . . . . . 2-4
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Tie Rod Adjustment . . . . . . . . . . . . . . . . . . . . 2-4
Seat Switch Turning Radius Adjustment . . . . . . . . . . . . . . 2-4
Removal and Installation . . . . . . . . . . . . . . . 4-92
Steering Relief Valve Pressure Test
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Tests and Adjustments . . . . . . . . . . . . . . . . . 2-6
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
Steering Valve
Specifications
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Accessories and Miscellaneous Repair . . . . . 4-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Removal and Installation . . . . . . . . . . . . . . . . 2-8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General Engine Specifications . . . . . . . . . . . . 3-2
Steering Valve Service Fixture . . . . . . . . . . 2-11
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hydrostatic Power Train . . . . . . . . . . . . . . . . . 5-3 Steering Valve Service Fixture
Quick Reference Specifications . . . . . . . . . . . 2-5 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . 2-11
Specifications and General Information . . . . . 2-5
Steering Wheel
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Removal and Installation . . . . . . . . . . . . . . . . 2-8
Specifications and General Information Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Component Location . . . . . . . . . . . . . . . . . . . 2-3
Switches
Mower Identification . . . . . . . . . . . . . . . . . . . . 2-2
Component Symbols . . . . . . . . . . . . . . . . . . . 4-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Standard Torque Values . . . . . . . . . . . . . . . 2-10 Switching Devices
Component Symbols . . . . . . . . . . . . . . . . . . . 4-5
Speed Limit Adjustment . . . . . . . . . . . . . . . . . . 5-31
Swivel Caster Wheels
Standard Torque Values
Disassembly and Assembly . . . . . . . . . . . . 3-28
Inch Fastener Torque Values . . . . . . . . . . . . 2-10
Removal and Installation . . . . . . . . . . . . . . . 3-27
Metric Fastener Torque Values . . . . . . . . . . 2-10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Specifications and General Information . . . . 2-10
Start Circuit
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Theory of Operation . . . . . . . . . . . . . . . . . . . 4-28
T
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-62
Tachometer
Starter Motor Removal and Installation . . . . . . . . . . . . . . 4-112
Removal and Installation . . . . . . . . . . . . . . . 4-86 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Steering
Component Location . . . . . . . . . . . . . . . . . . . 2-3
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tests and Adjustments . . . . . . . . . . . . . . . . . . 2-4
Steering Console
Removal and Installation . . . . . . . . . . . . . . . 2-18
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

IX
IX-10 4203780 First Edition
 INDEX

Test Theory of Operation

4WD Rev Solenoid . . . . . . . . . . . . . . . . . . . . 4-83 Charging Circuit . . . . . . . . . . . . . . . . . . . . . 4-34
4WD Solenoid . . . . . . . . . . . . . . . . . . . . . . . 4-83 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . 4-44
4WD Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-80 Four Wheel Drive Circuit . . . . . . . . . . . . . . . 4-40
Brake Pedal Switch . . . . . . . . . . . . . . . . . . . 4-81 Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . 4-26
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . 4-73 Horn/Test Circuit . . . . . . . . . . . . . . . . . . . . . 4-58
Cruise Control Switch . . . . . . . . . . . . . . . . . 4-80 Instrumentation Circuit . . . . . . . . . . . . . . . . 4-53
Diff Lock Solenoid . . . . . . . . . . . . . . . . . . . . 4-83 Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Diff Lock Switch . . . . . . . . . . . . . . . . . . . . . . 4-82 Power Circuit . . . . . . . . . . . . . . . . . . . . . . . 4-18
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Front Limit Switch . . . . . . . . . . . . . . . . . . . . 4-77 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Front Mow Enable Switch . . . . . . . . . . . . . . 4-78 Traction Circuit—Forward 2WD . . . . . . . . . 5-11
Front Mow Solenoid . . . . . . . . . . . . . . . . . . . 4-83 Traction Circuit—Forward 4WD . . . . . . . . . 5-19
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 4-82 Traction Circuit—Neutral . . . . . . . . . . . . . . . 5-7
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 Traction Circuit—Reverse 2WD . . . . . . . . . 5-15
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . 4-84 Traction Circuit—Reverse 4WD . . . . . . . . . 5-23
Glow Pug Switch . . . . . . . . . . . . . . . . . . . . . 4-76 Work Light Circuit . . . . . . . . . . . . . . . . . . . . 4-50
Horn/Test Switch . . . . . . . . . . . . . . . . . . . . . 4-75
Theory of Operation and Sub Circuit Schematics
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Left Mow Solenoid . . . . . . . . . . . . . . . . . . . . 4-83
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-78 Thermal Circuit Breakers
Micro Switches . . . . . . . . . . . . . . . . . . . . . . . 4-81 Removal and Installation . . . . . . . . . . . . . . 4-87
Park Brake Switch . . . . . . . . . . . . . . . . . . . . 4-81 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Thermostat
Reverse Kick-Out Switch . . . . . . . . . . . . . . . 4-81
Removal and Installation . . . . . . . . . . . . . . 3-14
Right Mow Solenoid . . . . . . . . . . . . . . . . . . . 4-83
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Rocker Switches . . . . . . . . . . . . 4-77, 4-78, 4-80
Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-76 Throttle Cable
Thermal Circuit Breakers . . . . . . . . . . . . . . . 4-73 Checks and Adjustments . . . . . . . . . . . . . . . 3-5
Time Delay Relay . . . . . . . . . . . . . . . . . . . . . 4-74
Throttle Cable and Control Lever
Wing Mow Enable Switch . . . . . . . . . . . . . . 4-78
Removal and Installation . . . . . . . . . . . . . . 3-14
Tests and Adjustments Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Tie Rod
Deck Leveling Adjustment . . . . . . . . . . . . . . . 3-4
Disassembly, Inspection, and Assembly . . 2-25
Deck Rake Adjustment . . . . . . . . . . . . . . . . . 3-4
Removal and Installation . . . . . . . . . . . . . . 2-24
Final Adjustments . . . . . . . . . . . . . . . . . . . . . 3-6
Hydrostatic Power Train . . . . . . . . . . . . . . . . 5-29 Time Delay Relay
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Removal and Installation . . . . . . . . . . . . . . 4-89
Steering Leakage Test . . . . . . . . . . . . . . . . . . 2-7 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Steering Linkage Adjustments . . . . . . . . . . . . 2-4 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Steering Relief Valve Pressure Test . . . . . . . 2-6
Tires
Traction Linkage Adjustments . . . . . . . . . . . 5-29
Service Safety . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Weight Transfer Adjustment . . . . . . . . . . . . 5-32
Traction Circuit—Forward 2WD
Hydraulic Schematic . . . . . . . . . . . . . . . . . . 5-12
Theory of Operation . . . . . . . . . . . . . . . . . . 5-11
Traction Circuit—Forward 4WD
Hydraulic Schematic . . . . . . . . . . . . . . . . . . 5-20
Theory of Operation . . . . . . . . . . . . . . . . . . 5-19
Traction Circuit—Neutral
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 5-8
Theory of Operation . . . . . . . . . . . . . . . . . . . 5-7

IX
4203780 First Edition IX-11
 INDEX

Traction Circuit—Reverse 2WD Weight Transfer

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 5-16 Tests and Adjustments. . . . . . . . . . . . . . . . . 5-32
Theory of Operation . . . . . . . . . . . . . . . . . . . 5-15
Wing Deck Lift Arms
Traction Circuit—Reverse 4WD Disassembly and Assembly . . . . . . . . . . . . 3-26
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . 5-24 Removal and Installation . . . . . . . . . . . . . . . 3-25
Theory of Operation . . . . . . . . . . . . . . . . . . . 5-23 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Traction Linkage Wing Decks
Disassembly and Assembly . . . . . . . . . . . . . 5-81 Deck Rake Adjustment . . . . . . . . . . . . . . . . . 3-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81 Disassembly and Assembly . . . . . . . . . . . . 3-24
Removal and Installation . . . . . . . . . . . . . . . 3-23
Traction Linkage Adjustments . . . . . . . . . . . . 5-29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Traction Pedal
Wing Lift Cylinders
Disassembly and Assembly . . . . . . . . . . . . . . 4-9
Disassembly, Inspection, and Assembly . . . 6-74
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Removal and Installation . . . . . . . . . . . . . . . 6-73
Traction Pedal Neutral Adjustment . . . . . . . . . 5-29 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-73
Traction Pump Wing Mow Enable Switch
Disassembly, Inspection, and Assembly . . . 5-51 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
Removal and Installation . . . . . . . . . . . . . . . 5-50 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
Traction Pump U-Joint Work Area
Removal and Installation . . . . . . . . . . . . . . . 5-48 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Work Light Circuit
Troubleshooting Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . 4-63 Theory of Operation . . . . . . . . . . . . . . . . . . 4-50
Cruise Control Circuit . . . . . . . . . . . . . . . . . . 4-66 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-66
Cutting Units . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Work Light Kit
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Removal and Installation . . . . . . . . . . . . . . . 4-17
Four Wheel Drive Circuit . . . . . . . . . . . . . . . 4-65
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . 4-62
Horn and Audible Alert Circuit . . . . . . . . . . . 4-71
Hydrostatic Power Train . . . . . . . . . . . . . . . . 5-26
Instrumentation Circuit . . . . . . . . . . . . . . . . . 4-67
Mechanical Troubleshooting . . . . . . . . . . . . . 3-7
Mow Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Quality of Cut Troubleshooting . . . . . . . . . . . . 3-8
Run Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Work Light Circuit . . . . . . . . . . . . . . . . . . . . . 4-66

V
Volatile Materials Storage . . . . . . . . . . . . . . . . . 1-8
Volt Meter
Removal and Installation . . . . . . . . . . . . . . 4-111
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111

W
Waste Materials
IX Safe Disposal . . . . . . . . . . . . . . . . . . . . . . . . 1-10

IX-12 4203780 First Edition

 Equipment from Jacobsen is built to exacting
standards ensured by ISO 9001 and ISO 14001
registration at all of our manufacturing locations.

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technicians backed by Jacobsen Parts Xpress
provide reliable, high-quality product support.

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Jacobsen, A Textron Company

11108 Quality Drive, Charlotte, NC 28273
www.Jacobsen.com
800-848-1636