Chapter 7 Steering Specifications 7-2 Component Location 7-3 Tests and Adjustments 7-4 Repair Rev B 7-1

Transcription

1 Chapter Steering Specifications Component Location Tests and Adjustments Steering Linkage Adjustments Repair Steering Wheel Steering Tower Cover (Earlier Machines) Steering Tower Cover (Later Machines) Steering Column Steering Unit Throttle Lever Assembly (Earlier Machines) Throttle Lever Assembly (Later Machines) Steering Tower Steering Cylinder Tie Rod Assembly Rear Axle Assembly Rev B -

2 STEERING Specifications Test and Adjustment Specifications Rear Axle Alignment Toe-In Measurement in. (mm) (0..) Rear Axle Steering Arm-to-Steering Stop in. (mm) (0..) Measurement Rear Axle Assembly End Play in. (mm) (0..) Repair Specifications Steering Wheel Nut lb-ft (N m) 0 ( ) Steering Unit End Cover-to-Housing Screw Torque lb-ft (N m) 0 ( ) Throttle Arm Screw Torque lb-in. (N m) 00 (.) Throttle Stop Carriage Bolt Torque lb-in. (N m) (.) Steering Cylinder Ball Joint-to-Steering Arm Torque lb-ft (N m) 0 0 (0 9) Tie Rod Ball Joint-to-Steering Arm Torque lb-ft (N m) 0 ( ) WD Cutting Units Tie Rod Ball Joint-to-Steering Arm Torque lb-ft (N m) 0 0 (0 9) WD Cutting Units Steering Arm-to-Motor Mount Screw Torque lb-ft (N m) ( 6) Rear Axle Assembly Jam Nut Torque lb-ft (N m) 0 0 (0 9) - 6-Rev B

3 STEERING Component Location See Figure Throttle Lever Steering Cylinder Steering Column Tilt Lever Tie Rod Steering Unit Rear Axle Assembly 6 Steering Wheel 9 Steering Tower Cover Figure - TN6, TN6, TN 6-Rev B -

4 STEERING Tests and Adjustments Steering Linkage Adjustments See Figures - through -. IMPORTANT The following adjustments must be performed in sequence to ensure correct steering linkage adjustment. Tie Rod Adjustment NOTE WD steering assembly is shown; WD steering assembly is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Turn the wheels to the straight-ahead position. Turn Stop Adjustment IMPORTANT The steering linkage must be adjusted in proper sequence. Do not perform this procedure until the tie rod adjustment has been performed. (See Tie Rod Adjustment on page -.) NOTE WD steering assembly is shown; WD steering assembly is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Turn steering wheel to the left until the steering cylinder is completely extended. Figure - TN9. Measure the distance between the center lines of the tires at the front () and rear () of the tires. The measurement (toe-in) at the front of the tires should be in. (0.. mm) less than the distance at the rear of the tires. If the toe-in does not meet specifications, adjust as follows: TN9 Figure - TN9 a. Loosen the tie rod jam nuts ( and ) on both sides of the tie rod (). b. Turn the tie rod () as needed to obtain proper toe-in (). c. Retighten the tie rod jam nuts ( and ).. Proceed to Turn Stop Adjustment on page Rev B

5 STEERING 0 Figure -. Measure the gap () between the left steering arm () and steering stop on the rear axle (). The measurement should be in. (0.. mm). If the measurement does not meet specifications, adjust as follows: a. Remove cotter pin (). b. Remove castle nut (9), and disengage steering cylinder () from the right steering arm (0). c. Loosen clamp bolt (6) and nut () on steering cylinder (). d. Adjust (turn) ball joint () in or out as needed to obtain proper distance. Tighten steering cylinder clamp bolt (6) and nut (). e. Install steering cylinder () and castle nut (9). Tighten castle nut to 0 0 lb-ft (0 9 N m). NOTE 9 TN9 6 Install cotter pin () after performing turning radius (equal angle) adjustment.. Proceed to Turning Radius (Equal Angle) Adjustment on page -. TN9 Turning Radius (Equal Angle) Adjustment IMPORTANT The steering linkage must be adjusted in proper sequence. Do not perform this procedure until the tie rod and turn stop adjustments have been performed. (See Tie Rod Adjustment on page - and Turn Stop Adjustment on page -.) NOTE WD steering assembly is shown; WD steering assembly is similar.. Check the turning radius by driving the mower in a circle in both a hard right and a hard left turn.. Measure the diameters of the tire track circles.. Park the mower safely. (See Park Mower Safely on page -6.). Turn the wheels to the straight-ahead position.. Check that ball joints are threaded equally into both ends of steering cylinder. TN9 6 0 Figure - TN9 6. Remove cotter pins ( and 6) and castle nuts ( and ), and disengage steering cylinder () from the right steering arm () and rear axle (9).. Loosen clamp bolts ( and 0) and nuts ( and ) on steering cylinder (). 9 6-Rev B -

6 STEERING IMPORTANT Ensure turn stop gap of in. (0.. mm) is maintained during turning radius (equal angle) adjustment. Check and adjust turn stop gap as necessary after performing any ball joint adjustments. (See Turn Stop Adjustment on page -.). Adjust (turn) ball joints ( and ) in or out equally as needed. Tighten clamp bolts ( and 0) and nuts ( and ). 9. Install steering cylinder () and castle nuts ( and ). Tighten castle nuts to 0 0 lb-ft (0 9 N m). 0. Check the turning radius in both directions.. Repeat steps through 0 as needed until the turning radius is equal in both directions.. Install new cotter pins ( and 6). Repair Steering Wheel Removal and Installation See Figure -6.. Park the mower safely. (See Park Mower Safely on page -6.) 6 Figure -6 TN969. Remove (unsnap) cap () from steering wheel ().. Remove nut () and internal-tooth lock washer ().. Remove steering wheel () and four washers () from steering column (6). Installation Notes Install steering wheel by reversing the order of removal. Tighten the steering wheel nut () to 0 lb-ft ( N m) Rev B

7 STEERING Steering Tower Cover (Earlier Machines) NOTE This procedure is for machines with the following serial numbers: Serial No ~ 6 Serial No ~ 9 Serial No ~ 66 Serial No ~ Serial No ~ 0 Serial No ~ 6 Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) Steering Tower Cover (Later Machines) NOTE This procedure is for machines with the following serial numbers: Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up Removal See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) Figure - TN9. Using the steering tilt control, tilt the steering column () rearward.. Push throttle handle () forward.. Remove knob ().. Remove six screws (). 6. Carefully lift steering tower cover () and remove from machine. Figure - TN9. Using the steering tilt control, tilt the steering column () rearward.. Push throttle handle () forward.. Remove knob ().. Remove six screws (). 6. Carefully lift steering tower cover () and remove from machine. Installation Note Install steering tower cover by reversing the order of removal. 6-Rev B -

8 STEERING Installation See Figure -9. Steering Column Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -6.). Remove steering wheel. (See Steering Wheel on page -6.). Remove steering tower cover. (See Steering Tower Cover (Earlier Machines) on page - or Steering Tower Cover (Later Machines) on page -.) E Figure -9 TN66. Position steering tower cover () over steering tower () and ensure head of carriage bolts () just touch steering tower cover on both sides as shown in Figure -9. Adjust carriage bolts () and nuts () as necessary to achieve proper contact.. Secure steering tower cover with six mounting screws (). Figure -0. Using the tilt lever, tilt the steering column forward.. Support steering column (). 6. Remove four screws (), four lock washers (), and steering column (). Installation Notes Install steering column by reversing the order of removal. TN - 6-Rev B

9 STEERING Steering Unit Removal and Installation See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove steering wheel. (See Steering Wheel on page -6.). Remove steering tower cover. (See Steering Tower Cover (Earlier Machines) on page - or Steering Tower Cover (Later Machines) on page -.). Remove steering column. (See Steering Column on page -.) NOTE 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.. Using the tilt lever, tilt the steering column rearward. NOTES Label all hydraulic hoses and record their locations to ensure correct installation. Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil. 6. Disconnect hydraulic hose () from steering unit port T.. Disconnect hydraulic hose () from steering unit port P.. Disconnect hydraulic hose () from steering unit port L. 9. Disconnect hydraulic hose () from steering unit port R. 0. Disconnect hydraulic hose () from steering unit port E. 6 9 TN6 Figure - TN66. Using the tilt lever, tilt the steering column forward.. Support steering unit (). E. Remove four screws (6), four lock washers (), four spacers (9), and steering unit (). Installation Notes Install steering unit by reversing the order of removal. Check hydraulic oil level. Add oil as needed. TN9 Start the machine and check for hydraulic leaks and cylinder operation. Repair as necessary. Figure - 6-Rev B -9

10 STEERING Steering Unit Service Fixture See Figures - and -. Required Tools or Equipment Steering Unit Service Fixture in. (. mm) 6.0 in. (0. mm) 0.60 in. (6.6 mm) Ø Hole ().0 in. (0. mm). in. (.0 mm) Ø. in. (. mm) Ø Hole.0 in. (0 mm) 9 ().0 in. (0. mm) Figure -: Steering Unit Service Fixture NOTICE TN Do not clamp the steering unit directly into a vise. Clamping the steering unit directly into a vise may damage or distort the steering unit. TN Figure - TN. Place the steering unit service fixture () securely in a vise.. Place the steering unit (0) into the service fixture (), input shaft down.. Secure the steering unit to the service fixture using four M6- x 0 mm screws and M6 lock washers ( and ) Rev B

11 P STEERING Disassembly See Figures - and -6. L R T TN9 Special Screw () Gearwheel Rim Spring Retaining Ring Ball Stop Special Screw () 9 Distributor Plate 6 Spool Emergency Steering Ball O-Ring () 0 Cardan Shaft Thick Bearing Race Housing End Cover O-Ring Bearing Name Plate Spacer Sleeve 9 Thin Bearing Race 6 Steering Relief Valve 6 O-Ring () Cross Pin 0 Shaft Seal Steering Relief Valve Spring Gearwheel Spring Set Check Valve Ball Figure - 6-Rev B -

12 P T STEERING NOTES! CAUTION Wear eye protection when assembling and disassembling the steering unit. Springs and other objects may be propelled into the air, causing eye injury. Before attempting repairs or disassembly of any hydraulic components, thoroughly clean the components and work area. A clean work area is essential to satisfactory operation of repaired hydraulic components. Utilize steering unit service fixture for disassembly. (See Steering Unit Service Fixture on page -0.). Scribe a line from port P to bottom of steering unit. This line can be used to determine port P with end cover removed and for proper orientation of sections for assembly.. Remove three special screws (), two special screws (), and five O-rings ().. Remove end cover () by sliding it off to the side.. Remove cardan shaft spacer ().. Hold a hand under the gearwheel rim () and gearwheel () to keep the gearwheel from falling out, and remove the gearwheel rim (), gearwheel (), and two O-rings (6). 6. Remove cardan shaft (0).. Remove distributor plate (9).. Remove O-ring () from housing (). 9. Remove spool assembly. 0. Remove thin bearing race (9), bearing (), and thick bearing race ().. Remove shaft seal (0).. Remove spring retaining ring ().. Carefully press cross pin () out of the spool (6) and sleeve (), and remove spool from sleeve.. Press spring set () out of spool (6).. Remove fixture from vise and shake out check valve ball (), emergency steering ball (), and ball stop (). Re-secure service fixture in vise with input shaft down. 6. Remove housing () from service fixture.. Remove steering relief valve (6) and steering relief valve spring (). Steps - Scribe line aligned with port P. L R Steps - Steps 6- Steps 9-0 Spool Assembly 9 Steps - Step Step Included in Seal Kit Figure -6 TN0-6-Rev B

13 P STEERING Assembly See Figures - through -9. L R T TN9 Special Screw () Gearwheel Rim Spring Retaining Ring Ball Stop Special Screw () 9 Distributor Plate 6 Spool Emergency Steering Ball O-Ring () 0 Cardan Shaft Thick Bearing Race Housing End Cover O-Ring Bearing Name Plate Spacer Sleeve 9 Thin Bearing Race 6 Steering Relief Valve 6 O-Ring () Cross Pin 0 Shaft Seal Steering Relief Valve Spring Gearwheel Spring Set Check Valve Ball Figure - 6-Rev B -

14 STEERING! CAUTION Wear eye protection when assembling and disassembling the steering unit. Springs and other objects may be propelled into the air, causing eye injury. 0. While holding the cross pin in place, guide the spool and sleeve assembly into housing (). When installed, cross pin () must point towards port P. Spool will push seal guide (A) out of housing as it is installed. Step Step Required Tools and Materials Seal Kit (Jacobsen PN 990) Shaft Seal Tool (Sauer Danfoss SJ0L0-0) 6 0 NOTES Inspect all parts for wear or damage and replace as necessary. Lubricate all parts with clean hydraulic oil before assembly. Always install new O-rings for assembly; used parts may leak. Utilize steering unit service fixture for assembly. (See Steering Unit Service Fixture on page -0.) Letter references (A-C) refer to components of Sauer Danfoss Shaft Seal Tool.. Assemble relief valve (6 and ) to housing (). Use new check valve o-ring included in seal kit.. Assemble shaft seal (0) onto guide (A).. Insert outer sleeve (B) into housing ().. Place guide (A) on end of guide tool (C). Lubricate shaft seal and O-ring.. Slide guide tool (C) into outer sleeve (B) and press shaft seal into position. Remove outer sleeve and guide tool. Guide (A) should remain inside housing after seal is installed. 6. Install thin bearing race (9), bearing (), and thick bearing race () into housing ().. Slide spool (6) into sleeve () and align so that cross pin slots are adjacent to each other.. Center the spring set () in the spool and sleeve assembly, and install spring retaining ring (). NOTES When installing spring set, insert the curved springs between the flat springs and push in place. Spring retaining ring () must be able to rotate unimpeded by the springs. 9. Press cross pin () in the spool and sleeve assembly. Steps - A Step 6 Steps -9 9 Step 0 Spool Assembly Figure - A Included in Seal Kit 6 P L T B C R E Cross Pin TN - 6-Rev B

15 P T STEERING. Place emergency steering ball () in port P.. Place ball stop () in port P.. Place check valve ball () in port P.. Install O-ring () in housing ().. Place distributor plate (9) on housing () and align scribe line and mounting holes. 6. Assemble cardan shaft (0) to spool (6) ensuring cardan shaft engages with cross pin ().. Place gearwheel () over the distributor plate (9). NOTE See step 6 in Figure -9. When installing the gearwheel, the gearwheel must be correctly aligned so that it engages with the cardan shaft. The cross pin () in the spool assembly must line up with the bottom of the spline in the gearwheel ().. Install O-rings (6) into groove on each side of the gearwheel rim. 9. Place gearwheel rim () over the distributor plate (9) and gearwheel (). Align scribe line and mounting holes. 0. Install spacer () over the cardan shaft (0). NOTE Place end cover so that the hole marked P lines up with port P in the housing.. Using scribe line, align end cover () to housing (). Install special screws () with O-rings () into ports T, P, and E. Install special screw () with O-ring () into ports L and R. Tighten screws in an alternating pattern to 0 lb-ft ( N m).. Remove the steering unit from the service fixture.. Assemble steering unit into mower. NOTE Do not tighten steering column mounting hardware until steering relief pressure has been set. Column must be removed when adjusting relief valve.. Set steering unit relief pressure. (See Lift/Steering Relief Valve Adjustment on page 6-.)! WARNING Keep hands and arms clear of steering wheel on initial startup of engine. Steering unit can become a hydraulic motor if step is not correctly performed. Steps - Steps -6 0 Step 6 9 Steps -0 Spline Bottoms Port P 6 Step 9 Cross Pin L P Scribe line aligned with port P. L R R E T Included in Seal Kit Figure -9 TN 6-Rev B -

16 STEERING Throttle Lever Assembly (Earlier Machines) NOTE This procedure is for machines with the following serial numbers: Serial No ~ 6 Serial No ~ 9 Serial No ~ 66 Serial No ~ Serial No ~ 0 Serial No ~ 6 Removal and Installation See Figures -0 and -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove steering column. (See Steering Column on page -.) Figure -0 TN96. Using the tilt lever, tilt the steering column forward.. Support steering unit () and steering unit bracket ().. Remove two screws () and two lock washers (). Move steering unit () and steering unit bracket () aside to provide clearance for throttle lever assembly removal Rev B

17 STEERING Nut 0 Conical Spring Washers (6) Carriage Bolt () 0 Flat Washer Pin 6 Flat Washer Flange Bushing 6 Steering Tower Screw 6 Nut Spacer Throttle Support Bracket Knob Flat Washer () Set Screw Screw Lock Nut () Throttle Handle Lock Washer () Nut 9 Throttle Arm Throttle Stop 9 Screw () Nut () 9 Throttle Cable Figure - 6. Remove nut (), flat washer (0), and screw ().. Loosen set screw () and disengage throttle cable (9) from pin ().. Remove nut (), flat washer (6), and spacer (). 9. Loosen nut (6) and remove throttle arm (9), conical spring washers (0), flange bushings (), and throttle handle () from steering tower (6). 0. Remove two nuts (), two lock washers (), two flat washers (), two screws (9), and throttle support bracket ().. Remove two lock nuts (), two carriage bolts (), and throttle stop (). TN9 Installation Notes Install throttle lever assembly by reversing the order of removal. Install throttle cable (9) on throttle support bracket () so that throttle cable aligns with hole in pin (). Tighten nut () until sufficient force is required to move throttle lever and engine speed is maintained during operation. After tightening nut (), tighten screw () to 00 lb-in. (. N m) to eliminate play in throttle lever assembly. Position throttle stop () so that it contacts throttle handle () when engine is at high idle. Tighten carriage bolts () to lb-in. (. N m). 6-Rev B -

18 STEERING Throttle Lever Assembly (Later Machines) NOTE This procedure is for machines with the following serial numbers: Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up Removal and Installation See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove steering column. (See Steering Column on page -.) 6 Figure - TN9. Using the tilt lever, tilt the steering unit bracket () forward.. Support steering unit (6) and steering unit bracket ().. Remove two nuts (), spacers (), flange bearings (), and shoulder bolts (). Move steering unit (6) and steering unit bracket () aside to provide clearance for steering tower removal. - 6-Rev B

19 STEERING Nut Conical Spring Washers (6) Carriage Bolt () Flat Washer Pin Flat Washer Flange Bushing Steering Tower Screw Nut 9 Spacer Throttle Support Bracket 9 Knob Flat Washer () 9 Set Screw 0 Screw Lock Nut () 0 Throttle Handle Lock Washer () 0 Nut Throttle Arm 6 Throttle Stop Screw () 6 Nut () Throttle Cable Figure - 6. Remove nut (0), flat washer (), and screw ().. Loosen set screw (9) and disengage throttle cable () from pin ().. Remove nut (), flat washer (), and spacer (9). 9. Loosen nut () and remove throttle arm (), conical spring washers (), flange bushings (), and throttle handle (0) from steering tower (). 0. Remove two nuts (6), two lock washers (), two flat washers (), two screws (), and throttle support bracket ().. Remove two lock nuts (), two carriage bolts (), and throttle stop (6). TN9 Installation Notes Install throttle lever assembly by reversing the order of removal. Install throttle cable () on throttle support bracket () so that throttle cable aligns with hole in pin (). Tighten nut () until sufficient force is required to move throttle lever and engine speed is maintained during operation. After tightening nut (), tighten screw (0) to 00 lb-in. (. N m) to eliminate play in throttle lever assembly. Position throttle stop (6) so that it contacts throttle handle (0) when engine is at high idle. Tighten carriage bolts () to lb-in. (. N m). 6-Rev B -9

20 STEERING Steering Tower Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove steering column. (See Steering Column on page -.). Remove throttle lever assembly. (See Throttle Lever Assembly (Earlier Machines) on page -6 or Throttle Lever Assembly (Later Machines) on page -.). Remove four carriage bolts () and flange nuts (9), and remove steering tower (6). Installation Note Install steering tower by reversing the order of removal. Do not overtighten nut (). Gas spring must pivot freely Figure - TN000 NOTE Left side of steering tower weldment removed for picture clarity.. Disengage tilt cable ().. Remove two screws () and tilt cable (). 6. Remove screw (0) and nut ().. Remove nut (), three washers () (if equipped), bolt (), and gas spring () Rev B

21 STEERING Steering Cylinder Removal and Installation See Figures - through -. 6 NOTE WD steering assembly is shown; WD steering assembly is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Thoroughly clean the area surrounding the steering cylinder, especially the hydraulic hose fittings. 9 NOTES Figure - TN Label all hydraulic hoses and record their locations to ensure correct installation. Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil.. Disconnect hydraulic hoses ( and ) from steering cylinder (). Figure -6 TN. Support the steering cylinder ().. Remove cotter pins ( and 9) and castle nuts (6 and ) from both ends of the steering cylinder (). 6. Using a ball joint removal tool, remove the ball joint from the steering arm. Remove the steering cylinder () from the steering arm () and rear axle (). 0 Figure - TN9 6-Rev B -

22 STEERING NOTES Record the location and orientation of the fittings ( and ) before removing to ensure correct installation. Record ball joint center-to-center overall distance (). Record the orientation of the ball joints before removing to ensure correct installation. Record the number of turns required to remove each ball joint.. Remove fittings ( and ) from steering cylinder ().. Remove the ball joints (0 and ) from the steering cylinder (). 9. Inspect ball joints. Replace as needed. Installation Notes Install steering cylinder by reversing the order of removal. Tighten castle nuts (6 and ) to 0 0 lb-ft (0 9 N m). Adjust nuts as needed to align the slots with the hole in the rod ends. Install new cotter pins ( and 9). Check hydraulic oil level. Add oil as needed. Start the machine and check for hydraulic leaks and cylinder operation. Repair as necessary. Check steering toe-in adjustment. (See Tie Rod Adjustment on page -.) - 6-Rev B

23 STEERING Disassembly, Inspection, and Assembly See Figure Barrel Piston 9 Seal Ring Rod Wiper Nut 6 O-Ring 0 Rod Guide Nut Ball Joint, Left Piston Ring O-Ring Ball Joint, Right Nut Rod Figure -. Use a spanner wrench to remove rod guide (0) from barrel ().. Pull rod assembly () out of barrel ().. Remove ball joint () and nut () from rod ().. Remove nut (), piston (), O-ring (6), and piston ring () from rod.! WARNING TN Use appropriate eye protection when using compressed air for cleaning or drying purposes. Compressed air can cause serious personal injury. Use safety reduction valves to reduce the air pressure to a safe level before use. 6-Rev B -

24 STEERING NOTICE It is important that all components 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.. Clean all parts using clean solvent, and dry using compressed air. 6. Inspect all parts for excessive wear, cracks, broken parts, and damaged threads.. Inspect the barrel for dents, score lines, or grooves inside.. Inspect the fittings for wear and damage. Assembly Notes Tie Rod Assembly Removal and Installation See Figure -9. NOTE WD steering assembly is shown; WD steering assembly is similar.. Park the mower safely. (See Park Mower Safely on page -6.) Required Materials Seal Kit (Jacobsen PN 9) Assemble the steering cylinder by reversing the order of disassembly. Lubricate all parts with clean hydraulic oil before assembly. Install new seals and O-rings. Figure -9 TN9. Support the tie rod assembly ().. Remove cotter pins () and castle nuts () from both steering arms ( and ), and remove the tie rod assembly (). Installation Notes Install tie rod by reversing the order of removal. For WD cutting units, tighten castle nuts () to 0 lb-ft ( N m). Adjust nuts as needed to align the slots with the hole in the tie rod ends. For WD cutting units, tighten castle nuts () to 0 0 lb-ft (0 9 N m). Adjust nuts as needed to align the slots with the hole in the tie rod ends. Install new cotter pins (). Adjust tie rod. (See Tie Rod Adjustment on page -.) - 6-Rev B

25 STEERING Disassembly, Inspection, and Assembly See Figure Castle Nut Tie Rod 9 Grease Fitting Ball Joint Measurement Lock Washer 6 Lock Washer 0 Threaded Ball Joint, Left Hex Head Bolt Nut Nut Tie Rod Clamp Grease Fitting Tie Rod Clamp Castle Nut Hex Head Bolt 6 Threaded Ball Joint, Right Figure -0 0 TN Disassembly Notes Before disassembling the tie rod assembly, measure and record the ball joint stud center-to-center distance (). 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. Verify the ball joint stud center-to-center distance; correct as needed. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. 6-Rev B -

26 STEERING Rear Axle Assembly Removal and Installation 6 See Figures - and -. NOTE WD steering assembly is shown; WD steering assembly is similar.. Park the mower safely. (See Park Mower Safely on page -6.) 0 9. For WD models, remove the rear wheel motors. (See Rear Wheel Motor on page -96.) For WD models, remove the rear wheel hubs. (See Rear Wheel Hub WD Units on page 9-6.) TN0 Figure -. Support the steering axle () using an appropriate lifting device. Figure - TN. Remove cotter pin (), two jam nuts (), and flat washer (6), and remove axle assembly () and spacer (0) from mower. NOTE Label all hydraulic hoses and record their locations to ensure correct installation. Plug hydraulic hoses after disconnecting to prevent loss of hydraulic oil.. Disconnect hydraulic hoses ( and ) from steering cylinder () Rev B

27 STEERING Installation Notes Install rear axle assembly by reversing the order of removal. Tighten steering arm-to-motor mount screws () to lb-ft ( 6 N m). For WD steering assembly, tighten castle nuts () to 0 lb-ft ( N m). Adjust nuts as needed to align the slots with the hole in the tie rod ends. For WD steering assembly, tighten castle nuts () to 0 0 lb-ft (0 9 N m). Adjust nuts as needed to align the slots with the hole in the tie rod ends. Tighten steering cylinder castle nuts () to 0 0 lb-ft (0 9 N m). Adjust nuts as needed to align the slots with the hole in the rod ends. Adjust jam nuts () to obtain in. (0.. mm) axle assembly () end play. Tighten jam nuts () to 0 0 lb-ft (0 9 N m). Install new cotter pins (). Lubricate grease fittings (9) with grease that meets or exceeds NLGI Grade LB specifications. Check hydraulic oil level. Add oil as needed. Start the machine and check for hydraulic leaks and cylinder operation. Repair as necessary. Check steering toe-in adjustment. (See Tie Rod Adjustment on page -.) 6-Rev B -

28 STEERING Disassembly, Inspection, and Assembly See Figure Bushing () Thrust Bearing () Thrust Washer () Steering Axle 9 Hex Bolt (WD Only) 6) 6 Tie Rod Cotter Pin () 0 Lock Washer (WD Only) (6) Castle Nut () Castle Nut () Steering Arm, Left (WD Only) Steering Cylinder Spring Pin () Spindle, Left (WD Only) 9 Ball Joint () 6 Thrust Washer (6) Motor Mount (WD Only) () 0 Steering Arm, Right (WD Only) Grease Fitting () Cotter Pin () Spindle, Right (WD Only) Figure - TN9-6-Rev B

29 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 Replace any bushings, bearings, and ball joints that were damaged or had excessive wear. Replace or repair steering cylinder if dented or leaking. Never reuse cotter pins; use new cotter pins of correct size. Lubricate grease fittings () with grease that meets or exceeds NLGI Grade LB specifications. 6-Rev B -9

30 STEERING -0 6-Rev B

31 Chapter Cutting Units Specifications Component Location Troubleshooting Quality-of-Cut Troubleshooting Mechanical Troubleshooting Checks and Adjustments Bedknife Adjuster Assembly Adjustment -Inch Cutting Unit Reel Squaring Adjustment -Inch Cutting Unit Bedknife-to-Reel Clearance Adjustment Height-of-Cut (HOC) Adjustment Down Pressure Adjustment Grass Shield Adjustment -Inch Cutting Unit Reel Bearing Pre-Load Adjustment -Inch Cutting Unit Repair Inch Cutting Unit Inch Cutting Unit Lift Yoke Lift Arms Reel Drive Motor -Inch Cutting Unit Reel Drive Motor -Inch Cutting Unit Grass Shield -Inch Cutting Unit Grass Deflector -Inch Cutting Unit Bedknife Backing Assembly -Inch Cutting Unit Bedknife Backing Assembly -Inch Cutting Unit Bedknife Reel Bearing Housing Assembly -Inch Cutting Unit Reel Bearing Housing Assembly -Inch Cutting Unit Reel Assembly -Inch Cutting Unit Reel Assembly -Inch Cutting Unit Front Roller Front Roller Bearings Rear Roller -Inch Cutting Unit Rear Roller Bearings -Inch Cutting Unit Rear Roller -Inch Cutting Unit Rear Roller Bearings -Inch Cutting Unit Rev B -

32 CUTTING UNITS Specifications Checks and Adjustments Reel Bearing Pre-Load in. (mm) 0.00 (.0) Bedknife Front Face Height in. (mm) (.) Bedknife Front Face Angle degrees Bedknife Top Face Angle (Rear Relief) degrees 0 Reel Blade Relief Angle degrees Bedknife-to-Reel Gap in. (mm) ( ) Repair Reel Drive Motor Rear Cover-to-Body Retaining Screw Torque -Inch Cutting Unit lb-ft (N m). () Reel Drive Motor with - ORFS Case Drain Case lb-ft (N m) (.9) Drain Fitting Torque -Inch Cutting Unit Reel Drive Motor with -6 ORFS Case Drain Case lb-ft (N m) () Drain Fitting Torque -Inch Cutting Unit Reel Drive Motor IN/OUT Port Fittings -Inch lb-ft (N m) 60 (.) Cutting Unit Reel Drive Motor Rear Cover-to-Body Retaining lb-ft (N m) () Screw Torque -Inch Cutting Unit Reel Drive Motor with - ORFS Case Drain Case lb-ft (N m) (.9) Drain Fitting Torque -Inch Cutting Unit Reel Drive Motor with -6 ORFS Case Drain Case lb-ft (N m) () Drain Fitting Torque -Inch Cutting Unit Reel Drive Motor IN/OUT Port Fittings -Inch lb-ft (N m) 60 (.) Cutting Unit Bedknife Backing Mounting Screw Torque -Inch lb-ft (N m) (.9 0.) Cutting Unit Bedknife Backing Mounting Screw Torque -Inch lb-ft (N m) 0 (0..) Cutting Unit Bedknife Mounting Screw Torque lb-in. (N m) 90 0 (0..6) Reel Bearing Housing Assembly Mounting Screw lb-ft (N m) (. 9.) Torque -Inch Cutting Unit Reel Bearing Assembly Coupler Screw Torque lb-ft (N m) 0 (0..) -Inch Cutting Unit Reel Bearing Assembly Mounting Screw Torque lb-ft (N m) 0 (0..) -Inch Cutting Unit Front and Rear Roller Lock Nut Initial Torque lb-in. (N m) 0 0 (.6 0.) Front and Rear Roller Rotational Torque lb-in. (N m) (0. 0.) Rear Roller Mounting Screw Torque -Inch Cutting lb-ft (N m) 6 (..) Unit Rear Roller Mounting Screw Torque -Inch Cutting Unit lb-ft (N m) 0 (0..) - 6-Rev B

33 CUTTING UNITS Component Location See Figure Right Front Cutting Unit Lift Cylinder 9 Reel Drive Motor Grass Shield Center Cutting Unit 6 Lift Arm 0 Reel Assembly Hose Support Left Front Cutting Unit Pivot Yoke Front Roller Rear Roller Left Rear Cutting Unit Lift Yoke Counterweight 6 Deflector Figure -: Component Location 6 TN6,TN6,TN66 6-Rev B -

34 CUTTING UNITS Troubleshooting Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Even though the cutting units are properly sharpened and adjusted, some mowing practices and turf conditions can cause poor cutting results. These include: Repetitious mowing patterns tires running over the same path may cause depressions and ruts. This is also known as compaction. Mowing with excessive moisture in the ground may result in varying cutting heights. The mower slides over the wet turf, leaving grass uncut and depressed. Repetitious cutting of grass in the same direction may cause the grass to take a permanent set in that direction. The reel and bedknife have difficulty lifting the grass into cutting position. This condition is called graining. Poor quality grass that is matted cannot be lifted and cut uniformly. Dry grass does not lubricate the blades and leads to early dulling of the blades. In most cases, information provided by the user/customer will provide the basis for the repairs and adjustments that may be required. However, it is recommended that a test cut be performed to evaluate the mower s performance before beginning repairs or adjustments. 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. Before performing a test cut to diagnose cut appearance and mower performance, verify the following items to ensure an accurate test cut:. Mowing (Ground) Speed. Reel Bearing Condition and Pre-Load (End Play) Adjustment. Reel and Bedknife Sharpness. Bedknife Alignment to Reel. Bedknife-to-Reel Contact 6. Height-of-Cut (HOC). Bedknife Application (Correct Bedknife). Roller and Roller Bearing Condition 9. Reel Speed 0. Frequency-of-Clip (FOC) Another test cut should be performed after the completion of the repairs and/or adjustments to verify the mower s performance. - 6-Rev B

35 CUTTING UNITS Definition of Terms The following terms are used to describe various cut appearance symptoms. Ragged Cut Ragged cutting occurs when blades of grass are torn or damaged rather than cut. This is usually caused by incorrect height-of-cut adjustment, incorrect bedknife-to-reel adjustment, or dull blades. NOTE: Arrow indicates direction of travel. TN6 Probable Cause Incorrect cutting height adjustment. Incorrect bedknife-to reel clearance. Worn or damaged reel bearings. Incorrectly adjusted bearing pre-load. Dull bedknife and/or reel blades. Wavy or rifled bedknife. Remedy Adjust to the proper height-of-cut. (See Height-of-Cut (HOC) Adjustment on page -0.) Adjust the bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Replace the reel bearings. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page - or Reel Bearing Housing Assembly -Inch Cutting Unit on page -.) Adjust the bearing pre-load. (See Reel Bearing Pre-Load Adjustment -Inch Cutting Unit on page -.) Sharpen the bedknife and reel blades. (Refer to Parts and Maintenance Manual. ) Grind and adjust the reel and bedknife. (Refer to Parts and Maintenance Manual and see Bedknife-to-Reel Clearance Adjustment on page -.) 6-Rev B -

36 CUTTING UNITS 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 in. ( 0 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. NOTE: Arrow indicates direction of travel. TN09 Probable Cause Mowing (ground) speed is too fast. Grass buildup on roller. Roller is out of round. Mowing in the same direction all the time. Use of a groomer on cleanup pass. Reel drive motor performance is reduced. Reduce mowing (ground) speed. Clean the roller and scraper. Remedy Replace roller. (See Front Roller on page -, Rear Roller -Inch Cutting Unit on page -, or Rear Roller -Inch Cutting Unit on page -.) Change mowing direction regularly. Use groomers only when cutting in a straight line. Check operation of reel motor(s) and repair/replace as necessary. (See Reel Drive Motor -Inch Cutting Unit on page - or Reel Drive Motor -Inch Cutting Unit on page -.) -6 6-Rev B

37 CUTTING UNITS Marcelling Marcelling is a wave-like cut appearance similar to washboarding but with a uniform cutting height and smaller wave tip-to-tip distance. In most cases, the wave tip-to-tip distance is in. ( cm) or less. Color variation (light-to-dark) may also be noticed. This condition is usually caused by an incorrect frequency-of-clip. NOTE: Arrow indicates direction of travel. TN00 Incorrect frequency-of-clip. Probable Cause Mowing (ground) speed is too fast. HOC (height-of-cut) setting is too low for the machine s capability. Reel speed is too low. Remedy Check and adjust frequency-of-clip. Frequency-of-clip must be equal to or less than height-of-cut. Verify proper reel is being used for the correct application and change if necessary. May need more blades. Reduce mowing (ground) speed. Confirm proper HOC range for reel/bedknife combination. Check/set reel speed rpm. (Refer to Safety and Operation Manual. ) 6-Rev B -

38 CUTTING UNITS Step Cutting 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 adjustment. NOTE: Arrow indicates direction of travel. TN0 Probable Cause HOC (height-of-cut) settings are different from one side of a reel to the other, or from one cutting unit to another. Worn roller bearings. Worn reel bearings. Bedknife-to-reel contact is different from one side of the cutting unit to the other. Cutting unit movement is restricted. Variations in turf density. Machine ride height is uneven from side to side. Mower frame is bent. Remedy Check HOC adjustment of cutting units. (See Height-of-Cut (HOC) Adjustment on page -0.) Check/replace roller bearings. (See Front Roller Bearings on page -, Rear Roller Bearings -Inch Cutting Unit on page -, or Rear Roller Bearings -Inch Cutting Unit on page -.) Replace reel bearings. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page - or Reel Bearing Housing Assembly -Inch Cutting Unit on page -.) Check bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Check/remove cutting unit movement restriction. Change mowing direction. Check/adjust tire inflation pressure. (Refer to Parts and Maintenance Manual. ) Repair or replace as needed. - 6-Rev B

39 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. NOTE: Arrow indicates direction of travel. TN0 Probable Cause HOC (height-of-cut) settings are lower than normal. Turf too uneven for the mower to follow. Incorrect bedknife for HOC. Cutting too much grass at one time. Mowing (ground) speed is too fast. Remedy Check HOC adjustment of cutting units. (See Height-of-Cut (HOC) Adjustment on page -0.) Change mowing direction. Install correct bedknife for desired HOC. Mow more often. Reduce mowing (ground) speed. 6-Rev B -9

40 CUTTING UNITS Stragglers Stragglers are scattered blades of uncut or poorly cut grass. NOTE: Arrow indicates direction of travel. TN0 Probable Cause Bedknife improperly adjusted. Dull cutting edges. Mowing (ground) speed is too fast. Incorrect roller. Grass is too tall. Mowing in the same direction all the time. Remedy Adjust bedknife. (See Bedknife-to-Reel Clearance Adjustment on page -.) Sharpen reel and bedknife. (Refer to Parts and Maintenance Manual. ) Reduce mowing (ground) speed. Install correct roller for application. Mow more often. Change mowing direction regularly Rev B

41 CUTTING UNITS Streaks A streak is a line of uncut grass. This is usually caused by a damaged bedknife or reel blade. NOTE: Arrow indicates direction of travel. TN0 Probable Cause Remedy Damaged bedknife. Replace bedknife. (See Bedknife on page -.) Damaged or unevenly worn reel. Loose or missing bedknife fasteners. Incorrect roller. Bedknife is matting the grass down. Turning too aggressively. Cutting units don t overlap during turns or on side hills. Tire mats down grass before it is cut. Wet grass is matted down before it is cut. Inspect reel. Replace as needed. (See Reel Assembly -Inch Cutting Unit on page -0 or Reel Assembly -Inch Cutting Unit on page -.) Check bedknife screws. Tighten loose screws; replace missing screws. (See Bedknife on page -.) Install correct roller for application. (See Front Roller on page -, Rear Roller -Inch Cutting Unit on page -, or Rear Roller -Inch Cutting Unit on page -.) Install correct bedknife for application. Turn less aggressively to allow cutting units to overlap. Change mowing direction or pattern on side hills. Check/adjust tire inflation pressure. (Refer to Parts and Maintenance Manual. ) Cut when grass is dry. 6-Rev B -

42 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. NOTE: Arrow indicates direction of travel. TN0 Probable Cause Remedy Grass is too tall. Mowing while grass is wet. Grass buildup on roller. Grass collecting on mower or cutting unit frame. Mow more often. Mow when grass is dry. Clean rollers and scrapers. Clear cutting unit(s) grass shield. - 6-Rev B

43 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. NOTE: Arrow indicates direction of travel. TN Probable Cause HOC inconsistent from one cutting unit to another. Remedy Adjust HOC on cutting units to same height. (See Height-of-Cut (HOC) Adjustment on page -0.) Check condition of cutting unit frame and/or mower frame. Repair or replace as needed. Difference in reel motor speeds. Difference in mower ride height from side to side. Check operation of reel motor(s) and repair/replace as necessary. (See Reel Drive Motor -Inch Cutting Unit on page - or Reel Drive Motor -Inch Cutting Unit on page -.) Check/adjust tire inflation pressure. (Refer to Parts and Maintenance Manual. ) 6-Rev B -

44 CUTTING UNITS Rifling or Tramlining Rifling or tramlining is a pattern of varying cutting heights, resulting in a wave-like cut appearance, usually due to heavy contact points across the reel and/or bedknife. NOTE: Arrow indicates direction of travel. TN09 Probable Cause Reel and/or bedknife unevenly worn. Remedy Inspect bedknife and reel. Grind or replace as needed. (Refer to Parts and Maintenance Manual and see Bedknife on page -.) Grass Graining Grass graining is a directional orientation of grass blades and/or stems usually due to mowing in one direction or constant traffic in one direction. NOTE: Arrow indicates direction of travel. TN Probable Cause Mowing in the same direction all the time. Constant traffic direction. Nature of grass growth influenced by water. Remedy Mow against the grain or change the mowing pattern. Use a brush attachment on the cutting unit. Use Turf Groomer or vertical mower. - 6-Rev B

45 CUTTING UNITS Mechanical Troubleshooting Condition Probable Cause Remedy Reel drive does not engage. Mow switch not engaged. Engage mow switch. (Refer to Safety and Operation Manual. ) Seat switch faulty. Mow switch faulty. Test seat switch. (See Seat Switch Test on page -69.) Test mow switch. (See Mow Switch Test on page -66.) Reel drive motor faulty. Repair or replace reel drive motor. (See Reel Drive Motor -Inch Cutting Unit on page - or Reel Drive Motor -Inch Cutting Unit on page -.) Reel drive does not reach full speed. Reel drive motor faulty. Repair or replace reel drive motor. (See Reel Drive Motor -Inch Cutting Unit on page - or Reel Drive Motor -Inch Cutting Unit on page -.) Bedknife-to-reel contact too tight. Check bedknife-to-reel clearance adjustment. (See Bedknife-to-Reel Clearance Adjustment on page -.) Cutting unit roller does not rotate. Roller is out of round and restricted by scraper and/or scraper is bent. Roller bearing faulty. Replace roller or scraper. (See Front Roller on page -, Rear Roller -Inch Cutting Unit on page -, or Rear Roller -Inch Cutting Unit on page -.) Replace roller bearing. (See Rear Roller Bearings -Inch Cutting Unit on page -.) 6-Rev B -

46 CUTTING UNITS Checks and Adjustments Bedknife Adjuster Assembly Adjustment -Inch Cutting Unit See Figures - and -.! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 9 0 Required Materials Anti-Seize Compound Lubriplate Marine Grease. Park the mower safely. (See Park Mower Safely on page -6.) 6. Remove special bolt (). Figure - TN9 6 NOTE Note orientation of cup spacers (9,, and ) prior to disassembly to ensure correct assembly.. Loosen set screw (), and remove rod (), cup spacers (9,, and ), and urethane spring (0).. Remove knob (). Figure - TN9. Remove spring pin ().. Hold knob () securely in position and loosen special bolt ().. Remove screws () and lock washers ().. Disengage bedknife adjuster assembly (6) from bedknife (). NOTE Prior to assembly, apply anti-seize to threads of special bolt () and threads of knob (). Lubricate all sliding surfaces of spacer cups (9,, and ), bedknife (), and rod () with Lubriplate marine grease. 9. Install knob () or turns in bedknife adjuster block. NOTE When installing rod (), ensure square head of rod is aligned and fully seated in knob (). 0. Install cup spacers (9,, and ), urethane spring (0), and rod (). Tighten set screw ().. Hold knob securely in position and install special bolt (), in the adjuster block.. Position adjuster block to the bedknife and install screws () and lock washers ().. Hold knob securely in position and tighten special bolt () until cup spacer () contacts bedknife () Rev B

47 CUTTING UNITS. Tighten knob () to eliminate clearance between knob (), cup spacers (9,, and ), urethane spring (0), bedknife (), and special bolt ().. Hold knob securely in position and turn special bolt () an additional. turns and continue to tighten until slot in special bolt aligns with hole in rod (), then install spring pin (). 6. Apply Lubriplate marine grease to exposed threads of knob () and special bolt () after assembly.. Repeat steps through 6 for other side of cutting unit.. Adjust bedknife-to reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Reel Squaring Adjustment -Inch Cutting Unit See Figures - through -.! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. Figure -. Remove three screws () and washers (). 6. Repeat step for other side of cutting unit. TN0. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit from machine. (See -Inch Cutting Unit on page -.). Remove reel motor. (See Reel Drive Motor -Inch Cutting Unit on page -.) 6 Figure -. Rotate rod () counterclockwise and remove counterweight (). TN0 9 Figure -6 TN0. Rotate bedknife (), by hand, until bedknife lightly contacts reel (9).. Using feeler gauge or paper, check bedknife contact on both ends of cutting unit. Is contact even on both ends? YES Proceed to step. NO Proceed to step Loosen, but do not remove, four screws (6) and screw () on end of cutting unit with clearance, 0. Rotate bearing housing () up or down until bedknife contacts reel evenly. 6-Rev B -

48 CUTTING UNITS NOTE It may be necessary to rotate both bearing housings in opposite directions if reel is severely out-of-square.. Tighten four screws (6) and screw () to 0 lb-ft (0.. N m).. Install three screws () and three washers () on one side of cutting unit only. Tighten screws to 0 lb-ft (0.. N m). Bedknife-to-Reel Clearance Adjustment See Figures -9 through -.! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 0. Park the mower safely. (See Park Mower Safely on page -6.). Prior to adjusting the bedknife-to-reel clearance on -inch cutting units, ensure the bedknife adjuster assembly is properly adjusted. (See Bedknife Adjuster Assembly Adjustment -Inch Cutting Unit on page -6.) Figure - TN0. On other side of cutting unit, hold bedknife adjuster () against the reel frame () and turn adjuster knob (0) until the three threaded holes () in the bedknife adjuster align with the three holes () in the reel frame. 6 NOTES Figure -9 TN Clearance between the bedknife and reel should be checked with a feeler gauge. Slide the feeler gauge between the bedknife and reel. There should be a slight drag on the feeler gauge. Do not turn the reel while making the check. Clearance should be checked at the outer ends of the reel, then at the inner set of spiders (), and then in the middle. The bedknife-to-reel adjustment should be made by starting with the leading end of the reel () and following with the trailing end (). The leading end of the reel blade is the end that passes over the bedknife first during normal reel rotation. Figure - TN0. Install three screws and washers ( and 6) and tighten to 0 lb-ft (0.. N m).. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) - 6-Rev B

49 CUTTING UNITS Figure -0: -Inch Reel TN99 NOTES Move the adjusting screws in very small increments when making bedknife-to-reel adjustments. Keep the adjusting screws tight against the bedknife backing for a positive clearance setting. Avoid aggressive tightening, or damage may occur to bedknife and reel blades. Poor bedknife-to-reel adjustment will occur if one screw is loosened too much and the other screw is brought in. Inconsistent bedknife-to-reel clearance settings will occur when opposing screws are at a low torque value. Final bedknife-to-reel adjustments may be done on the appropriate (single) opposing screw. During final adjustments, screws must be tightened, never loosened. When the reel and bedknife are properly adjusted, the reel will spin freely and will cut a piece of newspaper along the full length of the reel when the paper is held at a 90 angle to the bedknife. 6 Figure -: -Inch Reel TN09. For -inch reels, adjust bedknife-to-reel gap to in. ( mm) between reel blade and bedknife using adjuster () on both leading and trailing edges of reel.. For -inch reels, adjust bedknife-to-reel gap to in. ( mm) between reel blade and bedknife using the upper adjuster () and lower adjuster (6) on both leading and trailing edges of reel. 6-Rev B -9

50 CUTTING UNITS Height-of-Cut (HOC) Adjustment See Figure -. NOTE -inch cutting unit is shown; -inch cutting unit is similar.! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.. Park the mower safely. (See Park Mower Safely on page -6.). Repeat steps through on opposite end of front roller (). 9. Recheck each end with height-of-cut bar and readjust as necessary. NOTES Check the position of each reel for desired height-of-cut. All reels must be accurately adjusted to exactly the same height for proper cutting. Down Pressure Adjustment See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) 9 NOTE 6 Figure - TN90 The bedknife-to-reel clearance should be properly adjusted before adjusting the cutting height. (See Bedknife-to-Reel Clearance Adjustment on page -.). Loosen lock nut (9) on the side of front roller bracket () just enough to allow adjusting knob () to raise or lower the bracket.. Set height-of-cut bar (6) to desired height-of-cut () by measuring between the underside of screw head and the surface of height-of-cut bar and tightening the wing nut ().. Place height-of-cut bar (6) across bottom of front and rear rollers ( and ) near one end.. Slide the head of the gauge screw over the bedknife (). 6. Turn adjusting knob () to close the gap between the front and rear rollers ( and ) and height-of-cut bar (6).. Tighten lock nut (9). 6 Figure - TN9. Raise reels and place rod cross pin () in the fourth hole from ball joint ().. Lower reels onto a flat surface.. Loosen lock nut () and turn rod (6) in or out of ball joint () to achieve an initial distance () of.9 ± 0.06 in. ( ± mm) between the center of the ball joint and the center of the rod cross pin. Set distance () for each reel.. Measure spring length () on all reels. Record the shortest spring length and set the other springs to that length ± 0.06 in. ( mm) by adjusting rod (6). Ensure rod cross pin () is horizontal and tighten lock nut (). 6. To adjust down pressure, move rod cross pin () one hole toward spring to increase pressure, or one hole away from spring to decrease pressure on rear roller Rev B

51 CUTTING UNITS Grass Shield Adjustment -Inch Cutting Unit See Figure -.! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. Reel Bearing Pre-Load Adjustment -Inch Cutting Unit See Figures - through -9.. Park the mower safely. (See Park Mower Safely on page -6.). Back the bedknife away from reel. (See Bedknife-to-Reel Clearance Adjustment on page -.). Park the mower safely. (See Park Mower Safely on page -6.) TN9 Figure - TN9. Loosen nut () on each end of grass shield () and adjust grass shield as close to reel blades as possible without making contact.. Tighten nut () on each end of grass shield. Figure -. Remove two screws (), two lock washers (), and counterweight (). TN966 Figure -6 TN6. Remove screw (6), lock washer (), washer (), and spacer (). 6 6-Rev B -

52 CUTTING UNITS 6 9 Figure - TN6. Tighten adjuster nut () until the spring (9) is completely collapsed, then back the nut out two or three turns, or until there is 0.00 in. (.0 mm) side-to-side movement of the reel. Figure -9 TN966. Install counterweight (6), two lock washers (), and two screws ().. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) 0 Figure - TN6 6. Install spacer (0), washer (), lock washer (), and screw (). - 6-Rev B

53 CUTTING UNITS Repair -Inch Cutting Unit Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -6.) -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) Figure -0 6 TN6. Remove two motor clips (), and remove reel drive motor () and coupler (6) from cutting unit ().. Remove pin ().. Raise lift arm () until yoke shaft () clears bottom of yoke shaft housing ().. Move cutting unit () away from machine. Installation Notes Install cutting unit by reversing the order of removal. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. Coat the reel drive motor shaft splines and coupler with grease that meets or exceeds NLGI Grade LB specifications before installing reel drive motor. 6 Figure - TN. Loosen rod () and remove reel drive motor () from cutting unit ().. Remove pin ().. Raise lift arm () until yoke shaft () clears bottom of yoke shaft housing (6).. Move cutting unit () away from machine. Installation Notes Install cutting unit by reversing the order of removal. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. Coat the reel drive motor shaft splines with grease that meets or exceeds NLGI Grade LB specifications before installing reel drive motor. 6-Rev B -

54 CUTTING UNITS Lift Yoke Removal and Installation See Figure -. NOTE -inch reel is shown; -inch reel is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page - or -Inch Cutting Unit on page -.) Figure -. Remove screw (), lock washer (), and nut (), and disengage rod assembly () from cutting unit ().. Remove rod end (), nut (), pin (6), washer (), and spring ().. Remove rod assembly () from lift yoke (). 6. Remove screw (), spacer (9), and washer (0) from each side of cutting unit.. Remove lift yoke (). Installation Notes Install lift yoke by reversing the order of removal. Adjust down pressure as necessary. (See Down Pressure Adjustment on page -0.) TN Lift Arms Removal and Installation See Figure -. NOTE Front left lift arm is shown; all other lift arms are similar.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page - or -Inch Cutting Unit on page -.). Remove lift cylinder. (See Center Lift Cylinder on page 6-6 and Left and Right Front Lift Cylinders on page 6-.) Figure - TN9. For outside lift arm assemblies, remove lock nut (), washers (), screw (), and hose support ().. Remove roll pin (9), machinery bushing (0), bushings (), and pivot yoke (). 6. Remove lock nut (), screw (6), collar (), wave washer (), and spacer ().. Remove lift arm (). Installation Notes Install lift arms by reversing the order of removal. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications Rev B

55 CUTTING UNITS Reel Drive Motor -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) 6 6 Figure - TN60 NOTES Label all hydraulic hoses before disconnecting to ensure correct installation. Plug hydraulic hoses after disconnecting to prevent the loss of hydraulic oil.. Disconnect hoses ( and ) from elbow fittings (6).. Disconnect hose () from fitting ().. Remove two motor clips ().. Remove reel drive motor () from cutting unit. 6. Remove coupler () from reel drive motor shaft. Installation Notes Install reel drive motor by reversing the order of removal. Coat the reel drive motor shaft splines and coupler with grease that meets or exceeds NLGI Grade LB specifications before installing reel drive motor. Check hydraulic oil level. Add oil as needed. (Refer to Parts and Maintenance Manual for correct oil specifications.) 6-Rev B -

56 CUTTING UNITS Disassembly, Inspection, and Assembly See Figures - and Mount O-Ring 6 Upper Seal Dowel Pin () 6 Retaining Screw () Snap Ring Drive Shaft Body Relief Valve () Shaft Seal Seal O-Ring Plug Front Cover 9 Anti-Extrusion Ring Rear Cover 9 Case Drain Fitting Anti-Extrusion Ring 0 O-Ring Washer () 0 IN/OUT Port Fitting () Figure - Disassembly Notes Do not disassemble reel drive motor for repair unless test procedures indicate internal leakage. Never pry components apart. Use a soft-faced hammer, and gently tap body and drive shaft to separate reel drive motor body. TN99 Figure -6 TN. Before removing gear set, mark a line across meshing teeth to ensure that gears are reassembled in the same position Rev B

57 CUTTING UNITS. Place parts in assembly order on a clean work area as they are removed.. Discard seals as they are removed. 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.. Clean all parts using clean solvent, and dry using compressed air.. Inspect seal kit components (,,,, 6,, 9, 0, and ), front cover (), relief valves (), case drain fitting (9), and port fittings (0) for cracks, nicks, burrs, and excessive wear. Inspect surfaces for scoring, galling, and scratches. Replace as necessary. 6. Inspect remaining reel drive motor components for excessive wear or damage. Replace reel drive motor if necessary. 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 Mount O-Ring (Jacobsen PN 9) Seal Kit (Jacobsen PN 009) Front Cover Kit (Jacobsen PN 006) Relief Valve (Jacobsen PN 000) Assemble the reel drive motor 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. Remove alignment mark from gear set after gears have been installed with teeth in proper mesh. Rotate drive shaft by hand after assembling to make sure there is no binding between parts; do not force. Use extreme care when installing shaft seal. Seal must seat squarely in seal bore. Install retaining screws (6) finger tight and rotate drive shaft to make sure it turns freely. Tighten retaining screws (6) evenly in steps to a final torque of. lb-ft ( N m) and check rotation of drive shaft. For reel motors with - ORFS case drain fitting, tighten case drain fitting (9) to lb-ft (.9 N m). For reel motors with -6 ORFS case drain fitting, tighten case drain fitting (9) to lb-ft ( N m). Tighten IN/OUT port fittings (0) to 60 lb-ft (. N m). Lubricate reel drive motor through ports with clean hydraulic oil prior to installing. 6-Rev B -

58 CUTTING UNITS Reel Drive Motor -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.) 6 6 Figure - TN NOTES Label all hydraulic hoses before disconnecting to ensure correct installation. Plug hydraulic hoses after disconnecting to prevent the loss of hydraulic oil.. Disconnect hoses ( and ) from elbow fittings (6).. Disconnect hose () from fitting ().. Loosen rod () and remove reel drive motor () from cutting unit. Installation Notes Install reel drive motor by reversing the order of removal. Coat the reel drive motor shaft splines with grease that meets or exceeds NLGI Grade LB specifications before installing reel drive motor. Check hydraulic oil level. Add oil as needed. (Refer to Parts and Maintenance Manual for correct oil specifications.) - 6-Rev B

59 CUTTING UNITS Disassembly, Inspection, and Assembly See Figures - and Snap Ring 6 Seal () Body 6 Case Drain Fitting Shaft Seal Thrust Plate () Relief Valve () IN/OUT Port Fitting () Mount O-Ring Drive Shaft Rear Cover Driven Gear Front Cover 9 Dowel Pin () Washer () 9 Pin () Anti-Extrusion Ring () 0 Body Seal () Retaining Screw () Figure - Disassembly Notes Do not disassemble reel drive motor for repair unless test procedures indicate internal leakage. Never pry components apart. Use a soft-faced hammer, and gently tap body and drive shaft to separate reel drive motor body. TN99 Figure -9 TN. Before removing gear set, mark a line across meshing teeth to ensure that gears are reassembled in the same position. 6-Rev B -9

60 CUTTING UNITS. Place parts in assembly order on a clean work area as they are removed.. Discard seals as they are removed. 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.. Clean all parts using clean solvent, and dry using compressed air.. Inspect seal kit components (,,, 6, and 0), front cover (), drive shaft (), relief valves (), case drain fitting (6), and port fittings () for cracks, nicks, burrs, and excessive wear. Inspect surfaces for scoring, galling, and scratches. Replace as necessary. 6. Inspect remaining reel drive motor components for excessive wear or damage. Replace reel drive motor if necessary. 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 (Jacobsen PN 60669) Assemble reel drive motor 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. Remove alignment mark from gear set after gears have been installed with teeth in proper mesh. Rotate drive shaft by hand after assembling to make sure there is no binding between parts; do not force. Use extreme care when installing shaft seal. Seal must seat squarely in seal bore. Install retaining screws () finger tight and rotate drive shaft to make sure it turns freely. Tighten retaining screws () evenly in steps to a final torque of lb-ft ( N m) and check rotation of drive shaft. For reel motors with - ORFS case drain fitting, tighten case drain fitting (6) to lb-ft (.9 N m). For reel motors with -6 ORFS case drain fitting, tighten case drain fitting (6) to lb-ft ( N m). Tighten IN/OUT port fittings () to 60 lb-ft (. N m). Lubricate reel drive motor through ports with clean hydraulic oil prior to installing Rev B

61 CUTTING UNITS Grass Shield -Inch Cutting Unit Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove front roller. (See Front Roller on page -.) Grass Deflector -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.) Figure -0 TN96. Remove nut (), lock washer (), flat washer (), and screw () from each side of cutting unit.. Remove grass shield (). Installation Notes Install grass shield by reversing the order of removal. Adjust the grass shield. (See Grass Shield Adjustment -Inch Cutting Unit on page -.) Figure - TN96. Remove screw () and lock washer () from each side of cutting unit.. Remove nut (), lock washer (), and screw (6) from each side of cutting unit.. Remove grass deflector (). Installation Note Install grass deflector by reversing the order of removal. 6 6-Rev B -

62 CUTTING UNITS Bedknife Backing Assembly -Inch Cutting Unit Removal and Installation See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Place cutting unit on a solid work surface. Installation Notes Anti-Seize Compound Required Materials Install bedknife backing assembly by reversing the order of removal. Apply anti-seize compound to the threads of the bedknife backing mounting screws before installing. Tighten bedknife backing mounting screws to lb-ft (.9 0. N m). Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Bedknife Backing Assembly -Inch Cutting Unit Figure - TN09. Loosen bedknife adjuster screws (and ) on each side of cutting unit. Removal and Installation See Figures - through -6.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.) Figure - TN9. Support bedknife backing assembly (). 6. Remove bedknife backing mounting screw () on each side of cutting unit.. Remove bedknife backing assembly (). Figure - TN99. Place cutting unit, front surface down, on a solid work surface.. Support the bedknife backing assembly (). - 6-Rev B

63 CUTTING UNITS Bedknife Removal and Installation See Figure -. NOTE -inch cutting unit is shown; -inch cutting unit is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Remove bedknife backing assembly. (See Bedknife Backing Assembly -Inch Cutting Unit on page - or Bedknife Backing Assembly -Inch Cutting Unit on page -.) Figure - TN96. Remove three screws (), three lock washers (), and adjuster () from each side of cutting unit. Figure Remove screw () and lock washer (6) from each side of cutting unit, and remove the bedknife backing assembly. Installation Note Install bedknife backing assembly by reversing the order of removal. Anti-Seize Compound Required Materials 6 TN60 Apply anti-seize compound to the threads of the bedknife backing mounting screws before installing. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Figure -. Remove thirteen screws () and bedknife () from the bedknife backing (). Installation Notes Anti-Seize Compound Required Materials TN6 Install bedknife by reversing the order of removal. Apply anti-seize compound to screws (). Tighten screws () to 90 0 lb-in. (0..6 N m), starting with screws in the center and working out to the ends of the bedknife. Grind bedknife after assembling to bedknife backing to achieve a in. (. mm) bedknife front face height, a bedknife front face angle, and an 0 bedknife top face angle (rear relief). Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) 6-Rev B -

64 CUTTING UNITS Reel Bearing Housing Assembly -Inch Cutting Unit Removal and Installation Drive Side See Figure -. Required Tools or Equipment Bearing Assembly Tool (Jacobsen PN JAC0) Reel Bearing Housing Puller (Jacobsen PN JAC0). Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove grass shield. (See Grass Shield -Inch Cutting Unit on page -.). Remove reel drive motor. (See Reel Drive Motor -Inch Cutting Unit on page -.) Installation Notes Install reel bearing housing assembly by reversing the order of removal. Use bearing assembly tool (Jacobsen PN JAC0) to install reel bearing housing assembly onto reel shaft. Inspect bearing (6) for wear or damage. Replace as needed. Pack bearing (6) with grease that meets or exceeds NLGI Grade LB specifications before assembly. Tighten mounting screws () to lb-ft (. 9. N m). Lubricate grease fitting () with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fitting before lubricating and apply grease to the fitting with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. Adjust bedknife-to-reel clearance prior to installing cutting unit to the mower. (See Bedknife-to-Reel Clearance Adjustment on page -.) Disassembly and Assembly See Figure Figure - TN9. Remove grease fitting (). 6. Remove snap ring ().. Remove four mounting screws () and nuts ().. Remove reel bearing housing assembly () using reel bearing housing puller (Jacobsen PN JAC0). 9. Inspect the reel shaft () for wear or damage. Replace reel if needed. (See Reel Assembly -Inch Cutting Unit on page -0.) TN090 Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting Figure -9-6-Rev B

65 CUTTING UNITS Assembly Notes Install new grease seal (). Inspect bearing cup and cone () for wear or damage. Replace as needed. Pack bearing () with grease that meets or exceeds NLGI Grade LB specifications before assembly. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of grease seal (). Removal Non-Drive Side See Figure -0. Required Tools or Equipment Reel Bearing Housing Puller (Jacobsen PN JAC0). Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove grass shield. (See Grass Shield -Inch Cutting Unit on page -.). Remove counterweight (). 6. Remove grease fitting ().. Remove screw (), lock washer (6), flat washer (), and spacer ().. Remove four mounting screws (6), washers (), and nuts (9). 9. Remove seal (). 0. Remove nut ().. Remove washer () and spring ().. Remove reel bearing housing assembly () using reel bearing housing puller (Jacobsen PN JAC0).. Inspect reel shaft (0) for wear or damage. Replace reel if needed. (See Reel Assembly -Inch Cutting Unit on page -0.) Disassembly and Assembly See Figure TN090 Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting Figure TN96 Figure -0. Remove two screws () and lock washers (). Assembly Notes Install new grease seal (). Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of grease seal (). Inspect bearing cup and cone () for wear or damage. Replace as needed. Pack bearing () with grease that meets or exceeds NLGI Grade LB specifications before assembly. 6-Rev B -

66 CUTTING UNITS Installation Non-Drive Side See Figure -. Required Tools or Equipment Bearing Assembly Tool (Jacobsen PN JAC0). Lubricate grease fitting () with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fitting before lubricating and apply grease to the fitting with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. 9. Install grass shield. (See Grass Shield -Inch Cutting Unit on page -.) 0. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.). Install cutting unit to mower. (See -Inch Cutting Unit on page -.) Figure -. Install reel bearing housing assembly () using bearing assembly tool (Jacobsen PN JAC0). TN96. Install seal () using mounting screws (6), washers (), and nuts (9).. Tighten mounting screws (6) to lb-ft (. 9. N m).. Install grease fitting ().. Adjust reel bearing pre-load. (See Reel Bearing Pre-Load Adjustment -Inch Cutting Unit on page -.) 6. Install spacer (), washer (), lock washer (6), and screw ().. Install counterweight (), two screws (), and two washers () Rev B

67 CUTTING UNITS Reel Bearing Housing Assembly -Inch Cutting Unit Removal and Installation Drive Side See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove reel drive motor. (See Reel Drive Motor -Inch Cutting Unit on page -.) Figure - TN96. Remove grease fitting ().. Remove screw (6). 6. Using a suitable puller, remove coupler () from reel shaft (). Remove spring ().. Remove bedknife mounting screw () and spring washer ().. Remove screw (), spacer (9), and flange nut (). 9. Remove four screws () and spacers (). 0. Remove reel bearing housing assembly (9).. Rotate rod () counterclockwise and remove rod and washer ().. Press spring pin () into reel bearing housing assembly (9) until spring pin clears reel bearing housing wall. Remove spring pin and clamp block (0) Inspect reel shaft () for wear or damage. Replace reel if needed. (See Reel Assembly -Inch Cutting Unit on page -.) Installation Notes Install reel bearing housing assembly by reversing the order of removal. Inspect bearing cup and cone () for wear or damage. Replace as needed. Pack bearing cup and cone with grease that meets or exceeds NLGI Grade LB specifications before assembly. Align slot on retaining ring (6) with grease fitting () prior to installation. Lubricate splines on coupler () with grease that meets or exceeds NLGI Grade LB specifications. Lubricate threads on rod () with Lubriplate marine grease prior to installation. Press spring pin () flush with reel bearing housing face. Tighten screws (,, 6, and ) to 0 lb-ft (0.. N m). Lubricate grease fitting () with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fitting before lubricating and apply grease to the fitting with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun.. Adjust bedknife-to-reel clearance prior to installing cutting unit to mower. (See Bedknife-to-Reel Clearance Adjustment on page -.) 6-Rev B -

68 CUTTING UNITS Disassembly and Assembly See Figure Bearing Cup and Cone Bushing Grease Seal Grease Fitting Reel Bearing Housing 6 Vent Fitting Figure - 6 TN96 6 Assembly Notes Install new grease seal (). Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of grease seal (). Inspect bearing cup and cone () for wear or damage. Replace as needed. Pack bearing () with grease that meets or exceeds NLGI Grade LB specifications before assembly. Removal Non-Drive Side See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.) Figure - TN96 TN96. Support counterweight (). Rotate rod () counterclockwise and remove rod and washer (0).. Remove counterweight () and O-ring (9).. Remove grease fitting (). 6. Remove screw ().. Using a suitable puller, remove coupler () from reel shaft (6). Remove reel spacer ().. Remove bedknife mounting screw () and spring washer (). 9. Remove screw (6), spacer (), and flange nut (). 0. Remove four screws (0) and spacers ().. Remove reel bearing housing assembly ().. Press spring pin () into reel bearing housing assembly () until spring pin clears reel bearing housing wall. Remove spring pin and clamp block (9).. Inspect reel shaft (6) for wear or damage. Replace reel if needed. (See Reel Assembly -Inch Cutting Unit on page -.) - 6-Rev B

69 CUTTING UNITS Disassembly and Assembly See Figure -6. Installation Non-Drive Side See Figure Bearing Cup and Cone Bushing Grease Seal Grease Fitting Reel Bearing Housing 6 Vent Fitting Figure -6 Assembly Notes TN96 Install new grease seal (). Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of grease seal (). Inspect bearing cup and cone () for wear or damage. Replace as needed. Pack bearing () with grease that meets or exceeds NLGI Grade LB specifications before assembly. Figure - TN96 TN96. Install clamp block (9) in reel bearing housing () and press spring pin () flush with reel bearing housing face.. Install reel bearing housing assembly ().. Align slot on retaining ring () with grease fitting () and install four screws (0) and spacers. Tighten screws (0) to 0 lb-ft (0.. N m).. Install screw (6), spacer (), and flange nut (). Tighten screw (6) to 0 lb-ft (0.. N m).. Install bedknife mounting screw () and spring washer (). Tighten bedknife mounting screw (6) to 0 lb-ft (0.. N m). 6. Lubricate splines on coupler () with grease that meets or exceeds NLGI Grade LB specifications. Install reel spacer (), coupler (), and screw (). Tighten screw () to 0 lb-ft (0.. N m).. Lubricate threads on rod () with Lubriplate marine grease and install washer (0) and rod (). Do not tighten rod ().. Lubricate O-ring (9) with grease that meets or exceeds NLGI Grade LB specifications. Install counterweight () and O-ring (9). Tighten rod (). 9. Install grease fitting (). 6 6-Rev B -9

70 CUTTING UNITS 0. Lubricate grease fitting () with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fitting before lubricating and apply grease to the fitting with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun.. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.). Install cutting unit to mower. (See -Inch Cutting Unit on page -.) Reel Assembly -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove bedknife backing assembly. (See Bedknife Backing Assembly -Inch Cutting Unit on page -.). Remove front roller. (See Front Roller on page -.). Remove grass shield. (See Grass Shield -Inch Cutting Unit on page -.) 6. Remove the drive side reel bearing housing assembly. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page -.). Remove the non-drive side reel bearing housing assembly. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page -.)! CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.. Remove reel () from frame (). Installation Notes Install reel assembly by reversing the order of removal. Adjust reel bearing pre-load. (See Reel Bearing Pre-Load Adjustment -Inch Cutting Unit on page -.) Adjust grass shield. (See Grass Shield Adjustment -Inch Cutting Unit on page -.) Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Check height-of-cut adjustment. (See Height-of-Cut (HOC) Adjustment on page -0.) Figure - TN6-0 6-Rev B

71 CUTTING UNITS Reel Assembly -Inch Cutting Unit Removal and Installation See Figures -9 and -0.. Park the mower safely. (See Park Mower Safely on page -6.). Remove cutting unit. (See -Inch Cutting Unit on page -.). Remove bedknife backing assembly. (See Bedknife Backing Assembly -Inch Cutting Unit on page -.). Remove front roller. (See Front Roller on page -.). Remove the drive side reel bearing housing assembly. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page -.) 6. Remove the non-drive side reel bearing housing assembly. (See Reel Bearing Housing Assembly -Inch Cutting Unit on page -.) Figure -0! CAUTION. Remove reel () from frame (). To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. Installation Notes Install reel assembly by reversing the order of removal. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Check height-of-cut adjustment. (See Height-of-Cut (HOC) Adjustment on page -0.) TN6 Figure -9. Remove grass shield (). TN90 6-Rev B -

72 CUTTING UNITS Front Roller Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller. Front Roller Bearings Removal See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove front roller. (See Front Roller on page -.) Figure - TN9. Remove nuts () and screws ().. Remove adjuster knobs ().. Remove adjuster brackets () and front roller () from cutting unit. 6. Loosen jam nut () and square head bolt (6) on each side of front roller ().. Remove front roller () from adjuster brackets (). Installation Notes Install front roller by reversing the order of removal. Center the roller between the adjuster brackets before tightening jam nuts and square head bolts. Align roller shaft flat with square head bolts before tightening bolt on flat on each end of shaft. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. Check height-of-cut adjustment. (See Height-of-Cut (HOC) Adjustment on page -0.) 6 Figure -. Remove lock nut (6) from each end of roller shaft ().. Support one end of roller tube (), and use a suitable hammer to drive outer seal () and wear sleeve () out of bearing housing (9) by tapping opposite end of shaft ().. Using a suitable puller, remove inner seal () and bearing (). Discard seals. 6. Repeat steps and for other end of roller. Installation NOTES 9 TN960 Clean and inspect bearings for wear or damage. Replace if necessary. Pack bearings () with grease that meets or exceeds NLGI Grade LB specifications prior to installation. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of seals ( and ) prior to installation.. Using a suitable press, install new inner seals () with single lip facing toward center of roller.. Press one bearing () onto end of roller shaft () and install wear sleeve (). 6-6-Rev B

73 CUTTING UNITS. Carefully install roller shaft into roller tube without damaging inner seals.. Using a suitable press, install new outer seal () with the lip facing the inside.. Install lock nut (6). Do not tighten lock nut. 6. Press one bearing () onto the other end of roller shaft () and install wear sleeve ().. Using a suitable press, install new outer seal () with the lip facing the inside.. Install lock nut (6). Do not tighten lock nut. 9. Evenly tighten lock nuts (6) to 0 0 lb-ft (.6 0. N m) to set the bearings. 0. Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun.. Loosen one lock nut and retighten the same lock nut to obtain lb-in. (0. 0. N m) of rotational torque resistance on roller shaft with no end play. Rear Roller -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller. Figure - TN96 TN99. Remove two screws (), two lock nuts (), and scraper ().. Remove screw with grease fitting () on each side of rear roller ().. Remove rear roller (). Installation Notes Install rear roller by reversing the order of removal. Tighten screws () to 6 lb-ft (.. N m). Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. 6-Rev B -

74 CUTTING UNITS Rear Roller Bearings -Inch Cutting Unit Removal See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Remove rear roller. (See Rear Roller -Inch Cutting Unit on page -.) Figure -. Remove lock nut () from each end of roller shaft ().. Support one end of roller tube (), and use a suitable hammer to drive outer seal (6), wear sleeve (), and washer () out of roller tube by tapping opposite end of shaft ().. Using a suitable puller, remove inner seal () and bearing (). Discard seals. 6. Repeat steps and for other end of roller. Installation NOTES Clean and inspect bearings for wear or damage. Replace if necessary. Pack bearings () with grease that meets or exceeds NLGI Grade LB specifications prior to installation. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of seals (6 and ) prior to installation.. Using a suitable press, install new inner seal () in one end of roller tube () with single lip facing toward center of roller. 6 TN9. Using a suitable press, install one bearing () onto end of roller shaft () until it contacts the shoulder on the roller shaft.. Carefully install roller shaft into roller tube without damaging inner seal.. Using a suitable press, install new outer seal (6) with the lip facing the inside.. Install wear sleeve () with the counterbore to the inside. 6. Install washer () and lock nut (). Do not tighten lock nut.. Using a suitable press, install one bearing () onto the other end of roller shaft ().. Using a suitable press, install new outer seal (6) with the lip facing the inside. 9. Install wear sleeve () with the counterbore to the inside. 0. Install washer (), and lock nut (). Do not tighten lock nut.. Evenly tighten lock nuts () to 0 0 lb-ft (.6 0. N m) to set the bearings.. Loosen one lock nut and retighten the same lock nut to obtain lb-in. (0. 0. N m) of rotational torque resistance on roller shaft with no end play. - 6-Rev B

75 CUTTING UNITS Rear Roller -Inch Cutting Unit Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -6.). Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller. Rear Roller Bearings -Inch Cutting Unit Removal See Figure -6.. Park the mower safely. (See Park Mower Safely on page -6.). Remove rear roller. (See Rear Roller -Inch Cutting Unit on page -.) 6 Figure -. Remove screw with grease fitting () on each side of rear roller ().. Remove rear roller (). Installation Notes Install rear roller by reversing the order of removal. Tighten screws () to 0 lb-ft (0.. N m). Lubricate grease fittings with grease that meets or exceeds NLGI Grade LB specifications. Clean grease fittings before lubricating and apply grease to the fittings with a hand grease gun only. Pump the gun slowly until a slight amount of pressure is felt, then stop do not overgrease. Do not use compressed air gun. TN96 Figure -6. Remove lock nut () from each end of roller shaft ().. Support one end of roller tube (6), and use a suitable hammer to drive wear sleeve () and grease seal () out of roller tube by tapping opposite end of shaft ().. Repeat step for other end of roller; then proceed to step Using a suitable puller, remove bearings (). Installation NOTES TN96 Clean and inspect bearings for wear or damage. Replace if necessary. Pack bearings () with grease that meets or exceeds NLGI Grade LB specifications prior to installation. Apply grease that meets or exceeds NLGI Grade LB specifications to the lip of grease seal () prior to installation.. Using a suitable press, install one bearing () onto end of roller shaft ().. Install roller shaft into roller tube (6).. Using a suitable press, install new grease seal () with the lip facing the inside. 6-Rev B -

76 CUTTING UNITS. Install wear sleeve () with the counterbore to the inside.. Install lock nut (). Do not tighten lock nut. 6. Using a suitable press, install one bearing () onto the other end of roller shaft ().. Using a suitable press, install new grease seal () with the lip facing the inside.. Install wear sleeve () with the counterbore to the inside. 9. Install lock nut (). Do not tighten lock nut. 0. Evenly tighten lock nuts () to 0 0 lb-ft (.6 0. N m) to set the bearings.. Loosen one lock nut and retighten the same lock nut to obtain lb-in. (0. 0. N m) of rotational torque resistance on roller shaft with no end play Rev B

77 Chapter 9 Accessories and Miscellaneous Repair Specifications Component Location Repair Canopy OPS Hood Fuel Tank Traction Pedal Work Light Seat and Seat Platform Seat Switch Hydro Cover Floorboard Platform Rear Wheel WD Units Rear Wheel WD Units Rear Wheel Hub WD Units Rear Wheel Hub WD Units Front Wheel (Earlier Machines) Front Wheel Hub (Earlier Machines) Front Wheel (Later Machines) Rev B 9-

78 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications OPS Mounting Hardware Mounting Hardware Torque lb-ft (N m) 0 90 (0 ) Fuel Tank Capacity gal (L) (6.) Work Light Work Light Adjustment Bolt lb-in. (N m) 60 (6..) Front Tires Size 6. x - Type Air Pressure psi (bar) 0 ( ) Mounting Bolt Torque lb-ft (N m) 9 ( 9) Machine Serial Numbers Ending 6 Through 99 Mounting Lug Nut Torque Machine Serial Numbers Ending 00 and Up lb-ft (N m) 90 () -Ply Rear Tires Size x 9.- Machine Serial Numbers Ending 6 Through 99 Size 0 x 0- Machine Serial Numbers Ending 00 and Up Type -Ply Air Pressure psi (bar) 0 ( ) WD Models Lug Nut Torque lb-ft (N m) 9 ( 9) WD Models Mounting Bolt Torque lb-ft (N m) ( 6) Front Wheel Hub 9 Castle Nut Torque lb-ft (N m) (0 6) Rear Wheel Hub WD Models Castle Nut Torque Just tight enough to remove bearing play WD Models Castle Nut Torque lb-ft (N m) ( 0) Mower Speed Transport mph (km/h) 0 (0 9) Mow mph (km/h) 0 (0 ) Reverse mph (km/h) 0 (0 ) 9-6-Rev B

79 ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure OPS Rear Wheel 9 Floorboard Fuel Tank 6 Hydro Cover 0 Traction Pedal Seat and Seat Platform Front Wheel Work Light Hood Platform Figure 9- TN6 6-Rev B 9-

80 ACCESSORIES AND MISCELLANEOUS REPAIR Repair Canopy Removal and Installation See Figures 9- and 9-.. Park the mower safely. (See Park Mower Safely on page -6.) OPS Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.). Remove canopy (if equipped). (See Canopy on page 9-.). Raise the hood. Figure 9- TN. Support canopy () using a suitable lifting device. 9 Figure 9-. Loosen nuts on the two front screws ().. Remove rear nuts (), screws (), and washers ().. Remove canopy (). Installation Notes Center the canopy before tightening the mounting hardware. Install the canopy by reversing the order of removal. TN Figure 9- TN6. Support OPS () using a suitable lifting device.. Remove four OPS mounting bolts () and lock washers () from left and right sides of mower frame. 6. Lift OPS () and slide toward rear of mower. Lift OPS up and out of mower. Installation Notes Install OPS by reversing the order of removal. Tighten OPS mounting bolts to 0 90 lb-ft (0 N m). 9-6-Rev B

81 ACCESSORIES AND MISCELLANEOUS REPAIR Hood Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.) 0 9 Figure TN6 Figure 9-. Open and support hood () using a suitable lifting device.. Remove hair pin (), washer (), and clevis pin () from each side of hood.. Carefully remove hood. Installation Notes Support the hood with a suitable lifting device to aid in installation. Install hood by reversing the order of removal. Fuel Tank Removal and Installation See Figure 9-6.! CAUTION TN69 Diesel fuel is highly flammable. Do not drain fuel indoors. Heaters can ignite fuel vapors. Use extreme caution when draining fuel. NOTE! CAUTION Contact with diesel fuel can damage skin. Use gloves when working with diesel fuel. If diesel fuel comes in contact with skin, wash skin immediately. Fuel tank capacity is gal (6. L). Have suitable container(s) available that can hold up to 0 gal (6 L) of fuel.. Place a suitable container under the fuel tank drain valve (6) and open the drain valve. Loosen the fuel cap to provide a vent for draining fuel.. When fuel tank () is completely empty, close drain valve and tighten fuel cap. 6. Loosen hose clamp () and disconnect fuel hose ().. Loosen hose clamp () and disconnect fuel hose ().. Support tank mounting plate (). 9. Remove five screws () and tank mounting plate (). 0. Remove two screws (9) located on left side of frame member (0).. Using a suitable lifting device, remove fuel tank (). 9. Park the mower safely. (See Park Mower Safely on page -6.). Raise the hood.. Disconnect the battery negative ( ) cable at the battery. 6-Rev B 9-

82 ACCESSORIES AND MISCELLANEOUS REPAIR Installation Notes Anti-Seize Compound Apply anti-seize compound to screws ( and 9) prior to installation. Do not overtighten these screws, or tank may crack and leak. Install fuel tank by reversing the order of removal. Use only clean # diesel fuel. If fuel was contaminated, install a new fuel filter. Fuel system will need to be purged of air. (See Purging the Fuel System on page -.) Traction Pedal Required Materials Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.) Work Light Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.). Disconnect the negative ( ) battery cable at the battery. 6 TN Figure 9-. Remove lock nut () and carriage bolt () from mounting bracket ().. Disconnect wire connector () from bulb (). 9 Figure 9- TN99 TN99. Remove two screws () and nuts (), and remove traction pedal (). Installation Note Install traction pedal by reversing the order of removal. NOTE If removing right work light, note location of cable tie securing right work light wire harness.. For right-side work light removal, cut cable tie securing wire harness. 6. Remove work light (6).. To replace bulb, rotate bulb () counterclockwise at harness connector end until bulb stops. Pull bulb straight out to remove. Installation Notes Install bulb and work light by reversing the order of removal. For right-side work light installation, use new cable tie to secure wire harness. Apply dielectric grease (Jacobsen PN 6) to any wire connectors disconnected. Adjust work lights to project the desired distance in front of mower. Tighten adjustment bolt () to 60 lb-in. (6.. N m) Rev B

83 ACCESSORIES AND MISCELLANEOUS REPAIR Seat and Seat Platform Removal and Installation See Figures 9-9 and 9-0. NOTE Standard seat is shown; deluxe seat is similar.. Park the mower safely. (See Park Mower Safely on page -6.). Disconnect the battery negative ( ) cable at the battery.. Remove hydro cover. (See Hydro Cover on page 9-.). Disconnect LDU wire connector (). 9. Using the lifting device, remove seat and seat platform (6) from the mower. Installation Notes Install seat and seat platform by reversing the order of removal. Carefully route seat switch wire harness to avoid damaging wires. Apply dielectric grease (Jacobsen PN 6) to any wire connectors disconnected. Figure 9-9. Remove screws (), lock washers (), and flat washers (). TN6 6 9 Figure TN69. Support the seat and seat platform (6) with a suitable lifting device. 6. Remove screws (), lock washers (), and flat washers (9).. Disconnect seat switch wire connector (). 6-Rev B 9-

84 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly Standard Seat (Earlier Machines) NOTE This procedure is for machines with the following serial numbers: Serial No ~ Serial No ~ Serial No ~ 99 Serial No ~ 6 Serial No ~ 6 Serial No ~ 69 See Figure TN96 Literature Pouch Screw () 9 Seat Spacer () Screw 6 Seat Switch Harness Flat Washer () 6 Seat Support 0 Screw () Seat Assembly Nut () T-Screw () Plug Seat Belt Kit Seat Switch Seat Pan Nut () Double-Latching Adjuster Lock Washer Figure Rev B

85 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly Standard Seat (Later Machines) NOTE This procedure is for machines with the following serial numbers: Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up Serial No and Up See Figure TN90 Literature Pouch Screw () 9 Plug Lock Washer 6 Seat Switch Flat Washer () 6 Screw () 0 Double-Latching Adjuster Screw Seat Switch Harness T-Screw () Seat Support () Seat Spacer () Seat Assembly Seat Pan Nut () Seat Support Seat Belt Kit Figure Rev B 9-9

86 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly Deluxe Seat See Figures 9- and Seat Nut () 6 Seat Spacer () Seat Pan 0 Plug Screw () Screw () Nut () 9 Double-Latching Adjuster Seat Support Nut () Figure 9- TN96 TN Rev B

87 ACCESSORIES AND MISCELLANEOUS REPAIR Backrest Cushion Left Side Adjustable Armrest Kit 9 Air Spring Kit Seat Belt Right Side Adjustable Armrest Kit 6 Left Side Cover 0 Shock Absorber Kit OPS Switch Kit Document Net Kit Backrest Adjustment Kit V Compressor Right Side Cover Lumbar Handle Kit Bellows Weight Adjust Handle 6 Seat Cushion Figure 9- TN 6-Rev B 9-

88 ACCESSORIES AND MISCELLANEOUS REPAIR Seat Switch Removal and Installation Standard Seat See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.). Disconnect the battery negative ( ) cable at the battery.. Disconnect the battery negative ( ) cable at the battery. Figure 9-6. Tilt seat () to forward position.. Cut cable ties (). TN9 NOTE Label all wires before disconnecting to ensure correct installation.. Lift rear of seat (); slide forward and remove seat. Figure 9- TN. Tag and disconnect the seat switch wire connector () Cut cable ties holding wire harness to frame.. Depress tabs on each side of seat switch () and remove from seat. Installation Notes Install seat switch by reversing the order of removal. Use new cable ties to secure wire harness and wire connector. Apply dielectric grease (Jacobsen PN 6) to any wire connectors disconnected. Figure 9-6. Disengage bellows () from hooks ().. Cut cable ties (6). TN0 Deluxe Seat See Figures 9-6 through Park the mower safely. (See Park Mower Safely on page -6.) 9-6-Rev B

89 ACCESSORIES AND MISCELLANEOUS REPAIR 0 Figure 9-. Cut cable tie (). 9. Disconnect wire connector (). 9 TN Figure 9-0 TN. Disengage switch cover tabs () and remove switch cover ().. Raise end of switch actuator (0) and remove seat switch (). Installation Notes Install seat switch by reversing the order of removal. Apply dielectric grease (Jacobsen PN 6) to any wire connectors disconnected. Use new cable ties to secure wire harness and wire connectors. 0. Cut cable tie (9). Figure 9-9 TN 9 6-Rev B 9-

90 ACCESSORIES AND MISCELLANEOUS REPAIR Hydro Cover Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.) Floorboard Removal and Installation See Figure 9-.. Park the mower safely. (See Park Mower Safely on page -6.). Remove hydro cover. (See Hydro Cover on page 9-.) TN6 Figure 9-. Remove two /-turn studs ().. Remove hydro cover (). Installation Note Install hydro cover by reversing the order of removal. TN6 Figure 9-. Lift latch ().. Remove floorboard () from machine. Installation Note Install floorboard by reversing the order of removal Rev B