Chapter 5 Chassis Specifications 5-2 Component Location 5-3 Checks and Adjustments 5-5 Repair Rev B 5-1

Transcription

1 Chapter Chassis Specifications Check and Adjustment Specifications Repair Specifications Component Location Checks and Adjustments Steering Chain Tension Adjustment Repair Reel Lift Actuators Right and Left Lift Arms Center Lift Arm Steering Yoke (WD) Steering Yoke (WD) Steering Chain and Gears Front Fenders Traction Pedal Brake Pedal Assembly Axle Shield and Front Splash Shield Floorboard Front Wheel Hub Front Axle Assembly Rev B -

2 CHASSIS Specifications Check and Adjustment Specifications Specification Steering Chain Deflection in. (mm) (..) [with 0 lb (9 N) push at mid-span of chain] Repair Specifications Specification Front Wheel Hub Castle Nut Torque lb-ft (N m) 9 (0..0) Front Axle Assembly lb-ft (N m) (88) Mounting Screw Torque Front Axle Assembly Axle Housing Face-to-Axle Shaft Seal Outer Face Measurement in. (mm). (8.) Front Axle Assembly Bearing Cap Screw Torque Front Axle Assembly Axle Housing Cover Screw Torque lb-ft (N m) (..) lb-ft (N m) (.8.) - 9-Rev B

3 CHASSIS Component Location See Figures - and Floorboard Assembly Left Cutting Unit Right Lift Arm Front Axle Assembly 9 Center Cutting Unit Traction Pedal Right Reel Lift Actuator Right Cutting Unit 8 Right Fender 0 Center Reel Lift Actuator Figure -: Component Location Right Side TN 9-Rev B -

4 CHASSIS Brake Pedal Assembly Steering Yoke Left Lift Arm Steering Chain and Gear Left Fender Left Reel Lift Actuator Figure -: Component Location Left Side TN - 9-Rev B

5 CHASSIS Checks and Adjustments Steering Chain Tension Adjustment See Figures - and -. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine.. Park the mower safely. (See Park Mower Safely on page -.). Raise the hood. Repair Reel Lift Actuators Removal and Installation See Figure -. NOTES The right reel lift actuator is shown; the left and center reel lift actuators are similar. If working on the center cutting unit, swing the cutting unit out from the machine and lock into position.. Park the mower safely. (See Park Mower Safely on page -.) NOTE For removal purposes, do not place the reel lift actuator in the fully down position. TN Figure -. Remove four screws (), flat washers (), and nuts ().. Remove rear controller cover (). TN8 TN8 Figure -. Loosen two screws ().. Adjust position of steering motor () to obtain in. (.. mm) deflection with 0 lb (9 N) push at mid-span of chain ().. Tighten two screws (). NOTE Figure - TN9 Label all wires before disconnecting to ensure correct installation.. Disconnect reel lift actuator wire connectors (8).. Remove cotter pin (), clevis pin (), two flat washers (), and two spacers () from the reel lift actuator ().. Remove cotter pin () and flat washer ().. Remove reel lift actuator. Installation Notes Install reel lift actuator by reversing the order of removal. Apply dielectric grease (Jacobsen PN ) to connections. 8 9-Rev B -

6 CHASSIS Right and Left Lift Arms Removal and Installation See Figures - and -. NOTE The right lift arm is shown; the left lift arm is similar.. Park the mower safely. (See Park Mower Safely on page -.). Remove reel lift actuator. (See Reel Lift Actuators on page -.). Remove reel leveling rod. (See Reel Leveling Rod on page -.) NOTE Figure - TN98 Label all wires before disconnecting to ensure correct installation.. Cut cable ties ().. Disconnect the reel drive motor wire connectors ().. Remove lock pin () from yoke shaft ().. Pull the lift arm () up and remove the reel assembly (). 8 Figure - 8. Remove cotter pin () and flat washer (8). 9. Remove lift arm. TN99 Installation Notes Pre-adjust the reel leveling rod before installation. (See Reel Leveling Rod Pre-Adjustment on page -.) Install lift arm by reversing the order of removal. Use new cable ties to secure the wire connectors and wire harness. Apply dielectric grease (Jacobsen PN ) to connections. Lubricate grease fittings. - 9-Rev B

7 CHASSIS Disassembly and Assembly See Figure Key () Screw (8) 9 Cotter Pin () Polygon Bushing () Right Front Lift Arm Flat Washer () Stop Bracket () 0 Link Arm () Shim Washer (as required) 8 Nut () Lock Washer () Bushing () Nut (8) Front Reel Steering Pivot () 9 Rubber Bumper () Screw () 8 Flat Washer () Left Front Lift Arm Grease Fitting () 0 Stop Bracket () Figure -8 TN 9-Rev B -

8 CHASSIS Disassembly Notes Before disassembly, clean all dirt and debris from lift arm. Inspect all bushings, link arms, lift arms, and reel steering pivots for damage or wear. Remove bushings only if replacement is required. Assembly Notes Anti-Seize Compound Required Materials NOTE Label all wires before disconnecting to ensure correct installation.. Cut cable ties ().. Disconnect the reel drive motor wire connectors (8).. Remove spring ().. Remove cap (). 8. Remove lock pin () from yoke shaft (). 9. Pull the center lift arm () up and remove reel assembly (). Before assembly, verify that the bushings and mating surfaces are free of burrs, dirt, and debris. Repair or replace the lift arms, link arms, or reel steering pivots, if necessary. Replace any bushings that are damaged or have excessive wear. Apply ant-seize compound to key () prior to assembly. Install shim washers (), as required, to remove excess gap between left front lift arm (), link arm (0), and front reel steering pivot (). Also install shim washers (), as required, to remove excess gap between right front lift arm (9), link arm (0), and front reel steering pivot (). Center Lift Arm Removal and Installation See Figures -9 and -0.. Park the mower safely. (See Park Mower Safely on page -.). Remove reel lift actuator. (See Reel Lift Actuators on page -.). Remove reel leveling rod. (See Reel Leveling Rod on page -.) 9 0 Figure Remove cotter pin (9) and flat washer (0).. Remove center lift arm. TN8 Installation Notes Pre-adjust the reel leveling rod before installation. (See Reel Leveling Rod Pre-Adjustment on page -.) Install center lift arm by reversing the order of removal. Use new cable ties to secure the wire connectors and wire harnesses. Apply dielectric grease (Jacobsen PN ) to connections. Lubricate grease fittings. 8 Figure -9 TN0-8 9-Rev B

9 CHASSIS Disassembly and Assembly See Figure TN Lock Pin 8 Flat Washer Thrust Washer 0 Nut Key Locking Collar 9 Screw Polygon Bushing Grease Fitting Link Arm Polygon Bushing 0 Lock Washer Flat Washer Center Reel Steering Pivot 8 Screw Bushing Flat Washer Cotter Pin Shim Washer (as required) 9 Flat Washer Center Swing Arm Locking Pin Bracket 8 Center Stop Bracket Polygon Bushing 0 Eye Bolt Nut Actuator Pivot Pin 9 Rubber Bumper Center Lift Arm Spring Lock Washer Figure TN8 9-Rev B -9

10 CHASSIS Disassembly Notes Before disassembly, clean all dirt and debris from center lift arm and center swing arm. Inspect link arm, center lift arm, center swing arm, reel steering pivot, and all bushings for damage or wear. Remove bushings only if replacement is required. Assembly Notes Anti-Seize Compound Required Materials Before assembly, verify that the bushings and mating surfaces are free of burrs, dirt, and debris. Repair or replace the link arm, center lift arm, center swing arm, or reel steering pivot, if necessary. Replace any bushings that are damaged or have excessive wear. Apply ant-seize compound to key () prior to assembly. Install shim washers (), as required, to remove excess gap between center lift arm (), link arm (), and center reel steering pivot (). Steering Yoke (WD) Removal and Installation See Figures - through -. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine.. Park the mower safely. (See Park Mower Safely on page -.) Figure -. Swing out and lock the center cutting unit () from under the machine. WARNING TN88 Support the machine using properly rated jackstands. Never work under a machine supported only by a jack. Do not use wood or concrete blocks to support the machine. Failure to properly support the machine may result in death or serious injury. IMPORTANT It is important to lift and support the machine, or the machine will move.. Lift the machine so that the rear wheel is off the ground, and support with appropriate jackstands Rev B

11 CHASSIS. Remove rear wheel and axle assembly. (See Rear Wheel and Axle Assembly (WD) on page -.). Remove steering sensor. (See Steering Sensor (WD) on page -.). Remove steering chain and steering gear. (See Steering Chain and Gears on page -.) TN8 Figure -. Support steering yoke (8) and remove retaining ring (). 8. Remove bushing () from steering yoke (8). 9. Lower the steering yoke (8) from frame (). 0. Remove two thrust washers () and thrust bushing (9) from steering yoke (8).. Remove thrust washer () from steering yoke (8).. Remove two polygon bushings () from frame (). 8 TN Figure -. Remove two screws (0).. Remove steering stop () from steering yoke (8). Installation Notes Install steering yoke by reversing the order of removal. Adjust the steering chain tension. (See Steering Chain Tension Adjustment on page -.) 9-Rev B -

12 CHASSIS Steering Yoke (WD) Removal and Installation See Figures - through -. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine.. Remove rear fender. (See Rear Fender (WD) on page -.). Remove rear traction motor. (See AC Traction Motor (WD) on page -8.). Remove steering sensor. (See Steering Sensor (WD) on page -0.) 8. Remove steering chain and steering gear. (See Steering Chain and Gears on page -.). Park the mower safely. (See Park Mower Safely on page -.). Remove steering sensor. (See Steering Sensor (WD) on page -0.) 9 Figure -. Swing out and lock the center cutting unit () from under the machine. IMPORTANT WARNING TN88 Support the machine using properly rated jackstands. Never work under a machine supported only by a jack. Do not use wood or concrete blocks to support the machine. Failure to properly support the machine may result in death or serious injury. It is important to lift and support the machine, or the machine will move.. Lift the machine so that the rear wheel is off the ground, and support with appropriate jackstands. TN Figure - 9. Support steering yoke (8) and remove retaining ring (). 0. Remove bushing () from steering yoke (8).. Lower the steering yoke (8) from frame ().. Remove two thrust washers () and thrust bushing (9) from steering yoke (8).. Remove thrust washer () from steering yoke (8).. Remove two polygon bushings () from frame (). 8-9-Rev B

13 CHASSIS 0 8 TN Figure -. Remove two screws (0).. Remove steering stop () from steering yoke (8). Required Materials Lubriplate A Grease Installation Notes Install steering yoke by reversing the order of removal. Fill the gap between polygon bushings () with Lubriplate A Grease. Adjust the steering chain tension. (See Steering Chain Tension Adjustment on page -.) Adjust the steering sensor air gap. (See Steering Sensor (WD) Adjustment on page -.) 9-Rev B -

14 CHASSIS Steering Chain and Gears Removal and Installation See Figures -8 and -9. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine.. Park the mower safely. (See Park Mower Safely on page -.). Remove steering sensor. (See Steering Sensor (WD) on page - or Steering Sensor (WD) on page -0.) NOTE Figure -8 TN Note orientation of the chain before removing to ensure correct installation.. Loosen two screws () and slide the steering motor bracket () to remove the chain ().. Remove chain from gears. NOTE 0 9 Figure -9 For installation purposes, measure from the top of the steering motor shaft () to the top of the steering motor gear () before removing and note the measurement.. Remove two set screws () from steering motor gear ().. Use the appropriate gear puller and remove steering motor gear () and key ().. Remove screw () from steering gear (9). 8. Use the appropriate gear puller and remove steering gear (9) and key (8). Anti-Seize Compound Required Materials TN0 Installation Notes Apply anti-seize compound to keys ( and 8) prior to installation. Install the gears and chain by reversing the order of removal. When installing the steering motor gear, install to the measurement taken prior to removing. Verify that the chain is clear of obstructions. Adjust the steering chain tension. (See Steering Chain Tension Adjustment on page -.) 8-9-Rev B

15 CHASSIS Front Fenders Removal and Installation See Figure -0. NOTE The left fender is shown; the right fender is similar.. Park the mower safely. (See Park Mower Safely on page -.). Remove cowlings. (See Cowlings on page -.) Traction Pedal Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) TN8 Figure -0. Remove three screws () and flat washers ().. Remove two screws () and nylon insulators ().. Remove front fender (). Installation Note Install front fenders by reversing the order of removal. TN0 Figure -. Remove screws (), lock washers (), and flat washers ().. Remove nut (), lock washer (), and flat washer ().. Remove traction pedal (). Installation Note Install traction pedal by reversing the order of removal. 9-Rev B -

16 CHASSIS Brake Pedal Assembly Removal and Installation See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -.). Remove brake pedal switch. (See Brake Pedal Switch on page -.). Remove brake pedal position sensor. (See Brake Pedal Position Sensor on page -.). Remove front cover. (See Front Cover on page -.). Remove rear cover. (See Rear Cover on page -.). Remove left fender. (See Front Fenders on page -.) Figure - TN 9. Remove pedal grip (). NOTE Move floor mat aside to access screws (). 0. Support brake pedal assembly () and remove screws ().. Rotate and lower the brake pedal assembly to remove the brake pedal assembly from the machine. Installation Note Install brake pedal assembly by reversing the order of removal. Figure -. Remove screws () and washers (). 8. Remove screws () and washers (). TN8-9-Rev B

17 CHASSIS Disassembly and Assembly See Figure Screw () Brake Arm Weldment 8 Switch Arm Spring Brake Pedal Position Sensor Spring Roll Pin () 9 Brake Pedal Switch Spacer () Brake Plate () Pedal Grip 0 Screw () Nut () Bushing () Figure - TN 9-Rev B -

18 CHASSIS Axle Shield and Front Splash Shield Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) ~ Figure -. Remove three shield fasteners (), and remove axle shield ().. Remove three panel fasteners (), and remove front splash shield (). TN Installation Notes Install axle shield and front splash shield by reversing the order of removal. Use new fasteners ( and ) to secure the front splash shield () and axle shield () Rev B

19 CHASSIS Floorboard Removal and Installation See Figures - through -9.. Park the mower safely. (See Park Mower Safely on page -.). Remove front fenders. (See Front Fenders on page -.). Remove front cover. (See Front Cover on page -.). Remove rear cover. (See Rear Cover on page -.). Remove traction pedal position sensor. (See Traction Pedal Position Sensor on page -8.). Remove brake pedal assembly. (See Brake Pedal Assembly on page -.). Remove axle shield and front splash shield. (See Axle Shield and Front Splash Shield on page -8.) Figure - 9. Remove three screws () and washers (). TN TN9 Figure - 8. Remove two screws (), and remove fender support () on each side of the floorboard. TN0 Figure Remove three screws (), washers (), and floor mat (). 9-Rev B -9

20 CHASSIS Front Wheel Hub Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.). Remove front wheel. (See Front Wheels on page -9.) 8 TN Figure -9. Remove four screws () and lock washers ().. Remove floorboard (8). Installation Note Install floorboard by reversing the order of removal. TN8 Figure -0. Remove cotter pin (). CAUTION The wheel hub may move unexpectedly when using a puller. To prevent injury and/or property damage, do not remove the castle nut until the wheel hub has been loosened from the axle. TN8. Loosen, but do not remove, castle nut ().. Loosen wheel hub () from front axle assembly () using a suitable puller.. Remove castle nut ().. Remove wheel hub () from front axle assembly (). Installation Notes Anti-Seize Compound Required Materials Apply anti-seize compound to axle shaft splines. Install front wheel hub by reversing the order of removal. Tighten castle nut () to 9 lb-ft (0..0 N m) Rev B

21 CHASSIS Front Axle Assembly Removal and Installation See Figures - through -. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine.. Park the mower safely. (See Park Mower Safely on page -.). Remove axle shield and front splash shield. (See Axle Shield and Front Splash Shield on page -8.) NOTE Figure - TN Label all wires before disconnecting to ensure correct installation.. Disconnect AC traction motor power cables ().. Remove cable ties securing the AC traction motor power cables to the frame. NOTE Figure - Label all wires before disconnecting to ensure correct installation.. Disconnect brake coil wire connector (), traction pedal position sensor wire connector (), and AC traction motor wire connectors (). WARNING TN Support the machine using properly rated jackstands. Never work under a machine supported only by a jack. Do not use wood or concrete blocks to support the machine. Failure to properly support the machine may result in death or serious injury.. Block front and rear of rear wheels using suitable wheel blocks.. Support the front axle assembly using a suitable lifting device. 9-Rev B -

22 CHASSIS TN0 Figure - 8. Cut cable ties (9). Carefully guide the AC traction motor power cables (0) through the machine and position the cables to be unrestricted during front axle removal. 9. Remove two nuts (), two lock washers (), four flat washers (), and two screws (8). 0. Repeat step 9 for other side of machine.. Remove front axle assembly (). Installation Notes Install front axle assembly by reversing the order of removal. Use new cable ties to secure wire harnesses. Tighten screws (8) to lb-ft (88 N m). Check the level of the front axle fluid and add Mobilfluid or SAE 0 oil as required to bring fluid to correct level. See the Parts and Maintenance Manual for additional information and illustrations. - 9-Rev B

23 CHASSIS Disassembly and Assembly See Figure Snap Ring O-Ring Left-Side Axle Shaft Differential Case Assembly Axle Shaft Bearing Input Shaft Ball Bearing Bearing Cap Cover Screw Snap Ring 8 Input Shaft Bearing Cap Screw Cover Axle Shaft Seal 9 Input Shaft Ball Bearing Differential Ball Bearing 8 Right-Side Axle Shaft Snap Ring 0 Axle Housing Figure - TN8 Axle Shaft Bearings Removal CAUTION Use care when removing components to avoid damaging bearing surfaces, seal seating surfaces, shaft splines, and gear teeth.. Remove front wheels. (See Front Wheels on page -9.). Remove front wheel hubs. (See Front Wheel Hub on page -0.). Remove snap ring () from right-side axle shaft (8).. Remove right-side axle shaft (8) and bearing assembly () using a suitable puller.. Remove snap ring () from right-side axle shaft.. Remove axle shaft seal () using a suitable puller.. Remove axle shaft bearing () from right-side axle shaft using a suitable press. 8. Repeat steps through for the left-side axle shaft () and bearing assembly (). 9-Rev B -

24 CHASSIS Assembly Notes Assemble axle shaft bearings in reverse order of disassembly. Clean and inspect axle shaft bearings () and seals () for wear or damage. Replace as needed. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of axle shaft seals () prior to installation. Install axle shaft seals in the axle housing (0) to a depth of. in. (8. mm) between the face of the axle housing and the outer face of the axle shaft seals. Pack bearings () with grease that meets or exceeds NLGI Grade LB specifications prior to installation. Install axle shaft bearings onto axle shafts until seated against axle shaft shoulder using a suitable press. Use a suitable driver to install axle shaft and bearing assemblies until firmly seated against snap rings (). Rotate shaft during installation to engage splines, if necessary. Differential Ball Bearings Removal CAUTION Use care when removing components to avoid damaging bearing surfaces and gear teeth or deforming cover. 9. Remove four bearing cap screws () and two bearing caps (). 0. Remove differential case assembly () from axle housing (0).. Remove differential ball bearings () from each side of differential case using a suitable puller. Assembly Notes Assemble differential ball bearings in reverse order of disassembly. Clean and inspect differential ball bearings () for wear or damage. Replace as needed. Lubricate differential ball bearings () with Mobilfluid or SAE 0 oil prior to installation. Install bearing caps in their original positions. Tighten bearing cap screws to lb-ft (.. N m). Clean all gasket material from cover and axle housing. Apply a bead of non-acidic silicone sealant to flange of cover and inside of cover mounting holes. Tighten cover screws to lb-ft (.8. N m). Input Shaft Ball Bearings Removal CAUTION Use care when removing components to avoid damaging bearing surfaces, shaft splines, and gear teeth.. Remove front wheels. (See Front Wheels on page -9.). Remove front wheel hubs. (See Front Wheel Hub on page -0.). Remove snap ring () from right-side axle shaft (8).. Remove right-side axle shaft (8) and bearing assembly () using a suitable puller.. Repeat steps and for the left-side axle shaft () and bearing assembly (). NOTE Have a suitable container available that can hold up to 0. gal (0. L) of axle fluid.. Place a suitable container under the axle housing to receive axle fluid.. Remove ten cover screws (). 8. Remove cover () from axle housing (0). NOTE Bearing caps () are marked with letters or numbers in horizontal and vertical positions. Note position of bearing caps and replace in original position during assembly.. Remove front wheels. (See Front Wheels on page -9.). Remove front wheel hubs. (See Front Wheel Hub on page -0.). Remove snap ring ().. Remove input shaft (8) and ball bearing assemblies ( and 9). NOTE The input shaft and bearing assembly should remove easily. Use a suitable puller if resistance is felt.. Remove input shaft ball bearings ( and 9) using a suitable puller.. Remove and discard O-ring () from axle housing (0). - 9-Rev B

25 CHASSIS Assembly Notes Assemble input shaft ball bearings in reverse order of disassembly. Clean and inspect input shaft ball bearings ( and 9) for wear or damage. Replace as needed. Lubricate input shaft ball bearings ( and 9) with Mobilfluid or SAE 0 oil prior to installation. Install input shaft ball bearings on input shaft until seated against bearing shoulders using a suitable press. Install new O-ring (). Lubricate O-ring with Mobilfluid or SAE 0 oil prior to installation. 9-Rev B -

26 CHASSIS - 9-Rev B

27 Chapter Cutting Units Specifications Check and Adjustment Specifications Repair Specifications Component Location Troubleshooting Quality-of-Cut Troubleshooting Mechanical Troubleshooting Checks and Adjustments Reel and Bedknife Inspection Bedknife-to-Reel Clearance Adjustment Height-of-Cut (HOC) Adjustment Grass Shield Adjustment Grass Catcher Yoke Adjustment Reel Bearing Pre-Load Adjustment Right and Left Reel Stop Bracket Adjustment Right and Left Reel Bumper Adjustment Center Reel Bumper Adjustment Reel Leveling Rod Pre-Adjustment Cutting Unit Leveling Adjustment Repair Reel Leveling Rod Reel Drive Motor Center Cutting Unit Right and Left Cutting Units Grass Shield Bedknife Backing Assembly Bedknife Reel Bearing Housing Assembly Reel Assembly Front Roller Rear Roller Roller Bearings Rev B -

28 CUTTING UNITS Specifications Check and Adjustment Specifications Specification Height-of-Cut Range in. (mm) (..) Reel-to-Bedknife Gap in. (mm) ( ) Reel Bearing Pre-Load in. (mm) 0.00 (.) Right/Left Reel Leveling Rod Rod End-to-Nut Face in. (mm). (.) Measurement (non-spring side) Center Reel Leveling Rod Rod End-to-Nut Face in. (mm).00 (.) Measurement (non-spring side) Reel Leveling Rod Rod End-to-Collar Face in. (mm).0 (.) Measurement (spring side) Reel Leveling Rod Rod End-to-Nut Face Measurement (spring side) in. (mm) 0. (.) Repair Specifications Specification Reel Motor Mounting Screw Torque lb-in. (N m) (8.) Bedknife Mounting Screw Torque lb-in. (N m) 90 0 (0..) Bedknife Front Face Height (minimum) in. (mm) 0.0 (0.9) Bedknife Front Face Angle (all bedknives) degrees Bedknife Top Face Angle (rear relief) (all bedknives degrees 8 0 except Super Tournament) Super Tournament Bedknife Top Face Angle degrees (rear relief) Reel Blade Relief Angle degrees - 9-Rev B

29 CUTTING UNITS Component Location See Figure TN,TN8,TN0 Left Cutting Unit Center Cutting Unit 9 Reel Assembly Yoke Cutting Unit Rear Roller Grass Catchers Center Reel Leveling Rod 0 Counterweight Lift Arm Bedknife Backing Assembly Right Reel Leveling Rod Drive Motor Grass Shield Adjusters Cutting Unit Frame Right Cutting Unit 8 Cutting Unit Front Roller Figure -: Component Location 9-Rev B -

30 CUTTING UNITS Troubleshooting Quality-of-Cut Troubleshooting Factors That Affect Cut Appearance Some of the mowing practices and turf conditions that can cause poor cutting results even though the mower is properly sharpened and adjusted are: Repetitious mowing patterns tires running over the same path causing 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 causing grass to take a permanent set in that same direction. It makes it difficult for the reel and bedknife to lift 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, the following items should be verified 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. Reel-to-Bedknife Contact. Height-of-Cut (HOC). Bedknife Application (Correct Bedknife) 8. 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. - 9-Rev B

31 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. TN Probable Cause Incorrect cutting height adjustment. Incorrect bedknife-to reel clearance. Worn or damaged bearings Incorrectly adjusted bearing pre-load. Dull bedknife and/or reel blades. Wavy or rifled bedknife. Adjust to the proper height-of-cut. Remedy Adjust the bedknife-to-reel clearance. (See Reel Bearing Housing Assembly on page -9.) Replace the reel bearings. (See Reel Bearing Housing Assembly on page -9.) Adjust the bearing pre-load.(see Reel Bearing Housing Assembly on page -9.) Sharpen the bedknife and reel blades. Grind and adjust the reel and bedknife. 9-Rev B -

32 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 8 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. Use of a groomer on cleanup pass. Reel drive motor performance is reduced. Reduce mowing (ground) speed. Remedy Clean the rollers and use scrapers or brushes. Replace roller. (See Front Roller on page - or Rear Roller on page -.) Change mowing direction regularly. Groomers should be used only in a straight line. Check operation of reel motor(s) and repair/replace as necessary. - 9-Rev B

33 CUTTING UNITS Marcelling Marcelling is a wave-like cut appearance similar to wasboarding 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. TN00 NOTE: One cutting unit width shown. Arrow indicates direction of travel. 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 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, Operation, and Maintenance Manual. ) 9-Rev B -

34 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. Reel-to-bedknife 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 side to side. Mower frame is bent. Remedy Check HOC adjustment of cutting units. (See Height-of-Cut (HOC) Adjustment on page -.) Check/replace roller bearings. (See Roller Bearings on page -.) Check/replace/adjust reel bearings. (See Reel Bearing Housing Assembly on page -9.) Check bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Check/remove cutting unit movement restriction. Change mowing direction. Check/adjust proper tire inflation pressure. (Refer to Safety, Operation, and Maintenance Manual. ) Repair or replace as needed Rev B

35 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 and adjust the HOC settings. (See Height-of-Cut (HOC) Adjustment on page -.) Change mowing direction. Install correct bedknife for desired HOC. (See Bedknife on page -8.) Mow more often. Reduce mowing (ground) speed. 9-Rev B -9

36 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. Remedy Adjust bedknife. (See Bedknife-to-Reel Clearance Adjustment on page -.) Sharpen reel and bedknife. (Refer to Safety, Operation, and Maintenance Manual. ) Reduce mowing (ground) speed. Install correct roller for application. (See Front Roller on page -.) Mow more often. Change mowing direction regularly Rev B

37 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 -8.) Damaged or unevenly worn reel. Inspect reel. Replace as needed. (See Reel Assembly on page -.) Loose or missing bedknife fasteners. Check bedknife screws. Tighten loose screws; replace missing screws. (See Bedknife on page -8.) Incorrect roller. Install correct roller for application. (See Front Roller on page - or Rear Roller on page -.) Bedknife is matting the grass down. Install correct bedknife for application. (See Bedknife on page -8.) 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. Turn less aggressively to allow cutting units to overlap. Change mowing direction or pattern on side hills. Check/adjust tire inflation pressure. (Refer to Safety, Operation, and Maintenance Manual. ) Cut when grass is dry. 9-Rev B -

38 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 the rollers and use scrapers or brushes. Clear cutting unit(s) grass shield. - 9-Rev B

39 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. TN8 Probable Cause HOC inconsistent from one cutting unit to another. Difference in reel motor speeds. Difference in mower ride height side-to-side. Remedy Check/adjust HOC on cutting units to same height. (See Height-of-Cut (HOC) Adjustment on page -.) Check condition of cutting unit frame and/or mower frame. Repair or replace as needed. Check operation of reel motor(s) and repair/replace as necessary. Check/adjust tire inflation pressure. (Refer to Safety, Operation, and Maintenance Manual. ) 9-Rev B -

40 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. TN098 NOTE: One cutting unit width shown. Arrow indicates direction of travel. Probable Cause Reel and/or bedknife unevenly worn. Remedy Inspect bedknife and reel. Grind or replace as needed. (Refer to Safety, Operation, and Maintenance Manual, Bedknife on page -8, or Reel Assembly on page -) - 9-Rev B

41 CUTTING UNITS Mechanical Troubleshooting Condition Probable Cause Remedy Reel drive does not engage. Reel enable switch and mow switch not engaged. Machine set to FOC mode and machine not moving. Reel drive motor harness connectors not connected. Reel drive motor harness not connected at controller. Seat switch faulty. Reel enable switch faulty. Mow switch faulty. Reel motor coupler or key missing. Engage reel enable switch and mow switch. (Refer to Operator s Manual.) Engage traction pedal and move machine. Connect reel drive motor harness connectors. (See Reel Drive Motor on page -.) Connect reel drive motor harness at controller. (See RCU on page -.) Test seat switch. (See Seat Switch Test on page -9.) Test reel enable switch. (See Rocker Switches Test on page -.) Test mow switch. (See Mow Switch Test on page -.) Check for missing coupler or key and replace as necessary. (See Reel Drive Motor on page -.) Reel drive motor faulty. Repair or replace reel drive motor. (See Reel Drive Motor on page -.) Reel drive does not reach full speed. Reel drive motor faulty. Repair or replace reel drive motor. (See Reel Drive Motor 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 is faulty Replace roller or scraper. (See Front Roller on page - or Rear Roller on page -.) Replace roller bearing. (See Roller Bearings on page -.) 9-Rev B -

42 CUTTING UNITS Checks and Adjustments Reel and Bedknife Inspection See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care.. Check the reel bearings for end play or radial play. If there is any abnormal movement of the reel, up and down or side to side, adjust or replace components as needed. (See Reel Bearing Pre-Load Adjustment on page -9.) 0.0 in. (0.9 mm) Figure -. Inspect the reel blades and bedknife to ensure good sharp edges without bends or nicks. a. The cutting edges of the reel blades and bedknife must be sharp, free of burrs, and show no signs of rounding off. b. The bedknife and bedknife backing must be securely tightened. The bedknife must be straight and sharp. c. A flat surface of 0.0 in. (0.9 mm) minimum must be maintained on the front face of the bedknife. Use a standard flat file to dress the bedknife.. If wear or damage is beyond the point where the reel or bedknife can be corrected by the lapping process, it must be reground. (See Bedknife on page -8.). Proper reel-to-bedknife adjustment is critical. A gap of in. ( mm) must be maintained across the entire length of the reel and bedknife.. The reel must be parallel to the bedknife. An improperly adjusted reel will lose its sharp edges prematurely and may result in serious damage to the reel and bedknife.. Grass conditions will also affect the adjustment. a. Dry, sparse conditions will require a wider gap to prevent heat buildup and damage to the reel and bedknife. b. High-quality grass with a good moisture content requires a closer gap (near zero). Bedknife-to-Reel Clearance Adjustment See Figures - through -. 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 -.). Inspect reel and bedknife before performing adjustment. (See Reel and Bedknife Inspection on page -.) NOTE Figure - TN88 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. - 9-Rev B

43 CUTTING UNITS NOTE Figure - 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 that end which passes over the bedknife first during normal reel rotation. TN8 NOTES The key consideration for bedknife-to-reel adjustment is to move the adjusting screws in very small increments. 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 setting tweaks may be done on the appropriate (single) opposing screw. Final tweaks must always be a tightening of the screw. When the reel and bedknife are properly adjusted, the reel will spin freely and will cut a piece of newspaper along the full length of the reel when the paper is held at 90 to the bedknife. 8 TN089 Figure -. Adjust bedknife-to-reel gap to in. ( mm) between the reel blade and bedknife using the upper adjuster () and the lower adjuster (8) on both the leading and trailing edges of reel. Height-of-Cut (HOC) Adjustment See Figure -. 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 -.) 8 9 Figure - TN089 9-Rev B -

44 CUTTING UNITS NOTE 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 (8) just enough to allow adjusting knob () to raise or lower the bracket.. Set height-of-cut bar () to desired height-of-cut () by measuring between the underside of screw head and height-of-cut bar surface and tighten wing nut ().. Place height-of-cut bar () across bottom of front and rear rollers ( and ) near one end.. Slide the head of the gauge screw over the bedknife ().. Turn adjusting knob () to close the gap between the front and rear rollers ( and ) and height-of-cut bar ().. Tighten lock nut (9). 8. Repeat steps through on opposite end of front roller (). 9. Recheck each end with height-of-cut bar and readjust as necessary. TN9 Figure -. Loosen nuts () and adjust grass shield () as close to reel blades as possible without making contact.. Tighten nuts (). 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. Grass Shield Adjustment See Figure -. 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 -.) -8 9-Rev B

45 CUTTING UNITS Grass Catcher Yoke Adjustment See Figure -8. CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. Reel Bearing Pre-Load Adjustment See Figures -9 through -.. Park the mower safely. (See Park Mower Safely on page -.). Back bedknife away from reel. (See Bedknife-to-Reel Clearance Adjustment on page -.). Park the mower safely. (See Park Mower Safely on page -.) TN Figure -8. Loosen nuts () on both sides of cutting unit.. Adjust grass catcher yoke () as required so lip of grass catcher () is resting evenly on reel crossbar (). Figure -9. Remove screws (), lock washers (), and counterweight (). TN0. Tighten nuts () on both sides of cutting unit. TN Figure -0. Remove screw (), lock washer (), washer (), and spacer (). 9-Rev B -9

46 CUTTING UNITS 8 9 TN Figure -. Tighten adjuster nut (8) until the spring (9) is completely collapsed, then back the nut turns, or until there is 0.00 in. (. mm) side-to-side movement of the reel. Figure -. Install counterweight (), screws (), and lock washers (). 8. Adjust bedknife-to-reel contact. (See Bedknife-to-Reel Clearance Adjustment on page -.) TN0 0 TN Figure -. Install spacer (0), washer (), lock washer (), and screw () Rev B

47 CUTTING UNITS Right and Left Reel Stop Bracket Adjustment See Figure -. NOTE The left reel stop bracket is shown; the right reel stop bracket is similar.. Park the mower safely. (See Park Mower Safely on page -.) Right and Left Reel Bumper Adjustment See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) TN Figure - Figure -. Loosen nuts () and lower the reel stop bracket ().. Engage the mow switch and raise cutting unit () to the fully up position. NOTE TN The cutting unit should stop against bumper ().. Position reel stop bracket () against the up stop shaft () and tighten nuts ().. Loosen nuts () and raise reel bumper (). Tighten nuts () to hold reel bumper in the up position.. Engage the mow switch and raise cutting unit () to the fully up position.. Loosen nuts ().. Position reel bumper () against cutting unit () and tighten nuts (). 9-Rev B -

48 CUTTING UNITS Center Reel Bumper Adjustment See Figures - through -8.. Park the mower safely. (See Park Mower Safely on page -.). Swing center cutting unit under the machine and lock into position. Figure -8 TN80. Loosen two screws (). 8. Adjust right side bumper () to contact the center cutting unit (). 9. Tighten two screws (). 0. Adjust center bumper () if required. Figure -: Gasoline and Diesel Models TN9 TN8 Figure -: Electric Models TN8 NOTE For gasoline and diesel models, see figure -. For electric models, see figure -.. Loosen two screws ().. Engage the mow switch and raise the center cutting unit () to the fully up position.. Adjust left side bumper () to contact the center cutting unit ().. Tighten two screws (). - 9-Rev B

49 CUTTING UNITS Reel Leveling Rod Pre-Adjustment See Figure -9.. Park the mower safely. (See Park Mower Safely on page -.). Remove reel leveling rod. (See Reel Leveling Rod on page -.) Cutting Unit Leveling Adjustment See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.). Pre-adjust reel leveling rod, if necessary. (See Reel Leveling Rod Pre-Adjustment on page -.) TN Figure -9. Measure distance between end of the leveling rod and face of nut (). The measurement should be. in. (. mm) for the right and left leveling rods and.00 in. (. mm) for the center leveling rod. If the measurement does not meet specifications, adjust as follows: a. Loosen nut (). b. Turn rod connecting pin () as needed to obtain proper distance (). c. Tighten nut ().. Measure distance between end of the leveling rod and face of collar (). The measurement should be.0 in. (. mm). If the measurement does not meet specifications, adjust as follows: a. Loosen the set screw on collar (). b. Slide collar () as needed to obtain proper distance ().. Tighten the set screw on collar ().. Measure distance between end of the leveling rod and face of nut (). The measurement should be 0. in. (. mm). If the measurement does not meet specifications, turn nut () as needed to obtain proper distance ().. Install reel leveling rod. (See Reel Leveling Rod on page -.) 8. Level cutting unit as necessary. (See Cutting Unit Leveling Adjustment on page -.) NOTES Figure -0 TN80 Ensure grass catcher is installed. Ensure center cutting unit is under machine and center lift arm is locked in position.. Fully lower cutting unit to a level solid surface, then raise cutting unit until slightly above surface.. Loosen nut ().. Loosen the set screw on collar () and adjust collar () and nut () until cutting unit is level and springs () are slightly compressed.. Tighten the set screw on collar ().. Tighten nut (). 9-Rev B -

50 CUTTING UNITS Repair Reel Leveling Rod Removal and Installation See Figure -. NOTE The center reel leveling rod is shown; the right and left reel leveling rods are similar.. Park the mower safely. (See Park Mower Safely on page -.) NOTES For removal purposes, do not place the lift actuator in the fully down position. If working on the center cutting unit, swing the cutting unit out from the machine and lock into position.. Lower the cutting unit to the ground and disengage all switches. Installation Notes Loctite (Blue) Apply marine lubrication grease to I.D. of rod connecting pin () and reel leveling rod () at area beneath the springs. Apply Loctite (Blue) to set screw (). Pre-adjust the reel leveling rod before installation. (See Reel Leveling Rod Pre-Adjustment on page -.) Install reel leveling rod by reversing the order of removal. Level the cutting unit. (See Cutting Unit Leveling Adjustment on page -.) Reel Drive Motor Removal and Installation See Figures - and -. Required Materials CAUTION Use care when handling reel drive motor to avoid damage to reel drive motor harness connectors.. Park the mower safely. (See Park Mower Safely on page -.) Figure -. Remove cotter pins () and flat washers (). TN. Remove reel leveling rod () from machine. TN Figure -. Disconnect reel drive motor harness connectors ().. Remove screws () and reel drive motor (). - 9-Rev B

51 CUTTING UNITS TN Figure -. Remove coupler () from reel drive motor shaft (). Figure -. Remove pin () on right side of machine. TN Installation Notes Install reel drive motor by reversing the order of removal. Coat the reel drive motor shaft () and coupler () with grease that meets or exceeds NLGI Grade LB specifications before installing reel drive motor (). Do not use paper clips or large conductive materials while troubleshooting turck connectors, as damage may occur. Align and positively engage connectors prior to engaging connector threads. Do not force the connectors. Position wire harness to relieve excessive strain on the connector. Be sure threads are fully engaged more than three full threads. Do NOT apply dielectric grease or any lubricant to turck connectors. Tighten screws () to lb-in. (8. N m). Center Cutting Unit Removal and Installation See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -.) NOTE If a grass catcher is fitted to the cutting unit, remove it before swinging cutting unit out from under machine. 8 TN8 Figure -. Swing center cutting unit () out from under machine.. Disconnect reel drive motor harness connectors (8).. Remove cap ().. Remove pin ().. Raise lift arm () until yoke shaft () clears bottom of yoke shaft housing (). 8. Move the 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 over-grease. Do not use compressed air gun. Level the cutting unit. (See Cutting Unit Leveling Adjustment on page -.) 9-Rev B -

52 CUTTING UNITS Right and Left Cutting Units Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) Grass Shield Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Remove cutting unit. (See Center Cutting Unit on page - or Right and Left Cutting Units on page -.). Remove front roller. (See Front Roller on page -.) TN Figure -. Disconnect reel drive motor harness connectors ().. Remove cap ().. 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 over-grease. Do not use compressed air gun. Level the cutting unit. (See Cutting Unit Leveling Adjustment on page -.) TN9 Figure -. Remove nut (), lock washer (), flat washer (), and screw () from both sides of cutting unit ().. Pull grass shield () away from cutting unit (). Installation Notes Install grass shield by reversing the order of removal. Adjust the grass shield. (See Grass Shield Adjustment on page -8.) - 9-Rev B

53 CUTTING UNITS Bedknife Backing Assembly Removal and Installation See Figures -8 and -9.. Park the mower safely. (See Park Mower Safely on page -.). Remove cutting unit from mower. (See Center Cutting Unit on page - or Right and Left Cutting Units 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. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) TN089 Figure -8. Loosen bedknife adjuster screws () and () on both sides of the cutting unit. TN0 Figure -9. Support bedknife backing assembly ().. Remove bedknife backing mounting screw () on both sides of cutting unit.. Remove bedknife backing assembly (). 9-Rev B -

54 CUTTING UNITS Bedknife Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.). Remove bedknife backing assembly. (See Bedknife Backing Assembly on page -.) Bedknife Specifications Bedknife Front Face Height in. (mm) 0.0 (0.9) (minimum) Bedknife Front Face Angle degrees (all bedknives) Bedknife Top Face Angle degrees 8 0 (rear relief) [all bedknives except Super Tournament] Super Tournament Bedknife Top Face Angle (rear relief) degrees Adjust the bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) Figure -0. Remove screws () and bedknife () from the bedknife backing (). TN Installation Notes Anti-Seize Compound Required Materials Install bedknife by reversing the order of removal. Apply anti-seize compound to screws (). Tighten screws () to 90 0 lb-in. (0.. N m), starting with screws in the center and working out to the ends of the bedknife. Grind bedknife after assembling to bedknife backing as specified below for the specific bedknife installed: -8 9-Rev B

55 CUTTING UNITS Reel Bearing Housing Assembly Removal and Installation Drive Side See Figure -. Required Tools or Equipment Bearing Assembly Tool (Jacobsen PN JAC08) Reel Bearing Housing Puller (Jacobsen PN JAC08). Park the mower safely. (See Park Mower Safely on page -.). Remove cutting unit from the mower. (See Center Cutting Unit on page - or Right and Left Cutting Units on page -.). Remove front roller. (See Front Roller on page -.). Remove grass shield. (See Grass Shield on page -.). Remove reel drive motor. (See Reel Drive Motor on page -.). Remove snap ring (9). 8. Remove four screws () and four nuts (). 9. Rotate reel bearing housing () to align grease fitting (0) with the clearance hole in the frame, and remove reel bearing housing from frame using reel bearing housing puller (Jacobsen PN JAC08). 0. Inspect the reel shaft () for wear or damage. Replace reel if needed. (See Reel Assembly on page -.) Installation Notes Install reel bearing housing assembly by reversing the order of removal. Use bearing assembly tool (Jacobsen PN JAC08) to install reel bearing housing assembly onto the reel shaft. Install new O-ring () and lubricate with grease that meets or exceeds NLGI Grade LB specifications. Inspect bearing () for wear or damage. Replace as needed. Pack bearing () with grease that meets or exceeds NLGI Grade LB specifications before assembly. Lubricate grease fitting (0) 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 over-grease. Do not use compressed air gun TN98 Figure -. Remove four socket-head screws () and adapter plate (8). 9-Rev B -9

56 CUTTING UNITS Disassembly and Assembly See Figure -. Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting Figure - TN090 Figure -. Remove screws () and lock washers ().. Remove counterweight (). TN0 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 the grease seal (). Removal Non-Drive Side See Figures - and Required Tools or Equipment Reel Bearing Housing Puller (Jacobsen PN JAC08). Park the mower safely. (See Park Mower Safely on page -.). Remove cutting unit from mower. (See Center Cutting Unit on page - or Right and Left Cutting Units on page -.). Remove front roller. (See Front Roller on page -.). Remove grass shield. (See Grass Shield on page -.) TN8 Figure -. Remove screw (), lock washer (), flat washer (8), and spacer (). 8. Remove four screws (), washers (), and nuts (). 9. Remove seal () Rev B

57 CUTTING UNITS 0. Remove nut ().. Remove washer (8) and spring (9).. Rotate reel bearing housing () to align grease fitting () with the clearance hole in the frame, and remove reel bearing housing from frame using reel bearing housing puller (Jacobsen PN JAC08).. Inspect reel shaft () for wear or damage. Replace reel if needed. (See Reel Assembly on page -.) Installation Non-Drive Side See Figures - and -. Disassembly and Assembly See Figure Bearing Cup and Cone Reel Bearing Housing Grease Seal Grease Fitting Vent Fitting Figure - TN090 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 the grease seal (). TN8 Figure -. Install reel bearing housing assembly (9).. Install spring (), washer (), and nut ().. Install seal () using screws (), washers (0), and nuts (8).. Lubricate grease fitting () 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 over-grease. Do not use compressed air gun.. Adjust reel bearing pre-load. (See Reel Bearing Pre-Load Adjustment on page -9.). Install spacer (), washer (), lock washer () and screw ().. Adjust bedknife-to-reel clearance. (See Bedknife-to-Reel Clearance Adjustment on page -.) 9-Rev B -

58 CUTTING UNITS Figure -8 TN Figure - 8. Install counterweight (), screws (), and washers (). 9. Install grass shield. (See Grass Shield on page -.) 0. Install cutting unit front roller. (See Front Roller on page -.). Install cutting unit to mower. (See Center Cutting Unit on page - or Right and Left Cutting Units on page -.) Reel Assembly Removal and Installation TN0 See Figures -8.. Park the mower safely. (See Park Mower Safely on page -.). Remove cutting unit from mower. (See Center Cutting Unit on page - or Right and Left Cutting Units on page -.). Remove bedknife backing assembly. (See Bedknife Backing Assembly on page -.). Remove front roller. (See Front Roller on page -.). Remove grass shield. (See Grass Shield on page -.). Remove drive side reel bearing housing assembly. (See Reel Bearing Housing Assembly on page -9.). Remove non-drive side reel bearing housing assembly. (See Removal Non-Drive Side on page -0.) CAUTION To prevent personal injury and damage to the cutting edges, handle the reel with extreme care. 8. 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 on page -9.) Adjust grass shield. (See Grass Shield Adjustment on page -8.) 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 -.) Level cutting unit. (See Cutting Unit Leveling Adjustment on page -.) - 9-Rev B

59 CUTTING UNITS Front Roller Removal and Installation NOTE Removal and installation of the front roller is described in Chapter Accessories and Miscellaneous Repair. (See Front Roller on page -0.) Roller Bearings Removal See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.). Remove roller. (See Front Roller on page - or Rear Roller on page -.) Rear Roller Removal and Installation See Figure -9.. Park the mower safely. (See Park Mower Safely on page -.). Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller. Figure -9. Remove screw with grease fitting () on both sides of rear roller ().. Remove rear roller (). Installation Notes Install rear roller 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 over-grease. Do not use compressed air gun. TN0 Figure -0. Using a suitable hammer, support one end of roller () and drive the bearing () and seal () out of roller by tapping opposite end of shaft ().. Remove bearing () and seal () from shaft ().. Repeat steps and for other end of roller. Installation NOTES TN Pack bearings () with grease that meets or exceeds NLGI Grade LB specifications before installation. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of the seals ().. Press one bearing () onto end of shaft () until it contacts the shoulder on the shaft.. Install shaft and bearing assembly to roller () and press bearing into roller.. Support bearing end of shaft and roller and press the other bearing onto the opposite end of shaft until it contacts the shoulder on the shaft.. Install seals (). 9-Rev B -

60 CUTTING UNITS - 9-Rev B

61 Chapter Accessories and Miscellaneous Repair Specifications General Specifications Check and Adjustment Specifications Repair Specifications Component Location Checks and Adjustments Turf Groomer Repair Front Roller Work Light Assembly Dome Light OPS Light OPS Hood Armrest Assembly Seat and Seat Platform Seat Switch Rear Fender (WD) Rear Fender (WD) Rear Wheel and Axle Assembly (WD) Rear Wheel (WD) Front Wheels Steering Wheel Front Cover Rear Cover Steering Tower Cowlings Turf Groomer Turf Groomer Drive and Driven Assemblies Turf Groomer Groomer Blade Assembly Turf Groomer Roller Assembly Rev B -

62 ACCESSORIES AND MISCELLANEOUS REPAIR Specifications General Specifications Front Tires Size 8 x 0.-8 Type -Ply Air Pressure psi (bar) (.) Front Wheel Lug Nut Torque lb-ft (N m) 80 (08.) Rear Tires Size WD 8 x 0.-8 Size WD 8 x 0.-0 Type -Ply Air Pressure psi (bar) 0 (.8) Rear Wheel Lug Nut Torque (WD) lb-ft (N m) 80 (08.) Rear Wheel Mounting Screw Torque (WD) lb-ft (N m) 80 (08.) Mower Speed Transport mph (km/h) (0.) Mowing mph (km/h) 0.0 (0 8.9) Reverse mph (km/h) 0.0 (0.) Check and Adjustment Specifications Specification Turf Groomer Eccentric Mounting Screw Torque lb-ft (N m) 8 0 (0.8.) Turf Groomer Belt Tension Link Mounting Screw lb-ft (N m) 0 (.) Torque - 9-Rev B

63 ACCESSORIES AND MISCELLANEOUS REPAIR Repair Specifications Specification Solid Front Roller Assembly Maximum Rotational lb-in. (N m) (0.8) Maximum with No End Play Resistance Solid Tube Front Roller Lock Nut Torque lb-ft (N m) 0 0 (. 0.) Solid Tube Front Roller Shaft-to-Bearing Rotational lb-in. (N m) 0 (0 0.) with No End Play Resistance Solid Tube Front Roller Assembly Maximum lb-in. (N m) (0.8) Maximum with No End Play Rotational Resistance Grooved Front Roller Lock Nut Torque lb-ft (N m) 0 0 (. 0.) Grooved Front Roller Shaft-to-Bearing Rotational lb-in. (N m) 0 (0 0.) with No End Play Resistance Grooved Front Roller Assembly Rotational Resistance lb-in. (N m) (0.8) Maximum with No End Play Grooved Disc Roller Assembly Maximum Rotational lb-in. (N m) (0.8) Maximum with No End Play Resistance Grooved Segmented Front Roller Jam Nut Torque lb-ft (N m) 0 (9) Grooved Segmented Front Roller Assembly Rotational lb-in. (N m) (0.8) Maximum with No End Play Resistance OPS Mounting Screw Torque lb-ft (N m) (9) Steering Wheel Nut Torque lb-ft (N m) 8 0 (8 ) Rear Axle Assembly Mounting Nut Torque lb-ft (N m) 0 (0) Steering Tower Mounting Screw Torque lb-ft (N m) 8 () 9-Rev B -

64 ACCESSORIES AND MISCELLANEOUS REPAIR Component Location See Figure OPS (Operator Protective Structure) Steering Tower 9 Front Wheel () Seat and Seat Platform Left Side Cowling 0 Right Side Cowling Armrest Assembly Work Light Rear Wheel Steering Wheel 8 Dome Light Hood Figure -: Component Location TN - 9-Rev B

65 ACCESSORIES AND MISCELLANEOUS REPAIR Checks and Adjustments Turf Groomer Raising the Groomer See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) NOTE The groomer is designed to be always on whenever the reel is turning. Figure - CAUTION TN Do not adjust groomer height by loosening screw () and pivoting groomer assembly (). Only use the groomer height knobs (). (See Height-of-Cut Adjustment on page -.). To raise or lower the groomer, loosen screw () on both ends of the reel and pivot the groomer up or down. Tighten screw ().. To return groomer to operation position, loosen screw () and fully pivot groomer down until pin () is at bottom of slot. 9-Rev B -

66 ACCESSORIES AND MISCELLANEOUS REPAIR Height-of-Cut Adjustment See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) NOTES Required Tools Height-of-Cut Gauge Bar (Jacobsen P/N 88) This procedure is only for mowers equipped with a turf groomer. For adjusting the height-of cut for mowers not equipped with a turf groomer, see Height-of-Cut (HOC) Adjustment on page -. Prior to adjusting the reel and groomer heights-of-cut, check the bedknife-to-reel gap for the cutting unit and adjust as necessary. (See Bedknife-to-Reel Clearance Adjustment on page -.) CAUTION Do not set the turf groomer blades at ground level or below. Mowing at this level may damage the machine as well as the turf. The Turf Groomer is designed to allow maximum groomer depth of one-half height of cut and is to be used as a conditioner not a vertical mower.. Loosen wing nut (0) and turn screw () in or out to obtain the desired turf groomer cutting depth (). The turf groomer cutting depth should not be set more than 0% below the height-of-cut.. Loosen screw () on each side of reel just enough to allow inside knobs () to raise or lower the roller.. Place gauge bar () across the front and rear rollers at one end of the reel.. Slide the head of screw () over the bedknife and adjust knob () to close the gap between the head of screw () and bedknife.. Repeat steps and for the other end of the reel. 8. Check both ends of reel for proper adjustment and tighten screw () on each side of reel. 9. Loosen screw () just enough to allow outside knobs () to raise or lower the groomer. 0. Place gauge bar () across the front and rear rollers at one end of the reel with the head of screw () over the bedknife.. Adjust knob () to close the gap between the end of screw () and groomer blades.. Repeat steps 0 and at the other end of the reel.. Check that turf groomer is adjusted evenly on both ends and tighten screw () at each end of reel TN Figure -. Loosen wing nut (9) and turn screw () in or out to obtain the desired reel height-of-cut (8) on gauge bar (). When dimension (8) is obtained, tighten wing nut (9). - 9-Rev B

67 ACCESSORIES AND MISCELLANEOUS REPAIR Bearing Adjustment See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Tighten turf groomer bracket screws (9) and carriage bolt () on both sides of the cutting unit to close the gap between the turf groomer brackets () and frame (0). The turf groomer brackets should be parallel tot he frame and allowed to pivot freely.. Adjust turf groomer lock nut (8) to make contact with spacer (). Tighten shaft screw ().. Align the turf groomer blades to the roller discs. (See Blade-to-Roller Alignment on page -9.). Adjust turf groomer belt. (See Belt Adjustment on page -8.) 8 TN9 Figure -. Remove screw (), lock washer (), flat washer (), and guide wheel () from the motor side of the cutting unit.. Loosen turf groomer lock nut (8), shaft screw (), and front roller lock nuts () on the motor side of the cutting unit Figure - TN 9-Rev B -

68 ACCESSORIES AND MISCELLANEOUS REPAIR Belt Adjustment See Figures - and -.. Park the mower safely. (See Park Mower Safely on page -.). Install groomer cover (), pulley cover (), four flat washers (), four lock washers (), two screws (), and two screws (). Figure -. Remove two screws (), two screws (), four lock washers (), four flat washers (), and remove pulley cover () and groomer cover (). TN9 0 9 Figure -. Loosen eccentric mounting screw (8) and belt tension link mounting screw (0).. Using a socket, turn eccentric (9) by hand until belt () is tight.. Tighten eccentric mounting screw (8) to 8 0 lb-ft (0.8. N m).. Tighten belt tension link mounting screw (0) to 0 lb-ft (. N m). 8 TN -8 9-Rev B

69 ACCESSORIES AND MISCELLANEOUS REPAIR Blade-to-Roller Alignment See Figures -8 and -9.. Park the mower safely. (See Park Mower Safely on page -.) Belt Cover End of Cutting Unit Turf Groomer Blades Front Roller Lock Nuts Front Roller Turf Groomer Motor End of Cutting Unit Roller Discs 8 Figure -8. Loosen front roller lock nuts ().. Shift the front roller () toward the belt cover end of the cutting unit () until the turf groomer blades () contact the roller discs (). For any blades that have a gap, install shims to move the blades to make contact. TN8 Belt Cover End of Cutting Unit Turf Groomer Blades Front Roller Lock Nuts Front Roller Turf Groomer Motor End of Cutting Unit Front Roller Discs 8 Figure -9. Ensure all blades make contact, then shift the front roller () until the turf groomer blades () are centered within the grooves of the roller discs ().. Tighten front roller lock nuts (). TN 9-Rev B -9

70 ACCESSORIES AND MISCELLANEOUS REPAIR Repair Front Roller Disassembly Solid Rollers See Figure -. Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.). Raise cutting unit assembly with a suitable lifting device and support the cutting unit frame to remove weight from roller. TN9 Figure -0. Remove nuts () and screws ().. Remove adjuster knobs ().. Remove adjuster brackets () and front roller () from cutting unit.. Loosen jam nuts () and square head bolts () on both sides 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 bolt before tightening bolts on each end of shaft. 8. Check height-of-cut adjustment. (See Height-of-Cut (HOC) Adjustment on page -.) TN0 Figure -. Remove grease fittings ( and ) from the roller shaft ().. Support one end of the roller (8), allowing enough free space for the seal () and bearing () to exit the roller (8).. Apply pressure to the other end of the roller shaft () until the seal () and bearing () are clear of the roller (8).. Repeat steps and to remove the seal () and bearing () from the other end of the roller (8) Rev B

71 ACCESSORIES AND MISCELLANEOUS REPAIR Assembly Solid Rollers See Figures - through -. Required Materials Permatex Anaerobic Sealer (or equivalent) 9 8 TN0 Figure -. Remove the shield () from one side of each new bearing (). TN0 Figure -. Install the roller shaft (9) with bearing () into the roller (8) until the bearing is seated against the shoulder () in the roller. 0 TN0 Figure -. Pack the bearing () with grease that meets or exceeds NLGI Grade LB specifications before installation.. Install one bearing () on the roller shaft () with the shielded side toward the step () on the shaft. Press the bearing on the shaft until it rests against the step. TN0 Figure -. Pack the bearing (0) with grease that meets or exceeds NLGI Grade LB specifications before installation.. Install bearing (0) over the other end of the roller shaft (), with the sealed side toward the inside of the roller. Seat the bearing against the shoulder (). 9-Rev B -

72 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly Solid Tube and Grooved Rollers See Figure -. Figure - TN08 NOTE Always use new grease seals for installation.. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seal (). Install the grease seals into each end of the roller (). 8. Install grease fittings () into each end of the roller shaft and 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 over-grease. Do not use compressed air gun Check the rotational resistance of the roller assembly after four revolutions. The resistance should be lb-in. (0.8 N m) maximum with no end play. TN0 0 9 Figure - TN0 NOTE Solid tube roller shown; grooved roller is similar.. Using a puller, remove the adapter seals ( and ) from both ends of the roller assembly.. Remove lock nuts ( and 0) and bearings ( and 9) from both ends of the roller assembly.. Remove the roller shaft (). - 9-Rev B

73 ACCESSORIES AND MISCELLANEOUS REPAIR. Inspect the bearings ( and 9). If replacement is required, use a blind hole bearing puller to remove the bearing cups ( and 8) from both ends of the roller ().. Remove grease seals ( and ) from the adapter seals ( and ). Assembly Solid Tube and Grooved Rollers See Figure -8. Required Materials Permatex Anaerobic Sealer (or equivalent) NOTE Always use new grease seals for installation.. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the new grease seals ( and ), and install the grease seals in the adapter seals ( and ). NOTE Bearings and bearing cups should always be replaced as a set.. If removed, press new bearing cups ( and 8) in the roller ().. Pack the bearings ( and 9) with grease that meets or exceeds NLGI Grade LB specifications before installation.. Install the roller () and bearings ( and 9) on the roller shaft (). Center the roller on the shaft, and install lock nuts ( and 0). Tighten lock nuts to 0 0 lb-ft (. 0. N m) to seat the bearings.. Check the rotational resistance of the roller on the shaft. The resistance should be 0 lb-in. (0 0. N m) with no end play. Adjust the lock nuts as needed.. Apply a thin film of Permatex Anaerobic Sealant (or equivalent) to the outside diameter of the adapter seals ( and ). Install (press) the adapter seals ( and ) in the roller ().. Check the rotational resistance of the roller assembly after four revolutions. The resistance should be lb-in. (0.8 N m) maximum with no end play. 8 TN0 0 9 Figure -8 TN0 9-Rev B -

74 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly Grooved Disc Roller See Figure -9. TN0 TN0 Figure -9. Remove grease fittings ( and 8) from the roller shaft ().. Support one end of the roller (), allowing enough free space for the seal () and bearing () to exit the roller ().. Apply pressure to the other end of the roller shaft () until the seal () and bearing () are clear of the roller ().. Repeat steps and to remove the seal () and bearing () from the other end of the roller (). 8-9-Rev B

75 ACCESSORIES AND MISCELLANEOUS REPAIR Assembly Grooved Disc Roller See Figure -0.. Lubricate grease fittings ( and 8) 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 over-grease. Do not use compressed air gun.. Check the rotational resistance of the roller assembly after four revolutions. The resistance should be lb-in. (0.8 N m) maximum with no end play. TN0 Figure -0. Install bearing () into the roller ().. Install the roller shaft () into the roller () and bearing ().. Install bearing () into the roller (). 8 TN0 NOTE Always use new grease seals for installation.. Install new grease seals ( and ) in the roller ().. Install both grease fittings ( and 8) in the roller shaft (). 9-Rev B -

76 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly Grooved Segmented Roller See Figures - and -. TN0 Figure - TN0 NOTE All three roller segment assemblies are disassembled in the same way.. Remove grease seals ( and ), ball bearings ( and ), and spacer () from the roller segment (). 8 TN0 TN0 Figure -. Remove hex-jam, nylon-insert nut (0) from the roller shaft () while holding the nut () at the other end of the shaft.. Remove short spacer (9) and roller segment assembly (8).. Remove long spacers ( and ) and roller segment assemblies ( and ).. Remove short spacer () from roller shaft () Rev B

77 ACCESSORIES AND MISCELLANEOUS REPAIR Assembly Grooved Segmented Roller See Figures - and TN0 Figure - TN0 0 NOTES All three roller segment assemblies are assembled in the same way. Always use new grease seals for installation.. Install a ball bearing () and a new grease seal () in one end of the roller segment ().. Apply grease that meets or exceeds NLGI Grade LB specifications to the inside of the spacer (), and install the spacer () into the roller segment ().. Install a ball bearing () and grease seal () in the other end of the roller segment ().. Apply grease that meets or exceeds NLGI Grade LB specifications to the lips of the grease seals ( and ). TN0 TN0 Figure -. Apply a thin film of NLGI Grade grease to the outside diameter of the short spacer (9), and install the spacer on the roller shaft (8) with the bevel facing away from the nut ().. Install the roller segment assemblies (0,, and ) on the roller shaft (8), placing a long spacer ( and ) between each of the roller segments.. Apply a thin film of grease that meets or exceeds NLGI Grade LB specifications to the inside diameter of the short spacer () on the roller shaft (8). 8. Install jam nut () on the roller shaft (8). 9. Ensure the distance from the ends of shaft (8) and each nut ( and ) remain within 0.00 in. (. mm) of each other and tighten nuts to 0 lb-ft (9 N m). 0. Check the rotational resistance of the roller assembly after four revolutions. The resistance should be lb-in. (0.8 N m) maximum with no end play. 9-Rev B -

78 ACCESSORIES AND MISCELLANEOUS REPAIR Work Light Assembly Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Remove front cover. (See Front Cover on page -.) Dome Light Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) TN Figure -. Tag and disconnect wire harness connector () from work light assembly ().. Remove nut (), washer (), and carriage bolt () from mounting bracket () and work light assembly ().. Remove work light assembly (). Installation Notes Install work light assembly by reversing the order of removal. Adjust the work light to project the desired distance in front of the machine. (See the Parts and Maintenance Manual for additional information and illustrations.) TN Figure -. Cut cable tie ().. Tag and disconnect dome light wire connector ().. Remove two nuts () and lock washers ().. Remove dome light (). Installation Notes Install dome light by reversing the order of removal. Use new cable tie to secure wire harness and wire connector Rev B

79 ACCESSORIES AND MISCELLANEOUS REPAIR OPS Light Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) OPS Removal and Installation See Figures -8 and -9.. Park the mower safely. (See Park Mower Safely on page -.). Remove OPS light (if equipped). (See OPS Light on page -9.). Raise the hood. TN Figure -. Tag and disconnect OPS wire connector ().. Remove nut (), screw (), and flat washer () from OPS.. Remove OPS light (). TN9 Figure -8. Remove two plugs () on each side of machine. Installation Note Install OPS light by reversing the order of removal. Figure -9. Support the OPS () using a suitable lifting device.. Remove three screws (), lock washers (), and flat washers () on each side of machine.. Remove OPS (). Installation Notes Install OPS by reversing the order of removal. Tighten OPS mounting screws () to lb-ft (9 N m). TN9 9-Rev B -9

80 ACCESSORIES AND MISCELLANEOUS REPAIR Hood Removal and Installation See Figure -0.. Park the mower safely. (See Park Mower Safely on page -.) Armrest Assembly Removal and Installation See Figures - and -. NOTE Armrest and instrument panel are removed as one assembly.. Park the mower safely. (See Park Mower Safely on page -.) TN9 Figure -0. Open and support hood () using a suitable lifting device.. Remove screws (), washers (), and nuts ().. Remove hood (). Installation Notes Support the hood with a suitable lifting device to aid in installation. Install hood by reversing the order of removal. NOTES Figure - Label all wires before disconnecting to ensure correct installation. If moving the armrest assembly aside, use caution to prevent stretching or pinching the wires.. Loosen lock collar screw ().. Loosen jam nut () and set screw () from the armrest assembly ().. Remove cable ties securing wire connectors and wire harness. TN Figure -. Disconnect wiring harness connectors (). TN -0 9-Rev B

81 ACCESSORIES AND MISCELLANEOUS REPAIR. Remove armrest assembly, carefully guiding the wire harness through the lock collar bracket. Installation Notes Apply dielectric grease (Jacobsen PN ) to any connectors removed. Use new cable ties to secure wire connectors and wire harness. Lubricate grease fitting (). Install armrest assembly by reversing the order of removal. Seat and Seat Platform Removal and Installation See Figures - through -.. Park the mower safely. (See Park Mower Safely on page -.). Remove cowlings. (See Cowlings on page -.). Remove armrest assembly. (See Armrest Assembly on page -0.) Figure - TN0 NOTE The seat switch wire harness connector for the standard seat is located below the seat.. Tag and disconnect the seat switch wire harness connector (). NOTE Steps through are for the optional seat only. For the standard seat, proceed to step 8.. Tilt the seat backrest () forward.. Raise rear of seat () and slide seat forward.. Remove seat (). 9-Rev B -

82 ACCESSORIES AND MISCELLANEOUS REPAIR Figure - 8. Remove nuts (), lock washers (), and carriage bolts (). 9. Remove lock collar bracket (). TN TN0 Figure - 0. Support seat and seat platform (8) with a suitable lifting device.. Remove nuts (9), washers (0), square-head bolts (), seat track rear stop (), and seat track forward stop ().. Using a suitable lifting device, remove seat and seat platform (8) from the machine. Installation Notes Install the seat and seat platform by reversing the order of removal. Carefully route and secure seat switch wire harness to avoid damage from pinched wires. - 9-Rev B

83 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly (Standard Seat) See Figure Seat Spacer Seat Switch Flange Nut (8) Lock Washer () Screw () Seat Belt Assembly Seat Switch Harness Seat Adjuster Rod Armrest and Seat Base Flat Washer (8) 8 Nut () Latching Seat Track 8 Seat Adjuster Handle Cable Tie () Product Literature Bag 9 Lock Washer () Push Nut () 9 Lock Nut Slave Seat Track Screw () 0 LH Seat Belt Bracket Flat Washer (8) 0 Screw () RH Seat Belt Bracket Figure - TN 9-Rev B -

84 ACCESSORIES AND MISCELLANEOUS REPAIR Disassembly and Assembly (Premium Seat) See Figure Seat Stop, Forward Seat 9 Flat Washer (8) Seat Adjuster Rod Flat Washer (8) Track Movement Document Net Screw, Square 0 Nut, Whizlock Seat Adjuster Handle 8 Armrest and Seat Base Head () Flange (8) Seat Switch Harness Latching Seat Screw () Lock Nut Track Slave Seat Track 8 Push Nut () Stop, Rear Seat Track Movement Screw () Figure TN - 9-Rev B

85 ACCESSORIES AND MISCELLANEOUS REPAIR Seat Switch Removal and Installation Standard Seat See Figure -8.. Park the mower safely. (See Park Mower Safely on page -.) Premium Seat See Figures -9 through -.. Park the mower safely. (See Park Mower Safely on page -.) Figure -8. Tag and disconnect the seat switch wire harness connector ().. Cut two cable ties holding wire harness to frame.. Remove two screws (), two lock washers (), and seat switch (). TN Installation Notes Install seat switch by reversing the order of removal. Use new cable ties to secure wire harness and wire harness connector. TN0 Figure -9. Tag and disconnect the seat switch wire harness connector ().. Cut cable ties ().. Tilt the seat backrest () forward.. Raise rear of seat () and slide seat forward.. Remove seat (). Figure -0 TN0. Cut cable ties (). 9-Rev B -

86 ACCESSORIES AND MISCELLANEOUS REPAIR 9 8 Figure - 8. Disengage switch cover tabs (8) and remove cover (9). 9. Raise end of switch actuator () and remove seat switch (). TN989. Remove two screws (), flanges (), rubber washers (), flat washers (), and nuts () on each side of rear fender ().. Remove rear fender (). Installation Note Install rear fender by reversing the order of removal. Rear Fender (WD) Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Remove rear wheel. (See Rear Wheel (WD) on page -9.) Installation Notes Install seat switch by reversing the order of removal. Use new cable ties to secure wire harness and wire connector. Rear Fender (WD) Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) TN Figure -. Remove two nuts () and screws ().. Remove rear fender (). Installation Note Install rear fender by reversing the order of removal. Figure - TN8-9-Rev B

87 ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheel and Axle Assembly (WD) Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Remove rear fender. (See Rear Fender (WD) on page -.) Installation Notes Inspect and clean any rust from rear axle assembly () or wheel mounting area. Install rear wheel and axle assembly by reversing the order of removal. Tighten lug nuts () to 80 lb-ft (08. N m) using an alternating pattern. Tighten rear axle assembly mounting nuts () to 0 lb-ft (0 N m). Set tire pressure to 0 psi (.8 bar). TN00 TN00 Figure -. Raise and support rear of machine with jackstands.. Support the rear wheel and axle assembly with a suitable lifting device.. Remove nuts (), lock washers (), and flat washers ().. Remove rear wheel and axle assembly from the machine.. Remove four lug nuts (). 8. Remove rear axle assembly () from wheel (). 9. Inspect tread area for tears or other damage. 0. Replace tire if damage is excessive. 9-Rev B -

88 ACCESSORIES AND MISCELLANEOUS REPAIR Rear Axle Assembly (WD) Disassembly and Assembly See Figure TN8 Seal Axle Tube Axle Shaft Wheel Bolt () 9 Bearing Adjuster Nut Bearing Cup and Cone Bearing Backing Ring Flat Washer 8 Grease Fitting 0 Nut Figure -: Rear Axle Assembly TN8-8 9-Rev B

89 ACCESSORIES AND MISCELLANEOUS REPAIR Rear Wheel (WD) Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) Front Wheels Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.). Block front and rear of rear wheel using suitable wheel blocks. TN Figure -. Raise and support rear of machine with jackstands.. Support the rear wheel with a suitable lifting device.. Remove four screws ().. Remove rear wheel () from motor hub.. Inspect tread area for tears or other damage.. Replace tire if damage is excessive. Installation Notes Tighten screws () to 80 lb-ft (08. N m) using an alternating pattern. Set tire pressure to 0 psi (.8 bar). TN0 Figure -. Loosen, but do not remove, lug nuts ().. Raise and support front of machine with jackstands.. Remove four lug nuts ().. Remove wheel () and inspect tread area for tears or other damage.. Replace tire if damage is excessive. Installation Notes Inspect and clean any rust from hub () or wheel mounting area. Install front wheel by reversing the order of removal. Tighten lug nuts to 80 lb-ft (08. N m) using an alternating pattern. Set tire pressure to psi (. bar). TN0 9-Rev B -9

90 ACCESSORIES AND MISCELLANEOUS REPAIR Steering Wheel Removal and Installation Required Tools or Equipment NAPA Puller BK908 See Figures -8 through -.. Park the mower safely. (See Park Mower Safely on page -.) 9 Figure -0 TN TN Figure -8. Assemble NAPA BK908 puller () or equivalent (. in. reach,.0 in. spread) using two jaws () and extensions (). 8 Figure -9. Remove (unsnap) cap () from steering wheel ().. Loosen, but do not remove, nut (). TN0 0 TN8 Figure -. Place screw (9) on the steering column shaft, using nut () as a pilot. Position the jaws to grasp the lip on the bottom of the steering wheel (0), with the top of the jaws resting on the bottom of the steering wheel.. Tighten screw (9) until the steering wheel disengages from the steering column shaft.. Remove puller () and nut (). 8. Pull up and remove steering wheel (). 9. Remove bearing () from steering column (8). Installation Notes Install steering wheel by reversing the order of removal. Tighten the steering wheel nut () to 8 0 lb-ft (8 N m) Rev B

91 ACCESSORIES AND MISCELLANEOUS REPAIR Front Cover Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) Rear Cover Removal and Installation See Figure -.. Park the mower safely. (See Park Mower Safely on page -.) Figure -. Remove six screws () and spacers ().. Remove front cover (). TN9 TN8 Figure -. Remove four screws () and spacers ().. Pull rear cover () away from steering column.. Disengage LED access cover () from rear cover. Installation Note Install front cover by reversing the order of removal. TN0 Figure -. Disconnect the cable () from the gas spring ().. Remove rear cover (). Installation Note Install rear cover by reversing the order of removal. 9-Rev B -

92 ACCESSORIES AND MISCELLANEOUS REPAIR Steering Tower Removal and Installation See Figures - and -. WARNING Be sure that the key switch is off, all electrical accessories are turned off, and the -volt and 8-volt power connectors are disconnected before starting work on machine Park the mower safely. (See Park Mower Safely on page -.). Remove front cover. (See Front Cover on page -.). Remove rear cover. (See Rear Cover on page -.). Remove work light assembly. (See Work Light Assembly on page -8.). Remove RCU. (See RCU on page -.). Remove steering wheel input device. (See Steering Wheel Input Device on page -.) Figure -. Remove four screws (9).. Remove steering tower (8). TN Loctite (Blue) Required Materials Installation Notes Install steering tower by reversing the order of removal. Apply Loctite (blue) to screws (9) prior to assembly. TN Tighten mounting screws (9) to 8 lb-ft ( N m). Figure - NOTE Steps through are for gasoline models only. For diesel and electric models, proceed to step.. Hold nut () and remove knob (). 8. Remove nut (). 9. Remove two nuts () and lock washer (). 0. Disengage choke cable () from steering tower ().. Remove grommet (). - 9-Rev B

93 ACCESSORIES AND MISCELLANEOUS REPAIR Cowlings Removal and Installation See Figures - and -8.. Park the mower safely. (See Park Mower Safely on page -.). Raise the hood. NOTE The left side cowling is shown; the right side cowling is similar.. Move seat forward.. Remove screws (), spacers (8), and rubber washers (9).. For left side only, remove screw (), spacer (), and rubber washer (). NOTE Reach under left cowling and secure the cup holder drain hose by hand prior to lifting cowling to prevent damage to left cowling hose nipple. 8. Remove cowling (0). Installation Note Install cowling by reversing the order of removal. TN Figure - TN NOTE Steps and are for diesel models only. For gasoline and electric models, proceed to step.. Loosen hose clamp () and disconnect hose () from plenum ().. Remove screw (), spacer (), rubber washer (), and plenum () Figure -8 TN8 9-Rev B -