Ransomes 62800, 62801, 62802, 62803, 62804, 62805, 62825, 62826 User manual

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5
4271491-Rev B 5-1
Chapter 5
Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Check and Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Steering Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Reel Lift Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Right and Left Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Center Lift Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Steering Yoke (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Steering Yoke (3WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Steering Chain and Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Front Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Traction Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Brake Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Axle Shield and Front Splash Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Front Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-2 4271491-Rev B
CHASSIS
5
Specifications
Check and Adjustment Specifications
Repair Specifications
Specification
Steering Chain Deflection in. (mm) 0.063–0.250 (1.6–6.4)
[with 2–10 lb (9–45 N)
push at mid-span of chain]
Specification
Front Wheel Hub Castle Nut Torque lb-ft (N·m) 95–115 (10.7–13.0)
Front Axle Assembly—
Mounting Screw Torque
lb-ft (N·m) 65 (88)
Front Axle Assembly—
Axle Housing Face-to-Axle Shaft Seal Outer Face
Measurement
in. (mm) 1.125 (28.6)
Front Axle Assembly—
Bearing Cap Screw Torque
lb-ft (N·m) 35–45 (3.4–5.1)
Front Axle Assembly—
Axle Housing Cover Screw Torque
lb-ft (N·m) 16–25 (1.8–2.7)
CHASSIS
4271491-Rev B 5-3
5
Component Location
See Figures 5-1 and 5-2.
Figure 5-1: Component Location—Right Side
1 Floorboard Assembly 3 Left Cutting Unit 5 Right Lift Arm 7 Front Axle Assembly 9 Center Cutting Unit
2 Traction Pedal 4 Right Reel Lift Actuator 6 Right Cutting Unit 8 Right Fender 10 Center Reel Lift Actuator
TN2744
1
2
8
3
9
4
10
5
6
7
5-4 4271491-Rev B
CHASSIS
5
Figure 5-2: Component Location—Left Side
1 Brake Pedal Assembly 3 Steering Yoke 5 Left Lift Arm
2 Steering Chain and Gear 4 Left Fender 6 Left Reel Lift Actuator
TN2746
3
2
1
4
6
5
CHASSIS
4271491-Rev B 5-5
5
Checks and Adjustments
Steering Chain Tension Adjustment
See Figures 5-3 and 5-4.
WARNING
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Raise the hood.
Figure 5-3
3. Remove four screws (1), flat washers (2), and nuts
(3).
4. Remove rear controller cover (4).
Figure 5-4
5. Loosen two screws (5).
6. Adjust position of steering motor (7) to obtain
0.063–0.250 in. (1.6–6.4 mm) deflection with 2–10 lb
(9–45 N) push at mid-span of chain (6).
7. Tighten two screws (5).
Repair
Reel Lift Actuators
Removal and Installation
See Figure 5-5.
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.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
NOTE
For removal purposes, do not place the reel lift actuator
in the fully down position.
Figure 5-5
NOTE
Label all wires before disconnecting to ensure correct
installation.
2. Disconnect reel lift actuator wire connectors (8).
3. Remove cotter pin (1), clevis pin (2), two flat washers
(3), and two spacers (4) from the reel lift actuator (7).
4. Remove cotter pin (5) and flat washer (6).
5. Remove reel lift actuator.
Installation Notes
Install reel lift actuator by reversing the order of
removal.
Apply dielectric grease (Jacobsen PN 365422) to
connections.
Be sure that the key switch is off, all electrical
accessories are turned off, and the 12-volt and
48-volt power connectors are disconnected
before starting work on machine.
TN2371
1 2 3
321
4
TN2782
TN2782
5
6
7
TN2395
5 6
1 32 4
8
7
5-6 4271491-Rev B
CHASSIS
5
Right and Left Lift Arms
Removal and Installation
See Figures 5-6 and 5-7.
NOTE
The right lift arm is shown; the left lift arm is similar.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove reel lift actuator. (See “Reel Lift Actuators”
on page 5-5.)
3. Remove reel leveling rod. (See “Reel Leveling Rod”
on page 6-24.)
Figure 5-6
NOTE
Label all wires before disconnecting to ensure correct
installation.
4. Cut cable ties (3).
5. Disconnect the reel drive motor wire connectors (1).
6. Remove lock pin (5) from yoke shaft (6).
7. Pull the lift arm (4) up and remove the reel assembly
(2).
Figure 5-7
8. Remove cotter pin (7) and flat washer (8).
9. Remove lift arm.
Installation Notes
Pre-adjust the reel leveling rod before installation.
(See “Reel Leveling Rod Pre-Adjustment” on
page 6-23.)
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 365422) to
connections.
Lubricate grease fittings.
TN2398
1
4
5
2
6
3
3
TN2399
7 8
CHASSIS
4271491-Rev B 5-7
5
Disassembly and Assembly
See Figure 5-8.
Figure 5-8
1Key (2) 5Screw (8) 9 Cotter Pin (2) 13 Polygon Bushing (4) 17 Right Front Lift Arm
2 Flat Washer (12) 6 Stop Bracket (2) 10 Link Arm (2) 14 Shim Washer (as required) 18 Nut (2)
3 Lock Washer (12) 7 Bushing (4) 11 Nut (8) 15 Front Reel Steering Pivot (2) 19 Rubber Bumper (2)
4Screw (2) 8 Flat Washer (2) 12 Left Front Lift Arm 16 Grease Fitting (2) 20 Stop Bracket (2)
1
3
2
TN4525
10
4
7
7
8
8
9
4
3
2
1
10
12
13
13
14
15
13
14
15
17
7
13
5
6
2
3
11
5
6
2
3
11
16
16
14
5
14
18
3
2
19
11
3
2
20
5-8 4271491-Rev B
CHASSIS
5
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
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 (1) prior to
assembly.
Install shim washers (14), as required, to remove
excess gap between left front lift arm (12), link arm
(10), and front reel steering pivot (15). Also install
shim washers (14), as required, to remove excess
gap between right front lift arm (19), link arm (10),
and front reel steering pivot (15).
Center Lift Arm
Removal and Installation
See Figures 5-9 and 5-10.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove reel lift actuator. (See “Reel Lift Actuators”
on page 5-5.)
3. Remove reel leveling rod. (See “Reel Leveling Rod”
on page 6-24.)
Figure 5-9
NOTE
Label all wires before disconnecting to ensure correct
installation.
4. Cut cable ties (1).
5. Disconnect the reel drive motor wire connectors (8).
6. Remove spring (7).
7. Remove cap (3).
8. Remove lock pin (4) from yoke shaft (6).
9.Pull the center lift arm (2) up and remove reel
assembly (5).
Figure 5-10
10. Remove cotter pin (9) and flat washer (10).
11. Remove center lift arm.
Installation Notes
Pre-adjust the reel leveling rod before installation.
(See “Reel Leveling Rod Pre-Adjustment” on
page 6-23.)
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 365422) to
connections.
Lubricate grease fittings.
Required Materials
Anti-Seize Compou nd
TN2410
8
4
5
1
6
2
7
3
TN2668
9 10
CHASSIS
4271491-Rev B 5-9
5
Disassembly and Assembly
See Figure 5-11.
Figure 5-11
1Lock Pin 8 Flat Washer 14 Thrust Washer 20 Nut26Key
2 Locking Collar 9 Screw 15 Polygon Bushing 21 Grease Fitting 27 Link Arm
3 Polygon Bushing 10 Lock Washer 16 Flat Washer 22 Center Reel Steering Pivot 28 Screw
4Bushing 11 Flat Washer 17 Cotter Pin 23 Shim Washer (as required) 29 Flat Washer
5 Center Swing Arm 12 Locking Pin Bracket 18 Center Stop Bracket 24 Polygon Bushing 30 Eye Bolt
6Nut13Actuator Pivot Pin 19 Rubber Bumper 25 Center Lift Arm 31 Spring
7Lock Washer
TN2786
1
TN2786
2
3
3
4
5
9
10
11
8
7
6
12
13
14
15
15
16
17
20
10
11
10
11
9
18
20
10
11
19
21
22
24
23
24
23
31
30
20
29
29
20
28
10
11
27
26
19
25
5-10 4271491-Rev B
CHASSIS
5
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
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 (26) prior to
assembly.
Install shim washers (23), as required, to remove
excess gap between center lift arm (26), link arm
(27), and center reel steering pivot (22).
Steering Yoke (2WD)
Removal and Installation
See Figures 5-12 through 5-14.
WARNING
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
Figure 5-12
2. Swing out and lock the center cutting unit (1) from
under the machine.
WARNING
IMPORTANT
It is important to lift and support the machine, or the
machine will move.
3. Lift the machine so that the rear wheel is off the
ground, and support with appropriate jackstands.
Required Materials
Anti-Seize Compou nd
Be sure that the key switch is off, all electrical
accessories are turned off, and the 12-volt and
48-volt power connectors are disconnected
before starting work on machine.
Support the machine using properly rated
jackstands. Never work under a machine
supported only by a jack.
Do not use wood or concrete blocks to
support the machine. Failure to properly
support the machine may result in death or
serious injury.
1
TN2388
CHASSIS
4271491-Rev B 5-11
5
4. Remove rear wheel and axle assembly. (See “Rear
Wheel and Axle Assembly (2WD)” on page 7-27.)
5. Remove steering sensor. (See “Steering Sensor
(2WD)” on page 4-157.)
6. Remove steering chain and steering gear. (See
“Steering Chain and Gears” on page 5-14.)
Figure 5-13
7. Support steering yoke (8) and remove retaining ring
(2).
8. Remove bushing (3) from steering yoke (8).
9. Lower the steering yoke (8) from frame (5).
10. Remove two thrust washers (6) and thrust bushing
(9) from steering yoke (8).
11. Remove thrust washer (7) from steering yoke (8).
12. Remove two polygon bushings (4) from frame (5).
Figure 5-14
13. Remove two screws (10).
14. Remove steering stop (11) 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 5-5.)
TN4538
8
2
3
4
4
5
6
7
9
TN4537
8
11
10
5-12 4271491-Rev B
CHASSIS
5
Steering Yoke (3WD)
Removal and Installation
See Figures 5-15 through 5-17.
WARNING
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove steering sensor. (See “Steering Sensor
(3WD)” on page 4-160.)
Figure 5-15
3. Swing out and lock the center cutting unit (1) from
under the machine.
WARNING
IMPORTANT
It is important to lift and support the machine, or the
machine will move.
4. Lift the machine so that the rear wheel is off the
ground, and support with appropriate jackstands.
5. Remove rear fender. (See “Rear Fender (3WD)” on
page 7-26.)
6. Remove rear traction motor. (See “AC Traction Motor
(3WD)” on page 4-182.)
7. Remove steering sensor. (See “Steering Sensor
(3WD)” on page 4-160.)
8. Remove steering chain and steering gear. (See
“Steering Chain and Gears” on page 5-14.)
Figure 5-16
9.Support steering yoke (8) and remove retaining ring
(2).
10. Remove bushing (3) from steering yoke (8).
11. Lower the steering yoke (8) from frame (5).
12. Remove two thrust washers (6) and thrust bushing
(9) from steering yoke (8).
13. Remove thrust washer (7) from steering yoke (8).
14. Remove two polygon bushings (4) from frame (5).
Be sure that the key switch is off, all electrical
accessories are turned off, and the 12-volt and
48-volt power connectors are disconnected
before starting work on machine.
Support the machine using properly rated
jackstands. Never work under a machine
supported only by a jack.
Do not use wood or concrete blocks to
support the machine. Failure to properly
support the machine may result in death or
serious injury.
1
TN2388
TN4456
2
3
4
5
9
8
6
4
7
CHASSIS
4271491-Rev B 5-13
5
Figure 5-17
15. Remove two screws (10).
16. Remove steering stop (11) from steering yoke (8).
Installation Notes
Install steering yoke by reversing the order of
removal.
Fill the gap between polygon bushings (4) with
Lubriplate A Grease.
Adjust the steering chain tension. (See “Steering
Chain Tension Adjustment” on page 5-5.)
Adjust the steering sensor air gap. (See “Steering
Sensor (3WD) Adjustment” on page 4-146.)
Required Materials
Lubriplate A Grease
TN4455
8
11
10
5-14 4271491-Rev B
CHASSIS
5
Steering Chain and Gears
Removal and Installation
See Figures 5-18 and 5-19.
WARNING
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove steering sensor. (See “Steering Sensor
(2WD)” on page 4-157 or “Steering Sensor (3WD)”
on page 4-160.)
Figure 5-18
NOTE
Note orientation of the chain before removing to ensure
correct installation.
3. Loosen two screws (2) and slide the steering motor
bracket (3) to remove the chain (1).
4. Remove chain from gears.
Figure 5-19
NOTE
For installation purposes, measure from the top of the
steering motor shaft (4) to the top of the steering motor
gear (11) before removing and note the measurement.
5. Remove two set screws (6) from steering motor gear
(11).
6. Use the appropriate gear puller and remove steering
motor gear (11) and key (5).
7. Remove screw (7) from steering gear (9).
8. Use the appropriate gear puller and remove steering
gear (9) and key (8).
Installation Notes
Apply anti-seize compound to keys (5 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 5-5.)
Be sure that the key switch is off, all electrical
accessories are turned off, and the 12-volt and
48-volt power connectors are disconnected
before starting work on machine.
TN4544
3
1
2
Required Materials
Anti-Seize Compound
TN2370
10
6
11
9
7
4
5
8
CHASSIS
4271491-Rev B 5-15
5
Front Fenders
Removal and Installation
See Figure 5-20.
NOTE
The left fender is shown; the right fender is similar.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove cowlings. (See “Cowlings” on page 7-33.)
Figure 5-20
3. Remove three screws (1) and flat washers (2).
4. Remove two screws (3) and nylon insulators (4).
5. Remove front fender (5).
Installation Note
Install front fenders by reversing the order of removal.
Traction Pedal
Removal and Installation
See Figure 5-21.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
Figure 5-21
2. Remove screws (1), lock washers (2), and flat
washers (3).
3. Remove nut (5), lock washer (6), and flat washer (7).
4. Remove traction pedal (4).
Installation Note
Install traction pedal by reversing the order of removal.
TN2383
1 2
5
43
TN2407
1
5 6 7
2
4
3
5-16 4271491-Rev B
CHASSIS
5
Brake Pedal Assembly
Removal and Installation
See Figures 5-22 and 5-23.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove brake pedal switch. (See “Brake Pedal
Switch” on page 4-175.)
3. Remove brake pedal position sensor. (See “Brake
Pedal Position Sensor” on page 4-176.)
4. Remove front cover. (See “Front Cover” on
page 7-31.)
5. Remove rear cover. (See “Rear Cover” on
page 7-31.)
6. Remove left fender. (See “Front Fenders” on
page 5-15.)
Figure 5-22
7. Remove screws (1) and washers (2).
8. Remove screws (3) and washers (4).
Figure 5-23
9. Remove pedal grip (5).
NOTE
Move floor mat aside to access screws (7).
10. Support brake pedal assembly (6) and remove
screws (7).
11. 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.
TN2682
1 2
43
TN2414
5
6
7
7
CHASSIS
4271491-Rev B 5-17
5
Disassembly and Assembly
See Figure 5-24.
Figure 5-24
1 Screw (4) 5 Brake Arm Weldment 8 Switch Arm 11 Spring
2 Brake Pedal Position Sensor 6 Spring Roll Pin (2) 9 Brake Pedal Switch 12 Spacer (4)
3 Brake Plate (2) 7 Pedal Grip 10 Screw (4) 13 Nut (4)
4Bushing (2)
1
3
2
TN2415
4
5
6
8
4
9
1
10
3
11
12
13
7
5-18 4271491-Rev B
CHASSIS
5
Axle Shield and Front Splash Shield
Removal and Installation
See Figure 5-25.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
Figure 5-25
2. Remove three shield fasteners (2), and remove axle
shield (1).
3. Remove three panel fasteners (4), and remove front
splash shield (3).
Installation Notes
Install axle shield and front splash shield by reversing
the order of removal.
Use new fasteners (2 and 4) to secure the front
splash shield (3) and axle shield (1).
TN4526
~
2
4
3
1
CHASSIS
4271491-Rev B 5-19
5
Floorboard
Removal and Installation
See Figures 5-26 through 5-29.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove front fenders. (See “Front Fenders” on
page 5-15.)
3. Remove front cover. (See “Front Cover” on
page 7-31.)
4. Remove rear cover. (See “Rear Cover” on
page 7-31.)
5. Remove traction pedal position sensor. (See
“Traction Pedal Position Sensor” on page 4-178.)
6. Remove brake pedal assembly. (See “Brake Pedal
Assembly” on page 5-16.)
7. Remove axle shield and front splash shield. (See
“Axle Shield and Front Splash Shield” on page 5-18.)
Figure 5-26
8. Remove two screws (2), and remove fender support
(1) on each side of the floorboard.
Figure 5-27
9. Remove three screws (3) and washers (4).
Figure 5-28
10. Remove three screws (5), washers (6), and floor mat
(7).
TN4529
1
2
TN2677
3 4
TN2670
5 6
7
5-20 4271491-Rev B
CHASSIS
5
Figure 5-29
11. Remove four screws (6) and lock washers (7).
12. Remove floorboard (8).
Installation Note
Install floorboard by reversing the order of removal.
Front Wheel Hub
Removal and Installation
See Figure 5-30.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Remove front wheel. (See “Front Wheels” on
page 7-29.)
Figure 5-30
3. Remove cotter pin (2).
CAUTION
4. Loosen, but do not remove, castle nut (1).
5. Loosen wheel hub (3) from front axle assembly (4)
using a suitable puller.
6. Remove castle nut (1).
7. Remove wheel hub (3) from front axle assembly (4).
Installation Notes
Apply anti-seize compound to axle shaft splines.
Install front wheel hub by reversing the order of
removal.
Tighten castle nut (1) to 95–115 lb-ft (10.7–13.0
N·m).
TN2413
6 7
8
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.
Required Materials
Anti-Seize Compound
TN2812
TN2812
4
1
2
3
/