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Technical Repair Manual
Hydraulic Drive Models
600 Series Turfcat
700 Series Frontline
Technical Repair Manual
Hydraulic Drive Models
600 Series Turfcat
700 Series Frontline
!
WARNING: If incorrectly used this machine can cause sever injury. Those
who use and maintain this machine should be trained in its proper use,
warned of its dangers and should read the entire manual before attempting
to set up, operate, adjust or service the machine.
©2008, Jacobsen, A Textron Company. All rights reserved.
Litho in the U.S.A. 11/2008 Part Number 4171722 Rev A
SECTION 1
INTRODUCTION
1A General Information ........................................................................................................................................ 1
Contents................................................................................................................................................... 1
Index Numbers......................................................................................................................................... 1
Replacement Parts................................................................................................................................... 1
California Proposition 65 Warning............................................................................................................ 2
Specifications ........................................................................................................................................... 2
Serial Numbers ........................................................................................................................................ 4
General Cleaning ..................................................................................................................................... 4
Safety ....................................................................................................................................................... 4
Torque Values .......................................................................................................................................... 5
1
INTRODUCTION
1A-1
SECTION 1A. GENERAL INFORMATION
CONTENTS
This manual contains repair instructions for major trac-
tor components, attachments, and options. The Table
of Contents at the start of each section lists the con-
tents of that section. Sections are identified by tabs in
the right hand margin.
This manual is to be used in conjunction with the Oper-
ator’s Manual and Parts Catalog.
Normal maintenance, adjustment, and operating pro-
cedures are also covered in the Operator’s Manual and
are only included where appropriate in this Service and
Repair Manual.
Engine repair is not covered in this manual. Refer to
the appropriate engine manufacturer’s instructions for
engine service and repair.
This manual includes all removal, disassembly, inspec-
tion, repair, reassembly, installation, adjustment, and
testing procedures. If you, as the user of this machine,
do not consider yourself or your repair facilities capable
of a given procedure, please contact your Jacobsen
dealer or distributor.
Information, specifications, illustrations, and proce-
dures in this manual are based on information in effect
at the time this manual was published. Improvements
and product changes due to continual advancements
of the product design may cause changes to your prod-
uct that may not be included in this manual. Each man-
ual is reviewed and updated as required to include
changes and product improvements.
Read each section completely before proceeding with
specific repairs in that section. You will minimize errors
by understanding what you will be doing and how the
component relates to others in its system. Lists of
repair tools and materials for each section of the man-
ual are given at the start of that section.
The designations L.H. (left hand) and R.H. (right hand)
are used throughout this manual and refer to the oper-
ator’s left or right when sitting in the normal operating
position.
INDEX NUMBERS
Illustrations showing removal, disassembly, reassem-
bly, and illustration may have index numbers to call out
the sequence of procedures.
Where the sequence of procedures is not important or
self-evident (e.g. linkages, hoses, clamps, etc.) index
numbers are not included.
Repair procedures for items not subject to wear (e.g.
panels, brackets, frames) are not included in this man-
ual except for the general procedures given.
Exercise common sense during disassembly or reas-
sembly; remove only the items required to accomplish
the necessary repair or service.
REPLACEMENT PARTS
Use the appropriate Parts & Maintenance Manual
when ordering replacement parts. Follow the installa-
tion instructions shipped with service parts or kits.
When ordering parts, always give the serial number
and product number and description of the parts
needed.
To eliminate error and speed delivery:
1. Write your NAME and ADDRESS on your order
plainly.
2. Explain WHERE and HOW to make shipment.
3. Give the PRODUCT NUMBER, NAME, and
SERIAL NUMBER that is stamped on the NAME
and SERIAL PLATE of your product.
4. Order by QUANTITY DESIRED, the PART NUM-
BER, and the PART DESCRIPTION.
5. Send your order to or visit your nearest Jacobsen
dealer or distributor.
6. INSPECT ALL SHIPMENTS UPON RECEIPT. If
any parts are damaged or missing, file a claim
with the carrier before accepting.
7. Do not return material to your Jacobsen dealer or
distributor without a letter of explanation. Make a
list of all returned parts, show your name and
address, and include the letter and list with the
shipment. TRANSPORTATION CHARGES MUST
BE PREPAID.
1A
INTRODUCTION
1A-2
CALIFORNIA PROPOSITION 65
WARNING
SPECIFICATIONS
Product Information
An identification plate, like the one shown, listing the
serial number, is attached to the frame of the tractor
near the center lift arm mount (Figure 1A-2).
Always provide the serial number of the unit when
ordering replacement parts or requesting service infor-
mation.
Figure 1A-1. Serial Plate
Engine
Make/Model .............................D1105Eb Kubota diesel
Cylinders ..................................................................... 3
Displacement ............................ 68.5 cu. in. (1122.5 cc)
Cooling.................... Liquid, sealed, pressurized w/high
capacity water pump and 14.6in (370 mm) -7 blade fan
Air filter..............Donaldson dry type w/evacuator valve
Alternator .......................................................... 40 amp
Max rated horsepower ...... 26.0 (19.4 kW) @ 3000 rpm
Net intermittent governed rate HP
.............................................25 (18.7 kW) @ 3000 rpm
Torque .........................54 ft-lbs (73.2 Nm) @ 2200 rpm
High idle speed ..................................................... 3150
Low idle speed ...................................................... 1750
Fuel capacity....................................9 US gal (34 liters)
Hydraulic System
Capacity ...........................................6.5 gal (24.6 liters)
Fluid Type ........................................... Jac. 10 (10W30)
Cooling (type)..........................................Hyd. oil cooler
Filter micron rating ......10 micron suction filter w/gauge
Traction System
Drive.....Oil gear hydrostatic transmission to front Ross
wheel motors, parallel-series flow to Parker rear wheel
motors (4WD)
Forward speed ...........................0-10 mph (0-16.1 kph)
Reverse speed ...............................0-4 mph (0-6.4 kph)
Traction Pump max flow.............. 18.4 gpm (69.65 lpm)
System relief setting......................... 3625 psi (250 bar)
Deck System
Drive...........Hydraulic gear pump and motor w/ electro/
hydraulic control valve
Deck number & size ... (1) 63 in or 72 in side discharge,
60 in or 72 in rear discharge, 60 in or 72 in Envirodeck,
or 60 in Fine-cut Flail
Deck section pump flow ................... 13 gpm (49.8 lpm)
Deck section relief setting ............. 3200 psi (220.7 bar)
60 in rear discharge
Number of blades & size per deck ............................(3)
................ 0.25 in (6.4 mm) thick x 21 in (533 mm) long
Blade tip speed ...................... 12744 ft/min (4189 m/m)
Deck material thickness
.......................................11 gauge 0.1196 in (3.74 mm)
...............................7 gauge skirts 0.1875 in (4.76 mm)
Height of cut range..................1-4.75 in (25.4-121 mm)
63 in side discharge
Number of blades & size per deck ............................(3)
................ 0.25 in (6.4 mm) thick x 22 in (559 mm) long
Blade tip speed ................... 14399 ft/min (4388.8 m/m)
Deck material thickness
.......................................11 gauge 0.1196 in (3.74 mm)
...............................7 gauge skirts 0.1875 in (4.76 mm)
Height of cut range..................1-4.75 in (25.4-121 mm)
72 in side and rear discharge
Number of blades & size per deck ............................(3)
................ 0.25 in (6.4 mm) thick x 25 in (635 mm) long
Blade tip speed ...................... 14071 ft/min (4289 m/m)
Deck material thickness
.......................................11 gauge 0.1196 in (3.74 mm)
...............................7 gauge skirts 0.1875 in (4.76 mm)
Height of cut range..................1-4.75 in (25.4-121 mm)
72 in Envirodeck
Number of blades & size per deck ............................(3)
.......... 0.25 in (6.4 mm) thick x 24.9 in (632.5 mm) long
Blade tip speed ...................... 17540 ft/min (5346 m/m)
WARNING
Certain vehicle components contain or emit chemi-
cals known to the state of California to cause cancer
and birth defects or other reproductive harm.
!
CHARLOTTE, NC
YEAR OF
PRODUCTION:
MADE IN U.S.A.
®
A Textron Company
INTRODUCTION
1A-3
Deck material thickness .... 10 gauge 0.135 in (3.4 mm)
Height of cut range..................1-4.75 in (25.4-121 mm)
60 in Flail
Number of blades.................................................... 144
Blade speed ............................. 8042 ft/min (2451 m/m)
Deck material thickness .... 10 gauge 0.135 in (3.4 mm)
Height of cut range............................0-4 in (0-102 mm)
Lift System
Type ..........Hand operated single lever hydraulic circuit
Lift system flow................................ 4.5 gpm (17.0 lpm)
Lift system relief setting...................... 915 psi (63 bars)
Steering System
Type ....................... Hydrostatic steering to rear wheels
Steering system pump flow ................ 4.5 gpm (17 lpm)
Steering system relief setting ............. 915 psi (63 bars)
Tractor Specifications
Tire size - front ......................23 x 10.5 - 12:4 ply rating
...................................... (584 mm x 266 mm - 305 mm)
Tire size -rear ..........................18 x 18.5 - 8:4 ply rating
...................................... (457 mm x 216 mm - 203 mm)
Brakes - service .................... Dynamic braking through
traction circuit
Brakes - parking..............7 x 1.75 in (177.8 x 44.4 mm)
........................................................... Mechanical drum
Turning radius ................................. 12.0 in (304.8 mm)
Zero at inside wheel with optional traction-assist brake
on left and right wheel
Sound level rating at operator’s ear (w/72 in deck).......
........................................................................ 88.1 dBa
Production
60 in .................................. 2.8 acres per hour at 6 mph
72 in .................................. 3.5 acres per hour at 6 mph
..................................................... (80% of full capacity)
Dimensions
Length with longest deck ................ 122.12 in (310 cm)
Height (to top of hood) .........................44.5 in (113 cm)
Height (to top of ROPS) ......................... 82 in (208 cm)
Width (tractor) ........................................ 52 in (132 cm)
Transport width w/ widest deck ........... 85.5 in (217 cm)
Ground clearance ................................ 6.5 in (16.5 cm)
Weights
Tractor only
2WD ...................................................1440 lbs (653 kg)
4WD ...................................................1490 lbs (676 kg)
Decks
63 in side discharge .............................474 lbs (215 kg)
60 in rear discharge .............................390 lbs (177 kg)
72 in side discharge .............................492 lbs (223 kg)
72 in rear discharge .............................505 lbs (229 kg)
72 in Envirodeck...................................485 lbs (220 kg)
60 in Flail..............................................366 lbs (166 kg)
NOTE:
All pump flows and blade tip speeds are at high
idle engine speed and maximum volumetric effi-
ciency.
Accessories and Support Literature
Contact your area Jacobsen dealer for a complete list-
ing of accessories and attachments
Accessories
Arm Rest Kit (Fits Standard or Deluxe Seat
Exhaust Spark Arrestor (Required in California
Leaf Mulcher (For 72 in. Side Discharge Cutting Deck)
2-Post ROPS.
Seat, Standard or Deluxe Milsco
Shock Absorber Kit (For Standard Seat)
Tie-Down Brackets
Support Literature
Safety & Operation Manual
Parts & Maintenance Manual
Diesel Engine Parts Catalog
Operator Training Video
Service & Repair Manual
CAUTION
Use of other than Jacobsen authorized parts and
accessories may cause personal injury or damage to
the equipment and will void the warranty.
!
INTRODUCTION
1A-4
SERIAL NUMBERS
See Figure 1A-2 for location of tractor assembly serial
number.
Figure 1A-2. Serial Number Location
GENERAL CLEANING
Improper cleaning and lubrication of your machine
results in equipment failures. Before any repairs are
undertaken, thoroughly clean the exterior of the com-
ponent to be removed.
Use a clean surface to lay out parts being removed.
Keep lubricants clean and cover containers not being
used. Plug or cap all hydraulic lines and ports to
hydraulic components immediately after disconnecting.
SAFETY
Safety should always be the rule when working on or
with machinery. Always use safe practices and com-
mon sense when using hand or power tools. Use the
suggested procedures in this manual when working
with the tractor.
Throughout this manual signal words will be used to
highlight special procedures. The signal words and
their meanings are as follows:
Any task needing specialized special care when
performing a procedure.
Decals on the machine denote cautions, warnings, and
dangers. These cautions, warnings, and danger decals
must be on the machine at all times. If they become
worn, torn, or painted over, new decals should be
installed as shown in SECTION 14A. of this manual.
DANGER
Imminent hazards which will result in severe per-
sonal injury or death if precautions are not taken.
Serial No. Plate
On Right Side of Frame
!
WARNING
Hazards or unsafe practices which could result in
severe personal injury or death.
CAUTION
Hazards or unsafe practices which may result in per-
sonal injury, or product or property damage.
NOTICE
Indicates a potentially hazardous situation which,
if not avoided, MAY result in property damage. It
may also be used to alert against unsafe
practices.
CAUTION
Disconnect leads at the alternator before electric
welding is done on components in common ground
with the engine.
WARNING
This machine is equipped with an interlock system
intended to protect the operator and others from
injury by preventing the engine from starting, unless
the PTO switch is in the “OFF” position, traction
pedal is in the “Neutral” position and the brake is set.
The system also shuts off the engine if the operator
leaves the seat with the PTO switch in the “Cut”
position. In the interest of safe operating conditions,
this machine must never be operated with the inter-
lock relays or interlock system disconnected or mal-
functioning.
!
!
!
!
INTRODUCTION
1A-5
TORQUE VALUES
Torque values are given in the “Torque Specifications
Chart.” Special torque values are called out in illustra-
tions and text throughout this manual.
Torque Specifications – Standard
AMERICAN NATIONAL STANDARD FASTENERS
SIZE UNITS
GRADE 5 GRADE 8
Lubricated Dry Lubricated Dry
#6-32 in-lb (Nm) – 20 (2.3) – –
#8-32 in-lb (Nm) – 24 (2.7) – 30 (3.4)
#10-24 in-lb (Nm) – 35 (4.0) – 45 (5.1)
#10-32 in-lb (Nm) – 40 (4.5) – 50 (5.7)
#12-24 in-lb (Nm) – 50 (5.7) – 65 (7.3)
1/4-20 in-lb (Nm) 75 (8.4) 100 (11.3) 107 (12.1) 143 (16.1)
1/4-28 in-lb (Nm) 85 (9.6) 115 (13.0) 120 (13.5) 163 (18.4)
5/16-18 in-lb (Nm) 157 (17.7) 210 (23.7) 220 (24.8) 305 (34.4)
5/16-24 in-lb (Nm) 173 (19.5) 230 (26.0) 245 (27.6) 325 (36.7)
3/8-16 ft-lb (Nm) 23 (31.1) 31 (42.0) 32 (43.3) 44 (59.6)
3/8-24 ft-lb (Nm) 26 (35.2) 35 (47.4) 37 (50.1) 50 (67.8)
7/16-14 ft-lb (Nm) 37 (50.1) 50 (67.8) 53 (71.8) 70 (94.9)
7/16-20 ft-lb (Nm) 42 (56.9) 55 (74.6) 59 (80.0) 78 (105)
1/2-13 ft-lb (Nm) 57 (77.2) 75 (101) 80 (108) 107 (145)
1/2-20 ft-lb (Nm) 64 (86.7) 85 (115) 90 (122) 120 (162)
9/16-12 ft-lb (Nm) 82 (111) 109 (148) 115 (156) 154 (209)
9/16-18 ft-lb (Nm) 92 (124) 122 (165) 129 (174) 172 (233)
5/8-11 ft-lb (Nm) 113 (153) 151 (204) 159 (215) 211 (286)
5/8-18 ft-lb (Nm) 128 (173) 170 (230) 180 (244) 240 (325)
3/4-10 ft-lb (Nm) 200 (271) 266 (360) 282 (382) 376 (509)
3/4-16 ft-lb (Nm) 223 (302) 298 404 315 (427) 420 (569)
7/8-14 ft-lb (Nm) 355 (481) 473 (641) 500 (678) 668 (905)
INTRODUCTION
1A-6
Torque Specifications – Metric
METRIC FASTENERS
SIZE UNITS
Non
Critical
Fasteners
into
Aluminum
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry
M4 Nm
(in-lb)
––––––3.83
(34)
5.11
(45)
2.0
(18)
M5 Nm
(in-lb)
1.80
(16)
2.40
(21)
4.63
(41)
6.18
(54)
6.63
(59)
8.84
(78)
7.75
(68)
10.3
(910
4.0
(35)
M6 Nm
(in-lb)
3.05
(27)
4.07
(36)
7.87
(69)
10.5
(93)
11.3
(102)
15.0
(133)
13.2
(117)
17.6
(156)
6.8
(60)
M8 Nm
(in-lb)
7.41
(65)
9.98
(88)
19.1
(69)
25.5
(226)
27.3
(241)
36.5
(323)
32.0
(283)
42.6
(377)
17.0
(150)
M10 Nm
(ft-lb)
14.7
(11)
19.6
(14)
37.8
(29)
50.5
(37)
54.1
(40)
72.2
(53)
63.3
(46)
84.4
(62)
33.9
(25)
M12 Nm
(ft-lb)
25.6
(19)
34.1
(25)
66.0
(48)
88.0
(65)
94.5
(70)
125 (92) 110
(81)
147
(108)
61.0
(45)
M14 Nm
(ft-lb)
40.8
(30)
54.3
(40)
105
(77)
140
(103)
150
(110)
200
(147)
175
(129)
234
(172)
94.9
(70)
4.6 8.8 10.9 12.9
CONTROLS
--1
SECTION 2
CONTROLS
2A Service Tools, Materials, and Specifications................................................................................................... 1
Materials Required ................................................................................................................................... 1
Specifications ........................................................................................................................................... 1
2B Failure Analysis .............................................................................................................................................. 3
General .................................................................................................................................................... 3
2C Control Adjustments ....................................................................................................................................... 5
General .................................................................................................................................................... 5
Throttle ..................................................................................................................................................... 5
Neutral Switch .......................................................................................................................................... 6
Traction Pedal Neutral Adjustment........................................................................................................... 6
Maximum Transport Speed ...................................................................................................................... 7
Parking Brake........................................................................................................................................... 7
Brake Interlock Switch.............................................................................................................................. 8
2D Gauges and Instruments ................................................................................................................................ 9
Repair....................................................................................................................................................... 9
2
CONTROLS
-0
CONTROLS
2A-1
SECTION 2A. SERVICE TOOLS, MATERIALS, AND SPECIFICATIONS
MATERIALS REQUIRED
l
SPECIFICATIONS
Throttle
Engine low idle speed .................................... 1750 rpm
Engine high idle speed................................... 3150 rpm
Neutral Switch
Neutral switch ......................................Normally closed
Traction Pedal
Transport speed ............................. 10 mph (16.1 km/h)
Parking Brake
Brake pedal free play ...... 0.750 to 1.5 in (19 to 38 mm)
Tools required:
Standard automotive hand tools
Cleaning
materials:
Stoddard solvent or equivalent
Detergent and water
Lubricants:
Refer to Section 11
2A
CONTROLS
2A-2
CONTROLS
2B-3
SECTION 2B. FAILURE ANALYSIS
GENERAL
The following table lists common problems, probable
causes, and suggested remedies with section refer-
ences to detailed descriptions of remedial procedures.
PROBLEM PROBABLE CAUSE REMEDY
1. Engine does not turn over a. Not in neutral
b. Electrical fault
c. Neutral start switch not
adjusted or faulty
d. Dead battery
a. Check neutral position
b. See Electrical Failure Analy-
sis (Section 10B)
c. Adjust (Section 2C)
Check (Section 10G)
d. Charge battery or replace as
necessary
2. Engine speed does not
increase when throttle con-
trol is moved
a. Throttle control is not properly
adjusted
b. Throttle control is broken
a. Adjust (Section 2C)
b. Repair or replace
(Section 2C)
3. The unit “creeps” in either
direction when the treadle
pedal is not depressed
a. Traction pedal linkage out of
adjustment
b. Centering spring out of
adjustment
a. Adjust traction (Section 2C)
b. Adjust centering spring
4. Parking brake fails a. Brake not adjusted
b. Worn brake shoes
c. Damaged or broken linkage
a. Adjust brake (Section 2C)
b. Replace pads (Section 5C)
c. Repair as necessary
5. Mower deck does not lift or
lower properly as lever is
activated
a. Control valve leaking or
defective
b. System relief valve too low
c. Faulty lift cylinder
d. Faulty charge pump
a. Test valve (Section 8L)
Repair valve (Section 8I)
b. Adjust (Section 8L)
c. Test cylinder (Section 8L and
Section 8M)
d. Test pump (Section 8M)
6. Slow traction speed a. Engine rpm too low
b. Pedal linkage not adjusted
c. Parking brake not releasing
d. Faulty hydro
a. Adjust (Section 2C)
b. Adjust (Section 2C)
c. Adjust (Section 2C)
d. Test hydro pump
(Section 8M)
2B
CONTROLS
2B-4
CONTROLS
2C-5
SECTION 2C. CONTROL ADJUSTMENTS
GENERAL
Repair of controls is limited to adjustment of linkages
and cables, straightening of bent rods, or replacement.
Replace, do not adjust, worn or damaged components.
A qualified technician should perform adjustments. If
proper adjustment cannot be made, contact an autho-
rized Jacobsen dealer.
THROTTLE
Located to the right of the operator’s seat, the throttle
control is used to regulate engine rpm. Replace a worn
throttle cable as shown in Figure 2C-1.
Adjustment
Check throttle adjustment if engine runs below recom-
mended rpm with throttle lever in the high-speed posi-
tion.
NOTE:
Refer to the Engine Owner’s Manual supplied by
the engine manufacturer.
1. Shut down the engine and remove the ignition
key.
2. Unlatch the seat platform. Pivot the seat and seat
platform to the full upward position.
3. Loosen the throttle cable swivel clamp on the
injection pump.
4. Position the throttle lever in the high-speed posi-
tion with 0.0625 - 0.25 inch (2-6 mm) gap between
lever and panel.
5. Place the engine throttle lever against the max
speed screw.
6. Tighten the throttle cable swivel clamp on the
injection pump.
Figure 2C-1. Throttle Control Adjustment
WARNING
To prevent injury, lower implements to the ground,
disengage all drives, engage parking brake, stop
engine, and remove the key from the ignition switch
before making any adjustments or performing main-
tenance.
Make sure the tractor is parked on a solid and level
surface. Never work on a tractor that is supported
only by a jack. Always use jack stands.
If only the front or rear of the tractor is raised, place
chocks in front of and behind the wheels that are not
raised.
CAUTION
Be careful to prevent entrapment of the hands and
fingers between moving and fixed components of
the machine.
!
!
2C
CONTROLS
2C-6
NEUTRAL SWITCH
The neutral switch is located on the traction pedal and
is controlled by the pedal latch. The switch is normally
closed and should have continuity when the pedal latch
is released and open when the latch is pressed.
Figure 2C-2. Traction Pedal Linkage
The neutral switch can be adjusted by loosening the
mounting screws and sliding the switch into position
with the pedal latch. The switch should be extended
and the circuit closed with the traction pedal in neutral.
NOTE:
The neutral switch forms part of the interlock system
and senses when the traction pedal is in neutral. If the
interlock system fails to operate properly, check and
replace the switch before operating the tractor.
TRACTION PEDAL NEUTRAL
ADJUSTMENT
The traction pedal is designed to return to neutral when
the forward or reverse foot pedal is released. The trac-
tion pedal is centered with a centering spring linkage
(Figure 2C-3) located on the hydro arm. If the tractor
continues to creep after the traction pedal is released,
check the neutral adjustment and adjust the traction
pedal centering spring.
Neutral Adjustment
1. Disconnect the control cable swivel joint from the
traction pedal (Figure 2C-3).
Figure 2C-3. Traction Pedal Linkage
2. Loosen the jam nut on the ball joint of the center-
ing spring linkage located at the hydrostatic con-
trol arm (Figure 2C-4).
Figure 2C-4. Neutral Adjustment
3. Adjust the centering spring by turning the adjust-
ment nut on the front side of the linkage until the
neutral position is obtained.
Mounting Screws
Neutral Switch Pedal Latch
Traction Pedal Linkage
Ball Joint Traction Pump Linkage
Jam Nut
Adjustment Nut
Return
/