This manual provides detailed information and
procedures to safely repair and maintain the followin g:
Jacobsen Greens King™ IV riding greens mower
and associated accessory attachments
This manual is intended to introduce and guide the user
through the latest factory-approved troubleshooting and
repair techniques and practices.
Before you attempt to troubleshoot or make re p air s, you
must be familiar with the operation of this machine. Refer
to the operator’s manual and parts manual for specific
information on these topics.
THE INFORMATION CONTAINED IN THIS MANUAL IS
BASED ON MACHINES MANUFACTURED UP TO THE
TIME OF PUBLICATION. JACOBSEN RESERVES THE
RIGHT TO CHANGE ANY OF THIS INFORMATION
WITHOUT NOTICE.
California
Proposition 65 Warning
WARNING
!
Certain vehicle components contain or emit
chemicals known to the State of California to
cause cancer and birth defects or other
reproductive harm.
Trademark Acknowledgement
Jacobsen acknowledges the following trademarks for
company names or products mentioned within this
publication:
®
Lubriplate
Loctite
Corporation.
is a trademark of Fiske Brothers Refining Co.
®
and Permatex
®
are trademarks of Henkel
4247530-Rev A5
Litho In U.S.A. 1-2012
FOREWORD
How to Use This Manual
This manual is designed to provide multiple ways to
locate and access repair information.
Read each section in its entirety before beginning a
procedure. Proper understanding of m ach in e op er a tion
and components is the key to successful diagnostics and
repair.
Make use of special information features within this
manual in order to be better prepared to perform repairs.
Always follow manual procedures and safety guidelines.
Never take shortcuts.
Table of Contents
Major machine components or topics of interest are
separated into specific chapters. Each manual lists these
chapters in a main Table of Contents.
Chapter Table of Contents
Each chapter begins with a detailed table of contents
related to the specific machine component or system.
Use the chapter table of contents to find specific
component or procedural information.
Index
An alphabetical Index is located at the back of the
manual.
Use the Index to find specific components and related
procedures.
Quick Reference Specifications
A list of all machine specifications can be found in
Chapter 2 Specifications and General Information . This is
a list of all specifications from each chapter, combined
and listed in one place for easy reference.
Warnings and Cautions
Warning and Caution indicators are located throughout
the manual at specific points of interest. These notices
are given to prevent personal injury, death, and/or
equipment damage. Always heed these notices, and
practice common sense when performing an y
maintenance or repair procedure.
Notes
Special notes are given in order to draw attention to
detailed instructions. These notes are intended to give
further important information regarding the machine
and/or a step in a procedure.
Troubleshooting
Troubleshooting charts are provided in each chapter to
aid in the diagnostic process. Use these suggestions to
aid in identifying a potential mechanical or mach in e
adjustment problem.
Required Tools and Materials
Some procedures will require the use of specific tools
and/or materials. These tools and/or materials will be
listed for reference, prior to beginning a procedure.
Specifications
Near the beginning of each chapter is a specifications
listing. This listing contains any specifications contained
within the chapter.
Copyright 2011, Jacobsen, A Textron Company
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”
Safety is the most important element of any repair
procedure. Knowledge of the procedure to be performed
and safe work habits are essential to preventing death,
personal injury, or property damage. Use the following
statements as a common-sense guide to proper work
and tool-use habits.
1
Prepare for the Job
Preparation is essential to complete a proced u re in a
safe and efficient manner.
• Wear proper clothing. Loose or baggy clothing could
become tangled in moving parts.
• Use eye/face protection. Always use proper eye/face
protection to protect your eyes from flying de br is or
chemical splatters.
• Wear protective footwear. Wear sa fety shoes
(steel-toe) to protect your feet from falling objects.
• Use gloves when handling parts. Parts may have
sharp edges or may be hot.
• Remove jewelry prior to servicing electrical systems.
• Prepare proper tools and equipmen t. Always use th e
correct tool for the job. Improper or homemade tools
can cause injury or machine damage.
• Prepare needed parts and materials. Gather the
needed parts and materials before beginning the
procedure.
• Allow machine to cool. Many components can get ho t
during operation. Be sure to allow enough time for
components to cool before beginning service.
• Prepare proper work-space lighting. A well-lit work
area can make the job easier.
• Follow procedures and safety warnings. Service
procedures are written to be as safe and efficient as
possible. Never take shortcuts.
• Be prepared for emergencies. Accidents can
happen, even under the best conditions. Fire
extinguishers and first aid kits should be well
maintained and easily accessible.
Safety Notices
Throughout this manual, the following key safety words
will be used to alert the reader of potential hazards.
Become familiar with these words and their meaning.
Take all precautions to avoid the hazards described.
This safety alert symbol is used to
!
Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.
Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious
injury.
Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate
injury and property damage. It may also be used
to alert against unsafe practices.
alert you to potential hazards.
DANGER
!
WARNING
!
CAUTION
!
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.
Safety Label Locations
1-24247530-Rev A
Become familiar with machine safety labels and
locations. The following illustrations show safety label
locations on the machine.
See Figure 1-1.
SAFETY
9
1
4
2
2
7
3
6
5
10
8
4247530-Rev A1-3
1
2
2
7
TN3246, TN3247
Figure 1-1
1
SAFETY
1
4181865
2
3
4181863
4181862
4
5
4181861
6
1-44247530-Rev A
41 81864
4199140
SAFETY
7
1
8
4182520
L
WA
105
9
10
dB
4247530-Rev A1-5
SAFETY
Inspect Safety Labels
Safety labels are critical to the safe operation of the
mower. Inspect the mower for any damaged, missing, or
unreadable labels. Replace labels as needed before
placing the mower back in service.
Keep Work Area Clean
1
A clean, organized, well-lit work area is important to
promote safe working conditions.
• Keep floor clean of debris and clear of parts and
tools.
• Clean up any spilled fuel, oil, and/or chemicals
immediately.
• Store all air hoses and electrical cords properly when
not in use.
Keep Work Area Well Ventilated
WARNING
!
Never operate the engine without proper
ventilation; exhaust fumes can be fata l if inhaled.
Certain test and adjustment procedures require the
engine to be running. Be sure work area is well
ventilated; never run the engine in an enclosed area .
Park Mower Safely
See Figure 1-2.
WARNING
!
Before cleaning, adjusting, or repairing this
equipment, disengage all drives, engage park
brake, and stop engine to prevent injuries.
When performing maintenance other than
adjustments that require the engine to be
running, disconnect the battery negative cables
to prevent accidental starting and bodily injury.
1. Park the mower on a solid, level surface.
1
2
3
4
Use Proper Eye and Face
Protection
WARNING
!
Always use approved personal protection
equipment. Avoid workplace hazards by wearing
properly maintained, approved eye and face
protection. Failure to use appropriate protection
equipment may result in death or serious injury.
Always wear eye protection while in a shop environment.
• Safety Glasses: Safety glasses offer a minimum level
of protection from flying debris.
• Face Shields: Face shields are often used along with
safety glasses to offer a higher level of protection
when sparks and flying debris are present.
• Vented Goggles: Goggles offer side protection n ot
offered by safety glasses alone.
• Unvented Goggles: Unvented goggles offer
protection from chemical splashes and vapors.
TN3248
Figure 1-2
2. Disengage the cutting units by returning the reel
control levers (1) to the neutral position.
3. Lower the cutting units by using the lower/lift pedal
(4).
4. Engage park brake lever (2) and rotate key switch (3)
fully counterclockwise to the off position.
5. Remove key from key switch.
1-64247530-Rev A
SAFETY
Use Lifting Equipment Safely
WARNING
!
Always check the lifting capacity and condition of
hoists, slings, cables, or chains before use.
Using underrated or worn lifting components can
result in death or serious injury.
• Always use a lifting device with a lifting capacity
greater than the weight of the item being lifted.
• Secure the load to the lifting device using cables,
chains, or slings rated to handle the load being lif ted.
Fasteners being used to connect lifting device s m ust
be strong enough to handle the load. Also be sure
the mounting point of load is strong enough to hand le
the load.
• When using a lifting device, always connect the load
so it is balanced.
• Always use a lifting device on a hard, level surface.
• Lower the lifting device to the lowest point before
moving. Move the load slowly.
• Always support the load as soon as possible; never
leave a load suspended in mid-air.
Support Machine Securely
WARNING
!
Use Compressed Air and Air
Tools Safely
WARNING
!
Always wear approved eye and ear protection
while using compressed air. Misuse of
compressed air could result in death or serious
injury.
• When using air nozzles, air pressure should
not exceed 30 psi (206.8 kPa).
• Never direct air nozzles or tools at a person.
• Never point air nozzles directly at skin.
• Compressed air is a useful tool when used in a safe
manner.
• Always use eye and ear protection while using
compressed air and air tools.
• When using air tools, do not exceed the air pressure
rating for the tool.
• When using an impact wrench, always use approved
impact sockets. Never use standard sockets on an
impact wrench.
• Disconnect the air supply before changing air tool
attachments.
• Never point air nozzles or air tools at another person.
• Always maintain air tools properly.
1
• 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.
4247530-Rev A1-7
SAFETY
Service Tires Safely
WARNING
!
An inflated tire contains explosive force. Use care
when handling wheels and tires.
• Always wear safety glasses or goggles.
1
• Use proper lifting methods when worki ng with wheels
and tires.
• When working on an inflated tire, never position
yourself directly over the work area.
• When dismounting or mounting tires, use a wheel
holder or tire machine. Use proper tire mounti ng tools
and equipment. Never use screwdrivers or makeshift
tools to force a tire on or off a wheel.
• Be sure tire irons and mounting tools are f ree of
grease and oil. Grip them firmly.
• Inspect wheel parts for rust, damage, or distortion.
Never use wheels that are out-of-round, rusted, or
cracked.
• Never hammer on wheels with a steel hammer. Use
rubber-covered hammers.
• When inflating tires, always use an inflation cage.
Always stand away from the valve stem.
• Use accurate, tested inflation gauges to set air
pressures.
Handle Fuel Safely
Handle fuel with care—it is highly flammable.
WARNING
!
• Never remove the fuel cap from the fuel tank,
or add fuel, when the engine is running or
while the engine is hot.
• Do not smoke when handling fuel. Never fill
or drain the fuel tank indoors.
• Do not spill fuel. Clean spilled fuel
immediately.
• Never handle or store fuel containers near an
open flame or any device that may create
sparks and ignite the fuel or fuel vapors.
• Be sure to reinstall and tighten fuel cap
securely.
• Use an approved container; the sp out must fit
inside the fuel filler neck. Avoid using cans
and funnels to transfer fuel.
Store fuel according to local, state, or fede ral ord ina nces
and recommendations from your fuel supplier.
Never overfill or allow the tank to become empty.
Use clean, fresh fuel.
Do not fill above the fuel filler neck.
Store Volatile and Hazardous
Materials Safely
Store volatile materials (gasoline, diesel fuel, oil, etc.) in
approved containers that are clearly marked. Containers
should be stored in an approved safety cabinet away
from possible sources of ignition. Storage areas and
cabinets should be well ventilated to prevent t he possible
build-up of fumes.
1-84247530-Rev A
SAFETY
Handle Chemical Products
Safely
WARNING
!
Exposure to chemical products could result in
serious injury. Handle chemical products with
care. Refer to the chemical manufacturer’s
Material Safety Data Sheet (MSDS) for
information regarding health hazards, safe
handling, and emergency response procedures.
Routine service often requires the use of various
chemical products, including lubricants and cleaning
solutions. Many of these chemicals are flammable and
can pose health risks if not handled properly.
• Never mix chemicals. Mixing chemicals can produce
toxic or explosive results.
• Follow the manufacture’s recommendations for safe
usage and handling of the product.
• Various materials may pose a health hazard if used
incorrectly. A Material Safety Data Sheet (MSDS)
contains important information regarding proper
handling and health hazards, as well as emer gency
response procedures. Contact the chemical
manufacturer to obtain an MSDS for the chemical
product.
Service Hydraulic System Safely
WARNING
!
The hydraulic system is under pressure , and the
oil may be hot!
• Always allow the machine to cool completely
before performing service.
• Always relieve pressure in the hydraulic
system before performing service.
• Always use appropriate safety equipment a nd
clothing to protect exposed skin and eyes
from high-pressure oil.
• Tighten all connections to proper
specifications before applyin g p ressure.
• Never use bare hands to check for leaks! Oi l
under pressure can penetrate the skin, and
can cause gangrene within a few hours if not
properly removed. Use a piece of cardboard
to check for leaks.
Failure to follow appropriate safety precautions
may result in death or serious injury.
Always dispose of used hydraulic oil properly. (See
“Dispose of Waste Materials Safely” on page 1-10.)
Service Cooling System Safely
1
WARNING
!
Engine coolant is hot and under pressure! Allow
the cooling system to cool completely before
performing service.
Rotate the filler cap 1/2-turn counterclockwise
and allow pressure to vent before removing filler
cap.
Failure to follow appropriate safety precautions
may result in death or serious injury.
WARNING
!
Contact with anti-freeze can damage your skin.
Use gloves when working with anti-freeze. If you
come in contact with anti-freeze, wash it off
immediately.
Always dispose of used engine coolant properly. (See
“Dispose of Waste Materials Safely” on page 1-10.)
4247530-Rev A1-9
SAFETY
Service Electrical Components
Safely
WARNING
!
Always disconnect the negative terminal first and
positive terminal last. Connect positive terminal
1
first and negative terminal last. Use care when
testing live circuits to prevent arcing. Arcing
could result in death or serious injury.
• Disconnect the battery negative (–) cable before
removing or installing electrical components. Always
connect the battery negative (–) cable last.
• Certain test and adjustment procedures must be
performed with the battery connected. Use care to
prevent arcing when working on live circuits or
components. Arcing can cause component damage
and could ignite flammable materials.
Dispose of Waste Materials
Safely
Routine service can produce waste products such as
used oil, coolant, grease, and used batteries.
If not handled properly, these materia ls can pose a threat
to the environment.
Collect fluids in well-marked, approved stora ge
containers. Some waste fluids can react with ce rta i n
types of plastics. Make sure the fluid to be stored is
compatible with the storage container. Ne ver us e food or
beverage containers to store waste fluids.
IMPORTANT
Never dispose of waste fluids by pouring on the
ground, down sewer drains, or into any body of
water.
• Dispose of waste fluids properly at approved local
recycling centers. If recycling facilities are not
available, contact your local community for the
correct disposal procedure for waste fluids.
• Dispose of old batteries properly. Battery electrolyte
contains sulfuric acid and other hazardous materials.
Never place an old battery in the trash. Batteries
must be disposed of in a manner consistent with EPA
and/or local regulations.
A machine emission control information label (1) lists the
engine model and family along with other specifications.
The serial number plate (2), which includes the machine
model number and weight, attaches to the rear frame of
the mower near the steering yoke. Always provide the
serial number of the machine when order ing replacement
parts or requesting service information.
Engine Serial Number (Diesel)
See Figure 2-3.
1
2
TN3244
Figure 2-3
The engine serial number plate (1) is attached to the top
of the rocker arm cover (2). The plate also includes the
engine model number and the engine code number.
1
TN3245, TN3243
Figure 2-2
2
2-24247530-Rev A
Engine Identification Number
(Gasoline)
See Figure 2-4.
1
SPECIFICATIONS AND GENERAL INFORMATION
2
XXXXXX XXXX-XX XXXXXXXX
23
Figure 2-4
The engine identification number plate (1) is located on
the side of the engine. It identifies the engine model (2),
type (3), and code number (4).
4
TN3566
Optional Machine Accessories
This manual is structured to cover all basic machine
components and repair. The addition of accessories can
affect certain troubleshooting, adjustment, and repair
procedures.
4247530-Rev A2-3
SPECIFICATIONS AND GENERAL INFORMATION
Component Location
See Figures 2-5 and 2-6.
CAUTION
!
Become familiar with operator controls, machine
components, and correct operating procedures
before beginning repair procedures.
2
1
10
9
8
1Seat6Right Cutting Unit
2Steering Wheel7Center Cutting Unit
3Instrument Panel8Hydraulic Pump
4Brake Pedal9Battery
5Traction Pedal10 Hydraulic Oil Tank
Figure 2-5: Component Location—Right Side
2
3
4
5
6
7
TN3247
2-44247530-Rev A
SPECIFICATIONS AND GENERAL INFORMATION
1
3
2
2
4
10
5
9
1OPS6Muffler
2Air Filter Housing7Radiator
3Literature Pouch8Front Wheel Motor (2)
4Fuel Tank9Left Cutting Unit
5Steering Axle10Mow/Lift Pedal
Number of Cylinders2
Displacement
Bore x Stroke
Power Output
Cooling SystemAir Cooled
Speed Range1200–3600 rpm
Lubrication Capacity
Alternator12 volt, 16 amp; Key Start
Dry Weight
Rating 85)
Number of Cylinders2
Displacement
Bore x Stroke
Power Output
Cooling SystemAir Cooled
Speed Range1200–3600 rpm
Lubrication Capacity
Alternator12 volt, 16 amp; Key Start
Dry Weight
cu in. (cc)34.8 (570)
in. (mm)2.83 x 2.75 (72 x 70)
hp (kW)18 (13.4)@3600 rpm
pt (L)3.5 (1.6)
lb (kg)84 (38)
Engine
Repair Specification
2
Muffler Mounting Nut Torque
(Diesel Model)
Engine Isolation Mount Torque (Gasolin e)
lb-ft (N·m)7.2–8.3 (9.8–11.3)
lb-ft (N·m)19.6–21.7 (27–29)
4247530-Rev A2-7
SPECIFICATIONS AND GENERAL INFORMATION
Electrical
Test and Adjustment Specifications
Resistance Across Fuel Shutoff Pull-In Coil at 68° Fohm0.5 ± 10%
Resistance Across Fuel Shutoff Hold-In Coil at 68° F
Resistance Across Carb Solenoid Coil at 68° F
Backlap Valve—Fitting Torquelb-ft (N·m)25 (34)
Load Control Valve—Fitting Torque
Control Valve—Section 6 Ports “A” and “B” Fitting
Torque
Control Valve—Section 6 Port “P1” Fitting Torque
Control Valve—Section 5 Port “P2” Fitting Torque
Control Valve—Section 4 Port “P3” Fitting Torque
Control Valve—Sections 3–5 Ports “A” and “B” Fitting
Torque
Control Valve—Section 2 Ports “A” and “B” Fitting
Torque
Control Valve—Section 1 Port “P4” Fitting Torque
Control Valve—Port “T1” Fitting Torque
Rear Lift Cylinder Hose and Fitting Torque
Front Lift Cylinder Hose and Fitting Torque
Measurement
Front Lift Cylinder—Cam Roller-to-Lift Cam
in. (mm)0.44–0.56 (11.1–14.2)
Measurement
Reel-to Bedknife Gap
Reel Bearing Pre-Load
Bedknife Front Face Height
Bedknife Front Face Angle
Bedknife Top Face Angle (rear relief)
Reel Blade Relief Angle
in. (mm)0.001–0.003 (0.025–0.076)
in. (mm)0.040 (1.27)
in. (mm)0.060 (1.5)
degrees5
degrees8–10
degrees45
Repair Specifications
Reel Motor Port Fittings Torquelb-ft (N·m)60 (81)
Front Reel Motor Hose (5) Torque (See page 8-32)
Front Reel Motor Hose (9) Torque (See page 8-32)
Center Reel Motor Hose (5) Torque (See page 8-32)
Center Reel Motor Hose (9) Torque (See page 8-32)
Reel Motor—Rear Cover-to-Body Retaining Screw
62305 (16 HP Gasoline): 1234 (560)
62306 (18 HP Gasoline): 1239 (562)
in. (mm)62 (1574)
in. (mm)Mow: 70 (1778)
Transport: 68 (1727)
in. (mm)78 (1981)
in. (mm)99.5 (2526)
4247530-Rev A2-13
SPECIFICATIONS AND GENERAL INFORMATION
Standard Torque Values
NOTICE
All torque values included in these charts are
approximate and are for reference only. Us e of
these torque values is at your sole ris k. Jacobsen
is not responsible for any loss, claim, or damage
arising from the use of these charts.
Extreme caution should always be used when
using any torque value.
Hold the fixed portion of the hose coupling with one
wrench; use a second wrench to tighten or loosen the
hose nut. This will avoid damaging the fitting seal. When
tightening a hose, do not permit the hose to twist; hold
the hose in a normal straight position.
When installing hoses, place fittings at angles to avoid
contact with fixed parts when turning. Make sure hoses
are assembled to proper “A” and “B” ports on
components.
Number of Cylinders2
Displacement
Bore x Stroke
Power Output
Cooling SystemAir Cooled
Speed Range1200–3600 rpm
Lubrication Capacity
Alternator12 volt, 16 amp; Key Start
Dry Weight
1Air Filter Assembly2Fuel Filter3Engine Oil Fill Cap4Engine Oil Dipstick5Muffler
Figure 3-4: Component Location—Left Side
TN3554
4247530-Rev A3-7
ENGINE
Checks and Adjustments
Throttle Cable Adjustment
See Figures 3-5 and 3-6.
NOTE
Diesel engine is shown; procedure for gasoline engin e is
similar.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
1
3
3
5. With throttle lever in the slowest position and engine
throttle lever in the fully closed position, tighte n
throttle cable clamp nut (3).
6. Operate the throttle control lever fully in both
directions and ensure that the throttle contro l wire
does not buckle, kink, or stretch when the engine
throttle lever hits the stops in the low idle and full
throttle positions. Readjust throttle cable if
necessary.
Purging the Fuel System (Diesel)
See Figures 3-7 through 3-9.
CAUTION
!
2
Do not purge fuel system when engine is hot.
NOTE
The fuel system will need to be purged of air whenever
the fuel filter or fuel lines are removed, the fuel tank is
completely emptied, or the engine has not been used for
an extended time.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
TN3323
Figure 3-5
2. Fully loosen throttle cable clamp nut (3).
3. Move engine throttle lever (2) unt il it ju st reac hes the
fully closed position.
4
5
6
Figure 3-6
4. With engine throttle lever in the fully closed position,
place throttle control lever (4) fully in the slowest
position against throttle bracket (5). Relocate throttle
control wire (6) to alternate mounting hole (7) if
necessary to maintain lever positions.
7
TN4292
NOTE
Be sure the fuel tank is filled with clean, fresh diesel fuel
before performing a purge of the fu el system.
1
2
TN3317
Figure 3-7
2. Open fuel valve (2) and loosen air vent screw (1) at
the top of the filter by turning it co unterclockwise two
turns. Place a suitable container under the filter to
catch fuel that will flow from the screw hole.
3-84247530-Rev A
ENGINE
3. When bubbles no longer appear in fuel coming o ut of
the air vent screw hole, tighten the air vent screw.
3
TN3323
Figure 3-8
4. Open air vent plug (3) at the top of the fuel injection
pump.
7. When the fuel system has been purged and the
engine is running, listen to the engine. If the en gine is
misfiring, repeat steps 4 through 6.
3
4
TN3322
Figure 3-9
WARNING
!
The engine may start during this process. Be
careful of injury due to moving components. If
the engine starts, continue purging the fuel
system.
5. Place throttle control lever (4) in the slowest posit ion,
and crank engine over for approximately 10 seconds.
6. Close air vent plug when bubbles no longer appear in
the fuel flow and turn the ignition switch to the off
position.
4247530-Rev A3-9
ENGINE
Repair—Model 62304 (Diesel)
Fan Belt (Diesel)
Removal
See Figures 3-10 and 3-11.
CAUTION
!
Use extreme care when working near the muff ler.
Do not attempt to service when the engine is hot .
Serious personal injury can occur.
NOTE
Inspect and adjust the new engine belt after the first 50
hours of operation. Check and adjust annually thereafter.
3
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2
1
5
4
Figure 3-11
3. Remove fan belt (1) from the alternator (3), coolant
pump (5), and crankshaft pulley (4).
3
1
TN1113
Installation
1. Install fan belt by reversing the order of removal.
2. Adjust belt tension by loosening alternator mounting
screws (2) and pulling the alternator (3) against the
belt (1) until proper tension is achieved.
3. Measure belt tension at the midpoint between
pulleys. Adjust fan belt to 0.28–0.35 in.
3
(7–9 mm) deflection with a tension of 22 lb (98 N).
2
TN3325
Figure 3-10
2. Loosen screws (2) and push the alternator (3) toward
the engine to loosen the fan belt (1).
NOTE
See the engine manufacturer’s manual for further
information.
3-104247530-Rev A
Air Filter Assembly (Diesel)
Removal and Installation
See Figures 3-12 and 3-13.
CAUTION
!
• Do not open the air filter assembly for
inspection or cleaning. Unnecessary removal
of the air filter increases the risk of injecting
dust and other impurities into the engine.
• Do not remove air filter with engine running.
NOTES
• The air filter on this engine is a dry type; never apply
oil to it.
• The dust cap should be removed and cleaned daily
in dusty conditions.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
ENGINE
4
Figure 3-13
4. Slide air filter (4) out of the assembly.
Installation Note
Install air filter assembly by reversing the order of
removal.
TN3329
3
2
1
3
1
TN3328
Figure 3-12
NOTE
To ensure correct installation, note the orientation of the
air inlet (3) before removing the air filter dust cap (2).
2. Release retaining clips (1) and remove the air filter
dust cap (2).
3. Using damp, lint-free cloths, thoroughly clean the
inside of the dust cap.
Throttle Cable (Diesel)
Removal and Installation
See Figures 3-14 and 3-15.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
1
2
8
456
Figure 3-14
7
3
TN3330
4247530-Rev A3-11
2. Remove nut (3) from throttle linkage screw (2).
3. Remove nut (4), lock washer (5), flat washer (6), and
screw (7) from linkage bracket (8).
4. Remove throttle cable (1) from throttle linkage screw
(2).
ENGINE
1
2
6
1
9
3
Figure 3-15
5. Remove other end of throttle cable (1) from throttle
lever bracket (9).
Installation Notes
• Install throttle cable by reversing the order of
removal.
• Adjust throttle cable as needed. (See “Thro ttle Cable
Adjustment” on page 3-8.)
Oil Fill Assembly (Diesel)
Removal and Installation
See Figures 3-16 and 3-17.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
TN3331
4
3
5
TN3342
Figure 3-16
2. Remove oil fill cap (1) from the oil fill assembly.
3. Loosen hose clamp (2) from the oil fill hose (4).
4. Remove two nuts (5) and remove the oil fill bracket
(6).
5. Remove hose clamp (3) and remove oil fill hose (4).
7
CAUTION
!
Care must be taken not to drop anything into the
oil fill opening. Always cover the oil fill opening.
Leaving an opening uncovered may allow foreign
matter to fall into the engine; and cause severe
damage to the engine.
3-124247530-Rev A
TN2687
Figure 3-17
6. Unscrew and remove oil fill adapter (7) from the
engine.
Installation Note
Install oil fill assembly by reversing the order of removal.
Muffler (Diesel)
Removal and Installation
See Figures 3-18 through 3-20.
CAUTION
!
Do not attempt to service the exhaust system
when the engine is hot. Serious personal injury
can occur.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
567
567
4
ENGINE
15141316
17
18
19 20 21
TN3345
Figure 3-19
6. Remove two nuts (13), lock nuts (14), flat washers
(15), and screws (16) from heat shield (17).
7. Remove screw (19), lock washer (20), and flat
washer (21), and remove heat shields (17 and 18).
3
321
9 10 11
8
12
TN3344
Figure 3-18
3. Remove nut (1), flat washer (2), and screw (3) from
the muffler bracket (12).
4. Remove screw (9), lock washer (10), and flat washer
(11) from the muffler.
5. Remove two screws (5), two lock washers (6), and
two flat washers (7), and remove heat sh ields (4 and
8).
22
23 24
23
25
Figure 3-20
8. Remove four nuts (23) and four lock nuts (24), and
remove muffler (25) from exhaust manifold (22).
9. Inspect the exhaust system for cracks, holes, and
distortion. Replace exhaust gasket.
Installation Notes
• Install muffler by reversing the order of removal.
• Install new gasket during installation.
• Tighten nuts (23) to 7.2–8.3 lb-ft (9.8– 11.3 N·m).
24
TN3346
4247530-Rev A3-13
ENGINE
Coolant Recovery Bottle (Diesel)
Removal and Installation
See Figures 3-21 and 3-22.
CAUTION
!
Do not attempt to service any part of the coolant
system when the engine is hot. Serious personal
injury can occur.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
1
3
4. Disconnect hoses (3 and 6) from coolant recovery
bottle (7).
5. Remove two nuts (4) and two lock washers (5), and
remove the coolant recovery bottle (7).
Installation Note
Install coolant recovery bottle by reversing the order of
removal.
Thermostat (Diesel)
Removal and Installation
See Figures 3-23 through 3-25.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
WARNING
!
Never remove the radiator cap when the coolant
is hot. The engine must be shut down and cooled
before the radiator cap is removed. Very hot
coolant will be sprayed from the radiator if the
cap is loosened before the engine has cooled.
Serious personal injury can occur.
TN3347
Figure 3-21
2. Remove the radiator cover (1).
2
6
7
Figure 3-22
3. Remove hose clamp (2) from recovery hose (3).
3
45
TN3352
1
TN3356
Figure 3-23
3. Place a suitable clean container, at least 1 gal (3.8 L)
capacity, under the radiator.
4. Open petcock (1) located on bottom of radiator,
remove radiator cap, and drain coolant.
3-144247530-Rev A
ENGINE
2
45
Figure 3-24
5. Loosen hose clamp (2) and remove hose (3).
6. Remove two screws (4) and lock washers (5).
6
7
3
TN3354
Radiator (Diesel)
Removal
See Figures 3-26 through 3-29.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
WARNING
!
Never remove the radiator cap when the coolant
is hot. The engine must be shut down and cooled
before the radiator cap is removed. Very hot
coolant will be sprayed from the radiator if the
cap is loosened before the engine has cooled.
Serious personal injury can occur.
3. Place a suitable clean container, at least 1 gal (3.8 L)
capacity, under the radiator.
4. Open petcock located on bottom of radiator, remove
radiator cap, and drain coolant.
NOTE
Label all hoses before removing to ensure correct
installation.
3
8
TN3354
Figure 3-25
7. Remove thermostat housing (6), gasket (8), and
thermostat (7).
Installation Notes
• Install thermostat by reversing the order of removal.
• Clean the gasket surface prior to assembly.
• Use a new gasket during installation.
• Use a new cable tie to secure wire harness.
• Fill the radiator with clean water and ethylene glycol
based antifreeze mixed for the coldest ambient
temperature.
1
TN3347
Figure 3-26
5. Remove the radiator cover (1).
4247530-Rev A3-15
ENGINE
2
9
3
6. Remove two screws (2), two lock washers (3), and
two flat washers (4), and remove top radiator cover
bracket (9).
7. Remove two screws (5), two lock washers (6), and
two flat washers (7), and remove lower radiator cover
bracket (8).
10
Figure 3-27
11
12
13 14 15 16
3
4
586
5
7
TN3371
26 27 28
29
5
Figure 3-29
13. Remove four screws (26), lock washers (27), and flat
washers (18), and move fan shroud (29) toward
engine enough to clear the radiator (5) .
14. Remove radiator (5).
26 27 28
TN3376
Installation
1. With the lower radiator hose removed from radiator,
flush the inside of the radiator with fresh water.
2. Install radiator by reversing the order of removal.
3. Fill the radiator with clean water and ethylene glycol
based antifreeze mixed for the coldest ambient
temperature.
4. Install radiator cap and start the engine following the
instructions in the “Safety and Operation Manual.”
23
18
19 20 21 22
24 25
TN3372
Figure 3-28
8. Remove hose clamp (11) and recovery hose (10).
9. Remove hose clamp (18) and upper radiator hose
(12).
10. Remove hose clamp (24) and lower radiator hose
(25).
11. Remove two screws (19), lock washers (20), flat
washers (21), and nuts (22), and remove bracket
(23).
12. Remove two screws (13), lock washers (14), flat
washers (15), and nuts (16), and remove bracket
(17).
17
CAUTION
!
Allow the engine coolant to completely cool
before removing the radiator cap. Hot coolant
sprayed from the cap can cause serious personal
injury.
5. When the engine reaches normal operating
temperature, check and fill the coolant reservoir to
the hot full level.
3-164247530-Rev A
ENGINE
Fuel Filter (Diesel)
Removal and Installation
See Figure 3-30.
CAUTION
!
Diesel fuel is highly flammable. Handle wit h care.
Use an approved container with a spout that will
fit inside the fuel filler neck. Avo id using
unapproved containers to transport fuel. Keep all
fuel containers clean and closed when not in use.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely before servicing.
1
2
CAUTION
!
Dispose of fuel properly. Contact the local
environmental department for instructions on
disposing of unwanted fuel products.
Installation Notes
• Clean the inside and outside of filter head (2).
• Lightly lubricate O-rings (6 and 7) with clean oil.
• Install fuel filter by reversing the order of removal.
• Tighten cup retaining nut (3) hand tight.
• Open fuel shutoff valve (1).
• Purge air from the fuel system after installing t he new
filter. (See “Purging the Fuel System (Diesel)” on
page 3-8.) See the engine manufacturer’s manual for
further instructions.
3
3
7
6
Figure 3-30
3. Turn the fuel shutoff lever (1) to the horizontal (off)
position.
4. Thoroughly clean cup (4) and area surrounding the
fuel filter.
5. Turn cup retaining nut (3) counterclockwise to
remove it.
6. Remove cup (4) and filter element (5). Drain excess
fuel into an appropriate container.
7. Remove O-rings (6 and 7).
4
5
TN3317
4247530-Rev A3-17
ENGINE
Fuel Pump (Diesel)
Removal and Installation
See Figure 3-31.
CAUTION
!
Diesel fuel is highly flammable. Handle wit h care.
Use an approved container with a spout that will
fit inside the fuel filler neck. Avoid using
unapproved containers to transport fuel. Keep a ll
fuel containers clean and closed when not in use.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
3. Turn the fuel shutoff valve clockwise until valve
3
bottoms lightly. Valve is located on the fuel filter.
2
1
Engine (Diesel)
Removal and Installation
See Figures 3-32 through 3-36.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely before
attempting to service the engine.
3. Tag and disconnect the negative (–) battery cable.
4. Remove fuel tank. (See “Fuel Tank (Diesel)” on
page 9-7.)
5. Remove fuel tank support pan. (See “Fuel Tank
Support Pan” on page 9-8.)
6. Remove muffler. (See “Muffler (Diesel)” on
page 3-13.)
7. Remove radiator. (See “Radiator (Diesel)” on
page 3-15.)
8. Remove air filter assembly. (See “Air Filter Assembly
3
4
(Diesel)” on page 3-11.)
NOTE
Label all wires before disconnecting to ensure correct
installation.
9. Tag and disconnect the wiring harness at the engine,
engine temperature sensor, alternator, fuel shutoff
solenoid, starter, engine oil pressure switch,and
glow plug.
5
5
6
TN3377
Figure 3-31
4. Loosen fuel hose clamps (2 and 4).
5. Disconnect fuel hoses (1 and 3) from fuel pump (6).
Use a suitable container to catch the fuel that will
flow from the fuel hoses. Cap the hoses.
6. Remove screws (5).
7. Remove fuel pump (6).
Installation Notes
• Install fuel pump by reversing the order of removal.
• Inspect the fuel pump gasket for any damage and
replace if necessary.
1
2
4
3
TN3390
Figure 3-32
10. Disconnect the fuel shut-off solenoid (4) and throttle
cable (3) at the speed control plate (2), located next
to the fuel injection pump (1).
3-184247530-Rev A
ENGINE
5
14
15
16
17
6
16 17
TN3377
Figure 3-33
11. Loosen hose clamp (6) and remove fuel line (5).
987
13
10
12
Figure 3-34
12. Remove gear pump (12). (See “Gear Pump” on
page 5-31.)
13. Remove anti-sway spring (11) from the center cutting
unit.
14. Remove nut (7), lock washer (8), screw (9), and plate
(10) from engine isolation mount (13).
11
TN3394
TN3395
Figure 3-35
15. Remove two screws (16) and washers (17), and
remove fuel shutoff (14) and fuel shut off bracke t (15).
WARNING
!
Prevent personal injury. Use a properly rated
lifting device. Always be sure the load is
balanced before lifting.
18 19
23
20 21
22
TN3398
Figure 3-36
3
4247530-Rev A3-19
16. Using a suitable engine hoist, support the engine and
remove nut (20), lock washer (21), and screw (22)
from engine isolation mount (23).
17. Remove two screws (18) and flat washers (19)
securing the engine mount to the frame.
18. Check for any connected wires and components, and
carefully remove the engine and engine mounts from
the machine.
ENGINE
19. Plac e th e en gin e on a suit ab le sta n d or workbench
that will support the full weight in a safe manner while
preventing damage to the engine.
NOTE
If the engine is being replaced, some components must
be removed and installed on the new engine. Refer to
“Parts and Maintenance Manual” for additional
information and illustrations.
Installation Notes
• Inspect engine isolation mounts and replace if
necessary.
• Install the engine by reversing the order of removal.
• If necessary, remove components from the engine
and install the components on the new engine.
3
• Use new gaskets when installing the exhaust
system.
• Use new cable ties to secure wire connectors and
wire harnesses.
• Apply dielectric grease (Jacobsen PN 365422) to any
wire connectors disconnected.
• Fill the radiator with clean water and ethylene glycol
based antifreeze mixed for the coldest ambient
temperature.
• Replace the engine oil filter and fill engine with oil.
• Purge air from the fuel system. (See “Purging the
Fuel System (Diesel)” on page 3-8.)
Engine Service (Diesel)
Repair—Models 62305 and 62306
(Gasoline)
Air Filter Assembly (Gasoline)
Removal and Installation
See Figure 3-37.
CAUTION
!
Do not remove air filter with engine running.
NOTE
The air filter cartridge on this engine is a dry type; never
apply oil to it.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
1
3
2
1
A separate engine manual, prepared by the engine
manufacturer, is supplied with this machine. Refer to the
engine manufacturer’s manual for all engine-related
service.
Proper attention to the engine manufacturer’s manual
directions will ensure maximum service life of the engine.
6
4
5
TN2703
Figure 3-37
3. Disengage retaining clips (1) and remove cover (2).
4. Remove knob (3) and air filter retainer (4).
5. Remove air filter pre-cleaner (5) and air filter
cartridge (6).
3-204247530-Rev A
ENGINE
Installation Notes
• Wash air filter pre-cleaner in liquid detergent and
water. Squeeze dry in a clean cloth. Saturate in clean
engine oil and squeeze out excess oil in a clean,
absorbent cloth. Replace air filter pre-cleaner if it
remains dirty or is damaged.
• Do not use petroleum solvents such as kerosene to
clean air filter cartridge.
• Do not use pressurized air to clean a ir filter cartridge.
• Install air filter assembly by reversing the order of
removal.
Canister (Gasoline)
Removal and Installation
See Figure 3-38.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2
Muffler (Gasoline)
Removal and Installation
See Figures 3-39 and 3-40.
CAUTION
!
Do not attempt to service the exhaust system
when the engine is hot. Serious personal injury
can occur.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
1
2
3
3
1
3
6
5
4
TN3550
Figure 3-38
2. Loosen hose clamps (5 and 6) and disconnect hoses
(2 and 3).
3. Remove screw (1) and canister (4).
Installation Note
Install canister by reversing the order of removal.
4
5
6
TN3477
Figure 3-39
3. Remove nut (2), lock washer (3), two washers (4),
and screw (5) from the muffler (1) and muffler
bracket (6).
4247530-Rev A3-21
ENGINE
Throttle Cable (Gasoline)
Removal and Installation
See Figure 3-41.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
6. Remove screw (12), lock washer (11), and muffler
support (10).
Installation Note
Install muffler by reversing the order of removal.
12
Figure 3-40
10
11
9
TN3478
1
5
4
3
2
TN3558
Figure 3-41
3. Remove two nuts (3), lock washers (4), and screws
(1), and remove throttle cable (2) from bracket (5).
4. Disengage throttle cable at the engine.
3-224247530-Rev A
Installation Notes
• Install throttle cable by reversing the order of
removal.
• Adjust throttle cable as needed. ( See “Thr ottle Cab le
Adjustment” on page 3-8.)
ENGINE
Choke (Gasoline)
Removal and Installation
See Figure 3-42.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
1
4
2
3
Fuel Filter (Gasoline)
Removal and Installation
See Figure 3-43.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely.
2
1
5
Figure 3-43
3. Loosen hose clamps (1 and 3).
4. Tag and disconnect fuel tank-to-fuel filter hose (2)
from the fuel filter (5). Cap fitting and plug hose to
prevent leakage and contamination.
5. Tag and disconnect fuel filter-to-fuel pump hose (4)
from the fuel filter (5). Cap fitting and plug hose to
prevent leakage and contamination.
3
4
TN3552
3
TN3559
Figure 3-42
3. Disengage choke at the engine.
4. Remove nut (3) and lock washer (2).
5. Remove choke (1) from bracket (4).
Installation Note
Install choke by reversing the order of removal.
4247530-Rev A3-23
Installation Notes
• Install fuel filter by reversing the order of removal.
• Make sure the flow arrow on the side of the fuel filter
is aligned with the fuel tank-to-fuel pump flow
direction.
ENGINE
Engine (Gasoline)
Removal and Installation
See Figure 3-44.
1. Park the mower safely. (See “Park Mower Safely” on
page 1-6.)
2. Allow the engine to cool completely before
attempting to service the engine.
3. Tag and disconnect the negative (–) battery cable.
4. Remove fuel tank. (See “Fuel Tank (Gasoline)” on
page 9-8.)
5. Remove fuel tank support pan. (See “Fuel Tank
Support Pan” on page 9-8.)
6. Remove muffler. (See “Muffler (Gasoline)” on
page 3-21.)
7. Remove gear pump. (See “Gear Pump” on
3
page 5-31.)
8. Disconnect the throttle cable and choke from the
engine.
NOTE
Label all wires before disconnecting to ensure correct
installation.
9. Tag and disconnect the wiring harness at the engine,
ignition modules, carb solenoid, starter mo tor, starter
solenoid, and engine oil pressure switch.
WARNING
!
Prevent personal injury. Use a properly rated
lifting device. Always be sure the load is
balanced before lifting.
1
2
3
6
5
4
3-244247530-Rev A
TN3560
Figure 3-44
10. Using the proper engine hoist, support the engine
and remove four nuts (5), lock washers (6), and
screws (2) securing the engine (1) to the engine
mount (4).
11. Move ground cable (3) aside.
12. Check for any connected wires and components, and
carefully remove the engine from the machine.
13. Place the en g ine on a su itab le stan d or wor kbe n ch
that will support the full weight in a safe manner while
preventing damage to the engine.
NOTE
If the engine is being replaced, some components must
be removed and installed on the new engine. Refer to
“Parts and Maintenance Manual” fo r addit ion al
information and illustrations.
Installation Notes
• Inspect engine isolation mounts and replace if
necessary. Tighten engine isolation mounts to 19.6–
21.7 lb-ft (27–29 N·m).
• Install the engine by reversing the order of removal.
• If necessary, remove components from the engine
and install the components on the new engine.
• Use new cable ties to secure wire connectors and
wire harnesses.
• Apply dielectric grease (Jacobsen PN 365422) to any
wire connectors disconnected.
• Replace the engine oil filter and fill engine with oil.
Engine Service (Gasoline)
A separate engine manual, prepared by the engine
manufacturer, is supplied with this machine. Refer to the
engine manufacturer’s manual for all engine-related
service.
Proper attention to the engine manufacturer’s manual
directions will ensure maximum service life of the engine.
ENGINE
3
4247530-Rev A3-25
3
ENGINE
3-264247530-Rev A
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