Jacobsen LF-3400 & LF-3800 Repair Service Manual

SERVICE & REPAIR INSTRUCTIONS LF-3400 & LF-3800 LF-3400 2 Wheel Drive LF-3800 2 Wheel Drive Product No. 67839 Product No. 67837 Product No. 67869 Product No. 67866 LF-3400 4 Wheel Drive LF-3800 4 Wheel Drive Product No. 67840 Product No. 67838 Product No. 67869 Product No. 67867 LF-3400 4 Wheel Drive Turbo Engine Product No. 67889 Includes Attachments and Product Options Litho in U.S.A. 5/01 WARNING: If incorrectly used this machine can cause severe injury. Those who use and maintain the 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. ! Copyright 2001 Textron Golf, Turf & Specialty Products “All rights reserved, including the right to reproduce this material or portions thereof in any form.” Publication Registration Information, specifications, illustrations and procedures in this manual are based on information in effect at the time of publication. Product improvements and changes due to advancements of product design may not be included in this manual. This manual is reviewed and updated as required to include changes and product improvements. By returning the completed Registration below TGTSP will notify you when an update is available. Send Registration to: Textron Golf,Turf & Specialty Products 1721 Packard Avenue Racine, WI 53403-2564 Attn: Product and Service Tr aining Litho Date: Company Name __________________________________________ Your Name ______________________________________________ Your E-mail Address ______________________________________ Address ________________________________________________ City, State __________________________________ Zip ________ Register Your CD Use the registration on back of tray card. CD-SRI-3400/3800 GOLF , TURF & SPECIALTY PRODUCTS

1 14 2 3 4 5 6 7 8 9 10 11 12 13 INTRODUCTION CONTROLS ENGINE DRIVE TRAIN BRAKE SYSTEM STEERING WHEELS & TIRES HYDRAULICS CHASSIS ELECTRICAL SYSTEM PREVENTIVE MAINTENANCE ATTACHMENTS OPTIONS MISCELLANEOUS

1 1A. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Index Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1 Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 General Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-2 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 Standard SAE Grade #5 Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 SECTION 1 INTRODUCTION

CONTENTS This manual contains repair instructions for major tractor components, attachments and options. The Table of Contents at the start of each section lists contents 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 procedures are also covered in the user 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 user of this machine, do not consider yourself or your repair facilities capable of a given procedure, please consult your dealer or distributor. Information, specifications, illustrations, and procedures 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 product that may not be included in this manual. Each manual 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 manual are given at the start of that section. The designations L.H. (left hand) and R.H. (right hand) used throughout this manual refer to the operator’s left or right when sitting in the normal operating position. REGISTRATION A registration card is provided in the back of this manual (bottom portion of page). Fill out the card, remove and mail immediately upon opening the manual for the first time. The registration entitles you to receive manual updates for a period of two years. Updates are sent free of charge. NOTE Only the original registration card will be accept- ed. Photo copies, cards from other manuals, sug- gestion cards, or any facsimile are not acceptable and will not constitute a registration. INDEX NUMBERS Illustrations showing removal, disassembly, reassembly and installation may have index numbers to call out the sequence of procedure. Where the sequence of procedure is not important or self-evident (eg. linkages, hoses, clamps, etc.) index numbers are not included. Repair procedures for items not subject to wear (eg. panels, brackets, frames) are not included in this manual except for the general procedures given below. Exercise common sense during disassembly or reassembly; remove only the items required to accomplish necessary repair or service. REPLACEMENT PARTS Use the appropriate Parts Catalog when ordering replacement parts. Follow installation instructions shipped with service parts or kits. When ordering parts, always give the serial number and product number of your machine as well as quantity, part 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 PRODUCT NUMBER, NAME and SERIAL NUMBER that is stamped on the NAME and SERI- AL PLATE of your product. 4. Order by QUANTITY DESIRED, the PART NUM- BER and the DESCRIPTION OF PART. 5. Send your order to or visit your nearest dealer or distributor. 6. INSPECT ALL SHIPMENTS ON RECEIPT. If any parts are damaged or missing, file a claim with the carrier before accepting. 7. Do not return material to your dealer or distributor without a letter of explanation. Make a list of all returned parts, show your name and address, and include it with the shipment. TRANSPORTATION CHARGES MUST BE PREPAID. SECTION 1A. GENERAL INFORMATION 1A-1 1A

SERIAL NUMBERS See Figure 1A-1 for location of tractor assembly serial number. GENERAL CLEANING Improper cleaning and lubrication of your machine results in many equipment failures. Before any repairs are undertaken, thoroughly clean the exterior of the component 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 common 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 meaning are as follows: NOTE Any procedure needing special care when per- forming 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 in- stalled as shown in Section 14 of this manual. TORQUE VALUES Torque values are given in the following “Torque Speci- fication Chart”. Special torque values are called out on illustrations and text throughout this manual. SECTION 1A. GENERAL INFORMATION 1A-2 Figure 1A-1. Serial Number Location ! CAUTION Hazards or unsafe practices which could result in personal injury or product or property damage. ! WARNING Hazards or unsafe practices which could result in severe personal injury or death. ! DANGER Imminent hazards which will result in severe personal injury or death if precautions are not taken. ! CAUTION Disconnect leads at alternator before electric welding is done on components in common ground with engine. ! DANGER This machine is equipped with an interlock system which is intended to protect the operator and others from injury, by preventing the engine from starting, unless the reel switch is in the “Off” position, traction pedal is in the “Neutral” position and the brake set. The system also shuts off the engine if the operator leaves the seat with the reel switch in “Cut” position. In the interest of safe operating conditions, this machine must never be operated with the interlock relays or interlock system disconnected or malfunctioning.

SECTION 1A. GENERAL INFORMATION 1A-3 1A TORQUE SPECIFICATIONS STANDARD SAE GRADE #5 SCREWS Size Torque Values Size Torque Values 8-32 27-33 in-lbs. (3-4 N.m) 1 / 2-13 67-83 ft-lbs. (90-113 N.m) 8-36 28-34 in-lbs. (3-4 N.m) 1 / 2-20 81-99 ft-lbs.(110-134 N.m) 10-24 39-47 in-lbs. (4-5 N.m) 9 / 16-12 99-121 ft-lbs. (134-164 N.m) 10-32 44-54 in-lbs. (5-6 N.m) 9 / 16-18 108-132 ft-lbs. (146-179 N.m) 1 / 4-20 7-9 ft-lbs. (9-12 N.m) 5 / 8-11 135-165 ft-lbs. (183-223 N.m) 1 / 4-28 9-11 ft-lbs. (12-15 N.m) 5 / 8-18 162-198 ft-lbs. (220-268 N.m) 5 / 16-18 15-18 ft-lbs. (20-24 N.m) 3 / 4-10 234-286 ft-lbs. (317-388 N.m) 5 / 16-24 17-21 ft-lbs. (23-28 N.m) 3 / 4-16 270-330 ft-lbs. (366-447 N.m) 3 / 8-16 27-33 ft-lbs. (37-45 N.m) 7 / 8-9 360-440 ft-lbs. (488-597 N.m) 3 / 8-24 31-39 ft-lbs. (42-53 N.m) 7 / 8-14 396-484 ft-lbs. (537-656 N.m) 7 / 16-14 45-55 ft-lbs. (61-75 N.m) 1-8 522-638 ft-lbs. (708-865 N.m) 7 / 16-20 49-61 ft-lbs. (66-83 N.m) 1-12 576-704 ft-lbs. (780-954 N.m) NOTE: These torque values are to be used for all hardware excluding: locknuts, self-tapping screws, thread forming screws, sheet metal screws and socket head setscrews. Metric Grade Diameter — 5.6 8.8 10.9 12.9 Coarse Thread N.m ft-lbs. N.m ft-lbs. N.m ft-lbs. N.m ft-lbs. M6 4.6 3.3 10.5 7.7 15 11 18 13 M7 7.8 5.6 17.5 12.9 26 18.4 29 21.3 M8 11 8.1 26 19 36 26 43 31 M10 22 16 51 37 72 53 87 64 M12 39 28 89 66 125 92 150 110 M14 62 45 141 103 198 146 240 177 M16 95 70 215 158 305 224 365 269 M18 130 95 295 217 420 309 500 368 M20 184 135 470 309 590 435 710 623 METRIC

2 2A. Repair and Service Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 2B. Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1 2C. Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Throttle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-1 Traction Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Traction Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-2 Mow Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Reel Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-3 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2C-4 2D. Gauges and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2D-1 SECTION 2 CONTROLS

Tools required: Standard automotive hand tools. Cleaning materials: Stoddard or equivalent solvent. Detergent and water. Lubricants: Refer to Section 11. SECTION 2A. REPAIR AND SERVICE TOOLS AND MATERIALS 2A-1 2A

SECTION 2B. FAILURE ANALYSIS 2B-1 2B PROBLEM PROBABLE CAUSE REMEDY 1. Engine turns over but a. Glow plug defective. a. Test and replace (if necessary) will not start. glow plug (Section 10L). b. Fuel supply. b. Check fuel supply. c. Fuel filter. c. Change. d. Fuel solenoid inoperative. d. Test solenoid (Section 10K). 2. Engine does not turn a. Traction pedal not in “neutral”. a. Adjust traction pedal (Section 2C). over. b. Brake pedal not latched. b. Set brake. c. Mower switch in ON position. c. Move switch to OFF. d. One of several switches d. Test switches and adjust if damaged or loose. required (Section 10G). e. Neutral start switch out of e. Adjust switch (Section 2C). adjustment or defective. Test switch (Section 10G). f. Battery defective or bad ground. f. Test battery (Section 10D). 3. Engine speed does not a. Throttle control is not properly a. Adjust (Section 2C). increase when throttle adjusted. control is moved. b. Throttle control is broken. b. Repair or replace (Section 2C). c. Fuel shutoff solenoid linkage is c. Adjust linkage (Section 2C). not properly adjusted. d. Fuel shutoff solenoid is not func- d. Perform test (Section 10K). tioning properly. 4. The unit “creeps” in a. Traction pedal linkage out of a. Adjust traction (Section 2C). either direction when the adjustment. traction pedal is not depressed. 5. Parking brake fails. a. Brake not adjusted. a. Adjust brake (Section 2C). b. Worn brake disks or linings. b. Replace disks or linings (Section 5B). 6. Mowers do not lift or a. Lift/lower lever switches faulty. a. Test, replace if necessary lower properly as lift/ (Section 10G). lower pedal is activated. b. Control valve leaking or defective. b. Test valve (Section 8O). Repair valve (Section 8M), depending on serial number. c. Faulty lift limit switch adjustment. c. Adjust (Section 2C). d. Faulty lift cylinder. d. Test and repair cylinder (Section 8M). GENERAL The following table gives common problems, probable causes and suggested remedies with page references to detailed description of remedial procedures.

GENERAL The repair of controls is limited to adjustment of linkages, straightening of bent rods or replacement of defective parts and hardware. Control functions are monitored by an electronic controller at the front of the engine compartment. See Section 10 for electronic controller tests/repairs. THROTTLE ADJUSTMENT (See Figure 2C-1) Located on the control panel to the right of the opera- tors seat, the throttle control is used to regulate engine speed. Adjust the throttle as shown in Figure 2C-1. SECTION 2C. CONTROL ADJUSTMENTS 2C-1 2C Figure 2C-1. Throttle Control Adjustment STEP 1 Push throttle to high idle position. Push injector pump throttle arm to the high idle (speed position. STEP 2 Slide outer cable housing in clamp until housing is 1/2 inch from injector pump throttle lever. Tighten clamp. STEP 3 Install wire stop against injector pump throttle pivot and tighten. STEP 4 Start engine and check low and high idle speeds of engine. Low idle should be 1330 RPM and high is 3150 RPM. Make fine adjustments using the injector pump throttle arm stop screws.

Jacobsen LF-3400 & LF-3800 Repair Service Manual

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