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Jacobsen AR-5
Textron Jacobsen AR-5 Technical/Repair Manual
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AR-5™ and AR-522™
Rotar
y Mo
wer
T
ec
hnical/Repair Manual
68080, 68082, 68098
2
Table of Contents
Table of Contents
7
Introduction
10
Prepare for the Job
10
Safety Notices
10
Safety Label Locations
10
Inspect Safety Labels
13
Keep Work Area Clean
13
Keep Work Area Well Ventilated
13
Use Proper Eye and Face Protection
13
Park Mower Safely
13
Use Lifting Equipment Safely
14
Support Machine Securely
14
Use Compressed Air and Air Tools Safely
14
Service Tires Safely
15
Handle Fuel Safely
15
Store Volatile and Hazardous Materials Safely
15
Handle Chemical Products Safely
16
Service Hydraulic System Safety
16
Service Cooling System Safely
16
Service Electrical Components Safely
17
Dispose of Waste Materials Safely
17
Chapter 3 Engine
31
General Engine Specifications
32
Specifications
32
Component Location
33
Kubota V2003-M-T E2B
33
Checks and Adjustments
35
Throttle Cable
35
Fan Belt
36
Repair
36
Air Cleaner Assembly
37
Muffler
38
Exhaust Manifold and Turbocharger
39
Radiator/Hydraulic Oil Cooler
40
Thermostat
42
Throttle Cable and Control Lever
43
Fuel Filter
44
Fuel Pump
44
Engine
45
Engine Service
47
Chapter 4 Electrical
49
Specifications
52
Test and Adjustment Specifications
52
Electrical Component Symbols
53
Theory and Diagnostic Information
53
Electrical Schematic Component Identification
56
Electrical Schematic
58
Power Circuit-Theory of Operation
63
Theory of Operation and Sub Circuit Schematics
63
Power Circuit Schematic
64
Charging Circuit-Theory of Operation
68
Charging Circuit Schematic
69
Start and Glow Plug Circuit-Theory of Operation
70
Start and Glow Plug Circuit Schematic
72
Run Circuit-Theory of Operation
75
Run Circuit Schematic-On Seat
76
Run Circuit Schematic-Off Seat
77
Raise/Lower Circuit-Theory of Operation
78
Raise Circuit Schematic
79
Lower Circuit Schematic
80
Mow Circuit-Theory of Operation
82
Mow Circuit Schematic
83
Traction Control Circuit-Theory of Operation
84
Traction Control Circuit Schematic
85
Instrumentation Circuit-Theory of Operation
86
Instrumentation Circuit Schematic
88
Horn and Light Circuit-Theory of Operation
90
Horn and Light Circuit Schematic
91
Optional Cruise Control-Theory of Operation
92
Cruise Control Circuit Schematic
93
Control Module
94
Neutral Circuit
94
Park Brake Circuit
94
Troubleshooting
94
Charging Circuit
95
Glow Plug Circuit
96
Start Circuit
96
Raise/Lower Circuit
97
Run Circuit
97
Mow Circuit
98
Traction Control Circuit
99
Instrumentation Circuit
100
Horn and Audible Alert Circuit
102
Light Circuit
103
Component Testing
104
Electrical System and Component Testing
104
General Information
104
Fuse Test
105
Relay Tests
105
Key Switch Test
106
Raise/Lower Switch Test
107
Light Switch Test
108
Traction Control Switch Test
108
Horn Switch
109
Seat Switch Test
109
Hydraulic Oil Level Switch Test
110
Mow Switch
110
Solenoid Test
111
Electrical
112
Engine
112
Engine Oil Pressure Switch Test
112
Fuel Level Sensor Test
112
Hydraulic Filter Pressure Switch Test
112
Circuit Breaker Test
113
Fuel Pump Test
113
Battery and Battery Tray
114
Repair
114
Alternator
115
Starter Motor
116
Circuit Breaker
117
Plug-In Fuses
117
Glow Plug Relay
118
Start Relay
118
Instrument Panel
119
Key Switch
119
Indicator Lamps
120
Rocker Switches
120
Park Brake Proximity Switch
121
Neutral Proximity Switch
122
Raise/Lower Switch
122
Seat Switch
122
Solenoid Coils
123
Fuel Solenoid
124
Engine Oil Pressure Switch
125
Hydraulic Oil Filter Switch
125
Control Module
126
Engine Temperature Switch
126
Fuel and Water Gauge
127
Fuel Level Sender
128
Horn
128
Chapter 5 Hydrostatic Power Train
129
Hydrostatic Power Train
129
Repair Specifications
130
Specifications
130
Test and Adjustment Specification
130
Component Location
131
Hot Oil Shuttle
132
Theory of Operation and Sub-Circuit Schematics
132
Traction Circuit Forward Schematic and Theory of Operation
132
Traction Circuit-Forward Schematic
132
Traction Pump Circuit
132
Traction Circuit Reverse Schematic and Theory of Operation
134
Traction Circuit-Reverse Schematic
134
Troubleshooting
136
Tests and Adjustments
138
Transmission Neutral Adjustment
138
Charge Pump Test
140
Field Test Procedures
140
Preliminary Checks
140
Traction System Test
140
Wheel Motor Test
141
Instrument Test Overview
142
Instrument Test Procedures
142
Charge Pressure Test
143
Traction System Test
144
Traction Pump Tests
146
Wheel Motors Test
148
Neutral Adjust-Servo
152
Drive Shaft
154
Repair
154
Traction Pump
155
4WD Valve
160
Front Wheel Motor
162
Rear Wheel Motor
167
Chapter 6 Hydraulics
171
Hydraulics
171
Repair Specifications
173
Specifications
173
Test and Adjustment Specifications
173
Component Location
174
Hydraulic Schematic
176
Steering Circuit Schematic and Theory of Operation
180
Theory of Operation and Diagnostic Information
180
Steering Circuit Schematic
181
Raise Circuit Schematic and Theory of Operation
182
Raise Circuit Schematic
183
Lower Circuit Schematic and Theory of Operation
184
Lower Circuit Schematic
185
Traction Control Circuit Schematic
186
Traction Control Circuit Schematic and Theory of Operation
186
Mow Circuit Schematic and Theory of Operation
188
Mow Circuit (On) Schematic
189
Mow Circuit (Off) Schematic
190
Field Test Procedures
191
Lift Cylinder Leakage Test
191
Cutting Unit System Test
192
Power Steering Circuit Test
192
Instrument Test Overview
193
Instrument Test Procedure
193
Front Cutting Units Circuit
194
Front Cutting Units Pump Test
195
Front Cutting Units Circuit Valve Tests
196
Adjust Cutting Unit System Relief Valve Pressure
198
Front Cutting Units Motors Test
198
Rear Cutting Units Circuit Test
200
Rear Cutting Units Pump Test
202
Rear Cutting Units Circuit Valve Tests
203
Rear Cutting Units Motors Test
204
Lift/Steer System Relief Valve Pressure Test
206
Lift System Test
207
Lift Valve Test
209
Lift/Steer Pump Test
209
Gear Pump
211
Repair
211
Cutting Unit Motors
213
Lift Valve
214
Deck Valve
215
Hydraulic Filter
217
Lift Cylinders
219
Hydraulic Oil Cooler
221
Hydraulic Oil Tank
221
Chapter 7 Steering
223
Steering
223
Component Location
225
Tests and Adjustments
226
Tie Rod Adjustment
226
Steering Relief Valve Pressure Test
227
Steering Leakage Test
228
Repair
229
Steering Valve
229
Steering Wheel
229
Steering Valve Service Fixture
230
Steering Tower
239
Steering Cylinder
241
Tie Rod Assembly
244
Rear Axle
246
Chapter 8 Cutting Units
249
Component Location
250
Mechanical Troubleshooting
251
Troubleshooting
251
Quality of Cut Troubleshooting
252
Deck Motor
260
Repair
260
Blade
262
Rotary Deck
262
Front Deck Yoke
263
Deck Caster Wheels
264
Rear Deck Yoke
264
Deck Roller
266
Mower Deck Housing
267
Chapter 9 Accessories and Miscellaneous Repair
269
Accessories and Miscellaneous Repair
269
Brake Pedal/Linkage Adjustment
272
Canopy
272
Checks and Adjustments
272
Repair
272
Hood
273
Ops
273
Fuel Tank
274
Traction Pedal
277
Seat and Mount Plate
278
Rear Wheels
279
Work Light Kit
279
Brake Unit
280
Front Wheels
280
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Textron Jacobsen AR-5 Specifications
General
Cutting Width
60 inches
Number of Reels
5
Transmission Type
Hydrostatic
Deck Material
Steel
Blade Type
Reel
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