Textron JACOBSEN GP400 User manual

GP400

Riding Greens Mower

Technical/Repair Manual

USAG004, USAD004

WARNING: If incorrectly used, this machine can cause severe 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.

When Performance Matters.

™

Jake manual cover separate front1 1 12/18/06 4:19:12 PM

GP400

Riding Greens Mower

Technical/Repair Manual

USAG004, USAD004

4252490-Rev A 5

Litho In U.S.A. 01-2013

Foreword

General

This manual provides detailed information and

procedures to safely repair and maintain the following:

Jacobsen GP400 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 repairs, 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

Trademark Acknowledgement

Jacobsen acknowledges the following trademarks for

company names or products mentioned within this

publication:

Lubriplate®is a trademark of Fiske Brothers Refining Co.

Loctite®and Permatex®are trademarks of Henkel

Corporation.

Certain vehicle components contain or emit

chemicals known to the State of California to

cause cancer and birth defects or other

reproductive harm.

64252490-Rev A

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 machine operation

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.

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.

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 any

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 machine

adjustment problem.

Table of Contents

4252490-Rev A 7

Safety

Specifications and

General Information

Engine

Electrical

Hydrostatic Power Train

Hydraulics

Steering

Cutting Units

Accessories and Miscellaneous

Repair

4252490-Rev A 1-1

Chapter 1

Safety

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Prepare for the Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Safety Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Inspect Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Keep Work Area Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Keep Work Area Well Ventilated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Use Proper Eye and Face Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Park Mower Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Use Lifting Equipment Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Support Machine Securely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Use Compressed Air and Air Tools Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Service Tires Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Handle Fuel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Store Volatile and Hazardous Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Handle Chemical Products Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Service Hydraulic System Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Service Cooling System Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Service Electrical Components Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Dispose of Waste Materials Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-2 4252490-Rev A

SAFETY

Introduction

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.

Prepare for the Job

Preparation is essential to complete a procedure 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 debris or

chemical splatters.

• Wear protective footwear. Wear safety 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 equipment. Always use the

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 hot

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.

DANGER

WARNING

CAUTION

NOTICE

Safety Label Locations

Become familiar with machine safety labels and

locations. The following illustrations show safety label

locations on the machine.

See Figure 1-1.

This safety alert symbol is used to

alert you to potential hazards.

Indicates an imminently hazardous situation

which, if not avoided, WILL result in death or

serious injury.

Indicates a potentially hazardoussituation which,

if not avoided, COULD result in death or serious

injury.

Indicates a potentially hazardoussituation which,

if not avoided, MAY result in minor or moderate

injury and property damage. It may also be used

to alert against unsafe practices.

Indicates a potentially hazardoussituation which,

if not avoided, MAY result in property damage. It

may also be used to alert against unsafe

practices.

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