Jacobsen HR800, Safety, Operation & Maintenance Manual

Page 1: ...aintain this machine should be trained in its proper use warned of its dangers and must read the entire manual before attempting to set up operate adjust or service the machine When Performance Matter...

Page 2: ...ntain its maximum efficiency If additional information is needed contact your Jacobsen Dealer SERVICE SUPPORT MATERIAL Part No Description 4372606 Safety Operation Maintenance Manual 4372607 Parts Man...

Page 3: ...nsion Seat Grammer Msg95 721 68 6 11 Torque Specification 72 Maintenance and Lubrication 7 1 Maintenance And Lubrication Charts 73 7 2 General Precautions 77 7 3 Engine 77 7 4 Engine Lubrication 78 7...

Page 4: ...ons of accessories for global regional use is subject to local regulations ALL operators MUST read through this manual and understand the Safety Instructions controls lubrication and maintenance proce...

Page 5: ...Stamp The Serial number and date code C are shown on the chassis between the serial plate and engine data labels D Engine Identification The engine serial number is found on the top of the valve cover...

Page 6: ...ES MOWING MACHINES WITH A MAXIMUM VEHICLE WEIGHT OF 5000 POUNDS OR 2268 Kg THIS DECAL MUST BE KEPT INTACT AT ALL TIMES INC A 3017 FULL VISION DR NEWTON KS USA 67114 67 50 FULL VISION ROPS MODEL 113 07...

Page 7: ...to use all of the necessary lifting equipment Use correct tools and Personal Protective Equipment PPE and take instruction from the technical manuals applicable to the machine Remove and store correct...

Page 8: ...ification of spare parts 2 Website www jacobsen com Select the MANUALS tab You have the option to view or Download a PDF version of the parts manual 1 5 KEY NUMBERS ___________________________________...

Page 9: ...does not operate correctly Do not disconnect or prevent the operation of any switch c Never operate equipment that is not in correct order or without labels guards shields deflectors or other protect...

Page 10: ...nkments Be careful of holes in the terrain and other hazards that are not visible g When you drive in the reverse direction look behind you and down to make sure the path is clear Do not operate the c...

Page 11: ...tainers inside a vehicle or on a truck or trailer with a plastic liner Always put the fuel container on the ground away from your vehicle before you fill the container e Refuel the mower before you st...

Page 12: ...can have enough force to enter your skin If hydraulic fluid has entered your skin a doctor must remove the hydraulic fluid surgically within a few hours or gangrene can occur o When you service the h...

Page 13: ...st always be done by an approved technician If additional information or service is needed contact your Authorized Jacobsen Dealer Your Dealer knows the current methods to service this equipment WARNI...

Page 14: ...seat belt must be worn only when a ROPS frame is in position This warning is because a seat belt must be worn with a ROPS to follow the Machinery Directive 2006 42 EC Sections 3 2 2 Seating 3 4 3 Rol...

Page 15: ...combined value of the activities WARNING Never Mow If There Is A Risk Of Lightning Or You Hear Thunder If You Are In The Middle Of Mowing Stop In A Safe Place Turn Off The Engine And Go Inside a Build...

Page 16: ...3 LABELS en 15 3Labels 3 1 SAFETY LABELS__________________________________________________________ 4153197 A B C D E F G H J N 18 4321506 a b c d e g f K 4170640 L M 4324674...

Page 17: ...ure wash the machine K 4170640 Caution stop engine remove the starter key lock deck in its vertical position before carrying out maintenance under deck L 4164860 Caution Hydraulic Oil M 4165644 Cautio...

Page 18: ...1 101 MM G G 2 2 114 MM H H 2 3 127 MM J J 2 4 127 MM J 3 1 2 3 0 140 MM K K 3 1 152 MM L L 3 2 4339908 K K X X 1 2 3 S S 1 0 IN 1 5 IN 2 0 IN 2 5 IN 3 0 IN 3 0 IN 3 5 IN 4 0 IN 4 5 IN 5 0 IN 5 0 IN...

Page 19: ...A 009034770 Guaranteed Sound Power Level B 4286422 Hydraulic Fluid C 009039870 Jack Hook Point D 164580 Lubrication Point E 4316686 Engine Oil Classification F 4355986 Height Of Cut Wing deck G 435912...

Page 20: ...9 4Controls 4 1 OPERATOR COMPARTMENT _______________________________________________ 4 3 4 8 4 4 6 10 1234 5 1234 5 12V 10A 4 2 1234 5 1234 5 1234 5 12V 10A 4 6 1234 5 1234 5 12V 12V 12V 10A 4 2 4 6 4...

Page 21: ...ch 4 2 2 Throttle Control 4 2 3 Parking Brakes 4 2 4 Transport Lock Switch 4 2 5 Mow Switch 4 2 6 4 Wheel Drive in Reverse Direction Switch 4 2 7 Cruise Control Switch 4 2 8 DPF Switch 4 2 9 High Spee...

Page 22: ...erate the engine at full speed NOTE When the controller is set to Auto Mode the engine speed is set by the controller The throttle control will not change the engine speed See Section 4 2 23 34 4 2 3...

Page 23: ..._____________ Engages 4 wheel drive while the vehicle is in reverse direction Hold the switch to keep engaged Push the front of the switch to turn ON Release the switch to turn OFF 4 2 7 CRUISE CONTRO...

Page 24: ...he mower until the Regen cycle is completed and the Regen Request light turns off See 8 15 4 2 9 HIGH SPEED SWITCH______________________________________________________ Used to switch the mower betwee...

Page 25: ...pulled momentarily rearwards the unit will raise to the cross cut position and continue to rotate for 3 seconds Lowering the unit within 3 seconds will let the blade continue rotating without stopping...

Page 26: ...the indicator stalk Section 4 8 4 2 22 POWER OUTLET _________________________________________________________ The Auxiliary Power Outlet is on the control panel next to the ignition switch It is for...

Page 27: ...se and maintain this machine should be trained in its proper use warned of its dangers and should read the entire operators manual before attempting to set up operate adjust or service the machine TST...

Page 28: ...l during transport operations 3 Creep Mode Cutting system disabled and max speed limited to 8kph 5mph for safe controlled use in workshops storage facilities and when loading onto vehicles 4 2 23 4 EN...

Page 29: ...operator is not in the seat Note The red LED s either side of the display will also flash The engine will not start until all the items in the list are correct SET UP 4 2 23 6 MANUAL REVERSE FAN CYCLE...

Page 30: ...2 23 9 MAIN MENU SELECT ____________________________________________________ Use the button below the to access the main menu 4 2 23 10 CLOCK SELECT ___________________________________________________...

Page 31: ...the button up and down to move the count Press the button to accept and move to the minute underlined Press the button up and down to move the count Press the button accept and move to the second unde...

Page 32: ...fault that next occurs will write over the oldest fault This information is accessed with the service tool or can be seen on the errors page of the service menu Press the button to select press the b...

Page 33: ...______________ Select the time until service and accept 4 2 23 19 TIME UNTIL SERVICE ___________________________________________________ This screen displays the time until the service is needed Press...

Page 34: ...he J1 connectors Press the left side button to return to I O diagnostics menu On and OFF shown for illustration purposes only Diagnostics Water Temp deg C 60 5 Fuel Level pct 100 Sys Voltage V 11 8 Cu...

Page 35: ...ht Lower OFF J2 2 Right Lift J2 3 Center Lift J2 4 High Speed Sol J2 5 Left Lower J2 6 Run w Int Out J2 7 EDC Coil A mA FRW J2 8 EDC Coil B mA RVS J2 9 Center Lower J2 10 Park Brake Sol J2 11 Left Lif...

Page 36: ...he ECU Monitor and accept Connector J5 J5 1 Center Deck LED Output J5 2 Left Mow Solenoid J5 3 Deck Lock Solenoid 3 4 J5 4 Center Mow Solenoid J5 5 Raise Enable Solenoid J5 6Deck Lock Solenoid 1 2 J5...

Page 37: ...0 ECU MONITOR INFORMATION J1939 _____________________________________ Select the ECU monitor information and accept 4 2 23 31 INFORMATION SCREEN ONE ____________________________________________ This s...

Page 38: ...chine is stopped Select the required mode and accept Press the button to return to previous menu 1 Manual Mode Works as a conventional mechanical over hydraulic drive system 2 Auto Mode Automatic driv...

Page 39: ...and KPa Press the button to return to previous menu Select volume and accept Press the button up and down to move between liter gal and imperial gal Press the button to return to previous menu Select...

Page 40: ...Press the button up and down to change the numbers Select to accept Owner PIN 1001 Owners should change PIN to protect settings 4 2 23 39 CRUISE CONTROL _______________________________________________...

Page 41: ...OSS CUT ___________________________________________________________ Select the cross cut and accept 4 2 23 42 CROSS CUT ACTIVE INACTIVE __________________________________________ Use the button up and...

Page 42: ...ton Too save Press the button to return to previous menu Do the procedure for creep mode 4 2 23 45 PIN CHANGE __________________________________________________________ Select the PIN change and accep...

Page 43: ...____________________ Select the Drive Modes and accept Select To accept Press the button up and down to move between YES or NO Select To accept Pin Menu Cruise Control Cross Cut Vehicle Speed Change P...

Page 44: ...ation Timer will automatically restart after each reverse fan cycle To prevent reverse fan rotation select OFF and select To accept To use manual start the reverse fan cycle select Manual and select T...

Page 45: ...warning This over rides all other information and will continue until the machine has been driven to an area with a slope of less than 16 Press the button below the to confirm the fault 4 2 23 53 WARN...

Page 46: ...the engine oil pressure has decreased below the normal level If this happens during operation Stop the engine and check the oil level Top up if necessary If the problem persists consult your service d...

Page 47: ...DAL FAULT __________________________________________ This screen is shown if there is a communications fault between the foot pedal and the controller Stop the machine as soon as possible and contact...

Page 48: ...fault 4 2 23 61 WARNING HYDRAULIC OIL LEVEL LOW___________________________________ When this screen is shown the hydraulic oil level is low Fill with clean hydraulic oil at the earliest opportunity Pr...

Page 49: ...WARNING TST TILT SENSOR TECHNOLOGY FAULT________________________ When this screen is shown there is a fault with the TST Stop as soon as possible and contact your service dealer Press the button belo...

Page 50: ...o the Neutral position To move in the reverse direction press the bottom B of the foot pedal 4 4 STEERING TILT CONTROL _________________________________________________ With the operators seat is in t...

Page 51: ...nut s fitted to studs i Rotate the armrest extension to the correct position j Tighten the three locknut s k Replace the armrest cushion with the four screws B 4 6 PARKING BRAKE RELEASE VALVE ________...

Page 52: ...g position 4 8 LIGHTING KIT OPTIONAL _________________________________________________ Lighting Control Stalk A Push away from operator to turn the dipped beam head lights on B Pull toward operator to...

Page 53: ...Control M Fuse Holder N Fuse Holder FUSE HOLDER Fuse Rating Protected Circuits M8 15A Wiper Front M7 25A Front Screen Heating M6 7 5A Radio 15 M5 20A Working Lights Locater Lighting Left M4 10A Wiper...

Page 54: ...l supply radiator coolant level crankcase oil level and air cleaner indicator When the engine is cold all fluids must be at the full level mark Check the radiator and oil cooler fins for dirt or grass...

Page 55: ...the OFF position The engine will start TEST 2 The engine must not start if the mow switch is in the ON position TEST 3 The engine must not start if the parking brake switch is in the OFF position TES...

Page 56: ...from the equipment can cause injuries to people and cause damage to the equipment 9 When you are not mowing grass always turn off the mow switch 10 Before you move across or operate on the paths or r...

Page 57: ...he mower in normal conditions 1 Turn the mow switch to the OFF position Drive the mower to a flat and level area to park the mower 2 Remove your foot from the traction pedal 3 Lower the front and rear...

Page 58: ...l can be pressed to stop the mower 5 7 MOWING_________________________________________________________________________ To mow 1 To mow the machine should be set to either manual or automatic mode 2 Re...

Page 59: ...es for damage and replace if necessary 7 Disengage the transport locks 8 Put the deck into the position for operation 9 Start the engine and run the cutter decks to check for correct operation 5 9 SLI...

Page 60: ...rturning 6 Correct tire pressure is necessary for maximum traction Mowers with 2 Post ROPS Front 16 psi 1 10 BAR Rear 30 psi 2 07 BAR Mowers with Cab Front 18 psi 1 24 BAR Rear 32 psi 2 21 BAR WARNING...

Page 61: ...fact that a seat belt must be worn with a ROPS to comply with the Machinery Directive 2006 42 EC Sections 3 2 2 Seating 3 4 3 Rollover Jacobsen recommends that a local risk assessment is completed by...

Page 62: ...200 11 3 20 0 7 5 11 8 20 8 225 12 7 22 5 9 250 14 25 0 275 15 4 27 5 10 15 5 27 8 300 16 7 30 0 11 17 0 30 6 325 18 0 32 5 12 18 4 33 3 350 19 3 35 0 13 19 9 36 1 375 20 6 37 5 14 21 3 38 9 400 21 8...

Page 63: ...the trailer Always follow any recommendations for maximum trailer weights given in your towing vehicles handbook Do Not exceed the maximum gross weight shown on the trailer plate Always read the trai...

Page 64: ...elt The fan belt tension is adjusted to prevent the stress on the alternator bearings and to prevent movement on the alternator pulley Use the procedure shown below to check the belt tension at the ce...

Page 65: ...rn at a time and the weight transfer tested 3 Tighten locknut A while holding the threaded shaft still with the Allen Key B 6 4 STEERING SHAFT ADJUSTMENT ____________________________________________ T...

Page 66: ...osition 2 Remove the quick pin A from the top of the caster wheel pivot spindle 3 Remove the caster wheel from caster support B 4 Select either Position 1 or Position 2 for wheel mounting bracket C To...

Page 67: ...nate location and bolt in place 6 Place the selected number of spacers E below the caster support Place the remaining spacers above the caster support 7 Replace the quick pin 8 Place pin F into the pr...

Page 68: ...ners to make sure that the seat is installed correctly If the seat does not operate correctly have the seat repaired in a GRAMMER workshop Check the seat for damage to the seat suspension and bellows...

Page 69: ..._ The seat height can be altered by fully pulling out or pressing in the actuator lever 1 The green marking in the weight and height indicator 2 should be visible In order to avoid damage do not opera...

Page 70: ...size 13mm and adjust the armrest to the desired position and tighten the nut again 6 10 7 BACKREST ADJUSTMENT OPTION ________________________________________ The backrest extension can be individuall...

Page 71: ...by the driver seat Position 1 fore aft isolator off Position 2 fore aft isolator on 6 10 11 FORE AFT ADJUSTMENT OPTION ________________________________________ The fore aft adjustment is released by...

Page 72: ...6 10 14 MAINTENANCE _________________________________________________________ Dirt can impair the function of the seat so make sure you keep your seat clean Upholstery can be quickly and simply remove...

Page 73: ...9 1 4 20 in lb Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159 215 211 286 5...

Page 74: ...irements Quantity Type Engine Oil with filter 11 2 liters 2 46 Imp gals 2 96 US gals 10 30W see specification below Hydraulic Oil with filter 75 7 liters 16 7 Imp gals 20 US gals Total Equivis ZS46 IS...

Page 75: ...MAINTENANCE AND LUBRICATION 7 en 74 B B A A B B B A B B A B B B...

Page 76: ...djust Fan Belt Tension Check Air Intake Hose Every 400 hours Change Engine Oil Change Engine Oil Filter Cartridge Every 500 hours Replace Fuel Filter Cartridge B Clean Water Separator A Remove the Sed...

Page 77: ...y must be done after the first 50 hours of operation 3 Consult your local Kubota Dealer for this Service The items listed above marked are registered as emission related critical parts by Kubota in th...

Page 78: ...manufacturer instructions you will make sure of the maximum service life of the engine Replacement engine manuals are available from the engine manufacturer The operation and maintenance during the fi...

Page 79: ...e oil drain plug C from the bottom of the crankcase and clean with a cloth b Drain engine oil into a container c Replace the drain plug C and fill the engine with the correct quantity and grade of oil...

Page 80: ...he engine fan belt see maintenance chart and replace the belt see maintenance chart Replace the clamps and hoses see maintenance chart Have your Jacobsen Dealer check the cooling system if you need to...

Page 81: ...hose A on to the radiator Make sure all the hose clips B are tight c Fill the cooling system with the correct anti freeze mixture See Section 7 1 Fill system through the radiator cap d The level of c...

Page 82: ...ank with hydraulic fluid through filler A d Start the engine and remove the air from the hydraulic system Operate all mower functions for 5 minutes to remove the air and to balance the hydraulic fluid...

Page 83: ...h hydraulic fluid before you assemble the new filter Tighten the filter with your hand b Operate the engine at idle speed for five minutes to remove the air from the hydraulic system The oil level lig...

Page 84: ...the engine unless specified at a different temperature TEST PORTS 1 Charge pressure 20 Bar 2 Bar 290 psi 29 psi 2 Forward traction pressure engine running no drive Wheel restraints installed Should ba...

Page 85: ...contact with the fuel plan to change the parts Low emission Diesel engines use higher pressure injection equipment The presence of Copper Lead and Zinc in Diesel fuel can accelerate wear in fuel pumps...

Page 86: ...to the filter base Tighten the cartridge with your hand e Bleed air from the fuel system How To Bleed The Air From The Fuel System After water is drained from the fuel system fuel filter cartridge is...

Page 87: ...ary 6 filter elements carefully Clean the inside of the filter housing Make sure dust and other particles do not get into the engine inlet hose Inspect the new elements Do not use a damaged element an...

Page 88: ...you try to jump start the mower check the condition of the drained battery b Connect the positive battery terminal of the charged battery to positive battery terminal of the drained battery c Connect...

Page 89: ...ify the problem and have the system repaired Torque all exhaust manifold hardware equally Tighten or replace the exhaust clamps WARNING Charge the battery in an area with good airflow The battery can...

Page 90: ...Engine will enter Active Regen state unless Inhibit Regen switch is in the INHIBIT position Normal Active Regen is completed in approximately 20 minutes If the particle material level does not decrea...

Page 91: ...ore you disconnect any hydraulic component tag or mark the location of each hose then clean the area around the fittings To stop the entry of dirt into the system when you disconnect the component be...

Page 92: ...ct the wheel to make sure of full contact between surface of wheel and hub Tighten all hardware with your fingers then torque hardware in the order shown When possible tighten nuts in the top position...

Page 93: ...k to the vertical position 5 Insert one of the height of cut pins at position E to lock deck in its vertical position All Cutter Decks 6 Remove blade bolt A 7 Remove blade B from deck 8 Fit new blade...

Page 94: ...ginal grind pattern Grind new cutting edges at an angle If the maximum of 1 2 inch 13 mm blade loss has occurred do not sharpen more replace the blade To stop blade balance problems make sure an equal...

Page 95: ...Never wear the seat belt with the ROPS in the folded position CAUTION Keep the ROPS hardware correctly fastened Do not do any welding operations Do not drill change or bend the ROPS Replace damaged RO...

Page 96: ...ic parts wax with a good grade of one step cleaner wax Repair damaged metal surfaces and use Jacobsen touch up paint Apply wax to the equipment for maximum paint protection NOTICE Do not wash any part...

Page 97: ...cation To decrease the self discharge rate the temperature must not be more than 80 F 27 C or less than 20 F 7 C Engine While the engine is warm remove the drain plug drain the oil from the crankcase...

Page 98: ...7 MAINTENANCE AND LUBRICATION en 97 7 25 LUBRICATION OF CUTTING UNIT ____________________________________________ Wing Pivot Arm A Front Pivot Arm B Caster Wheel Mounting Pivot C A A B C C...

Page 99: ...engine will not crank Charge the battery In The winter always remove the battery from the machine Keep the battery charged and store in a dry safe environment Loss of Power Cause Action No fuel Check...

Page 100: ...Action Engine oil low Check oil level Fill to specified level The fan belt is broken or has defects Change the belt or adjust the belt tension Coolant low Fill to the specified level The Anti freeze...

Page 101: ...ding is a repeated pattern of different cutting heights that causes an appearance that is like a wave In most cases the wave tip to tip distance is approximately 6 8 in 15 20 cm A change in the color...

Page 102: ...HOC height of cut settings are different from one side of a cutting unit to the other side or from one cutting unit to another unit Check HOC adjustment of cutting units See Section 6 6 Worn deck cas...

Page 103: ...ght green or brown A low HOC setting or turf that is not level can cause scalping Probable Cause Remedy HOC height of cut settings are lower than normal Check and adjust the HOC settings See Section 6...

Page 104: ...Edge of the cutting blade s are not sharp Sharpen the blade s See Section 7 21 Cut ground speed is higher than normal Reduce the cut ground speed The grass is higher than the level at which the mower...

Page 105: ...t is faster than the mower can turn and cut correctly The cutting units do not overlap around turns or on side hills Turn at a speed that will allow the cutting units to overlap Change the direction o...

Page 106: ...d at one end of cutting unit s or between cutting units Windrowing can make a line in the direction of travel Probable Cause Remedy The grass is higher than the level at which the mower can cut correc...

Page 107: ...a mismatched HOC height of cut adjustment from one cutting unit to another unit Probable Cause Remedy HOC is different from one cutting unit to another unit Check and adjust the HOC on cutting units t...

Page 108: ...10 FUSES RELAYS AND CONTROLLER en 107 10Fuses Relays and Controller 10 1 FUSE AND RELAY COMPONENT IDENTIFICATION______________________________ 1 3 1 2 3 4 5 6 1 2 3 4 5 6 5 1 R5 R1 R4 R2 2 1 2 3 4 5 6...

Page 109: ...ch to Hazard Switch 4 15A Not Used 5 7 5A Key Switch to Indicators 6 FUSE HOLDER 3 Fuse Rating Protected Circuits 1 5A Battery Positive Distribution Box to Alternator 2 10A Key Switch to Indicators 3...

Page 110: ...SAEJ1349 HP rpm 55 4 kW 2600 rpm 74 3 HP 2700 rpm Maximum Torque Rotating Speed 265 N m min 1500 rpm 196 ft lb min 1500 rpm Maximum Bare Speed 2820 rpm No load Idle Speed 775 to 825 rpm Firing order...

Page 111: ...eel Track Front 152 cm 59 8 in M Wheel Track Rear 116 cm 45 7 in Ground Clearance 18 7 cm 7 375 in Turning Circle Curb to Curb outside tire to outside tire in Transport Left Turn 560 220 5 in Turning...

Page 112: ...11 SPECIFICATIONS en 111 A B HR800 with ROPS Right deck not shown HR800 with Cab Right deck not shown E D L M C K H M J E D L M C...

Page 113: ...km h 0 20 mph Forward Transport 0 16 1 km h 0 10 mph Reverse Low Speed 0 25 km h 0 15 5 mph Forward Transport 0 6 4 km h 0 6 mph Reverse Creep 0 8 km h 0 5 mph Forward 0 5 km h 0 3 1 mph Reverse Steer...

Page 114: ...ole body vibration measurement was carried out with the machine traveling in a straight line at a speed close to 6 km h on a flat horizontal level surface The height of cut was set at the lowest posit...

Page 115: ...vironment The Machinery Safety Directive 2006 42 EC And Noise Emission In The Environment By Equipment For Use Outdoors Directive 2000 14 EC By compliance to Sound Power Standard EN ISO 3744 2010 ROPS...

Page 116: ...ers on the front of deck and three anti scalp rollers on the rear Transmission By Hydraulic motor to each cutter blade Product HR800 Wing Deck Deck Width 167 cm 66 inch Deck Wing Construction Bull nos...

Page 117: ...Kit Number 4382306 11 10 1 THIRD PARTY ACCESSORIES The following attachments have been designed and approved for use by the respective manufacturer on the HR series mowers and are approved by Jacobsen...

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Page 120: ...pessoa com poderes para emitir a declara o em nome do fabricante que possui a documenta o t cnica que est autorizada a compilar o processo t cnico e que est estabelecida na Comunidade Semn tura persoa...

Page 121: ...NOTES 12 en 120 12Notes...

Page 122: ...dwide dealer network and factory trained technicians backed by Genuine Jacobsen Parts provide reliable high quality product support Textron Specialized Vehicles 1451 Marvin Griffin Rd Augusta GA 30906...