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.
!
©2011 Jacobsen, A Textron Company. All rights reserved.
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.
Copyright 2011, Jacobsen, A Textron Company
“All rights reserved, including the right to reproduce this material or portions thereof in any form.”

9
2
3
4
5
6
7
8
Table of Contents
4252490-Rev A 7
1
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
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
1
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.
!