John Deere Sabre Yard Garden Tractors 1948gv Hv 2148hv 2354hv 2554hv - Technical Service Repair Oem_ by www.heydownloads.com

SABRE YARD & GARDEN TRACTORS 1948GV/HV, 2148HV, 2354HV, 2554HV

TECHNICAL MANUAL

John Deere Worldwide Commercial and Consumer Equipment Division TM1841 (03Mar00) Litho in U.S.A

M89683

1948GV/HV Sabre Yard Tractors and 2148HV, 2354HV, 2554HV (S/N -25001) Sabre Garden Tractors

INTRODUCTION This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

Safety Specifications and Information

The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • • • • • • • • •

Table of Contents Specifications Component Location System Schematic Theory of Operation Troubleshooting Chart Diagnostics Tests & Adjustments Repair

Note:

Depending on the particular section or system being covered, not all of the above groups may be used.

Engines

Electrical System Gear Power Train Hydrostatic Power Train

Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered.

Steering We appreciate your input on this manual. If you find any errors, or want to comment on the layout of the manual, please mail your comments back to us.

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

Brakes Attachments

Miscellaneous

3/3/00

1-1

SAFETY

HANDLE FLUIDS SAFELY-AVOID FIRES

RECOGNIZE SAFETY INFORMATION

Be Prepared For Emergencies

This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe servicing practices.

Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

REPLACE SAFETY SIGNS

When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

1-2

3/3/00

SAFETY

USE CARE IN HANDLING AND SERVICING BATTERIES

USE SAFE SERVICE PROCEDURES

Prevent Battery Explosions

Wear close fitting clothing and safety equipment appropriate to the job.

• Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. • Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. • Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prevent Acid Burns • Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Wear Protective Clothing

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

Service Machines Safely

• Avoid acid burns by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. • If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10_15 minutes. 4. Get medical attention immediately. • If acid is swallowed: 1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. 3. Get medical attention immediately.

3/3/00

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

1-3

SAFETY

Park Machine Safely

Using High Pressure Washers Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle.

Illuminate Work Area Safely

Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a â&#x20AC;&#x153;DO NOT OPERATEâ&#x20AC;? tag in operator station.

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

Work In Ventilated Area

Support Machine Properly And Use Proper Lifting Equipment

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

WARNING: California Proposition 65 If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Work In Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.

1-4

Warning: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Remove Paint Before Welding Or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

3/3/00

SAFETY

Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.

Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts.

SERVICE TIRES SAFELY SERVICE COOLING SYSTEM SAFELY

Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off machine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

3/3/00

1-5

SAFETY

HANDLE CHEMICAL PRODUCTS SAFELY

LIVE WITH SAFETY

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

1-6

3/3/00

CONTENTS

SPECIFICATIONS & INFORMATION

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INCH TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 6 7 8

GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE BREAKâ&#x20AC;&#x201C;IN OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HYDROSTATIC TRANSMISSION OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 TRACTOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GEAR TRANSAXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HYDROSTATIC TRANSMISSION SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . 10

3/3/00

2-1

NOTES

2-2

SPECIFICATIONS & INFORMATION

3/3/00

SPECIFICATIONS & INFORMATION

SPECIFICATIONS

SPECIFICATIONS Engine (CV19 / CV21 / CV23) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV19 / CV21 / CV23 Horsepower CV19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 kW (19 hp) CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.66 kW (21 hp) CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.15 kW (23 hp) Displacement CV19/CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 cm3 (38.1 cu.in.) CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677 cm3 (41.3 cu.in.) Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame Engine (CV25) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV25 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6 kW (25 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 cm3 (44.0 cu.in.) Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 L (2.1 qt.) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame Fuel System Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 L (3 U.S. gal) Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float-Type Side Draft Carburetor Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable In-Line Electrical Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Capacitor Discharge Ignition (CDI) Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Alternator Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group, U1 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V Battery Reserve Capacity at 25 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 minutes Battery Cold Cranking Amps at -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . .295 amps

3/3/00

2-3

SPECIFICATIONS

SPECIFICATIONS & INFORMATION

Gear Transaxle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Peerless 820 Speeds Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Speeds Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gear Speed Range Forward 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 km/h (1.3 mph) 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 km/h (1.9 mph) 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 km/h (2.7 mph) 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 km/h (3.3 mph) 5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 km/h (4.4 mph) 6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 km/h (6.1 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 km/h (2.9 mph) Hydrostatic Transaxle Drive Train . . . . . . . . . . . . Belt Drive Transaxle with foot-controlled variable speed drive Transaxle (1948HV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff-Torq Model K-62C Transaxle (2148HV/2354HV/2554HV). . . . . . . . . . . . . . . . . . . . . Tuff-Torq Model K-66C PTO Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine-Mounted, Electric Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch on dash Implement Lift Lift System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual with Lift-Assist Spring Lift Lever Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left-hand side of hood Mower Deck (48-Inch) Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cutting Height-Approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–102 mm (1–4 in.) Blade Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423 mm (16.6 in.) Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1219 mm (48 in.) Mower Deck (54-Inch) Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cutting Height-Approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–102 mm (1–4 in.) Blade Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474 mm (18.7 in.) Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1372 mm (54 in.) Steering Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual – Pinion/Sector Axle Pivot Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shim Adjustable Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose Grease Lubrication Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 hrs (Maximum) Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) – Non-Adjustable Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584 mm (23 in.)

2-4

3/3/00

SPECIFICATIONS & INFORMATION

SPECIFICATIONS

PTO Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-Belt Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Belt Tensioning Control Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever on dash

3/3/00

2-5

INCH TORQUE VALUES

SPECIFICATIONS & INFORMATION

INCH TORQUE VALUES 1 or 2b

SAE Grade and Head Markings

5.1

8.2

No Marks

2 SAE Grade and Nut Markings

Size

5.2

No Marks

Grade 1

Grade 2b

Grade 5, 5.1 or 5.2

Grade 8 or 8.2

Lubricateda Drya

lb-ft

1/4

3.8

2.8

4.7

3.5

4.4

7.5

5.5

9.5

13.5

12.5

5/16

7.7

5.7

9.8

7.2

15.5

11.5

19.5

14.5

18.5

20.5

3/8

13.5

17.5

27.5

32.5

7/16

20.5

32.5

100

1/2

110

120

155

115

9/16

35.5

125

155

115

175

130

220

165

5/8

105

135

100

170

125

215

160

240

175

305

225

3/4

120

150

110

190

140

240

175

300

220

380

280

425

315

540

400

7/8

190

140

240

175

190

140

240

175

490

360

615

455

690

510

870

640

285

210

360

265

285

210

360

265

730

540

920

680

1030 760

1-1/8 400

300

510

375

400

300

510

375

910

670

1150 850

1-1/4 570

420

725

535

570

420

725

535

1280 945

1-3/8 750

550

950

700

750

550

950

700

1700 1250 2140 1580 2700 2000 3400 2500

1-1/2 990

730

1250 930

990

730

1250 930

2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

1300 960

1450 1075 1850 1350

1630 1200 2050 1500 2600 1920

Tighten toothed or serrated-type lock nuts to the full torque value. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication. b Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over 152 mm (6 in.) long, and for all other types of bolts and screws of any length.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

2-6

3/3/00

METRIC TORQUE VALUES

SPECIFICATIONS & INFORMATION

METRIC TORQUE VALUES 4.8

Size

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

5 5

12.9 12

Property Class and Nut Markings

12.9

8.8

Property Class and Head Markings

Class 4.8

Class 8.8 or 9.8

Class 10.9

Class 12.9

Lubricateda Drya

lb-ft

4.7

3.5

4.4

6.6

11.5

8.5

9.5

16.5

12.5

15.5

11.5

19.5

14.5

11.5

8.5

14.5

10.7

20.5

23.5

29.5

27.5

M10

M12

29.5

110

140

105

130

165

120

M14

120

150

110

175

130

220

165

205

150

260

190

M16

100

125

190

140

240

175

275

200

350

225

320

235

400

300

M18

135

100

175

125

265

195

330

245

375

275

475

350

440

325

560

410

M20

190

140

245

180

375

275

475

350

530

390

675

500

625

460

790

580

M22

265

195

330

245

510

375

650

480

725

535

920

680

850

625

108

800

M24

330

245

425

315

650

480

820

600

920

680

115

850

108

800

135

100

M27

490

360

625

460

950

700

1200 885

M30

660

490

850

625

1290 950

M33

900

665

1150 850

M36

1150 850

1350 1000 1700 1250 1580 1160 200

1500

1630 1200 1850 1350 2300 1700 2140 1700 2700 2000

1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to 3/3/00

2-7

GASOLINE SPECIFICATIONS

CAUTION

SPECIFICATIONS & INFORMATION

LUBRICANT SPECIFICATIONS ENGINE OIL

Handle fuel with care, it is highly flammable. DO NOT refuel machine:

Use oil viscosity based on the expected air temperature range during the period between oil changes.

• Indoors. Always fill fuel tank outdoors. • While you smoke. • When machine is near and open flame or sparks. • When engine is running. STOP engine. • When engine is hot. Allow it to cool.

The following oil is preferred: • 10W30

Help prevent fires: • • • •

Fill fuel tank only to bottom of filler neck. Clean oil, grease and dirt from machine. Clean up spilled fuel immediately. Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark.

To prevent fire and explosion caused by static electric discharge while you fill tank: • Use approved, non-metal fuel container. • When using a funnel, MAKE SURE it is PLASTIC. • Avoid using a funnel which has a metal screen or filter. IMPORTANT: To avoid engine damage: • DO NOT mix oil with gasoline • Use only clean oil and fuel • Use clean approved containers and funnels. • Store oil and fuel in an area protected from dust, moisture and other contamination. Unleaded fuel is recommended because it burns cleaner and leaves less unburned deposits in engine combustion chamber. Regular unleaded gasoline with an anti-knock index of 85 octane or higher may be used. Use of gasohol is acceptable as long as the ethyl alcohol blend does not exceed 11 percent. Do not use gasoline that contains Methanol.

Other oils may be used if they meet one of the following: • API Service Classification SG • API Service Classification SF • CCMC Specification G4 Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

Fill fuel tank at end of each day's operation. Fill only to bottom of filler neck.

ENGINE BREAK–IN OIL

GASOLINE STORAGE

IMPORTANT: ONLY use a quality break-in oil in rebuilt or remanufactured engines for the first 5 hours (maximum) of operation. DO NOT use oils with heavier viscosity weights than SAE 5W-30 or oils meeting specifications API SG, SH; or oils meeting CCMC Specification G5. These oils will not allow rebuilt or remanufactured engines to break-in properly.

Keep fuel in a clean container in a protected area. Do not use deicers to remove water from fuel. Do not depend on fuel filters to remove water. If possible, install a water separator at the storage tank outlet. IMPORTANT: Keep all dirt, scale, water or other foreign material out of fuel. If mower is stored for the winter, add gasoline storage stabilizer to the fuel. Follow directions on can.

2-8

3/3/00

LUBRICANT SPECIFICATIONS

SPECIFICATIONS & INFORMATION

HYDROSTATIC TRANSMISSION OIL

GREASE

Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission failure.

Use grease based on the expected air temperature range during the service interval.

IMPORTANT: ONLY use a quality SAE 5W-30 (2048) or 5W-50 SYNTHETIC (2554) engine oil in this transmission. Mixing of two viscosity grade oils is NOT RECOMMENED. DO NOT use BIO–HY– GARD® in this transmission.

The following greases are preferred: • MOLY HIGH TEMPERATURE EP GREASE • HIGH TEMPERATURE EP GREASE • MULTI-PURPOSE GREASE

The following oil is RECOMMENDED: • S2048 use 5W-30 or 10W-30 • S2554 use 5W-50 SYNTHETIC Use only oils that meet the following specifications:

SAE 5W-30

SAE 10W-30

• API Service Classifications SG or higher. • CCMC Specifications G4 or higher.

Other greases may be used if they meet one of the following: • SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide. • SAE Multipurpose EP Grease Greases meeting Military Specification MIL-G-10924F may be used as arctic grease.

ALTERNATIVE LUBRICANTS

AIR TEMPERATURE

M58275

John Deere Dealers: You may want to cross-reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032.

3/3/00

Conditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than these printed in this manual or the operator's manual. Consult with your John Deere Dealer, or Sales Branch to obtain the alternative lubricant recommendations.

OIL FILTERS Filtration of oils is critical to proper lubrication. Always change filters regularly. Use filters meeting specification.

John

Deere

performance

2-9

SERIAL NUMBER LOCATIONS

SPECIFICATIONS & INFORMATION

LUBRICANT STORAGE This machine can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides.

SERIAL NUMBER LOCATIONS Engine ID Number

When working on machines or components that are covered by warranty, it is IMPORTANT that you include the tractor identification number and the component serial numbers on the warranty claim form.

M99841

The location of tractor identification number and component serial numbers are shown below.

GEAR TRANSAXLE SERIAL NUMBER

TRACTOR IDENTIFICATION NUMBER

Transmission ID Number

P.I.N. Number

M55792a M87550

Gear transaxle serial number sticker (C) is on rear of housing.

ENGINE SERIAL NUMBER

HYDROSTATIC TRANSMISSION SERIAL NUMBER

Engine ID Number

Transmission ID Number

M99840

M87551

2 - 10

3/3/00

CONTENTS

KOHLER ENGINE

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TEST & ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIAL OR REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CRANKCASE BREATHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 AIR INTAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GOVERNOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ENGINE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . 11 CARBURETOR TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ENGINE TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . 13 ENGINE HARD TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ENGINE MALFUNCTIONS AT LOW SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ENGINE RUNS ERRATICALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OIL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ENGINE HAS LOW POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUEL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GOVERNOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CHOKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FAST IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SLOW IDLE SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FUEL SHUTOFF SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ENGINE OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SPARK TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SPARK PLUG GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 IGNITION MODULE AIR GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 FLYWHEEL MAGNETS TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SPARK ADVANCE MODULE (SAM) TEST (25 HP) . . . . . . . . . . . . . . . . . . . . . . . . . 28

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3/3/00

3-1

CONTENTS CONTNUED

KOHLER ENGINE

Page AIR CLEANER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP, REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARMS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC VALVE LIFTERS INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR REMOVAL AND INSTALLATION (19/21/23 HP) . . . . . . . . . . . STARTING MOTOR REMOVAL AND INSTALLATION (25 HP) . . . . . . . . . . . . . . . . CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND SPRINGS REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . VALVE SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE GUIDES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECONDITION VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAP VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE REED VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GOVERNOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . GOVERNOR CONTROL SHAFT REMOVAL AND INSTALLATION . . . . . . . . . . . . . PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON DISASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON RING SIDE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON TO BORE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTON INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN CRANKSHAFT SEAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH, REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLOCK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER BORE DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

31 32 32 33 34 35 35 36 38 39 39 40 40 40 41 41 41 42 42 43 44 44 45 45 46 46 47 47 47 47 48 49 50 51 51 52 52 53 53 54 54

3/3/00

KOHLER ENGINE

GENERAL SPECIFICATIONS

SPECIFICATIONS GENERAL SPECIFICATIONS Engine (19 hp) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV19 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17 kW (19 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624 cm3 (38.1 cu.in.) Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 mm (3.03 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.) Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage Engine (21 / 23 hp) Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV22 Horsepower CV21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.66 kW (21 hp) CV23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.15 kW (23 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674 cm3 (41.1 cu.in.) Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm (3.15 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.) Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt.) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage Engine (25 hp) Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CV25 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.4 kW (25 hp) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725 cm3 (44.0 cu.in.) Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 mm (3.27 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.64 in.) Oil Capacity (w/ oil filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 L (2.1 qt.) Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On Filter Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stage

3/7/00

3-3

TEST & ADJUSTMENT SPECIFICATIONS

KOHLER ENGINE

TEST & ADJUSTMENT SPECIFICATIONS Engine Oil pressure sensor activates . . . . . . . . . . . . . . . . . . . . . . . . 21.1 – 35.3 kPa (3 – 5 psi) Cylinder compression pressure (min) . . . . . . . . . . . . . . . . . . . . . . . . 1125 kPa (160 psi) Maximum compression pressure variation between cylinders . . . . . . . 138 kPa (20 psi) Slow idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700 ±75 rpm Fast Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3350 ±75 rpm Spark Plug Type (Champion® or Equivalent) . . . . . . . . . . . . . . . . . . . . . . . . . . RC12YC Spark Plug Gap (All Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 – 29.8 N•m (216 – 264 lb-in.) Ignition Module Air Gap. . . . . . . . . . . . . . . . . . . . . . . 0.2 – 0.3 mm (0.008 – 0.0012 in.) Fuel Pump Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 L/hr. (2 gph) Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.07 kPa (0.3 psi)

REPAIR SPECIFICATIONS Camshaft End Play (With Shim) . . . . . . . . . . . . . . . . . . . . . . 0.076 – 0.127 mm (0.003 – 0.005 in.) Running Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.025 – 0.063 mm (0.001 – 0.0025 in.) Camshaft Bore ID Case (New) . . . . . . . . . . . . . . . 20.0 – 20.025 mm (0.787 – 0.788 in.) Camshaft Bore ID Case (Wear Limit) . . . . . . . . . . . . . . . . . . . . 20.038 mm (0.789 in.) Camshaft Bearing Surface OD (New) . . . . . . . . 19.962 – 19.975 mm (0.786 – 0.786 in.) Camshaft Bore OD (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . 19.959 mm (0.786 in.) Connecting Rod Piston Pin ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.015 – 17.023 mm (0.670 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.036 mm (0.671 in.) Rod to Crankpin Side Clearance. . . . . . . . . . . . . . . .0.26 – 0.63 mm (0.010 – 0.025 in.) Crankshaft PTO & Flywheel End Main Journal OD . . . . . . 40.913 – 40.935 mm (1.611 – 1.612 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.84 mm (1.608 in.) Connecting Rod Journal . . . . . . . . . . . . . . . 35.955 – 35.973 mm (1.4156 – 1.4163 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.94 mm (1.415 in.) Maximum Total Indicated Runout (TIR). . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 – 0.48 mm (0.003 – 0.019 in.) Crankshaft Plain Bearings Crankcase Cover (Oil Pan) Bearing ID . . . . . . . 40.974 – 40.987 mm (1.613 – 1.614 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.025 mm (1.615 in.) Crankcase Bearing ID . . . . . . . . . . . . . . . . . . . . 40.965 – 41.003 mm (1.613 – 1.614 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.016 mm (1.615 in.) Cylinder Bore 19 hp: Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.00 – 77.025 mm (3.0315 – 3.0325 in.) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.063 mm (3.034 in.) Maximum Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Maximum Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

3-4

3/7/00

KOHLER ENGINE

REPAIR SPECIFICATIONS

Cylinder Bore 21/23 hp: Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.00 – 80.025 mm (3.1496 – 3.1506 in.) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80.065 mm (3.1522 in.) Maximum Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Maximum Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Cylinder Bore 25 hp: Standard ID . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.98 – 83.02 mm (3.2669 – 3.2685 in.) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.051 mm (3.2697 in.) Maximum Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Maximum Taper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Piston 19 hp: Maximum ring groove clearance Top Compression Ring . . . . . . . . . . . . . . . . . . . . . . 0.04 – 0.08 mm (0.002 – 0.003 in.) Middle Compression Ring . . . . . . . . . . . . . . . . . . . 0.04 – 0.08 mm (0.002 – 0.003 in.) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 – 0.20 mm (0.002 – 0.008 in.) Top and Center compression ring end gap Used Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) New Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . 0.3 – 0.5 mm (0.012 – 0.020 in.) Distance from bottom of piston skirt Height of piston OD measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.236 in.) Piston OD New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.967 – 76.985 mm (3.030 – 3.031 in.) Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.840 mm (3.0252 in.) Piston-to-cylinder bore clearance . . . . . . . . . . 0.035 – 0.078 mm (0.0014 – 0.0031 in.) Piston Pin Bore ID. . . . . . . . . . . . . . . . . . . . . 17.006 – 17.012 mm (0.6695 – 0.6698 in.) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.025 mm (0.6703 in.) Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.995 – 17.00 mm (0.6691 – 0.6693) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.994 mm (0.6691) Piston 21/23 hp: Maximum ring groove clearance Top Compression Ring . . . . . . . . . . . . . . . . . . . . . . 0.03 – 0.05 mm (0.001 – 0.002 in.) Middle Compression Ring . . . . . . . . . . . . . . . . . . . 0.02 – 0.04 mm (0.002 – 0.003 in.) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 – 0.20 mm (0.001 – 0.007 in.) Top and Center compression ring end gap Used Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) New Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . 0.3 – 0.5 mm (0.012 – 0.020 in.) Distance from bottom of piston skirt Height of piston OD measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.236 in.) Piston OD New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.963 – 79.979 mm (3.148 – 3.149 in.) Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.831 mm (3.143 in.) Piston-to-cylinder bore clearance . . . . . . . . . . 0.021 – 0.062 mm (0.0008 – 0.0024 in.) Piston Pin Bore ID. . . . . . . . . . . . . . . . . . . . . 17.006 – 17.012 mm (0.6695 – 0.6698 in.) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.025 mm (0.6703 in.) Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.995 – 17.00 mm (0.6691 – 0.6693) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.994 mm (0.6691)

3/7/00

3-5

REPAIR SPECIFICATIONS

KOHLER ENGINE

Piston 25 hp: Maximum ring groove side clearance Top Compression Ring . . . . . . . . . . . . . . . . . . . . . 0.03 – 0.05 mm (0.001 – 0.002 in.) Middle Compression Ring . . . . . . . . . . . . . . . . . . . 0.02 – 0.04 mm (0.001 – 0.002 in.) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 – 0.18 mm (0.001 – 0.007 in.) Top and Center compression ring end gap Used Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) New Bore (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . 0.3 – 0.5 mm (0.012 – 0.020 in.) Distance from bottom of piston skirt Height of piston OD measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.236 in.) Piston OD New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.956 – 82.974 mm (3.2660 – 3.2667 in.) Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.841 mm (3.2615 in.) Piston-to-cylinder bore clearance . . . . . . . . . . 0.003 – 0.067 mm (0.0001 – 0.0026 in.) Piston Pin Bore ID. . . . . . . . . . . . . . . . . . . . . 17.006 – 17.012 mm (0.6695 – 0.6698 in.) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.025 mm (0.6703 in.) Piston Pin OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.995 – 17.00 mm (0.6691 – 0.6693) Maximum Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.994 mm (0.6691) Cylinder Head Cylinder Head Flatness (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . 0.076 mm (0.003 in.) Valve guide ID (New) . . . . . . . . . . . . . . . . . . . . 7.038 – 7.058 mm (0.277 – 0.2779 in.) Valve guide ID (Wear limit-Intake) . . . . . . . . . . . . . . . . . . . . . . 7.134 mm (0.2809 in.) Valve guide ID (Wear limit-Exhaust) . . . . . . . . . . . . . . . . . . . . 7.159 mm (0.2819 in.) Valve Stem-to-Valve Clearance (Intake) . . . . . 0.038 – 0.076 mm (0.0015 – 0.0030 in.) Valve Stem-to-Valve Clearance (Exhaust) . . . 0.050 – 0.088 mm (0.0020 – 0.0035 in.) Valve Guide Reamer Size Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.048 mm (0.2775 in.) 0.25 mm Over Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.298 mm (0.2873 in.) Valve Stem Diameter (New) Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.982 – 7.000 mm (0.2749 – 0.2756 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.970 – 6.988 mm (0.2744 – 0.2751 in.) Intake Valve Minimum Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.07 mm (0.3177 in.) Exhaust Valve Minimum Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.07 mm (0.3177 in.) Valve Margin (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.0591 in.) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5° (89°) Valve Face Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° (90°) Governor: Governor Gear Shaft Height (Top of Shaft to Case) . . . . . . . . . . . . . . . . 34.0 – 33.5 mm (1.338 – 1.319 in.) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.990 – 6.000 mm (0.2358 – 0.2362 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.977 mm (0.2353) Governor Control Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.975 – 6.012 mm (0.2352 – 0.2367 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.962 mm (0.2347) Shaft to Crankcase Clearance . . . . . . . . . . .0.013 – 0.075 mm (0.0005 – 0.0030 in.)

3-6

3/7/00

KOHLER ENGINE

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS Blower Housing and Sheet Metal M5 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 N•m (35 lb-in.) M6 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 N•m (60 lb-in.) Rectifier Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 N•m (35 lb-in.) Carburetor And Intake Manifold Intake Manifold Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.9 N•m (88 lb-in.) Carburetor Mounting Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.9 N•m (88 lb-in.) Air Cleaner Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.9 N•m (88 lb-in.) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 – 29.8 N•m (216 – 264 lb-in.) Connecting Rod Cap Fasteners 8 mm straight shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 N•m (200 lb-in.) 8 mm step-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 N•m (130 lb-in.) 6 mm straight shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 N•m (100 lb-in.) Crankcase Cover (Oil Pan) Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 N•m (216 lb-in.) Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 N•m (120 lb-in.) Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.) Breather Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 N•m (65 lb-in.) Oil Pump to Oil Pan First Time Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 N•m (95 lb-in.) All Reinstallations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 N•m (60 lb-in.) Cylinder Head Fastener— initial torque, in sequence . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (180 lb-in.) Fastener— final torque, in sequence . . . . . . . . . . . . . . . . . . . . . . . . 40.7 N•m (30 lb-ft) Rocker Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 N•m (100 lb-in.) Valve Cover With Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) With O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 N•m (70 lb-in.) Flywheel Fan Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 N•m (88 lb-in.) Flywheel Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.4 N•m (49 lb-ft) Stator Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 N•m (35 lb-in.) Miscellaneous Fasteners Engine Mounting Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N•m (24 lb-ft) Drive Sheave Cap Screw to Crankshaft . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (85 lb-ft) Fuel Pump Mounting Flange Screws . . . . . . . . . . . . . . . . . . . . . . . . 2.3 N•m (20 lb-in.) Governor Control Lever Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 N•m (88 lb-in.) Speed Control Bracket Assembly Fasteners . . . . . . . . . . 7.3 – 10.7 N•m (65 – 95 lb-in.) Muffler Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4 N•m (216 lb-in.) Ignition Module Fastener. . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 – 6.2 N•m (35 – 55 lb-in.) Electric Starting Motor Mounting Screws . . . . . . . . . . . . . . . . . . . . 15.3 N•m (135 lb-in.)

3/7/00

3-7

SPECIAL OR REQUIRED TOOLS

KOHLER ENGINE

SPECIAL OR REQUIRED TOOLS

Tool

3-8

Description

Purpose

Dial Indicator

Automatic compression relief test, Valve inspection

JT07270 JTO5719

Digital Pulse Tachometer, or Photo Tachometer

Set idle speed adjustments

JDM59 JDM-74A-5

Compression Gauge Ignition Test Plug

Cylinder compression test

JTO3502

Cylinder Leak Tester

Cylinder leak test

JTO5697 JTO3503

U-Tube Manometer Test Kit; or, Crankcase Vacuum Test Kit

Crankcase vacuum check

JTO3344 JTO3017 JTO3338

Pressure Gauge Assembly Hose Assembly 0Â° Elbow Fitting

Oil pressure test

JDG356

Pressure Gauge Graduated Container

Fuel pump test

D-05351ST

Spark Tester

Spark test

Lapping Tool

Valve lapping

3/7/00

GENERAL

KOHLER ENGINE

THEORY OF OPERATION GENERAL The power plant for this unit is a air cooled four stroke two cylinder vertical shaft gasoline fueled normally aspirated engine. Fuel is provided by a pulse type fuel pump from the fuel tank to a non-adjustable carburetor. Speed is controlled by a fly-weight type governor. Ignition is provided by a capacitive discharge (CD) ignition module (19/21/23 hp engines) with fixed timing; and a capacitive discharge (CD) ignition module (25 hp engines) controlled by a electronic spark advance module (Smart Spark™). A 15 Amp regulated charging system with externally mounted rectifier regulator provides operating current. Starting is by electric starting motor. No provision is provided for manual (pull) starting.

COOLING SYSTEM A fan, mounted on the engine flywheel, draws air through the intake screen as the engine rotates. Air flow is directed under the engine shroud and over the engine cooling fins. It is important that the intake screen remains open for proper air flow. The engine shroud should never be altered or removed, as cooling capacity will be affected. Cylinder block and cylinder head cooling fins must remain clean and open to properly dissipate heat. Engines must never be overloaded or operated beyond the intended power range or rpm or overheating will occur.

CRANKCASE BREATHER SYSTEM The crankcase breather assembly allows excess crankcase pressure to pass from the crankcase to the carburetor and be burned in the engine. The breather system consists of a reed valve, oil separator, and supply tube to intake manifold. A reed valve is located in each cylinder head and allows pressure out of the crankcase, but does not allowing air back in. A properly functioning reed valve maintains a partial vacuum in the crankcase. This prevents oil from being forced out of the crankcase oil seals. The oil separator is located on one of the valve covers and separates oil from the air before it inters the air cleaner.

LUBRICATION SYSTEM The engines utilizes a fully pressurized lubrication system. A gear driven Gerotor oil pump is located in the engine sump and provides oil under pressure to all major engine components. A external spin on type oil filter is provided to keep the oil clean. A externally mounted oil cooler is located on the blower housing for the 23 and 25 hp engines.

3/7/00

FUEL SYSTEM These engines are equipped with an external mounted pulse operated fuel pump. The pumping action is created by the oscillation of positive and negative pressures within the crankcase. this pressure is transmitted to the fuel pump through a rubber hose connected between the pump and crankcase. the pumping action caused the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke. Two check valves prevent fuel from going backward through the pump.

CARBURETOR Provides the correct air/fuel mixture to allow the engine to run at maximum efficiently under a wide variety of temperature and load conditions. The carburetor has a electrically operated fuel shut off solenoid mounted externally on the fuel bowl that interrupts the fuel flow to the main jet when the operator turns of the ignition switch. The carburetor contains no serviceable components.

AIR INTAKE SYSTEM OPERATION Consists of a dual element air filter. The outer, foam, element is removable and can be cleaned and reused. the inner, paper, element is replaceable. Air enters the air filter from the opening in the cover and is filtered. Clean air is drawn into the carburetor and the engine for combustion.

GOVERNOR OPERATION Controls the maximum speed of the engine to a specified limit, and maintains a “set” engine speed. Throttle valve position (and engine speed) is controlled by the engine governor. The governor lever is being acted on by two forces, in opposite directions; in one direction the pull of the throttle control lever and cable, in the other direction the centrifugal force of the governor flyweights inside the engine. The governor flyweights will always override the pull of the throttle control spring once the engine reaches maximum governed speed. The governor gear and flyweights are located inside the crankcase and driven by the camshaft gear. As engine speed is increased, the flyweights are pushed outward by centrifugal force. As the flyweights move outward they push on the plunger, which contacts the governor arm. The governor arm passes through the crankcase housing, and has the governor lever mounted on it’s end. The governor lever is connected by a link to the throttle shaft, and will pull the throttle valve closed when the engine reaches maximum governed speed.

3-9

IGNITION When operating the engine under varying loads with a fixed throttle control lever position, the governor has the effect of maintaining a constant engine speed as the load increases. This is because as the engine speed decreases because of the load, the governor flyweights move in, and the governor linkage allows the throttle valve to open, speeding up the engine. This will occur until the engine reaches maximum load, at which time the throttle is wide open. The high idle limiter screw determines the amount of travel the throttle control lever can move, and amount of tension the governor spring can exert on the governor lever. This determines the governed high idle speed.

IGNITION Ignition is provided by a capacitive discharge (CD) ignition module (19/21/23 hp engines) with fixed timing; and a capacitive discharge (CD) ignition module (25 hp engines) controlled by a electronic spark advance module (Smart Spark™).

KOHLER ENGINE

When the charge on the delay capacitor exceeds the charge on the charge pump capacitor the comparator changes state, activating the pulse generator. This pulse turn “ON” the CD ignition module semiconductor. Energy is then transferred to the primary of the output transformer. As the capacitor discharges, the current initiates a fast rising flux field in the transformer core. A high voltage pulse is generated from this action into the secondary winding of the transformer. This pulse is delivered to the spark plug. Ionization of fuel-air mixture in the spark plug gap occurs, resulting in an ark between the plug electrodes. This spark ignites the fuel-air mixture in the combustion chamber. As the trigger pulse is generated, all associated circuits are reset, their capacitors discharged. The longer it takes the delay circuit to surpass the charge pump capacitor voltage, the later the trigger pulse will occur, retarding the timing accordingly.

Capacitance Discharge Ignition (CDI) As the flywheel rotates, the magnet grouping passes the input coil. The corresponding magnetic field induces energy into the input coil. The resultant pulse is rectified and charges a capacitor. As the magnet assembly completes its pass, it activates the triggering device which causes a semiconductor switch (SCS) to turn on. With the device switch ON, the charging capacitor is directly connected across the primary coil of the output transformer. As the capacitor discharges, the current initiates a fast rising flux field in the transformer core. A high voltage pulse is generated from this action into the secondary winding of the transformer. This pulse is delivered to the spark plug. Ionization of fuel-air mixture in the spark plug gap occurs, resulting in an ark between the plug electrodes. This spark ignites the fuel-air mixture in the combustion chamber. Smart Spark™ As the flywheel rotates, the magnet grouping passes the input coil. The corresponding magnetic field induces energy into the input coil. The resultant pulse is fed to the input of the conditioning circuit. The conditioning circuit shapes this pulse, putting it in a usable form for the additional circuits. This pulse starts the charge pump, which charges a capacitor in a linear fashion that can be directly related to the engine speed. At the same time the pulse resets the delay circuit for length of the pulse width. The comparator is off during this period and no output is generated. As soon as the original pulse drops back to zero (magnet clearing the coil), the capacitor in the delay circuit begins to charge.

3 - 10

3/7/00

IGNITION

KOHLER ENGINE

3/7/00

●

● ●

●

● ●

●

● ●

●

● ●

Excessive engine noise or vibration

●

Engine overheats

●

Exhaust smoke blue or uses oil

●

Exhaust smoke black, engine floods

●

Engine has no spark

●

Engine surges–has uneven rpm

Engine has low power under load

●

Engine misses

Engine backfires

Spark Plug Fouled, Or Gap Not Correct. Wrong Spark Plug Spark Advance Module Ground Wire Shorted To Ground Low Voltage Supply to Spark Advance Module Ignition Module Bad Tank Outlet Screen or Fuel Line Restricted. Fuel Stale, Contains Water, or Wrong Type Air filter element plugged, oil soaked, or restricted Choke, or Governor Linkage Worn or out of adjustment Carburetor Dirty or Shafts Worn Carburetor, Intake Manifold, or Cylinder Head Gaskets Leaking Low Compression from Worn Piston, Rings, Cylinder, Valves or Warped Head Valve Clearance Incorrect. Burned or Warped Valves and Seats. Defective Springs Engine Oil Type or Level Wrong Engine Gaskets or Seals Leaking Crankcase Breather Restricted, Reed Valve Damaged, Clearance Incorrect, or Drain Hole Plugged Valve Guides or Stems Worn Worn, Stuck, Broken Piston Rings. Cylinder Worn. Check Compression and Vacuum Connecting Rod/Crankshaft Worn Engine Mounting Hardware Loose, Broken, or Missing

Engine stalls frequently

Check or Solution

Engine won’t stay running or runs rough

Problem or Symptom

Engine cranks but will not start

ENGINE TROUBLESHOOTING CHART

●

● ● ●

3 - 11

CARBURETOR TROUBLESHOOTING CHART

KOHLER ENGINE

3 - 12

●

● ●

● ● ● ●

●

● ● ●

● ● ● ●

●

● ●

●

● ● ● ● ●

● ● ● ●

● ●

●

● ●

●

● ●

●

● ●

●

Engine Over Speeds

●

Runs With High speed needle Closed

●

Hunts at High Speed

●

Low Power

● ●

●

Hesitates

●

Over Rich Acceleration

●

Will Not Accelerate

● ●

Rich Idle

Will Not Idle

Engine Floods ●

Idles Fast–Won’t Adjust

● ●

Hunts / Erratic Idle

Plugged Air Filter Leaky Manifold Gasket Throttle / Choke Shaft Worn Choke Not Closing Choke Not Opening Plugged Bowl Vent Air Bleed Restricted Leaky Bowl Gasket Plugged Tank Filter Screen Or Cap Vent Fuel Pump Not Providing Enough Fuel Incorrect Float Height Main Nozzle Restricted Dirty or Stuck Float Needle and Seat Fuel Inlet Plugged Adjust Governor Linkage

Fuel Leak at Carburetor

Check or Solution

Hard Starting

Problem or Symptom

Will Not Run At High Speed

CARBURETOR TROUBLESHOOTING CHART

●

3/7/00

ENGINE HARD TO START

KOHLER ENGINE

ENGINE TROUBLESHOOTING GUIDE ENGINE HARD TO START Remove spark plug and NO check spark by cranking engine while having the YES plug grounded against engine block. Install spare plug to avoid fuel spitting from the hole. (See “SPARK TEST” on page 25.) CAUTION: To avoid electric shock, do not hold plug. Make sure to hold plug cap.

Is compression sufficient? (See “CYLINDER COMPRESSION PRESSURE TEST” on page 20.)

Are sparks produced when spark plug YES • Faulty spark plug. is replaced? NO

Are sparks produced between high tension lead and engine block with plug cap removed?

3/7/00

YES NO

• Faulty contact of plug cap terminal to lead.

Correct

• Faulty control unit.

Replace

• Faulty ignition coil with module. • Faulty high tension lead. • Incorrect ignition coil with module air gap. (See “IGNITION MODULE AIR GAP ADJUSTMENT” on page 27.). • Demagnetized flywheel.

Replace

YES

Are sparks produced between high tension lead and engine block when control unit is replaced? (See “SPARK NO ADVANCE MODULE (SAM) TEST (25 HP)” on page 28.)

YES Crank engine several times, then

remove spark plug and observe electrodes. Are they wet?

Check carburetor.

Replace

• • • •

Check for plugged fuel passage. Check for plugged air passage. Check shutoff solenoid. Check carburetor setting.

• • • •

No fuel in the tank. Closed shutoff valve. Clogged fuel filter. Closed shutoff solenoid. YES • Plugged air hole in tank cap. • Plugged fuel line.

Replace Correct

Replace Add Open Clean Check or replace Clean Clean

• Excessive use of choke. • Clogged air cleaner. • Fuel level too high in float bowl.

Open choke

• Worn piston/piston rings. • Stuck piston rings. • Worn cylinder bore. • Insufficient cylinder head tightening. • Faulty contact of valve seat. • Warped cylinder head. • Broken valve spring. • Stuck valve. • Leaking head gasket.

Replace

Clean Adjust

Clean or replace Bore or replace Retighten Lap or grind Repair or replace Replace Clean or grind Replace

3 - 13

ENGINE MALFUNCTIONS AT LOW SPEED

KOHLER ENGINE

ENGINE MALFUNCTIONS AT LOW SPEED Remove spark plug and check spark by cranking engine while having the plug grounded against engine block. Install spare plug to avoid fuel spitting from the hole.

• Faulty plug insulation. • Fouled electrodes. • Faulty high tension lead. • Incorrect ignition coil air gap. • Faulty ignition system. (See “SPARK ADVANCE MODULE (SAM) TEST (25 HP)” on page 28.).

WEAK

STRONG

CAUTION: To avoid electric shock, do not hold plug. Make sure to hold plug cap.

Is unusual smoke emitted out of muffler?

Gradually open throttle valve by hand. Does engine speed drop or does engine stall at a certain position?

Is air drawn through carburetor flange?

Correct Check

Clean Clean

Correct

YES

• Passages in carburetor plugged.

Clean

YES

• Loose flange nuts. • Damaged gasket. • Warped flange.

Tighten Replace Replace

• Collapsed lifter. • Worn camshaft lobes, pushrods.

Replace Replace

• Incorrect valve timing.

Correct

YES

Adjust

Repair Replace Correct

YES

3 - 14

Replace

• Plugged air filter. • Deposits in exhaust port. • Choke set incorrectly . • Overfilled crankcase. • Worn piston/piston rings. • Worn cylinder bore. • Defective breather valve.

Are hydraulic lifters working correctly?

Is alignment of timing gear marks correct?

Replace Clean

3/7/00

ENGINE RUNS ERRATICALLY

KOHLER ENGINE

ENGINE RUNS ERRATICALLY Problem in fuel system (lack of fuel).

• Fuel pump not functioning. (See “FUEL PUMP TEST” on page 25.). • Dust or water in fuel pipe or fuel filter. • Air or vapor lock in fuel line. • Plugged air vent in fuel tank cap. • Plugged air/fuel passages in carburetor. • Too little opening of carburetor pilot air screw.

Problem in governor system.

Engine knocks.

Test Clean Remove Clean Clean Correct

• Incorrect governor linkage adjustment. (See “GOVERNOR ADJUSTMENT” on page 17.). • Faulty/incorrect governor spring. • Governor gear assembly malfunction.

Correct

• • • •

Change

Stale fuel. Excessive carbon deposit in engine. Excessive engine load. Engine overheating.

Replace Check

Clean Adjust See Has Low Power

OIL CONSUMPTION IS EXCESSIVE Is compression sufficient? (See “CYLINDER COMPRESSION PRESSURE TEST” on page 20.)

YES NO

• • • • • • •

Plugged oil ring groove. High oil level. Worn valve stems and valve guides. Oil leakage along Governor Shaft Oil seals leaking. Head gasket leaking. Drain plug leaking.

• Breather valve clogged. • Drainback hole in tappet chamber plugged. • Incorrect oil viscosity.

Clean Adjust Replace Replace Replace Replace Retighten or replace Clean Clean Change

• Same as Hard To Start.

3/7/00

3 - 15

ENGINE HAS LOW POWER

KOHLER ENGINE

ENGINE HAS LOW POWER Is engine overheated?

YES NO

Is lubricating condition normal?

NO YES

Is unusual smoke emitted out of muffler?

YES NO

Is compression sufficient? (See “CYLINDER COMPRESSION PRESSURE TEST” on page 20.).

• Excessive engine load. • Ignition not operating correctly. (See “SPARK ADVANCE MODULE (SAM) TEST (25 HP)” on page 28.). • Dirty or clogged air intake screen, shroud and engine fins. • Carbon deposit in combustion chamber. • Incorrect oil level.

Adjust load Replace

• Too much or too little oil in crankcase. • Excessively contaminated lubricating oil/filter. • Faulty oil pump.

Correct Change Replace

• • • •

Clean

Air cleaner clogged. Carbon deposit in exhaust port and muffler. Carburetor not properly adjusted. Too much oil in crankcase.

Clean Clean Adjust

Clean Adjust Correct

• Same as Hard To Start.

FUEL CONSUMPTION IS EXCESSIVE Is compression sufficient? (See “CYLINDER COMPRESSION PRESSURE TEST” on page 20.).

YES NO

• Carburetor float or pilot air screw not properly adjusted. • Air cleaner clogged. • High idling speed. (See “FAST IDLE SPEED ADJUSTMENT” on page 19.). • Choke valve not fully open. (See “CHOKE ADJUSTMENT” on page 18.).

Adjust Clean Adjust Adjust

• Same as Hard To Start.

IGNITION SYSTEM Is only one cylinder firing

YES NO

Is timing advance operating correctly? (See “SPARK ADVANCE MODULE (SAM) TEST (25 HP)” on page 28.).

3 - 16

• Check all wiring for side not firing. If OK, replace ignition module and retest. • Make sure that ignition switch is in correct position. • Check for shorted “kill” lead. • Check to make sure that 7VDC is available at SAM.

Replace

• Replace Spark Advance Module (SAM).

Replace

Adjust Correct Adjust

3/7/00

GOVERNOR ADJUSTMENT

KOHLER ENGINE

TESTS AND ADJUSTMENTS High Idle Adjustment Screw

GOVERNOR ADJUSTMENT Reason: To make sure the governor is operating correctly. Initial Adjustment: 1. Park tractor and engage parking brake. 2. Disconnect headlight wiring harness and remove hood.

Throttle Linkage Governor Arm

Throttle Lever

M89885 M89726

3. Loosen the throttle cable clamp (A) enough to allow the throttle cable to slide freely through the clamp. 4. Move throttle control lever, on the operators control panel, to FAST idle position. A solid "detent" should be felt to assure that the control lever is in the FAST idle position. 5. Rotate fast idle control arm until fast idle screw head contacts fast idle stop. Clamp throttle cable in this position.

6. Make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor. 7. Loosen the nut holding the governor arm to the governor shaft. Move the governor arm towards the carburetor as far as it will move and hold. 8. Insert a pin or small punch into the hole on the governor shaft and rotate the shaft counterclockwise as far as it will turn, then tighten nut. Remove the pin or punch. 9. Replace air filter backing plate.

c CAUTION DO NOT run engine without replacing air filter backing plate, or using nuts to secure carburetor to manifold! 10. Start engine and use fast idle screw to adjust fast idle to specification. Specification: All Engines . . . . . . . . . . . . . . . . . . . . . . 3350 Âą75 rpm 11. Perform sensitivity adjustment.

3/7/00

3 - 17

CHOKE ADJUSTMENT

KOHLER ENGINE

CHOKE ADJUSTMENT

Governor Spring Settings:

Reason: To make sure that the choke plate is fully closed when the choke control is retracted and fully open when choke control is fully depressed. Test Procedure: A

MX0954

High Idle RPM 3350 ± 75

Hole A

1. Park tractor and set parking brake. 2. Disconnect headlight wiring harness and remove hood. 3. Remove air cleaner.

Spring Color Code Silver

Sensitivity Adjustment:

M89887

4. Retract choke lever, on operators control panel, to full CHOKE ON position. 5. Look in carburetor to make sure that choke is closed.

Governor Arm Increase

Decrease

Governor Spring

M89885

Governor sensitivity is adjusted by repositioning the governor spring in the holes on the governor arm. If speed surging occurs with a change in engine load the governor is set to sensitive. If a big drop in speed occurs when normal load is applied, the governor should be set for greater sensitivity follows: • To INCREASE sensitivity - move the spring closer to the governor lever pivot point. • To DECREASE sensitivity - move the spring further from the governor lever pivot point. Readjust fast idle to specification.

3 - 18

M89886

3/7/00

FAST IDLE SPEED ADJUSTMENT

KOHLER ENGINE

6. Depress choke lever, on operators control panel, to full CHOKE OFF position. 7. Look in carburetor to make sure that choke is fully open.

FAST IDLE SPEED ADJUSTMENT Reason: To set engine FAST idle speed.

Adjustment Procedure: 1. Depress choke lever, on operators control panel, to full CHOKE OFF position.

Equipment: • JT07270 Digital Pulse Tachometer Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Disconnect headlight wiring harness and remove hood. 4. Start and run engine at MEDIUM idle for 5 minutes to warm engine to normal operating temperature.

c CAUTION

M89726

2. Loosen screw (A) securing choke cable and slide cable away from engine as far as it will go. Tighten screw. 3. Look in carburetor to make sure that choke is fully open. If not, inspect linkage and choke plate for damage, replace parts as required.

Engine will be HOT. Be careful not to burn hands. 5. Move throttle control lever to FAST idle position.

M85646

6. Use a JT07270 Digital Pulse Tachometer at spark plug wire to set engine FAST idle speed at specification. Specification: M89887

Specification: All Engines . . . . . . . . . . . . . . . . . . . . . . 3350 ±75 rpm 4. Retract choke lever, on operators control panel, to full CHOKE ON position. 5. Look in carburetor to make sure that choke is closed. If not, slightly bend choke linkage (B) slightly until choke is closed. DO NOT overbend. 6. Re-check open position.

3/7/00

Results: If FAST idle speed DOES NOT meet specifications: • Use fast idle screw to adjust fast idle to 3350 rpm ±75 rpm.

3 - 19

SLOW IDLE SPEED ADJUSTMENT

KOHLER ENGINE

SLOW IDLE SPEED ADJUSTMENT Reason:

7. Adjust carburetor SLOW idle stop screw (A) to set carburetor SLOW idle speed to specification. Specification:

To set engine SLOW idle speed.

All Engines . . . . . . . . . . . . . . . . . . . . . . 1700 ±75 rpm

Equipment:

Procedure for Slow Idle Mixture:

• JT07270 Digital Pulse Tachometer Procedure (All Engines): 1. Park machine on level surface. 2. Turn key switch OFF. 3. Disconnect headlight wiring harness and remove hood. 4. Start and run engine at MEDIUM idle for five minutes to warm engine to normal operating temperature. 5. Move throttle control lever to SLOW idle position.

M99751

M85646

6. Use a JT07270 Digital Pulse Tachometer at the spark plug wire to check engine rpm.

NOTE: Do not remove the air intake filter. Filter shown removed for clarity.

1. Turn the slow idle fuel mixture screw (A) in (slowly) until engine speed decreases and then back out approximately 3/4 turn to obtain the best slow idle speed performance. 2. Recheck the slow idle speed using a Digital Pulse Tachometer at the spark plug wire. Readjust slow idle stop screw as necessary to obtain slow idle speed.

CYLINDER COMPRESSION PRESSURE TEST Reason: To determine if the engine is developing adequate cylinder compression. Test Equipment:

• JDM59 Compression Gauge • JDM-74A-5 Ignition Test Plug Procedure: 1. Park machine on level surface and turn key switch OFF. 2. Raise or remove (optional) engine hood.

M89886

3 - 20

3/7/00

CYLINDER COMPRESSION PRESSURE TEST

KOHLER ENGINE

c CAUTION With spark plugs removed, the magnetos must be grounded to the engine to prevent a spark that could ignite anything combustible.

M70834

IMPORTANT: Spark Plug wire must be grounded or electronic ignition could be damaged. 3. Remove BOTH spark plugs and ground spark plug leads to engine using JDM-74A-5 Ignition Test Plug. 4. Install JDM59 Compression Gauge. 5. Move throttle control lever to FAST idle position – throttle and choke plates must be fully open to obtain an accurate reading.

2. Remove BOTH spark plugs and ground spark plug leads to engine using JDM-74A-5 Ignition Test Plug. IMPORTANT: The piston must be positioned at Top Dead Center (TDC) to ensure that the intake valves are away from the compression relief balls. If not, the intake valve will be open and the leak test will be invalid. 3. Remove valve covers. 4. Turn crankshaft until piston is at Top Dead Center (TDC), on the compression stroke (Both Valves Closed). 5. Screw the adaptor into the spark plug hole but do not attach it to the tester at this time.

IMPORTANT: DO NOT overheat starting motor during test. Starter duty cycle is 5 seconds ON, 10 seconds OFF. Battery must be at a full state of charge to perform test. Charge battery first, if necessary. 6. Crank engine until gauge needle settles out at its highest position. 7. Record pressure reading. Minimum compression should be 1125 kPa (160 psi). Results: • If compression is below minimum specification, perform cylinder leak test to better determine the state of engines condition.

CYLINDER LEAK TEST Required Tools: • JTO3502 Cylinder Leak Tester • Breaker Bar & 30 mm Socket

NOTE: If the directions that come with the tester being used are different than the following, use the directions that came with the tester. 1. The engine should be run for at least 5 minutes to bring the engine to operating temperature.

3/7/00

M88974

6. Pull back the locking ring and rotate the regulator knob fully counterclockwise. Connect an air line to the tester. IMPORTANT: The air supply must have enough supply pressure to calibrate the tester (Usually 85 – 95 psi). 7. Pull back the locking ring and rotate the regulator knob clockwise until the gauge needle rests in the SET range of the gauge. Push the locking ring towards the tester to lock it.

3 - 21

FUEL SHUTOFF SOLENOID TEST

KOHLER ENGINE

M88957

M89887

8. Connect the adaptor hose to the tester and record the needle position while holding the flywheel in position with a breaker bar.

2. Listen for an audible click from solenoid when ignition switch is turned from OFF to ON.

NOTE:

A small amount of air escaping from the crankcase breather is normal.

Results: • Excessive air escaping from the crankcase breather indicates worn piston rings or cylinder wall • Air escaping from the carburetor indicates a worn intake valve or seat • Air escaping from the exhaust pipe indicates a worn exhaust valve or seat • Gauge reading in the Green (low) area indicates good compression. (Less Than 25% Is Considered Normal) • Gauge reading in the Yellow (Moderate) area indicates borderline compression. The engine is still usable but an overhaul or replacement should be considered • Gauge reading in the Red (High) area indicates excessive compression loss and engine reconditioning or replacement is necessary

FUEL SHUTOFF SOLENOID TEST Reason: To test proper operation of fuel shutoff solenoid.

NOTE: If battery voltage drops below 9 volts when cranking engine or while engine is running, the solenoid will not function. Results: • If solenoid clicks, solenoid is good and vehicle wiring is good. • If solenoid does not click, solenoid could be bad or problem could be in equipment wiring. Proceed with following tests: 1. Disconnect solenoid wire at connector (A). 2. Momentarily place a jumper wire from solenoid wire to battery positive terminal. 3. If solenoid now clicks, the solenoid is working properly. Results: • If solenoid does not perform properly, replace solenoid. • If solenoid activates when jumpered, but not when connected to the vehicle wire harness, repair wire harness. (See ELECTRICAL Section.)

CRANKCASE VACUUM TEST

Required Tools: • Jumper wire Procedure: 1. Remove air cleaner assembly, and base.

3 - 22

Reason: To measure the amount of crankcase vacuum, which ensures the crankcase is not pressurized. A pressurized crankcase will force oil past the seals and gaskets and through the breather into the carburetor.

3/7/00

CRANKCASE VACUUM TEST

KOHLER ENGINE

JTO3503 Crankcase Vacuum Test Kit—

Test Equipment: • JT05697 U-Tube Manometer Test Kit; or, • JT03503 Crankcase Vacuum Test Kit Procedure: JT05697 U-Tube Manometer Test Kit— 1. Park machine on level surface. 2. Raise engine hood and remove dipstick. IMPORTANT: Check oil fill cap and O-ring for cracks or damage, replace as necessary.

M85637

1. Repeat Steps 1 – 4 in JTO5697 test procedure. IMPORTANT: DO NOT make connection between test gauge and rubber plug BEFORE engine is running at FAST idle or gauge damage may result. After test reading is made, DO disconnect test gauge WHILE engine is running at FAST idle to prevent damage to gauge. M45642

3. Install appropriate size rubber plug in dipstick tube. 4. Insert barbed fitting in rubber plug and connect clear line to barbed fitting. IMPORTANT: DO NOT make connection between U-Tube Manometer and clear line BEFORE engine is running or fluid in manometer could be drawn into crankcase. DO NOT turn engine OFF until clear line has been disconnected from U-Tube Manometer. 5. Align ruler “zero” markings with top of water level in U-tube. 6. Start and run engine at FAST idle. 7. Connect clear line to open U-Tube Manometer spigot. 8. Record crankcase vacuum reading. Manometer should show a minimum vacuum of 15 cm (6 in.) of water movement. 9. Run engine at SLOW idle. DO NOT TURN ENGINE OFF! 10. Disconnect clear line from open manometer spigot. 11. Turn engine OFF. 12. Remove plug from dipstick tube and install dipstick.

3/7/00

2. Hold finger over rubber plug hole to keep oil from spraying out. Start engine and run at FAST idle. 3. Connect gauge, clear line, and barbed fitting to rubber plug. 4. Record crankcase vacuum reading. Gauge should show a minimum vacuum of 15 cm (6 in.) of water movement. 5. Disconnect barbed fitting, clear line, and gauge from rubber plug while engine is running at FAST idle. Hold finger over rubber plug hole to keep oil from spraying out. 6. Move throttle to SLOW idle and turn engine OFF. 7. Remove rubber plug and install dipstick. Results: If crankcase vacuum is BELOW specification, check the following: • Breather reed valve clearance and condition. • Breather port is obstructed. • Rings, piston, and cylinder bore for wear or damage.

3 - 23

ENGINE OIL PRESSURE TEST

KOHLER ENGINE

ENGINE OIL PRESSURE TEST Reason: To verify if the engine has enough oil pressure to lubricate internal components.

NOTE: The 19/21/23 hp engines have an engine oil pressure switch. With the ignition switch in the ON position and the engine OFF, the engine will have no oil pressure. The oil pressure switch is normally closed and has continuity that provides a ground circuit for the oil pressure light. The light should be ON. The oil pressure switch opens at 3 – 5 psi and the light should be OFF. (See OIL PRESSURE SWITCH TEST (CV23/CV25) on page 61 of ELECTRICAL Section.) Test Equipment: • JTO3344 Pressure Gauge Assembly • JTO3017 Hose Assembly • JTO3338 90° Elbow Fitting

M45643

8. Install JT03338 90° Elbow Fitting, JT03017 Hose Assembly and JT03344 Pressure Gauge Assembly. 9. Monitor oil pressure while cranking engine. If no or very low oil pressure is present, discontinue cranking engine. Determine and correct cause before running engine. IMPORTANT: If pressure reading is below 69 kPa (10 psi) at FAST idle, STOP ENGINE IMMEDIATELY and determine cause.

Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. Allow engine to cool. 3. Move transaxle shift lever or forward/reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise engine hood.

c CAUTION Engine components may be HOT. Be careful not to touch while making adjustments.

10. Start and run engine at MEDIUM idle for five minutes to heat engine oil to normal operating temperature. 11. Run engine at FAST idle (3350 ± 75 rpm), then record oil pressure reading. Oil pressure should read a minimum of 240 kPa (35 psi). 12. Run engine at SLOW idle, then record oil pressure reading. Oil pressure should be a minimum of 28 kPa (4 psi).

NOTE: Minimum oil pressure specification at FAST or SLOW idle indicates engine wear. Results:

6. Check engine oil level, bring level to full mark. 7. Disconnect oil pressure switch wiring lead and remove oil pressure switch.

3 - 24

If oil pressure is BELOW specifications, inspect or replace the following: • Oil pressure relief valve for broken or worn spring. • Oil pressure relief valve for stuck or damaged valve. • Worn or damaged oil pump. • Oil filter plugged. • Oil pump suction screen or oil passages plugged. • Excessive wear of connecting rod and main bearing journals.

3/7/00

FUEL PUMP TEST

KOHLER ENGINE

FUEL PUMP TEST

13. Remove pressure gauge and connect fuel pump outlet hose to fuel pump.

Reason: To check condition of fuel pump and determine fuel pressure and flow. Test Equipment: • JDG356 Pressure Gauge • Graduated Container Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Move transaxle shift lever or forward/reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise engine hood. 6. Make sure fuel tank is at least 1/4 full with fresh fuel. 7. Start engine and run at SLOW idle for one minute to fill carburetor with fuel. 8. Stop the engine.

M89889

14. Disconnect fuel pump outlet hose from carburetor and place it in graduated container. 15. Start and run engine at FAST idle for 15 seconds, then stop engine and record container measurement. Minimum flow should be 7.5 L/hr. (2 gph). Results: If fuel pressure and/or flow specifications, check the following:

does

not

meet

• Fuel lines, filter, shutoff valve, and fuel tank cap for restrictions. • Clean and inspect fuel pump.

SPARK TEST Reason: Check overall condition of ignition system. M89888

Test Equipment:

c CAUTION Gasoline is extremely flammable. DO NOT SMOKE. Always work in a well ventilated area away from open flame or spark producing equipment; including equipment that utilizes pilot lights.

• D-05351ST Spark Tester Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Move transaxle shift lever or forward/reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Disengage PTO. 6. Raise engine hood.

9. Disconnect and plug fuel pump outlet hose. 10. Connect JDG356 Pressure Gauge hose to fuel pump outlet. 11. Start and run engine at FAST idle for 15 seconds. Minimum pressure should be 10 kPa (0.3 psi). 12. Stop engine. 3/7/00

3 - 25

SPARK PLUG GAP ADJUSTMENT

KOHLER ENGINE

c CAUTION Engine components may be HOT. Be careful not to touch while making adjustments, especially the exhaust pipe or muffler. M49887

5. Remove spark plug. IMPORTANT: Do not clean spark plug with sand paper or abrasives. Engine scoring can result.

7. Disconnect high tension lead from spark plug. 8. Connect D-05351ST Spark Tester to spark plug. 9. Connect high tension lead to Spark Tester.

6. Scrap deposits from spark plug. 7. Inspect spark plug for: • Cracked porcelain • Pitted or damaged electrodes

IMPORTANT: Do not adjust Spark Tester gap beyond 5.0 mm (0.200 in.) (5 turns), as damage to ignition components could occur. 10. Adjust spark tester gap to 4.2 mm (0.166 in.) (4 turns) with adjustment screw. 11. Move key switch to RUN position. 12. Spin engine with starting motor and watch spark at Spark Tester. If engine will start, watch spark with engine running. A steady, strong, blue spark should be observed. Results: • If spark is weak, or no spark is present, install a new spark plug and repeat test. • If spark is still weak, or no spark is present, run tests on individual components to find the cause of the malfunction.

SPARK PLUG GAP ADJUSTMENT

0.76 mm (0.03 in.)

M85608

8. Check spark plug gap using a wire feeler gauge. Set gap to specification.

Reason: To ensure spark plug air gap is within specification.

Specification: All Engines . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Test Equipment: • Wire Feeler Gauge Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Move transaxle shift lever or forward/reverse pedals to NEUTRAL position. 4. Engage park brake.

3 - 26

9. Install and tighten spark plug to specification. Specification: All Engines . . . . . . 24.4 – 29.8 N•m (216 – 264 lb-in.)

3/7/00

IGNITION MODULE AIR GAP ADJUSTMENT

KOHLER ENGINE

IGNITION MODULE AIR GAP ADJUSTMENT

FLYWHEEL MAGNETS TESTS Reason:

Reason: To adjust the air gap between the ignition module and the flywheel to a specific dimension needed for proper ignition timing.

To make sure flywheel magnet(s) have enough force to induce current in ignition coil and stator. Equipment: • Screwdriver.

Equipment: • 0.25 mm (0.010 in.) feeler gauge

Procedure:

Procedure: 1. Put transaxle in neutral. 2. Put key switch in OFF position. 3. Remove blower housing. 4. Turn flywheel magnet away from ignition module. 5. Loosen ignition module mounting screws and hold module as far back as possible. 6. Turn flywheel magnet so it is centered on ignition module.

1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED. 3. Remove flywheel housing and flywheel from engine.

M55884

M89897

7. Insert 0.25 mm (0.010 in.) feeler gauge (A) between flywheel magnet and all three ignition module polls. Allow module to draw against feeler gauge and flywheel magnet. 8. Hold module coil in this position and tighten mounting screws to specification. 9. Turn flywheel to remove feeler gauge. 10. Install blower housing. M55883

Specifications: Ignition Module Air Gap . . . . . . 0.25 mm (0.010 in.) Ignition Module Cap Screws . . . . . . . . . . . . . . . . . . . . 4.0–6.2 N•m (35–55 lb-in.)

4. Place screwdriver about 25 mm (1.0 in.) from magnets. Results:

NOTE: Use a 0.30 mm (0.012 in.) feeler gage to check ignition module air gap. Feeler gage should NOT fit between ignition module poles and magnet. If it does, readjust air gap.

3/7/00

• If screwdriver pulled into magnet, flywheel is good. • If screwdriver NOT pulled into magnet, flywheel is bad and should be replaced.

3 - 27

SPARK ADVANCE MODULE (SAM) TEST (25 HP)

SPARK ADVANCE MODULE (SAM) TEST (25 HP) Reason: To make sure that the Spark Advance Module (SAM) is operating correctly and advancing spark as required. Equipment:

KOHLER ENGINE

• If marks on the blower housing are at the same position, one of the ignition modules is firing out of time, usually indicating a wiring problem between the SAM and the ignition module. Check all wiring and connectors. If problem persists, replace SAM.

NOTE: If spark is erratic or engine misses or performs erratically, check voltage on red wire to SAM to insure that a minimum of 7 Volt DC is available. If not correct and rerun test.

• Timing Light. • Marking Pen or Narrow Tape. Procedure: 1. Park machine on level surface and turn key switch OFF. 2. Shift lever in NEUTRAL and park brake LOCKED.

M89854

3. Use a marking pen or a piece of narrow tape to make a line (A) on the edge of the flywheel screen. 4. Connect an automotive timing light to monitor spark on the #1 cylinder. 5. Start the engine and run at slow idle. 6. Use the timing light beam to locate the timing line located on the screen. 7. Carefully draw a mark (B) on the blower housing in line with the timing line on the screen. 8. While watching the marks, accelerate engine to fast Idle. 9. Stop engine, disconnect timing light and connect timing light to cylinder #2. Repeat steps 4 to 8 on second cylinder. Results: • The marks made on the blower housing correspond to the firing pints of the respective cylinders and should be 90° apart. • As engine was accelerated to fast Idle, the mark on the screen should move counterclockwise to position (C); 16 – 19 mm (0.625 – 0.750 in.), or, 5° to 15° from position at slow idle.

3 - 28

3/7/00

ENGINE REMOVAL

KOHLER ENGINE

REPAIR

6. Disconnect engine electrical connector (B), starting motor cable (C) and wire (D).

ENGINE REMOVAL 1. Drain engine oil. Oil Capacity With Filter . . . . . . . . . 2.0 L (2.1 U.S. qt)

c CAUTION Gasoline is extremely flammable. DO NOT SMOKE. Always work in a well ventilated area away from open flame or spark producing equipment; including equipment that utilizes pilot lights.

2. Disconnect battery negative (–) terminal. 3. Disconnect headlight wiring and remove hood. (See “HOOD REMOVAL AND INSTALLATION” on page 9 of MISCELLANEOUS SECTION.) 4. Remove traction drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 68 of HYDROSTATIC POWER TRAIN SECTION.)

E M89726

7. Loosen cable clamp screws (E) and disconnect throttle and choke cables.

A F M89727

M89725

8. Remove exhaust heat shields (F) from both sides of engine.

5. Disconnect fuel line (A) at fuel pump and plug.

C B

M88578

D M89728

3/7/00

9. Remove front heat shield cap screws (G) and remove heat shield from above muffler. 10. Remove transaxle and attachment drive belts.

3 - 29

ENGINE INSTALLATION

KOHLER ENGINE

11. Disconnect wire for PTO clutch. Remove cap screw and clutch.

c CAUTION Engine is heavy. Use proper lifting techniques to remove engine from frame. Serious personal injury can result. I

16. Use a hoist or obtain assistance and remove engine.

ENGINE INSTALLATION H M89916 I

12. Disconnect electric clutch connector (H). 13. Remove cap screw (I), washer and electric clutch from engine shaft.

NOTE: Drive key is a part of the electric clutch. DO NOT attempt to remove key from clutch bore.

H M89916

1. Use a hoist or obtain assistance and place engine on frame. Align mounting holes and secure with four cap screws. Tighten to specification. 2. Apply NEVER-SEEZ lubricant to engine output shaft. 3. Install key and sheave. 4. Install PTO clutch. Secure with heavy washer and cap screw (I). Tighten to specification.

M89917

14. Remove traction drive belt and sheave from engine shaft.

NOTE: Drive key is a part of the sheave. DO NOT attempt to remove key from sheave bore.

Torque Specifications: Engine Mounting Bolts . . . . . . . . . . 32 N•m (24 lb-ft) Sheave To Crankshaft Bolt . . . . . . 115 N•m (85 lb-ft) 5. Connect clutch electrical connector (H). 6. Install transaxle drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 68 of HYDROSTATIC POWER TRAIN SECTION.)

15. Remove four engine mounting bolts (J) and engine.

3 - 30

3/7/00

AIR CLEANER REMOVAL AND INSTALLATION

KOHLER ENGINE

AIR CLEANER REMOVAL AND INSTALLATION 1. Remove the wing nut and the air cleaner cover.

M89728 A

7. Connect engine electrical connector and starting motor wires. 8. Install front and side exhaust heat shields.

M89856

2. Remove the wing nut (A) and the air cleaner element cover. Remove the air filter. 3. Remove the foam precleaner from the paper air filter element.

M89726

9. Connect throttle and choke controls. 10. Connect fuel line. 11. Connect battery negative (â&#x20AC;&#x201C;) terminal. 12. Check engine oil and top off or fill if necessary.

IMPORTANT: DO NOT use petroleum solvents, such as kerosene, to clean foam pre-cleaner. They may cause foam to deteriorate. DO NOT oil paper cartridge. DO NOT use pressurized air to clean or dry paper cartridge. If paper cartridge is excessively dirty replace with new cartridge. 4. Wash the precleaner in warm water with detergent. Rinse thoroughly, squeeze dry in a clean cloth. 5. Saturate the pre-cleaner with new engine oil. Squeeze in a clean absorbent cloth to remove excess oil. 6. Replace the paper element if it is dirty, damaged or bent. C B D

M89857

3/7/00

3 - 31

FUEL PUMP, REMOVAL AND INSTALLATION 7. Disconnect the breather hose (B) from the oil separator (C). 8. Remove nuts (D) securing air cleaner base to carburetor. Remove the air cleaner base.

NOTE: Nuts securing air cleaner base to carburetor also secure carburetor to intake manifold. DO NOT run engine with nuts removed. Installation:

KOHLER ENGINE

4. Inspect pump for wear or damage. If any damage is noted replace pump. Installation: 1. Secure pump with two hex flange screws. Tighten to specifications. 2. Connect vacuum and fuel lines. 3. Connect spark plugs. Specifications:

Installation is the reverse of removal.

Pump Mounting Screws . . . . . . . 2.3 N•m (20 lb-in.)

• Tighten air cleaner nuts to specification. Specification: Air Cleaner Mounting Nuts . . . . . 9.9 N•m (88 lb-in.)

CARBURETOR REMOVAL AND INSTALLATION Removal:

FUEL PUMP, REMOVAL AND INSTALLATION

c CAUTION

Removal: Gasoline is explosive. Do not expose to spark or flame. Serious personal injury can result.

c CAUTION

1. Remove the air cleaner elements.

Gasoline is explosive. Do not expose to spark or flame. Serious personal injury can result. 1. Disconnect spark plugs.

M89725

2. Disconnect fuel lines. Close all openings using caps and plugs. 3. Remove two hex flange screws securing fuel pump to side of blower housing. Remove fuel pump. M89858

NOTE:

3 - 32

Fuel pump components are not seviceable separately. If inspection detects any damage the entire fuel pump must be replaced. 3/7/00

ROCKER ARMS REMOVAL AND INSTALLATION

KOHLER ENGINE

2. Disconnect the electrical connections and fuel supply hose from the carburetor. 3. Disconnect the governor and throttle linkage from the carburetor. Remove the carburetor.

NOTE: The carburetor has no serviceable parts. If the carburetor has any worn out or damaged parts, the carburetor must replaced. Installation:

NOTE: Installation is the reverse of removal. B

1. Replace the gaskets, and install the carburetor to the intake manifold. 2. Connect the electrical connections, and the fuel supply hose. 3. Install the air cleaner base. See “AIR CLEANER REMOVAL AND INSTALLATION” on page 31.

ROCKER ARMS REMOVAL AND INSTALLATION 1. Remove air cleaner. It is not necessary to remove base.

M89867

2. Remove four valve cover cap screws (B) and remove valve cover.

D M89843

M89857

NOTE: If removing the #1 valve cover it is necessary to disconnect the breather hose from the breather (A).

3/7/00

IMPORTANT: Mark rocker arms, pivot ball spacers, push rods, and lifters for assembly in original locations. 3. Remove cap screws (C) and pivot ball spacers (D). 4. Remove rocker arms. 5. Remove and inspect push rods. (See “PUSH ROD INSPECTION” on page 41.)

3 - 33

HYDRAULIC VALVE LIFTERS INSPECTION

KOHLER ENGINE

HYDRAULIC VALVE LIFTERS INSPECTION E

IMPORTANT: Damaged or worn lifters usually indicate a damaged camshaft. Check camshaft before replacing lifters. Always replace lifters when replacing camshaft. DO NOT attempt to disassemble hydraulic lifters. There are no serviceable components in lifter.

M89844

1. Inspect lifter face for wear. Face should be smooth, free of any damage. 2. Use push rod to depress plunger. Plunger should offer resistance but move smoothly. 3. Check that oil hole is clear to inner piston. 4. Measure outside diameter of lifter. 5. Replace lifters that are worn or damaged.

IMPORTANT: Used lifters are mated to their camshaft lobes. Mark them for installation in the correct bore. If cam shaft is to be replaced, replace ALL lifters. DO NOT use old lifter with new cam. 6. Using a magnetic probe or a lifter puller, remove lifters (E). 7. Inspect lifters for wear, replace as necessary. (See “HYDRAULIC VALVE LIFTERS INSPECTION” on page 34.) 8. Inspect and replace components as necessary. Installation: Install components in reverse order of removal. IMPORTANT: Make sure that lifters, push rods, rocker arms, and pivot ball spacers are returned to their original positions.

M89880

NOTE: When installing new lifters, make sure lifters are full of oil. Submerse lifters in oil. Use old push rod to depress lifter several times to purge air and fill with oil or force oil into lifter with oil can.

• Coat lifters with engine oil and install in bore. • Tighten rocker pivot bolts to specifications. Specifications: Rocker Pivot Bolts . . . . . . . . . . 11.3 N•m (100 lb-in.) M89861

6. Measure inside diameter of crankcase lifter bores (A). 7. Subtract lifter OD from bore ID to determine if clearance is within specification. Replace components as necessary.

3 - 34

3/7/00

STARTING MOTOR REMOVAL AND INSTALLATION (19/21/23 HP)

KOHLER ENGINE

Installation:

Specification: Lifter Clearance . . . . . . . . . . . . . . 0.0241-0.0501 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.0009-0.0020 in.)

STARTING MOTOR REMOVAL AND INSTALLATION (19/21/23 HP)

E F

Procedure:

1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect battery negative terminal (–).

A C

M99744

Upper Engine Shroud Removed for Clarity. E

10. Position starting motor on engine. Install the front capscrew (C) with one spacer washer (F) between the bendix guard (E) and the starting motor. Install the rear capscrew (C) with a spacer washer (F) between the bendix guard (E) and the starting motor and the other spacer washer (F) between the bendix guard (E) and the lifting bracket (D). Tighten capscrews to specification. 11. Connect battery cable (A) to starting motor and reconnect battery negative cable. 12. Install the capscrew securing the oil filler tube to the lifting bracket and tighten to specification.

B C D

Specifications: Starting Motor Capscrews. . . . 15.3 N•m (135 lb-in.) Oil Filler Tube Capscrews . . . . . . 7.8 N•m (69 lb-in.)

M99743

Upper Engine Shroud Removed for Clarity. 7. Disconnect battery terminal (A) from starting motor. 8. Remove capscrew (B) securing oil filler tube to lifting bracket. 9. Remove the two capscrews (C), three spacer washers, lifting bracket (D) and bendix guard (E) securing the starting motor to the engine.

3/7/00

STARTING MOTOR REMOVAL AND INSTALLATION (25 HP) Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect battery negative terminal (–).

3 - 35

CYLINDER HEAD REMOVAL AND INSTALLATION

KOHLER ENGINE

CYLINDER HEAD REMOVAL AND INSTALLATION

Removal: 1. Remove engine from vehicle. (See “ENGINE REMOVAL” on page 29.) 2. Remove air cleaner. 3. Remove rocker arms and push rods. (See “ROCKER ARMS REMOVAL AND INSTALLATION” on page 33.) 4. Remove fuel pump from side of fan shroud. (See “FUEL PUMP, REMOVAL AND INSTALLATION” on page 32.) D C

B A

M99747

Upper Engine Shroud Removed for Clarity. 7. Disconnect battery terminal (A) and signal wire (B) from starting motor solenoid. 8. Remove capscrew (C) securing oil filler tube to lifting bracket. 9. Remove the two capscrews (D) and lifting bracket (E) securing the starting motor to the engine. Installation: 10. Position starting motor on engine. Install the capscrews (D) and the lifting bracket (E). Tighten capscrews to specification. 11. Connect battery cable (A) and signal wire (B) to starting motor solenoid and reconnect battery negative cable. 12. Install the capscrew (C) securing the oil filler tube to the lifting bracket and tighten to specification.

M89869

5. To remove carburetor: • disconnect fuel solenoid connector • disconnect ground wire from manifold to carburetor • disconnect fuel inlet hose • disconnect choke linkage • disconnect governor linkage • disconnect wire to oil sensor

Specifications: Starting Motor Capscrews . . . 15.3 N•m (135 lb-in.) Oil Filler Tube Capscrews . . . . . . 7.8 N•m (69 lb-in.)

3 - 36

3/7/00

CYLINDER HEAD REMOVAL AND INSTALLATION

KOHLER ENGINE

C M89867 M89870

6. If equipped, remove screws securing oil cooler to fan shroud. 7. Remove ground screw (A) and disconnect regulator module harness from regulator module. 8. Remove screws securing fan shroud. Remove fan shroud.

25 hp Engine 12. 25 hp only: Remove screws (C) securing spark control module to head shroud. Move wire harness to one side.

M89869

9. Remove cap screw (B) (if installed) securing wire harness to manifold. 10. Disconnect wire harness from ignition modules. 11. Remove cap screws securing manifold to heads. Remove manifold.

M99743

19/21/23 hp Engines 13. Remove cap screws (D) securing starting motor to engine.

3/7/00

3 - 37

VALVES AND SPRINGS REMOVAL AND INSTALLATION

KOHLER ENGINE

Installation:

NOTE: Proper care and procedure must be taken to avoid damage to lifters or push rods. Before proceeding, rotate piston to top dead center (TDC) on the compression stroke of the #1 cylinder. Crankshaft PTO keyway will be in the 12 o’clock position.

E M89864

14. Remove screws (E) securing outer and inner head shrouds to heads and block. Remove outer and inner shrouds. IMPORTANT: Engine must be cold before removing cap screws to avoid warping aluminum cylinder head.

1. Install new cylinder head gasket. 2. Place cylinder head on block and secure with four cap screws. 3. Tighten cylinder head cap screws to specification in 7 N•m (60 lb-in.) increments in cross pattern. 4. Install hydraulic lifters, push rods and rocker arms.

NOTE: Use high temperature anti seize (copper) on cap screws securing housings to engine. 5. Place valve cover on head, secure with cap screws and tighten to specification. 6. Place the muffler bracket (lifting hole up) in position and secure with cap screws. 7. Tighten valve cover cap screws, in sequence illustrated, to specifications. 8. Place new gasket on intake port and install intake manifold. 9. Install muffler, using new gasket. 10. Install carburetor and filter box, secure with two flange head nuts. 11. Place breather hose on fitting in valve cover. 12. Reinstall engine. (See “ENGINE INSTALLATION” on page 30.) Specification: Cylinder Head Cap Screws . . . . . 40.7 N•m (30 lb-ft) Valve Cover Cap Screws With Gasket . . . . . . . . . . . . . . . 3.4 N•m (30 lb-in.) With O-Ring . . . . . . . . . . . . . . . 7.9 N•m (70 lb-in.)

M89845

15. Remove cap screws (F) and cylinder head. Discard gasket, clean cylinder head and engine block mating surfaces.

NOTE: Do not scrape surfaces when cleaning as this will damage the aluminum surface and could cause leaks. The use of a gasket removing solvent is recommended.

3 - 38

VALVES AND SPRINGS REMOVAL AND INSTALLATION NOTE:

Valve guides are NOT replaceable. If worn beyond specifications, either ream for 0.25 mm (0.010 in.) oversize valve, or replace head. (See “VALVE GUIDES INSPECTION” on page 40.)

3/7/00

VALVE SPRING INSPECTION

KOHLER ENGINE

IMPORTANT: Make sure keepers are properly seated in valve stem groove.

VALVE SPRING INSPECTION 1. Clean and inspect valve springs. 2. Inspect spring for pitting, rust, cracked or broken and burrs. Replace if necessary.

VALVE INSPECTION 1. Remove carbon from valve head, face, and stem with a power-operated wire brush. Be sure carbon is removed, not merely burnished. 2. Inspect valve head, face, and stems for defects. Replace if necessary.

Warped M89875

1. Compress intake and exhaust springs using an appropriate size spring compressor. 2. Remove keepers, spring caps, springs, and valves. 3. Inspect components, replace as required. • (See “VALVE SPRING INSPECTION” on page 39.) • (See “VALVE INSPECTION” on page 39.) • (See “VALVE GUIDES INSPECTION” on page 40.) Installation: Installation of the valves is the reverse of removal.

1.5 mm (0.0591 in.)

M38087

3. Replace warped valves or valves with less than 1.5 mm (0.0591 in.) margin. Valve stem ends should be ground square before checking valve to tappet clearance.

• Inspect all parts for wear or damage. (See Inspection/Replacement procedures.) • Intake and exhaust valve guides cannot be replaced; replace head if worn. IMPORTANT: Exhaust guide keeper MUST be in place and tight on exhaust valve guide. If not, replace with a new keeper. M53961

IMPORTANT: Intake valve is equipped with a valve stem seal. Always use a new seals when valves are removed from cylinder head. The seals should also be replaced if deteriorated or damaged in any way. NEVER reuse an old seals. • If necessary to replace stem seal, remove with screwdriver. • Apply clean engine oil on intake and exhaust valve stems during assembly.

3/7/00

4. Measure outside diameter of valve stem. Replace if diameter is less than specifications. Valve Stem OD Specifications: Intake. . . . . . 6.982 – 7.000 mm (0.2749 – 0.2756 in.) Exhaust . . . . 6.970 – 6.988 mm (0.2744 – 0.2751 in.)

3 - 39

VALVE GUIDES INSPECTION

KOHLER ENGINE

Exhaust Guide (Maximum Wear) . . . . . . . . . . . . . . . . . . . . . . . 7.159 mm (0.2819 in.) Valve Guide Ream (oversize) . . . . . . . . . . . . . . . . . . . . . . . 7.298 mm (0.2873 in.) Valve Stem Diameter Intake. . . . 6.982 – 7.000 mm (0.2749 – 0.2756 in.) Exhaust . . 6.970 – 6.988 mm (0.2744 – 0.2751 in.)

CYLINDER HEAD INSPECTION M51753

5. Check valve stem for bend using V-blocks and a dial indicator. Turn valve slowly and read variation on indicator. Replace if variation is greater than 0.03 mm (0.001 in.).

1. Remove carbon deposits and clean gasket surface with SCOTCH-BRITE® abrasive or equivalent. 2. Inspect head for cracks or damage. Make sure oil drain port is open.

VALVE GUIDES INSPECTION 1. Clean inside of valve guide. Standard 7.00 mm valve guide reamer can be used.

M89874

2. Measure inside diameter of guides (A). 3. Measure outside diameter of valve stem. 4. Replace valve if stem-to-guide clearance is greater than specification. IMPORTANT: If guide is reamed to oversize, an oversize valve must be installed. 5. Use oversize reaming tool to ream guide, if necessary. 6. Replace cylinder head if inside diameter of guide is greater than oversize specification. Specifications: Valve Guide ID (New) . . . . . . . . . . . 7.038 – 7.058 mm . . . . . . . . . . . . . . . . . . . . . . . . . .(0.277 – 0.2779 in.) Intake Stem-to-Guide Clearance . . . . . . . . . 0.038 – 0.076 mm (0.0015 – 0.0030 in.) Intake Guide (Maximum Wear) . . . . . . . . . . . . . . . . . . . . . . . 7.134 mm (0.2809 in.) Exhaust Stem-to-Guide Clearance . . . . . . . . . 0.050 – 0.088 mm (0.0020 – 0.0035 in.)

3 - 40

3. Put head on a flat surface plate. Check for distortion at several points with a feeler gauge. Replace head if distorted beyond specification. Specification: Cylinder Head Distortion (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)

RECONDITION VALVE SEATS NOTE: Valve seats are not replaceable. Valve guides are not replaceable. DO NOT attempt to remove seats or guides. If they can not be reconditioned, replace entire head. 1. Inspect valve seats. Replace cylinder head if seats are warped or distorted beyond reconditioning. 2. If required reface valve seat using valve grinder to 44.5° (89°) seat angle.

3/7/00

LAP VALVES

KOHLER ENGINE

PUSH ROD INSPECTION 1.5 mm (0.0591 in.) 45.5°

45°

M50044

MX0956

3. Lap valves after refacing. 4. Check seat for good contact using Prussian Blue Compound.

• Inspect push rod for bend using V-blocks and a dial indicator. Turn rod slowly and read variation on indicator. Replace if variation is greater than 0.076 mm (0.003 in.). Specification: Push Rod Bend (maximum) . . 0.076 mm (0.003 in.)

CRANKCASE REED VALVE INSPECTION

LAP VALVES IMPORTANT: Valves and seats should be lapped if they do not make good contact.

1. Remove heads from block. (See “CYLINDER HEAD REMOVAL AND INSTALLATION” on page 36.)

1. Apply light coat of lapping compound to valve face.

Cap Screw Reed Valve

M52134

2. Grip top of valve with a vacuum cup tool and turn valve to lap valve to seat. 3. Lift valve from seat every 8 strokes. Lap until a uniform ring appears around surface of valve face. 4. Wash parts in solvent to remove lapping compound. Dry parts. 5. Check position of lap mark on face–lap mark must be on or near center of valve face. 6. Apply a light coat of clean engine oil to seat and valve to prevent rusting.

M89861

2. Remove cap screw securing reed valve assembly to block. 0.2 mm (0.008 in.)

M51757

3. Inspect reed valve for breakage, hairline cracks or distortion; replace if necessary. 4. Inspect back plate for damage or a rough contact surface; replace if necessary.

3/7/00

3 - 41

FLYWHEEL REMOVAL AND INSTALLATION 5. Check reed valve tip air gap. Gap should be 0.2 mm (0.008 in.). Replace reed valve if gap is greater than specifications. 6. Check that vent hole, below reed valve, is clear. 7. Install reed, plate, and secure with cap screw. IMPORTANT: Be sure that reed is installed with gap between reed and block and that reed is centered over vent hole and plate is centered on reed. 8. Tighten cap screw to 6.8 N•m (60 lb-in.).

KOHLER ENGINE

3. Remove cap screw (B) and Belleville washer securing flywheel to crankshaft. Use four threaded holes to secure a suitable puller and remove flywheel from crankshaft.

NOTE: Ring gear and magnets are not serviceable. If either are damaged, replace flywheel. 4. Inspect flywheel for cracks, chips, and broken teeth. Replace as necessary. 5. Inspect for sheared or partially sheared key, replace as necessary. Installation:

FLYWHEEL REMOVAL AND INSTALLATION

IMPORTANT: Check that crankshaft end and flywheel hub are clean and free of lubricant, and flywheel key is installed properly in keyway.

1. Remove blower housing.

c CAUTION A

Improperly installed flywheel can cause machine damage and serious personal injury

M98893

2. If the fan requires removal from flywheel, remove four cap screws (A), spacers, washers and the fan.

NOTE:

Do not lose the bushings located in the mounting holes of the fan. They may fall out when the fan is removed from the flywheel.

1. Install key and flywheel on crankshaft. 2. Hold flywheel with strap wrench. Place Belleville washer, concave side down, and cap screw in crankshaft and tighten cap screw to specification. 3. Check ignition module air gap. 4. Install fan on flywheel, if removed, and secure with four (4) cap screws and washers. Tighten to specification. 5. Install blower housing sheet metal taking care that heat shield is in correct position BEHIND both block shroud and head shroud. Specification: Flywheel Cap Screw. . . . . . . . . . . 66.4 N•m (49 lb-ft). Fan Cap Screws . . . . . . . . . . . . . . 9.9 N•m (88 lb-in.)

STATOR REMOVAL AND INSTALLATION

Removal: 1. Remove flywheel. (See “FLYWHEEL REMOVAL AND INSTALLATION” on page 42.) M89892

3 - 42

3/7/00

CAMSHAFT REMOVAL AND INSTALLATION

KOHLER ENGINE

CAMSHAFT REMOVAL AND INSTALLATION

1. Remove oil pan. 2. Remove hydraulic lifters. (See “ROCKER ARMS REMOVAL AND INSTALLATION” on page 33.)

M89895

2. Remove cap screws (A) securing shields to engine block.

M89842

3. Remove camshaft (A). 4. Inspect camshaft closely, replace as necessary.

Installation: 1. Coat entire camshaft with engine oil.

M89896

3. Remove screws (B) securing stator to engine block. Remove stator wire harness from groove in engine block. remove stator. 4. Inspect for damage.

Installation: Installation is the reverse of removal. Make sure that stator wire harness is in groove in engine block before installing shields.

M89894

Tighten stator cap screws to specification. Adjust ignition module air gap per specifications. (See “IGNITION MODULE AIR GAP ADJUSTMENT” on page 27.)

2. Install camshaft with timing marks (B) on camshaft gear and crankshaft gear aligned. 3. Check camshaft end play. (See “CAMSHAFT END PLAY” on page 44.)

Specifications: Ignition Module Cap Screws . . . . . . . . . . . . . . . . . . 4.0 – 6.2 N•m (35 – 55 lb-in.) Stator Cap Screws . . . . . . . . . . . . . . 4 N•m (35 lb-in.)

3/7/00

IMPORTANT: If oil pan does not seat fully on block DO NOT force it down. STOP and find out why it does not seat properly.

3 - 43

CAMSHAFT INSPECTION

KOHLER ENGINE

CAMSHAFT INSPECTION

CAMSHAFT END PLAY 1. Install the camshaft shim removed during engine disassembly. 2. Check that camshaft is seated in crankcase bore.

1. Inspect camshaft for worn or broken teeth. 2. Measure journals (A). Replace camshaft if measurements do not meet specifications. 3. Inspect lobes. Replace camshaft if lobes show excessive wear. 4. Measure camshaft bore in oil pan. 5. Subtract journal OD from bore ID to determine clearance with camshaft journal. Replace if not within specifications. 6. Measure camshaft bore in crankcase. 7. Subtract journal OD from bore ID to determine clearance with camshaft journal. Replace if not within specification. Specifications: Running Clearance . . . . . . . . . . . . 0.025 – 0.063 mm . . . . . . . . . . . . . . . . . . . . . . . . . .(0.001 – 0.0025 in.) Camshaft Bore ID (New) . . . . . . 20.0 – 20.025 mm (0.787 – 0.788 in.) (Wear Limit). . . . . . . . . . . . . 20.038 mm (0.789 in.) Camshaft Bearing Surface OD (New) . . . . 19.962 – 19.975 mm (0.786 – 0.786 in.) (Wear Limit). . . . . . . . . . . . . 19.959 mm (0.789 in.)

3 - 44

M89881

3. Install end play checking tool (A) on engine case, over end of cam. 4. Simultaneously push tool down on engine case and camshaft toward crankshaft. Measure play between camshaft thrust bearing surface and special tool using feeler gauge. 5. Use shims from shim kit as necessary until end play is within specification. Specification: Maximum Camshaft End Play (with shim) . . . . . . . . . . . 0.076 – 0.127 mm (0.003 – 0.005 in.) Shim Thickness Range: White . . . . . . . . . . 0.69 – 0.73 mm (0.027 – 0.029 in.) Blue . . . . . . . . . . . 0.74 – 0.78 mm (0.029 – 0.031 in.) Red . . . . . . . . . . . 0.79 – 0.83 mm (0.031 – 0.033 in.) Yellow . . . . . . . . . 0.84 – 0.88 mm (0.033 – 0.035 in.) Green. . . . . . . . . . 0.89 – 0.99 mm (0.035 – 0.037 in.) Gray . . . . . . . . . . . 0.95 – 0.98 mm (0.037 – 0.039 in.) Black . . . . . . . . . . 1.00 – 1.03 mm (0.039 – 0.041 in.)

3/7/00

GOVERNOR REMOVAL AND INSTALLATION

KOHLER ENGINE

GOVERNOR REMOVAL AND INSTALLATION

5. Measure governor shaft, if not to specifications, replace as follows: • With a small punch, CAREFULLY drive governor gear shaft toward inside of crankcase to remove it. • From inside of crankcase, install new governor shaft/gear assembly by pressing or lightly tapping shaft into crankcase bore to specified height. Governor Gear Shaft Specifications: Height . . . . . . . . . 34.0 – 33.5 mm (1.338 – 1.319 in.) Diameter . . . . . . . . . . . . . . . . . . . . 6.0 mm (0.236 in.) Installation: Installation is the reverse of removal.

A M89847

1. Use a pair of screws drivers to remove governor from end governor shaft. 2. Remove thrust washer from governor shaft. Note orientation of tang (A) on washer. It must be installed in the “down” position.

GOVERNOR CONTROL SHAFT REMOVAL AND INSTALLATION

B C

M89852

3. Spread fly weights and remove shaft cap (B). 4. Inspect flyweights for proper operation and free movement. Replace governor assembly as necessary.

Inside of Crankcase

34.0 – 33.5 mm (1.338 – 1.319 in.)

To Remove Shaft

M89851

1. Remove clip and washer (A) retaining governor control arm in block. Remove governor control arm and small washer (B) from inside of case. 2. Remove seal (C) from top of case. 3. Measure inside diameter of crankcase bore. 4. Determine governor control arm shaft-to- bore clearance. Replace governor control arm as necessary.

NOTE:

3/7/00

When installing governor control arm make sure that the retaining pin is located in the second, smaller, hole in the end of the governor control arm.

3 - 45

PISTON REMOVAL

KOHLER ENGINE

Specification: Diameter . . . 5.975 – 6.012 mm (0.2352 – 0.2367 in.) Wear Limit. . . . . . . . . . . . . . . . . . . 5.962 mm (0.2347) Shaft to Crankcase Clearance . . .0.013 – 0.075 mm . . . . . . . . . . . . . . . . . . . . . . . . .(0.0005 – 0.0030 in.)

2. Remove cap screws (A) to remove cap from connecting rod. 3. Remove piston assembly through top of cylinder. 4. Inspect piston assembly.

PISTON DISASSEMBLE Cross Shaft Oil Seal: If the shaft oil seal is damaged or leaks, replace it.

2.0 mm (0.079 in.)

1. Remove the oil seal from the crankcase. Install new seal (D) to depth of 2.0 mm (0.079 in.)

PISTON REMOVAL

M89891

1. Remove compression rings (A) from piston using ring expander. 2. Remove rails (B). 3. Remove spacer (C).

IMPORTANT: Always use ridge reamer on edge of piston bore to remove any ridge that may be present and to provide a slight taper to ease piston assembly.

E D

1. Using a ridge reamer remove carbon/wear ridge at top of cylinder.

M55878

4. Remove retaining rings (D) by prying at indent. 5. Use wooden dowel to remove pin (E) from piston and connecting rod. 6. Inspect parts.

3 - 46

M89863

3/7/00

PISTON PIN INSPECTION

KOHLER ENGINE

PISTON PIN INSPECTION

PISTON RING END GAP IMPORTANT: If new rings are to be installed, deglaze cylinder so rings will seat properly. (See Deglaze Cylinder Bore, later in this section.) 1. Use a clean or new piston to push piston compression ring squarely into bore, to a point where it normally runs.

M82050

7. Measure piston pin outside diameter at six places. Replace pin if measurement is less than Specifications. Specifications: Piston Pin OD . . . . . . . . . . . . . . 17.00 mm (0.669 in.) Wear Limit. . . . . . . . . . . . . . . . . 16.99 mm (0.668 in.)

PISTON INSPECTION

M52110

2. Measure end gap. 3. Remove ring and file ends squarely until gap meets specification. Rings with too large a gap must be replaced. If one piston ring needs to be replaced, all must be replaced as a set. Specifications, Piston Ring End Gap:

1. Carefully remove piston rings.

Used Bore . . . . . . . . . . . . . . . . . . 0.75 mm (0.030 in.) New Bore. . . . . . . . . 0.3 â&#x20AC;&#x201C; 0.5 mm (0.012 â&#x20AC;&#x201C; 0.020 in.)

PISTON RING SIDE CLEARANCE

M29946

IMPORTANT: Do not use caustic cleaners or wire brush to clean aluminum piston. Piston damage can result..

Side Clearance

M52111

2. Clean piston. Inspect for scoring or fractures. 3. Clean carbon from grooves using ring groove tool. 1. Measure piston ring side clearance as shown at several points around piston. 2. Replace piston if measurements exceed clearance specifications. 3/7/00

3 - 47

PISTON TO BORE MEASUREMENT

KOHLER ENGINE

Specifications (19 hp):

Specifications:

Top and Middle Compression Rings . . . . . . . . . . . . . 0.04 – 0.08 mm (0.002 – 0.003 in.) Oil Control Ring . . . . . . . . . . . . . 0.06 – 0.20 mm (0.002 – 0.008 in.)

Cylinder Bore (19 hp):

Specifications (21/23 hp): Top Compression Ring . . . . . . . . . . . . . 0.04 – 0.05 mm (0.002 – 0.002 in.) Middle Compression Ring . . . . . . . . . . . . . 0.04 – 0.04 mm (0.002 – 0.003 in.) Oil Control Ring . . . . . . . . . . . . . 0.03 – 0.20 mm (0.001 – 0.007 in.)

Standard ID 77.00 – 77.025 mm (3.0315 – 3.0325 in.) Maximum Wear Limit . . . . . . . 77.063 mm (3.034 in.) Cylinder Bore (21/23 hp): Standard ID 80.00 – 80.025 mm (3.1496 – 3.1506 in.) Maximum Wear Limit . . . . . . 80.065 mm (3.1522 in.) Cylinder Bore (25 hp): Standard ID . 82.98 – 83.02 mm (3.2669 – 3.2685 in.) Maximum Wear Limit . . . . . . 80.065 mm (3.1522 in.)

Specifications (25 hp): Top Compression Ring . . . . . . . . . . . . . 0.03 – 0.05 mm (0.001 – 0.002 in.) Middle Compression Ring . . . . . . . . . . . . . 0.02 – 0.04 mm (0.001 – 0.003 in.) Oil Control Ring . . . . . . . . . . . . . 0.03 – 0.18 mm (0.001 – 0.007 in.)

PISTON TO BORE MEASUREMENT M52148

Cylinder Bore (All Engines): Maximum Out-of-Round . . . . . . . . . 0.12 mm (0.005) Maximum Taper . . . . . . . . . . . . . 0.05 mm (0.002 in.) Piston (19 hp): Piston OD . . 76.967 – 76.985 mm (3.030 – 3.031 in.) Piston Wear Limit . . . . . . . . . 76.840 mm (3.0252 in.) Piston-to-cylinder bore clearance . . . . . . . . . 0.035 – 0.078 mm (0.0014 – 0.0031 in.) Piston (21/23 hp):

1. Measure diameter of piston at point (A). Point (A) is 6 mm (0.25 in.) from skirt bottom and perpendicular to piston pin. 2. Measure piston pin bore on both sides of piston.

Piston OD . . 79.963 – 79.979 mm (3.148 – 3.149 in.) Piston Wear Limit . . . . . . . . . 76.840 mm (3.0252 in.) Piston-to-cylinder bore clearance . . . . . . . . . 0.021 – 0.062 mm (0.0008 – 0.0024 in.) Piston (25 hp): Piston OD 82.956 – 82.974 mm (3.2660 – 3.2667 in.) Piston Wear Limit . . . . . . . . . 82.841 mm (3.2615 in.) Piston-to-cylinder bore clearance . . . . . . . . . 0.003 – 0.067 mm (0.0001 – 0.0026 in.) Piston Pin Specifications (All Engines):

M52125

Bore ID . . 17.006 – 17.012 mm (0.6695 – 0.6698 in.) Wear Limit . . . . . . . . . . . . . 17.025 mm (0.6703 in.) Piston Pin OD16.995 – 17.00 mm (0.6691 – 0.669 in.) Wear Limit . . . . . . . . . . . . . 16.994 mm (0.6690 in.)

3. Measure cylinder bore inside diameter at six places; two measurements 90° apart at top, middle, and bottom of ring travel. 4. Replace piston and/or cylinder block if not within specifications.

3 - 48

3/7/00

CRANKSHAFT MEASUREMENT

KOHLER ENGINE

CRANKSHAFT MEASUREMENT

9. Measure inside diameter of crankshaft main bearing bore in oil pan. 10. Measure inside diameter of crankshaft main bearing bore in crankcase. 11. Subtract journal OD from bore ID to determine if clearance is within specifications. Replace parts if not within specifications.

M80432 A

M89879

In alignment jig:

NOTE: Connecting rod is available 0.25 mm (0.010 in.) undersize. 1. Tighten cap screws (A) to specification. 2. Measure inside diameter of connecting rod. 3. Measure outside diameter of crankshaft journal. 4. Determine connecting rod-to-crankshaft clearance. 5. Assemble connecting rods on crankshaft. Check connecting rod to crankshaft side clearance. 6. Replace parts that are not within specifications. See specifications on next page.

• Rotate crankshaft slowly. Dial indicators measure maximum Total Indicated Runout (TIR). Specifications (All Engines): Connecting Rod: Piston Pin ID . . . . . . 17.015 – 17.023 mm (0.670 in.) Wear Limit . . . . . . . . . . . . . . 17.036 mm (0.671 in.) Rod to Crankpin Side Clearance . . .0.26 – 0.63 mm . . . . . . . . . . . . . . . . . . . . . . . . . . .(0.010 – 0.025 in.) Crankshaft:

M89878

7. Measure main bearing journals. 8. Replace crankshaft if not within specifications.

PTO & Flywheel End Main Journal OD . . . . . . . . . 40.913 – 40.935 mm (1.611 – 1.612 in.) Wear Limit . . . . . . . . . . . . . . . 40.84 mm (1.608 in.) Connecting Rod Journal . . . . . 35.955 – 35.973 mm . . . . . . . . . . . . . . . . . . . . . . . . .(1.4156 – 1.4163 in.) Wear Limit . . . . . . . . . . . . . . . 35.94 mm (1.415 in.) Total Indicated Runout (TIR) Max. . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) End Play . . . . . . . 0.07 – 0.48 mm (0.003 – 0.019 in.) Crankshaft Plain Bearings: Crankcase Cover (Oil Pan) Bearing ID . . . . . . . . . 40.974 – 40.987 mm (1.613 – 1.614 in.) Wear Limit . . . . . . . . . . . . . . 41.025 mm (1.615 in.) Crankcase Bearing ID . . . . . . . . . 40.965 – 41.003 mm (1.613 – 1.614 in.) Wear Limit . . . . . . . . . . . . . . 41.016 mm (1.615 in.)

M89846

3/7/00

3 - 49

PISTON ASSEMBLY

KOHLER ENGINE

PISTON ASSEMBLY

NOTE: Install piston pin before retaining ring to prevent possible scoring of bore.

IMPORTANT: Side of ring marked TOP faces top of piston with Dykem stripe to left of end gap. Top compression ring has a blue Dykem stripe. Bottom compression ring has a pink Dykem stripe.

“FLY” Mark

Connecting Rod Offset #1 Piston

Connecting Rod Offset #2 Piston “Pip” Mark Dykem Stripe

M89882

“FLY” Mark

Top Compression Ring

Center Compression Ring

2. Select one piston and assemble to a connecting rod with the “FLY” mark on face of piston oriented to the same side as the offset of the connecting rod. Mark top of piston with a #1 for reference.

Oil Rail Oil Spacer Oil Rail

M55898

1. Install rings as shown on piston using ring expander. • Compression ring gaps should be staggered 120°. • Note shape of compression rings and install as shown. • Compression rings should be installed with “Pip” mark up and Dykem stripe to left of ring gap. • Install oil ring spacer first. Make sure that its ends do not overlap. • Stagger end gaps of oil rails 180° apart. • Rings should turn freely in grooves. IMPORTANT: Proper orientation of the piston/connecting rod assemblies inside the engine is extremely important. Improper orientation can cause extensive wear or damage. be certain the pistons and connecting rods are assembled exactly as shown.

3 - 50

IMPORTANT: Retaining rings should be installed with end gap towards the top of the piston.

NOTE: Install piston pin before retaining ring to prevent possible scoring of bore. 3. Place a snap ring in piston pin bore groove, coat piston pin bore and piston pin with engine oil and insert piston pin. Secure with second snap ring.

NOTE: Piston pins should slide into piston and rod with finger pressure. DO NOT force pin into piston or rod. 4. Select one piston and assemble to a connecting rod with the “FLY” mark on face of piston oriented to the opposite side as the offset of the connecting rod. Mark top of piston with a #2 for reference. 5. Place a snap ring in piston pin bore groove, coat piston pin bore and piston pin with engine oil and insert piston pin. Secure with second snap ring.

3/7/00

PISTON INSTALLATION

KOHLER ENGINE

PISTON INSTALLATION 1. Select the piston marked #1 and check piston ring orientation to be sure that piston ring end gaps are staggered 120° apart. 2. Coat cylinder, piston skirt, rod, and cap bearing surfaces with oil. 3. Compress rings with ring compressor tool.

#1 Piston

7. Install, camshaft, oil pan, and cylinder head. See appropriate procedures in this section. Cap Screw Torque Specifications: 8 mm straight shank . . . . . . . . 22.7 N•m (200 lb-in.) 8 mm step-down. . . . . . . . . . . . 14.7 N•m (130 lb-in.) 6 mm straight shank . . . . . . . . 11.3 N•m (100 lb-in.)

OIL PAN REMOVAL AND INSTALLATION Removal:

FLY

1. Remove cap screws securing pan. IMPORTANT: Do not pry on gasket surface when removing oil pan from crankcase.

M89883

4. Install #1 piston with FLY mark toward top of case and arrow pointing to flywheel side of crankcase. Use wooden dowel to push piston into bore. 5. Install #2 piston with FLY mark toward bottom of case and arrow pointing to flywheel side of crankcase. Use wooden dowel to push piston into bore.

2. Tap side of oil pan at engine mounting bosses to separate oil pan from crankcase. 3. Clean mating surfaces of crankcase and oil pan. 4. Replace crankshaft seals. (See “CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION” on page 52.) Installation: 1. Apply grease to inside lip of crankshaft main bearing seal. RTV silicone sealant is used as a gasket between the oil pan and the crankcase on the engines except the 25 hp engine. the 25 hp engine uses an oil pan gasket. 2. Check that there are no nicks or burrs on the sealing surfaces of the oil pan or crankcase. 3. Apply a 1.5 mm (1/16 in.) bead of sealant to the sealing surfaces of the oil pan. See figure for sealant pattern. Fill groove between points “A” and “B” with RTV. RTV must be all around O-Ring groove “C”. 4. Use a gasket on the 25 hp engine. IMPORTANT: Use a thin blade screw driver to help align gears on oil pump and governor.

M89863

6. Install end cap on matching connecting rod and secure with cap screws (A). Tighten to specification.

3/7/00

5. Make sure end of governor control shaft is lying against the bottom of cylinder 2 inside of crankcase. 6. Install oil pan over crankshaft carefully to avoid damaging crankshaft bearing seal. IMPORTANT: If oil pan does not seat fully on block DO NOT force it down. STOP and find out why it does not seat properly.

3 - 51

OIL PAN CRANKSHAFT SEAL REMOVAL AND INSTALLATION

KOHLER ENGINE

OIL PAN CRANKSHAFT SEAL REMOVAL AND INSTALLATION

“C”

“A” M55903

“B”

IMPORTANT: DO NOT damage seal bore when removing seal.

MX0958

7. Install oil pan onto crankcase. Carefully seat the camshaft with shim and crankshaft into their mating bearings. Rotate the crankshaft to help engage oil pump and governor gear meshes.

1. Remove and discard seal. 2. When replacing crankshaft seals, apply a thin film of LOCTITE® 598 or equivalent to the OD of seal. 3. Using a suitable driver and disc, install new oil seal until it seats fully in oil pan.

CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION

1 3 10

5 8

7 6

M89884

M55902

8. Install the ten cap screws. On some engines one of the ten cap screws is plated. The plated screw should be installed in the #6 hole. 9. In sequence shown, tighten oil pan cap screws to specification. Specification:

IMPORTANT: DO NOT damage crankcase seal bore when removing seal. 1. Remove and discard crankcase seal. 2. When replacing crankshaft seal, apply a thin film of engine oil to the OD of seal. 3. Using a suitable driver and disc, install new oil seal in crankcase bore until it seats on bottom of bore.

Oil Pan Cap Screws . . . . . . . . . 24.4 N•m (216 lb-in.).

3 - 52

3/7/00

OIL PRESSURE SWITCH, REPLACE

KOHLER ENGINE

OIL PRESSURE SWITCH, REPLACE 1. Remove the carburetor air cleaner.

OIL PUMP REMOVAL AND INSTALLATION 1. Remove oil pan. (See “OIL PAN REMOVAL AND INSTALLATION” on page 51.)

A A

M89857 M89873

2. Disconnect the breather hose from the breather (A). 3. Remove nuts securing air cleaner base to carburetor. Remove the air cleaner base.

2. Remove cap screws (A) securing oil pump in oil pan. 3. Remove and clean intake screen (B).

M87734

4. Remove oil pressure switch wire. 5. Remove oil pressure switch (B). Installation: Installation is the reverse of removal. • Tighten oil pressure switch to specification. Specification: Switch Torque. . . . . . . . . . . . . . . . 4.5 N•m (40 lb-in.)

M89849

4. Inspect pump, surface of crankcase cover, and rotor for scoring, discoloration, and wear.

NOTE: The oil pump has no serviceable components. If any pump components shows wear or damage entire oil pump must be replaced. 5. Replace oil pump as necessary. Installation: Installation is the reverse of removal. 1. Tighten oil pump cap screws to specification. Specification: First Time Installation . . . . . . . . 10.7 N•m (95 lb-in.) All Reinstallations . . . . . . . . . . . . 6.7 N•m (60 lb-in.)

3/7/00

3 - 53

BLOCK INSPECTION

KOHLER ENGINE

2. After tightening cap screws, rotate gear to check for freedom of movement. If binding occurs, loosen screws, reposition pump, retighten, and recheck movement. 3. Install oil pan. (See “OIL PAN REMOVAL AND INSTALLATION” on page 51.)

BLOCK INSPECTION 1. Clean and check block for cracks. 2. Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 percent kerosene and 75 percent light engine oil. 3. Wipe area dry and immediately apply coating of zinc oxide dissolved in wood alcohol. If crack is present, coating becomes discolored at the defective area. 4. Replace block if any cracks are found.

CYLINDER BORE DEGLAZE IMPORTANT: Remove crankshaft and internal engine components when deglazing cylinder. Abrasives can cause engine damage. 1. Use the appropriate size flex-hone to deglaze cylinder bore. 2. Deglaze cylinder bore using flex-hone to obtain 23 – 33° crosshatch pattern. 3. Clean abrasive residue from cylinder using warm soapy water until clean white rags show no discoloration. 4. Dry cylinder and apply engine oil. IMPORTANT: Do not use solvents to clean cylinder bore. Solvents will not remove metal particles produced during honing. 5. Clean cylinder thoroughly using warm soapy water until clean white cloths show no discoloration. 6. Dry cylinder completely and apply thin coat of engine oil to appropriate mating surfaces. Specifications: Deglaze Crosshatch Pattern . . . . . . . . . . . . . 23 – 33° Final Hone—Finish Stone . . . . . . . . . . Using 200 – 300 grit finishing stones

3 - 54

3/7/00

CONTENTS

ELECTRICAL

CONTENTS Page

THEORY OF OPERATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 3 DIAGNOSTIC INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WIRE COLOR ABBREVIATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 READING ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 COMMON CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CONDUCTORS FOR 12 VOLT CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . 8 ELECTRICAL SECTION WIRING HARNESS LEGEND . . . . . . . . . . . . . . . . . . . . . . . 8 STANDARD ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 W1 MAIN WIRING HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 W2 HEADLIGHT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W3 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W4 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W5 (CV19/CV21/CV23) ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . 11 W6 ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 W7 (CV25) ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 W8 (CV25) ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 THEORY AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 POWER CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CRANKING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CRANKING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CRANKING CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 IGNITION CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 IGNITION CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 IGNITION CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ENGINE SHUTOFF CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ENGINE SHUTOFF CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 ENGINE SHUTOFF CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 CHARGING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CHARGING CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 PTO CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PTO CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PTO CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION . . . . . . . . . . . . . . . 40 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . 41 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . 42 REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . 44 HEADLIGHT CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3/3/00

4-1

CONTENTS CONTINUED

ELECTRICAL

Page HEADLIGHT CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 W2 HEADLIGHT WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 HEADLIGHT CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 GROUND CIRCUIT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR SOLENOID TEST (CV25 ENGINE) . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR LOADED AMPERAGE DRAW TEST . . . . . . . . . . . . . . . . . . . . STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV19/CV21/CV23 ENGINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV25 ENGINE) . . . . SPARK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIGHT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO/RIP SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE or REVERSE IMPLEMENT OPTION SWITCH TEST . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH TEST (CV23/CV25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL MAGNET TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STATOR OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VOLTAGE REGULATOR/RECTIFIER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE WITH COIL (CV19/CV212/CV23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR GAP ADJUSTMENT (CV19/CV212/CV23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE TEST (CV19/CV212/CV23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE WITH COIL (CV25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR GAP ADJUSTMENT (CV25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARMATURE TEST (CV25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 51 51 52 53 53 54 55 56 58 58 59 59 60 60 61 62 62 63 63 64 64 64 65 65 65

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 STARTING MOTOR REMOVAL & INSTALLATION (CV19/CV212/CV23) . . . . . . . . STARTING MOTOR DRIVE REPLACEMENT (CV19/CV212/CV23) . . . . . . . . . . . . BRUSH REPLACEMENT & ARMATURE TEST (CV19/CV212/CV23). . . . . . . . . . . STARTING MOTOR REMOVAL & INSTALLATION (CV25) . . . . . . . . . . . . . . . . . . . STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25) . . . . . . . . . . . . . . . . . .

4-2

66 67 67 69 70

3/3/00

ELECTRICAL

THEORY OF OPERATION INFORMATION

WIRE COLOR ABBREVIATION CHART

The theory of operation stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom.

Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange Pnk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple

DIAGNOSTIC INFORMATION The diagnostic procedures is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading. The diagnostic procedure lists: • Test conditions • Test sequence • Test location • Normal reading • Check or test to perform if reading is not normal When performing the test or check, be sure to set your machine up to the test conditions listed and follow the sequence carefully. The middle “NORMAL” column gives the reading or condition that should be obtained when performing the test or check. If the results of the test or check are not normal, perform the test, check, or adjustment listed in the third “IF NOT NORMAL” column to repair the malfunction. The detailed tests or adjustments referred to in the “IF NOT NORMAL” column are located at the end of that group. The system diagram that accompanies each test procedure is drawn to resemble machine components. The key number on the art matches the number in the “TEST LOCATION” column and the leader line points to the exact point the test is to be made.

Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Black/White Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . .Brown/Yellow Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green Dk Brn/Red . . . . . . . . . . . . . . . . . Dark Brown/Red Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . White/Black Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

3/7/00

4-3

READING ELECTRICAL SCHEMATICS

ELECTRICAL

READING ELECTRICAL SCHEMATICS

The identifying letter is always the same for a specific component, but the identifying numbers are numbered consecutively from upper left to lower right. The terminal designation (J) is placed directly outside the symbol next to the connecting wire path. Switch positions (K) are also placed directly outside the symbol. The solid line (L) shows the position the switch is currently in and dash lines (M) represent other switch positions.

The schematic is made up of individual circuits laid out in a sequence of related functions. It is formatted with all power wires (A) across the top and all ground wires (B) across the bottom. Current flow is generally from top to bottom through each circuit and component. All components are shown in the OFF position. The diagram does not list connector (C) information unless needed to avoid confusion. If the connector is shown, the number next to it is the terminal pin location (D) in the connector.

Each circuit is identified at the bottom of the drawing by a section number (N) and section name (O). The circuit number (P) and wire color (Q) of the wires are shown directly next to the wire path.

Each component is shown by a symbol (E), its name (F), and an identification code (G). The identification code contains a device identifying letter (H) and number (I).

The same component name and identification code are used consistently on all diagrams in this section. Components can be easily cross-referenced.

S1 Key Switch B

F2 15 Amp Fuse

Wht

Red

S2 Seat Switch

K2 Ignition Relay

Run Off

F3 15 Amp Fuse

K1 Start Relay

F1 Fusible Link

215 Org

X2 721 Pur/ Wht

Red

X3 G1 Battery

M1 Starting Motor

W2 Engine X4 Wiring Yel/ Harness T1 Wht Ignition X5 Yel/Wht Yel/Wht Coil

X3 T2 Ignition Coil P

E1 Spark Plug

SE1-Power and Starting Circuit

4-4

805 Pnk/Blk

W1 Shielded Ground

710 Pur

Blk

800 Pink

Start 210 Red

Off Seat

On Seat

414 Yel/ Blk

E2 Spark Plug

Yel/ Wht Wht

SE2-Ignition and Interlock Circuit

Blk/Yel

105 Blk

SE3-PTO and Interlock

3/7/00

COMMON CIRCUIT TESTS

ELECTRICAL

COMMON CIRCUIT TESTS

2. If terminals are not corroded or loose, the problem is in the component or wiring.

Shorted Circuit: A shorted circuit may result in the wrong component operating (i.e. improper wire-to-wire contact). To test for a shorted or improperly wired circuit: 1. Turn component switch ON. 2. Start at the controlling switch of the component that should not be operating. 3. Follow the circuit and disconnect wires at connectors until component stops operating. 4. Shorted or improper connections will be the last two wires disconnected.

M85601 mif

Grounded Circuit: Grounded circuits usually result in no component operation, a blown fuse, or a blown fusible link.

M85600 mif M85602 mif

High Resistance or Open Circuit: High resistance or open circuits usually result in slow, dim or no component operation (i.e. poor, corroded, or disconnected connections). Voltage at the component will be low when the component is in operation. To test for high resistance and open circuits: 1. Check all terminals and grounds of the circuit for corrosion.

CONDUCTORS FOR 12 VOLT CIRCUITS

STRANDED CONDUCTORS FOR 12 VOLT CIRCUITS SAE WIRE SIZE (GAUGE)

METRIC WIRE SIZE (MM)

0.5

0.8

1.0

2.0

3.0

5.0

TYPICAL STRANDING

7 X 28

16 X 30

19 X 29

19 X 27

19 X 25

19 X 23

MINIMUM CONDUCTOR AREA IN CIRCULAR MILS

1072

1537

2336

3702

5833

9343

3/7/00

4-5

SPECIFICATIONS

ELECTRICAL

SPECIFICATIONS Battery: Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Cold Cranking Amps at -18°C (0°F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 amps Reserve Capacity At 27°C (80°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 minutes Specific Gravity (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.225 points Electrolyte Quantity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt) Ignition: Air gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 – 0.3 mm (0.008 – 0.012 in.) Spark Plug: Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Champion RC12YC Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.) Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 N•m (240 lb-in.) Starting Motor: Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Shift Starting motor amp draw (on vehicle) . . . . . . . . . . . . . . . . . . 90 – 100 amps at 750 rpm Starting motor no-load amp draw (free running) . . . . . . . . . 20 amps (max.) at 2500 rpm Stator: Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 amps Regulated Amperage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15 amps Regulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . 12.2—14.7 volts DC Unregulated Voltage (Minimum) at Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . 28 volts AC Electric PTO Clutch: Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4—2.7 ohms Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 amps Lighting: Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GE 1156 or equivalent

4-6

3/7/00

COMPONENT LOCATION

ELECTRICAL

COMPONENT LOCATION S1 Key Switch

S2 PTO/RIP Switch S4 Light Switch

H1 Discharge Light

D1 Hourmeter

K3 RIO Latch Relay

S5 Seat Switch

K2 RIO Relay

H2 Oil Pressure Light (CV23/CV25)

K1 Starting Motor Relay

S6 RIO Switch

Y1 PTO Clutch

G1 Battery S3 Brake Switch

(CV25) (CV19/CV21/CV23) M1 Starting Motor

3/7/00

4-7

ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND

ELECTRICAL SCHEMATIC AND WIRING HARNESS LEGEND A1—Discharge Module (SE3, W1) A2—Spark Advance Module (CV25)(SE4, W8) B1—Engine Oil Pressure Switch (CV23/ CV25) (SE4, W3) D1—Hour Meter (Opt.) (SE2, W1) E1—RH Headlight (SE3, W2) E2—LH Headlight (SE3, W2) E3—Spark Plug (CV19/CV21/CV23)(SE4, W5) E4—Spark Plug (CV19/CV21/CV23)(SE4, W5) E5—Spark Plug (CV25)(SE4, W8) E6—Spark Plug (CV25)(SE4, W8) F1—Fuse (SE1, W1) F2—Fusible Link (SE1, W1) G1—Battery (SE1, W1) G2—Stator (SE3, W3)

ELECTRICAL

CONNECTORS: X1—W1 Main Wiring Harness to M1 Starting Motor (CV25 Engine Use Only) (SE1, W1) X2—W1 Main Wiring Harness to Hour Meter (Optional) (SE2, W1) X3—W1 Main Wiring Harness to W2 Headlight Wiring Harness (SE3, W1) X4—W1 Main Wiring Harness to W3 Engine Wiring Harness (SE4, W1) X5—W3 Engine Wiring Harness to W6 (CV19/CV21/ CV23) Engine Fuel Solenoid Wiring Harness (SE4, W3); or to W7 (CV25) Engine Adaptor Wiring Harness (SE4, W3) X6—W3 Engine Wiring Harness to W5 (CV19/CV21/ CV23) Engine Wiring Harness (SE4, W3); or to W8 Engine Wiring Harness (SE4, W3) X7—W7 Engine Adaptor Wiring Harness to W8 Engine Wiring Harness (SE4, W7) X8—W7 Engine Adaptor Wiring Harness to W6 Engine Fuel Solenoid Wiring Harness (SE4, W7)

H1—Discharge Light (SE3, W1) K1—Starting Motor Relay (SE1, W1)

ELECTRICAL SECTION WIRING HARNESS LEGEND

K2—Reverse Implement Option (RIO) Relay (SE2, W1)

W1—Main Wiring Harness

K3—Reverse Implement Option (RIO) Latch Relay (SE2, W1)

W2—Headlight Wiring Harness

M1—Starting Motor (SE1, W1)

W4—Engine Voltage Regulator/Rectifier Ground Wire

N1—Voltage Regulator/Rectifier (SE3, W3)

W5—Engine Magneto Ignition Coil Wiring Harness

S1—Key Switch (SE1, W1)

W6—Engine Fuel Solenoid Wiring Harness

S2—PTO/RIP Switch (SE2, W1)

W7—Engine Adaptor Wiring Harness

S3—Brake Switch (SE2, W1)

W8—Engine Spark Advance Module Wiring Harness

H2—Oil Pressure Light (CV23/CV25)(SE3, W1)

W3—Engine Wiring Harness

S4—Light Switch (SE2, W1) S5—Seat Switch (SE3, W1) S6—Reverse Implement Option(RIO)Switch (SE2, W1) T1—Magneto Ignition Coil (CV19/CV21/CV23) (SE4, W5) T2—Magneto Ignition Coil (CV19/CV21/CV23) (SE4, W5) T3—Ignition Module (CV25)(SE4, W8) T4—Ignition Module (CV25)(SE4, W8) W1—Shielded Ground (SE1, W1) Y1—PTO Clutch (SE2, W1) Y2—Fuel Solenoid (SE4, W6)

4-8

3/7/00

ELECTRICAL SCHEMATIC

ELECTRICAL

ELECTRICAL SCHEMATIC Off

W2 Headlight Wiring Harness

S1 Key Switch

400 Yel/Blk

211 Red

401 Yel

710 Pur/Blk

700 Pur

S4 Light Switch

E2 L.H. Headlight

E1 R.H. Headlight

720 Pur

Start

450 Yel/Wht

407 Yel

105 Blk

940 Wht

Run Off 116 Blk

F1 Fuse 15 A

940 Wht

401 Yel

S2 PTO/RIP Switch

730 Pur

700 Pur

K1 Start Relay 720 Pur

725 Pur 115 Blk 120 Blk

X1 - Use With CV25S Engine

108 Blk

750 Blu

101 Blk

W4 Engine Ground Wire

600 Brn

406 Yel

404 Yel

A1 Discharge Module

Red Wht

D1 Hourmeter

600 Brn

101 Blk

100 Blk

Operator Off Operator On 120 Blk

Red

2/24/00

Y2 Fuel Solenoid

X7 Red

H2 Oil Pressure Light

Wht

W8 Engine Wiring Harness (CV25)

A2 Spark Advance Module

620 Tan

Grn Yel

Brn

107 Blk

T4 Ignition Module

T3 Ignition Module

S5 Seat Switch

W1 Battery Frame Ground

E5 Spark Plug SE1 - STARTING

SE2 - IGNITION

4-9

E4 Spark Plug

Brn Yel

Y1 PTO Clutch

E3 Spark Plug

+ _

H1 Discharge Light

T2 Magneto Ignition Coil

W7 Engine Adaptor Wiring Harness (CV25) W6 Engine Wiring Harness X5 Red Red

X4 To W3 Main Wiring Harness 407 Yel 940 Wht 941 Wht

403 Yel

T1 Magneto Ignition Coil

B1 Engine Oil P Pressure Switch (CV23/CV25)

G2 Stator

(CV21/CV23/CV25)

102 Blk

W5 Engine Ignition Wiring Harness (CV19/CV21/CV23)

Wht Wht

103 107 Blk Blk

(On)

Blk

N1 Voltage Regulator/Rectifier

S6 Switch

(Off)

941 Wht

M1 Starting Motor

Y2 Fuel Solenoid

104 Blk

710 Pur/ Blk

Red

Pur

(O) Forward RIO Neutral

S3 Brake Switch

G1 Battery

Pur

W6 Engine Wiring Harness

Wht

(I) Reverse

106 Blk

Red

205 Red

110 Blk/Wht

205 Red

215 Blu

Grn

Blk

114 Blk

113 Blk

205 Red

F2 Fuse Link

Red Wht

407 Yel 940 Wht 941 Wht 620 Tan

113 Blk

405 Yel/Blk

109 Blk

710 Pur/Blk

X4 To W3 Engine Adaptor Wiring Harness

117 Blk

K2 Backup Relay

402 Yel/Blk

116 Blk

406 Yel

111 Blk/Wht 114 Blk 115 Blk 750 Blu 730 Pur 725 Pur

942 Wht

210 Red

K3 RIO Latch Relay

Momentary On (RIP) On Off 110 Blk/Wht

100 Blk

W3 Engine Wiring Harness (All Engines)

SE3 - CHARGING

E6 Spark Plug SE4 - ENGINE

ELECTRICAL SCHEMATIC

ELECTRICAL

ELECTRICAL SCHEMATIC Off

W2 Headlight Wiring Harness

S1 Key Switch

400 Yel/Blk

211 Red

401 Yel

710 Pur/Blk

700 Pur

S4 Light Switch

E2 L.H. Headlight

E1 R.H. Headlight

720 Pur

Start

450 Yel/Wht

407 Yel

105 Blk

940 Wht

Run Off 116 Blk

F1 Fuse 15 A

940 Wht

401 Yel

S2 PTO/RIP Switch

730 Pur

700 Pur

K1 Start Relay 720 Pur

725 Pur 115 Blk 120 Blk

X1 - Use With CV25S Engine

108 Blk

750 Blu

101 Blk

W4 Engine Ground Wire

600 Brn

406 Yel

404 Yel

A1 Discharge Module

Red Wht

D1 Hourmeter

600 Brn

101 Blk

100 Blk

Operator Off Operator On 120 Blk

Red

2/24/00

Y2 Fuel Solenoid

X7 Red

H2 Oil Pressure Light

Wht

W8 Engine Wiring Harness (CV25)

A2 Spark Advance Module

620 Tan

Grn Yel

Brn

107 Blk

T4 Ignition Module

T3 Ignition Module

S5 Seat Switch

W1 Battery Frame Ground

E5 Spark Plug SE1 - STARTING

SE2 - IGNITION

4-9

E4 Spark Plug

Brn Yel

Y1 PTO Clutch

E3 Spark Plug

+ _

H1 Discharge Light

T2 Magneto Ignition Coil

W7 Engine Adaptor Wiring Harness (CV25) W6 Engine Wiring Harness X5 Red Red

X4 To W3 Main Wiring Harness 407 Yel 940 Wht 941 Wht

403 Yel

T1 Magneto Ignition Coil

B1 Engine Oil P Pressure Switch (CV23/CV25)

G2 Stator

(CV21/CV23/CV25)

102 Blk

W5 Engine Ignition Wiring Harness (CV19/CV21/CV23)

Wht Wht

103 107 Blk Blk

(On)

Blk

N1 Voltage Regulator/Rectifier

S6 Switch

(Off)

941 Wht

M1 Starting Motor

Y2 Fuel Solenoid

104 Blk

710 Pur/ Blk

Red

Pur

(O) Forward RIO Neutral

S3 Brake Switch

G1 Battery

Pur

W6 Engine Wiring Harness

Wht

(I) Reverse

106 Blk

Red

205 Red

110 Blk/Wht

205 Red

215 Blu

Grn

Blk

114 Blk

113 Blk

205 Red

F2 Fuse Link

Red Wht

407 Yel 940 Wht 941 Wht 620 Tan

113 Blk

405 Yel/Blk

109 Blk

710 Pur/Blk

X4 To W3 Engine Adaptor Wiring Harness

117 Blk

K2 Backup Relay

402 Yel/Blk

116 Blk

406 Yel

111 Blk/Wht 114 Blk 115 Blk 750 Blu 730 Pur 725 Pur

942 Wht

210 Red

K3 RIO Latch Relay

Momentary On (RIP) On Off 110 Blk/Wht

100 Blk

W3 Engine Wiring Harness (All Engines)

SE3 - CHARGING

E6 Spark Plug SE4 - ENGINE

ELECTRICAL SCHEMATIC

ELECTRICAL

ELECTRICAL SCHEMATIC Off

W2 Headlight Wiring Harness

S1 Key Switch

400 Yel/Blk

211 Red

401 Yel

710 Pur/Blk

700 Pur

S4 Light Switch

E2 L.H. Headlight

E1 R.H. Headlight

720 Pur

Start

450 Yel/Wht

407 Yel

105 Blk

940 Wht

Run Off 116 Blk

F1 Fuse 15 A

940 Wht

401 Yel

S2 PTO/RIP Switch

730 Pur

700 Pur

K1 Start Relay 720 Pur

725 Pur 115 Blk 120 Blk

X1 - Use With CV25S Engine

108 Blk

750 Blu

101 Blk

W4 Engine Ground Wire

600 Brn

406 Yel

404 Yel

A1 Discharge Module

Red Wht

D1 Hourmeter

600 Brn

101 Blk

100 Blk

Operator Off Operator On 120 Blk

Red

2/24/00

Y2 Fuel Solenoid

X7 Red

H2 Oil Pressure Light

Wht

W8 Engine Wiring Harness (CV25)

A2 Spark Advance Module

620 Tan

Grn Yel

Brn

107 Blk

T4 Ignition Module

T3 Ignition Module

S5 Seat Switch

W1 Battery Frame Ground

E5 Spark Plug SE1 - STARTING

SE2 - IGNITION

4-9

E4 Spark Plug

Brn Yel

Y1 PTO Clutch

E3 Spark Plug

+ _

H1 Discharge Light

T2 Magneto Ignition Coil

W7 Engine Adaptor Wiring Harness (CV25) W6 Engine Wiring Harness X5 Red Red

X4 To W3 Main Wiring Harness 407 Yel 940 Wht 941 Wht

403 Yel

T1 Magneto Ignition Coil

B1 Engine Oil P Pressure Switch (CV23/CV25)

G2 Stator

(CV21/CV23/CV25)

102 Blk

W5 Engine Ignition Wiring Harness (CV19/CV21/CV23)

Wht Wht

103 107 Blk Blk

(On)

Blk

N1 Voltage Regulator/Rectifier

S6 Switch

(Off)

941 Wht

M1 Starting Motor

Y2 Fuel Solenoid

104 Blk

710 Pur/ Blk

Red

Pur

(O) Forward RIO Neutral

S3 Brake Switch

G1 Battery

Pur

W6 Engine Wiring Harness

Wht

(I) Reverse

106 Blk

Red

205 Red

110 Blk/Wht

205 Red

215 Blu

Grn

Blk

114 Blk

113 Blk

205 Red

F2 Fuse Link

Red Wht

407 Yel 940 Wht 941 Wht 620 Tan

113 Blk

405 Yel/Blk

109 Blk

710 Pur/Blk

X4 To W3 Engine Adaptor Wiring Harness

117 Blk

K2 Backup Relay

402 Yel/Blk

116 Blk

406 Yel

111 Blk/Wht 114 Blk 115 Blk 750 Blu 730 Pur 725 Pur

942 Wht

210 Red

K3 RIO Latch Relay

Momentary On (RIP) On Off 110 Blk/Wht

100 Blk

W3 Engine Wiring Harness (All Engines)

SE3 - CHARGING

E6 Spark Plug SE4 - ENGINE

W1 MAIN WIRING HARNESS

ELECTRICAL

W1 MAIN WIRING HARNESS WIRE COLOR CODES

406

108

X1 To D1 Hour Meter (CV21/CV23/CV25)

400 407

600

403 404

620

X4 To W3 Engine Wiring Harness

106

700

205

H1 Discharge Light

401 402

407

450

S4 Light Switch

S2 PTO/RIP Switch 750

K1 Start Relay Negative

K1 Start Relay Positive

940 941

To G1 Battery Positive

H2 Oil Pressure Light 620

215

404 405

F2 Fusible Link

Splice 210

725 730

X3 To W2 Headlight Wiring Harness

205

942 114 115

100 116

100 101

110 111

400 401

211

105

700 720

S1 Key Switch

405 406

F1 Fuse 15 A

X2 To M1 Starting Motor

710 S3 Brake Switch

725

Y1 PTO Clutch

941 101 102

115 120

750

117 730

S6 RIO Switch

111 114

113

K3 RIO Latch Relay

W1 Ground

210

A1 Discharge Light Module

940 942

710

720

211

402 103 403 104

600

116 117

103 107

110

113 109

K2 Backup Relay

S5 Seat Switch

120

107

4 - 10

450

Circuit Wire Color Number Size

Termination Points

100 101 102 103 104 105 106 107 108 109 110 111 113 114 115 116 117 120 205 210 211 215 400 401 402 403 404 405 406 407 450 600 620 700 710 720 725 730 750 940 941 942

X3, W1 Y1, W1 Y1, GND S6, GND A1, GND S1, GND K1, GND S5, S6 X1, GND K2, GND S2, S6 K3, S2 K2, K3 K2, S2 S3, S2 K3, S2 K3, K3 S5, S3 Splice F2 Fusible Link, X4 Splice F2 Fusible Link, F1 F1, S1 Battery, Splice 205/210 S1, S4 S1, S2 S2, A1 A1, H2 H2, H1 H1, K3 K3, X1 S4, X4 S4, X3 H1, A1 H2, X4 S1, K1 S1, S3 S1, X2 S2, S3 S2, K2 S2, Y1 S1, X4 S3, X4 S1, S2

1.0 1.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.0 2.0 2.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 0.8 0.8

Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk Blk/Wht Blk/Wht Blk Blk Blk Blk Blk Blk Red Red Red Fuse Link Yel/Blk Yel Yel/Blk Yel Yel Yel/Blk Yel Yel Yel/Wht Brn Tan Pur Pur/Blk Pur Pur Pur Blu Wht Wht Wht

2/24/00

W1 MAIN WIRING HARNESS

ELECTRICAL

W1 MAIN WIRING HARNESS WIRE COLOR CODES

406

108

X1 To D1 Hour Meter (CV21/CV23/CV25)

400 407

600

403 404

620

X4 To W3 Engine Wiring Harness

106

700

205

H1 Discharge Light

401 402

407

450

S4 Light Switch

S2 PTO/RIP Switch 750

K1 Start Relay Negative

K1 Start Relay Positive

940 941

To G1 Battery Positive

H2 Oil Pressure Light 620

215

404 405

F2 Fusible Link

Splice 210

725 730

X3 To W2 Headlight Wiring Harness

205

942 114 115

100 116

100 101

110 111

400 401

211

105

700 720

S1 Key Switch

405 406

F1 Fuse 15 A

X2 To M1 Starting Motor

710 S3 Brake Switch

725

Y1 PTO Clutch

941 101 102

115 120

750

117 730

S6 RIO Switch

111 114

113

K3 RIO Latch Relay

W1 Ground

210

A1 Discharge Light Module

940 942

710

720

211

402 103 403 104

600

116 117

103 107

110

113 109

K2 Backup Relay

S5 Seat Switch

120

107

4 - 10

450

Circuit Wire Color Number Size

Termination Points

100 101 102 103 104 105 106 107 108 109 110 111 113 114 115 116 117 120 205 210 211 215 400 401 402 403 404 405 406 407 450 600 620 700 710 720 725 730 750 940 941 942

1.0 1.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.0 2.0 2.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 0.8 0.8

2/24/00

W1 MAIN WIRING HARNESS

ELECTRICAL

W1 MAIN WIRING HARNESS WIRE COLOR CODES

406

108

X1 To D1 Hour Meter (CV21/CV23/CV25)

400 407

600

403 404

620

X4 To W3 Engine Wiring Harness

106

700

205

H1 Discharge Light

401 402

407

450

S4 Light Switch

S2 PTO/RIP Switch 750

K1 Start Relay Negative

K1 Start Relay Positive

940 941

To G1 Battery Positive

H2 Oil Pressure Light 620

215

404 405

F2 Fusible Link

Splice 210

725 730

X3 To W2 Headlight Wiring Harness

205

942 114 115

100 116

100 101

110 111

400 401

211

105

700 720

S1 Key Switch

405 406

F1 Fuse 15 A

X2 To M1 Starting Motor

710 S3 Brake Switch

725

Y1 PTO Clutch

941 101 102

115 120

750

117 730

S6 RIO Switch

111 114

113

K3 RIO Latch Relay

W1 Ground

210

A1 Discharge Light Module

940 942

710

720

211

402 103 403 104

600

116 117

103 107

110

113 109

K2 Backup Relay

S5 Seat Switch

120

107

4 - 10

450

Circuit Wire Color Number Size

Termination Points

100 101 102 103 104 105 106 107 108 109 110 111 113 114 115 116 117 120 205 210 211 215 400 401 402 403 404 405 406 407 450 600 620 700 710 720 725 730 750 940 941 942

1.0 1.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 2.0 2.0 2.0 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 1.0 0.8 0.8 0.8 0.8 0.8 0.8

2/24/00

W2 HEADLIGHT WIRING HARNESS

ELECTRICAL

W2 HEADLIGHT WIRING HARNESS E2 LH Headlight Yel

Blk

X3 To W1 Main Wiring Harness

Blk

E1 RH Headlight

Yel

W3 ENGINE WIRING HARNESS

Wht Pur

To N2 Voltage Regulator/Rectifier

Wht

X5 To W6 Engine Wiring Harness (CV19/CV21/CV23) Pur

407

Red

X5 To W7 Engine Wiring Harness (CV25)

620

X4 To W1 Main Wiring Harness 205

Grn

To B1 Engine Oil Pressure Switch

Wht

940

X6 To W5 Engine Wiring Harness

W4 ENGINE WIRING HARNESS To N2 Voltage Regulator/Rectifier

To Engine Ground

W5 (CV19/CV21/CV23) ENGINE WIRING HARNESS X6 To W3 Engine Wiring Harness T1 Magneto Ignition Coil

Blk

T2 Magneto Ignition Coil

W6 ENGINE WIRING HARNESS X5 To W3 Engine Wiring Harness

3/7/00

Red

Y2 Fuel Solenoid

4 - 11

W7 (CV25) ENGINE WIRING HARNESS

ELECTRICAL

W7 (CV25) ENGINE WIRING HARNESS X8 To W6 Engine Wiring Harness

Red

X5 To W3 Engine Wiring Harness

Red

X7 To A2 Spark Advance Module

W8 (CV25) ENGINE WIRING HARNESS X7 To W7 Engine Wiring Harness

Wht

X6 To W3 Engine Wiring Harness

Red

A2 Spark Advance Module

Yel

T3 Ignition Module

Brn

Grn Yel

Brn

To Engine Ground

T4 Ignition Module

4 - 12

3/7/00

TROUBLESHOOTING

ELECTRICAL

TROUBLESHOOTING

See power circuit diagnosis

●

See cranking circuit diagnosis

●

Check ground circuit

●

Test battery and battery connections

●

See ignition circuit diagnosis

See headlight circuit diagnosis

3/7/00

Headlight problem

●

● ●

See charging circuit diagnosis Check for shorted circuit

Battery goes dead, discharges or overcharges

Engine will not shut off

No spark

Engine cranks but will not start

Check or Solution

Starting motor cranking problems

Problem or Symptom

Improper component operating with switch

This chart will give possible solutions to a problem or refer you to the probable circuit diagnostic sequence.

●

● ●

4 - 13

THEORY AND DIAGNOSIS

ELECTRICAL

THEORY AND DIAGNOSIS POWER CIRCUIT OPERATION Function: Provides unswitched power to the primary components whenever the battery is connected. Operating Conditions, Unswitched Circuits: Voltage must be present at the following components with the key switch in the OFF position: • Battery Positive Terminal • Start Relay Positive Contact Stud • Key Switch • Red Wire at Engine Wiring Harness Connector • DC Voltage Pin of Voltage Regulator/Rectifier The positive battery cable connects the battery to the starting motor relay bolt. The ground cable connection is equally important as the positive cable. Proper starting operation depends on these cables and connections to carry the high current for its operation. The fusible link, 210 Red wire, 15 amp fuse, and 211 Red wire provide unswitched voltage to the key switch. The fusible link and 205 Red wire provide unswitched voltage to the engine wiring harness connector. The engine wiring harness provides voltage to the DC voltage pin of the engine voltage regulator/rectifier. Operating Conditions, Switched Circuits: Placing the key switch in the START position provides voltage to the start relay solenoid coil through the key switch contacts and 700 Pur wire. Placing the key switch in the START or RUN position provides current to the X4 connector and W3 Engine Wiring Harness yellow wire, through the 400 Yel/Blk and 407 Yel wires. Voltage is also provided to the PTO/RIP switch, discharge module, oil pressure light, discharge light, Reverse Implement Option (RIO) latch relay, and the connector to the hour meter through the 401 Yel, 402 Yel/Blk, 403 Yel, 404 Yel, 405 Yel/Blk, and 406 Yel wires.

4 - 14

3/7/00

POWER CIRCUIT SCHEMATIC

ELECTRICAL

POWER CIRCUIT SCHEMATIC S1 Key Switch (Off)

Off On

S4 Light Switch

400 Yel/Blk 401 Yel

211 Red

407 Yel

700 Pur

205 Red

Momentary On On Off

Start Run Off

S2 PTO/RIP Switch 406 Yel

405 Yel/Blk

720 Pur

210 Red

404 Yel

X2 X1 - Use With CV25 Engine

+ _

D1 Hourmeter

H1 Discharge Light

205 Red

F2 Fusible Link

403 Yel

K3 RIO Latch Relay

F1 Fuse 15 A

X4 To W3 Engine Wiring Harness

A1 Discharge Module

402 Yel/Blk

H2 Oil Pressure Light (23 & 25)

700 Pur 215 Blu

Red

K1 Start Relay

G1 Battery

M1 Starting Motor

SE1 - STARTING

SE3 - CHARGING

W7 Engine Wiring Harness (CV25)

W3 Engine Wiring Harness X4 To W3 Main Wiring Harness 407 Yel

Yel

205 Red

Red

W6 Engine Wiring Harness Red

Y2 Fuel Solenoid

X4 To W3 Main Wiring Harness 407 Yel

Red

205 Red

Pur

W6 Engine Wiring Harness Red

Red

X12 Red

W3 Engine Wiring Harness

Red

N1 Voltage Regulator/Rectifier

CV19/CV21/CV23 ENGINES

N1 Voltage Regulator/Rectifier

X11

Y2 Fuel Solenoid

Red

A2 Spark Advance Module

CV25 ENGINE

3/7/00

4 - 15

POWER CIRCUIT DIAGNOSIS

ELECTRICAL

POWER CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position Test/Check Point

Normal

If Not Normal

1. Positive and negative battery post

12.4 volts or above

Clean battery terminals and test battery.

2. Start relay stud terminal

Battery voltage

Clean and check battery cable and tighten connections.

3. F1 Fuse

Battery voltage

Check F2 fusible link, 210 Red wire connections. Replace fuse.

4. Key switch

Battery voltage

Check F1 fuse, and 211 Red wire and connections. Replace fusible link or fuse.

5. Engine connector

Battery voltage

Check wire 205 Red wire and connections.

6. Ground cable frame connection to negative battery terminal

Less than 0.1 ohm resistance

Check harness wires and negative cable connections to frame, removing any paint, rust or corrosion. Clean negative battery connection to battery post.

Test Conditions: • Key switch in RUN position • Engine OFF Test/Check Point

Normal

If Not Normal

7. Key switch

Battery voltage

Replace key switch. “KEY SWITCH TEST” on page 59

8. Light switch

Battery voltage

Check 400 Yel/Blk wire and connections.

9. Engine harness connector

Battery voltage

Check 407 Yel/Blk wire and connections.

4 - 16

3/7/00

POWER CIRCUIT DIAGNOSIS

ELECTRICAL

2 101 Blk 102 Blk

W1 Shielded Ground

G1 Battery

K1 Start Relay

3 211 Red

210 Red F1 Fuse (15 Amp) 8 400 Yel/Blk 407 Yel S4 Light Switch

4 9

211 Red 407 Yel

S1 Key Switch

5 205 Red

400 Yel/Blk 401 Yel

X4 To Engine Wiring Harness

3/7/00

4 - 17

POWER CIRCUIT DIAGNOSIS

ELECTRICAL

Test Conditions: • Key switch in RUN position • Engine OFF Test/Check Point

Normal

If Not Normal

10. PTO/RIP switch

Battery voltage

Check 401 Yel wire and connections.

11. Discharge module

Battery voltage

Check 402 Yel/Blk wire and connections.

12. Oil pressure light

Battery voltage

Check 403 Yel wire and connections.

13. Discharge light

Battery voltage

Check 404 Yel wire and connections.

14. Reverse Implement Option (RIO) Latch Relay

Battery voltage

Check 405 Yel/Blk wire and connections.

15. Hourmeter (If equipped)

Battery voltage

Check 406 Yel wire and connections.

4 - 18

3/7/00

POWER CIRCUIT DIAGNOSIS

ELECTRICAL

10 401 Yel 402 Yel/Blk

11 A1 Discharge Module 403 Yel 402 Yel/Blk S2 PTO/RIP Switch

406 Yel

403 Yel

H2 Oil Pressure Light (CV23/CV25 Only)

404 Yel D1 Hourmeter

14 405 Yel/Blk 406 Yel

H1 Discharge Light

404 Yel K3 RIO Latch Relay 405 Yel/Blk

3/7/00

4 - 19

CRANKING CIRCUIT OPERATION

ELECTRICAL

CRANKING CIRCUIT OPERATION Function: To energize the start relay and engage the starting motor which cranks the engine. Operating Conditions: To crank the engine the key switch must be in the START position, the brake must be ON and the PTO/ RIP switch must be in the OFF (disengaged) position. The operator DOES NOT have to be on the seat to crank the engine. Theory of Operation: Current flows from the battery through F2 fusible link and F1 fuse to the key switch. With key switch in the START position current flows through the key switch, through 401 Yel wire to the closed PTO/RIP switch contacts (PTO DISENGAGED), 725 Pur wire, closed brake switch contacts (brake ON), 710 Pur/Blk wire back to the key switch through 700 Pur wire to the start relay, and 106 Blk wire to ground. The PTO/RIP switch and brake switch are used in the start relay power circuit to prevent the engine from cranking if the PTO is engaged and the brake is not engaged. With the start relay energized, high battery current flows to the starting motor, causing it to crank the engine. An additional wire (720 Pur) is used with the CV25 engine. This wire provides current to activate the starting motor solenoid shift which engages the starting motor with the engine flywheel.

4 - 20

3/7/00

CRANKING CIRCUIT SCHEMATIC

ELECTRICAL

CRANKING CIRCUIT SCHEMATIC

S1 Key Switch 401 Yel

211 Red

700 Pur 710 Pur Blk 105 Blk

Momentary On On Off

720 Pur

104 Blk

Start 401 Yel

Run

725 Pur

A1 Discharge Module

Off

S2 PTO/RIP Switch

103 Blk

F1 Fuse 15 A

210 Red

Off On 710 Pur/Blk

725 Pur

S3 Brake Switch F2 Fusible Link

215 Blu

700 Pur

106 Blk

Red

Red 103 Blk

G1 Battery

720 Pur

K1 Start Relay

X1 X1- Use With CV25 Engine Blk

M M1 Starting Motor

102 Blk 101 Blk

101 Blk

Y1 PTO Clutch

W1 Battery Frame Ground

SE1 - STARTING

3/7/00

SE4 - ENGINE

4 - 21

CRANKING CIRCUIT DIAGNOSIS

ELECTRICAL

CRANKING CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON Test/Check Point

• PTO/RIP switch OFF • Spark plug disconnected Normal

If Not Normal

1. Key switch

Battery voltage

See “POWER CIRCUIT DIAGNOSIS” on page 16

2. Start Relay

Battery voltage

See “POWER CIRCUIT DIAGNOSIS” on page 16

3. Start Relay

Less than 0.1 ohms resistance to frame ground

Check 106 Blk wire and connections

Test Conditions: • Key switch in RUN position • Park brake ON

• PTO/RIP switch OFF • Spark plug disconnected

4. Key switch

Battery voltage

Replace Key switch “KEY SWITCH TEST” on page 59

5. PTO/RIP switch

Battery voltage

Check 401 Yel wire and connections

6. PTO/RIP switch

Battery voltage

Replace PTO/RIP switch “PTO/RIP SWITCH TEST” on page 59

7. Brake switch

Battery voltage

Check 725 Pur wire and connections

8. Brake switch

Battery voltage

Replace brake switch See “BRAKE or REVERSE IMPLEMENT OPTION SWITCH TEST” on page 60.

9. Key switch

Battery voltage

Check 710 Pur/Blk wire and connections

Test Conditions: • Key switch in START position while preforming each test step • Park brake ON Test/Check Point

• PTO/RIP switch OFF • Spark Plug disconnected

NOTE: Engine will turn over during this test. Normal

If Not Normal

10. Key switch

Battery voltage

Replace key switch. “KEY SWITCH TEST” on page 59

11. Start relay

Battery voltage

Check 700 Pur wire and connections. Also check 720 Pur wire and connections on CV25 engine.

12. Start relay

Battery voltage

Replace relay. “STARTING SOLENOID TEST” on page 53

13. Starting motor

Battery voltage

Check Red starting motor cable.

4 - 22

3/7/00

CRANKING CIRCUIT DIAGNOSIS

ELECTRICAL

10 700 Pur 9

11 710 Pur/Blk 700 Pur S1 Key Switch 1 211 Red 4 401 Yel 3 K1 Start Relay 106 Blk

5 401 Yel

725 Pur

8 710 Pur/Blk

S4 Brake Switch

725 Pur

S2 PTO/RIP Switch

13 M1 Starting Motor (CV19/CV21/CV23)

3/7/00

M1 Starting Motor (CV25)

4 - 23

IGNITION CIRCUIT OPERATION

IGNITION CIRCUIT OPERATION Function: To create a spark at the correct time that ignites the fuel/air mixture in the cylinder. To ground the system to keep the engine from starting or to shut off the engine. Operating Conditions: To produce a spark, the key switch must be in the START or RUN position. The operator can be ON or OFF the seat; however, the PTO/RIP switch must be OFF position and the brake switch must be ENGAGED (brake pedal depressed) to start the engine. Once the engine is running, the operator must be ON the seat to engage the transaxle (brake OFF) or engage the PTO. System Operation (CV20/CV21/CV23): The ignition system is a transistor-controlled magneto design. Ignition timing is controlled by the transistor and is not adjustable. The engine is shut off by grounding both sides of the ignition primary coil. With the ignition primary coil grounded, a spark cannot be produced. Placing the key switch in the START or RUN position eliminates one path to ground for the ignition. The second path to ground is eliminated if the operator is ON the seat (seat switch OPEN), or the operator is OFF the seat (seat switch closed), and the brake switch is ENGAGED (brake switch open). A third path to ground will be created with engine running, if the operator places the tractor in reverse while the PTO is engaged and the Reverse Implement Position of the PTO/RIP switch is not engaged. See “REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION” on page 40. As the engine turns over (see “CRANKING CIRCUIT OPERATION” on page 20) the flywheel magnet induces current into the magneto ignition coil, which in turn produces current high enough to jump the spark plug gap(s), creating spark to ignite the engine fuel/air mixture.

4 - 24

ELECTRICAL

System Operation (CV25): The ignition system is capacitive discharge system with an electronic spark advance (Smart Spark™). The engine is shut off by grounding the spark advance module. The spark advance module is grounded through the main wiring harness circuit. Placing the key switch in the START or RUN position eliminates one path to ground for the ignition. The second path to ground is eliminated if the operator is ON the seat (seat switch OPEN), or the operator is OFF the seat (seat switch closed), and the brake switch is ENGAGED (brake switch open). A third path to ground will be created with engine running, if the operator places the tractor in reverse while the PTO is engaged and the Reverse Implement Position of the PTO/RIP switch is not engaged. See “REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION” on page 40. As the engine turns over (see “CRANKING CIRCUIT OPERATION” on page 20) the flywheel magnet induces current into the magneto ignition coil, which in turn produces current high enough to jump the spark plug gap(s), creating spark to ignite the engine fuel/air mixture. Circuitry in the spark advance module shapes the pulse in a linear form based on engine speed. A comparator activates a pulse generator when the linear charge in the capacitor exceeds the charge on a second capacitor. The pulse generator triggers a semiconductor switch in the ignition module causing it to turn on. With the semiconductor switch “ON”, the charging capacitor in the ignition module is directly connected across the primary coil of the output transformer. As the capacitor discharges, a high voltage spike is generated in the secondary coil of the transformer. This high voltage spike flows to the spark plug(s) and jumps the spark plug gap creating a spark which ignites the fuel/air mixture in the engine cylinder(s).

3/7/00

IGNITION CIRCUIT SCHEMATIC

ELECTRICAL

IGNITION CIRCUIT SCHEMATIC S1 Key Switch (Off) 400 Yel/Blk 401 Yel

407 Yel 940 Wht

S6 RIO Switch

Start

104 Blk

107 Blk

116 Blk

103 Blk

A1 Discharge Module

K3 RIO Latch Relay

Momentary On On Off 110 Blk/Wht 111 Blk/Wht

940 Wht 942 Wht

Wht

(I) Reverse

110 Blk/Wht

Off

W3 Engine Adaptor Wiring Harness (CV19/Cv21/CV23)

(O) Forward/Neutral

105 Blk

Run

941 Wht

W5 Engine Wiring Harness (CV19/Cv21/CV23)

Wht Wht

117 Blk

114 Blk

113 Blk

115 Blk

E3 Spark Plug

401 Yel

Off

S2 PTO/RIP Switch

113 Blk 109 Blk

725 Pur

Off Seat On Seat

115 Blk 120 Blk

120 Blk

S3 Brake Switch

E4 Spark Plug

K2 Backup Relay

725 Pur

T2 Magneto Ignition Coil

T1 Magneto Ignition Coil

116 Blk

107 Blk

S5 Seat Switch

941 Wht

407 Yel 940 Wht 941 Wht

X4 To W1 Main Wiring Harness X5

W7 Engine Wiring Harness (CV25)

Red

Wht

X6 Red

X7 W3 Engine Wiring Harness (CV25)

Wht

Red

A2 Spark Advance Module

Grn

Yel

W8 Engine Wiring Harness (CV25)

Brn Yel

Brn

T4 Ignition Module

T3 Ignition Module

E5 Spark Plug

SE2 - IGNITION

3/7/00

E6 Spark Plug

SE4 - ENGINE

4 - 25

IGNITION CIRCUIT DIAGNOSIS

ELECTRICAL

IGNITION CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON Test/Check Point 1. Spark plug

• PTO/RIP switch OFF (DISENGAGED) • Engine cool to avoid burns Normal Spark plug not fouled. Correct air gap.

If Not Normal Adjust air gap. Replace spark plug.

Test Conditions: • Key switch in START position • Park brake ON

• PTO/RIP switch OFF (DISENGAGED)

NOTE: Engine will turn over and can start during this test 2. Spark plug tester installed. See “SPARK TEST” on page 58.

Spark present at tester.

No spark: Check armature air gap. Check for grounded primary lead. Check in-line diodes to ignition coils. (See “RELAY TEST” on page 60.) Check for continuity between engine kill wire and ground (should be infinite). Check ignition coil. Weak Spark: Check spark plug(s).

Test Conditions: • Key switch in ON position • Park brake ON

• PTO/RIP switch OFF (DISENGAGED) • Engine wiring harness disconnected from main wiring harness

3. Engine wiring harness connector

No continuity to ground.

See See “ENGINE SHUTOFF CIRCUIT DIAGNOSIS” on page 30..

4. Key switch

Battery voltage

See “KEY SWITCH TEST” on page 59. Replace switch.

5. Engine wiring harness connector

Battery voltage

Check 400 Yel/Blk and 407 Yel wires and connections.

Test Conditions: • Key switch in OFF position; or, • Operator OFF seat; and, • Park brake OFF 6. Engine wiring harness connector

4 - 26

• Engine wiring harness disconnected from main wiring harness

Continuity between to ground.

See See “ENGINE SHUTOFF CIRCUIT DIAGNOSIS” on page 30..

3/7/00

IGNITION CIRCUIT DIAGNOSIS

ELECTRICAL

Spark Plug Tester

X4 To Engine Wiring Harness 2

407 Yel 5

1 3 6 941 Wht Spark Plug

S1 Key Switch

4 400 Yel/Blk 401 Yel

3/7/00

4 - 27

ENGINE SHUTOFF CIRCUIT OPERATION

ELECTRICAL

ENGINE SHUTOFF CIRCUIT OPERATION Operating Conditions: The engine will be shutoff by any one of four methods First; the engine is shut off by producing a ground path for the engine ignition circuit through the 940 Wht wire, key switch contacts (OFF position), and 105 Blk wire. Second; the engine is shut off if the operator gets OFF the seat with the brake OFF. A ground path is provided through the 941 Wht wire, brake switch contacts (normally closed), 120 Blk wire, seat switch contacts (normally closed), and 107/103/104 Blk wires. Third; the engine is shut off if the operator gets OFF the seat with the PTO/RIP switch ON (engaged). A ground path is provided through the 940/942 Wht wires, PTO/ RIP switch contacts (ON position), 115/120 Blk wires, seat switch contacts (normally closed), and 107/103/ 104 Blk wires Fourth; the engine is shut off if the operator places the tractor in reverse while the PTO/RIP switch is engaged and the Reverse Implement Option (RIO) circuit is not engaged. See “REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION” on page 40. A ground path is provided through the 940/942 Wht wires, PTO/ RIP contacts (ON position), 114 Blk wire, backup relay contacts (normally closed), 113 Blk wire, RIO latch relay contacts (normally closed), 111/110 Blk/Wht wires, RIO switch contacts (normally open), and 103/ 104 Blk wires. Voltage is supplied to the fuel shutoff solenoid through the 400 and 407 Yel wires, and the individual engine wiring harnesses. The fuel shutoff solenoid is located on the bottom of the carburetor float bowl. When the key switch is placed in the OFF position, voltage is stopped to the fuel shutoff solenoid and the fuel supply to the carburetor is immediately shut off.

4 - 28

3/7/00

ENGINE SHUTOFF CIRCUIT SCHEMATIC

ELECTRICAL

ENGINE SHUTOFF CIRCUIT SCHEMATIC S1 Key Switch (Off) 400 Yel/Blk 401 Yel

407 Yel 940 Wht

S6 RIO Switch

Start

104 Blk

107 Blk

116 Blk

103 Blk

A1 Discharge Module

K3 RIO Latch Relay

Momentary On On Off 110 Blk/Wht 111 Blk/Wht

940 Wht 942 Wht

Wht

(I) Reverse

110 Blk/Wht

Off

W3 Engine Adaptor Wiring Harness (CV19/CV21/CV23)

(O) Forward/Neutral

105 Blk

Run

941 Wht

W5 Engine Wiring Harness (CV19/CV21/CV23)

Wht Wht

117 Blk

114 Blk

113 Blk

115 Blk

E3 Spark Plug

401 Yel

Off

S2 PTO/RIP Switch

113 Blk 109 Blk

725 Pur

Off Seat On Seat

115 Blk 120 Blk

120 Blk

S3 Brake Switch

E4 Spark Plug

K2 Backup Relay

725 Pur

T2 Magneto Ignition Coil

T1 Magneto Ignition Coil

116 Blk

107 Blk

S5 Seat Switch

941 Wht

407 Yel 940 Wht 941 Wht

X4 To W1 Main Wiring Harness X5

W7 Engine Wiring Harness (CV25)

Red

Wht

X6 Red

X7 W3 Engine Wiring Harness (CV25)

Wht

Red

A2 Spark Advance Module

Grn

Yel

W8 Engine Wiring Harness (CV25)

Brn Yel

Brn

T4 Ignition Module

T3 Ignition Module

E5 Spark Plug

SE2 - IGNITION

3/7/00

E6 Spark Plug

SE4 - ENGINE

4 - 29

ENGINE SHUTOFF CIRCUIT DIAGNOSIS

ELECTRICAL

ENGINE SHUTOFF CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON

Test/Check Point

• PTO/RIP switch OFF (DISENGAGED) • Operator OFF seat (Seat switch not depressed) • Engine wiring harness disconnected from main wiring harness Normal

If Not Normal

1. Key switch

Continuity to ground.

Check 105 Blk wire and connections.

2. Key switch

Continuity to ground.

Faulty key switch. See “KEY SWITCH TEST” on page 59. Replace switch.

3. Engine connector

Continuity to ground.

Check 940 Wht wire and connections.

4. Brake switch

Continuity to ground.

Check 941 Wht wire and connections.

5. PTO/RIP switch

Continuity to ground.

Check 942 Wht wire and connections.

6. Reverse Implement Option (RIO) switch

Continuity to ground.

Check 103 Blk wire and connections.

7. Seat switch

Continuity to ground.

Check 107 Blk wire and connections

8. Seat switch

Continuity to ground.

Replace Seat switch See “SEAT SWITCH TEST” on page 62.

9. Brake switch

Continuity to ground.

Check 120 Blk wire and connections

10. PTO/RIP switch

Continuity to ground.

Check 115 Blk wire and connections

11. Backup relay

Continuity to ground.

Check 114 Blk wire and connections

12. Backup relay

Continuity to ground.

Replace Backup relay “RELAY TEST” on page 60

13. RIO latch relay

Continuity to ground.

Check 113 Blk wire and connections

14. RIO latch relay

Continuity to ground.

Replace RIO latch relay “RELAY TEST” on page 60

15. PTO/RIP switch

Continuity to ground.

Check 111 Blk/Wht wire and connections

16. Reverse Implement Option (RIO) switch

Continuity to ground.

Check 110 Blk/Wht wire and connections

4 - 30

3/7/00

ENGINE SHUTOFF CIRCUIT DIAGNOSIS

ELECTRICAL

2 940 Wht 942 Wht 1

S1 Key Switch

105 Blk X4 To Engine Wiring Harness

940 Wht 941 Wht

S3 Brake Switch

941 Wht

111 Blk/Wht

9 120 Blk 115 Blk 13 113 Blk K3 RIO Latch Relay S2 PTO/RIP Switch 11 5

114 Blk

942 Wht 12 10

113 Blk

115 Blk 114 Blk

K2 Backup Relay 15 110 Blk/Wht

S6 RIO Switch

107 Blk 8

S5 Seat Switch

103 Blk 107 Blk

16 110 Blk/Wht

120 Blk

3/7/00

4 - 31

CHARGING CIRCUIT OPERATION

ELECTRICAL

CHARGING CIRCUIT OPERATION Function: To maintain battery voltage to 12.4 volts or higher. Operating Conditions: The engine must be running for the charging system to operate. System Operation: The charging system is a rotor and stator design. Charging output is controlled by the N1 voltage regulator/rectifier. With the engine running, current flows from the voltage regulator/rectifier to the battery positive (+) terminal through the 205 Red wire and F2 fusible link. The 205 Red wire allows the voltage regulator/rectifier to charge the battery. When voltage drops below 14.4 VDC the voltage regulator/rectifier electronically closes the internal charging coil ground circuit to ground. With the charging coil ground circuit closed, current is induced in the charging circuit coils and flows to the positive battery terminal. The H1 discharge light indicates a low voltage condition in the battery and is controlled by the A1 discharge module. The discharge module monitors battery voltage through the 402 and 401 Yel wires, key switch contacts, 211 Red wire, F1 fuse, 210 Red wire and F2 fusible link. The circuit is completed through the 104 Blk wire to frame ground cable and the battery. When battery voltage drops, the discharge module closes an internal switch providing a ground path for the discharge light.

4 - 32

3/7/00

CHARGING CIRCUIT SCHEMATIC

ELECTRICAL

CHARGING CIRCUIT SCHEMATIC

S1 Key Switch 401 Yel

211 Red

104 Blk

A1 Discharge Module

402 Yel/Blk

Start Run

Off

403 Yel

600 Brn

Momentary On On Off 404 Yel

F1 Fuse 15 A

402 Yel/Blk

+ _

401 Yel

H1 Discharge Light

S2 PTO/RIP Switch

H2 Oil Pressure Light (CV23/CV25)

600 Brn

210 Red

X4 To W3 Engine Wiring Harness 205 Red

F2 Fusible Link

Pur

205 Red

215 Blu Pur Blk

G1 Battery

N1 Voltage Regulator/Rectifier Wht Wht

W4 Engine Ground Wire

Blk

G2 Stator 101 Blk

SE1 - STARTING

3/7/00

SE2 - IGNITION

SE3 - CHARGING

SE4 - ENGINE

4 - 33

CHARGING CIRCUIT DIAGNOSIS

ELECTRICAL

CHARGING CIRCUIT DIAGNOSIS Test Conditions: • Key switch OFF • PTO/RIP switch OFF

• Park brake ON

Test/Check Point 1. Battery positive terminal

Normal 12.4 volts or higher

If Not Normal Test battery. See “BATTERY TEST” on page 51.

Test Conditions: • Key switch ON (Engine NOT running) • PTO/RIP switch OFF • Park Brake ON 2. Discharge light

Discharge light ON

Check for 12.4 VDC. Check 104 Blk wire and 600 Brn wire and connections. See “POWER CIRCUIT DIAGNOSIS” on page 16. Replace lamp. Replace discharge module.

Test Conditions: • Disconnect regulator/rectifier connection • PTO/RIP switch OFF • Park Brake ON • Start engine and adjust throttle to obtain 3300 RPM 3. Regulator/rectifier connection

28 volts AC or greater

Ensure regulator/rectifier grounding strap connections are clean and tight. Test stator. See “STATOR OUTPUT TEST” on page 63.

4. Discharge light

Discharge light goes OFF as engine RPM is increased.

Replace discharge module.

Test Conditions: • Stop engine • Connect regulator/rectifier connection • PTO/RIP switch OFF • Park Brake ON • Start engine and adjust throttle to obtain 3000 RPM 5. Voltage regulator/rectifier

4 - 34

Minimum voltage – 14.7 ± 0.5 volts DC

Check battery and connections. Replace voltage regulator/rectifier.

3/7/00

CHARGING CIRCUIT DIAGNOSIS

ELECTRICAL

600 Brn

H1 Discharge Light

G1 Battery

403 Yel 404 Yel

104 Blk

A1 Discharge Module

600 Brn

N1 Voltage Rectifier/Regulator Connector Wht

G2 Stator

N1 Voltage Rectifier/Regulator

3 Wht Blk (B+)

3/7/00

4 - 35

PTO CIRCUIT OPERATION

PTO CIRCUIT OPERATION Function: To provide power to energize the PTO clutch. To provide an interlock to the starting circuit to insure that the PTO is in the OFF position when starting the engine. As part of the Reverse Implement Option circuit to provide a ground path for the primary ignition coil to stop the engine if the operator performs a reverse function while the PTO is engaged, without placing the PTO/RIP switch in the Reverse Implement Option (RIO) position. See “REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION” on page 40. The PTO/ RIP switch also provides a ground path for the primary ignition coil to stop the engine if the operator leaves the seat with the PTO ENGAGED.

ELECTRICAL

PTO— When the PTO/RIP switch is placed in the ON position (PTO engaged), current flows through the 750 Blu wire to the Y1 PTO Clutch windings. The energized PTO clutch magnet engages the PTO clutch allowing the sheave plate to turn with the engine crankshaft. If the operator gets OFF the seat, the seat switch will close, provide a ground path for the ignition circuit, and the engine shuts off. Once the engine has been shut off, the PTO switch must be placed in the OFF position (PTO disengaged) before the cranking circuit can be engaged to restart the engine.

PTO Operating Conditions: The key switch must be in the RUN position, the operator must be ON the seat, and the PTO/RIP switch must be in the ENGAGED position. Theory of Operation: Ignition— The PTO/RIP switch is used as a safety switch to stop the engine or prevent cranking the engine if the PTO is engaged and the operator is not ON the seat. With the PTO OFF (disengaged), a power circuit path is provided to the K1 start relay coil through the 700 Pur wire, key switch start contacts (momentary closed), 710 Pur/Blk wire, brake switch (ON) contacts (normally open), 725 Pur wire, PTO/RIP switch contacts (normally closed), 401 Yel wire, key switch run contacts (normally open), and 211 Red wire (12V power in). (See “CRANKING CIRCUIT OPERATION” on page 20.) With the PTO engaged, the start relay coil does not have a power circuit path and the coil will not pull the relay contacts closed preventing engine ignition. The PTO switch (ON position) is used to prevent ignition or stop the engine, if the operator is not present, by grounding the engine magneto coil through the 942 Wht, PTO/RIP switch, 115/120 Blk wires, seat switch (normally closed), and 107/103 Blk wires. (See “IGNITION CIRCUIT OPERATION” on page 24.)

4 - 36

3/7/00

PTO CIRCUIT SCHEMATIC

ELECTRICAL

PTO CIRCUIT SCHEMATIC X4 To W3 Engine Wiring Harness

S1 Key Switch 211 Red 710 Pur

400 Yel/Blk 401 Yel

407 Yel

700 Pur

940 Wht

S6 RIO Switch

(I) Reverse

103 Blk

110 Blk/Wht 116 Blk

Off

F1 Fuse 15 A

104 Blk

107 Blk

Run

A1 Discharge Module

K3 RIO Latch Relay

Momentary On (RIP) On Off 110 Blk/Wht 111 Blk/Wht

940 Wht 942 Wht

(O) Forward/Neutral

105 Blk Start

Off

S2 PTO/RIP Switch

116 Blk

113 Blk

750 Blu

401 Yel

941 Wht

117 Blk

114 Blk 115 Blk

210 Red

K2 Backup Relay

725 Pur

113 Blk On

109 Blk

725 Pur

Off Seat On Seat

115 Blk 215 Blu

941 Wht

F2 Fusible Link

120 Blk

S3 Brake Switch

107 Blk

S5 Seat Switch

G1 Battery

700 Pur

106 Blk

Blk

K1 Start Relay 101 Blk

101 Blk

750 Blu

102 Blk

W1 Battery Frame Ground

SE1 - STARTING

3/7/00

Y1 PTO Clutch

SE2 - IGNITION

SE4 - ENGINE

4 - 37

PTO CIRCUIT DIAGNOSIS

ELECTRICAL

PTO CIRCUIT DIAGNOSIS Test Conditions: • Key switch ON (Engine NOT running) • Park brake ON Test/Check Point

• PTO/RIP switch OFF (DISENGAGED) • Operator OFF seat (Seat switch not depressed) Normal

If Not Normal

1. PTO/RIP switch

12.4 volts or higher

Check 401 Yel wire and connections. See “POWER CIRCUIT DIAGNOSIS” on page 16.

2. PTO/RIP switch

12.4 volts or higher

Replace switch See “PTO/RIP SWITCH TEST” on page 59.

3. Seat switch

Continuity to ground

Check 104, 103, 107 Blk wires and connections.

4. Seat switch

Continuity to ground

Replace switch See “SEAT SWITCH TEST” on page 62.

5. PTO/RIP switch

Continuity to ground

Check 115, 120 Blk wires and connections.

Test Conditions: • Key switch ON (Engine NOT running) • Park brake ON • PTO/RIP switch ON (ENGAGED) 6. PTO/RIP switch

12.4 volts or higher

See “PTO/RIP SWITCH TEST” on page 59.

7. PTO clutch

12.4 volts or higher

Check 750 Blu wire and connections.

8. PTO clutch

Continuity to ground

Check 102, 101 Blk wires and connections.

Test Conditions: • Key switch OFF • Park brake ON • PTO/RIP switch OFF (DISENGAGED) • Disconnect PTO clutch connector 9. PTO clutch coil

4 - 38

0.2 to 0.3 ohms resistance though coil. Infinite resistance from coil to clutch body

Replace PTO clutch.

3/7/00

PTO CIRCUIT DIAGNOSIS

ELECTRICAL

750 Blu

1 401 Yel 402 Yel/Blk

S2 PTO/RIP Switch

2 725 Pur 5

115 Blk

3 107 Blk S5 Seat Switch

4 120 Blk

Y1 PTO Clutch Connector

8 101 Blk 102 Blk

9 7

750 Blu

Y1 PTO Clutch

3/7/00

4 - 39

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT OPERATION Function: To provide a safety interlock between the tractor being operated in reverse while the PTO is engaged, by providing a ground path to be used by either the ignition coil to shutoff the engine, or the RIO latch relay to open its contacts (normally closed) used to provide this ground path and use it for its own ground path. An operator who deems it necessary, and chooses to keep the PTO engaged while backing up, must take a deliberate action to actuate the PTO/RIP switch, by pulling up on the knob momentarily while pressing the reverse pedal. RIO Operating Conditions: The key switch must be in the RUN position, engine running, the operator must be ON the seat, and the PTO/RIP switch must be in the RIO (momentary) position while starting operation in reverse. Theory of Operation: The Reverse Implement Option (RIO) is controlled by two relays and a switch wired in a circuit with the ignition coil, PTO/RIP switch, and Seat switch. This combination of components provide for control of three different functional situations: • PTO/RIP Switch OFF • PTO/RIP Switch ON and operating in reverse without activating the RIO circuit • PTO/RIP Switch ON and operating in reverse while activating the RIO circuit PTO/RIP Switch OFF When the PTO is disengaged, the tractor will operate in both forward and reverse without activating any other switch(s). Power is supplied to the Backup relay with wire 730 Pur, PTO/RIP contacts (normally closed) 401 Yel wire, Key switch run contacts (normally open), and wire 211 Red. This causes the backup relay to be energized and pull the contacts to the normally open position. This breaks (opens) the ground path for the ignition coil and the engine will continue to run normally.

4 - 40

ELECTRICAL

PTO/RIP Switch ON and operating in reverse without activating the RIO circuit During this condition when the PTO is engaged and the tractor is operated in reverse, there is a ground path created for the ignition coil through wire 103 Blk, RIO switch contacts (normally open), 110/111 Blk/Wht wires, RIO latch relay contacts (normally closed), 113 Blk wire, backup relay contacts (normally closed), 114 Blk wire, PTO/RIP switch contacts (normally open), and 942/940 Wht wires. (See “ENGINE SHUTOFF CIRCUIT OPERATION” on page 28.) PTO/RIP Switch ON and operating in reverse while activating the RIO circuit During this condition, when the PTO is engaged and the tractor is operated in reverse, there is a ground path created for the RIO latch relay, both momentary and continuous. The continuous path is through wire 103 Blk, RIO switch contacts (normally open), 110/111 Blk/ Wht wires, RIO latch relay contacts (normally open), 117 Blk wire, RIO latch relay coil, and 405 Yel/Blk suppling 12 volt power into the relay coil. (See “POWER CIRCUIT OPERATION” on page 14.) The momentary path is connected into the continuous path at the RIO latch relay at wire 117 Blk, 116 Blk wire, PTO/RIP switch contacts (momentary closed), and back to wire 110 Blk/Wht. The momentary ground path allows the RIO latch relay to pull in, closing the contacts between the common and normally open contacts of the relay. The normally open contact is wired into the ground side of the relay coil, providing a ground across the relay to wires 111 and 110 Blk/Wht, the RIO switch, and 103 Blk wire to ground, while the tractor is in reverse. When the operator places the foot pedal(s) back to neutral or forward, the RIO switch is allowed to return to its normal (static) condition, breaking the ground path holding the latch relay in the ON condition. This allows the circuit to be self reset and ready for the next reverse operation with PTO engaged.

3/7/00

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT SCHEMATIC

ELECTRICAL

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT SCHEMATIC X4 To W3 Engine Wiring Harness

S1 Key Switch 211 Red 710 Pur

400 Yel/Blk 401 Yel

407 Yel

700 Pur

940 Wht

S6 RIO Switch

(I) Reverse

105 Blk

116 Blk

Off

F1 Fuse 15 A

103 Blk

405 Yel/Blk

402 Yel/Blk

S2 PTO/RIP Switch

725 Pur

K2 Backup Relay

Off On

113 Blk 109 Blk

725 Pur

710 Pur

115 Blk 941 Wht

G1 Battery

S3 Brake Switch

700 Pur

116 Blk

113 Blk

750 Blu 730 Pur

401 Yel

941 Wht

117 Blk

114 Blk 115 Blk

210 Red

215 Blu

A1 Discharge Module

K3 RIO Latch Relay

Momentary On On Off 110 Blk/Wht 111 Blk/Wht

940 Wht 942 Wht

F2 Fusible Link

104 Blk

110 Blk/Wht

Run

(O) Forward/Neutral

107 Blk

Start

Off Seat On Seat 120 Blk

120 Blk

107 Blk

S5 Seat Switch

106 Blk

Blk

K1 Start Relay 101 Blk

101 Blk

750 Blu

102 Blk

W1 Battery Frame Ground

SE1 - STARTING

3/7/00

Y1 PTO Clutch SE2 - IGNITION

SE4 - ENGINE

4 - 41

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS

ELECTRICAL

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS Test Conditions: • Key switch in OFF position • Park brake ON

Test/Check Point

• PTO/RIP switch OFF (DISENGAGED) • Operator OFF seat (Seat switch not depressed) • Engine wiring harness disconnected from main wiring harness Normal

If Not Normal

1. Key switch

Continuity to ground.

Check 105 Blk wire and connections.

2. Key switch

Continuity to ground.

Test key switch. See “KEY SWITCH TEST” on page 59. Replace switch as needed.

3. Engine connector

Continuity to ground.

Check 940 Wht wire and connections.

4. Brake switch

Continuity to ground.

Check 941 Wht wire and connections.

5. PTO/RIP switch

Continuity to ground.

Check 942 Wht wire and connections.

6. Reverse Implement Option (RIO) switch

Continuity to ground.

Check 103 Blk wire and connections.

7. Seat switch

Continuity to ground.

Check 107 Blk wire and connections.

8. Seat switch

Continuity to ground.

Test seat switch See “SEAT SWITCH TEST” on page 62. Replace as needed.

9. Brake switch

Continuity to ground.

Check 120 Blk wire and connections.

10. PTO/RIP switch

Continuity to ground.

Check 115 Blk wire and connections.

11. Backup relay

Continuity to ground.

Check 114 Blk wire and connections.

12. Backup relay

Continuity to ground.

Test backup relay. See “RELAY TEST” on page 60. Replace as needed.

13. RIO latch relay

Continuity to ground.

Check 113 Blk wire and connections.

14. RIO latch relay

Continuity to ground.

Test RIO latch relay. See “RELAY TEST” on page 60. Replace as needed.

15. PTO/RIP switch

Continuity to ground.

Check 111 Blk/Wht wire and connections.

16. Reverse Implement Option (RIO) switch

Continuity to ground.

Check 110 Blk/Wht wire and connections.

4 - 42

3/7/00

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS

ELECTRICAL

2 940 Wht 942 Wht 1

S1 Key Switch

105 Blk

940 Wht 941 Wht

X4 To Engine Wiring Harness

S4 Brake Switch

14 111 Blk/Wht

4 941 Wht

113 Blk

120 Blk 115 Blk

K3 RIO Latch Relay

S2 PTO/RIP Switch

11 114 Blk

5 942 Wht

12 113 Blk

K2 Backup Relay

115 Blk 114 Blk 15 110 Blk/Wht

S6 RIO Switch

7 6 107 Blk 8

S5 Seat Switch

103 Blk 107 Blk

16 110 Blk/Wht

120 Blk

3/7/00

4 - 43

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS

ELECTRICAL

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS Test Conditions: • Key switch ON (Engine NOT running) • Park brake ON Test/Check Point

• PTO/RIP switch OFF (DISENGAGED) • Operator OFF seat (Seat switch not depressed) Normal

If Not Normal

17. PTO/RIP switch

Battery voltage

Check 401 Yel wire and connections.

18. Discharge module

Battery voltage

Check 402 Yel/Blk wire and connections.

19. Oil pressure light

Battery voltage

Check 403 Yel wire and connections.

20. Discharge light

Battery voltage

Check 404 Yel wire and connections.

21. Reverse Implement Option (RIO) Latch Relay

Battery voltage

Check 405 Yel/Blk wire and connections.

22. PTO/RIP switch

Battery voltage

Test switch. See “PTO/RIP SWITCH TEST” on page 59. Replace as needed.

23. Backup relay

Battery voltage

Check 730 Pur wire and connections.

24. Backup relay

Continuity to ground

Check 109 Blk wire and connections.

4 - 44

3/7/00

REVERSE IMPLEMENT OPTION (RIO) CIRCUIT DIAGNOSIS

ELECTRICAL

17 401 Yel 402 Yel/Blk 18 A1 Discharge Module 403 Yel 402 Yel/Blk S2 PTO/RIP Switch 22 730 Pur

K2 Backup Relay 19

23 730 Pur

403 Yel

H2 Oil Pressure Light (CV23 & CV25)

404 Yel

109 Blk

H1 Discharge Light

404 Yel 405 Yel/Blk

21 405 Yel/Blk 406 Yel

K3 RIO Latch Relay

3/7/00

4 - 45

HEADLIGHT CIRCUIT OPERATION

ELECTRICAL

HEADLIGHT CIRCUIT OPERATION Function: Provides power to the headlights. Operating Conditions: The key switch must be in the RUN position. Theory of Operation: The W2 headlight wiring harness is attached to the W1 main wiring harness. Power from the S4 light switch flows through the 450 Yel/Wht wire to the to the headlight harness connector (X3). Current flows from the connector to the headlights. Ground circuit is obtained through the headlight harness connector (X3) and 100 Blk wire to ground.

4 - 46

3/7/00

HEADLIGHT CIRCUIT SCHEMATIC

ELECTRICAL

HEADLIGHT CIRCUIT SCHEMATIC S1 Key Switch (Off)

Off On 400 Yel/Blk

211 Red

450 Yel/Wht

S4 Light Switch

F1 Fuse 15 A

E1 RH Headlight

Start 210 Red

E2 LH Headlight

Run

100 Blk

Off

F2 Fusible Link

W2 Headlight Wiring Harness

215 Blu

G1 Battery Blk 100 Blk

W1 Battery Frame Ground

W2 HEADLIGHT WIRING HARNESS

E2 LH Headlight Blk

Yel

Blk

E1 RH

X3 To W1 Main Wiring Harness

Yel

Headlight

3/7/00

4 - 47

HEADLIGHT CIRCUIT DIAGNOSIS

ELECTRICAL

HEADLIGHT CIRCUIT DIAGNOSIS Test Conditions: • Key switch must be in the RUN position • Park brake ENGAGED (ON) • Light switch ON Test/Check Point

Normal

If Not Normal

1. Light switch

Battery voltage

See Power Circuit Diagnosis.

2. Light switch

Battery voltage

See “LIGHT SWITCH TEST” on page 58. Replace light switch.

3. X3 headlight wiring harness connector

Battery voltage

Check 450 Yel/Wht wire and connections.

4. LH headlight

Battery voltage

Check headlight wiring harness and connector.

5. LH headlight

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight Greater than 0.2 volts: Check harness connector (X3) and 100 Blk wire and connections.

6. RH headlight

Battery voltage

Check Yel/Wht jumper wire and connections between headlights.

7. RH headlight

Greater than 0 volts - less than 0.2 volts.

0 volts: Replace headlight. Greater than 0.2 volts: Check Blk jumper wire and connections between headlights.

4 - 48

3/7/00

HEADLIGHT CIRCUIT DIAGNOSIS

ELECTRICAL

100 Blk

1 400 Yel/Blk 407 Yel

450 Yel/Wht

X3 To W2 Headlight Wiring Harness 3

S4 Light Switch

7 4

Blk

Blk E2 LH Headlight

E1 R. H. Headlight

Yel/Wht Yel/Wht 5

To X3

3/7/00

4 - 49

TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS GROUND CIRCUIT TESTS Reason: To check for opens, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. Equipment: • Ohmmeter or Voltmeter. The voltmeter method checks ground connections under load. Procedure: OHMMETER METHOD: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Connect ohmmeter negative (black) lead to negative terminal of battery. Put meter positive (red) lead on negative terminal of battery and record reading. Reading should be 0.1 ohm or less. 7. Put meter red lead on ground terminal of circuit or component to be tested that is closest to the battery negative terminal. Resistance reading must be very close to or the same as the battery negative terminal reading. Work backwards from the battery on the ground side of the problem circuit until the resistance reading increases above 0.1 ohms. The problem is between the last two test points. If a problem is indicated, disconnect the wiring harness connector to isolate the wire or component and check resistance again. Maximum allowable resistance in the circuit is 0.1 ohms. Check both sides of connectors closely as disconnecting and connecting may temporarily solve problem.

4 - 50

ELECTRICAL

VOLTMETER METHOD: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Place key switch in ON position. 7. Connect voltmeter negative (black) lead to negative terminal of battery. 8. Put meter positive (red) lead on ground terminal of circuit or component to be tested. Be sure the component circuit is activated (key on, switches closed) so voltage will be present at the component. Record voltage. Voltage must be greater than 0 but less than 1 volt. Some components will have a very small voltage reading on the ground side and still be operating correctly. Results: • If voltage is 0, the component is open. • If voltage is greater than 1 volt, the ground circuit is bad. Check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit.

3/7/00

BATTERY TEST

ELECTRICAL

BATTERY TEST

8. Use a voltmeter or JTO5685 Battery Tester to check for a minimum battery voltageof 12.4 volts.

Reason: To check condition of battery and determine battery voltage.

Results: • If battery voltage less than 12.4 VDC, charge battery (see Charge Battery);

NOTE: Battery is maintenance free.

CHARGE BATTERY Equipment: • Voltmeter or JTO5685 Battery Tester Procedure:

Reason: To increase battery charge after battery has been discharged. Equipment:

c CAUTION Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into the eyes. Avoid the hazard by: 1. Wearing eye protection and rubber gloves. 2. Avoiding breathing fumes when electrolyte is added. 3. Avoid spilling or dripping electrolyte. 4. Use proper jump start procedure.

• Battery charger (variable rate) Procedure:

NOTE:

See BATTERY TEST in this group before charging battery.

1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Clean cable ends, battery terminals and top of battery.

If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 1.9 L (2 qts.). 3. Get medical attention immediately. 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedal to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Clean cable ends, battery terminals and top of battery. 7. Inspect battery terminals and case for breakage or cracks. 3/7/00

Battery Charger and Booster

7. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost setting is 10 minutes. Allow additional 5 minutes for each 10 degrees below 70° F. 8. Start charger at SLOW rate. Increase charge rate ONE setting at a time. Check charger ampmeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary. 9. Check if battery is accepting a 10 amp charge after 10 minutes at boost setting.

4 - 51

BATTERY LOAD TEST Results: • If battery WILL NOT accept 10 amp charge after 10 minutes at boost setting, replace battery; • If battery is accepting 10 amp charge after 10 minutes at boost setting, and battery did NOT need water, go to Steps 10 and 11; • If battery is accepting 10 amp charge after 10 minutes at boost setting, but battery DID need water or all cells were BELOW 1.175, go to Steps 9 and 10. 10. Set charger at 15-25 amps. IMPORTANT: Decrease charge rate if battery gases or bubbles excessively or becomes too warm to touch. 11. Check specific gravity after 30 minutes (60 minutes for maintenance-free battery).

ELECTRICAL

BATTERY LOAD TEST Reason: To check condition of battery under load. Equipment: • JTO5685 Battery Tester Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Clean cable ends, battery terminals and top of battery.

Results: • If MORE THAN 50 point variation between cells, replace battery; • If LESS THAN 50 point variation between cells, go to Steps 11 and 12.

D.C. AMPS

NOTE: If battery was discharged at slow or unknown rate, charge at 10-15 amps for 6-12 hours. (Maintenance-free battery: 12-24 hours.) If battery was discharged at fast rate, charge at 20-25 amps for 2-4 hours. (Maintenance-free battery: 4-8 hours.) 12. Continue to charge battery until specific gravity is 1.230-1.265 points. 13. Load test battery. (See Battery Load Test.) 14. Install battery.

B D.C. VOLTS

7. Turn load knob (A) counterclockwise to OFF position. 8. Connect tester positive cable (red) to battery positive (+) terminal (B). 9. Connect tester negative cable (black) to battery negative (–) terminal (C). 10. Turn load knob (A) of tester clockwise (in) until amperage reading (D) is equal to: • cold cranking amperage rating of battery (use blue scale). —or— • three times ampere hour rating (use black scale). 11. Hold for 15 seconds and turn load knob (A) of tester counterclockwise (out) into OFF position. 12. Repeat Steps 9 and 10 above and read condition of battery at DC Volts scale (E). Results: • If battery DOES NOT pass test and has NOT been charged, charge battery and retest (see Charge Battery). • If battery DOES NOT pass the test and HAS BEEN charged, replace the battery.

4 - 52

3/7/00

STARTING SOLENOID TEST (CV19/CV21/CV23)

ELECTRICAL

STARTING SOLENOID TEST (CV19/ CV21/CV23) Reason:

solenoid. 11. Momentarily turn ignition key to START position and check for battery voltage. Results:

To determine if starting solenoid is defective.

• No battery voltage – See “CRANKING CIRCUIT DIAGNOSIS” on page 22. • Battery voltage – Check 106 Blk wire and connections between starting motor solenoid and frame ground. If OK, starting motor solenoid is defective. Replace solenoid.

Equipment: • Volt Ohm Meter Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect and ground spark plug lead.

STARTING MOTOR SOLENOID TEST (CV25) Reason: To determine if starting motor solenoid is defective. Equipment:

• Volt Ohm Meter C

Procedure: v

D A

1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect and ground spark plug lead.

M87617

7. Connect VOM to negative (–) battery terminal (A) and terminal (B) of starting motor solenoid. Check for battery voltage.

Results: • No battery voltage – See “POWER CIRCUIT DIAGNOSIS” on page 16. Check battery positive (+) terminal and starting motor solenoid terminal (B) for loose connections. Clean any corrosion. • Battery voltage – go to next step. 8. Connect VOM to negative (–) battery terminal (A) and terminal (C) of starting motor solenoid. 9. Momentarily turn ignition key to START position and check for battery voltage. Results • Battery voltage – starting motor solenoid is not defective. • No battery voltage – go to next step. 10. Connect VOM to negative (–) battery terminal (A) and terminal (D) (Pur wire) of starting motor 3/7/00

B C

M87617

7. Connect VOM to negative (–) battery terminal (A) and terminal (B) of starting motor. 8. Momentarily turn ignition key to START position and

4 - 53

STARTING MOTOR LOADED AMPERAGE DRAW TEST

ELECTRICAL

check for battery voltage. Results:

• No battery voltage – See “POWER CIRCUIT DIAGNOSIS” on page 16. Check starting motor solenoid terminal and starting motor terminal (B) for loose connections. Clean any corrosion. • Battery voltage – go to next step. 9. Connect VOM to negative (–) battery terminal (A) and connector (C) of starting motor shift solenoid. 10. Momentarily turn ignition key to START position and check for battery voltage.

D.C. AMPS

D.C. VOLTS

Results • Battery voltage – Starting motor is defective. See “STARTING MOTOR LOADED AMPERAGE DRAW TEST” on page 54. • No battery voltage. Check 720 Pur wire and connections between starting solenoid and starting motor shift solenoid.

STARTING MOTOR LOADED AMPERAGE DRAW TEST Reason:

IMPORTANT: Turn load knob (A) fully counterclockwise (out) into OFF position before making any test connections. 8. Connect JTO5685 Battery Tester to battery. 9. Crank engine—read and record voltage on DC voltage scale (B) of battery tester. 10. Turn key switch to OFF position. IMPORTANT: Perform following procedure within 15 seconds to prevent damage to tester and/or machine components.

To determine the amperage required to crank the engine and check starting motor operation under load. Equipment: • JTO5685 Battery Tester Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Test system ground connections and battery (see Ground Circuit Test and Battery Load Test). 7. Disconnect and ground spark plug lead.

11. Turn load knob (A) clockwise (in) until DC voltage (B) reads the same as when cranking. 12. Read and record DC amperage (C). IMPORTANT: Turn load knob (A) completely counterclockwise (out) into OFF position. Results: • Maximum starting motor draw should be at or below specification. • If amperage is above specification, perform Starting Motor No-Load Amperage and RPM Test to determine if starting motor is binding or damaged. Specifications: Amp Draw . . . . . . . . . . . . . . . . . . . . . . 90 – 100 amps IMPORTANT: If starting motor is good, check internal engine components for binding, wear, or damage.

4 - 54

3/7/00

ELECTRICAL

STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV19/CV21/CV23

ENGINES)

STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV19/ CV21/CV23 ENGINES) Reason: To determine starting motor condition under no-load conditions.

IMPORTANT: Park machine on level surface. 1. Turn key switch to OFF position. 2. Move Forward/Reverse pedals to NEUTRAL position. 3. Engage park brake. 4. Raise hood. 5. Remove starting motor.

Required Tools: • JT05791 Multitester • JT02153 Current Clamp • 12 Volt Battery • Jumper Cables • JTO7270 Hand-Held Digital Tachometer Procedure:

c CAUTION Do not clamp starting motor housing in vise or strike with a hammer. Clamp only on the mounting bracket. Starting motor contains two ceramic magnets that can be broken or cracked if the starting motor housing is hit, deformed or dented.

NOTE:

Check that battery is fully charged and of proper size to ensure accuracy of test.

IMPORTANT: When connecting wires and meter, ensure connections are not touching any surface where a ground short may occur. Wrap connections with electrical tape if necessary. Clamp the starting motor mounting bracket in a vise. 6. Connect the NEG jumper cable to the battery NEG post and the frame of the starting motor. 7. Connect the POS jumper cable to the POS post of the battery. IMPORTANT: Connect current clamp RED lead to the VOLTS jack of the multitester and the BLACK lead of the current clamp to the COM jack on the multitester. 8. Clamp jaws of current clamp around the positive jumper cable. 9. Set the current clamp to 2000A and the multitester to 300mV. JTO7270 Hand-Held Digital Tachometer

JTO2153 Current Clamp

JTO5791 Multitester

3/7/00

4 - 55

STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV25 ENGINE) 10. Adjust the DCA ZERO ADJUST dial on the current clamp for a zero reading on the multitester.

NOTE: The core of the jaws may hold some magnetic force after the current clamp has been used for measurement. If you cannot zero adjust the display, open the jaws and snap them closed several times. 11. Momentarily touch the POS jumper cable lead to the starting motor POS post and read the starting motor amperage draw.

NOTE: If using a multitester other than JT05791, use a meter that will read millivolts. Millivolts = current in amps; 1mV= 1 amp. 12. Disconnect and remove the current clamp. 13. Place a piece of reflective tape on the starting motor gear shaft. 14. Momentarily touch the POS jumper cable lead to the starting motor POS post and read the starting motor rpm. Results: • A good starting motor should have a maximum amperage reading of 35 amps and a minimum rotational reading 6500 rpm. • If amperage reading is above 35 amps or starting motor rpm is less than 6000, check for binding or seized bearings, sticky brushes, and dirty or worn commutator. Repair or replace starting motor.

ELECTRICAL

STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV25 ENGINE) Reason: To determine starting motor condition under no-load conditions. Required Tools: • JT05791 Multitester • JT02153 Current Clamp • 12 Volt Battery • JTO7270 Hand-Held Digital Tachometer • Jumper Cables • Jumper Wire (To connect the starting motor POS post and the solenoid shift connector) Procedure:

c CAUTION Do not clamp starting motor housing in vise or strike with a hammer. Clamp only on the mounting bracket. Starting motors contain two ceramic magnets that can be broken or cracked if the motor housing is hit, deformed or dented.

NOTE:

Check that battery is fully charged and of proper size to ensure accuracy of test.

1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Remove starting motor. IMPORTANT: When connecting wires and meter, ensure connections are not touching any surface where a ground short may occur. Wrap connections with electrical tape if necessary. Clamp the starting motor mounting bracket in a vise. 7. Connect the NEG jumper cable to the battery NEG post and the frame of the starting motor. 8. Connect the POS jumper cable to the POS post of the battery. 9. Connect current clamp RED lead to the VOLTS jack of the multitester and the BLACK lead of the current clamp to the COM jack on the multitester.

4 - 56

3/7/00

ELECTRICAL

STARTING MOTOR NO-LOAD AMPERAGE & RPM TESTS (CV25 ENGINE)

10. Clamp jaws of current clamp around the positive jumper cable. 11. Set the current clamp to 2000A and the multitester to 300mV.

15. Momentarily touch the POS jumper cable lead to the starting motor POS post and read the starting motor rpm. Results:

IMPORTANT: Adjust the DCA ZERO ADJUST dial on the current clamp for a zero reading on the multitester.

NOTE: The core of the jaws may hold some magnetic force after the current clamp has been used for measurement. If you cannot adjust the display, to zero, open the jaws and snap them closed several times.

â&#x20AC;˘ A good starting motor should have a maximum amperage reading of 20 amps and a minimum rotational reading 2500 rpm. â&#x20AC;˘ If amperage reading is above 20 amps or starting motor rpm is less than 1000, check for binding or seized bearings, sticky brushes, and dirty or worn commutator. Repair or replace starting motor.

IMPORTANT: Connect the POS jumper cable lead to the starting motor POS post (A). 12. Momentarily connect the starting motor POS post (A), to the starting motor solenoid shift connector (B), and read the starting motor amperage draw.

NOTE: If using a multitester other than JT05791, use a meter that will read millivolts. Millivolts = current in amps; 1mV = 1 amp. 13. Disconnect and remove the current clamp. 14. Place a piece of reflective tape on the starting motor gear shaft.

JTO7270 Hand-Held Digital Tachometer

A B JTO2153 Current Clamp

JTO5712 Multitester

3/7/00

4 - 57

SPARK TEST

ELECTRICAL

SPARK TEST

LIGHT SWITCH TEST

Reason:

To check overall condition of ignition system.

To make sure the light switch terminals have continuity when the light switch is ON.

Equipment: Equipment:

• D-05351ST Spark Tester

• Ohmmeter or Continuity Tester Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Raise hood. 5. Wheels blocked and park brake OFF. 6. Remove high tension lead (A) from spark plug and connect to spark tester (B).

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect light switch connector.

A C

B D

7. Connect spark tester lead to spark plug. 8. Adjust spark tester gap to 4.2 mm (0.166 in.) with screw (C).

NOTE: Do not adjust spark tester gap beyond 5.0 mm (0.200 in.) as damage to ignition system components could occur. 9. Turn key switch to RUN position and start engine. 10. Watch spark (D) at spark tester.

7. Move light switch to the ON and then the OFF position. Check continuity between terminals (A and B). Results: • Terminals should have continuity with switch ON. • Terminals should NOT have continuity with switch OFF. • If continuity is NOT correct, replace light switch.

Results: •

If engine will start, watch spark with engine running. There should be a strong, steady, blue spark • If spark is weak, or if no spark, install a new spark plug and test again. • If spark is still weak, or still no spark, run tests on individual components to find cause of malfunction.

4 - 58

3/7/00

KEY SWITCH TEST

ELECTRICAL

KEY SWITCH TEST

PTO/RIP SWITCH TEST

Reason:

To verify key switch functions are operating properly.

To verify PTO/RIP switch functions are operating properly.

Equipment: Equipment:

• Ohmmeter or Continuity Tester

• Ohmmeter or Continuity Tester Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect key switch connector.

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Disconnect PTO/RIP switch connector. C

A D B

F D

7. Use an ohmmeter to test switch continuity in OFF, RUN, and START positions.

6. Use an ohmmeter to test switch continuity in OFF and ON positions.

Key Switch Continuity:

PTO/RIP Switch Continuity:

Switch Position . . . . . . . . . . . . . Terminal Continuity

Switch Position. . . . . . . . . . . . . .Terminal Continuity

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and F

RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C and D START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C and D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E and F Results: • If continuity is NOT found in any of these positions, or continuity is found in any other position, replace switch.

ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E Momentary ON . . . . . . . . . . . . . . . . . . . . . . . .A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D and E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G and H Results: • All other possible combinations have infinite resistance. If any continuity is NOT correct, replace switch.

3/7/00

4 - 59

RELAY TEST

ELECTRICAL

RELAY TEST

Results:

Reason: To check relay terminal continuity in the energized and de-energized condition.

• There should be continuity between terminals A (30) and E (87). • If continuity is NOT correct, replace relay.

BRAKE or REVERSE IMPLEMENT OPTION SWITCH TEST

Equipment: • Ohmmeter or continuity tester • 12 volt battery and small jumper wires

Reason: To verify switch functions are operating properly.

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood 6. Disconnect relay connector. 7. Check terminal continuity using an ohmmeter or continuity tester. 86

Equipment: • Ohmmeter or Continuity Tester Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Disconnect switch connector. A C

87a

A D

86 D

87a 87

85 C

6. Use an ohmmeter to test switch continuity in OFF and ON positions.

B M91294

Switch Continuity: Switch Position . . . . . . . . . . . . . Terminal Continuity Results: • There should be continuity between terminals A (30) and B (87a). • There should be approximately 80 ohms resistance between terminals C (85) and D (86). • There should NOT be continuity between any other terminals. 8. Connect a small jumper wire from battery positive (+) terminal to relay terminal C (85). Connect a small jumper wire from relay terminal D (86) to battery negative terminal (–).

4 - 60

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A and B ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C and D Results: • All other possible combinations have infinite resistance. If any continuity is NOT correct, replace switch.

3/7/00

OIL PRESSURE SWITCH TEST (CV23/CV25)

ELECTRICAL

OIL PRESSURE SWITCH TEST (CV23/CV25)

12. Remove the oil pressure switch.

Reason: To determine the proper operation of the oil pressure switch. Test Equipment: B

• Ohmmeter Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage parking brake. 5. Raise hood. 6. Turn key switch to RUN position (Engine OFF).

13. Connect red ohmmeter lead to terminal of switch (A) and black ohmmeter lead to threads (B) of oil pressure switch. 14. Set ohmmeter for 1x scale. 15. Measure resistance between terminal and threads of switch. Results: • There SHOULD be continuity. • If switch does not have continuity, replace switch.

620 Tan

403/404 Yel H2 Oil Pressure Light

620 Tan X4 To Engine Wiring Harness

7. The engine oil pressure light should be ON.

NOTE: The Oil Pressure Switch is a normally closed switch. With the engine OFF, the engine oil pressure switch provides a ground circuit for the Oil Pressure Light. 8. Check for voltage in the 620 Tan wire at the engine wiring harness connector. There should be no voltage. • If there is voltage: The engine wiring harness wire from the connector to the oil pressure switch may be open; or, The oil pressure switch may be open and will have to be removed for testing. 9. Turn ignition switch to OFF position. 10. Remove the air cleaner and air cleaner base. 11. Disconnect the green wire from oil pressure switch.

3/7/00

CAUTION

Reduce compressed air to less than 105 kPa (15 psi) when using for testing purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. 16. Using a rubber tipped air nozzle, apply 70 - 105 kPa (10 - 15 psi) to the base (C) of the oil pressure switch. 17. Measure resistance between terminal and threads of switch with the air pressure applied. Results: • There SHOULD NOT be continuity. • If switch does have continuity, replace switch.

NOTE: Be sure to apply Pipe Sealant with TEFLON to threads of switch anytime it is installed.

4 - 61

SEAT SWITCH TEST

ELECTRICAL

SEAT SWITCH TEST

FLYWHEEL MAGNET TEST

Reason:

To verify seat switch functions are operating properly.

To make sure flywheel magnet(s) have enough force to induce current into ignition coil.

Equipment: • Ohmmeter or Continuity Tester

Equipment: • Screwdriver.

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Disconnect seat switch connector.

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Remove flywheel blower housing from engine. 7. Loosely hold screwdriver blade about 25 mm (1.0 in.) away from magnet. Results: • Magnet should attract blade to it. • If blade is NOT attracted to magnet, flywheel must be replaced.

6. Use an ohmmeter to test switch continuity in OFF and ON positions. Seat Switch Continuity: Switch Position . . . . . . . . . . . . . Terminal Continuity OFF (Normally Closed) . . . . . . . . . . . . . . . . .A and B Results: • Switch is open (infinite resistance) when switch is depressed. If continuity is NOT correct, replace switch.

4 - 62

3/7/00

STATOR OUTPUT TEST

ELECTRICAL

STATOR OUTPUT TEST

Results: • If resistance (or continuity) is measured, stator leads are shorted to ground. Replace stator.

Reason: To measure AC voltage output of stator and verify correct resistance of stator. Equipment: • Fluke Multi-Meter (Set to AC volt scale)

VOLTAGE REGULATOR/RECTIFIER TEST Reason: To verify proper operation capability of the voltage regulator/rectifier.

Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Set meter to 50 VAC or Autorange scale. 7. Disconnect regulator/rectifier connector.

Equipment: • Fluke Multi-Meter (Set to Ohms scale) Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood.

8. Start and run at fast idle (3350 ± 75 RPM). 9. Measure stator voltage. Voltage should read a minimum of 28 volts AC. Results: • If voltage is less than specification, test stator with an ohmmeter. 10. Stop engine. 11. Change meter to ohms scale. 12. Measure resistance across stator leads. Resistance should read 0.1 to 0.2 ohms.

C B

6. Disconnect stator connector from the voltage regulator/rectifier. 7. Set the multi-Meter to the Ohms scale. 8. Measure resistance between each point as shown in the chart. If resistance is not within specification, replace voltage regulator/rectifier. A A

8-9m

31.2 m

0.2

31.2 m

8-9m

Results: • If resistance is infinite ohms, stator is open. Replace stator.

OL 8-9m

13. Measure resistance from each stator lead to ground. Resistance should read infinite ohms.

3/7/00

4 - 63

ARMATURE WITH COIL (CV19/CV21/CV23)

ARMATURE WITH COIL (CV19/CV21/ CV23)

ELECTRICAL

ARMATURE TEST (CV19/CV21/ CV23)

Removal & Installation A B

B A

M99738

1. Remove blower housing. 2. Disconnect wiring lead (A). 3. Remove cap screws (B) and armature with coil (C). 4. Test armature with coil. (See Test procedure.)

M99740

1. Measure resistance between each point as shown in the chart. If resistance is not within specification, replace armature with coil.

Installation is done in the reverse order of removal. •

Adjust armature procedure.)

air

gap.

(See

Adjustment

AIR GAP ADJUSTMENT (CV19/ CV212/CV23)

A+ A– B–

2.14 m

C–

8.66 k

B+

C+

8.66 k 2.14 m

M99739

1. Center flywheel magnet under armature. 2. Insert a 0.2 - 0.3 mm (0.008 - 0.012 in.) feeler gauge (A) between flywheel and armature. 3. Push armature against flywheel and tighten screws (B) to 7.8 N•m (69 lb-in.). 4. Turn flywheel to remove feeler gauge. Specifications: Air Gap . . . . . . . . . . . 0.2 - 0.3 mm (0.008 - 0.012 in.) Armature Capscrews . . . . . . . . . . 7.8 N•m (69 lb-in.)

4 - 64

3/7/00

ARMATURE WITH COIL (CV25)

ELECTRICAL

ARMATURE WITH COIL (CV25)

ARMATURE TEST (CV25)

Removal & Installation B

C B

D A

C A

M99741

1. Remove blower housing. 2. Disconnect wiring leads (A). 3. Remove cap screws (B) and armature with coil (C). 4. Test armature with coil. (See Test procedure.)

M99742

1. Measure resistance between each point as shown in the chart. If resistance is not within specification, replace armature with coil. A+

Installation is done in the reverse order of removal. •

Adjust armature procedure.)

air

gap.

(See

Adjustment

AIR GAP ADJUSTMENT (CV25)

A–

B+

C+

D+

4.23 k

5.18 k

4.08 k

1245

149.2

B–

4.23 k

C–

5.18 k

1245

D–

4.08 k

149.2

1096 1096

M99741

3/7/00

4 - 65

REPAIR

ELECTRICAL

REPAIR

Installation:

STARTING MOTOR REMOVAL & INSTALLATION (CV19/CV21/CV23) E

Procedure:

A C

M99744

Upper Engine Shroud Removed for Clarity. 10. Position starting motor on engine. Install the front capscrew (C) with one spacer washer (F) between the bendix guard (E) and the starting motor. Install the rear capscrew (C) with a spacer washer (F) between the bendix guard (E) and the starting motor and the other spacer washer (F) between the bendix guard (E) and the lifting bracket (D). Tighten capscrews to 24 N•m (216 lb-in.). 11. Connect battery cable (A) to starting motor and reconnect battery negative cable. 12. Install the capscrew securing the oil filler tube to the lifting bracket and tighten to 7.8 N•m (69 lb-in.).

B C D

Specifications: Starting Motor Capscrews. . . . . . 24 N•m (216 lb-in.) Oil Filler Tube Capscrews . . . . . . 7.8 N•m (69 lb-in.) M99743

4 - 66

3/7/00

ELECTRICAL

STARTING MOTOR DRIVE REPLACEMENT (CV19/CV21/CV23)

STARTING MOTOR DRIVE REPLACEMENT (CV19/CV21/CV23) NOTE:

Check for available service parts before disassembling motor.

BRUSH REPLACEMENT & ARMATURE TEST (CV19/CV21/ CV23) IMPORTANT: Starting motor armature should be tested anytime the starting motor is disassembled.

M99745

1. Remove starting motor. Remove dust cover. 2. Compress retainer and remove stop clip. 3. Disassemble bendix drive. 4. Replace with new bendix drive kit.

M99746

1. Mark or scribe top and bottom end caps to frame for reassembly. 2. Remove long cap screws and separate top end cap and armature from frame and bottom end cap (brush holder).

M55918

3. Clean contact points of negative brushes. Using an ohmmeter, check for continuity between brushes and end cap. Replace brushes if no continuity is indicated. 3/7/00

4 - 67

BRUSH REPLACEMENT & ARMATURE TEST (CV19/CV21/CV23)

ELECTRICAL

NOTE: Shorts between bars are sometimes caused by dirt or copper between bars. Clean and retest before replacing armature.

M55917

4. Clean stud terminal, if threads are stripped replace stud. 5. Replace insulator if cracked. 6. Clean contact points of positive brushes. Using an ohmmeter, check for no continuity between positive brushes and end cap and stud terminal and end cap. Replace brushes if continuity is indicated.

M55923

9. Check for grounded windings using an ohmmeter. If any continuity is indicated the winding is grounded and must be replaced.

IMPORTANT: Use mineral spirits only to clean armature windings.

NOTE: If commutator is grooved or damaged, turn it on a lathe or replace it. 7. Clean commutator of armature with crocus cloth. DO NOT use emery cloth. M55924

NOTE: Armature windings are connected in parallel, each bar must be tested. 10. Check for open windings with an ohmmeter. If no continuity is indicated, there is an open circuit and armature must be replaced. 11. Match upper case marks and carefully assemble top end cap and armature in frame.

M46892

8. Rotate armature on a growler while holding a steel strip (hacksaw blade) on armature. Strip will vibrate in area that is shorted.

4 - 68

3/7/00

ELECTRICAL

STARTING MOTOR REMOVAL & INSTALLATION (CV25)

M55919

12. Compress brushes into brush holders of bottom end cap using two thin screwdrivers.

D C

B A

M99747

13. Match lower case marks and carefully assemble starting motor so brushes rest on commutator. Remove screwdrivers carefully. 14. Install long cap screws and tighten evenly.

STARTING MOTOR REMOVAL & INSTALLATION (CV25) Procedure: 1. Park machine on level surface. 2. Turn key switch to OFF position. 3. Move Forward/Reverse pedals to NEUTRAL position. 4. Engage park brake. 5. Raise hood. 6. Disconnect battery negative terminal (–).

3/7/00

10. Position starting motor on engine. Install the capscrews (D) and the lifting bracket (E). Tighten capscrews to 24 N•m (216 lb-in.). 11. Connect battery cable (A) and signal wire (B) to starting motor solenoid and reconnect battery negative cable. 12. Install the capscrew (C) securing the oil filler tube to the lifting bracket and tighten to 7.8 N•m (69 lbin.). Specifications: Starting Motor Capscrews. . . . . . 24 N•m (216 lb-in.) Oil Filler Tube Capscrews . . . . . . 7.8 N•m (69 lb-in.)

4 - 69

STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25)

ELECTRICAL

STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25) Disassembly:

Nut

M95075 E D

1. Remove nut securing braided copper wire to solenoid. 2. Slide wire off of solenoid lug.

Nuts

M95076 H G

3. Remove nuts from solenoid mounting bolts.

NOTE: Solenoid plunger is hooked over solenoid shift lever in starting motor housing. M94902

A - Front Cover B - Shift Lever C - Solenoid D - Retaining Clip E - Pinion Stopper F - Pinion G - Armature H - End Cover I - Insulator J - Brush Springs K - Brush Holder L - Brush

4. Slide solenoid out of staring motor housing and lift away from starting motor housing to remove plunger from shift lever.

Plunger

NOTE:

4 - 70

M95078

Check for available service parts before disassembling motor. 3/7/00

STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25)

ELECTRICAL

5. Inspect plunger for wear or damage. Press plunger into solenoid to check spring compression and freedom of movement. 6. If the solenoid plunger is broken, does not move freely, or there is little or no spring tension, replace the solenoid.

Shift Lever

M95084

M95077

10. Inspect the shift lever for damage. Ensure that shift lever operates pinion gear. If the shift lever is damaged or does not move the pinion gear in and out of starting motor, replace the lever.

7. Using a multimeter or ohm meter, check the following for correct resistance: A to B . . . . . . . . . . . . . . . . . . . . . . . . . .No Continuity B to C . . . . . . . . . . . . . . . . . . . . . . . . . .No Continuity A to C . . . . . . . . . . . . . . . . . . . . . . . Less than 1 ohm A and C to solenoid housing . . . . . . . . 1 to 2 ohms 8. If the resistance measured is not correct, replace the solenoid. Shift Lever M95079

11. Remove the two bolts securing the starting motor housing halves together. Slide the armature housing off of the starting motor. 12. Remove the shift lever and pivot. Pinion Gear Pinion Gear

M95083

9. Inspect starting motor pinion gear. The pinion gear should rotate and slide on the armature shaft smoothly.

Commutator

Armature

M95080

13. Remove the armature assembly from starting motor housing.

3/7/00

4 - 71

STARTING MOTOR DISASSEMBLY & ASSEMBLY (CV25)

c CAUTION

ELECTRICAL

Shift Lever

DO NOT use emery cloth to clean the commutator. The particles from the cloth will become embedded in the commutator and cause rapid brush wear.

NOTE:

The armature should not be soaked in a cleaning solution. Fine sandpaper, such as crocus cloth, can be used to clean the armature.

14. Check the brushes should for proper seating, weak brush springs, dirt, oil or corrosion. When all parts have been thoroughly cleaned, lightly lubricate the bearings with #20 oil.

M95084

4. Liberally lubricate shift lever with grease. 5. Install solenoid to starting motor. Ensure solenoid plunger seats over shift lever fork.

Nuts

Assembly:

Collar

M95076

Shift Lever M95079

1. Place armature in housing end. 2. Install shift lever. Ensure shift lever fork is seated in pinion gear shift collar. 3. Install armature housing, brush housing and end cap over armature. Secure with two long cap screws

6. Secure solenoid with two nuts.

Nut

M95075

7. Carefully slide braided copper wire over solenoid lug. Secure wire to lug with flange nut.

4 - 72

3/7/00

CONTENTS

POWER TRAIN—GEAR

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 BELT DRIVE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TRANSAXLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MANUAL SHIFT LINKAGE COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . 7 CLUTCH PEDAL LINKAGE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 8

TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MACHINE WILL NOT MOVE IN FORWARD OR REVERSE . . . . . . . . . . . . . . . . . . 10 MACHINE WILL NOT MOVE IN FORWARD OR REVERSE . . . . . . . . . . . . . . . . . . 12 MACHINE MOVES IN ONE DIRECTION ONLY, OR DOESN’T MOVE IN ONE OR MORE GEARS. . . . . . . . . . . . . . . . . . . . . . . . . 14 LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE. . . . . . . . . . . . . . . 16 LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE. . . . . . . . . . . . . . . 18 JERKY AND AGGRESSIVE ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SHIFTS HARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 NOISY OPERATION, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 GEARSHIFT LEVER NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 TRACTION DRIVE BELT TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 28

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TRANSAXLE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 TRANSAXLE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DIFFERENTIAL REMOVAL, DISASSEMBLY AND INSTALLATION . . . . . . . . . . . . . 39 TRACTION DRIVE CLUTCH ASSEMBLY REMOVAL AND INSTALLATION . . . . . . 41 TRACTION DRIVE BELT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . 42

3/3/00

5-1

NOTES

5-2

POWER TRAINâ&#x20AC;&#x201D;GEAR

3/3/00

SPECIFICATIONS

POWER TRAIN—GEAR

SPECIFICATIONS Model Peerless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 Speeds Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gear Speed Range Forward 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 km/h (1.3 mph) 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 km/h (1.9 mph) 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 km/h (2.7 mph) 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 km/h (3.3 mph) 5th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 km/h (4.4 mph) 6th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 km/h (6.1 mph) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 km/h (2.9 mph)

ADJUSTMENT SPECIFICATIONS Clutch Spring Assembly (dimension between caps) . . . . . . . 31 – 33 mm (1.2 – 1.3 in.)

REPAIR SPECIFICATIONS Shift Key Height . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 – 11.68 mm (0.400 – 0.460 in.) Transaxle Case Cover Inside Needle Bearing (depth below inside case surface) . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 mm (0.150 in.) Pinion Gear Bearings (depth below each end of pinion gear) . . . . . . 3.6 mm (0.142 in.) Grease Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.06 L (32 oz.)

TORQUE SPECIFICATIONS Transaxle-to-Frame Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (80 lb-in.) Transaxle Case Cover-to-Case Cap Screw Torque . . 20.3 – 24.4 N•m (180 – 216 lb-in.) Reduction Bearing Cap-to-Transaxle Case . . . . . . . . . 10.2 – 11.2 N•m (90 – 100 lb-in.) Front Case Supports to Transaxle Case . . . . . . . . . . . . . . . . . . . . . . 27 N•m (240 lb-in.) Clutch Pedal Bracket-to-Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (300 lb-in.)

OTHER MATERIALS Number

Name

Use

AN102562

Corn Head Grease

Apply to all internal parts of transaxle

3/7/00

5-3

THEORY OF OPERATION

POWER TRAINâ&#x20AC;&#x201D;GEAR

THEORY OF OPERATION BELT DRIVE SYSTEM OPERATION

Engine Drive Sheave

Tensioning V-Idler

Clutch Actuating Spring

Belt Tension Spring Clutch Lever

Clutch Pedal

Clutch Shaft Drive Belt Bellcrank Assembly Transaxle Drive Sheave M83362

Function: The function of the clutching system is to transfer power from the engine drive sheave through the drive belt and bellcrank tensioning assembly to the transaxle drive sheave. This system also allows the power to be interrupted in order to stop the tractor while in gear, or to change to a different gear. Theory of Operation: The clutch pedal is located on the left side of the vehicle and is operated by the operators left foot. The clutch is also operated whenever the brake is applied. As the clutch pedal is depressed, the clutch shaft rotates and the arm welded to the clutch shaft pulls the clutch actuating spring forward. Initial movement of the pedal compresses the actuating spring; once compressed, it transfers forward movement into rotating movement of the bellcrank assembly. As the

5-4

bellcrank is rotated drive belt tension is released, allowing the drive belt to slip on the engine drive sheave due to slack now present in the drive belt. When the clutch is in the fully depressed position, the operator can shift the transaxle into any gear (forward, neutral, or reverse) As the clutch pedal is released the bellcrank assembly rotates to its original position and gradually applies tension to the drive belt. This allows power to be transferred from the rotating engine drive sheave through the drive belt to the transaxle drive sheave. At the same time, the spring loaded movement of the bellcrank tensioning assembly is transferred through the clutch actuating spring to the clutch shaft arm, clutch shaft, and clutch pedal; bringing the pedal back to the top of its travel as the operator removes his left foot from the clutch pedal.

3/7/00

POWER TRAIN—GEAR

THEORY OF OPERATION

TRANSAXLE OPERATION

Reverse Theory of Operation:

Function:

A chain connects the reduction shaft sprocket to the shift shaft sprocket. Because of the chain drive, the shift shaft sprocket turns in the reverse direction of the gears on the shift shaft. The shift shaft sprocket spins freely on the shift shaft when reverse is not selected.

The gear transaxle provides a means of transferring power from the drive system, from the engine through the drive belt, to the rear wheels. It also provides a means of controlling the movement, forward or reverse, and the ground speed of the vehicle and also disconnecting power from the drive system to the drive wheels (neutral). Neutral Theory of Operation: The transaxle drive sheave is keyed to the input shaft. Splined to the inboard end of the input shaft is a bevel gear that engages the bevel gear splined to the reduction shaft. Also splined to the reduction shaft are the 1st—5th gears and the reverse sprocket. Whenever the input shaft is turning, so are the 1st – 5th gears and the reverse sprocket.

When the transmission is shifted into reverse, the shift fork and shift collar move the keys into pockets in the shift shaft sprocket. The shift shaft sprocket transfers power through the keys to the shift shaft which now turns in the reverse (opposite) direction. This transfers power to the shift shaft output gear, through the transfer shaft gears, to the external differential carrier gear. The differential carrier transfers power through the pinned differential pinion gears. These pinion gears mesh with the bevel gears that are splined to the drive axles. Power is then transferred out the drive axles to the rear drive wheels, which are keyed to the axles, moving the tractor in a rearward direction.

The 1st – 5th shift shaft gears are in constant mesh with the 1st – 5th reduction shaft gears and are turning in freewheeling fashion on the shift shaft. The shift shaft sprocket is driven by the chain connected to the sprocket on the reduction shaft. When the shift lever is in neutral position, the shift fork and collar places the shift keys in the neutral spacers thus allowing all gears, and sprocket, to spin freely on the shift shaft and no power is transmitted to the shift shaft. Forward Theory of Operation (1st – 5th GEARS): The shift shaft has 4 keyways that hold the shift keys. The shift keys are retained by the shift collar which is actuated by the shift fork. The shift fork is connected by a linkage to the operator controlled shift lever. When the operator selects a gear by moving the shift lever the linkage moves the shift fork inside the transaxle. As the shift fork is moved it slides the shift collar, with the shift keys, along the shift shaft until the shift keys engage the pockets of the selected gear, or the reverse sprocket. Once a gear is selected, power from the gear is transferred to the shift shaft through the shift keys. The shift shaft output gear transfers power to the reduction shaft gears, which meshes with the differential carrier gear. The differential carrier transfers power through the differential pinion gears. These pinion gears mesh with the bevel gears that are splined to the drive axles. Power is then transferred out the drive axles to the rear drive wheels, which are keyed to the axles, moving the tractor in a forward direction at the desired ground speed.

3/7/00

5-5

THEORY OF OPERATION

5-6

Shifter Collar Reverse Shifter Shaft Sprocket

Shifter Keys Shifter Fork

Shifter Gears (1st—5th)

Shifter Shaft Input Shaft

Input Sheave

Reduction Shaft

Reverse Reduction Sprocket

Reduction Gears (1st—5th) Bevel Transfer Gear

M83364

3/7/00

POWER TRAIN—GEAR

Moving Components

Bevel Input Drive Gear

THEORY OF OPERATION

POWER TRAIN—GEAR

MANUAL SHIFT LINKAGE COMPONENT LOCATION Knob Nut LH Bearing Flange Nut

Flange Nut

(4 used)

Shift Arm

LH Star Washer Cap Screw

Shift Lever / Shaft RH Bearing (adjustable)

Cap Screw Ball Joint Link

Lock Nut Cap Screw 15 N•m (133 lb-in.) Washer

Cap Screw (2 used)

Flange Nut Transmission Shift Arm Washer RH Star Washer (between lock washer and frame) Lock Washer Belt Guide Flange Nut

(2 used)

M54717

3/7/00

5-7

THEORY OF OPERATION

POWER TRAIN—GEAR

CLUTCH PEDAL LINKAGE COMPONENT LOCATION

Tensioning Bellcrank Assembly

Spring Cap (2 used) Clutch Pedal Actuating Rod (2 used) Belt Tensioning Spring

Clutch Actuating Spring

Nut (3 used) 34 N•m (300 lb-in.)

Cap Screw (3 used)

Clutch Pedal Shaft Assembly

M54741A

5-8

3/7/00

TROUBLESHOOTING CHART

POWER TRAIN—GEAR

Brake linkage damaged.

●

Drive belt broken, worn, etc.

●

Wrong grease in transaxle.

●

Shift linkage out of adjustment or damaged.

●

Engine/transaxle sheaves worn or damaged.

●

Clutch pedal springs/linkage damaged.

●

Differential gears damaged.

●

Internal transaxle damage.

●

Belt tension out of adjustment.

●

Bellcrank assembly worn or damaged.

●

Belt guides worn or damaged.

●

3/7/00

Noisy operation.

Shifts hard.

Jerky and aggressive engagement.

Loses power under load, belt slips, erratic drive.

Check or Solution

Machine will not move in forward or reverse.

Problem or Symptom

Machine moves in one direction only or doesn’t move in one or more gears.

TROUBLESHOOTING CHART

●

5-9

DIAGNOSIS

POWER TRAIN—GEAR

DIAGNOSIS MACHINE WILL NOT MOVE IN FORWARD OR REVERSE Test Conditions: • Key switch in STOP position. • Transaxle in NEUTRAL.

• Machine parked on a level surface. • Wheels blocked. • Park brake RELEASED.

Test/Check Point

Normal

If Not Normal

1. Brake linkage and arm.

Moves freely.

Check linkage and adjustment. Check brake disk to shoe adjustment.

2. Traction drive belt.

Not broken, worn, frayed, glazed or stretched.

Replace traction drive belt.

3. Belt tension – measured at clutch spring.

Spring coil length: 31 – 35 mm (1.2 – 1.3 in.).

Adjust belt tension. (See ‘TRACTION DRIVE BELT TENSION ADJUSTMENT’ on page 28.)

4. Engine and transaxle sheaves.

Tight on shafts, No damage to drive keys, not distorted. No evidence of belt riding in bottom of groove.

Replace damaged sheave and/or keys.

5. Shift lever and linkage.

Properly adjusted. Actuates transaxle into all gear ranges. Does not lock in any gear and shifts smoothly.

Adjust linkage. (See ‘GEARSHIFT LEVER NEUTRAL ADJUSTMENT’ on page 28.)

6. Clutch pedal and bellcrank linkage.

Not binding or damaged.

Eliminate binding. Replace damaged or faulty components.

7. Belt tensioning spring.

Spring holds bellcrank and belt in tension when clutch is disengaged. Not stretched or fatigued.

Replace stretched or fatigued spring.

5 - 10

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

3 1 7

4 6 2 6

1 4

5 1

M85614

3/7/00

5 - 11

DIAGNOSIS

POWER TRAIN—GEAR

MACHINE WILL NOT MOVE IN FORWARD OR REVERSE Test Conditions: • Raise and support rear wheels off the ground and observe. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area. OR • Test drive on a level surface and up a 30° (or less) grade. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area.

Test/Check Point

Normal

If Not Normal

1. Input shaft bevel pinion and reduction shaft bevel gear.a

Gear teeth not chipped or worn. Splines not worn or striped. Positive engagement.

Replace damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

2. Shifter fork and collar.a

Slide smoothly on shifter shaft. Positive detents felt in all gears. Not bent or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

3. Shifter shaft, keys, gears, and reverse sprocket.a

Positive and smooth operation in all gears. Engages positively in pockets of gears and sprocket. Not worn or damaged. Splines in good condition.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

4. Reduction shaft, gears and reverse sprocket.a

Positive and smooth operation in all gears. Splines not worn or damaged. Gear and sprocket teeth not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

5. Shifter shaft, drive gear, and reverse sprocket and chain.a

Positive and smooth operation in all gears. Not worn or damaged. Gear pockets not worn. Chain in good condition.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

6. Differential transfer drive gear and carrier gear.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

7. Differential bevel pinion gears and axle bevel drive gears and splines.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

8. Axle shafts, bushings, ball bearings, keys and keyways, and snap rings.a

Positive and smooth operation in all gears. Axles straight, not worn or damaged. Keys and keyways and snap rings in good shape.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

Requires removal of transaxle from machine and disassembly.

5 - 12

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

8 12

11 11

13 15

14 M85614

3/7/00

5 - 13

DIAGNOSIS

POWER TRAIN—GEAR

MACHINE MOVES IN ONE DIRECTION ONLY, OR DOESN’T MOVE IN ONE OR MORE GEARS Test Conditions: • Raise and support rear wheels off the ground and observe. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area. OR • Test drive on a level surface and up a 30° (or less) grade. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area.

Test/Check Point

Normal

If Not Normal

Shift linkage moves freely; must actuate transaxle gear selector into all ranges and directions. Shift lever should not bottom in quadrant.

Adjust linkage. (See ‘GEARSHIFT LEVER NEUTRAL ADJUSTMENT’ on page 28.)

Linkage not worn or damaged.

Replace worn or faulty components. (See ‘GEARSHIFT LEVER NEUTRAL ADJUSTMENT’ on page 28.)

2. Shifter fork and collar.a

Positive detents felt in all gears. Slides smoothly. Not bent or damaged.

Replace worn or damaged components. (See ‘DIFFERENTIAL REMOVAL, DISASSEMBLY AND INSTALLATION’ on page 39.)

3. Shifter shaft and keys.a

Positive and smooth operation in all gears. Not damaged or worn at ends. Tension when engaged in gear or sprocket pockets.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

4. Input shaft bevel pinion gear, reduction shaft bevel drive gear, reduction gears and reverse sprocket and splines.a

Positive and smooth operation in all gears. Splines not worn or damaged. Gear and sprocket teeth not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

5. Shifter shaft, gears and reverse sprocket.a

Positive and smooth operation in all gears. Gear and sprocket teeth not worn or damaged. Engagement pockets not worn.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

6. Reverse chain.a

Positive and smooth operation. Not worn or damaged, no excessive slack. Engages sprocket teeth. Does not ratchet on sprockets.

Replace chain. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

1. Shift lever and linkage.

Requires removal of transaxle from machine and disassembly.

5 - 14

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

3 5

5 4

M83526 M85614

3/7/00

5 - 15

DIAGNOSIS

POWER TRAIN—GEAR

LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE Test Conditions: • Machine parked on a level surface. • Key switch in OFF position. • Wheels blocked. • Park brake RELEASED. • Transaxle in NEUTRAL. • Clutch pedal DISENGAGED.

Test/Check Point

Normal

If Not Normal

1. Traction drive belt.

Not worn, frayed, glazed or stretched. Routed correctly.

Replace traction drive belt. (See ‘TRACTION DRIVE BELT REMOVAL AND INSTALLATION’ on page 42.)

2. Belt tension – measured at clutch spring.

Spring length: 31 – 35 mm (1.2 – 1.3 in.).

Adjust belt tension. (See ‘TRACTION DRIVE BELT TENSION ADJUSTMENT’ on page 28.)

3. Engine and transaxle sheaves.

Tight on shaft. No damage to drive keys, not distorted. No evidence of belt riding in bottom of groove.

Replace faulty sheave(s).

4. Bellcrank assembly.

Moves freely, does not bind, not bent or damaged.

Eliminate binding. Repair or replace damaged components.

5. Belt tensioning spring.

Spring holds belt in tension when clutch is disengaged. Not stretched or fatigued.

Replace stretched or fatigued spring.

6. Clutch pedal and linkage.

Has complete travel. Not binding or damaged.

Eliminate binding. Replace damaged or faulty components. (See ‘CLUTCH PEDAL LINKAGE COMPONENT LOCATION’ on page 8.)

7. Shift lever and linkage.

Linkage not binding. Detents and linkage hold selected position.

Replace worn or faulty components. (See ‘CLUTCH PEDAL LINKAGE COMPONENT LOCATION’ on page 8.)

5 - 16

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

6 7 3

3 1 4 7 3

M85614

3/7/00

5 - 17

DIAGNOSIS

POWER TRAIN—GEAR

LOSES POWER UNDER LOAD, BELT SLIPS, ERRATIC DRIVE Test Conditions: • Raise and support rear wheels off the ground and observe. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area. OR • Test drive on a level surface and up a 30° (or less) grade. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area.

Test/Check Point

Normal

If Not Normal

8. Input bevel pinion gear and reduction bevel gear.a

Gear teeth not chipped or worn. Positive engagement.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

9. Shifter shaft, keys, gears, and reverse sprocket and chain.a

Positive and smooth operation in all gears. Engages positively in pockets of gears and sprocket. Not worn or damaged.

Replace worn or damaged components.(See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

10. Reduction shaft, gears and reverse sprocket.a

Positive and smooth operation in all gears. Splines not worn or damaged. Gear and sprocket teeth not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

11. Differential transfer drive gear and carrier gear.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

12. Differential bevel pinion gears and axle bevel gears and splines.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

13. Axle shafts, bushings, ball bearings, keys and keyways, and snap rings.a

Positive and smooth operation in all gears. Axles straight, not worn or damaged. Keys and keyways and snap rings in good shape.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

Requires removal of transaxle from machine and disassembly.

5 - 18

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

11 13

M85614

3/7/00

5 - 19

DIAGNOSIS

POWER TRAIN—GEAR

JERKY AND AGGRESSIVE ENGAGEMENT Test Conditions: • Machine parked on a level surface. • Key switch in STOP position. • Transaxle in NEUTRAL. • Clutch pedal DISENGAGED.

Test/Check Point

Normal

If Not Normal

1. Traction drive belt.

Correct belt for application. Belt in good condition, not glazed, worn, or frayed.

Install correct drive belt. (See ‘TRACTION DRIVE BELT REMOVAL AND INSTALLATION’ on page 42.)

2. Engine and transaxle sheaves.

Installed and functioning properly. Not distorted or damaged. V-groove clean and dry. Belt guides adjusted properly.

Clean or replace sheave(s). Properly adjust belt guides.

3. Belt tension – measured at clutch spring.

Spring length: 31 – 35 mm (1.2 – 1.3 in.). Not stretched or distorted.

Properly adjust belt tension or replace worn or damaged components. (See ‘TRACTION DRIVE BELT TENSION ADJUSTMENT’ on page 28.)

4. Belt tensioning spring.

Correct spring, installed correctly. Not stretched or distorted.

Replace spring.

5. Bellcrank assembly.

Moves freely through travel, does not bind, not distorted. Idlers operate smoothly and quietly.

Repair or replace bellcrank assembly.

6. Clutch pedal, shaft, and arm.

Obtains full travel, does not bind. Not worn or distorted.

Eliminate binding. Replace damaged or faulty components.

5 - 20

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

M83528

3/7/00

5 - 21

DIAGNOSIS

POWER TRAIN—GEAR

SHIFTS HARD Test Conditions: • Machine parked on a level surface. • Key switch in STOP position. • Transaxle in NEUTRAL. • Clutch pedal DISENGAGED.

Test/Check Point

Normal

If Not Normal

1. Shift lever and linkage.

Moves freely throughout normal travel.

Repair faulty components and adjust linkage. (See ‘GEARSHIFT LEVER NEUTRAL ADJUSTMENT’ on page 28.)

2. Transaxle control arm.

Properly installed. Not worn or distorted.

Replace control arm.

3. Transaxle.

Filled with correct grease.

Fill transaxle with correct lubricant.

Test Conditions: • Raise and support rear wheels off the ground and observe. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area. OR • Test drive on a level surface and up a 30° (or less) grade. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area.

Test/Check Point

Normal

If Not Normal

4. Transaxle.a

Internal components not rusty or damaged.

Clean or replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

5. Shifter fork and collar.a

Positive and smooth operation in all gears. Not binding, worn or damaged.

Eliminate binding, replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

6. Shifter shaft keys and keyways, gears, and reverse sprocket.a

Positive and smooth operation in all gears. Keys not worn, damaged, rusted or binding.

Replace keys. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

Requires removal of transaxle from machine and disassembly.

5 - 22

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

1 3

3/7/00

M83529

5 - 23

DIAGNOSIS

POWER TRAIN—GEAR

NOISY OPERATION Test Conditions: • Machine parked on a level surface. • Key switch in STOP position. • Transaxle in NEUTRAL. • Clutch pedal DISENGAGED.

Test/Check Point

Normal

If Not Normal

1. Traction drive belt.

Not worn, frayed, glazed or stretched. Routed correctly.

Replace traction drive belt. (See ‘TRACTION DRIVE BELT REMOVAL AND INSTALLATION’ on page 42.)

2. Belt tension.

Properly tensioned.

Perform traction drive belt tension adjustment. (See ‘TRACTION DRIVE BELT TENSION ADJUSTMENT’ on page 28.)

3. Engine and transaxle sheaves, idlers.

Not distorted or damaged.

Replace faulty sheave(s) and/or idler(s).

4. Bellcrank assembly.

Moves freely, does not bind. Components not damaged.

Eliminate binding, replace worn or damaged components.

5. Belt guides.

Installed correctly, not damaged.

Repair or replace belt guides.

6. Transaxle.

Filled to proper level with correct grease.

Fill transaxle with correct lubricant.

7. Brake assembly.

Adjusted to specifications.

Adjust brakes.

Brake assembly not worn.

Repair or replace worn or damaged components. (See “BRAKE REMOVAL AND INSTALLATION— GEAR TRANSAXLE” on page 14 in BRAKE SECTION.)

5 - 24

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

5 3

4 5

1 3

5 3 6 7

M83529

3/7/00

5 - 25

DIAGNOSIS

POWER TRAIN—GEAR

NOISY OPERATION, continued Test Conditions: • Raise and support rear wheels off the ground and observe. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area. OR • Test drive on a level surface and up a 30° (or less) grade. • Engine running at FAST idle. • Operate machine in all gears to isolate the problem area.

Test/Check Point

Normal

If Not Normal

8. Reduction shaft, gears, sprocket and chain.a

Positive and smooth operation in all gears. Splines not worn or damaged. Gear and sprocket teeth and chain not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

9. Shifter shaft, gears, sprocket and chain.a

Positive and smooth operation in all gears. Not worn or damaged. Gear pockets not worn. Sprocket teeth and chain not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

10. Differential bevel pinion gears, bevel drive gears and splines.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

11. Differential transfer drive gear and carrier gear.a

Positive and smooth operation in all gears. Not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

12. Axle shafts and ball bearings.a

Positive and smooth operation in all gears. Axles straight, not worn or damaged.

Replace worn or damaged components. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.)

Requires removal of transaxle from machine and disassembly.

5 - 26

3/7/00

DIAGNOSIS

POWER TRAINâ&#x20AC;&#x201D;GEAR

11 12 12

3/7/00

M85615

5 - 27

ADJUSTMENTS

POWER TRAIN—GEAR

ADJUSTMENTS

TRACTION DRIVE BELT TENSION ADJUSTMENT

GEARSHIFT LEVER NEUTRAL ADJUSTMENT

Reason: To maintain proper drive belt tension so belt does not slip, and to position belt guides so that belt jumping is minimized.

Reason: To ensure that the transaxle can achieve all ranges and directions available. It also ensures that the selector lever is coordinated with the markings on the shift quadrant. Procedure:

Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Place transaxle in NEUTRAL. 4. Park brake locked to release belt tension. 5. Remove mower deck.

Front

1. Park machine on level surface. 2. Turn key switch OFF. 3. Place transaxle in NEUTRAL.

31 – 35 mm (1.2 – 1.3 in.) Shift Lever Linkage Nuts

M45742

M89801

Front

4. Loosen shift lever linkage nuts located on each side of the frame behind the rear wheels. 5. Slide the bracket forward or rearward to position the gear selector lever in the center on the neutral slot on shift quadrant. Tighten nut. 6. Check that the gear selector lever will engage in all ranges and directions. If not, adjust the position of the lever slightly to achieve all gears.

6. Unlock park brake to tension drive belt. 7. Check that the belt is adjusted properly. The dimension between the inside edges of the end caps on the ends of the clutch actuating spring should be 31 – 33 mm (1.2 – 1.3 in.).

Tensioning V-Idler

Belt Guide

Nut

Drive Belt

Results: • The gear selector lever should be in neutral position when the transaxle is in neutral. • The transaxle should be able to achieve all speed ranges and direction selections, without bottoming the lever in the quadrant.

M45741

8. Lock park brake to release drive belt tension.

NOTE: Moving front tensioning v-idler towards the FRONT of the machine will shorten the clutch spring. Moving the front tensioning v-idler towards the BACK of the machine will increase the clutch spring length. 9. Move front (engine) tensioning v-idler outward and

5 - 28

3/7/00

REPAIR

POWER TRAIN—GEAR

forward to increase belt tension, or move it rearward and inward to decrease belt tension. 10. At the same time adjust tensioning v-idler belt guide so it is parallel with and approximately 3.2 mm (0.125 in.) away from belt and v-idler. Tighten fastening nut. 11. Unlock park brake to tension drive belt and remeasure clutch actuating spring cap lips dimension after each adjustment. (See step #7) 12. Repeat adjustment procedure until specified measurement is obtained or replace belt.

Front

Engine Drive Sheave

Front Tensioning V-Idler

Drive Belt

REPAIR TRANSAXLE REMOVAL AND INSTALLATION Removal: 1. Remove fender deck. (See “FENDER DECK REMOVAL AND INSTALLATION” on page 9 in MISC. SECTION.) 2. Remove traction drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 42.) 3. Depress clutch pedal and lock park brake. 4. Safely lift the rear of the machine and place appropriate sized jackstands under both sides of frame.

Clutch Lever Clutch Pedal

Clutch Actuating Spring

Clutch Shaft Tensioning Bellcrank Assembly

C-Clip Washer

V-Idler

Flat Idler Belt Tensioning Spring

Transaxle Input Sheave

M89747 M85616

Top View

5. Remove dust cover from both rear axles. Remove C-clip and washer from end of axle. Slide rear wheels and hubs off of axles.

Shift Link

Front Belt Guide

Drive Belt

Cap Screws

Rear Belt Guide M54715

3/7/00

5 - 29

REPAIR

POWER TRAIN—GEAR

6. Remove cap screw securing right side of rear belt guide to frame. Remove belt guide. 7. Remove drive belt from driven sheave. 8. Disconnect shift link from transaxle. 9. Remove two (2) cap screws connecting front transaxle mounts to transaxle. Remove front belt guide.

TRANSAXLE DISASSEMBLY AND INSPECTION 1. Thoroughly clean and dry the outside of the transaxle. Shift Lever Front Support

Front Support

Brake Rod Snap Ring Drive Sheave

M M54715

Nut (4 used) 9 N•m (80 lb-in.)

10. Remove cotter pin securing brake rod to brake arm. Remove brake rod aside. 11. Disconnect brake link from transaxle. 12. Support transaxle with a floor jack. 13. Remove four (4) nuts securing transaxle to frame. Remove transaxle from frame.

2. Remove cap screws and front support. 3. Remove snap ring. 4. Remove transaxle drive sheave and key. 5. Remove nut securing shift lever to shift shaft. Remove shift lever. Brake Lever Nut

Installation:

Shield

Installation is done in the reverse order of removal. • Tighten six (6) transaxle mounting nuts to 9 N•m (80 lb-in.).

Cap Screw

M54709

6. Remove nut securing brake lever to brake housing. 7. Remove cap screws securing brake assembly to transmission housing. 8. Remove brake lever and shield.

5 - 30

3/7/00

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

15. Push shift shaft down while lifting top case half off lower case half. Differential Assembly

Brake Disk Outer Brake Pad

Plate

Housing

Pins M89806

9. Remove pins, housing, plate, and outer brake pad. 10. Remove brake disk. 11. Remove inner brake pad from recess in transmission housing.

16. Remove differential assembly from lower case half. Shift Fork

Allen Head Screw Spring

Detent Ball M898

M898

17. Remove excess grease from cover and lower case. 18. Remove shifter fork assembly.

12. Remove allen head screw. 13. Remove spring and detent ball with a magnet.

Transfer Shaft

Cap Screws (17)

Shift Shaft M898 M89800

19. Remove transfer shaft assembly. 14. Remove 17 cap screws. Tap sides of case with a plastic hammer to separate case halves. 3/7/00

5 - 31

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

Washer

O-Ring

Washer O-Ring Reduction Shaft

Needle Bearing Needle Bearing Gear

M89815

20. Remove needle bearing, O-ring, and washer from each end of transfer shaft. 21. Remove gear from one end of transfer shaft.

Shifter Shaft

M89805

25. Lift shifter shaft and reduction shaft assemblies out of case as a unit. Needle Bearing

Washer

O-Ring

Thrust Washers

Transfer Shaft M89818

Needle Bearing Thrust Bearing

22. Inspect transfer shaft for damage to splines, gear, and bearing surfaces. If damaged, replace transfer shaft. 23. Inspect needle bearing surfaces. If scored or discolored, replace transfer shaft.

Bearing Cap

M89808

26. Remove needle bearing, O-ring, and washer from sprocket end of reduction shaft. 27. Remove needle bearing, O-ring, thrust washer, thrust bearing and second thrust washer from large gear end of reduction shaft.

M50401 M89804

24. Remove cap screws securing bearing cap to housing. Remove bearing cap.

5 - 32

3/7/00

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

34. Remove neutral spacers from shift shaft. 35. Remove sprocket from shift shaft. 36. Remove washer from shift shaft. 37. Remove needle bearing, O-ring, washer, and gear from collar end of shift shaft. 38. Remove double snap rings from shift shaft. 39. Remove shift collar and keys from shift shaft. 40. Inspect all components for wear or damage. Replace as required.

Reduction Shaft Bevel Gear Sprocket Chain

M89809

10.16 - 11.68mm (0.400 - 0.460 in.)

Shift Shaft

28. Withdraw reduction shaft through gear pack until it clears sprocket and bevel gear. Disengage and remove gear pack with reduction shaft. 29. Disassemble and clean gear pack and reduction shaft. Note orientation of gears and bevel gear. 30. Remove reduction shaft sprocket from chain. 31. Remove chain from sprocket on shift shaft.

41. Inspect keys for damage. Replace as required. 42. Place keys on a flat surface and measure from surface to top of key. If not in specification, replace key.

Cup Washer O-Ring O-Ring

M89814

Needle Bearing

M89812

32. Remove needle bearing, O-rings, and cup washer from end of shift shaft. 33. Remove gear pack from shift shaft.

43. Inspect shift shaft for damage to splines, shift key slots, and bearing surfaces. 44. Measure needle bearing surfaces. If not in specifications, replace shift shaft. 45. Measure shaft O.D. in several places in gear pack area. If not in specifications, replace shift shaft.

Neutral Spacers

Washer

Sprocket

Snap Rings

Shift Collar

M89811

M89813

Gear Needle Bearing

3/7/00

46. Inspect reduction shaft for damage to splines, and bearing surfaces.

5 - 33

REPAIR

POWER TRAIN—GEAR

47. Inspect needle bearing surfaces. If scored or discolored, replace reduction shaft. Specifications

Snap Ring

Shift Key Height . . . . . . . . . . . . . . . 10.16 – 11.68 mm (0.400 – 0.460 in.)

Ball Bearing Input Shaft

Key

Snap Ring

Needle Bearing Seal Large Washer O-Ring

M89819

Thrust Washer (Small) Thrust Bearing

48. In not already done, remove key from input shaft. 49. Remove snap ring from input shaft.

Thrust Washer (Small) Cupped Washer

NOTE: Use a fine cut file to remove any burrs around key slot or end of input shaft prior to attempting to remove input shaft from bearings.

Pinion Gear Snap Ring M89821

Pinion Gear Cupped Washer With Thrust Washer Assembly Input Shaft

53. Remove cupped washer with thrust bearing assembly from input shaft. Disassemble, clean and inspect thrust washer components. Replace as required. 54. Remove snap ring and pinion gear from input shaft. Inspect pinion teeth and internal splines for wear or damage. Replace as required.

Input Shaft Seal Needle Bearing

Input Shaft

M89820

50. From inside of transmission case, remove input shaft with thrust bearing assembly and pinion gear 51. Remove input shaft seal from bore in case. 52. Inspect needle bearing and ball bearing in case for wear or damage. Replace only if necessary. If replacement is required use a bearing, bushing and seal driver set. Install upper bearing flush with case surface. Install lower bearing 3.8 mm (0.150 in.) below inside surface of case cover. Install seal tight to needle bearing.

5 - 34

M89822

55. Inspect input shaft for damage or wear. Inspect bearing surfaces of input shaft. If scored or discolored, replace input shaft. 56. Thoroughly clean all components and case halves with approved solvent and blow dry with less than 3/7/00

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

210 kPa (2 bar) (30 psi) compressed air. 57. Remove all remaining gasket material from case halves mating surfaces. 58. Inspect case halves for cracks, wear, or damage. Replace as necessary.

1. Assemble pinion gear on input shaft. Secure with snap ring. 2. Lubricate thrust washers and thrust bearing components with EP grease. Assemble in cup washer and place on input shaft. Pinion Gear

TRANSAXLE ASSEMBLY

Cupped Washer With Thrust Washer Assembly

IMPORTANT: Always install new seals and O-rings. Damaged or used seals and O-rings will leak.

Input Shaft

IMPORTANT: Needle bearings are lubricated with EP grease. Do not use Corn Head Grease on any needle bearing. For maximum gear train life use only Corn Head Grease on all shafts and gears. DO NOT use EP grease on shafts and gears. IMPORTANT: Apply John Deere Corn Head Grease (#AN102562) (or equivalent SAE #0, or J13E6 grease ) to all gears and shafts during assembly. Use 1.06 L (32 oz.) of grease during assembly and to pack transaxle.

Snap Ring

Input Shaft Seal Needle Bearing

M89820

3. If input shaft bearings and seal were removed use a bearing, bushing and seal driver set to install upper bearing flush with case surface. Pack needle bearing with EP grease and install needle bearing 3.8 mm (0.150 in.) below inside surface of case cover. Install seal tight to needle bearing. 4. From inside of transmission case, install input shaft with thrust bearing assembly and pinion gear.

Ball Bearing Input Shaft Snap Ring

Key

Needle Bearing Seal Thrust Washer O-Ring M89819

Thrust Washer (Small) Thrust Bearing Thrust Washer (Small)

5. Secure input shaft in case with snap ring.

NOTE: Liberally lubricate keys and shaft with Corn Head Grease during assembly.

Cupped Washer Pinion Gear Snap Ring M89821

3/7/00

5 - 35

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

Sprocket

Shifter Keys (4 used)

Neutral Spacers

Gears

Washer

Shifter Collar Recess

C-Clips (2 used) M89816

6. Position keys in keyways near end of shifter shaft. Install shifter collar, with recess toward keys, over key tabs. Slide collar and keys onto center of shaft. 7. Install two C-clips on shifter shaft. Do not place in groove at this time. 8. Slide keys under C-Clips. Move C-clips into groove. Needle Bearing O-Ring

Thrust Washer

Gear

C-Clips (2 used)

Large Radius

Thrust Washers (5 used)

Cup Washer

10. Install washer and reverse sprocket, with thicker shoulder away from shifter collar on shift shaft. 11. Install neutral spacers, with large inner diameters facing each other. Make sure that neutral spacer with larger internal radius shoulder is placed next to sprocket. 12. Install gear pack on shift shaft with thrust washers between gears. make sure that raised side of thrust washers faces first gear.

Collar

Cup Washer Shift Shaft

O-Ring

M89817

O-Ring

9. Install output gear, thrust washer, O-ring, and needle bearing on collar end of shifter shaft.

NOTE: Liberally lubricate gears and shaft with Corn Head Grease during assembly.

Needle Bearing

M89812

13. Install cup washer, with cup towards gear. O-ring, needle bearing, and second O-ring, on shift shaft.

5 - 36

3/7/00

REPAIR

POWER TRAIN—GEAR

Reduction Shaft Bevel Gear

Reduction Shaft

Sprocket Chain

M89809

Shift Shaft

14. Install chain on sprocket on shift shaft. 15. Install reduction shaft sprocket in chain. 16. Align bevel gear with sprocket. 17. Withdraw reduction shaft through gear pack until end is flush with end gear. Mate reduction shaft gear pack with gears on shift shaft. Push transfer shaft through gear pack, bevel gear, and sprocket. Needle Bearing

M89805

20. Install shift shaft and reduction shaft assemblies in case as a unit. 21. Make sure that needle bearing case seat firmly in respective saddles in transmission case.

Bearing Cap

Washer

O-Ring

Thrust Washers

Needle Bearing Thrust Bearing

M89804 M89808

22. Install bearing cap and secure with two cap screws. Torque to 10.2 – 11.2 N•m (90 – 100 lb-in.).

18. Install washer, O-ring, and needle bearing, on sprocket end of reduction shaft. 19. Install thrust washer, thrust bearing, second thrust washer, O-ring and needle bearing on small gear end of reduction shaft.

3/7/00

5 - 37

REPAIR

POWER TRAIN—GEAR

28. Install differential assembly in case. 29. Make sure shoulders on needle bearings are rotated into contact with case. 30. Pack remainder of the 1.06 L (32 oz.) of Corn Head Grease (or equivalent) around all transaxle components and wear areas in the bottom half of the transaxle case.

Transfer Shaft

Cap Screws (17 used) 20.3 – 24.4 N•m (180 – 216 lb-in.)

M89803

23. Assemble transfer gear on transfer shaft. 24. Install washer, O-ring, and needle bearing on each end of transfer shaft. 25. Install transfer shaft assembly in transaxle case. M89800

Shift Fork

31. Align shifter fork shaft with cover hole and install cover. Tighten 17 cap screws to 20.3 – 24.4 N•m (180 – 216 lb-in.).

Shifter Collar

Allen Head Screw

Case Bore

Spring End Of Shaft M89802

26. Coat end of shaft and case bore surfaces with grease. 27. Install shifter fork, putting pins in groove of shifter collar first, then rotate end of shaft into case bore. Differential Assembly

Detent Ball

Plug M89799

32. Install detent ball, spring and allen-head screw. Tighten screw one turn below flush with case cover. 33. Install plug in case, if removed. 34. Install new shifter fork shaft seal until it contacts case surface.

M89806

5 - 38

3/7/00

REPAIR

POWER TRAIN—GEAR

Shift Lever Front Support

Front Support

Snap Ring

Brake Disk Outer Brake Pad

Plate

Drive Sheave

Housing

Pins

M89793

35. Install inner brake pad in transaxle case. Install brake disk. Assemble plate, outer brake pad and pins in housing.

M89791

38. Install front supports and secure with cap screws. Torque to 27 N•m (240 lb-in.). 39. Install shift lever and secure with cap screw. 40. Install key, transaxle drive sheave, and snap ring.

Brake Lever

DIFFERENTIAL REMOVAL, DISASSEMBLY AND INSTALLATION

Nut Shield

Removal: 1. Remove transaxle from vehicle. (See ‘TRANSAXLE REMOVAL AND INSTALLATION’ on page 29.) 2. Split case halves. (See ‘TRANSAXLE DISASSEMBLY AND INSPECTION’ on page 30.) Cap Screw

M89792

Differential Assembly

36. Secure housing to transaxle case with one cap screws on left side. 37. Install brake lever and shield on threaded shaft. Secure with Nut. Install second cap screws securing brake assembly to transmission housing.

M89806

3. Lift differential assembly, with axles from case. 4. Clean differential assembly with a suitable solvent.

NOTE: Orientation of differential cap screws in relation to long and short axles and location of gear on carrier.

3/7/00

5 - 39

REPAIR

POWER TRAINâ&#x20AC;&#x201D;GEAR

Disassembly: End Cap

Thrust Washer Cap Screws (8 Used)

5. Remove cap screws securing end caps to ring gear. Pinions

10. Remove thrust washer from recess in end cap. Remove end cap from end of axle.

O-Ring

End Cap

Pinion Shaft

O-Ring

Snap Ring Bearing Blocks End Cap

Washers Ring Gear

6. Separate end caps from ring gear. 7. Clean internal components in suitable solvent. 8. Remove pinions, bearing blocks, pinion shaft from ring gear. End Cap

11. Remove washers, and needle bearing from end of axle. 12. Remove O-rings from inside needle bearing housing. 13. Inspect all components for damage and/or wear. Replace as required. 14. Measure axles in needle bearing area. If not in specifications, replace axle. Installation: Assembly and installation of differential are performed in the reverse order of disassembly and removal. IMPORTANT: Always install new seals and O-rings. Damaged or used seals and O-rings will leak.

Bevel Gear

9. Remove snap ring from end of axle. Remove bevel gear from end of axle. IMPORTANT: Apply John Deere Corn Head Grease

5 - 40

3/7/00

REPAIR

POWER TRAIN—GEAR

(#AN102562) (or equivalent SAE #0, or J13E6 grease) to all gears and shafts during assembly. Use 6 oz. of grease during assembly and to pack differential.

Bushing Carriage Bolt

TRACTION DRIVE CLUTCH ASSEMBLY REMOVAL AND INSTALLATION

Flange Nut Plastic Bushing

Bellcrank Plastic Bushing

Removal: 1. Remove fender deck. (See “FENDER DECK REMOVAL AND INSTALLATION” on page 9 in MISC. SECTION.)

Flat Idler Sheave

Washer

V-Idler Sheave

Clutch Actuating Spring Flanged Nut

Cap Screw Belt Guide

Belt Tensioning Spring M83289

2. Disconnect clutch actuating spring and belt tension spring. 3. Remove drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 42 in BRAKE SECTION.)

M83379

4. Remove: • Flat idler sheave. • V-idler sheave. • Bellcrank. • Bushings. 5. Inspect all parts for wear or damage. Replace parts as necessary. Installation is done in the reverse order of removal: • Adjust belt tension. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 28 in BRAKE SECTION. and See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 42 in BRAKE SECTION.)

3/7/00

5 - 41

REPAIR

POWER TRAIN—GEAR

Wire Form Belt Guide

Front

TRACTION DRIVE BELT REMOVAL AND INSTALLATION

Belt Guide

Removal: Nut

1. Lock parking brake to release belt tension.

Traction Drive Belt Front

Engine Drive Sheave

Front Tensioning V-Idler

PTO Wiring Connector

Drive Belt Steering Drag Link

Clutch Lever Clutch Pedal

Clutch Actuating Spring

Clutch Shaft Tensioning Bellcrank Assembly

V-Idler

Flat Idler Belt Tensioning Spring

Transaxle Input Sheave

M83290

7. Remove front tensioning v-idler nut to remove belt guide. 8. Remove wire form belt guide. 9. Disconnect PTO wiring connector. 10. Disconnect steering drag link from steering arm. 11. Replace traction drive belt. Installation: Installation is done in the reverse order of removal:

M85616

• Adjust belt tension. (See ‘TRACTION DRIVE BELT TENSION ADJUSTMENT’ on page 28.)

Top View

Front

V-Idler and Guide Flat Idler and Guide

Looped Belt Guide

Transaxle Belt Guide and Drive Sheave

Later Model Shown

M83289

2. Loosen transaxle belt guide. 3. Remove belt from transaxle drive sheave. 4. Remove belt from looped belt guide. 5. Remove guide. 6. Loosen flat idler and guide to remove belt.

5 - 42

3/7/00

CONTENTS

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TRANSAXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DRIVE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 HYDROSTATIC SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GEAR POWER FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TRANSAXLE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 TRACTOR WILL NOT MOVE FORWARD OR REVERSE . . . . . . . . . . . . . . . . . . . . 20 NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 TRACTOR CREEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TRACTOR MOVES IN ONE DIRECTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 ERRATIC SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED . . . . . . . . . . . . . . . . . . . 32 PARK BRAKE DOES NOT HOLD TRACTOR ON HILL . . . . . . . . . . . . . . . . . . . . . . 36 TRACTOR IS TOO AGGRESSIVE IN FORWARD OR REVERSE . . . . . . . . . . . . . . 38 FREEWHEEL VALVE WILL NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . 40 NEUTRAL CREEP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 PEDAL HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 BRAKE LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 TRACTION DRIVE BELT TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 42

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 TRANSAXLE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 TRANSAXLE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 TRACTION DRIVE BELT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . 68 DRIVE BELT TENSIONER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3/3/00

6-1

NOTES

6-2

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

3/3/00

POWER TRAIN—HYDROSTATIC

SPECIFICATIONS

SPECIFICATIONS TRANSAXLES 1948HV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff-Torq Model K-62C 2148HV/2354HV/2554HV(S/N -25001) . . . . . . . . . . . . . . . . . . . . Tuff-Torq Model K-66C

ADJUSTMENT SPECIFICATIONS Forward Pedal-to-Frame Height . . . . . . . . . . . . . . . . . . . . . 76 – 80 mm (3.00 – 3.15 in.)

REPAIR SPECIFICATIONS Transaxle Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.7 qt) Reservoir Oil Top Off Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.47 L (0.5 qt) Reduction Gear Assembly Reduction Pinion Gear ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.04 mm (0.592 in.) Reduction Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.99 mm (0.590 in.) Reduction Pinion Gear/Shaft Clearance . . . . . . . 0.09 – 0.19 mm (0.003 – 0.007 in.) (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Differential Gear Assembly Pinion Gear ID (New) . . . . . . . . . . . . . . . . . . . . 15.03 – 15.13 mm (0.592 – 0.596 in.) Pinion Shaft OD (New) . . . . . . . . . . . . . . . . . . . 14.90 – 14.98 mm (0.587 – 0.590 in.) Pinion Gear/Shaft Clearance . . . . . . . . . . . . . . . . 0.05 – 0.23 mm (0.002 – 0.009 in.) (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Axle Shaft (Right Hand and Left Hand) Case Bushing ID (Press Fit in Upper Case). . . . 25.505-25.585 mm (1.004-1.007 in.) Axle Bushing ID . . . . . . . . . . . . . . . . . . . . . . . . . 25.381-25.525 mm (0.999-1.005 in.) Axle Shaft OD . . . . . . . . . . . . . . . . . . . . . . . . . . 25.301-25.355 mm (0.996-0.998 in.) Clearance Wear Limit (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Swash Plate/Shift Block Clearance Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 – 0.11 mm (0.0004 – 0.004 in.) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Thrust Plate Thickness. . . . . . . . . . . . . . . . . . . . . . . 1.45 – 1.55 mm (0.057 – 0.061 in.) (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.) Brake Shoe to Brake Disk Clearance. . . . . . . . . . . . . . . . . . . 0.8-1.3 mm (0.03-0.05 in.)

TORQUE SPECIFICATIONS Drain Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 N•m (130 lb-in.) Center Case Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 N•m (32 lb-ft) Case Half Cap Screw Same Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (205 lb-in.) New Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N•m (252 lb-in.) Transaxle-to-Frame Mounting Cap Screws and Nuts. . . . . . . . . . . . . . . 40 N•m (30 lb-ft) Reverse Pedal Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 N•m (20 lb-in.) Transaxle Fan Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Rear Wheel Bolts (AWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 N•m (41 lb-ft) Rear Tie Rod End Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N•m (44 lb-ft) Eccentric Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 – 32 N•m (18 – 24 lb-ft)

3/7/00

6-3

OTHER MATERIALS

POWER TRAIN—HYDROSTATIC

OTHER MATERIALS

Number

Description

Use

TY9375/ TY9480/ 592

Pipe Sealant with TEFLON

Seal pipe plug

TY6305/ TY9485/ 764

Clean and Cure Primer

Clean transaxle case mating surfaces

TY6304/ TY9484/ 518

Flexible Sealant

Seal transaxle case

U.S./ Canadian/ LOCTITE No.

LOCTITE is a registered trademark of the Loctite Corp. TEFLON is a registered trademark of the DuPont Co.

6-4

3/7/00

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

COMPONENT LOCATION TRANSAXLE CASE HALVES (K62 & K66)

Seal

Cap Screw Reservoir Fitting

Snap Ring

Oil Fill Cap O-Ring O-Ring

Seal Bushing (Pressed In) Upper Case Housing

Bushing (Pressed In) Seal

Magnet Cover

Filter

Magnet

Lower Case Housing

Cap Screw Washer Seal

Cap Screw

Cap Screw M94894

3/7/00

6-5

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CENTER CASE AND VALVES (K62 & K66)

Check Valve Bushing

Center Case Check Valve Plug Cap Screw

Filter

Lower Case Housing

M99731

6-6

3/7/00

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

MOTOR AND PISTON PUMP (K62) Bearing Snap Ring Snap Ring Bearing Snap Ring

Input Shaft

Piston

Swash Plate

Washer Spring

Cylinder Block

Spring Washer Piston Center Case Thrust Washer

Cylinder Block

Snap Ring Bearing

Bearing Housing Bearing Output Shaft

M99732

3/7/00

6-7

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

MOTOR AND PISTON PUMP (K66) Bearing Snap Ring Snap Ring Bearing Snap Ring

Input Shaft

Pin Piston

Swash Plate

Washer Spring

Cylinder Block

Spring Washer

Piston Center Case Thrust Washer Cylinder Block

Bearing Bearing Housing

Inner Gerotor Outer Gerotor

Charge Pump

Check Valve Case

Snap Ring

Output Shaft

Bearing Spring

Filter

M99750

6-8

3/7/00

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CONTROL SHAFT E-Clip

Shock Absorber

E-Clip Spacer

Bracket Freewheeling Lever

Spring Pin

O-Rings Shaft

Spring Pin

Shaft

Cap Screw

Seal Spring Pin

Center Case

Nut Washer O-Rings

Eccentric Snap Ring Washer Collar

Spring Snap Ring

Spring Control Arm

Thrust Bearing Swash Plate Bushing Thrust Plate Bearing Rotating Group

Thrust Plate

M99733A

3/7/00

6-9

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

REDUCTION GEARS, DIFFERENTIAL, AND AXLES

RH Axle Shaft Bushing

Ring Gear

Thrust Washer C-Ring Spacer

Pinion Gear

Side Gear

Side Gear C-Ring Thrust Washer Bushing

Pinion Shaft Washer Pinion Shaft

Needle Bearing ** Bushing ** Reduction Pinion Needle Bearing **

LH Axle Shaft

(** Note: K66 Only) Reduction Gear

Washer

M99734A

BRAKE Arm

Upper Case Housing

Spring Pins

Spring O-Ring Washer Snap Ring

Shaft

Brake Shoe Shims Actuator M99735A

6 - 10

3/7/00

COMPONENT LOCATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CONTROL PEDALS AND LINKAGE Spring Spring Guide

Brake Rod

Control Rod

Spring Retainer

Rod End

Mounting Plate RIO Switch Actuator

Rod End

Belt Tension Release Rod Bushing

Bushing

Brake Pedal Return Spring Brake Pedal Pad

Forward Pedal Link Arm

Forward Pedal Pad Brake Pedal

Bushings

Spring

Brake Pedal Interlock Lever

Spacer

Reverse Link Reverse Pedal

Reverse Shaft

M99803

3/7/00

Bushings

6 - 11

THEORY OF OPERATION

THEORY OF OPERATION DRIVE SYSTEM OPERATION Function: The drive system provides a means to transfer power from the engine to the transaxle. It also controls the forward and reverse motion, and speed of travel, of the vehicle.

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Neutral: When neither the forward or reverse pedals are depressed, the internal neutral return spring of the hydrostatic transmission positions the pump variable displacement swash plate into a flat, zero displacement relationship with the pump cylinder block rotating group. No pressure or rotation is generated between the pump and motor rotation groups. Foot control linkage return springs aid in returning and holding neutral position.

The foot pedal actuates a linkage under the vehicle frame attached to the transaxle, which controls forward and reverse hydrostatic power. The pedal system also controls the brake and interlock linkage that stops machine motion and disengages power from the engine to the transaxle.

Forward:

Belt Drive:

The reverse link spring is tensioned slightly to aid in keeping the reverse link from vibrating in its no-motion slot while the forward pedal is engaged.

The engine drive sheave is keyed to the engine crankshaft. Power is transferred through the drive belt to the transaxle input sheave. Belt tension is maintained by the bellcrank/idler assembly and belt tension spring. Belt tension is adjusted by moving the idler in its slotted mounting hole. Belt guides keep the belt in the correct position and reduce unwanted vibration. The cooling fan helps cool transaxle by forcing blown air down over transaxle, lowering lubricant temperature. Brake Linkage: When the brake pedal is depressed it rotates the pedal shaft and lever forward. Attached to the lever is the belt tension release rod. Movement of the lever is transferred to the rod which engages the end of the slot in the idler arm assembly. Continued movement pulls the left side of the idler arm forward and disengages drive belt tension of the V-idler.

When the forward pedal is depressed, the lever which is part of the forward pedal assembly rotates toward the front of the machine. As the lever moves, the control rod connected to the lever and the hydrostatic control arm also moves forward. This causes the transaxle to shift into forward drive.

Reverse: The reverse pedal is connected to the lever by the reverse link. As the reverse pedal is depressed, the reverse link, lever and control rod are driven toward the rear of the machine. This causes the transmission to shift into reverse drive. When the forward/reverse pedals are released, the transmission is returned to the neutral position by a swash plate linkage neutral return spring located inside the transaxle. This motion is dampened by the shock absorber to eliminate sudden jerks.

At the same time, the brake pedal interlock lever is rotated, moving a pin inside a cam profile on the forward/reverse pedal linkage. This returns the forward and reverse pedals to the neutral position, and holds them in place when the park brake is locked. Also attached to the lever is the brake actuating rod and spring assembly. Movement of the lever is transferred through the rod to the transaxle brake control arm and internal brake assembly.

6 - 12

3/7/00

DRIVE SYSTEM OPERATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Forward Pedal

Pin Cam Profile Brake Pedal Interlock Lever

Brake Pedal

Forward Pedal Engine Drive Sheave Reverse Link

Reverse Pedal Belt Tension Spring Bellcrank/Idler Assembly V-Idler Flat Idler Control Rod

Belt Guide Drive Belt

Belt Guide

Cooling Fan

Lever

Transaxle Input Sheave

Brake Pedal Shaft

Belt Tension Release Rod Belt Guide Brake Actuating Arm and Spring Assembly

3/7/00

M99779

6 - 13

HYDROSTATIC SYSTEM OPERATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

HYDROSTATIC SYSTEM OPERATION

Pump Input Shaft Variable Displacement Swash Plate Motor Rotating Group

Reservoir Pump Rotating Group Filter

Fixed Displacement Swash Plate

Motor Output Shaft M95065

Function: The hydrostatic transaxle provides a means of transferring power from the input sheave to the axle shafts of the transaxle. It also provides infinitely variable speed control and the capability of forward or reverse directional travel of the vehicle. Theory of Operation: As the input sheave is rotated by the traction drive belt it rotates the pump input shaft. The pump input shaft is splined to the pump rotating group and the charge pump. The pump rotating group is composed of an axial piston pump and a variable displacement swash

6 - 14

plate. The charge pump is composed of a Gerotor pump that draws pressure-free oil from the reservoir through the filter and supplies oil to the pump rotating group. The pump rotating group provides oil under pressure to the motor rotating group. The motor rotating group is composed of an axial piston motor with a fixed position swash plate, and converts hydraulic energy into rotary motion, which is output through the motor output shaft. This rotary motion of the motor output shaft is the beginning of the gear power flow.

3/7/00

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Neutral: With the transmission in the neutral position, the swash plate is held perpendicular to the piston. Springs in the pump cylinder block force the pump pistons against the swash plate. Since the variable displacement swash plate is perpendicular to the axis of the pistons, there is no reciprocating motion of the pistons in the cylinders, and no oil is displaced. Because there is no demand for oil in the pump, both directional check valves are closed, and the tractor remains stationary. Forward As the direction control arm is moved to the forward position, the variable displacement swash plate is rotated from its neutral position. Springs inside the pistons force them against the swash plate. As the swash plate angle increases, the pistons are forced in and out of the pump body as the piston block turns, displacing oil. As the pistons rotate, they follow the angled swash plate, and move outward in their bores, drawing in oil. As the pistons continue to rotate, the swash plate angle forces the pistons back into their bores, and oil is displaced through ports in the center case.

HYDROSTATIC SYSTEM OPERATION A certain amount of oil is lost from the pump and motor rotating groups. This is due to normal leakage, or may be caused by component wear. Since the pump/motor operate in a closed loop system, oil lost from the system must be replenished. Any additional oil required by the system is drawn from the sump, through the filter, by the charge pump. The charge pump keeps a constant pressure and volume of oil supplied to the piston pump. Charge pressure is controlled by the spring holding the charge pump housing on the center case. Reverse: The operation in reverse is the same as in forward. The only difference being that the variable displacement swash plate is rotated in the opposite direction, thus causing oil flow through the center case in the opposite direction. This causes the reverse check valve to close and supply high pressure oil to the opposite side of the motor rotating group. This causes the output shaft to rotate in the opposite direction, and results in reverse travel of the vehicle. When in reverse, the reverse check valve is closed due to high pressure oil forcing it against the seat. The forward check valve will open to sump.

Pressurized oil from the pump forces the forward check valve closed and supplies high pressure oil to the motor rotating group. The rotating group of the motor presses against a fixed angle swash plate. Oil enters the piston bore through a port in the center case at a point where the piston is compressed in its bore. As the oil fills the piston bore, the piston is forced out and follows the angle created by fixed swash plate. This causes the motor rotating group to rotate. The motor rotating group is splined to the output shaft. Oil pressure within these components is directly proportional to the load encountered. This is known as the high pressure side. The piston continues to be forced out of its bore and follows the fixed angle swash plate until it is no longer aligned with the delivery port of the center case. Since oil is no longer being displaced to the piston, it no longer adds to the rotary motion of the motor. But, since the pistons next in line to it are now filling with oil, the rotary motion is continued. As the motor continues to rotate, the pistons pass from the high pressure port to the low pressure port and, as the pistons are forced back into their bores by the angle of the swash plate, oil is forced from the piston bores through the center case and back to the inlet port of the pump. This is known as the low pressure side. The oil path from the pump to the motor is known as the high pressure side, because oil pressure increases, depending on the system load. The oil path from the motor back to the pump is known as the low pressure side. From forward drive to reverse drive these two paths switch, which gives opposite rotation to the motor. 3/7/00

6 - 15

GEAR POWER FLOW

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

GEAR POWER FLOW

Splined to the end of the motor output shaft is the brake disc of the brake assembly. The brake is an internal wet disk brake.

Function:

When the brake is applied, a lever operated cam presses a brake shoe against the brake disk.

The gear components transfer power from the hydrostatic transaxle components of the transaxle, out the drive axles and to the drive wheels. They also provide a means of making turns with differential action for smooth operation. Theory of Operation: The output shaft and output shaft gear are splined to the hydrostatic motor. Power from the motor is transferred to the shaft. The output shaft gear meshes with the reduction gear which drives the reduction shaft. The reduction shaft drives the differential ring gear. Power is transferred from the ring gear to the differential pinion shaft and differential pinion gears. The differential bevel gears are splined to the axle shafts and transfer power directly out to the drive wheels.

Differential Pinion Gear Differential Bevel Gear Axle Shaft

Axle Shaft

Differential Ring Gear

Fixed Swash Plate

Reduction Shaft Reduction Gear

Output Shaft Brake Disk Hydrostatic Motor

6 - 16

M95571

Output Shaft Gear

3/7/00

TRANSAXLE BRAKE

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

TRANSAXLE BRAKE The transaxle brake is an internal wet disk brake. When the brake pedal is depressed or the parking brake is set, the brake linkage rotates the brake arm. The brake arm rotates the brake shaft and the brake shaft, acting as a cam, presses the brake shoe against the brake disk. The brake disk is splined to the hydrostatic motor output shaft.

Brake Arm

Cam

Pump Rotating Group Brake Disk Motor Output Shaft Fixed Displacement Swash Plate

3/7/00

Brake Shoes M95066

6 - 17

TROUBLESHOOTING

POWER TRAIN—HYDROSTATIC

TROUBLESHOOTING

Temperature too cold.

●

Wrong oil/incorrect viscosity.

●

Control linkage out of adjustment or damaged.

●

Brake linkage damaged.

●

● ●

●

Traction drive belt broken, worn, etc.

●

Air in system. ●

● ●

●

● ●

Debris/trash on transmission. Oil too hot.

● ●

Water in oil. ●

●

● ●

●

Neutral eccentric out of adjustment.

6 - 18

Freewheel valve will not stay open with engine off.

●

Cooling fan broken. Oil too hot.

Control arm roll pin broken.

● ●

Park brake engaged.

Shock absorber binding/damaged.

Freewheel valve will not work.

●

Defective brake switch.

Internal oil filter plugged.

Brake switch will not engage.

●

Park brake does not hold tractor on hill.

●

Tractor is too aggressive in forward or reverse.

Tractor does not achieve full ground speed.

●

Tractor moves in one direction only.

●

Erratic speed.

Oil level low.

Tractor creeps.

Check or Solution

Transmission noisy.

Problem or Symptom

Tractor will not move forward or reverse.

TROUBLESHOOTING CHART

●

3/7/00

Internal transmission damage (pump or motor). a

●

Input shaft broken. a

●

Freewheel linkage stuck or damaged. a

●

Reverse check valve stuck open. a

●

Forward check valve stuck open. a

●

Motor shaft damaged. a

●

Motor shaft gear damaged. a

●

Final drive pinion damaged. a

●

Final ring gear damaged. a

●

Differential gears damaged. a

●

Axle shaft damaged. a

●

Freewheel valve will not stay open with engine off.

●

Freewheel valve will not work.

Control arm broken. a

Brake switch will not engage.

Park brake does not hold tractor on hill.

●

Tractor does not achieve full ground speed.

Tractor moves in one direction only.

●

Erratic speed.

Tractor creeps.

Transmission noisy.

Check or Solution

Tractor will not move forward or reverse.

Problem or Symptom

Tractor is too aggressive in forward or reverse.

TROUBLESHOOTING

POWER TRAIN—HYDROSTATIC

●

Requires removal of transmission from tractor and disassembly

3/7/00

6 - 19

DIAGNOSIS

POWER TRAIN—HYDROSTATIC

DIAGNOSIS TRACTOR WILL NOT MOVE FORWARD OR REVERSE Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

If Not Normal

1. Hydrostatic transaxle reservoir

Hydraulic oil at full mark.

Fill reservoir to correct level with specified oil. (See "HYDROSTATIC TRANSMISSION OIL" on page 9 in "SPECIFICATIONS" Section.)

2. Hydrostatic oil filter

Clean, free of debris, not plugged.

Replace filter.

3. Traction drive belt

Properly tensioned.

Adjust tension. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 42.)

Not broken, worn, frayed, glazed or stretched.

Replace traction drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 68.)

4. Park brake

Brake not depressed and locked.

Release park brake.

5. Brake linkage

Brake linkage properly adjusted.

Adjust brake linkage. (See “BRAKE LINKAGE ADJUSTMENT” on page 42.)

Brake rod and lever not damaged or binding.

Eliminate binding, replace damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

6. Forward/reverse pedal linkage

Linkage moves freely, not damaged.

Eliminate binding, replace faulty or damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

7. Control arm

Not damaged. Roll pin not broken or missing.

Replace control arm. Replace roll pin.

8. Shock absorber

Not binding or damaged.

Replace shock absorber.

6 - 20

3/7/00

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

TRACTOR WILL NOT MOVE FORWARD OR REVERSE

8 7

2 M95070

4 8

M99791

6 3

M99779 5

3/7/00

6 - 21

TRACTOR WILL NOT MOVE FORWARD OR REVERSE

POWER TRAIN—HYDROSTATIC

TRACTOR WILL NOT MOVE FORWARD OR REVERSE Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point 9. Engine/transaxle drive sheaves

Normal

If Not Normal

No damage to drive key or keyway, splines on transaxle drive sheave.

Replace drive key or sheave.

10. Belt tensioning idler arm assembly

Pivots freely, no wear in bearing.

Lubricate or replace assembly.

11. Belt idler assembly tension spring

Maintains tension on drive belt, not stretched or damaged.

Replace tensioning spring.

12. Freewheel linkage a

Components move freely. Components not damaged.

Eliminate binding and/or replace damaged components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

13. Forward/reverse check valves and seat assemblies a

Balls and seats not deformed, damaged, or stuck in bores, sealing properly.

Clean, free up valves or replace forward/reverse check valve(s). (See “TRANSAXLE DISASSEMBLY” on page 50.)

14. Input (pump) shaft a

Splines not worn or damaged.

Replace shaft. (See “TRANSAXLE DISASSEMBLY” on page 50.)

15. Pump/motor rotating groups a

No scoring on cylinder blocks or center case mating surfaces, no scoring on pistons.

Replace pump and motor rotating groups and center case. (See “TRANSAXLE DISASSEMBLY” on page 50.)

16. Motor output shaft with gear a

Shaft with gear not worn or damaged.

Replace shaft. (See “TRANSAXLE DISASSEMBLY” on page 50.)

17. Final pinion and ring gear a

Pinion and gear not damaged or worn.

Replace damaged or worn components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

18. Differential gears a

Gears not damaged.

Replace gears. (See “TRANSAXLE DISASSEMBLY” on page 50.)

19. Axle shafts a

Shafts not damaged.

Replace axle shafts. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 22

3/7/00

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

TRACTOR WILL NOT MOVE FORWARD OR REVERSE

19 13 14

17 18

M95070

12 9

M99791

M99779

3/7/00

6 - 23

NOISY OPERATION

POWER TRAIN—HYDROSTATIC

NOISY OPERATION Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

If Not Normal

1. Hydrostatic transaxle reservoir

Hydraulic oil at full mark. Oil at room temperature. Check when cold.

Fill reservoir to correct level with specified oil. (See "HYDROSTATIC TRANSMISSION OIL" on page 9 in "SPECIFICATIONS" Section.)

Oil not contaminated, no water in oil.

Drain transaxle and fill to correct level with specified oil.

Hydraulic oil clean and not foamy (no air in system).

Bleed air from system. (See “HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE” on page 40.)

2. Hydrostatic oil filter

Clean, free of debris, not plugged.

Replace filter.

3. Park brake

Brake not depressed and locked.

Release park brake.

4. Brake linkage

Brake linkage properly adjusted.

Adjust brake linkage. (See “BRAKE LINKAGE ADJUSTMENT” on page 42.)

Brake rod and lever not damaged or binding.

Eliminate binding and/or replace damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

5. Pump/motor rotating groups a

No scoring on cylinder blocks or center case mating surfaces, no scoring on pistons.

Replace pump and motor rotating groups and center case. (See “TRANSAXLE DISASSEMBLY” on page 50.)

6. Freewheel linkage and check valves a

Components move freely. Components not damaged.

Clean, free up valves or replace forward/reverse check valve(s). (See “TRANSAXLE DISASSEMBLY” on page 50.)

7. Final pinion and ring gear a

Pinion and gear not damaged or worn.

Replace damaged or worn components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 24

3/7/00

NOISY OPERATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

7 6

5 2 M95070

6 3

M99791

M99779

3/7/00

6 - 25

TRACTOR CREEPS

POWER TRAIN—HYDROSTATIC

TRACTOR CREEPS Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

If Not Normal

1. Hydrostatic transaxle reservoir

Hydraulic oil at full mark. Oil at room temperature. Check cold.

Fill reservoir to correct level with specified oil. (See "HYDROSTATIC TRANSMISSION OIL" on page 9 in "SPECIFICATIONS" Section.)

2. Neutral eccentric

Properly adjusted for no wheel movement at fast idle, one wheel off the ground.

Adjust neutral eccentric. (See “NEUTRAL CREEP ADJUSTMENT” on page 40.)

3. Forward/reverse pedal linkage

Linkage moves freely, not damaged.

Eliminate binding, replace faulty or damaged components.

4. Control arm

Control arm not damaged. Roll pin not broken or missing.

Replace control arm. Replace roll pin.

5. Shock absorber

Not binding or damaged.

Eliminate binding and/or replace shock absorber.

6. Variable position swash plate a

Cradle bearings not worn or damaged, thrust washers and bearings not binding.

Replace damaged or worn components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

7. Control lever pivot a

Pivot not bent or worn.

Replace swash plate control arm. (See “TRANSAXLE DISASSEMBLY” on page 50.)

8. Neutral return spring a

Returns swash plate to neutral when forward/reverse pedals released. Not fatigued or damaged.

Replace spring. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 26

3/7/00

TRACTOR CREEPS

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

M95070

M99791

M99779

3/7/00

6 - 27

TRACTOR MOVES IN ONE DIRECTION ONLY

POWER TRAIN—HYDROSTATIC

TRACTOR MOVES IN ONE DIRECTION ONLY Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point 1. Forward/reverse pedal linkage

Normal

If Not Normal

Linkage properly adjusted.

Adjust linkage. (See “PEDAL HEIGHT ADJUSTMENT” on page 41.)

Linkage moves freely, not damaged.

Eliminate binding, replace faulty or damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

2. Shock absorber

Not binding or damaged.

Eliminate binding and/or replace shock absorber.

3. Control arm

Control arm not damaged.

Replace control arm.

4. Forward or reverse check valve a

Moves freely, not stuck in open position.

Clean, unstick and/or replace check valve. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 28

3/7/00

TRACTOR MOVES IN ONE DIRECTION ONLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

M95070

M99779

3/7/00

6 - 29

ERRATIC SPEED

POWER TRAIN—HYDROSTATIC

ERRATIC SPEED Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

1. Hydrostatic transaxle reservoir

Hydraulic oil at full mark. Oil at room temperature. Check cold. Oil not contaminated, no water in oil.

Fill reservoir to correct level with specified oil.

Hydraulic oil clean and not foamy (no air in system).

Bleed air from system. (See “HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE” on page 40.)

2. Hydrostatic oil filter

Clean, free of debris, not plugged.

Replace filter.

3. Traction drive belt

Properly tensioned.

Adjust tension. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 42.)

Not broken, worn, frayed, glazed or stretched.

Replace traction drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 68.)

Brake linkage properly adjusted.

Adjust brake linkage. (See “BRAKE LINKAGE ADJUSTMENT” on page 42.)

Brake rod and lever not damaged or binding.

Eliminate binding and/or replace damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

5. Freewheel linkage, forward/ reverse check valves and seat assemblies a

Components move freely. Components not damaged.

Clean, free up valves or replace check valve components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

6. Pump/motor rotating groups a

No scoring on cylinder blocks or center case mating surfaces, no scoring on pistons.

Replace pump and motor rotating groups and center case. (See “TRANSAXLE DISASSEMBLY” on page 50.)

7. Motor output shaft with gear a

Shaft with gear not worn or damaged.

Replace shaft. (See “TRANSAXLE DISASSEMBLY” on page 50.)

8. Final drive pinion and differential ring gear assembly a

Pinion and differential ring gear assembly not worn or damaged.

Replace worn or damaged components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

4. Brake pedal and linkage

If Not Normal

Requires removal of transaxle from tractor and disassembly.

6 - 30

3/7/00

ERRATIC SPEED

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

6 2 M95070 7

M99791

M99779

3/7/00

6 - 31

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED

POWER TRAIN—HYDROSTATIC

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

If Not Normal

1. Hydrostatic transaxle

Transaxle free of debris.

Remove debris from transaxle.

2. Cooling fan

Not damaged.

Replace cooling fan.

3. Hydrostatic transaxle reservoir

Hydraulic oil at full mark. Oil at room temperature. Check cold.

Fill reservoir to correct level with specified oil.

Hydraulic oil clean and not foamy (no air in system).

Bleed air from system. (See “HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE” on page 40.)

4. Hydrostatic oil filter a

Clean, free of debris, not plugged.

Replace filter.

5. Traction drive belt

Properly tensioned.

Adjust tension. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 42.)

Not worn, frayed, glazed or stretched.

Replace traction drive belt. (See “TRACTION DRIVE BELT REMOVAL AND INSTALLATION” on page 68.)

6. Engine/transaxle drive sheaves

No damage to drive key or keyway, splines on transaxle drive sheave.

Replace drive key or sheave.

7. Park brake

Brake not depressed and locked.

Release park brake.

8. Brake linkage

Brake linkage properly adjusted.

Adjust brake linkage. (See “BRAKE LINKAGE ADJUSTMENT” on page 42.)

Brake rod and lever not damaged or binding.

Eliminate binding and/or replace damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

Linkage properly adjusted.

Adjust linkage. (See “PEDAL HEIGHT ADJUSTMENT” on page 41.)

Linkage moves freely, not damaged.

Eliminate binding, replace faulty or damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11.)

9. Forward/reverse pedal linkage

Requires removal of transaxle from tractor and disassembly.

6 - 32

3/7/00

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED

4 M95070

M99791

M99779

3/7/00

6 - 33

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED

POWER TRAIN—HYDROSTATIC

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

If Not Normal

10. Swash plate control arm and shock absorber

Not binding or damaged. Roll pin not broken or missing.

Replace faulty or damaged components. Replace roll pin.

11. Shock absorber

Not binding or damaged.

Replace shock absorber.

12. Pump/motor rotating groups a

No scoring on cylinder blocks or center case mating surfaces, no scoring on pistons.

Replace pump and motor rotating groups and center case. (See “TRANSAXLE DISASSEMBLY” on page 50.)

13. Freewheel linkage a

Components move freely. Components not damaged.

Eliminate binding and/or replace damaged components.

14. Forward/reverse check valves and seat assemblies a

Move freely, not stuck in open position.

Clean, unstick and/or replace check valves. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 34

3/7/00

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

TRACTOR DOES NOT ACHIEVE FULL GROUND SPEED

10 11

M95070

M99791

3/7/00

6 - 35

PARK BRAKE DOES NOT HOLD TRACTOR ON HILL

POWER TRAIN—HYDROSTATIC

PARK BRAKE DOES NOT HOLD TRACTOR ON HILL Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL.

Test/Check Point

Normal

1. Brake pedal, internal/external linkage and brake assembly

Brake pedal linkage internal/external components, brake assembly not damaged, worn, or binding.

If Not Normal Eliminate binding and/or replace damaged components. (See “CONTROL PEDALS AND LINKAGE” on page 11 or “TRANSAXLE DISASSEMBLY” on page 50.) If internal problem, remove transaxle, disassemble/inspect/ replace damaged components/and install. (See “TRANSAXLE DISASSEMBLY” on page 50.)

2. Motor output shaft with gear a

Shaft with gear not worn or damaged.

Replace shaft. (See “TRANSAXLE DISASSEMBLY” on page 50.)

3. Reduction shaft and gear a

Shaft and gear not worn or damaged.

Replace worn or damaged components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

4. Final pinion and ring gear a

Pinion and gear not damaged or worn.

Replace damaged or worn components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

5. Differential gears a

Gears not damaged.

Replace gears. (See “TRANSAXLE DISASSEMBLY” on page 50.)

6. Axle shafts a

Shafts not damaged.

Replace axle shafts. (See “TRANSAXLE DISASSEMBLY” on page 50.)

Requires removal of transaxle from tractor and disassembly.

6 - 36

3/7/00

PARK BRAKE DOES NOT HOLD TRACTOR ON HILL

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

6 4

M95070

M99779

3/7/00

6 - 37

TRACTOR IS TOO AGGRESSIVE IN FORWARD OR REVERSE POWER TRAIN—HYDROSTATIC

TRACTOR IS TOO AGGRESSIVE IN FORWARD OR REVERSE Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL. Test/Check Point 1. Shock absorber

Normal

If Not Normal

Not binding or damaged.

Replace shock absorber.

M95070

6 - 38

3/7/00

FREEWHEEL VALVE WILL NOT WORK

POWER TRAIN—HYDROSTATIC

FREEWHEEL VALVE WILL NOT WORK Test Conditions: • Tractor parked on level surface. • Key switch in STOP position. • Park brake DISENGAGED. • Transmission in NEUTRAL Test/Check Point 1. Freewheel linkage, pin and thrust washer a

Normal Components move freely. Components not damaged.

If Not Normal Clean, unstick pin and/or replace damaged components. (See “TRANSAXLE DISASSEMBLY” on page 50.)

M99791

Requires removal of transaxle from tractor and disassembly.

3/7/00

6 - 39

ADJUSTMENTS

POWER TRAIN—HYDROSTATIC

ADJUSTMENTS Full Line

HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE Reason: This procedure is performed to eliminate air from the hydrostatic transaxle after repair or leakage of the transaxle.

Add Line M99765

Procedure: Check hydrostatic transaxle oil reservoir oil level. If necessary, fill to correct level with oil. 1. Raise rear wheels off the ground. Support rear axles with jack stands. 2. Place blocks in front of and behind front wheels. 3. Start and run engine at SLOW idle.

9. Park tractor on a level surface. Stop engine and check oil level in reservoir bottle. Add oil if needed to bring level up to FULL line: • S2048 uses 5W30 or 10W30. • S2554 uses 5W50 Synthetic. Results:

c CAUTION

• Tractor moves without hesitation when forward or reverse pedals are depressed.

MOVING PARTS. Keep loose articles of clothing, hands and feet away from wheels during procedure to reduce the risk of personal injury.

NEUTRAL CREEP ADJUSTMENT Reason:

4. While alternately depressing the forward and reverse pedals, engage and disengage the freewheel valve lever. Continue this procedure until the rear wheels start to rotate. This step may take 5 to 10 minutes to perform. 5. Turn off engine. Raise rear of tractor, remove stands, and lower the tractor to the ground. Remove blocks in front of and behind front wheels. 6. With engine off and control pedals in neutral, push the tractor forward and then rearward to turn the motor rotating group. 7. Start and run the engine at FAST idle. 8. Quickly depress and release the forward and reverse pedals until the tractor moves without hesitation.

If the tractor creeps forward or backward with the forward/reverse pedals in the neutral position, parking brake released, and the engine running, the neutral eccentric must be adjusted. Procedure: 1. Park tractor on level surface. 2. Turn key switch to STOP position. 3. Move forward/reverse pedals to NEUTRAL position. Engage park brake. 4. Remove mower deck from tractor. 5. Lift rear of tractor until wheels are off the ground, and support tractor with jack stand. 6. Place blocks in front of and behind front wheels.

NOTE: The eccentric shaft is located on the right side of the transmission above and forward of the right hand axle.

Filler Cap

M99764

6 - 40

3/7/00

PEDAL HEIGHT ADJUSTMENT

POWER TRAIN—HYDROSTATIC

Eccentric Shaft

Lock Nut

M95063

c CAUTION MOVING PARTS. Keep loose articles of clothing, hands and feet away from wheels during procedure to reduce the risk of personal injury.

9. Loosen lock nut and turn the eccentric shaft clockwise until the axle shaft(s) rotates in reverse. Mark the top of the eccentric shaft for position. 10. Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) stops rotating. Mark the transaxle case as the reverse stop position. 11. Turn the eccentric shaft slowly counterclockwise until the axle shaft(s) rotates forward. 12. Turn the eccentric shaft clockwise until the axle shaft(s) stops rotating. Mark the transaxle case as the forward stop position. 13. Turn the eccentric shaft slowly clockwise until the mark is approximately 1/3 the distance between the forward and reverse stop positions. This is neutral position. 14. Hold eccentric shaft with wrench and tighten lock nut.

NOTE: If the axle shafts do not rotate in reverse although the eccentric shaft has been turned one full turn, adjust neutral as follows: 15. Turn eccentric shaft counterclockwise until axle shaft(s) rotate forward.

NOTE: Engine will not start with seat switch disconnected. Use a jumper wire to bypass switch. 7. Remove right hand rear wheel. 8. Start and run engine at FAST idle.

NOTE: If axle shafts do not rotate in reverse after turning the eccentric shaft one full turn, see steps 15 – 17.

8°

Forward Stop Position

Neutral Position

16. Turn eccentric shaft clockwise until the axle shaft stops. Mark the top of the eccentric shaft and transaxle case. 17. Turn the eccentric shaft clockwise approximately 8° from forward stop position. 18. Hold eccentric shaft with wrench and tighten lock nut.

Reverse Stop Position

PEDAL HEIGHT ADJUSTMENT

1/3

1/3 Neutral Position

3/7/00

1/3

Forward Stop Position

Reason: To insure full travel speeds in forward and reverse directions. This also insures that the transaxle swash plate and control arm will not act as a mechanical stop

6 - 41

BRAKE LINKAGE ADJUSTMENT

POWER TRAIN—HYDROSTATIC

for the pedal linkage. Procedure: 1. Remove fender deck. (See ‘FENDER DECK REMOVAL AND INSTALLATION’ on page 9. in "MISCELLANEOUS" section.) 2. Pull fuel tank forward to gain access to the adjustment.

3. Remove mower deck. (See "MOWER DECK REMOVAL/INSTALLATION" for the appropriate mower deck in the ATTACHMENTS section.) 4. Remove cotter pin and washer attaching brake rod to transmission brake arm. Disconnect brake rod from transmission brake arm. 5. Inspect transmission brake arm, and brake pedal and linkage. Be sure that both transmission brake arm and brake pedal are in full rearward (OFF) positions.

Retaining Nuts (Two Used)

Jam Nuts

Brake Rod

M99787

3. Loosen control rod end retaining nuts.

Transmission Brake Arm

Cotter Pin and Washer

M99794

6. Loosen two jam nuts and adjust length of brake rod so that rod end slips easily into hole in transaxle brake arm. 7. Tighten jam nuts. 8. Install washer and cotter pin.

76—80 mm (3.00—3.15 in.) M45770A

4. With transmission in neutral, adjust the position of control rod end, until distance between the forward pedal arm and the frame is 76 – 80 mm (3.00 – 3.15 in.).

NOTE: Make sure neutral switch actuator on control rod properly contacts neutral switch before tightening retaining nuts. 5. Tighten retaining nuts.

BRAKE LINKAGE ADJUSTMENT

TRACTION DRIVE BELT TENSION ADJUSTMENT Reason: To provide proper traction belt tension to keep the belt from slipping, and to position the guides so that possibility of belt “jumping” is minimized. Procedure: 1. Park the tractor on a level surface. 2. Turn key switch to STOP position. 3. Move forward/reverse pedals to NEUTRAL position and engage park brake.

1. Park tractor on level surface. 2. Turn key switch to STOP position.

6 - 42

3/7/00

TRACTION DRIVE BELT TENSION ADJUSTMENT

POWER TRAIN—HYDROSTATIC

Front

Engine Drive Sheave

• If mark is off the rod toward the rear of the tractor, belt tension is too loose.

Front

Belt Tension Release Rod

Tensioning Spring/Boot

Belt Tensioning Spring/Boot Brake Shaft Lever

Brake Pedal/ Shaft

Tensioner Bellcrank

Belt Guide

V-Idler Alignment Mark

Belt Tension Release Rod

Flat Idler

Tensioning Bellcrank

V-Idler Retaining Nut

Transaxle Input Sheave M85617

Flat Idler

Top View

NOTE: Slide flat idler to the rear of the tractor to increase belt tension and to the front of the tractor to decrease belt tension. If alignment mark on tensioning bellcrank is not clearly visible, measure 19 mm (0.75 in.) from open end of slot to center of belt tension release rod.

6. Engage park brake to release belt tension. 7. Inspect V-idler to make sure that it is fully forward in its slot on the tensioner bellcrank, and that its belt guide is correctly aligned, and approximately 3.2 mm (0.125 in.) away from belt on all sides.

NOTE: When adjusting, the distance from tensioner rod to alignment mark is equal to the amount that the flat idler must be moved in its slotted hole.

Belt Tension Release Rod

Front

Alignment Mark M83385a

4. Release park brake to apply tension to traction drive belt. 5. Check for proper alignment of the mark on the belt tensioning bellcrank and the belt tension release rod – mark should be aligned with center of rod, as shown: • If mark is off the rod toward the front of the tractor, belt tension is too tight.

3/7/00

M83385A

8. At short increments, adjust flat idler position, engaging and disengaging park brake with each incremental adjustment, until alignment mark on the bellcrank idler arm aligns with the center of the belt tension release rod, as shown. 9. When adjusting flat idler, adjust belt guide at the same time so it is correctly aligned with and approximately 3.2 mm (0.125 in.) away from belt on all sides.

6 - 43

REPAIR

POWER TRAIN—HYDROSTATIC

REPAIR Counterbore

Spacer

TRANSAXLE REMOVAL AND INSTALLATION Removal: 1. Remove mower deck. (See “MOWER DECK REMOVAL/INSTALLATION” for the appropriate mower deck in the “ATTACHMENTS” Section.) 2. Remove fender deck. (See ‘FENDER DECK REMOVAL AND INSTALLATION’ on page 9. in "MISCELLANEOUS" section.) 3. Engage park brake to release tension on traction drive belt.

Extended Hub M89781

10. If flat idler is removed, components must be replaced in correct order. Counterbore in one end of spacer must be against the frame. Extended hub on flat idler must face toward belt guard and belt guard must be on frame side of flat idler. 11. Cycle park brake several times and check alignment of mark and rod with park brake disengaged. Adjust flat idler and belt guide as necessary until alignment is correct.

Lock Nut Washer

M99753

5. Remove lock nut, washer and transaxle cooling fan. 6. Remove sheave from transaxle input shaft. Slip traction drive belt off of sheave, and move aside. 7. Release park brake.

NOTE: When removing transaxle, rear of tractor must be supported by the frame. 8. Raise rear of tractor and support on suitable stands by the frame.

6 - 44

3/7/00

TRANSAXLE REMOVAL AND INSTALLATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Control Rod Cotter Pin and Washer E-Clip and Washer

Bushing

Control Lever

M99755 M89747

14. Remove cotter pin and washer connecting control rod to control lever. 9. Remove dust cover from both rear axles. 10. Remove E-clip and washer. 11. Slide rear wheels and hubs off of axles.

NOTE: Inspect bushing on control rod end. Replace if missing, or damaged, or badly worn.

Bracket Cap Screws and Lock Nuts

M99752

12. Remove thrust washer from both axle shafts. M99756

Brake Rod

15. Remove two cap screws and lock nuts, and disconnect reservoir bracket from tractor frame.

Washer Cotter Pin

Cotter Pin

Brake Lever

Rod M99754

13. On LH side of tractor, remove cotter pin and washer, and disconnect brake rod from transaxle brake lever.

M99761

16. Remove cotter pin and disconnect freewheeling control rod from transaxle lever. Remove rod. 3/7/00

6 - 45

TRANSAXLE REMOVAL AND INSTALLATION

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Belt Guide

Cap Screw Cap Screws

M99759

Nut M99757

17. On LH side of tractor, remove cap screw and nut attaching transaxle and belt guide to angle bracket. Nuts Belt Guide Cap Screw M99760

Nut

M99758

18. On RH side of tractor, remove cap screw and nut attaching transaxle and belt guide to angle bracket. Remove belt guide. 19. Support transaxle using a suitable transmission or floor jack.

20. Remove four cap screws and nuts attaching transaxle to tractor frame. 21. Lower transaxle slightly and disconnect control rod from control lever. 22. Remove transaxle from tractor. Use care when removing to avoid damage to reservoir bottle and hose. Installation: 1. Place transaxle on a suitable transmission or floor jack, and raise into position below tractor frame.

Bushing

Control Rod

M99804

2. Check control rod to make sure bushing is in place on rod end. Connect forward/reverse control rod to transaxle control lever.

6 - 46

3/7/00

TRANSAXLE REMOVAL AND INSTALLATION

POWER TRAIN—HYDROSTATIC

Belt Guide

Cap Screw Cap Screws

M99759

Nut M99757

5. On LH side of tractor, install cap screw and nut attaching transaxle and belt guide to angle bracket. Tighten to 40 N•m (30 lb-ft). Nuts Cotter Pin Rod

M99760

3. Install transaxle onto four cap screws attaching transaxle to tractor frame. Retain with four nuts. Tighten to 40 N•m (30 lb-ft). M99761

Belt Guide Cap Screw

6. Install freewheeling control rod through rear of tractor frame and to transaxle lever. Retain with cotter pin.

Bracket

Nut

Cap Screws and Lock Nuts

M99758

4. On RH side of tractor, install belt guide. Install cap screw and nut attaching transaxle and belt guide to angle bracket. Tighten to 40 N•m (30 lb-ft). Reservoir M99756

7. Attach reservoir mounting bracket to tractor frame. Retain with two cap screws and lock nuts.

3/7/00

6 - 47

TRANSAXLE REMOVAL AND INSTALLATION

POWER TRAIN—HYDROSTATIC

Control Rod Cotter Pin and Washer

Bushing

E-Clip and Washer

M99755 M89747

8. Inspect control rod to ensure bushing is in place on rod end. 9. Install washer and cotter pin to retain forward/ reverse control rod to transaxle control lever.

Brake Rod

12. Slide rear wheels and hubs onto axles. 13. Install washer and E-clip to both rear axles. 14. Install dust covers. 15. Engage park brake to release tension on traction drive belt.

Washer Cotter Pin Lock Nut

Brake Lever

Washer M99754

10. Attach transaxle brake rod to brake lever. Retain with washer and cotter pin. M99753

16. Slip traction drive belt onto sheave. Install sheave to transaxle input shaft. 17. Check belt on underside of tractor to ensure proper belt routing. 18. Install transaxle cooling fan. Retain with washer and lock nut. M99752

11. Install thrust washer to both axle shafts.

6 - 48

2048 Tractors (K62 transaxle): • Locate and remove fill plug on top of transaxle. This plug will fill the differential gear side. Add approximately 1.25 L (1.3 qt) of 5W30 oil. When oil is at bottom of threads in filler, install and tighten fill plug. • Remove filler cap on reservoir bottle. The reservoir bottle tube will fill the hydrostatic transmission side. Add approximately 1.65 L (1.75 qt) of 5W30 oil. When oil reaches FULL line on reservoir bottle, install and tighten filler cap. 3/7/00

POWER TRAIN—HYDROSTATIC

TRANSAXLE REMOVAL AND INSTALLATION

NOTE: For further information on transmission oil, see “HYDROSTATIC TRANSMISSION OIL” in the Specifications section. Filler Cap

2554 Tractors (K66 transaxle): • Locate and remove fill plug on top of transaxle. This plug will fill the differential gear side. Add approximately 1.25 L (1.3 qt) of 5W50 Synthetic oil. When oil is at bottom of threads in filler, install and tighten fill plug. • Remove filler cap on reservoir bottle. The reservoir bottle tube will fill the hydrostatic transmission side. Add approximately 1.65 L (1.75 qt) of 5W50 Synthetic oil. When oil reaches FULL line on reservoir bottle, install and tighten filler cap.

M99764

Full Line

c CAUTION Gasoline vapor is explosive. Serious personal injury may result if gasoline vapor is ignited by a spark or open flame. Keep gasoline away from all sources of ignition, including pilot lights. DO NOT SMOKE. 19. Install fuel tank to tractor frame. 20. Install fender deck. (See ‘FENDER DECK REMOVAL AND INSTALLATION’ on page 9. in "MISCELLANEOUS" section.) 21. Raise rear of tractor and remove stands. 22. Lower tractor to the ground.

NOTE: Due to internal filters and baffles, it is necessary to fill the transaxle though the fill tube and the overflow reservoir tube. Total transaxle capacity is approximately 2.5 L (2.7 qt).

Add Line M99765

27. Park tractor on a level surface. Stop engine and check oil level in reservoir bottle. Add oil if needed to bring level up to FULL line. 28. Start engine and release park brake. If tractor moves with engine running and hydrostatic control in neutral, perform neutral creep adjustment. (See “NEUTRAL CREEP ADJUSTMENT” on page 40.) 29. Install mower deck. (See "MOWER DECK REMOVAL/INSTALLATION" for the appropriate mower deck in the "ATTACHMENTS" section.)

NOTE: For further information on transmission oil, see “HYDROSTATIC TRANSMISSION OIL” in the Specifications section. 23. If not already done, install seat. 24. Perform transaxle bleeding procedure. (See “HYDROSTATIC TRANSAXLE BLEEDING PROCEDURE” on page 40.) 25. Start engine; disengage park brake and drive tractor forward and backward. 26. Check for oil leaks.

3/7/00

6 - 49

TRANSAXLE DISASSEMBLY

POWER TRAIN—HYDROSTATIC

TRANSAXLE DISASSEMBLY CASE DISASSEMBLY Procedure: 1. Remove transaxle from tractor. (See “TRANSAXLE REMOVAL AND INSTALLATION” on page 44.) 2. Thoroughly clean outside surface of transaxle.

NOTE: Capacity of the transaxle is approximately 2.5 L (2.7 qt). Have a suitable container ready before removing drain plugs.

M99762

Drain Bolts

M94895

4. Loosen fill cap on reservoir bottle, and fill plug on transmission case to allow air to enter the transmission case and speed oil drainage. 5. Loosen clamp and remove reservoir bottle.

3. Remove two drain bolts on bottom of transaxle. Drain transaxle oil into a suitable container.

NOTE: Replace two seal washers on drain bolts before installing.

Tab

M99781

6. Using two small screwdrivers, pry gently on clip until tab is free of groove in pin.

6 - 50

3/7/00

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Clip

(K66 Only)

M95344

11. (K66) Remove spring from top of charge pump. Clip

M99763

(K62 Shown)

7. Remove two clips from shock absorber. Remove shock absorber. 8. Turn transaxle over and support it with blocks. 9. Remove five bolts and 12 screws securing lower case to upper case. Remove lower case from transaxle.

M94898

12. Remove reduction gear assembly from upper case.

NOTE: K66 reduction gear assembly contains two needle bearings. Disassemble shaft and gears, and inspect bearings for wear or damage. Be sure bearing cages are in good condition. Replace parts as needed.

Oil Filter (K62 Shown)

M94897

NOTE: Large filter may stay with lower case half when case halves are separated.

(K62 Shown)

10. Remove oil filters from transaxle. Inspect oil filters and replace if needed.

M94899

3/7/00

6 - 51

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

13. Remove thrust washer from left hand and right hand axles.

17. Measure OD of both axle shafts. If axle is smaller than specification, replace axle. 18. Measure ID of bushings. If bushing(s) ID is larger than specification, replace bushing(s). Specifications: Bushing ID . . . . 25.381-25.525 mm (0.999-1.005 in.) Axle OD . . . . . . . 25.301-25.355 mm (0.996-0.998 in.) Clearance (Maximum) . . . . . . . . . 0.5 mm (0.020 in.)

NOTE: Replace axle shaft seals with new seals when assembling transaxle. M94908

19. Remove the two axle seals from upper case. Measure ID of bushings press fit into case.

NOTE: To remove the C-rings, pull the axles slightly out of the case.

Bushing

14. Remove C-ring from left hand and right hand axles.

(K62 Shown) M94911

20. If bushing(s) ID measurement is larger than specification, replace bushing(s). Specification: M94909

Bushing ID . . . . 25.505-25.585 mm (1.004-1.007 in.)

15. Remove differential gear assembly.

Bushings

M94912

Collar

(K62 Shown)

M94910

16. Remove both axle shafts, collar, and bushings.

6 - 52

21. Inspect differential gear assembly for wear or damage. Replace as needed. 22. Measure ID of differential pinion gears and OD of differential pinion shaft. Replace if measurements do not meet specifications.

3/7/00

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Specifications: Pinion Gear ID . . . 15.03-15.13 mm (0.592-0.597 in.) Pinion Shaft OD . . . . . . . . . . . . . . 14.904-14.984 mm (0.587-0.590 in.) Clearance (maximum) . . . . . . . . . 0.5 mm (0.020 in.)

Check Valve

(K62 Shown)

Charge Pump Case

M95460

3. Inspect check valve in charge pump case. Check that ball is in valve cage and moves freely. Clean or replace parts as needed. M94934

23. Inspect reduction gear assembly for wear or damage. Replace as needed. 24. Measure ID of reduction pinion gear and OD of reduction shaft. Replace shaft and/or gear if measurements do not meet specifications.

Outer Rotor M95358

Specifications: Reduction Pinion Gear ID . . . . . . . . . . . . 15.044-15.174 mm (0.592-0.597 in.) Reduction Shaft OD . . . . . . . . . . . . 14.954-14.984 mm (0.589-0.560 in.) Clearance (Maximum) . . . . . . . . . 0.5 mm (0.020 in.)

4. Remove outer rotor.

CHARGE PUMP REMOVAL (K66) Procedure: Inner Rotor

M95359

5. Remove inner rotor.

Charge Pump Case

M95357

1. If not already done, remove spring from top of charge pump case. 2. Remove charge pump case.

3/7/00

6 - 53

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

(K62 Shown) Swash Plate

Cylinder Blocks

M95360 M94914

6. Remove pin. 3. Press brake disk, swash plate and cylinder block against the center case and remove as a single unit. Set assembly on a clean lint free cloth or surface.

CENTER CASE REMOVAL Procedure:

(K62 Shown)

NOTE: When separating cylinder block from center case, freewheeling pin and thrust washer may fall out. 4. Separate cylinder block from center case. 5. Remove thrust washer and freewheeling pin from center case.

Cap Screws

M94913

1. Before removing center case assembly, note position and orientation of swash plate. 2. Remove three cap screws securing center case assembly to transaxle case. IMPORTANT: When removing center case assembly, be careful to avoid scratching or damaging mating surfaces of center case and cylinder blocks.

M94916

6. Slide cylinder block off of brake shaft. 7. Remove pistons and inspect springs and piston holes for wear or damage. Inspect cylinder block mating surface for damage or scratches.

NOTE: If any parts of the cylinder block assembly need to be replaced, replace center case and both cylinder blocks at the same time. 8. Remove brake disk and shaft from swash plate.

6 - 54

3/7/00

TRANSAXLE DISASSEMBLY

POWER TRAIN—HYDROSTATIC

Thrust Bearing

M94917 M94919

9. Inspect swash plate and thrust bearing for wear or damage. Check that all ball bearings move freely and that swash plate and housing bearing contact surfaces are in good condition. 10. Inspect brake shaft bearing for wear or damage. Replace as needed.

NOTE: When removing the cylinder block, use care to prevent the pistons from falling out and being damaged. 13. Remove the cylinder block from upper case.

M94918 M94920

11. To remove brake shaft bearing: • Remove C-clips securing gear and bearing • Remove gear and bearing

14. Remove pistons and inspect springs and piston holes for wear or damage. Inspect cylinder block mating surface for damage or scratches.

Shim

M94915 M94921

12. Remove outer brake shoe and shim from case. Note that convex side of brake shoe faces shim and outer side of case.

3/7/00

15. Remove swash plate sub assembly from upper case.

6 - 55

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CENTER CASE DISASSEMBLY Procedure:

Plug Mating Surfaces

M94922 M94937

16. Inspect swash plate, thrust bearing, thrust plate and bushing for wear or damage. Replace as needed.

Thrust Plates

1. Inspect center case mating surfaces. If scratches can be detected by feel (either finger nail or lead pencil), replace center case, pump and motor cylinder blocks at the same time. 2. Remove plug from center case. Inspect O-ring for scratches or deformation. Lubricate plug with clean oil and reinstall.

Mating Surface M94923

17. Remove thrust plates. Inspect plates for wear or damage. Measure thrust plate thickness. Replace thrust plates as a set if either one or both do not meet specification.

Spring Pins

Specification: Thrust Plate Thickness . . . . . . . . . . . . . . . . 1.45-1.55 mm (0.057-0.061 in.) Wear Limit. . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)

(K66 Only)

M95459

3. (K66 Only) Inspect center case to charge pump mating surface. If deep scoring or damage is present, replace center case, charge pump, motor, and drive pump cylinder blocks at the same time.

6 - 56

3/7/00

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Snap Ring

M99778 M94938

4. Remove valve assemblies from center case and inspect surfaces for wear or scratches. Inspect plunger assemblies for smooth operation, damage, broken springs, or dirt build-up. Clean or replace as needed.

3. Remove snap ring from case.

PUMP SHAFT REMOVAL Procedure: 1. Turn the upper case over and inspect the pump shaft and shaft seal.

NOTE: If the shaft turns freely and the oil seal is not leaking, there is no need to remove the pump shaft.

M99777

4. Remove pump shaft and bearing assembly from case.

Snap Ring

M94926

M94924A

2. Pry out and remove oil seal from pump shaft.

NOTE: Replace seal for installation.

5. Remove snap ring from each side of bearing and press bearing off of shaft.

NOTE: Before installing bearing to shaft, lightly coat shaft and inside of bearing with grease. Before installing a new seal, lightly coat inside lip and outside of oil seal with clean fresh transmission oil. Installation is done in the reverse order of removal.

3/7/00

6 - 57

TRANSAXLE DISASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CONTROL SHAFT REMOVAL

4. Remove snap ring from control shaft. Remove washer, collar and torsion spring.

Procedure:

Control Shaft Seal Fulcrum (Eccentric)

Roll Pin

M94931 M94928

1. Remove roll pin from control arm, and remove control arm from control shaft.

5. Replace control shaft seal before installing control arm assembly.

Snap Ring

Nut

Spring

M94933 M94929

2. Turn the case over and slide the control arm assembly out of case.

Snap Ring

6. Remove snap ring from freewheeling shaft. Remove spring. Remove freewheeling shaft from case. 7. Inspect freewheeling shaft O-rings for damage or deformation. Replace as needed.

Eccentric Washer Collar

Control Arm Pin

O-Rings M94930

3. To remove spring from assembly, firmly clamp the end of the torsion spring (closest to arm) in a bench vise. Firmly clamp the other end of the spring with a locking pliers and lift end over control arm pin.

6 - 58

M94932

8. Remove nut securing eccentric. Remove washer. 9. Remove fulcrum from case and inspect. Remove Orings from case.

3/7/00

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

NOTE: Before installation, lightly coat control shaft seal and O-rings with grease. Lightly coat all other parts with clean fresh transmission oil.

TRANSAXLE ASSEMBLY Procedure:

BRAKE SHAFT REMOVAL NOTE: During assembly, coat all parts with clean fresh oil. Procedure: 1. Clean case half mating surfaces of any old sealant. Clean case halves with a suitable solvent and dry with compressed air.

Flat Side of Brake Shaft Spring Roll Pin

M99776

1. Disconnect spring from brake arm. 2. Drive roll pin out of brake arm and shaft. Remove brake arm.

M94936

2. Apply a light coat of grease to the brake shaft hole in the upper case. Turn flat side of brake shaft to position shown. 3. If removed, install washer and snap ring to brake shaft.

Flat Side of Brake Shaft

M94936

Spring Roll Pin

3. Turn case over and note position of flat side of brake shaft. 4. Remove brake shaft from case. Inspect O-ring for damage or deformation. Replace as needed.

M99776

4. Lightly coat a new O-ring with grease and install onto brake shaft. 5. Install spring over shaft and onto case. Do not install to arm at this time. 6. Install brake arm to shaft. Retain with roll pin. 7. Tension spring and attach end to brake arm.

3/7/00

6 - 59

TRANSAXLE ASSEMBLY

POWER TRAIN—HYDROSTATIC

12. If removed, install freewheeling arm to freewheeling shaft and secure with roll pin. 13. Lightly grease new O-rings and install on freewheeling shaft. 14. Apply a light coat of grease to the freewheeling shaft hole in the upper case. Install freewheeling shaft.

Eccentric

O-Rings M94932

8. Apply a light coat of grease to the eccentric and install in case. 9. Lightly coat a new O-rings with grease and install to eccentric.

Snap Ring

Spring M94933

15. Place spring on freewheeling shaft. Install snap ring.

Nut Snap Ring Washer Collar M94931

Control Arm Pin

10. Install washer and nut on eccentric. 11. While holding the fulcrum with a wrench, tighten nut to specification. Specification: Eccentric Nut Torque . . 24.5 – 32 N•m (18 – 24 lb-ft)

M94930

16. Install spring, collar and washer on control arm. 17. Install snap ring. 18. Secure end of spring (closest to control arm) in a vise. Using a locking pliers, tension spring and hook other end of spring over control arm pin.

Snap Ring

Spring M94933

6 - 60

3/7/00

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

Seal

M94929

19. Install a new control arm seal in the case. Apply a light coat of grease to the inside of the seal. 20. Apply a light coat of grease to the control arm shaft hole in the upper case. 21. Install control arm assembly. Make sure the ends of the spring are on either side of the eccentric shaft.

Roll Pin

M99777

24. Install pump shaft and bearing assembly in case.

M99778 M94928

22. Install control arm on the control shaft. Install roll pin.

25. Install snap ring into case. Ensure snap ring is fully seated in groove. 26. Apply grease to the lip of a new seal. Cover the splines of the pump shaft with tape to avoid damage to the new seal.

Snap Ring

M94927

23. Install bearing and two snap rings on the pump shaft. M94924A

27. Install seal on pump shaft and seat seal fully in case.

3/7/00

6 - 61

TRANSAXLE ASSEMBLY

POWER TRAIN—HYDROSTATIC

NOTE: Swash plate notch installs toward control arm assembly and mates with shift block.

Thrust Plates

M94923

31. Install swash plate assembly in upper case. Ensure swash plate seats fully. 32. Measure space between the swash plate and shift block. If measurement does not meet specification, replace swash plate and/or shift block. Swash Plate/Shift Block Clearance Standard . . . . 0.01 – 0.11 mm (0.0004 – 0.004 in.) Wear Limit . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)

28. Coat the thrust plates with fresh oil. Install and seat thrust plates in case.

Thrust Plate (Thick)

M94919

Thrust Plate (Thin) M94922

29. Coat all parts of swash plate assembly with clean transmission oil before installation.

NOTE: Thinner thrust plate installs in swash plate first.

33. Coat cylinder block, springs and pistons with oil.

NOTE: Pistons can be installed in any cylinder block hole. 34. Assemble cylinder block, springs and pistons. 35. Install cylinder block assembly over pump shaft. Use care to prevent pistons from falling out. After piston block assembly is installed, push down on assembly to ensure freedom of movement of all pistons.

30. Install thin thrust plate, bearing and thick thrust plate into swash plate.

Notch

M94918

M94921

6 - 62

36. If disassembled, install bearing and gear on motor shaft. Secure with E-clips.

3/7/00

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

NOTE: Pistons can be installed in any cylinder block hole. Thrust Bearing

43. Assemble motor cylinder block, springs and pistons.

NOTE: Flat side of brake disk installs toward swash plate as shown.

M94917

37. Install thrust bearing and plate in swash plate.

M94916

44. Install motor shaft through swash plate. Install brake disk onto motor shaft.

Valve Assembly M94938

38. Coat valve assemblies with oil and install into center case. 39. If removed, coat plug with oil and install into center case.

NOTE: When installing motor cylinder on motor shaft, be sure splines on shaft seat properly in motor cylinder block bore. 45. Place motor cylinder block assembly over motor shaft. (K62 Shown) Swash Plate

Cylinder Blocks Washer

Freewheeling Pin M94914

Plug

M95058

40. Apply grease to freewheeling pin to hold it in place and install in center case. 41. Apply grease to thrust washer to hold it in place. Place washer into recess in center case. 42. Coat motor cylinder block, springs and pistons with clean, fresh oil.

3/7/00

IMPORTANT: Be careful to correctly orient swash plate. If swash plate is installed upside down the transmission will work in reverse.

6 - 63

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

51. Turn the brake disk and input shaft by hand to ensure that all rotating groups turn freely. If necessary, use the drive sheave to ease turning of pump by hand.

Bottom of Transaxle

Top of Transaxle

IMPORTANT: When installing center case assembly, be careful to avoid scratching or damaging mating surfaces of center case and cylinder blocks. 46. Press brake disk, swash plate and cylinder block against the center case and compress motor pistons into cylinder block. 47. Carefully set assembly into transmission case. Ensure assembly seats fully with alignment pins and motor shaft bearing seated properly in upper transaxle case half. Cap Screws

M95059

52. Install new axle seals. Press seals into case until fully seated. 53. Apply grease to inner lip of seals to help avoid damage when installing axles. Apply tape to axle splines before installing axles to help avoid damage to seals. 54. Install longer axle through seal, case and bushing.

(K62 Shown)

Bushings

Collar

M94910 M94913

48. Install three cap screws securing center case assembly to transaxle case. 49. Operate freewheeling lever to ensure that freewheeling pin has not been dislodged while installing center case and motor assemblies. If motor cylinder block does not move away from center case when operating lever, remove center case, and inspect freewheeling pin. 50. Tighten cap screws to specification. DO NOT FORCE. If cap screws are hard to tighten, STOP. Damage can result.

55. Install collar on axle. Do not insert axle fully. 56. Install bushing for shorter axle. 57. Install axle though seal, case and bushing. Do not insert axle fully. 58. Install differential bevel gears onto axles. Slide axles slightly toward each other to set bevel gears on axle splines.

Specification: Cap Screw Torque . . . . . . . . . . . . . . 43 Nâ&#x20AC;˘m (32 lb-ft)

6 - 64

3/7/00

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

M94909

59. Assemble differential gear assembly and set between axles. 60. Rotate differential gears and axles until all gears mesh.

M94898

64. Install reduction gear assembly in upper case. Rotate gears if needed to fully seat gear assembly. IMPORTANT: Note flat on outer end of reduction shaft. Flat surface must be fully seated in upper case, and flat surface must be 90Â° to case mating surfaces to allow seating of lower case on upper case.

0.8-1.3 mm (0.03-0.05 in.)

M94908

Shim(s)

61. Install C-ring on each axle. 62. Push axles fully into transaxle case. Rotate differential gear to assure freedom of movement. 65. Install brake shoe. Measure distance between brake shoe and brake disk. Shim brake shoe to set clearance to specification. Specification: Clearance . . . . . . . . . . . . . 0.8-1.3 mm (0.03-0.05 in.)

NOTE: Shim set includes 0.3 mm (0.01 in.) shim and 0.5 mm (0.02 in.) shim. M94899

63. Install thrust washer on left hand and right hand axles.

3/7/00

6 - 65

TRANSAXLE ASSEMBLY

POWER TRAINâ&#x20AC;&#x201D;HYDROSTATIC

CHARGE PUMP INSTALLATION (K66 ONLY) Procedure:

M95360

1. Install pin into hole in motor shaft.

M95357

IMPORTANT: Be sure charge pump case is installed with openings in direction shown. 4. Install charge pump case. 5. Install charge pump spring.

CASE ASSEMBLY

M95359

2. Install inner rotor. M94897

1. Install oil filters.

NOTE: When applying sealant to mating surfaces, be sure bead extends through web between gear section and hydrostatic transaxle (pump/motor) section. M95358

3. Install outer rotor.

6 - 66

2. Install a bead of sealant on mating surfaces of lower case. Use care to ensure an even bead that extends around all bolt and cap screw holes. 3. Place lower case on upper case. Ensure cases fully seat without having to use force.

3/7/00

TRANSAXLE ASSEMBLY

POWER TRAIN—HYDROSTATIC

4. Install twelve cap screws and five bolts. Tighten cap screws and bolts to specification. Specification: Cap Screw Torque Same Case . . . . . . . . . . . . . . . . . . 24 N•m (17 lb-ft) New Case . . . . . . . . . . . . . . . . . . . 29 N•m (21 lb-ft) Bolt Torque . . . . . . . . . . . . . . . . . . 26.5 N•m (19 lb-ft)

Drain Bolts

Clip

M94895

NOTE: Install new seal washers on drain bolts before installing. 6. Install oil drain bolts with new seal washers into transaxle. Tighten to specification. Specification: Drain Bolt Torque . . . . . . . . . . . 14.7 N•m (130 lb-in.) Clip

M99763

M99782

NOTE: Inspect clips that retain shock absorber. If clips are damaged or deformed, replace. 5. If removed, install clips to each end of shock absorber. Install shock absorber onto pins on transaxle. Gently squeeze clip as shown until flange of clip seats in groove of pin with an audible click. Pull on shock absorber to ensure that clips will firmly retain shock absorber to transaxle.

3/7/00

M99762

7. Attach reservoir bottle, bracket, and hose to transmission. Secure with hose clamp.

6 - 67

TRACTION DRIVE BELT REMOVAL AND INSTALLATION NOTE: Total transaxle capacity is approximately 2.5 L (2.7 qt). Due to internal filters and baffles, it is necessary to complete filling the transaxle though the fill tube and the overflow reservoir tube. 2048 Tractors (K62 transaxle): • Locate and remove fill plug on top of transaxle. This plug will fill the differential gear side. Add approximately 1.25 L (1.3 qt) of 5W30 oil. When oil is at bottom of threads in filler, install and tighten fill plug. • Remove filler cap on reservoir bottle. The reservoir bottle tube will fill the hydrostatic transmission side. Add approximately 1.65 L (1.75 qt) of 5W30 oil. When oil reaches FULL line on reservoir bottle, install and tighten filler cap.

POWER TRAIN—HYDROSTATIC

Lock Nut

NOTE: For further information on transmission oil, see “HYDROSTATIC TRANSMISSION OIL” in the Specifications section.

Washer

M99753

5. Remove lock nut, washer and transaxle cooling fan. 6. Remove sheave from transaxle input shaft. Slip traction drive belt off of sheave.

Belt Guide

NOTE: For further information on transmission oil, see “HYDROSTATIC TRANSMISSION OIL” in the Specifications section.

Spacer

TRACTION DRIVE BELT REMOVAL AND INSTALLATION 1. Remove mower deck. (See “MOWER DECK REMOVAL/INSTALLATION” for the appropriate mower deck in the “ATTACHMENTS” Section.) 2. Remove fender deck. (See ‘FENDER DECK REMOVAL AND INSTALLATION’ on page 9. in "MISCELLANEOUS" section.) 3. Engage park brake to release tension on traction drive belt.

6 - 68

M99783

7. On underside of tractor, locate and remove nut on flat idler sheave. Remove flat idler, belt guide, and spacer.

3/7/00

DRIVE BELT TENSIONER ASSEMBLY

POWER TRAIN—HYDROSTATIC

Installation: Installation is the reverse of removal. Counterbore

Spacer

Belt Guide

Nut

M99783

8. Remove nut retaining belt guide to V-idler. Remove belt guide.

Extended Hub M89781

Lock Nut

M99784

9. On left front of tractor, locate steering arm and drag link. Remove lock nut, and disconnect drag link from steering arm.

• When reinstalling flat idler, components must be replaced in correct order. Counterbore in one end of spacer must be against the frame. Extended hub on flat idler must face toward belt guard and belt guard must be on frame side of flat idler. • After installation is complete, perform traction drive belt tension adjustment. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 42.)

DRIVE BELT TENSIONER ASSEMBLY Removal: 1. Remove mower deck. (See “MOWER DECK REMOVAL/INSTALLATION” for the appropriate mower deck in the “ATTACHMENTS” Section.) 2. Remove fender deck. (See ‘FENDER DECK REMOVAL AND INSTALLATION’ on page 9. in "MISCELLANEOUS" section.) 3. Engage park brake to release tension on traction drive belt.

Nut Belt Guide

M99786

10. Disconnect PTO clutch electrical connector. 11. Loosen nut on belt guide. 12. Slip traction drive belt off of engine sheave, and past belt guide. Remove belt from tractor.

3/7/00

6 - 69

DRIVE BELT TENSIONER ASSEMBLY

POWER TRAIN—HYDROSTATIC

Front

Lock Nut Tensioning Spring/Boot

Washer

V-Idler

M99753

Belt Tensioner Assembly

5. Remove lock nut, washer and transaxle cooling fan. 6. Remove sheave from transaxle input shaft. Slip traction drive belt off of sheave, and move aside.

Belt Guide M83385A

Nut

M99783

7. On underside of tractor, locate and remove nut retaining belt guide to V-idler. Remove belt guide. 8. Slip traction drive belt off of V-idler sheave. 9. Release park brake to reduce spring tension on idler assembly.

c CAUTION Tensioned Spring. Wear gloves and a face shield when removing spring to reduce the risk of personal injury.

6 - 70

10. Using a suitable spring puller, disconnect tensioning spring from belt tensioner assembly. 11. Remove nut retaining belt tensioner assembly to tractor frame. 12. Remove belt tensioner assembly. 13. Inspect bushings, spacer, washer and pivot cap screw for wear or damage. Replace parts as needed. Installation: Installation is the reverse of removal. • If V-idler is removed from tensioner assembly, install with carriage bolt all the way to the front in its slot. • After installation is complete, perform traction drive belt tension adjustment. (See “TRACTION DRIVE BELT TENSION ADJUSTMENT” on page 42.)

3/7/00

CONTENTS

STEERING

CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STEERING SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . 5 STEERING SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DRAG LINK ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STEERING WHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7 STEERING SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STEERING SECTOR REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LEFT TURN STOP MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3/3/00

7-1

NOTES

7-2

STEERING

3/3/00

STEERING

SPECIFICATIONS Torque Specifications: Spindle assembly lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N•m (40 lb-ft) Front wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ± 10 N•m (65 ±7 lb-ft) Tie rod Lock nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 N•m (37 lb-ft) Jam nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 N•m (52 lb-ft) Steering wheel nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Snug Only Lubrication Interval: Spindle grease fitting and kingpin . . . . . . . . . . . . . . Every 25 hours (severe conditions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Every 50 hours (normal conditions) Toe-In Adjustment: Front-to-rear difference . . . . . . . . . . . . front is 4 ± 3 mm (0.16 ± 0.12 in.) less than rear

3/7/00

7-3

STEERING SYSTEM

STEERING

THEORY OF OPERATION

As the steering wheel is turned, the steering shaft and gear rotate. The steering gear meshes with the sector gear, causing the sector gear and steering arm to rotate.

STEERING SYSTEM Function: To allow the operator to change machine travel direction.

As the steering arm moves, the drag link is moved (forward – left turn, backward – right turn) causing the left spindle to rotate. Since the spindles are connected by the tie rod both spindles are turned at the same time.

Theory of Operation: Steering Wheel

Upper Bearing Fastening Hardware

Steering Shaft

Lower Bearing Gear and Sector Assembly Stop Bushing Adjustment Ball Joint Drag Link

Bearings Steering Arm

Tie Rod

Spindle Beam Axle Assembly

M82724AE

7-4

3/7/00

STEERING SYSTEM TROUBLESHOOTING CHART

STEERING

TROUBLESHOOTING

Steering wheel loose on column.

●

Steering linkage loose or worn.

●

Gear and/or sector teeth worn or damaged.

●

Tie rod bent. Enlarge stop post.

3/7/00

Left wheel contacts drag arm in extreme left turn.

Wheels won’t track straight.

● ●

Drag link out of adjustment. Tie rod ends worn.

Steering wheel turns further in one direction.

Check or Solution

Steering wander.

Problem or Symptom

Lash (lost motion) at steering wheel.

STEERING SYSTEM TROUBLESHOOTING CHART

●

● ● ●

7-5

STEERING SYSTEM DIAGNOSIS

STEERING

STEERING SYSTEM DIAGNOSIS NOTE: Before checking for a steering problem, make sure that tire inflation is correct, front ballast is not excessive, and/or front implement is properly installed. Test Conditions: • Machine parked on a level surface. • Parking brake ENGAGED. • Front axle raised safely off ground. • Key switch in OFF position. Test/Check Point

Normal

If Not Normal

1. Front wheel bushings

Wheels rotate freely without feeling rough spots.

Check front wheel bushings and lubrication.

2. Spindles

Spindles move freely without feeling rough spots.

Check axle spindle holes and lubrication.

3. Axle pivot

Not binding, damaged, or worn. beam axle rotates freely.

Adjust drag link. Check bearings in center of beam axle.

4. Tie rod

Not binding, damaged, bent, or worn.

Replace tie rod.

5. Gear and sector assembly

Teeth not worn or damaged. Not binding.

Replace gear and sector assembly. Check bearings.

6. Drag link and steering arm

Not binding, damaged or worn.

Replace linkage.

5 3 4

2 2 1

3 M82824AE

7-6

3/7/00

DRAG LINK ADJUSTMENT

STEERING

DRAG LINK ADJUSTMENT

REPAIR

Reason:

STEERING WHEEL REMOVAL AND INSTALLATION

To adjust the steering linkage so that wheels are straight ahead. Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Set gear selector to NEUTRAL. On Hydrostatic models move forward/reverse pedals to NEUTRAL position. 4. Engage parking brake. 5. Disconnect drag link ball joint (A). 6. Align sector gear mark (B) with pinion gear mark (C). 7. Put wheels in straight forward position. 8. Loosen nut (D). Turn drag link ball joint until stud aligns with the hole in the steering arm (E). Tighten nut (D). 9. Connect drag link ball joint (A). Tighten nut to 30 N•m (22 lb-ft.). 10. Turn steering wheel to the full left position and check that the sector gear contacts the stop before the tie rod hits the axle. 11. Repeat check for full right turn. Adjust drag link slightly if tie rod contacts axle.

1. Remove nut securing shoulder bolt in steering hub. 2. Drive shoulder bolt from steering hub. 3. Remove steering wheel. Installation is done in the reverse order of removal.

Shoulder Bolt

M54651

STEERING SHAFT Removal: 1. Remove the mower deck. 2. Remove steering wheel. (See “STEERING WHEEL REMOVAL AND INSTALLATION” on page 7.) 3. Disconnect terminals from battery and remove battery from frame.

NOTE: Turn steering shaft to gain clearance to cotter pin.

B E D

M82724AE

A. Ball Joint B. Alignment Mark (Sector Gear) C. Alignment Mark (Pinion Gear) D. Nut Arm 3/7/00

7-7

STEERING SHAFT

STEERING

Snap Ring Bushing Steering Shaft

Cotter Pin

Cotter Pin M M80832

Washer

K - Sector Gear Alignment Mark

Support

L - Pinion Gear Alignment Mark M - Steering Shaft Alignment Mark Bushing Washer Pinion Gear

• Check that front wheels are straight and alignment mark (K) is centered with steering shaft. • When installing pinion gear, align marks (K, L and M).

M80830

4. Remove cotter pins. 5. Remove gear and washers. 6. Loosen four instrument panel mounting cap screws.

NOTE: Some force is required for the snap ring to pass through panel. 7. Remove shaft through top of the instrument panel.

NOTE: Bushings are slip fit. Inspection: Inspect all parts for wear or damage. Replace parts as necessary. • If gear requires replacement, also replace steering sector gear. • If support requires replacement, remove steering sector assembly. Installation: Installation is done in the reverse order of removal.

7-8

3/7/00

STEERING SECTOR REMOVAL & INSTALLATION

STEERING

STEERING SECTOR REMOVAL & INSTALLATION

Washers

Bushing (2 used)

Sector Gear Nut Stop Bushing Support Housing Cap Screw Sector Shaft Nut

Cotter Pin

Ball Joint Lock Nut Drag Link

Spindle

M80833A

Removal: 1. Remove the mower deck. (See procedure in ATTACHMENTS section.) 2. Remove the battery. 3. Remove the nut securing the ball joint to the sector shaft. Drop ball joint/drag link away from sector shaft arm. 4. Remove cotter pin from sector shaft. Remove washers and sector gear from sector shaft.

Pinion Gear Alignment Mark Steering Shaft Alignment Mark

NOTE: Bushings are slip fit in support housing. M54657A

5. Remove bushings from support housing 6. Inspect all parts for wear or damage. Replace parts as necessary. • If sector gear requires replacement, also replace pinion gear. • If support housing requires replacement, remove steering shaft. (See “STEERING WHEEL REMOVAL AND INSTALLATION” on page 7.)

• When installing sector gear on sector shaft, make sure that marks on sector gear and pinion gear are aligned. Sector shaft should be perpendicular to sector gear, and aimed towards the left side of the vehicle.

Installation: Installation is done in the reverse order of removal.

3/7/00

7-9

LEFT TURN STOP MODIFICATION

STEERING

Sector Gear Alignment Mark Nut Sector Shaft Alignment Mark

Cotter Pin

Bushing

M54658B M79793

• Tighten drag link nuts to 30 N•m (22 lb-ft.). • Adjust drag link. (See “DRAG LINK ADJUSTMENT” on page 7.)

LEFT TURN STOP MODIFICATION IMPORTANT: Before carrying out this procedure check all steering system components to make sure that all parts are in good condition. Especially check drag link and tie rod to make sure they are not bent and that rod ends are not worn.

7. Holding left hand steering stop bolt from beneath the frame, remove nut retaining bushing to steering support. 8. Remove bolt and bushing.

1-#24H1294 Washer

Nut

9-#24H1746 Washers

Reason: Left wheel in contact with drag arm when in extreme left turn. Required Parts:

M79792

Order No.

Qty.

Description

Qty/Pkg

24H1746

1 Pkg.

0.781" ID X 1.125" OD X 0.125 Thick

10/Pkg.

24H1294

1 Pkg.

0.344" ID X 1.125" OD X 0.063 Thick

50/Pkg.

Procedure:

9. Install 9 washers (24H1746) over the top of the bushing. 10. Install 1 washer (24H1294) on top of the bushing and the 9 washers. 11. Place assembled washers and bushing over left stop bolt and insert bolt from the bottom through the assembled washers and bushing. 12. Secure assembly with the nut previously removed.

1. Park machine on level surface. 2. Turn key switch to OFF. 3. Move forward/reverse pedals to NEUTRAL position. or on gear models, set gear selector to neutral. 4. Engage parking brake. 5. Open hood and remove battery. 6. Align wheels so they are pointed straight ahead.

7 - 10

3/7/00

CONTENTS

BRAKES

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

COMPONENT LOCATION AND OPERATION . . . . . . . . . . . . . . . . . . . . . 4 BRAKE SYSTEM OPERATION—GEAR TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . 4 BRAKE SYSTEM OPERATION—HYDROSTATIC TRANSAXLE . . . . . . . . . . . . . . . . 5 HYDROSTATIC INTERNAL BRAKE LINKAGE OPERATION . . . . . . . . . . . . . . . . . . . 6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 BRAKES DO NOT ENGAGE WHEN PEDAL DEPRESSED . . . . . . . . . . . . . . . . . . . . 8 PARK BRAKE DOES NOT HOLD MACHINE ON HILL . . . . . . . . . . . . . . . . . . . . . . . . 8 NOISY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MACHINE WILL NOT MOVE, OR IS SLOW IN FORWARD . . . . . . . . . . . . . . . . . . . . 9 MACHINE WILL NOT MOVE, OR IS SLOW REVERSE . . . . . . . . . . . . . . . . . . . . . . 10 BRAKE SWITCH DOES NOT ENGAGE WHEN BRAKE PEDAL IS DEPRESSED . 10

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 BRAKE ADJUSTMENT—HYDROSTATIC TRANSAXLE . . . . . . . . . . . . . . . . . . . . . 11 BRAKE ADJUSTMENT—GEAR TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BRAKE LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BRAKE PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BRAKE REMOVAL AND INSTALLATION—HYDROSTATIC . . . . . . . . . . . . . . . . . . . 13 BRAKE REMOVAL AND INSTALLATION—GEAR TRANSAXLE . . . . . . . . . . . . . . . 14 PARK BRAKE LEVER AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3/3/00

8-1

NOTES

8-2

BRAKES

3/3/00

SPECIFICATIONS

BRAKES

SPECIFICATIONS ADJUSTMENT SPECIFICATIONS Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm (0.005 in.)

REPAIR SPECIFICATIONS Brake Holder Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 N•m (95 lb-in.)

OTHER MATERIALS Number

Name

Use

TY6431

John Deere LUBRIPLATE Lubricanta

Apply to brake shaft and pins.

a.  LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.

3/7/00

8-3

COMPONENT LOCATION AND OPERATION

BRAKES

COMPONENT LOCATION AND OPERATION BRAKE SYSTEM OPERATIONâ&#x20AC;&#x201D;GEAR TRANSAXLE Brake Pedal

Brake Actuating Spring Return Spring

Brake Rod Disk Brake Cam Lever

Disk Pins

Brake Cam Lever

Pads M83369

Function: To slow down or stop the machine. Theory of Operation: The brake system is mounted on the transaxle. When the brake pedal is depressed, the brake actuating spring assembly moves forward which starts to compress the spring. The spring force pulls the brake rod forward and rotates the brake cam lever at the adjuster nut. There is a cam stamped into the lever.

8-4

The cam forces pins to press against the outer brake pad, which presses the brake disk against the inner brake pad and the friction stops the unit. The brake disk is splined to the shifter shaft. When the brake pedal is released, the return spring pulls the brake linkage to the disengaged position.

3/7/00

BRAKE SYSTEM OPERATIONâ&#x20AC;&#x201D;HYDROSTATIC TRANSAXLE

BRAKES

BRAKE SYSTEM OPERATIONâ&#x20AC;&#x201D;HYDROSTATIC TRANSAXLE

Brake Pedal

Idler Arm Assembly Brake Pedal Shaft

Belt Tension Release Rod

Actuating Arm and Spring Assembly

Brake Control Arm

M83371

Function: To stop machine motion and disengage power from the engine to the transmission. Theory of Operation: When the brake pedal is depressed, it rotates the brake pedal shaft forward. Attached to the shaft is the belt tension release rod. Movement of the shaft is transferred to the rod which engages the end of the slot in the idler arm assembly. Continued movement pulls the left side of the idler arm forward and disengages drive belt tension. Also attached to the brake pedal shaft is the brake actuating arm and spring assembly. Movement of the lever is transferred through the rod to the transmission brake actuator arm to provide braking action. 3/7/00

8-5

HYDROSTATIC INTERNAL BRAKE LINKAGE OPERATION

BRAKES

HYDROSTATIC INTERNAL BRAKE LINKAGE OPERATION Brake Lever

Brake Control Arm

Swash Plate Control Cam Slot Brake Rod Swash Plate Control Cam

Brake Shaft Tab

Swash Plate

Brake Arm

Neutral Return Spring

Freewheel Valve Rod

Brake Shaft

Brake Control Arm

Freewheel Valve Control Arm Brake Spring Assembly Brake Drum

Brake Lever

Brake Cover Brake Band

Actuator

Freewheel Valve Plunger

Brake Lever Lobe

Function: The internal linkage performs multiple functions. First it applies the transaxle brake which is used as a park or emergency brake. Through the same linkage it activates the neutral start switch, which requires the brake be applied in order to crank and start the engine. Along with these two functions, the forward/reverse pedals are locked in place (neutral), and the freewheel valve is deactivated, if it was previously engaged. Theory of Operation: When the brake pedal is applied, the external linkage pulls the brake control arm forward and rotates the brake lever. The motion is transferred to the brake rod, which rotates the brake shaft. The brake shaft protrudes through the top of the case and is attached to the brake arm. As the brake arm rotates, it actuates the brake spring assembly. The brake link assembly allows only a limited amount of force to be applied to the brake band for braking action. The band encompasses the

8-6

M45761

brake drum that is splined to the hydrostatic motor output shaft and this action stops the machine. Without the brake applied, a tab on the brake shaft contacts the neutral start switch and interrupts the current flow in the cranking circuit. When the brake is applied, the tab no longer contacts the switch and the starting circuit can be activated. At the same time, a lobe on the brake lever acts upon the cam slot profile of the swash plate control cam and locks the hydrostatic control linkage in place (neutral). When the hydrostatic freewheel valve is activated, the brake rod is pulled to the end of the slot in the brake lever. When the brake is applied, the rod rotates the freewheel valve shaft and actuator and deactivates the freewheel valve plungers.

3/7/00

TROUBLESHOOTING

BRAKES

Engine can be started without depressing brake pedal.

●

Brake linkage out of adjustment.

●

Belt idler assembly return spring weak or damaged.

●

Brake return spring weak or broken.

●

Brake band damaged or worn.

●

Brake drum damaged or worn.

●

Internal brake actuator lever damaged or worn.

●

Machine is slow in reverse.

●

Park brake engaged.

Machine will not move in forward or is slow in forward.

●

Machine does not achieve full ground speed.

●

Erratic speed.

●

Noisy operation.

●

Check or Solution

Park brake does not hold machine on a hill.

Brake linkage damaged.

Problem or Symptom

Brakes do not engage when pedal depressed.

Brake switch does not engage when depressing brake pedal.

TROUBLESHOOTING

●

Faulty brake switch. Belt tension release rod.

3/7/00

●

8-7

DIAGNOSIS

BRAKES

DIAGNOSIS BRAKES DO NOT ENGAGE WHEN PEDAL DEPRESSED Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

2. Brake band

Band not binding, worn or damaged.

Replace brake band.

3. Brake drum

Drum not binding, worn or damaged.

Replace brake drum.

4. Internal brake actuator lever

Engages brake actuator plate when brakes applied.

Replace if worn or damaged.

1. Brake linkage

PARK BRAKE DOES NOT HOLD MACHINE ON HILL Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

2. Brake band

Band not binding, worn or damaged.

Replace brake band.

3. Brake drum

Drum not binding, worn or damaged.

Replace brake drum.

1. Brake linkage

8-8

3/7/00

NOISY OPERATION

BRAKES

NOISY OPERATION Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

1. Park brake

Pedal depressed and linkage not locked.

Release park brake. Adjust brake linkage.

2. Brake linkage

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

MACHINE WILL NOT MOVE, OR IS SLOW IN FORWARD Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

1. Park brake

Pedal depressed and linkage not locked.

Release park brake. Adjust brake linkage.

2. Brake linkage

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

3. Traction drive belt tensioner assembly return spring

Spring returns idler assembly to tension traction drive belt when brake pedal is released.

Replace stretched or broken spring.

4. Brake return spring

Returns brake pedal and linkage to rest position when brake pedal is released.

Replace stretched or damaged spring.

5. Traction drive belt tension release rod

Rod not binding, worn or damaged.

Replace rod.

3/7/00

8-9

MACHINE WILL NOT MOVE, OR IS SLOW REVERSE

BRAKES

MACHINE WILL NOT MOVE, OR IS SLOW REVERSE Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

1. Park brake

Pedal depressed and linkage not locked.

Release park brake. Adjust brake linkage.

2. Brake linkage

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

3. Traction drive belt tensioner assembly return spring

Spring returns idler assembly to tension traction drive belt when brake pedal is released.

Replace stretched or broken spring.

4. Brake return spring

Returns brake pedal and linkage to rest position when brake pedal is released.

Replace stretched or damaged spring.

5. Traction drive belt tension release rod

Rod not binding, worn or damaged.

Replace rod.

BRAKE SWITCH DOES NOT ENGAGE WHEN BRAKE PEDAL IS DEPRESSED Test Conditions: • Machine parked on level surface. • Park brake DISENGAGED.

Test/Check Point

• Transaxle in NEUTRAL. • Key switch in OFF position.

Normal

If Not Normal

Brake rod, control lever, linkage and spring assembly not binding or damaged.

Eliminate binding, replace damaged components.

Brake linkage properly adjusted.

Adjust brake linkage.

2. Brake return spring

Returns brake pedal and linkage to rest position when brake pedal is released.

Replace stretched or damaged spring.

3. Brake switch

Continuity across terminals when activated by linkage.

Test neutral start/brake switch.

1. Brake linkage

8 - 10

3/7/00

ADJUSTMENTS

BRAKES

ADJUSTMENTS

BRAKE ADJUSTMENT—GEAR TRANSAXLE

BRAKE ADJUSTMENT— HYDROSTATIC TRANSAXLE

Reason: To ensure proper brake pedal travel and brake shoe engagement.

Reason: To ensure proper brake pedal travel and synchronize brake shoe engagement with linkage movement within the transaxle. Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Place transmission in NEUTRAL position. 4. Block wheels to prevent machine from moving. 5. Remove fender deck. (See “FENDER DECK REMOVAL AND INSTALLATION” on page 9 in "MISCELLANEOUS" Section.)

Procedure: 1. Park machine on level surface. 2. Turn key switch OFF. 3. Place transmission in NEUTRAL position. 4. Block wheels to prevent machine from moving. 5. Depress clutch and brake pedals and move park brake lever to lock position. Brake Rod

Rod A

Brake Shoe Assembly

0.2-0.3 in. (5-8 mm)

MX0973

Shown from LH side of tractor

6. Measure distance between actuating spring bracket (A) and cotter pin (B). 7. If distance is 0.2-0.3 in. (5-8 mm), the brakes are OK. No further adjustment is required. 8. If distance is less than 0.2 in. (5 mm), adjust the brakes as follows:

Control Rod

Nuts

Brake Arm Brake Disk Outer Brake Pad

M83240

Adjustment Nut M83374

6. Disconnect control rod from brake arm. 7. Disconnect rod from brake shoe assembly. 8. Hold brake arm all the way rearward and adjust the length of the rod so that it slips easily into the hole in the brake shoe actuator. 9. Hold brake arm all the way rearward and adjust nuts so that the control rod pin slips easily into the hole in the brake arm.

3/7/00

Located behind RH rear tire

• Tighten or loosen the brake adjustment nut (C) to achieve 0.2-0.3 in. (5-8 mm) distance. • Depress clutch and brake pedals and move park brake lever to lock position. • Measure gap between actuating spring bracket and cotter pin. • Repeat until gap is 0.2-0.3 in. (5-8 mm).

8 - 11

REPAIR

BRAKES

REPAIR BRAKE LINKAGE

Lift Linkage Arm

Removal/Inspection/Installation:

Brake Linkage Rod

1. Remove mower deck. 2. Remove right rear wheel. Clutch Actuating Rod Brake Rod

Brake Return Spring

Retainer Belt Tension Spring

M83378

Compression Spring Return Spring M83376

3. Inspect all parts for wear or damage. Replace parts as necessary.

4. Disconnect: • Belt tension spring. • Clutch actuating rod. • Brake return spring. • Brake linkage rod. • Left-hand lift linkage arm.

Installation is done in the reverse order of removal. • Adjust brakes. (See “BRAKE ADJUSTMENT— GEAR TRANSAXLE” on page 11.)

BRAKE PEDAL ASSEMBLY Removal/Inspection/Installation: 1. Remove mower deck. (See “MOWER DECK REMOVAL AND INSTALLATION” on page 18 in "ATTACHMENT" Section.) 2. Remove fender deck. (See “FENDER DECK REMOVAL AND INSTALLATION” on page 9 in "MISCELLANEOUS" Section.) 3. Remove right rear wheel.

8 - 12

3/7/00

BRAKES

BRAKE REMOVAL AND INSTALLATION—HYDROSTATIC

BRAKE REMOVAL AND INSTALLATION—HYDROSTATIC 1. Remove left side rear wheel.

Nut (3 used) Cap Screw (3 used)

Brake Assembly

Cotter Pin & Washer

Brake/Clutch Pedal Shaft

Brake Pedal Snap Ring

M83377

5. Remove snap ring. 6. Remove cap screws and nuts. 7. Remove brake/clutch pedal shaft and brake pedal. 8. Inspect all parts for wear or damage. Replace parts as necessary. Installation is done in the reverse order of removal. • Adjust brakes. (See “BRAKE ADJUSTMENT— GEAR TRANSAXLE” on page 11., or See “BRAKE ADJUSTMENT—HYDROSTATIC TRANSAXLE” on page 11.)

Cap Screws

M89914

2. Remove cap screws securing brake assembly to transaxle case. 3. Remove cotter pin and washer from end of brake rod. 4. Remove brake assembly from side of transaxle case.

NOTE: Brake assembly and brake band are only available as a unit. DO NOT attempt to separate brake band from brake assembly.

M89915

3/7/00

8 - 13

BRAKE REMOVAL AND INSTALLATION—GEAR TRANSAXLE

BRAKES

5. Remove external snap ring securing brake disk to the end of the motor output shaft. Remove brake disk. 6. Inspect and replace components as required. Installation: Installation is the reverse of removal. • Torque brake assembly cap screws to 10 N•m (95 lb-in.) • Adjust brakes. (See “BRAKE ADJUSTMENT— HYDROSTATIC TRANSAXLE” on page 11.)

Brake Disk Outer Brake Pad

Plate

Housing

BRAKE REMOVAL AND INSTALLATION—GEAR TRANSAXLE

M89793

Pins

6. Remove pins, housing, plate, and outer brake pad. 7. Remove brake disk. 8. Remove inner brake pad from recess in transmission housing. 9. Inspect and replace components as required.

1. Remove right side rear wheel.

Brake Rod

Installation: Installation is done in the reverse order of removal.

Cotter Pin

M83378

• Replace brake pads if less than 6 mm (0.250 in.). • Apply a light coat of John Deere LUBRIPLATE lubricant or equivalent to brake shaft dowel pins and washer. • Tighten cap screws to 10 N•m (95 lb-in.). • Adjust brakes. (See “BRAKE ADJUSTMENT— GEAR TRANSAXLE” on page 11.)

2. Remove cotter pin securing brake rod to brake lever. Brake Lever Nut Shield

Cap Screw

M89792

3. Remove nut securing brake lever to brake housing. 4. Remove cap screws securing brake assembly to transmission housing. 5. Remove brake lever and shield.

8 - 14

3/7/00

PARK BRAKE LEVER AND LINKAGE

BRAKES

PARK BRAKE LEVER AND LINKAGE Removal/Inspection/Installation: 1. Remove battery.

3. Remove carriage bolt, nut and bushing. 4. Remove brake handle. 5. Remove cotter pin, springs and rod. 6. Inspect all parts for wear or damage. Replace parts as necessary.

Spring

M83247

2. Remove spring. Handle

Rod

Washer Spring

Spring (2 used)

Latch

Cotter Pin

Nut

Carriage Bolt Bushing M83373

3/7/00

8 - 15

PARK BRAKE LEVER AND LINKAGE

8 - 16

BRAKES

3/7/00

CONTENTS

ATTACHMENTS

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL OR ESSENTIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MOWER DECK COMPONENTS 48/54 INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DRAFT ARMS COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GAUGE WHEELS COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 IDLERS AND SHEAVES 48/54 INCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MOWER DECK TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MOWER DRIVE CHECKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MOWER DECK WILL NOT RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 MOWER DECK VIBRATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CUTS UNEVENLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MOWER LEVEL SIDE-TO-SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MOWER LEVEL FRONT-TO-REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 MOWER GAGE WHEELS ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 MOWER BLADES REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 SHARPEN MOWER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 BALANCING MOWER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 MOWER DECK REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SPINDLES 48/54 INCH REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . 19 SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . 19

3/3/00

9-1

NOTES

9-2

ATTACHMENTS

3/3/00

SPECIFICATIONS

ATTACHMENTS

SPECIFICATIONS ADJUSTMENT SPECIFICATIONS Blade Height Side-to-Side Difference (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 mm (0.125 in.) Front-to-Rear Difference . . . . . . . . . . . . 6 – 9 mm (0.24 – 0.35 in.) front lower than rear

REPAIR SPECIFICATIONS 48/54-Inch Mower Deck Gauge Wheels Roller Shaft Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft) Idlers and Sheaves Jack Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 N•m (100 lb-ft) Tensioning Idler Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (240 lb-in.) Spindle Mounting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N•m (216 lb-in.) Sheave Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 N•m (120 lb-ft) Lower Seal Installation Position. . . . . . . . . . . . . . . 7.8 mm (0.31 in.) below hub flange Blade Blade Cap Screw Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N•m (50 lb-ft) Cutting Edge Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.016 in.)

SPECIAL OR ESSENTIAL TOOLS NOTE: Order tools according to information given in the U.S. SERVICEGARD Catalog or in the European Microfiche Tool Catalog (MTC). Number

Name

Use

TY15272

Blade Height Guide

Use to check mower side-to-side level.

SERVICE PARTS KITS The following kits are available through your parts catalog: • QUIK-TATCH J-Pin Kit • Spindle Bearing Replacement Kit • Spindle Housing Kit • Tensioning Assembly Kit • Bushing Replacement Kit • Rear Draft Kit • Gauge Wheel Kit

3/7/00

9-3

9-4

Fixed Secondary Belt Idler Sheave

Left Front Gauge Wheel

Blade

Quick-Release Belt Tensioning Handle

Front Draft Arm Hangers

PTO Drive Sheave

PTO Clutch

Secondary Drive Belt Idler Sheave

Primary Drive Belt

Primary Belt Tensioning Rod

QUIK-TATCHâ&#x201E;¢ J-Pin Assembly

Rear Draft Arm Attaching Bracket

Primary Belt Tensioning Spring

Jack Sheave Assembly

Secondary Drive Belt

Spindles (3 used)

Right Rear Gauge Wheel

Discharge Chute

Hinge Assembly

Secondary Drive Belt Idler Tensioning Spring

Left Rear Gauge Wheel Assembly

Traction Drive Sheave

COMPONENT LOCATION ATTACHMENTS

COMPONENT LOCATION

MOWER DECK COMPONENTS 48/54 INCH

M89831

3/7/00

DRAFT ARMS COMPONENT LOCATION

ATTACHMENTS

DRAFT ARMS COMPONENT LOCATION

Pivot Lift Arm

Spacer (2 used) Clevis (2 used) Front Draft Rod

Lift Link Assembly (2 used)

Lift Arm

QUIK-TATCHTM J-Pin Assembly (2 used)

Cotter Pin (2 used)

M89830

3/7/00

9-5

GAUGE WHEELS COMPONENT LOCATION

ATTACHMENTS

GAUGE WHEELS COMPONENT LOCATION

Cap Screw Bushing Gage Wheel

Washer Nut

Cap Screw

Nut

Center Gage Wheels 48 & 54 in. Only

M89898

9-6

3/7/00

IDLERS AND SHEAVES 48/54 INCH

ATTACHMENTS

IDLERS AND SHEAVES 48/54 INCH I J

H P

AC G

F L W

D O

AC M

B N

AB O AA

K Z

N Y

S N T P

M83240

A—Spacer B—Fixed Idler Sheave C—Shield D—Jack Sheave E—Ball Bearing (2 used) F—Snap Ring G—Plug H—Tensioning Spring Arm (Secondary) I—Tensioning Idler Sheave Spring J—Hook K—Carriage Bolt L—Tensioning Idler Sheave Arm (Secondary) M—Tensioning Idler Sheave N—Bushing O—Nut

3/7/00

P—Cap Screw Q—Clevis R—Primary Belt Tensioning Spring S—Shaft T—Spring Pin U—Primary Belt Tensioning Rod V—Cotter Pin and Washer W—Washer X—Quick Release Belt Tensioning Handle Y—Nut Z—Jack Sheave Arm AA—Jack Sheave Tensioning Arm AB—Spacer AC—Bushing (4 used)

9-7

TROUBLESHOOTING

ATTACHMENTS

TROUBLESHOOTING

Belt squeals.

Cuts unevenly

Check or Solution

Mower deck vibrates.

Problem or Symptom

Mower deck will not run.

MOWER DECK TROUBLESHOOTING CHART

PTO clutch and sheave will not engage.

●

Primary drive belt broken, worn, frayed, glazed, stretched or wrong belt.

●

Secondary drive belt broken, worn, frayed, glazed, stretched or wrong belt.

●

Primary belt Quick-Release belt tensioning handle not locked in place, weak spring, spring

●

unhooked or broken. Secondary drive belt tensioning spring weak, unhooked or broken.

●

Blades out of balance.

●

Blades bent.

●

Blade level side-to-side out of adjustment.

●

Blade level front-to-rear out of adjustment.

●

Blades dull.

●

Gauge wheels not adjusted correctly.

●

Drive sheaves and idlers loose, damaged, dry or locked-up.

9-8

●

3/7/00

DIAGNOSIS

ATTACHMENTS

DIAGNOSIS MOWER DRIVE CHECKS Test Conditions: • Machine parked on a clean, level surface. • PTO disengaged.

Test/Check Point 1. PTO clutch and drive sheave

• Key switch in STOP position.

Normal

If Not Normal

Tight on crankshaft and key not damaged or missing. Air gap properly adjusted. Belt on sheave. Sheave not binding, damaged or worn. Sheave angle matching belt angle.

Tighten cap screw. Replace key. Repair and adjust as needed. Install belt. Replace sheave.

2. Primary drive belt

Correct belt installed. Not damaged, worn, or broken. Not turned over.

Replace belt.

3. Jack sheave

Belt on sheave. Sheave not binding, damaged or worn. Sheave angle matching belt angle.

Install belt. Replace sheave and bearing.

Nut at correct torque.

Check jack sheave, PTO sheave and belt.

Check jack sheave, PTO sheave and belt. Tighten nut to specifications.

4. Primary belt tension spring and rod

Not damaged, worn or weak. Belt tensioning handle in tension position.

Replace spring or rod. Move to tension position.

5. Jack sheave arm

Not binding, damaged or worn.

Replace jack sheave arm.

6. Secondary drive belt

Correct belt installed. Not damaged, worn or broken. Not turned over.

Replace belt.

7. Secondary drive belt tensioning spring

Not damaged, worn or weak.

Replace spring.

8. Secondary drive belt idler and pivot arm

Not binding, damaged or worn. Belt in place. Pivot arm not bent, locating idler parallel to belt.

Replace idler. Install belt. Replace pivot arm.

9. Spindle sheave.

Tight on spindle and key in place.

Tighten nut and install key as needed. Repair, or replace as needed. Install belt. Replace sheave. Check jack sheave, PTO sheave and belt.

Not damaged or bent. Running straight. Belt on sheave. Sheave angle matches belt angle.

3/7/00

9-9

MOWER DRIVE CHECKS

ATTACHMENTS

Test Conditions: • Machine parked on a clean, level surface. • PTO disengaged.

Test/Check Point

• Key switch in STOP position.

Normal

If Not Normal

10. Fixed idler

Not binding, damaged or worn. Belt in place.

Replace idler. Install belt.

11. Spindle and housing

Bearings not failed, full of grease. Blade tight on spindle.

Replace as needed, fill with grease. Tighten hardware to specifications.

12. Blade

Not bent, worn or damaged.

Replace blade and tighten to specifications. Sharpen and balance. Adjust. Adjust.

Sharp and balanced. Level side-to-side. Correctly adjusted front-to-rear. 13. Mower deck lift linkage

Mounting hardware tight, not worn or binding.

Tighten or replace as needed.

14. Engine

Check that engine is running at correct rpm.

Adjust engine fast idle and governor. Check engine adjustments and condition.

Test Conditions: • Machine parked on a clean, level surface, away from people and objects. • Engine at operating temperature.

Test/Check Point

• Engine running at FAST idle. • Perform PTO clutch break-in procedure.

Normal

If Not Normal

15. PTO clutch and drive sheave

Functioning properly.

Repair or replace components.

16. Mower deck

Operating smoothly without any unusual noises and stops quickly.

Slowly reduce rpm and listen for problem area – Stop PTO and engine, repair or replace faulty components.

9 - 10

3/7/00

MOWER DECK WILL NOT RUN

ATTACHMENTS

MOWER DECK WILL NOT RUN Test Conditions: • Machine parked on a clean, level surface. • PTO disengaged.

Test/Check Point 1. PTO clutch and drive sheave

• Key switch in STOP position.

Normal PTO circuit operating properly. Tight on crankshaft and key not damaged or missing. Air gap properly adjusted. Belt on sheave. Sheave not binding, damaged or worn.

If Not Normal Test PTO circuit. (See “PTO CIRCUIT DIAGNOSIS” in Electrical Section.) Tighten cap screw. Replace key. Repair and adjust as needed. Install belt. Replace sheave.

2. Primary drive belt

Correct belt installed. Not damaged, worn, or broken. Not turned over.

Replace with correct belt.

3. Jack sheave

Belt on sheave. Sheave not bent or locked.

Install belt. Replace jack sheave.

4. Primary belt tension spring and rod

Not damaged, worn, or weak. Belt tensioning handle in tension position.

Replace spring or rod. Move to tension position.

5. Secondary drive belt

Correct belt installed. Not damaged, worn, or broken. Not turned over.

Replace with correct belt.

6. Secondary drive belt tensioning spring

Not damaged, worn, or weak.

Replace spring.

7. Secondary drive belt idler

Belt in place. Idler not bent or locked up.

Install belt. Replace idler.

8. Spindles and drive sheaves

Belt in place. Spindles and drive sheaves not bent or locked up.

Install correct belt. Replace spindles and drive sheaves.

3/7/00

9 - 11

MOWER DECK VIBRATES

ATTACHMENTS

MOWER DECK VIBRATES Test Conditions: • Machine parked on a level surface. • PTO disengaged.

Test/Check Point

• Key switch in STOP position.

Normal

If Not Normal

1. PTO clutch and drive sheave

Sheave angle matching belt angle.

Check jack sheave, PTO sheave and belt.

2. Jack sheave

Sheave not binding, damaged or worn. Nut at correct torque.

Replace sheave and bearing.

3. Jack sheave arm

Not damaged, binding or worn.

Replace jack sheave arm.

4. Secondary drive belt idler and pivot arm

Not damaged, binding or worn. Pivot arm not bent, locating idler parallel to belt.

Replace idler. Replace pivot arm.

5. Fixed idler

Not binding, damaged or worn.

Replace idler.

6. Spindle sheave

Tight on spindle. Not damaged or bent. Running straight. Sheave angle matching belt angle.

Tighten nut and install key as needed. Repair or replace as needed. Check spindle sheave and belt.

7. Spindle and housing

Bearings not failed. Blade tight on spindle.

Replace as needed. Tighten hardware to specifications.

8. Blade

Not bent, worn or damaged.

Replace blade. Balance blade.

9 - 12

Tighten nut to specifications.

3/7/00

CUTS UNEVENLY

ATTACHMENTS

CUTS UNEVENLY Test Conditions: • Machine parked on a level surface. • PTO disengaged.

Test/Check Point

• Key switch in STOP position.

Normal

If Not Normal

1. Blade

Sharp. Level side-to-side. Correctly adjusted front-to-back.

Sharpen. Adjust. Adjust.

2. Mower deck lift linkage

Mounting hardware tight, not worn.

Tighten or replace as needed.

3. Engine

Check that engine is running at correct rpm.

Adjust engine fast idle and governor. Check engine adjustments and condition.

3/7/00

9 - 13

ADJUSTMENTS

ATTACHMENTS

ADJUSTMENTS MOWER LEVEL SIDE-TO-SIDE Reason:

Measurement

To set mower deck for an even side-to-side cut. Equipment: • TY15272 Blade Height Gauge

TY15272 Blade Height Gauge M40161

Procedure:

c CAUTION Before you adjust the mower, stop engine and remove ignition key.

1. Disengage PTO. 2. Park machine on a hard, level surface. 3. Turn key switch OFF. 4. Move forward/reverse pedals to NEUTRAL position (hydrostatic models, transaxle in neutral on gear shift models). 5. Engage park brake. 6. Check for correct tire pressures. 7. Remove gauge wheels to insure they do not contact the ground during leveling.

11. Using a TY15272 Blade Height Gauge, measure distance of outside tips of blade to floor surface. The maximum blade outside tip-to-outside tip height difference should be 3 mm (0.125 in.). Results:

NOTE: Adjustable lift links are on both sides of the mower. Cutting height can closely match knob setting by using adjustment on both sides. DO NOT adjust deck too high or it will not lock in the transport (upper) position.

c CAUTION Wear gloves or wrap blade with rag to prevent personal injury.

Adjustment Nut M89832

8. Rotate blade by hand to check for bent blade or spindle. 9. Set mower at the cutting height that will be used. 10. Set mower blade ends toward outside edges of mower deck.

9 - 14

If the mower side-to-side height difference is greater than specifications, adjust lift link on right side of mower. Turn adjustment nut: • Clockwise to raise right side of mower. • Counterclockwise to lower right side. After adjusting mower side-to-side height check gage wheels to insure they are adjusted properly. (See “MOWER GAGE WHEELS ADJUST” on page 16.)

3/7/00

MOWER LEVEL FRONT-TO-REAR

ATTACHMENTS

MOWER LEVEL FRONT-TO-REAR Reason: To insure that the mower deck is set to correct specifications for optimum cutting efficiency at the selected cut height.

11. Use TY15272 Blade Height Gauge or a small ruler to measure front blade tip to ground and measure rear blade tip to ground. The front end of the blade should measure lower than the rear. Specifications: Front-to-Rear Blade Height Difference

Equipment:

42 – 54-Inch Deck (front lower than rear) . . . . . . . . . . . . . . . . . . . . 6 – 9 mm (0.24 – 0.35 in.)

• TY15272 Blade Height Gauge Procedure:

Results:

c CAUTION

If the blade front-to-rear height difference is out of specification, adjust as follows.

Before you adjust the mower, stop engine and remove ignition key.

NOTE: On decks equipped with bagger performance is generally greater when the front-to-rear adjustment is at the maximum end of specifications.

Adjustment Procedure:

Front Nuts

c CAUTION Wear gloves or wrap blade with rag to prevent personal injury Rear Nuts

8. Rotate blade by hand to check for bent blade or spindle. 9. Set mower at the cutting height that will be used. 10. Set mower blades parallel to the center axis of machine.

M88578

• Loosen REAR nuts on front draft rod. • Turn FRONT adjustment nuts clockwise to raise front of mower deck or counterclockwise to lower front of mower deck. • Tighten REAR nuts after adjustment is completed. After adjusting mower height check gage wheels to insure they are adjusted properly. (See “MOWER GAGE WHEELS ADJUST” on page 16.)

M39912

3/7/00

9 - 15

MOWER GAGE WHEELS ADJUST

ATTACHMENTS

MOWER GAGE WHEELS ADJUST

REPAIR MOWER BLADES REMOVAL AND INSTALLATION

c CAUTION To avoid injury, before adjusting gage wheels: STOP engine, remove key, and wait for blades to STOP.

IMPORTANT: Mower gage wheels must not ride on ground or support mower weight. Adjust gage wheels each time cutting height is changed. 1. Park tractor on a hard, level surface. 2. Stop engine and remove key. 3. Make sure tractor tires are inflated to the correct pressures. 4. Raise mower lift lever to TRANSPORT (upper) position and adjust cutting height to desired setting with cutting height knob. 5. Move mower lift lever to mowing (lower) position and check distance between gage wheels and level surface. Bottom of gage wheels should be 6 – 13 mm (1/4 – 1/2 in.) from the ground when properly adjusted.

1. Remove mower deck. (See “MOWER DECK REMOVAL AND INSTALLATION” on page 18.)

c CAUTION Wear gloves or wrap blade with rag to prevent personal injury.

Blade Washer Cap Screw 68 N•m (50 lb-ft.)

2. Remove cap screw, washer and blade. 3. Inspect blade for cracks, wear or damage. Replace blade if necessary. 4. Sharpen and balance as necessary. Installation is done in the reverse order of removal.

M89724

6. If gage wheel adjustment is necessary, remove nut and bolt for gage wheel and relocate to appropriate hole to obtain correct measurement as in step 5.

9 - 16

IMPORTANT: Make sure that concave side of washer faces blade. 5. Install blade with bent tips up. 6. Tighten cap screw to 68 N•m (50 lb-ft.).

3/7/00

SHARPEN MOWER BLADES

ATTACHMENTS

SHARPEN MOWER BLADES

. Balancer

c CAUTION Wear goggles and gloves when sharpening blade. 1. Sharpen blades using grinder, file or power sharpener.

M29527

Bevel 0.40 mm (0.016 in.)

3. Set blade on JT07076 Rotary Blade Balancer and turn blade to the horizontal position. .

2. Do not alter original bevel. Blade should have 0.40 mm (0.016 in.) cutting edge rather than a razortype edge to prevent excessive chipping of the cutting edge.

NOTE: If excessive browning of ends of mown grass occurs or if mower is to be used on tough grasses it may be necessary to grind the blade to a sharp edge. 3. Balance blades. (See “BALANCING MOWER BLADES” on page 17.)

Balancer Track

M29528

1.5 mm (0.059 in.)

BALANCING MOWER BLADES

c CAUTION Wear gloves when handling blade. 1. Sharpen blade, if required. (See “SHARPEN MOWER BLADES” on page 17.) 2. Clean blade and remove any accumulated grass/ dirt with scraper or wire brush and wipe blade clean.

3/7/00

4. If blade is not balanced, heavy end will drop. 5. Lightly grind bevel of the heavy end, WITHOUT changing the original angle of blade. 6. Recheck balance. 7. Adjust balancer track to just touch blade tip. 8. Turn blade to opposite tip. 9. Blade should also touch in same way. IMPORTANT: Install new blade if difference between blade tips and balancer track measures over 1.5 mm (0.059 in.).

9 - 17

MOWER DECK REMOVAL AND INSTALLATION

ATTACHMENTS

MOWER DECK REMOVAL AND INSTALLATION

c CAUTION STOP engine. Remove ignition key. Wait for all moving parts to STOP. 1. Pull lift lever all the way back and lock in the TRANSPORT position. 2. Turn mower depth control knob to blank mark. Put wood blocks under each side of mower. 3. Move lift lever all the way forward and lock in DOWN position. Deck should be in contact with the blocks.

Lift Rod Assembly M54690

6. Pull out and push down on pivot to disconnect front lift rod assembly. Remove lift rod assembly from machine.

c CAUTION Do not remove mower deck J-pins until lift lever is moved forward in locked-down position. Spring pressure on rear draft arms could cause injury when mower deck is disconnected. Bracket Belt Tensioner Handle

NOTE: It may be necessary to lift up on rear of mower deck to pull out J-pins. M89833

4. Disconnect tensioner handle from bracket. Pull handle out to relieve belt tension. 5. Remove drive belt from PTO and mower jack sheave.

Lock Lever

J-Pin M89832

7. Pull out J-pin on each side of mower deck and turn pin to unlock position.

Lift Rod Assembly M88578

9 - 18

3/7/00

ATTACHMENTS

SPINDLES 48/54 INCH REMOVAL AND INSTALLATION IMPORTANT: Do not install hexagon end of spindle shaft in a vise to remove spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation.

c CAUTION Lift lever is spring loaded and will snap rearward when lever is released from locked-down position, with no attachment on machine.

Nut Spindle Sheave

8. Pull lift lever all the way back and lock in the TRANSPORT position. 9. Slide mower deck out the side of the machine.

Seal Ring (2 used) Seal (2 used) Bearing (2 used)

Installation is done in the reverse order of removal.

Spindle Hub

SPINDLES 48/54 INCH REMOVAL AND INSTALLATION 1. Remove mower deck. (See “MOWER DECK REMOVAL AND INSTALLATION” on page 18.) 2. Remove mower blade. (See “MOWER BLADES REMOVAL AND INSTALLATION” on page 16.)

Nuts (4 used) 24 N•m (18 lb-ft.)

Spacer Spindle Hub Shoulder Spindle Shaft

Lubrication Fitting Blade

Washer Spindle Assembly M54685

3. Remove four nuts and washers and spindle assembly. 4. Make repairs as necessary. (See Disassembly/ Inspection procedure.) Installation is done in the reverse order of removal. • Tighten spindle mounting nuts to 24 N•m (18 lb-ft.).

SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION

c CAUTION Wear gloves or wrap blade with rag to prevent personal injury.

3/7/00

Cap Screw

M44948

1. Install blade, washer, and cap screw on spindle shaft. If only the nut or spindle sheave need to be replaced, and the spindle is still in the deck, use a block of wood to prevent the blade from turning. If spindle is not in the deck, put blade in a soft-jaw vise. Tighten cap screw to specifications. 2. Hold the blade with a vise or a block of wood. Remove nut, spindle sheave, and lubrication fitting. 3. Remove cap screw, washer and blade. 4. Pull spindle shaft out of spindle hub. 5. Remove seal rings, noting location of notched side.

NOTE: Remove bearings only if replacement is necessary. 6. Bearings are seated against spindle hub shoulder and cannot be removed with a press. Remove seals and bearings using a punch. 7. Remove spacer. 8. Inspect all parts for wear or damage. Replace parts as necessary.

9 - 19

SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION

ATTACHMENTS

Cross Section 48/54 Inch Deck

Grease Notch Upper-Face Towards Bearing Lower-Face Away From Bearing Lubrication Fitting Nut 163 N•m (120 lb-ft.) Upper Seal Ring Upper Seal Spindle Sheave

Upper Bearing

Spacer Spindle Shaft

Hub

Lower Bearing

Seal Depth 7.8 mm (0.310 in.)

Nut (4 used ) 24 N•m (18 lb-ft.)

Washer Lower Seal Ring

Lower Seal Cap Screw 68 N•m (50 lb-ft.)

Blade

Assembly: IMPORTANT: Upper seal ring is installed with grease notch facing TOWARD upper bearing. Lower seal ring is installed with grease notch facing AWAY from lower bearing.

Grease Notch

Upper Seal Ring Spindle Hub Shoulder

Upper Seal

Upper Seal Ring

M44950

1. Install upper bearing tight against spindle hub shoulder using a 1-13/16 in. disk and press. 2. Install upper seal with lip toward bearing, tight against bearing using a 1-13/16 in. disk and press. 3. Install upper seal ring, with grease notch toward bearing, inside seal lip.

Upper Bearing M44949

9 - 20

3/7/00

SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION

ATTACHMENTS

IMPORTANT: Make sure the hexagon shaped hole in spindle sheave is aligned with the hexagon portion of the spindle shaft.

Spindle Hub Shoulder Lower Bearing

Spacer

10. Hold the blade with a soft-jaw vise or if spindle is in the mower deck, with a block of wood. Install spindle sheave, nut, and lubrication fitting. Tighten nut to 163 Nâ&#x20AC;˘m (120 lb-ft.). 11. Remove cap screw, washer and blade. 12. Lubricate spindle with multipurpose grease at lubrication fitting. Lower Seal Lower Seal Ring

Lower Seal Hub Flange

M44951

7.8 mm (0.31 in.) below hub flange

M44952

4. Install spacer. IMPORTANT: Do not press lower bearing tight against spindle hub shoulder. The bearing and seal must be installed to a specific dimension for proper sealing of spindle. 5. Install lower bearing in hub using a 1-13/16 in. disk and press, just enough so the lower seal can be installed. 6. Install lower seal with lip toward bearing using a 1-13/16 in. disk and a press. 7. Install lower seal ring, with grease notch away from bearing, and inside seal lip. 8. Install spindle shaft. IMPORTANT: Do not install hexagon end of spindle shaft in a vise to install spindle sheave nut. The hexagon end of the spindle shaft will be damaged resulting in improper blade operation. 9. Install blade, washer, and cap screw on spindle shaft. Make sure that hole in washer is aligned with hexagon portion of spindle. Tighten cap screw.

3/7/00

9 - 21

SPINDLES 48/54 INCH DISASSEMBLY AND INSPECTION

9 - 22

ATTACHMENTS

3/7/00

CONTENTS

MISCELLANEOUS

CONTENTS Page

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FRONT AXLE AND TIRES COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . . . 4 LIFT ASSIST AND DEPTH STOP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FRONT AXLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FRONT WHEEL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FRONT WHEEL BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HOOD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SEAT AND SUPPORT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 9 FENDER DECK REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 MOWER DECK LIFT LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 HEIGHT ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3/3/00

10 - 1

NOTES

10 - 2

MISCELLANEOUS

3/3/00

OTHER MATERIALS

MISCELLANEOUS

SPECIFICATIONS OTHER MATERIALS

3/7/00

Number

Name

Use

TY6305

John Deere Clean and Cure Primer

Cleans parts and speeds cure of sealant

TY16135

John Deere Ultra-Blueâ&#x201E;¢ RTV Silicone Form-In-Place Gasket

Seals gear case cover

T43512

John Deere Thread Lock and Sealer (Medium Strength)

Apply to threads of sheave set screws

10 - 3

FRONT AXLE AND TIRES COMPONENT LOCATION

MISCELLANEOUS

COMPONENT LOCATION FRONT AXLE AND TIRES COMPONENT LOCATION Pivot Bushing Nut Lock Plate

Washer Pivot Bushing

Capscrew

Plastic Cap C-Clip Washer

Zerk

Wear Block Beam Axle

Right Hand Spindle

Rivet

Zerk

Nut

Tie Rod

Plastic Cap C-Clip Washer

Zerk

Left Hand Spindle

Bushing Wheel Tire

Bushing

Shims Valve Stem

10 - 4

Cap

M89930

3/7/00

LIFT ASSIST AND DEPTH STOP OPERATION

MISCELLANEOUS

LIFT ASSIST AND DEPTH STOP OPERATION Lift Button Return Button Spring and Cup

Lift Handle Assembly

Latch Rod Lift Assist Spring

Mower Deck Cutting Height Adjustment Knob Latch Strike Latch

Mower Depth Stop Cam

Lift Link

Mower Deck Lift Arm

Depth Stop Arm

Function: To provide a means of controlling the cutting height of the deck and to allow the deck to be raised to a transport position. Theory of Operation: As the lift lever is pulled rearward (to raise attachment), it pulls the lift link forward. The lift link is attached to the lift shaft. The lift shaft rotates forward raising the lift arms and attachment. Also attached to the lift link is the lift assist spring. Spring tension helps pull the link forward, reducing the effort required to lift the attachment. The lift handle locks in the fully raised position with a latch and strike.

3/7/00

M45783A

When the lift handle is lowered, the lift arms lower the attachment until the depth stop arm on the lift shaft contacts the depth stop cam. The depth stop cam has different cam heights which are selected by using the cutting height knob. This allows the attachment to return to a specific height each time the attachment is lowered. The lift assist spring can be locked out by pushing the lift handle fully forward. A slot in the lift link allows the lift shaft and arms that hold the attachment to move without any effect from the lift assist spring. This results in full implement weight on the ground.

10 - 5

FRONT AXLE REMOVAL AND INSTALLATION

MISCELLANEOUS

REPAIR FRONT AXLE REMOVAL AND INSTALLATION

Lock Nut

Removal: 1. Remove hood. (See “HOOD REMOVAL AND INSTALLATION” on page 9.) 2. Jack up the front end of vehicle and block securely.

NOTE: It is not necessary to remove the front wheels prior to removing the front axle.

Cap Screws

Drag Link M89732

5. Remove lock nut securing drag link to left front wheel steering arm. Move drag link out of the way. 6. Remove the four nuts and lock washers securing the muffler. Remove muffler. IMPORTANT: Beam axle is free to fall from frame once retaining cap screw is removed. Use care when removing cap screw so as not to drop beam axle.

Left Heat Shield

M89727

3. Remove exhaust heat shields from both sides of engine.

Cap Screw

Lock Plate Front Heat Shield Cap Screws M89735 M88578

4. Remove front heat shield cap screws and remove heat shield from above muffler.

10 - 6

7. Remove lock nut from cap screw securing beam axle in frame. Remove cap screw and lock plate. 8. Remove beam axle from frame.

3/7/00

FRONT AXLE REMOVAL AND INSTALLATION

MISCELLANEOUS

Beam Axle

Pivot Bushing Beam Axle

Spindle Hole Thrust Surface

M89740

9. Remove two pivot bushings from center of beam axle. Measure outside diameters of pivot bushings. If not in specifications, replace. 10. Remove wheels from beam axle. (See “FRONT WHEEL REMOVAL AND INSTALLATION” on page 8.)

M89741

14. Measure spindle holes in beam axle. If not in specifications, replace beam axle. 15. Measure spindle O.D. If not in specifications, replace spindle assembly. 16. Inspect thrust surface on steering arm. If excessively worn or grooved, replace spindle assembly.

Tie Rod Washer C-Clip

Specifications:

Lock Nut

Pivot Bushing O.D, Wear Limit . 22.4 mm (0.882 in.) Beam Axle Spindle Hole I.D. . . 19.15 mm (0.754 in.) Spindle O.D. . . . . . . . . . . . . . . . 18.97 mm (0.747 in.) Installation: Installation is the reverse of removal. • Make sure that beam axle pivot bushings are in place and greased. • Tighten nut on axle pivot cap screw to 128.8 N•m (95 lb-ft). • Tighten muffler nuts to 24.4 N•m (216 lb-in.).

M89739

IMPORTANT: DO NOT overtighten screws securing heat shield, front shield, and muffler.

11. Remove lock nut securing tie rod to spindle steering arm. Remove tie rod. 12. Remove plastic cap protection top of spindle. 13. Remove C-clip from end of spindle. Remove washer and slide spindle out the bottom of the beam axle.

3/7/00

10 - 7

FRONT WHEEL REMOVAL AND INSTALLATION

FRONT WHEEL REMOVAL AND INSTALLATION 1. Jack up side of vehicle to be serviced.

FRONT WHEEL BUSHING REMOVAL 1. Remove wheel. (See “FRONT WHEEL REMOVAL AND INSTALLATION” on page 8.)

Bushing

Plastic Cap

M89738

M89737

2. Remove plastic cap from end of wheel hub.

C-Clip

MISCELLANEOUS

2. Measure I.D. of bushing. If not in specifications, replace bushing. 3. Use a finger puller on a slide hammer to remove bushing from wheel hub.

Washer

IMPORTANT: If bushings are loose in wheel hub replace wheel. Specifications: Wheel Bushing OD . . . . . . . . . . . . . . . . . . . . . . . . . . 35 mm (1.378 in.) ID . . . . . . . . . . . . . . . . . . . . . . . . 19.15 mm (0.754 in.) Axle Diameter . . . . . . . . . . . . . . 18.97 mm (0.747 in.) M89736

3. Remove C-clip from end of axle. 4. Remove washer, wheel, and shim washers from axle. Installation: Installation is the reverse of removal.

10 - 8

3/7/00

HOOD REMOVAL AND INSTALLATION

MISCELLANEOUS

HOOD REMOVAL AND INSTALLATION

SEAT AND SUPPORT REMOVAL AND INSTALLATION

Removal:

1. Pivot hood to open position.

Wiring Connector

Connector M89743

2. On right side of the vehicle frame, near the right front pivot, disconnect electrical connector for headlights.

Seat Adjustment Knobs

M89746

1. Lift seat and disconnect wiring connector. 2. Remove seat adjustment knobs. 3. Remove seat and support. Installation: Left Hood Pin

Installation is the reverse of removal.

FENDER DECK REMOVAL AND INSTALLATION Removal: M89744

3. Rotate hood back about ten degrees until tabs on left hood pin line up with slots in hood mounting bracket. 4. Slide hood toward the right hand side of the vehicle and remove hood. Installation:

1. Remove seat and support. (See “SEAT AND SUPPORT REMOVAL AND INSTALLATION” on page 9.)

Carriage Bolts Height Adjustment Knob Cap Screws

Installation is the reverse of removal.

M54626

3/7/00

10 - 9

MOWER DECK LIFT LINKAGE

MISCELLANEOUS

2. Remove height adjustment knob. 3. Remove gear shift knob if equipped. 4. Remove two (2) cap screws and two (2) carriage bolts securing deck to frame.

Grip Button

Spring

Lift Lever

NOTE: Carriage bolts securing deck to frame are located under rubber foot mat. 5. Remove fender deck taking care not to damage seat connector.

Rod Spring Retainer

Latch Block

Installation: Installation is done in the reverse order of removal. • Be sure to thread the seat connector and wire harness through the hole in the deck during installation.

Set Screw

Bearing Block Lift Assist Spring

Ring Clip

Latch Ring Clip

MOWER DECK LIFT LINKAGE

Snap Ring

Lift Lever and Linkage 1. Remove fuel tank. 2. Remove engine hood. (See “HOOD REMOVAL AND INSTALLATION” on page 9.) 3. Remove battery.

Neutral Start Switch Wiring Connector Brake Switch Wiring Connector

Rear Lift Shaft

Lift Link

M89922A

8. Remove lift assist spring from machine frame. 9. Inspect all parts for wear or damage. Replace parts as necessary. Installation is done in the reverse order of removal.

HEIGHT ADJUSTER

Park Brake Lever Bushing

• Remove fender deck. (See “FENDER DECK REMOVAL AND INSTALLATION” on page 9.) Adjuster

Clip

Shaft Wiring Loom Hold-Down Tab Pedestal Mount Nuts (4 used)

Detent Wire

M83245

M54681

4. Remove cotter pin from steering shaft at pinion gear. 5. Remove park brake lever bushing. 6. Remove four pedestal mounting nuts. 7. Disconnect wiring connector and loom hold-down tab.

• Inspect all parts for wear or damage. Replace parts as necessary. Installation: Installation is done in the reverse order of removal.

10 - 10

3/7/00

INDEX

A Adjustments Attachments Mower Gage Wheels Adjust . . . . . . . . . . 9-16 Mower Level Front-to-Rear . . . . . . . . . . . 9-15 Mower Level Side-to-Side . . . . . . . . . . . . 9-14 Brake Adjustment . . . . . . . . . . . . . . . . . . . . 8-11 Gear Power Train Gearshift Lever Neutral Adjustment . . . . . 5-28 Traction Belt Tension Adjustment . . . . . . 5-28 Hydrostatic Power Train Pedal Height Adjustment . . . . . . . . . . . . . 6-41 Traction Drive Belt Tension Adjustment . . 6-42 Kohler Engine Choke Adjustment . . . . . . . . . . . . . . . . . . 3-18 Crankcase Vacuum Test . . . . . . . . . . . . . 3-22 Cylinder Compression Pressure Test . . . 3-20 Cylinder Leak Test . . . . . . . . . . . . . . . . . . 3-21 Engine Oil Pressure Test . . . . . . . . . . . . . 3-24 Fast Idle Speed Adjustment . . . . . . . . . . . 3-19 Fuel Pump Test . . . . . . . . . . . . . . . . . . . . 3-25 Fuel Shutoff Solenoid Test . . . . . . . . . . . . 3-22 Governor Adjustment . . . . . . . . . . . . . . . . 3-17 Magnets Test . . . . . . . . . . . . . . . . . . . . . . 3-27 Module Air Gap Adjustment . . . . . . . . . . . 3-27 Slow Idle Speed Adjustment . . . . . . . . . . 3-20 Spark Plug Gap Adjustment . . . . . . . . . . . 3-26 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Steering Drag Link Adjustment . . . . . . . . . . . 7-7 Attachments 48/54-Inch Mower Deck Components . . . . . . 9-4 Adjustment Specifications . . . . . . . . . . . . . . . 9-3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Balancing Mower Blades . . . . . . . . . . . . . . . 9-17 Cross Section 48/54-Inch Deck . . . . . . . . . . 9-20 Cuts Unevenly . . . . . . . . . . . . . . . . . . . . . . . 9-13 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Draft Arms Component Location . . . . . . . . . . 9-5 Gauge Wheels Component Location . . . . . . . 9-6 Idlers and Sheaves 48/54-Inch . . . . . . . . . . . 9-7 Mower Blades Removal/Installation . . . . . . . 9-16 Mower Deck Deck Vibrates . . . . . . . . . . . . . . . . . . . . . . 9-12 Removal/Installation . . . . . . . . . . . . . . . . . 9-18 Will Not Run . . . . . . . . . . . . . . . . . . . . . . . 9-11 Mower Deck Troubleshooting Chart . . . . . . . 9-8 Mower Drive Checks . . . . . . . . . . . . . . . . . . . 9-9 Mower Gage Wheels Adjust . . . . . . . . . . . . 9-16

3/3/00

Mower Level Front-to-Rear . . . . . . . . . . . . . 9-15 Mower Level Side-to-Side . . . . . . . . . . . . . . 9-14 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Repair Specifications . . . . . . . . . . . . . . . . . . . 9-3 Service Parts Kits . . . . . . . . . . . . . . . . . . . . . 9-3 Sharpen Mower Blades . . . . . . . . . . . . . . . . 9-17 Special or Essential Tools . . . . . . . . . . . . . . . 9-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Spindles 48/54-Inch Disassembly/Inspection . . . . . . . . . . . . . . 9-19 Removal/Installation . . . . . . . . . . . . . . . . . 9-19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 9-8

B Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Belt Drive System Operation Gear Power Train . . . . . . . . . . . . . . . . . . . . . 5-4 Brakes Adjustment Specifications . . . . . . . . . . . . . . . 8-3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Brake Adjustment . . . . . . . . . . . . . . . . . . . . 8-11 Brake Linkage . . . . . . . . . . . . . . . . . . . . . . . 8-12 Brake Pedal Assembly . . . . . . . . . . . . . . . . . 8-12 Brake System Operation . . . . . . . . . . . . . . . . 8-4 Component Location and Operation . . . . . . . 8-4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Brake Switch Does Not Engage . . . . . . . . 8-10 Brakes Do Not Engage . . . . . . . . . . . . . . . 8-8 Machine is Slow in Reverse . . . . . . . . . . . 8-10 Machine Will Not Move in Forward or Reverse or is Slow in Forward . . . . . . . . . . . . . . . . . . 8-9 Noisy Operation . . . . . . . . . . . . . . . . . . . . . 8-9 Park Brake Does Not Hold On Slope . . . . . 8-8 Internal Brake Linkage Operation . . . . . . . . . 8-6 Other Materials . . . . . . . . . . . . . . . . . . . . . . . 8-3 Pedal and Linkage Adjustment . . . . . . . . . . 6-42 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Repair Specifications . . . . . . . . . . . . . . . . . . . 8-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 8-7

C Component Location Attachments

INDEX - 1

INDEX 48/54-Inch Mower Deck Components . . . . 9-4 Draft Arms . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Gauge Wheels . . . . . . . . . . . . . . . . . . . . . . 9-6 Idlers and Sheaves 48/54-Inch . . . . . . . . . 9-7 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Brakes Brake System Operation . . . . . . . . . . . . . . 8-4 Internal Brake Linkage Operation . . . . . . . 8-6 Center Case and Valves . . . . . . . . . . . . . . . . 6-6 Control Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Electrical Components . . . . . . . . . . . . . . . . . . 4-7 Miscellaneous Front Axle and Tires . . . . . . . . . . . . . . . . . 10-4 Lift Assist and Depth Stop Operation . . . . 10-5 Reduction Gears . . . . . . . . . . . . . . . . . . . . . 6-10 Transaxle Case Halves . . . . . . . . . . . . . . . . . 6-5 Transaxle Motor & Piston Pump-K62 . . . . . . 6-7 Transaxle Motor & Piston Pump-K66 . . . . . . 6-8 Transaxle Swash Plate . . . . . . . . . . . . . . . . . 6-9 Component Location and Operation Gear Power Train . . . . . . . . . . . . . . . . . . . . . 5-4 Belt Drive System Operation . . . . . . . . . . . 5-4 Transaxle Operation . . . . . . . . . . . . . . . . . 5-5

D Diagnosis Attachments Cuts Unevenly . . . . . . . . . . . . . . . . . . . . . 9-13 Mower Deck Vibrates . . . . . . . . . . . . . . . . 9-12 Mower Deck Will Not Run . . . . . . . . . . . . 9-11 Mower Drive Checks . . . . . . . . . . . . . . . . . 9-9 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Brake Switch Does Not Engage . . . . . . . . 8-10 Brakes Do Not Engage . . . . . . . . . . . . . . . 8-8 Diagnosis Machine is Slow in Reverse . . . . . . . . 8-10 Machine Will Not Move in Forward or Reverse or is Slow in Forward . . . . . . . . . . . . . . . . . . 8-9 Noisy Operation . . . . . . . . . . . . . . . . . . . . . 8-9 Park Brake Does Not Hold On Slope . . . . . 8-8 Gear Power Train . . . . . . . . . . . . . . . . . . . . 5-10 Belt Slips, Erratic Drive . . . . . . . . . . . . . . 5-16 Jerky and Aggressive Engagement . . . . . 5-20 Machine Moves In One Direction Only . . 5-14 Machine Will Not Move . . . . . . . . . . . . . . 5-10 Noisy Operation . . . . . . . . . . . . . . . . . . . . 5-24 Shifts Hard . . . . . . . . . . . . . . . . . . . . . . . . 5-22

INDEX - 2

Hydrostatic Power Train Erratic Speed . . . . . . . . . . . . . . . . . . . . . . 6-30 Freewheel Valve Will Not Work . . . . . . . . 6-39 Noisy Operation . . . . . . . . . . . . . . . . . . . . 6-24 Park Brake Does Not Hold Tractor On Hill 6-36 Tractor Creeps . . . . . . . . . . . . . . . . . . . . . 6-26 Tractor Does Not Achieve Full Speed . . . 6-32 Tractor is Too Aggressive in Forward or Reverse 6-38 Tractor Moves In One Direction Only . . . . 6-28 Tractor Will Not Move Forward or Reverse 6-20 Steering System . . . . . . . . . . . . . . . . . . . . . . 7-6 Differential Removal Disassembly and Installation Gear Power Train . . . . . . . . . . . . . . . . . . . 5-39

E Electrical Brake Switch Test . . . . . . . . . . . . . . . . . . . . 4-60 Charging Circuit Diagnosis . . . . . . . . . . . . . 4-34 Charging Circuit Operation . . . . . . . . . . . . . 4-32 Charging Circuit Schematic . . . . . . . . . . . . . 4-33 Common Circuit Tests . . . . . . . . . . . . . . . . . . 4-5 Component Location . . . . . . . . . . . . . . . . . . . 4-7 Cranking Circuit Diagnosis . . . . . . . . . . . . . 4-22 Cranking Circuit Operation . . . . . . . . . . . . . 4-20 Cranking Circuit Schematic . . . . . . . . . . . . . 4-21 Diagnostic Information . . . . . . . . . . . . . . . . . . 4-3 Engine Shutoff Circuit Operation . . . . . . . . . 4-28 Engine Shutoff Circuit Schematic . . . . . . . . 4-29 Ground Circuit Tests . . . . . . . . . . . . . . . . . . 4-50 Headlight Wiring Harness . . . . . . . . . . . . . . 4-11 Ignition Circuit Diagnosis . . . . . . . . . . . . . . . 4-26 Ignition Circuit Operation . . . . . . . . . . . . . . . 4-24 Key Switch Test . . . . . . . . . . . . . . . . . . . . . . 4-59 Kohler Engine Wiring Harnesses . . . . . . . . . 4-11 Light Switch Test . . . . . . . . . . . . . . . . . . . . . 4-58 Main Electrical Schematic . . . . . . . . . . . . . . . 4-9 Main Wiring Harness . . . . . . . . . . . . . . . . . . 4-10 Module Air Gap Adjustment . . . . . . . . . . . . . 3-27 Power Circuit Diagnosis . . . . . . . . . . . . . . . . 4-16 Power Circuit Operation . . . . . . . . . . . . . . . . 4-14 Power Circuit Schematic . . . . . . . . . . . . . . . 4-15 PTO Switch Test . . . . . . . . . . . . . . . . . . . . . 4-59 Reading Electrical Schematics . . . . . . . . . . . 4-4 Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . 4-60 Schematics and Wiring Harness Legend . . . . 4-8 Seat Switch Test . . . . . . . . . . . . . . . . . . . . . 4-62 3/3/00

INDEX Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Standard Headlight Circuit Diagnosis . . . . . 4-48 Standard Headlight Circuit Operation . . . . . 4-46 Starting Motor Amperage & RPM Test . . . . . . . . . . . . . . 4-56 Brush Replacement . . . . . . . . . . . . . . . . . 4-67 Drive Replacement . . . . . . . . . . . . . . . . . 4-67 Loaded Amperage Draw Test . . . . . . . . . 4-54 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . 4-53 Tests & Adjustments . . . . . . . . . . . . . . . . . . 4-50 Theory of Operation Information . . . . . . . . . . 4-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 4-13 Wire Color Abbreviation Chart . . . . . . . . . . . . 4-3 Electrical Wiring Harness Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . Main Harness W1 . . . . . . . . . . . . . . . . . . . . Standard Headlight Harness W3 . . . . . . . . . W2 Headlight Wiring Harness . . . . . . . . . . .

4-11 4-11 4-10 4-47 4-11

Engine Serial Number . . . . . . . . . . . . . . . . . . . . 2-10

F Fender Deck Removal and Installation . . . . . . . 10-9 Front Axle and Tires - Component Location . . . 10-4 Front Wheel Bushing Removal . . . . . . . . . . . . . 10-8 Front Wheel Removal and Installation . . . . . . . 10-8

G Gasoline Specifications . . . . . . . . . . . . . . . . . . . . 2-8 Gear Power Train Gearshift Lever Neutral Adjustment . . . . . . . Jerky and Aggressive Engagement . . . . . . . Noisy Operation . . . . . . . . . . . . . . . . . . . . . . Traction Belt Tension Adjustment . . . . . . . .

5-28 5-20 5-24 5-28

General Specifications Mower Deck Drive Belt . . . . . . . . . . . . . . . . . 2-5 PTO Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

H Hood Removal and Installation . . . . . . . . . . . . . 10-9 Hydrostatic Power Train Adjustments Pedal Height Adjustment . . . . . . . . . . . . . 6-41 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-3 3/3/00

Traction Drive Belt Tension Adjustment . . 6-42 Component Location Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Brake Linkage . . . . . . . . . . . . . . . . . . . . . 6-11 Case Halves . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Center Case and Valves . . . . . . . . . . . . . . 6-6 Control Pedals and Linkage . . . . . . . . . . . 6-11 Control Shaft . . . . . . . . . . . . . . . . . . . . . . . 6-9 Differential . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Motor and Piston Pump-K62 . . . . . . . . . . . 6-7 Motor and Piston Pump-K66 . . . . . . . . . . . 6-8 Reduction Gears . . . . . . . . . . . . . . . . . . . 6-10 Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Diagnosis Erratic Speed . . . . . . . . . . . . . . . . . . . . . . 6-30 Freewheel Valve Will Not Work . . . . . . . . 6-39 Noisy Operation . . . . . . . . . . . . . . . . . . . . 6-24 Park Brake Does Not Hold Tractor On Hill 6-36 Tractor Creeps . . . . . . . . . . . . . . . . . . . . . 6-26 Tractor Does Not Achieve Full Speed . . . 6-32 Tractor is Too Aggressive in Forward or Reverse 6-38 Tractor Moves In One Direction Only . . . . 6-28 Tractor Will Not Move Forward or Reverse 6-20 Neutral Creep Adjustment . . . . . . . . . . . . . . 6-40 Other Materials . . . . . . . . . . . . . . . . . . . . . . . 6-4 Repair Specifications . . . . . . . . . . . . . . . . . . . 6-3 Theory of Operation Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Drive System Operation . . . . . . . . . . . . . . 6-12 Gear Power Flow . . . . . . . . . . . . . . . . . . . 6-16 Hydrostatic System . . . . . . . . . . . . . . . . . 6-14 Transaxle Bleeding Procedure . . . . . . . . . . 6-40 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 6-18 Hydrostatic Transmission Oil . . . . . . . . . . . . . . . 2-9

K Kohler Engine Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Removal . . . . . . . . . . . . . . . . Block Inspection . . . . . . . . . . . . . . . . . . . . Camshaft End Play . . . . . . . . . . . . . . . . . Camshaft Inspection . . . . . . . . . . . . . . . . Camshaft Removal and Installation . . . . . Carburetor Removal and Installation . . . . Crankcase Reed Valve Inspection . . . . . . Crankshaft Measurement . . . . . . . . . . . . .

3-29 3-31 3-54 3-44 3-44 3-43 3-32 3-41 3-49

INDEX - 3

INDEX Crankshaft Oil Seal Removal and Installation . 3-52 Cylinder Bore Deglaze . . . . . . . . . . . . . . . 3-54 Cylinder Head Inspection . . . . . . . . . . . . . 3-40 Cylinder Head Removal and Installation . 3-36 Engine Installation . . . . . . . . . . . . . . . . . . 3-30 Engine Removal . . . . . . . . . . . . . . . . . . . . 3-29 Flywheel Remove and Install . . . . . . . . . . 3-42 Fuel Pump, Removal and Installation . . . 3-32 Governor Control Arm Removal and Installation 3-45 Governor Removal and Installation . . . . . 3-45 Hydraulic Valve Lifters Inspection . . . . . . 3-34 Lap Valves . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Oil Pan Crankshaft Seal Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Oil Pan Removal and Installation . . . . . . . 3-51 Oil Pressure Switch, Replace . . . . . . . . . 3-53 Oil Pump Removal and Installation . . . . . 3-53 Piston Assembly . . . . . . . . . . . . . . . . . . . 3-50 Piston Disassemble . . . . . . . . . . . . . . . . . 3-46 Piston Inspection . . . . . . . . . . . . . . . . . . . 3-47 Piston Installation . . . . . . . . . . . . . . . . . . . 3-51 Piston Pin Inspection . . . . . . . . . . . . . . . . 3-47 Piston Removal . . . . . . . . . . . . . . . . . . . . 3-46 Piston Ring End Gap . . . . . . . . . . . . . . . . 3-47 Piston Ring Side Clearance . . . . . . . . . . . 3-47 Piston to Bore Measurement . . . . . . . . . . 3-48 Push Rod Inspection . . . . . . . . . . . . . . . . 3-41 Recondition Valve Seats . . . . . . . . . . . . . 3-40 Rocker Arms Removal & Installation . . . . 3-33 Stator Remove and Install . . . . . . . . . . . . 3-42 Valve Guides Inspection . . . . . . . . . . . . . 3-40 Valve Inspection . . . . . . . . . . . . . . . . . . . . 3-39 Valve Spring Inspection . . . . . . . . . . . . . . 3-39 Valves and Springs Removal & Installation . . . . . . . . . . . . 3-38 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 General Specifications . . . . . . . . . . . . . . . . 3-3 Repair Specifications . . . . . . . . . . . . . . . . . 3-4 Test & Adjustment Specifications . . . . . . . 3-4 Torque Specifications . . . . . . . . . . . . . . . . 3-7 Tests and Adjustments . . . . . . . . . . . . . . . . 3-17 Choke Adjustment . . . . . . . . . . . . . . . . . . 3-18 Crankcase Vacuum Test . . . . . . . . . . . . . 3-22 Cylinder Compression Pressure Test . . . 3-20 Cylinder Leak Test . . . . . . . . . . . . . . . . . . 3-21 Engine Oil Pressure Test . . . . . . . . . . . . . 3-24 Fast Idle Speed Adjustment . . . . . . . . . . . 3-19 Flywheel Magnets Tests . . . . . . . . . . . . . 3-27

INDEX - 4

Fuel Pump Test . . . . . . . . . . . . . . . . . . . . 3-25 Fuel Shutoff Solenoid Test . . . . . . . . . . . . 3-22 Governor Adjustment . . . . . . . . . . . . . . . . 3-17 Slow Idle Speed Adjustment . . . . . . . . . . 3-20 Spark Plug Gap Adjustment . . . . . . . . . . . 3-26 Spark Test . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Theory of Operation Cooling System . . . . . . . . . . . . . . . . . . . . . 3-9 Crankcase Breather System . . . . . . . . . . . 3-9 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Troubleshooting Chart . . . . . . . . . . . . . . . . . 3-11

L Lift Assist and Depth Stop Operation . . . . . . . . 10-5 Lubricants Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Engine Break-In Oil-North America . . . . . . . . 2-8 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

M Miscellaneous Component Locations . . . . . . . . . . . . . . . . . 10-4 Fender Deck Removal and Installation . . . . 10-9 Front Axle and Tires . . . . . . . . . . . . . . . . . . 10-4 Front Axle Removal and Installation . . . . . . 10-6 Front Wheel Bushing Removal . . . . . . . . . . 10-8 Front Wheel Removal and Installation . . . . . 10-8 Height Adjuster . . . . . . . . . . . . . . . . . . . . . 10-10 Hood Removal and Installation . . . . . . . . . . 10-9 Lift Assist and Depth Stop Operation . . . . . . 10-5 Mower Deck Lift Linkage . . . . . . . . . . . . . . 10-10 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Seat & Support Removal & Installation . . . . 10-9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Mower Deck Lift Linkage . . . . . . . . . . . . . . . . . 10-10

N Neutral Creep Adjustment . . . . . . . . . . . . . . . . . 6-40

O Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3/3/00

INDEX

P PTO Clutch Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

R Relay Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Repair Attachments Balancing Mower Blades . . . . . . . . . . . . . 9-17 Cross Section 48/54-Inch Deck . . . . . . . . 9-20 Mower Blades Removal/Installation . . . . . 9-16 Mower Deck Removal/Installation . . . . . . 9-18 Sharpen Mower Blades . . . . . . . . . . . . . . 9-17 Spindles 48/54-Inch Disassembly/Inspection . . . . . . . . . . . 9-19 Removal/Installation . . . . . . . . . . . . . . 9-19 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Brake Linkage . . . . . . . . . . . . . . . . . . . . . 8-12 Brake Pedal Assembly . . . . . . . . . . . . . . . 8-12 Gear Power Train . . . . . . . . . . . . . . . . . . . . 5-29 Differential Removal Disassembly & Installation . . 5-39 Traction Drive Belt Removal & Installation . . . . . . . . . . . . 5-42 Traction Drive Clutch Assembly Removal & Installation . . . . 5-41 Transaxle Assembly . . . . . . . . . . . . . . . . . 5-35 Transaxle Disassembly and Inspection . . 5-30 Transaxle Removal and Installation . . . . . 5-29 Miscellaneous Fender Deck Removal and Installation . . 10-9 Front Axle Removal and Installation . . . . 10-6 Front Wheel Bushing Removal . . . . . . . . 10-8 Front Wheel Removal and Installation . . . 10-8 Height Adjuster . . . . . . . . . . . . . . . . . . . 10-10 Hood Removal and Installation . . . . . . . . 10-9 Mower Deck Lift Linkage . . . . . . . . . . . . 10-10 Seat & Support Removal & Installation . . 10-9 Steering Left Turn Stop Modification . . . . . . . . . . . 7-10 Steering Sector Removal and Installation . 7-9 Steering Shaft . . . . . . . . . . . . . . . . . . . . . . 7-7 Steering Wheel Removal and Installation . 7-7 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6-59 Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6-50 Removal and Installation . . . . . . . . . . . . . 6-44

3/3/00

S Safety Avoid Injury Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO Shafts . . . . . . . . . . . . . . . . . . . . . . . . Rotating Blades . . . . . . . . . . . . . . . . . . . . . Handling and Servicing Batteries . . . . . . . . . . Handling Chemical Products . . . . . . . . . . . . . Handling Fluids - Avoid Fires . . . . . . . . . . . . . High-Pressure Fluid Lines . . . . . . . . . . . . . . . Recognize Safety Information . . . . . . . . . . . . Replace Signs . . . . . . . . . . . . . . . . . . . . . . . . Service Cooling System . . . . . . . . . . . . . . . . . . . . . Procedures . . . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understand Signal Words . . . . . . . . . . . . . . .

1-5 1-5 1-5 1-3 1-6 1-2 1-3 1-2 1-2 1-5 1-3 1-5 1-2

Schematics Charging Circuit . . . . . . . . . . . . . . . . . . . . . . 4-33 Cranking Circuit . . . . . . . . . . . . . . . . . . . . . . 4-21 Engine Shutoff Circuit . . . . . . . . . . . . . . . . . 4-29 Main Schematic . . . . . . . . . . . . . . . . . . . . . . . 4-9 Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Standard Headlight Circuit . . . . . . . . . . . . . . 4-47 Seat& Support Removal & Installation . . . . . . . 10-9 Serial Number Locations . . . . . . . . . . . . . . . . . . 2-10 Specifications Attachments Adjustment Specifications . . . . . . . . . . . . . 9-3 Repair Specifications . . . . . . . . . . . . . . . . . 9-3 Service Parts Kits . . . . . . . . . . . . . . . . . . . . 9-3 Special or Essential Tools . . . . . . . . . . . . . 9-3 Brakes Adjustment Specifications . . . . . . . . . . . . . 8-3 Other Materials . . . . . . . . . . . . . . . . . . . . . 8-3 Repair Specifications . . . . . . . . . . . . . . . . . 8-3 Electric PTO Clutch . . . . . . . . . . . . . . . . . . . . 4-6 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Gear Power Train Adjustment Specifications . . . . . . . . . . . . . 5-3 Other Materials . . . . . . . . . . . . . . . . . . . . . 5-3 Repair Specifications . . . . . . . . . . . . . . . . . 5-3 Hydrostatic Power Train Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Other Materials . . . . . . . . . . . . . . . . . . . . . 6-4 Repair Specifications . . . . . . . . . . . . . . . . . 6-3 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . 10-3

INDEX - 5

INDEX Steering Lubrication Interval . . . . . . . . . . . . . . . . . . . 7-3 Toe-In Adjustments . . . . . . . . . . . . . . . . . . 7-3 Torque Specifications . . . . . . . . . . . . . . . . 7-3 Starting Motor Loaded Amperage Draw Test . . . . . . . . . . . 4-54 No-Load Amperage & RPM Test . . . . . . . . . 4-56 Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Drag Link Adjustment . . . . . . . . . . . . . . . . . . 7-7 Left Turn Stop Modification . . . . . . . . . . . . . 7-10 Lubrication Interval . . . . . . . . . . . . . . . . . . . . 7-3 Steering Sector Removal and Installation . . . 7-9 Steering Shaft . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Steering Wheel Removal and Installation . . . 7-7 System Theory of Operation . . . . . . . . . . . . . 7-4 Toe-In Adjustment . . . . . . . . . . . . . . . . . . . . . 7-3 Toe-In Adjustments . . . . . . . . . . . . . . . . . . . . 7-3 Torque Specifications . . . . . . . . . . . . . . . . . . 7-3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 7-5

T Tests & Adjustments Battery Load Test . . . . . . . . . . . . . . . . . . . . Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . Brake Linkage Adjustment . . . . . . . . . . . . . . Brake Switch Test . . . . . . . . . . . . . . . . . . . . Charge Battery . . . . . . . . . . . . . . . . . . . . . . . Ground Circuit Tests . . . . . . . . . . . . . . . . . . Key Switch Test . . . . . . . . . . . . . . . . . . . . . . Light Switch Test . . . . . . . . . . . . . . . . . . . . . Neutral Creep Adjustment . . . . . . . . . . . . . . Pedal Height Adjustment . . . . . . . . . . . . . . . PTO Switch Test . . . . . . . . . . . . . . . . . . . . . RIO Switch Test . . . . . . . . . . . . . . . . . . . . . . Seat Switch Test . . . . . . . . . . . . . . . . . . . . . Spark Test . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Motor Loaded Amperage Draw Test . . . . . . . . . No-Load Amperage and RPM Tests . . . . Solenoid Test . . . . . . . . . . . . . . . . . . . . . .

4-52 4-51 6-42 4-60 4-51 4-50 4-59 4-58 6-40 6-41 4-59 4-60 4-62 4-58

Hydrostatic System . . . . . . . . . . . . . . . . . 6-14 Steering System . . . . . . . . . . . . . . . . . . . . . . 7-4 Torque Values Inch Torque Values . . . . . . . . . . . . . . . . . . . . 2-6 Metric Torque Values . . . . . . . . . . . . . . . . . . . 2-7 Traction Drive-Gear Power Train Belt Removal & Installation . . . . . . . . . . . . . 5-42 Clutch Assembly Removal & Installation . . . 5-41 Tractor Identification Number . . . . . . . . . . . . . . 2-10 Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Serial Number Location . . . . . . . . . . . . . . . .

6-59 6-50 6-44 2-10

Transaxle-Gear Power Train Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Disassembly and Inspection . . . . . . . . . . . . 5-30 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Removal and Installation . . . . . . . . . . . . . . . 5-29 Troubleshooting Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Gear Power Train . . . . . . . . . . . . . . . . . . . . . 5-9 Hydrostatic Power Train . . . . . . . . . . . . . . . 6-18 Kohler Engine Chart . . . . . . . . . . . . . . . . . . 3-11 Kohler Engine Guide Excessive Fuel Consumption . . . . . . . . . . 3-16 Excessive Oil Consumption . . . . . . . . . . . 3-15 Hard To Start . . . . . . . . . . . . . . . . . . . . . . 3-13 Low Power . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Malfunction at Low Speed . . . . . . . . . . . . 3-14 Runs Erratically . . . . . . . . . . . . . . . . . . . . 3-15 Mower Deck Troubleshooting Chart . . . . . . . 9-8 Steering System Chart . . . . . . . . . . . . . . . . . . 7-5

4-54 4-56 4-53

Theory of Operation Cooling System-Kohler . . . . . . . . . . . . . . . . . 3-9 Crankcase Breather System-Kohler . . . . . . . 3-9 Fuel System-Kohler . . . . . . . . . . . . . . . . . . . . 3-9 Hydrostatic Power Train Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Gear Power Flow . . . . . . . . . . . . . . . . . . . 6-16

INDEX - 6

3/3/00