Briggs & Stratton 1687286 User Manual

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Installation

Instructions

Power Steering Conversion Kit

Mfg. No. 1687286, 1687302

For Prestige / 500 / 1800 / 2800 Series Tractors

Power Steering Conversion Kit

Table of Contents

SECTION CONTENTS

 

General Information

 

Safety

 

Personal Protective Equipment ...................................................

1-1

Battery/Electrolyte Saftey .............................................................

1-1

Electrical System Safety ...............................................................

1-1

Elevating Unit Safety ....................................................................

1-1

Proper Tool Use............................................................................

1-1

Work Area Safety..........................................................................

1-2

Compressed Air Safety.................................................................

1-2

Grease & Lubricant Safety............................................................

1-2

General Servicinfg Safety .............................................................

1-2

General Repair

 

Bearings & Bushings ...................................................................

1-3

Belts & Pulleys.............................................................................

1-3

Electrical Parts..............................................................................

1-3

Fasteners & Harware....................................................................

1-4

Genuine Replacement Parts.........................................................

1-4

Hydraulic Parts .............................................................................

1-4

Paint..............................................................................................

1-4

Reuired Tools & Equipment..........................................................

1-4

System Checks.............................................................................

1-4

Notes ............................................................................................

1-5

Installation Instructions

 

Kit Contents .................................................................................

2-1

Parts, Descriptions.......................................................................

2-2

Hitch Replacement .......................................................................

2-3

Front Axle Replacement ...............................................................

2-3

Steering Replacement ..................................................................

2-7

Tilt & Steering Wheel Installation................................................

2-11

i

Installation Instructions

Table of Contents

ii

Safety Rules

General Information

SERVICE AND MAINTENANCE

Electrical System Safety

Personal Protective Equipment

• Loose connectors, worn wires, damaged wire insula-

• Wear protective safety glasses whenever using hand

tion, and loose termination hardware can cause

sparks, short-circuits,and erratic equipment opera-

or power tools, shop equipment, and whenever work-

tion. Always check wiring for damage, and make

ing under power equipment to protect your eyes from

appropriate repairs before placing unit back into oper-

falling debris and small parts.

ation.

• Wear safety goggles or full face protection when han-

• Use care when working around exposed terminals to

dling battery electrolyte fluid, or when performing

prevent short-circuitingthe electrical system.

grinding or sharpening operations that produce

Sparking, electric shocks, and damage to the system

sparks or flying debris. Extensive grinding may

may result from accidental contact between terminals

require the use of protective sleeves and an apron.

and metal hand tools.

• Wear work gloves when handling sharp surfaces

Elevating Unit Safely

such as mower blades, or when working around

• Always support unit on approved jack stands when

sharp edges. Never wear gloves that are loose fitting

or that have tie straps, as these could cause your

working on an elevated unit, and keep unit from

hands to get caught by rotating parts, resulting in seri-

rolling by engaging parking brake and placing wheel

ous injury. Chemical-resistantRubber gloves are rec-

chocks behind wheels still on floor or work table.

ommended when handling or pouring battery elec-

• Secure unit to work-surfaceofscissor-liftworktables

trolyte.

or other powered lift tables in accordance with the

Steel-toesafety shoes are highly recommended to

manufacturer’s instructions. Unsecured units may roll

protect feet from falling tools, heavy parts, and other

unexpectedly while work is being done, causing

shop equipment.

injuries.

Battery/Electrolyte Safety

• Never work under an elevated unit unless it is proper-

Lead-Acidbatteries use an electrolyte containing sul-

ly supported by jack stands, locked from rolling with

wheel chocks or equivalent, and you can quickly

phuric acid, a highly corrosive liquid that can cause

escape from under the unit in an emergency using a

severe chemical burns if allowed to come into contact

rolling device such as a mechanic’s creeper.

with skin, or blindness if allowed to contact your eyes.

• Always protect your eyes from falling debris or small

Always wear approved eye goggles or a full face

parts by wearing approved safety glasses or goggles.

shield and protective gloves when handling elec-

 

trolyte or filling the battery.

• Remove the ignition key and disconnect the spark

Lead-acidbatteries also produce hydrogen, a color-

plug wires before working under a unit. Accidental or

inadvertent starting could result in serious injuries.

less, highly explosive gas that can be easily ignited

Proper Tool Use

by a single spark. Charging the battery incorrectly or

hooking up jumper cables improperly can cause

 

sparking, and must be avoided. Always follow rec-

• Use power and hand tools only for the use that they

were designed. Never alter or modify tools, or impro-

ommended battery charging and jumper cable pro-

vise using tools that are not suitable for the job at

cedures.

hand.

• When removing or installing battery cables, discon-

• Keep all hand and power tools in good repair, and put

nect the negative cable FIRST, and reconnect it

them away when done to avoid cluttering the work

LAST. If not done in this order, the positive terminal

area. Use extra care when using corded tools around

could be accidentally shorted to the frame by a tool,

moving or rotating parts such as belts and pulleys,

creating a dangerous spark that can ignite nearby fuel

since the cord could get caught and suddenly pull the

vapors or escaping hydrogen gas from the battery.

tool, or you, into the area of moving parts.

• Keep battery securely fastened in position with vent

• Always check the unit to ensure that all hand and

tube directed down and out of battery compartment.

power tools and tool attachments have been removed

Replace battery if electrolyte leakage occurs. Make

from the unit after use. Small tools and tool attach-

sure the battery vent tube is properly installed, and is

ments left on the equipment can fall into the cutting

not plugged with clippings or other debris. Replace

path when the unit is placed into service, and become

the vent tube if cracked, damaged, or missing from

a hazard to bystanders if struck by mower blades.

unit.

 

• Old batteries should be disposed of by recycling.

 

1-1

 

General Information

Safety Rules

Work Area Safety

General Servicing Safety

Always keep the work area clear of clutter from discarded parts, and debris from parts boxes or packaging materials. Small parts, hardware items, and other debris or refuse left lying around can become slip, trip, and fall hazards if not removed and discarded of properly.

Always observe general shop safety rules for housekeeping, and tend to oil spills and other spilled fluids promptly to prevent slip and fall injuries.

Allow sufficient work area around the equipment you are working on to permit comfortable working positions. Never put yourself in a position that would prevent you from escaping quickly in the event of emergencies such as sudden shifts in equipment position, fire, or other situations requiring an immediate reaction on your part.

Compressed Air Safety

Always use care when using compressed air to blow dirt and debris off equipment - always direct the air blast away from yourself and others in the area, and protect your eyes with safety glasses to prevent injury from particles that may blow back toward your face.

Never use high pressure air directly against your skin to clean dirt and debris - the air pressure could actually force foreign material or fluids into your skin, causing serious injuries.

Use care when filling tires - lawn and garden tractors utilize low pressure tires, and over-pressurizationis hazardous to you and anyone who operates the equipment with improper tire pressures. Always consult the air pressure recommendations for the unit involved before adding additional air to the tires.

Grease & Lubricant Safety

Normal service and maintenance involves the use of oils and greases that could present a fire hazard if not handled properly. Always dispose of oily rags properly to prevent fires caused by spontaneous combustion.

Spilled lubricants pose dangerous slip hazards and must be taken care of immediately. Wipe up spills carefully, or use absorbent materials to soak up spilled fluids. Always dispose of rags, paper towels, and other saturated absorbent properly.

Store oils and greases away from flame or other ignition sources. Petroleum-basedfluids can be ignited by smoking materials and sparks - always treat oils and greases as potentially flammable materials. Always cap oil and grease containers when done using, and store or dispose of properly.

Always check safety devices and switches for proper operation - never alter these devices or make temporary or makeshift repairs. Use only factory-autho-rized parts and procedures, and check newlyinstalled parts for proper operation.

Make sure all hardware items are properly tightened, especially blade attachment bolts. Replace any hardware that appears damaged.

Check brake operation, and adjust or repair as required. Always comply with factory specifications on settings and adjustments.

Check grass catcher components for wear, damage, or deterioration, and replace with factory authorized parts if necessary.

Always make repairs using factory authorized replacement parts only. Using parts that don’t meet factory specifications can result in sudden or premature failures, poor or erratic equipment performance, and potential safety hazards to operators and bystanders.

Always comply with factory specifications on settings and adjustments when installing new parts, making repairs, or performing routine service procedures.

Always test repairs before releasing units to customers, paying special attention to any items that are safety-related.Correct any problems noted, and recheck to ensure that the problems have been fully remedied.

Make sure all safety and operating instruction decals are legible, properly located, and securely attached. Replace any decals that can’t be read or are in danger of falling off.

Always advise equipment owners of any potential operating or safety problems that may be arising due to anticipated wear, and request that the owner address the problem before a hazard develops.

Never allow a unit to be placed back into service if a serious safety or operating problem is evident. Advise the owner of the problem and the possible hazards associated with the problem, and request permission to correct the deficiencies.

Use extreme care when working on older models that do not have all of the latest safety devices and switches. Disengage the PTO and transmission before starting the unit, or commencing repairs.

Always use care when removing or installing parts to prevent damage from dropping or rough handling. Support heavy parts properly to prevent damage or personal injury to yourself and others.

1-2

Safety Rules

General Information

GENERAL REPAIR INFORMATION

In addition to providing specific repair procedures for the equipment listed at the beginning of this section, this manual provides the following additional general instructions for dealing with repairs to various types of components.

This information is designed to help you deal more effectively with these components by providing basic service knowledge and other useful tips.

Bearings & Bushings

Roller bearings, ball bearings, and bushings are used to provide support to rotating shafts and other parts such as gears, pulleys, and sprockets that are used to transmit rotary motion. Over time, bearings and bushings may require additional lubrication to transmit this rotary motion with minimal friction, or may need replacement due to normal operation and wear. Normal service for bearings and bushings includes removal, cleaning, inspection, lubrication, and replacement.

REMOVAL

Most bearings and bushings used on the listed equipment can be easily removed by following the appropriate detailed procedures found throughout this manual. Care should always be exercised to avoid scratching or damaging the bearing or bushing, the mounting shaft, and surrounding components. Bearing or bushing removal is usually necessary when excessive play or wobble is noticed on the part it supports, when unusual noise or vibration is apparent, or when a burning smell is present at the bearing location.

CLEANING

Sealed bearings and bushings can be cleaned by careful wiping with a cloth. Bearings with one-sidedor removable shields and plain bushings can be cleaned by immersion in safety solvent, and brushing with a part cleaning brush.Oil-impregnatedbushings, and bushings made of nylon or other synthetic materials, can be cleaned with safety solvents, or wiped clean, but should not be immersed in solvent for periods longer than that necessary to remove heavy orcaked-onbuild-upsof grease. Allpetroleum-basedsolvents are flammable, so appropriate precautions regarding flames, sparks, and other ignition sources should always be observed. Gasoline should never be used because of its volatility and its highly toxic nature.

INSPECTION

Once cleaned, bearings can be properly inspected for wear, scratches, visible damage such as corrosion, cracked seals or scorching, and rough, or noisy, operation. Bushings can be visually checked for scratches, uneven wear, or other visual damage.

LUBRICATION

After passing inspection, bearings and bushings should be lubricated in accordance with factory specifications, and reinstalled according to the appropriate installation instructions. New bearings and bushings must also be properly lubricated before use. For optimal performance, and as a practical preventive maintenance measure, bearings and bushings used in pairs or multiple sets should all be replaced at the same time.

Belts & Pulleys

Belts and pulleys transmit rotary motion from power sources to work components, providing the force needed to drive transmissions, operate mower decks, and power various attachments. This continual use eventually causes belts to wear out, and over time may also require the replacement of pulleys and pulley bearings.

Belt wear and various types of damage are easily checked by visual examination, which is covered in greater detail elsewhere in this manual. Pulleys may also be checked visually for wear or apparent damage, but pulley bearings usually require removal, cleaning, and inspection to determine if replacement is required.

Belt and pulley life can be optimized by making sure that proper belt tension and alignment are observed when belts are installed. Proper belt tension and alignment should also be maintained by performing periodic checks and adjustments. In addition, only factory authorized replacement belts will minimize problems caused by size, thermal instability, and variations in quality.

Electrical Parts

The electrical parts used on these units have been specifically engineered for outdoor power equipment, and are designed to provide years of reliable operation. As with all electrical components and systems, electrical contacts must be kept clean and dry, and all terminations must be securely fastened or connected. Also, all electrical components, wiring, and connectors should be periodically inspected for corrosion, signs of excessive heat build-up,or other damage that signals that it is time to repair or replace the item.

Specific procedures for electrical troubleshooting and most common repairs is covered in separate sections of this manual.

1-3

General Information

Safety Rules

Fasteners & Hardware

All hardware and fasteners used in this equipment must meet factory specifications for SAE grade, size, and torque, and must be kept securely tightened. Locking hardware that degrades with use should be replaced when service is performed in affected areas. Always observe factory specifications for torque, or consult the torque chart for torque information.

Genuine Replacement Parts

Only factory authorized replacement parts should be used when making repairs or performing routine maintenance. The use of parts that do not meet stringent factory specifications can cause poor performance, premature failures, and lead to potential safety hazards. In addition, the use of non-factoryauthorized replacement parts will void your warranty.

Hydraulic Parts

Hydraulic parts are adversely affected by dirt and contamination, and care must be exercised when performing service on these parts to prevent foreign material from entering. Specific service information appears elsewhere in this manual, and all precautions and procedures must be followed when repairing or servicing these parts.

Paint

The paint on outdoor power equipment provides for an attractive appearance, as well as a barrier to corrosion caused by exposure to moisture in the environment.

Scratches, abrasions, and other damage to painted surfaces should be repaired promptly to prevent the formation of rust and premature part failure. Factory supplied paints are available that provide both an accurate color match and superior corrosion resistance.

Required Tools & Equipment

All repairs in this manual can be accomplished with standard mechanic’s hand tools. The use of appropriate power tools such as impact wrenches and power drivers may aid in part removal and replacement, but care must be exercised to avoid causing damage to components from excessive tightening. Transmission service, steering service, tire and wheel service, and service to components located under the frame also requires the use of a jack with suitable capacity, and jack stands to support the unit being worked on.

Systems Checks

In addition to performing individual component service, components affected by related parts changes should also receive attention at the time service is performed.

Examples of this include part replacements that are part of a safety device, electrical components, transmission components, and pulleys that are part of the same power delivery system. Giving attention to related parts will help ensure that the parts most likely to be affected by the wear of similar or nearby parts, or parts subjected to the same amount of stress or wear, are given appropriate attention before a failure can occur.

1-4

Safety Rules

General Information

NOTES

1-5