Briggs & Stratton 1687302, 1687286 User Manual

Installation
Instructions

Power Steering Conversion Kit

Mfg. No. 1687286, 1687302

For Prestige / 500 / 1800 / 2800 Series Tractors

i

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

ii

Installation Instructions Table of Contents

1-1

Safety Rules General Information

SERVICE AND MAINTENANCE

Personal Protective Equipment

• Wear protective safety glasses whenever using hand
or power tools, shop equipment, and whenever work­ing under power equipment to protect your eyes from
falling debris and small parts.

• Wear safety goggles or full face protection when han­dling battery electrolyte fluid, or when performing
grinding or sharpening operations that produce
sparks or flying debris. Extensive grinding may
require the use of protective sleeves and an apron.

• Wear work gloves when handling sharp surfaces
such as mower blades, or when working around
sharp edges. Never wear gloves that are loose fitting
or that have tie straps, as these could cause your
hands to get caught by rotating parts, resulting in seri­ous injury. Chemical-resistant Rubber gloves are rec­ommended when handling or pouring battery elec­trolyte.

• Steel-toe safety shoes are highly recommended to
protect feet from falling tools, heavy parts, and other
shop equipment.

Battery/Electrolyte Safety

• Lead-Acid batteries use an electrolyte containing sul­phuric acid, a highly corrosive liquid that can cause
severe chemical burns if allowed to come into contact
with skin, or blindness if allowed to contact your eyes.
Always wear approved eye goggles or a full face
shield and protective gloves when handling elec­trolyte or filling the battery.

• Lead-acid batteries also produce hydrogen, a color­less, highly explosive gas that can be easily ignited
by a single spark. Charging the battery incorrectly or
hooking up jumper cables improperly can cause
sparking, and must be avoided. Always follow rec­ommended battery charging and jumper cable pro­cedures.

• When removing or installing battery cables, discon­nect the negative cable FIRST, and reconnect it
LAST. If not done in this order, the positive terminal
could be accidentally shorted to the frame by a tool,
creating a dangerous spark that can ignite nearby fuel
vapors or escaping hydrogen gas from the battery.

• Keep battery securely fastened in position with vent
tube directed down and out of battery compartment.
Replace battery if electrolyte leakage occurs. Make
sure the battery vent tube is properly installed, and is
not plugged with clippings or other debris. Replace
the vent tube if cracked, damaged, or missing from
unit.

• Old batteries should be disposed of by recycling.

Electrical System Safety

• Loose connectors, worn wires, damaged wire insula­tion, and loose termination hardware can cause
sparks, short-circuits, and erratic equipment opera­tion. Always check wiring for damage, and make
appropriate repairs before placing unit back into oper­ation.

• Use care when working around exposed terminals to
prevent short-circuiting the electrical system.
Sparking, electric shocks, and damage to the system
may result from accidental contact between terminals
and metal hand tools.

Elevating Unit Safely

• Always support unit on approved jack stands when
working on an elevated unit, and keep unit from
rolling by engaging parking brake and placing wheel
chocks behind wheels still on floor or work table.

• Secure unit to work-surface of scissor-lift worktables
or other powered lift tables in accordance with the
manufacturer’s instructions. Unsecured units may roll
unexpectedly while work is being done, causing
injuries.

• Never work under an elevated unit unless it is proper­ly supported by jack stands, locked from rolling with
wheel chocks or equivalent, and you can quickly
escape from under the unit in an emergency using a
rolling device such as a mechanic’s creeper.

• Always protect your eyes from falling debris or small
parts by wearing approved safety glasses or goggles.

• Remove the ignition key and disconnect the spark
plug wires before working under a unit. Accidental or
inadvertent starting could result in serious injuries.

Proper T ool Use

• Use power and hand tools only for the use that they
were designed. Never alter or modify tools, or impro­vise using tools that are not suitable for the job at
hand.

• Keep all hand and power tools in good repair, and put
them away when done to avoid cluttering the work
area. Use extra care when using corded tools around
moving or rotating parts such as belts and pulleys,
since the cord could get caught and suddenly pull the
tool, or you, into the area of moving parts.

• Always check the unit to ensure that all hand and
power tools and tool attachments have been removed
from the unit after use. Small tools and tool attach­ments left on the equipment can fall into the cutting
path when the unit is placed into service, and become
a hazard to bystanders if struck by mower blades.

1-2

General Information Safety Rules

Work Area 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-pressurization is
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-based fluids 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.

General Servicing Safety

• Always check safety devices and switches for proper
operation - never alter these devices or make tempo­rary or makeshift repairs. Use only factory-autho­rized 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.

1-3

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-sided or remov­able shields and plain bushings can be cleaned by
immersion in safety solvent, and brushing with a part
cleaning brush. Oil-impregnated bushings, 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 or caked-on build-ups of
grease. All petroleum-based solvents 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.

1-4

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-factory authorized 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.