Cub Cadet 2000 User Manual
Professional Shop Manual
2000 Series Tractors
(2011 Model year and Newer)
NOTE: These materials are for use by trained technicians who are experi enced in the service and repair of outdo or power
equipment of the kind described in this publication, and are not intende d for use by untrained or inexperienced individuals.
These materials are intended to provide supplemental information to assist the trained technician. Untrained or inexperienced individuals should seek the assistance of an experie nced and trained professio nal. Read, understand, and follow all
instructions and use common sense when working on powe r e quip ment. T his includes the contents of the product’s Operators Manual, supplied with the equipment. No liability can be accepted for any inaccuracies or omission in this publication,
although care has been taken to make it as complete and accurate as possible at the time of publication. However, due to
the variety of outdoor power equipment and continuing product changes that occur over time, updates will be made to these
instructions from time to time. Therefore, it may be necessary to obtain the latest materials before servicing or repairing a
product. The company reserves the right to make changes at any time to this publication without prior notice and without
incurring an obligation to make such changes to previously published versions. Instructions, photographs and illustrations
used in this publication are for reference use only and may not depict actual model and component parts.
© Copyright 2011 MTD Products Inc. All Rights Reserved
MTD Products Inc. - Product Training and Education Department
Table of Contents
Chapter 1: Introduction
Professional shop manual intent ........................................................................1
Fasteners ...........................................................................................................1
Assembly ...........................................................................................................3
Description of the 2000 series tractor ................................................................3
Model and Serial Numbers ................................................................................ 4
Chapter 2: Engine Related Parts
Muffler ................................................................................................................5
Fuel tank removal/replacement ..........................................................................6
Throttle cable adjustment .................................................................................10
Choke cable adjustment ..................................................................................10
Choke and Throttle levers and cables .............................................................11
Engine removal/installation ..............................................................................13
Chapter 3: Brakes
Brake adjustment .............................................................................................17
Brake puck/rotor replacement ..........................................................................19
Brake shaft assembly .......................................................................................21
Brake rod adjustment 2.......................................................................................3
Chapter 4: Body
What is covered by this chapter .......................................................................25
Hood ................................................................................................................25
Hood components: side vent removal ..............................................................26
Hood components: Headlight removal .............................................................27
Hood components: grille removal ....................................................................28
Hood components: pivot bracket removal ........................................................30
Fender and running board ...............................................................................31
Dash Panel ......................................................................................................35
Chapter 5: Drive system
Transmission fluid filter ....................................................................................39
Transmission fluid change ............................................................................... 40
Drive shaft ........................................................................................................41
Hydro neutral control adjustment..................................................................... 42
Transmission removal/replacement .................................................................44
Forward drive pedal shaft ................................................................................48
Reverse drive pedal shaft ................................................................................ 50
Transmission Disassembly.............................................................................. 52
Transmission Assembly ...................................................................................61
I
Chapter 6A: Manual Steering
Steering alignment ...........................................................................................67
Front wheels ....................................................................................................69
Front wheel bearings .......................................................................................70
Axles ................................................................................................................71
Steering sector gear and steering pinion gear .................................................72
Steering shaft ...................................................................................................74
Pivot bar ...........................................................................................................78
Steering housing ..............................................................................................79
Greasing the steering housing .........................................................................80
Chapter 6B: Electronic Power Steering
Rubber Torsion Coupling................................................................................. 81
EPS Module .....................................................................................................81
EPS motor & gearbox ......................................................................................82
Troubleshooting the EPS................................................................................. 83
EPS removal/replacement ...............................................................................88
Chapter 7: electrical system
Introduction ......................................................................................................93
RMC Module ....................................................................................................93
Key switch ........................................................................................................94
RMC Module ....................................................................................................96
To identify a faulty RMC module: .....................................................................97
PTO Switch ......................................................................................................99
Brake Switch ....................................................................................................99
Reverse Safety Switch ...................................................................................100
Seat Safety Switch .........................................................................................100
Seat circuit (GTX2154LE) ..............................................................................101
Starter solenoid ..............................................................................................102
PTO Relay ..................................................................................................... 102
Start Circuit ....................................................................................................103
Run Circuit .....................................................................................................106
Run Circuit / Reverse Caution mode .............................................................107
Engine shut-down circuits ..............................................................................108
Charging circuit ..............................................................................................109
PTO Circuit ....................................................................................................114
Reverse Mower Control (RMC) circuit operation ........................................... 116
Deck lift circuit ................................................................................................118
Electrical diagnosis ........................................................................................119
Electronics .....................................................................................................119
Electrical environment: AC Vs. DC ................................................................ 120
Ohm’s Law .....................................................................................................121
Kirchhoff’s current law ....................................................................................121
Kirchhoff’s voltage law . .................................................................................. 122
How the system is wired together ..................................................................122
Types of circuits .............................................................................................123
Series .............................................................................................................123
II
Parallel ...........................................................................................................123
Series/parallel ................................................................................................124
Shorts .............................................................................................................124
Opens ............................................................................................................124
Increased resistance ......................................................................................124
The Tools .......................................................................................................125
Digital Multi-meter ..........................................................................................126
Wiring diagram or schematic .........................................................................127
Fused jumper wires ........................................................................................127
Test lights .......................................................................................................127
Self-powered continuity lights ........................................................................127
Ammeters and specialized charging system testers ......................................128
Batteries .........................................................................................................129
Charging the battery ......................................................................................129
Checking battery condition .............................................................................130
Battery Testers ...............................................................................................131
Adjustable load testers ...................................................................................131
Fixed load testers ...........................................................................................132
Conductance testers ......................................................................................132
Battery discharge test ....................................................................................133
Storage of batteries ........................................................................................133
Electrical Troubleshooting ..............................................................................134
Voltage Drop Test ..........................................................................................136
Testing switches ............................................................................................139
Diodes ............................................................................................................140
Relay.............................................................................................................. 142
Schematics ....................................................................................................143
Chapter 8: Decks and lift systems
Cutting decks .................................................................................................147
Deck removal/installation ...............................................................................147
Cleaning the deck ..........................................................................................149
Blades ............................................................................................................150
PTO belt .........................................................................................................152
Deck Belt ........................................................................................................154
Deck Belt Routings ........................................................................................155
Spindle pulleys and spindle shafts .................................................................158
Spindle removal/installation ...........................................................................159
Spindle overhaul ............................................................................................160
Leveling the deck ...........................................................................................162
Deck Gauge Wheel Adjustment .....................................................................164
Deck lift shaft bushings ..................................................................................165
Deck lift shaft assembly (manual) ..................................................................166
Deck lift shaft assembly (electric) ..................................................................169
Deck lift actuator (electric lift)......................................................................... 172
Electric PTO clutch ........................................................................................174
Evaluating the PTO clutch .............................................................................176
III
Chapter 9: Maintenance intervals
Lubrication .....................................................................................................179
Engine maintenance .......................................................................................179
The spark plugs .............................................................................................180
Air filter and pre-cleaner................................................................................. 181
Oil change ......................................................................................................183
Oil filter........................................................................................................... 184
Fuel system.................................................................................................... 184
Servicing the fuel system ...............................................................................185
Fuel filter ........................................................................................................185
Clean the engine............................................................................................ 186
IV
Introduction
CHAPTER 1: INTRODUCTION
Professional Shop Manual intent
This Manual is intended to provide service dealers with an introduction to the electrical and mechanical aspects
of the 2000 series tractor.
• Detailed service information about the engine will be provided by the engine manufacturer.
Disclaimer: The information contained in this manual is correct at the time of writing. Both the product and the information about the product are subject to change without notice.
About the text format:
NOTE: is used to point out information that is relevant to the pro cedure, bu t doe s not fit as a step in the pr ocedure.
• Bullet points: indicate sub-steps or points.
! CA UTION! CA UTION
! WA RNIN G! WA RNIN G
! DANGER! DANGER
Disclaimer: This manual is intended for use by trained, professional technicians.
• Common sense in operation and safety is assumed.
• In no event shall MTD or Cub Cadet be liable for poor text interpretation or poor execution of the procedures described in the text.
• If the person using this manual is uncomfortable with any procedures they encounter, they should seek
the help of a qualified technician or Cub Cadet Technical Support.
Fasteners
Caution is used to point out potential danger to the technician, operator, bystanders, or surrounding property.
Warning indicates a potentially hazardous situation that, if not avoi ded, could result in death of
serious injury.
Danger indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury. This signal word is to be limited to the most extreme situations
• Most of the fasteners used on these mowers are sized in fractional in ches. The eng ine and tran smissions
are metric. For this reason, wrench sizes are frequently identified in the text, and measur ements are given
in U.S. and metric scales.
• If a fastener has a locking feature that has worn, replace the fastener or apply a small amount of releasable thread locking compound such as Loctite® 242 (blue).
• Some fasteners like cotter pins are single-use items that are not to be reused. Other fasteners such as
lock washers, retaining rings, and internal cotter pins (hairpin clips) may be reused if they do not show
signs of wear or damage. This manual leaves that decision to the judgement of the technician.
1
2000 Series Tractors
! CAUTION! CAUTION
• Be prepared in case of emergency:
Keep a fire extinguisher nearby
Keep a first aid kit nearby
Keep emergency contact numbers handy
• Replace any missing or damaged safety labels on shop equipment.
• Replace any missing or damaged safety labels on equipment being serviced.
• Grooming and attire:
! WARNING! WARNING
! CAUTION! CAUTION
Do not wear loose fitting clothing that may become entangled in equipment.
Long hair should be secured to prevent entanglement in equipment.
Jewelry is best removed.
• Protective gear: includes, but is not limited to
Clear eye protection ................................ while working around any machinery
Protective gloves ..................................... where necessary
Armored footwear.................................... when working around any machinery
Hearing protection ................................... in noisy environments
Chemically resistant gloves..................... when working with chemicals or solvents
Respirator................................................ when working with chemical or solvents
Appropriate tinted eye protection............. when cutting or welding
Flame resistant headgear, jacket, chaps. when cutting or welding
• Remember that some hazards have a cumulative effect. A single exposure may
cause little or no harm, but continual or repeated exposure may cause very serious
harm.
• Clean spills and fix obviously dangerous conditions as soon as they are noticed.
! DANGER! DANGER
2
• Lift and support heavy objects safely and securely.
• Be aware of your surroundings and potential hazards that are inherent to all power
equipment. All the labels in the world cannot protect a technician from an instant of
carelessness.
• Exhaust fumes from running engines contain carbon monoxide (CO). Carbon
monoxide is a colorless odorless gas that is fatal if inhaled in sufficient quantity.
Only run engines in well ventilated areas. If running engines indoors, use an
exhaust evacuation system with adequate make-up air ventilated into the shop.
Introduction
Assembly
Torque specifications may be noted in the part of the text that covers assembly, they may also be summarized in
tables along with special instructions regarding thread locking or lubrication. Whichever method is more appr o pr i at e
will be used. In many cases, both will be used so that the manual is handy as a quick-reference guide as well as a
step-by-step procedure guide that does not require the user to hunt for information.
The level of assembly instructions provided will be determined by the complexity and of reassembly, and by the
potential for unsafe conditions to arise from mistakes made in assembly.
Some instructions may refer to other parts of the manual for subsidiary procedures. This avoids repeating the same
procedure two or three times in the manual.
Description of the 2000 series tractor
The Cub Cadet 2000 series tractor has been substantially up-dated for the 201 1 season. These tractors feature:
• Kohler Command horizontal shaft engines.
Figure 1.1
• A drive shaft that transfers power efficiently to the
transmission without the need for belts.
• Cast-iron transmission and front axle.
• 12 gauge steel ladder frame.
• Electric PTO Clutch.
• Manual and electric deck lift systems are available.
• Adjustable tilt steering column (available on most
models.
The 50
th
Anniversary model also features:
• Electronic Power Steering.
• Electric deck lift is standard.
• 54” fabricated deck.
• A special 2-tone painted hood.
Figure 1.2
• A custom front bumper.
3
2000 Series Tractors
Model and Serial Numbers
The model and serial number tag can be found
under the seat. See Figure 1.3.
The serial number is located to the right of the model
number as shown above. See Figure 1.3.
The model number is 14W-3AE-010. The break down of what the number mean is as follows:
Model number
Figure 1.3
Serial number
14 ........................................Garden tractor
.......W..................................Sales revision
...........-................................Marketing revision
.............3. ............................Frame
.................A.........................Engine (A = Kohler twin 23 hp)
....................E......................Deck lift (E = electric)
.........................- ..................Deck (The 50
.............................010 .........Customer number
The serial number is 1C281B20053. The serial number reads as follows:
1 ..............................................................................................Engineering level
..C............................................................................................ Month of production (C=March)
.....28 .......................................................................................Day of the month
.........1 .....................................................................................Last digit of the year
...........B................................................................................... Plant it was built in (Willard, OH)
..............2 ................................................................................Assembly line number
th
anniversary model is the only version that comes equipped with a deck)
.................0053 ....................................................................... Number of unit built
4
Engine Related Parts
CHAPTER 2: ENGINE RELATED PARTS
This chapter covers the engine accessories th at ar e m anuf ac tu re d by Cu b Ca de t.
IMPORTANT: The engine is manufactured by Kohler. Refer to the Kohler manual for engine specific service
information.
Muffler
To Remove/replace the muffler:
1. Remove the hood by following the procedures
described in Chapter 4: Body.
2. Remove the screw that holds the conduit clamp to
Conduit clamp
the heat shield using a 1/2” wrench. See Figure 2.1.
3. Remove the four screws (two on each side) that hold
the heat shield to the engine using a 5/16” wrench.
Exhaust pipe
Heat shield screws
4. Slide the heat shield off of the engine.
Figure 2.1
5. Remove the two nuts that hold each exhaust pipe to
the cylinder head using a 1/2” wrench.
See Figure 2.2.
6. Remove the muffler and exhaust pipes.
NOTE: The exhaust pipes are welded to the muffler. The
pipes and the muffler are serviced as one assembly.
7. Clean and remove all gasket material from the cylinder head (and the exhaust pipes if they are being
reused).
8. Using new gaskets, install the muffler by following the
previous steps in reverse order.
Figure 2.2
NOTE: Tighten the exhaust nuts to a torque of 246 in lbs
(27.8 Nm).
9. Test drive the mower in a safe area before returning
it to service.
5
2000 Series Tractors
Fuel tank removal/replacement
Remove/replace the fuel tank by following these steps:
Gasoline and its vapors are extremely flammable. Use common sens e when working aroun d
! CAUTION! CAUTION
1. Safely drain the gasoline from the fuel tank.
2. Disconnect the seat switch. See Figure 2.3.
NOTE: On the GTX2154LE, it will be necessary to
cut the wire tie that holds the seat switch
connector to the seat frame.
NOTE: When reconnecting the seat switch plug on
the GTX2154LE, it must be wire tied back
together and attached to the seat frame.
Failure to do this can cause the connector to
get caught in the seat bracket and rip the
wires out of the seat. If this happens, the
tractor will shut down when the brake is
released and the whole seat must be
replaced.
3. Push the barbed fastener on the seat switch harness out of the hole in the fender.
the fuel system
Figure 2.3
4. Remove the four socket headed cap screws that
hold the seat tracks to the fender using a T-40 torx
driver. See Figure 2.4.
Figure 2.4
6
Figure 2.5
Engine Related Parts
NOTE: On the GTX2154LE:
• Remove the four screws, indicated by the arrows
in Figure 2.5, that hold the seat frame to the fender
using a 7/16” wrench.
• Remove the two screws that hold the rear of the
fender to the frame using a 7/16” wrench.
On manual deck lift models:
5. Remove the deck lift lever grip. See Figure 2.6.
NOTE: A blow-gun with air pressure regulate d to less than
Grip
Figure 2.6
On electric deck lift models:
6. Remove the screw that holds the deck cutting height
7. Pull the cutting height lever off of the shaft.
8. Disconnect the deck lift switch.
25 PSI (1.72 Bars), may be inserted into the small
hole at the end of a rubber grip to inflate it slightly,
easing removal.
lever to the shaft using a T40 torx driver.
Screw
Figure 2.7
7
2000 Series Tractors
9. Unthread the fuel cap.
10. Pull the fuel cap tether retainer out of the fuel tank
using a long pair of pliers. See Figure 2.8.
NOTE: The fuel cap tether is manda ted by the EPA.
If it is broken, the fuel cap must be replaced.
Tether
Figure 2.8
11. Gently pry out the barbed fasteners that hold the
end of the running board mats to the fender.
See Figure 2.9.
12. Remove the six nuts and bolts, indicated by the
arrows in Figure 2.10, that hold the fender to the
running board using a pair of 7/16” wrenches.
13. Lift the fender off of the tractor.
Barbed fasteners
Figure 2.9
Figure 2.10
8
Vent hose
Engine Related Parts
14. Re-install the fuel cap.
15. Disconnect the vent hose from the roll over valve.
See Figure 2.11.
Roll over valve
Figure 2.11
Roll out
16. Roll the fuel tank towards the rear of the tractor until it
is free from the tractor. See Figure 2.12.
17. Disconnect the fuel line from the fuel tank.
18. Install the fuel tank by following the previous steps in
reverse order.
19. Test run the tractor in a safe area before returning it
to service.
Figure 2.12
9
2000 Series Tractors
Throttle cable adjustment
If the engine does not achieve its high (no load) speed when the throttle is moved to the full throttle position,
check the cable adjustment before performing any other engine or carburetor inspections.
To adjust the throttle cable:
1. Raise the hood and locate the engine contro l panel.
2. Operate the throttle lever while observing its direction of movement. See Figure 2.13.
3. Loosen the screw that secures the throttle cable
clamp.
4. Push and hold the throttle arm at the full throttle
position.
5. While holding the throttle arm, remove the slack in
the cable by pulling the cable jacket back through
the clamp.
Choke cable
6. Tighten the screw in the clamp to secure the cable.
7. Start the engine.
8. Check the engine RPMs using a tachometer.
NOTE: Refer to the service manual provided by the
engine manufacturer for any further engine
speed adjustments needed.
Choke cable adjustment
If the engine is difficult to start or runs roughly after it warm s up, ch eck the choke c able setting befor e performing
any other engine or carburetor inspections.
To adjust the choke cable:
1. Remove the air filter.
2. Locate the engine control panel.
3. Loosen the screw that secures the choke cable
clamp.
4. Move the choke arm until the choke plate is fully
closed.
NOTE: Look down the carburetor throat to confirm
that the choke plate is fully closed.
See Figure 2.14.
Throttle cable
Figure 2.13
5. While holding the choke arm, remove the slac k in
the cable by pulling the cable jacket back through
the clamp.
6. Tighten the screw in the clamp to secure the cable.
7. Check the operation of the cable and choke plate.
8. Re-install the air filter.
9. Test run the tractor in a safe area before returnin g it to ser vic e.
10
Choke plate closed
Figure 2.14
Choke and Throttle levers and cables
Control lever assemblies
Figure 2.15
Engine Related Parts
To remove/replace levers and cables:
NOTE: The choke and throttle cables must be removed
with the lever assemblies before they can be separated and replaced.
1. Remove the dash by following the procedures
described in Chapter 4: Body.
2. Remove the three screws that secure the control
lever assemblies in place using a 3/8” wrench.
See Figure 2.15.
3. Rotate the levers while pulling the assemblies out of
the dash.
4. Remove the cables:
Figure 2.16
Screw
4a. Squeeze in the ears on the cable jacket fittings.
See Figure 2.16.
4b. Slide the cable jackets out of the bracket.
4c. Un-hook the cables from the levers.
NOTE: If just replacing the cables, install the cables by fol-
low steps 1 - 4 in reverse order.
5. Remove the screw that holds the lever ret ainer to the
bracket using a 5/16” wrench. See Figure 2.17.
Figure 2.17
11
2000 Series Tractors
6. On the side of the lever assembly that has the slot,
lift the shaft that the levers pivot on enough to slide
the spring off. See Figure 2.18.
7. Slide the lever assembly toward the side with the
slot until the assembly clears the other side.
8. Slide the levers off of the indexing plate.
See Figure 2.19.
9. Install the levers and cables by following the previous steps in reverse order.
Spring
Slot
Figure 2.18
12
Indexing plate
Figure 2.19
Engine removal/installation
Figure 2.20
Fuel pump
Engine Related Parts
It may be necessary to remove the engine to perform
engine repairs such as replacing the ignition coil, flywheel,
alternator or to work on the cylinder heads.
To remove the engine:
1. Remove the hood by following the procedures
described in Chapter 4: Body.
2. Disconnect the negative battery cable from the battery.
3. Remove the muffler by following the proced ures
described in the muffler section of this chapter.
4. Clamp off the fuel line just below the fuel pump.
See Figure 2.20.
Oil drain hose
Ground cable
Figure 2.21
Engine harness
Starter trigger wire
Starter cable
5. Disconnect the ground cable from the left side of the
engine using a 1/2” wrench. See Figure 2.21 .
6. Disconnect the PTO clutch harness.
7. Disconnect the engine harness.
8. Disconnect the starter wires. See Figure 2.22.
9. Remove the starter.
Figure 2.22
13
2000 Series Tractors
10. Remove the dash by following the procedures
described in Chapter 4: Body.
11. Disconnect the drive shaft from the engine by
removing the four patch bolts using a 7/16” wr en ch .
See Figure 2.23.
12. Remove the four nuts and bolts, indicated by the
arrows in Figure 2.24, that hold the engine to the
sub frame using a pair of 9/16” wrenches.
Drive shaft
Figure 2.23
13. Attach a lift chain to the engine’s lifting points.
See Figure 2.25.
NOTE: The lift chain should be approximately 2’ -
2.5’ (61 - 76 cm) long and is of sufficient
strength to safely support weight of the
engine.
14. Using an engine hoist, gently lift the engine while
sliding it off of the drive shaft and out the front of the
tractor.
NOTE: Be careful sliding the engine off of the drive
shaft. If the drive shaft coupling gets caugh t,
it will come apart, spilling the blue rollers on
the ground.
14
Figure 2.24
Lift points
Figure 2.25
Blue rollers
Engine Related Parts
NOTE: If the front drive shaft coupling comes apart:
• Remove the engine.
• Insert the rollers in between the drive shaft end
and the coupler housing one at a time, until all
eight are in place. See Figure 2.26.
Figure 2.26
To install the engine:
1. Install an alignment stud into one of the drive shaft
coupler holes on the engine. See Figure 2.27.
Alignment stud
Coupling spacer
Coupling
Figure 2.27
Alignment stud
NOTE: To make an alignment stud: See Figure 2.27.
• Obtain a 1/4” x 20 bolt that is a minimum of 4” long.
• Cut the head off of the bolt.
• Grind a tapper onto the side of the bolt the head
was on.
2. Insert three of the bolts into the coupling and the
spacer.
3. Slide the engine into place, using the alignment stud
to guide the drive shaft coupler into place.
See Figure 2.28.
4. Start the three coupling bolts.
5. Remove the alignment stud.
Figure 2.28
Coupling bolts
6. Install the fourth coupling bolt.
7. Tighten all of the coupling bolts to a torque of 10 - 12
ft lbs (14 - 16 Nm).
15
2000 Series Tractors
8. Install the engine mounting nuts and bolts.
9. Remove the engine lift chain.
10. Install the dash by following the steps described in Chapter 4: Body.
11. Install the starter.
12. Reconnect the starter wires.
13. Reconnect the engine harness.
14. Reconnect the ground cable to the base of the engine.
15. Reconnect the fuel line to the fuel pump.
16. Install the muffler by following the procedures described in the muffler section of this chapter.
17. Install the hood.
18. Check the oil and fuel levels, top off as needed.
19. Test drive the tractor in a safe area before returning it to service.
16
Brakes
CHAPTER 3: BRAKES
Brake adjustment
The transmission on the 2000 series tractor is driven by a Hydro-Gear BDU-10L pump. The pump will provide the
braking action when it is in operation. There is a mechani cal brake on the side of the tran smission. This brake is used
primarily as a parking brake. It is also used as a back up brake in cas e of a failure of the hydro pump.
The operation of the brakes should be tested before performing any adjustments.
To test the operation of the brakes:
1. Disengage the hydro pump by-pass rod by pulling it
out and hooking it. See Figure 3.1.
2. Set the parking brake by depressing the brake pe da l
and lifting-up on the parking brake lever.
3. Attempt to push the tractor. If it can be pushed by
hand without skidding a rear wheel, check and adjust
the brakes.
4. Release the parking brake.
By-pass rod
Outer latch plate
travel limit pin
5. Attempt to push the tractor again. If it cannot be
pushed with reasonable effort, check the hydro pump
by-pass and adjust the brakes.
Figure 3.1
Inner latch plate
6. Visually inspect the linkage to confirm that it functions
properly.
• Beneath the floor panel, on the left side of the trac-
tor there are two semi-circular latch plates (bell
cranks).
• The outer latch plate rotates with the drive control
pedals. The inner latch plate rotates with the
clutch/brake pedal.
6a. With the clutch/brake pedal fully released:
• The travel limit pin should be resting against the
front of the curved slot. See Figure 3.2.
Figure 3.2
17
2000 Series Tractors
• The rod that connects the clutch/brake latch
plate to the heavy brake actuator spring should
not droop. See Figure 3.3.
• Check the brake pedal shaft bushings for wear.
Adjust the brakes by:
NOTE: The brake is located between the frame and
the transmission on the right side of the tractor. It is a tight fit, but it can be reached from
the under side of the tractor aft, of the rear
axle.
No droop
Figure 3.3
0.010” feeler gauge
NOTE: In Figure 3.4, the by-pass rod was removed
for a clearer view of the caliper.
1. Wiggle the brake rotor slightly, and attempt to insert
a 0.010” (0.38mm) feeler gauge between the rotor
and either pad.
NOTE: There is a fixed pad in the transaxle hous-
ing.
NOTE: There is a moving pad in the brake caliper.
2. Adjust the gap, if necessary, so that the feeler
gauge slips between the pad and the rotor with light pressure. See Figure 3.4.
2a. Turn the nut to adjust the gap.
NOTE: The gap should be in the range of 0.010” - 0.015” (0.25mm - 0.38mm)
2b. Apply and release the brake pedal, then re-check the gap.
NOTE: If the brake seems to be sticking, or the rotor is discolored from dragging, fix the cause of the sticking
and replace the rotor.
3. Re-test the operation of the brakes before returning the tractor to service.
Figure 3.4
Adjuster nut
18
Brakes
Brake puck/rotor replacement
On transmission used on the 2000 series tractor , the brake pucks are wearing p a rts that will need to be serviced
from time to time. If the tractor is operated with the parking brake dragging, the pucks will wear out rapidly and the
brake rotor will develop hot spots. If the tractor is operated long enough, the rotor may have grinding marks on it with
excessively worn pucks.
! CA UTION! CA UTION
NOTE: The brake pucks and the rotors are serviced at the same time.
Screws
If the rotor shows hot spots or any other signs of damage, including warpage, it must be
replaced. Failure to do so can result in the failure of the brakes
To remove/replace the brake pucks and rotor:
1. Lift and safely support the rear of the tractor.
2. Remove the transmission by following the procedures describe in Chapter 5: Drive.
3. Remove the two screws that secure the brake caliper
to the right transmission housing using a 3/8” wrench.
See Figure 3.5.
4. Lift the caliper off of the transmission.
Figure 3.5
Figure 3.6
5. Remove the brake disk from the output shaft.
See Figure 3.6.
NOTE: The center flange of the brake disk faces outward.
Flange
19
2000 Series Tractors
6. With the caliper on a work bench, remove the brake
puck, backing plate and the two brake pins.
See Figure 3.7.
7. Inspect all the components of the brake assembly
for damage or wear: brake pads, puck plate, actu ator pins, actuator arm, anti-rotation bracket, yoke,
torsion spring, flat washer and locking hex nut.
8. Check for free movement of the brake pins. A dry
lubricant can be used on the brake pins sparingly.
Never put grease or anti-seize on
! CA UTION! CA UTION
of the pucks.
9. Slide the brake pins into the caliper.
10. Place the backing plate in the caliper.
11. Place a new puck into the caliper. See Figure 3.8.
NOTE: A piece of scotch tape may be used to hold
brake pins. It can migrate to the brake
pucks, preventing the braking action
the new brake pucks in place for assembly.
The tape will grind away when the brakes
are applied.
Caliper
Pins
Backing plate
Pucks
Figure 3.7
12. Place a new brake puck into the recess in the transmission. Use a piece of scotch tape to hold it in
place.
13. Slide the brake rotor in place, shoulder out.
14. Mount the brake caliper to the transmission. Apply a
small amount of releasable thread locking compound such as Loctite® 242 (blue) to the mounting
bolts and tighten to a torque of 80 - 120 in-lbs (9 -
13.5 Nm).
15. Wiggle the brake rotor slightly and insert a 0.010”
(0.38mm) feeler gauge between the rotor and either
pad.
16. Adjust the gap, if necessary, so that the feeler
gauge slips between the pa d and the rotor with light
pressure. See Figure 3.9.
16a. Turn the nut to adjust the gap.
NOTE: The gap should be in the range of 0.010” -
0.015” (0.25mm - 0.38mm)
16b. Operate the brake cam arm a few times, then
re-check the gap.
17. Install the transmission by following the procedures
described in Chapter 5: Drive System.
Figure 3.8
0.010” feeler gauge
18. Test drive the tractor in a safe area before returning
it to service.
20
Figure 3.9
Brake shaft assembly
Brake pedal
Brakes
To remove/replace the brake shaft:
1. Remove the cutting deck by following the procedures
described in Chapter 8: Cutting Decks and Lift shaft.
2. Lift and safely support the tractor.
3. Remove the forward drive pedal shaft by following
the procedures described in Chapter 5: Drive System.
4. Disconnect the brake pedal by removing the two nuts
and bolts that attach it to the brake pedal shaft using
a pair of 1/2” wrenches. See Figure 3.10.
Figure 3.10
Brake shaft return spring
Figure 3.11
5. Disconnect the brake shaft return spring.
See Figure 3.11.
6. Remove the E-ring and washer(s) fr om the right side
of the brake shaft. See Figure 3.12.
7. Remove the hex bushings from both ends of the
brake pedal shaft.
E-ring
Figure 3.12
21
2000 Series Tractors
8. Slide the brake pedal shaft to the left enough for it to
clear the frame on the right side.
9. Lower the shaft enough to gain access to the cotter
pin that secures the brake rod to the pedal shaft.
10. Remove and discard the cotter pin.
See Figure 3.13.
11. Remove the pedal shaft from the tractor.
12. Install the brake pedal shaft by following the previous steps in reverse order.
NOTE: The cotter pin that secures the br ak e ro d to
the pedal shaft can be replaced with a bow
tie clip (714-04040). This will make it easier
to perform the brake rod adjustment.
13. Perform a brake rod adjustment by following the
procedures described in the brake rod ad jus tm en t section of this chapter.
14. Test drive the tractor in a safe area before returning it to service.
Cotter pin
Figure 3.13
22
Brake rod adjustment
E-ring
Brakes
NOTE: The brake rod should not come out of adjustment
on its own. If the brake rod does need to be
adjusted, check for a bent rod, worn bushing and
worn brake pucks.
To adjust the brake rod:
1. Remove the cutting deck by following the procedures
described in Chapter 8: Cutting Decks and Lift Systems.
2. Lift and safely support the tractor.
3. Remove the E-ring and washers from the right side of
the forward drive pedal shaft. See Figure 3.14.
Figure 3.14
Figure 3.15
4. Slide the drive pedal shaft to the left until it stops.
5. Remove the E-ring and washer(s) fr om the right side
of the brake pedal shaft. See Figure 3.15.
6. Slide the brake pedal shaft to the left until it stops.
E-ring
7. Disconnect the brake rod from the brake pedal shaft
by removing the cotter pin and discarding it.
See Figure 3.16.
Figure 3.16
Cotter pin
23
2000 Series Tractors
8. Loosen the jam nut. See Figure 3.17.
9. Tighten or loosen the ferrule as needed so that it
aligns with the hole in the bell crank of the brake
pedal shaft with no slack in the brake spring.
10. Tighten the jam nut.
11. Attach the brake rod to the brake pedal shaft.
NOTE: The cotter pin that secures the br ak e ro d to
the pedal shaft can be replaced with a bow
tie clip (714-04040).
12. Slide the brake pedal shaft to the right until it stops.
13. Install the E-ring and washer(s) on to the brake
pedal shaft.
NOTE: If the bushings popped out while shifting the
shafts, re-install them before installing the E-rings.
14. Slide the forward drive pedal shaft to the right until it stops.
15. Install the E-ring and washer(s) on to the drive pedal shaft.
16. Test drive the tractor in a safe area before returning it to service.
Ferrule
Jam nut
Figure 3.17
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