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NOTES
2
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Table of Contents 3
Seat Pan changed for easier assembly 4
Oil Drain 4
Solenoid / Fuse / PTO Switch 5
Solenoid Diagnostic Procedure 6
Electrical Components Quick List 7
Hydro Gear 0510 Service Information 8
Hydro Gear 0510 Neutral Adjustment for Lever LT 9
Lever Controlled Automatic LT Neutral Adjustment 10
Foot Controlled Automatic LT Speed Adjustment 11
Quick Attach Bagger 11
Cruise Control for Foot Pedal Operated LT Automatic 12
New GT Automatic Belt Replacement Procedure 13
New GT Automatic Starting Procedure for Extreme Cold 13
Hydro Gear 3000 for Garden Tractors Service Information 14
Hydro Gear 3500 Return to Neutral Adjustment for Trans 15
GT Automatic Speed Lever Neutral Adjustment for Tractor 16
GT Muffler changes 16
Blade Listing 17
New Front Suspension for Mowers 18
New Mandrel for 48” Mower 18
New 48” H.D. Mower 19
KOHLER Liquid Cooled V-Twin 20-21
New 21” Front Drive Mower 22-24
Touch-Up Paints 25
New Weed Trimmer 26-27
21" Rear Drive Adjustments 28-29
42" Mower Cable Clutch Kit # 175067 30
3
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Quick Attach Tractor Seat
Tractors will now be shipped with a quick attach seat that will have a quick install feature for the seat shoulder bolt. The seat will have the shoulder bolt mounted from the
factory. The customer will place the shoulder bolt over the front end of the slot and
push down. The head of the shoulder bolt will go through and is retained. The seat
knob and washer is then installed.
Quick Release Tractor Engine Oil Drain Valve
148456 Oil Drain Tube
162295 Elbow
148315 Oil Drain
A quick release oil drain valve will be on many 2001 tractor engines. The drain is
released with a slight push and a counterclockwise turn. There is a yellow cap on end
that will retain oil if the valve is not properly closed. Customers will be supplied a 10”
clear PVC tube to help drain the oil into a container. The tube is a 3/8” I.D. clear PVC
and can be purchased in bulk locally.
The valve has special threads that do not require pipe dope or teflon tape that is
needed for the brass elbow used on some twin cylinder engines.
4
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New Solenoid # 171141
• Yellow Di-Chromate finish for improved corro-
sion resistance inside and out over previously
used zinc finish.
• Lowered Voltage contact surface pull in, as
low as 8.5 VDC.
• Coil Resistance is 3.8 to 4.3 Ohms. Previous
solenoids were 5.0 to 6.5 Ohms.
• The Solenoid Kit number will continue to be
146154.
FUSE change on Lawn Tractors
A 20 AMP fuse part number 175158 will now
be used on lawn tractors. Lawn tractors made
in 1999 and 2000 with a 15 AMP fuse can also
use the 20 AMP fuse.
GTs will still use the 30 AMP fuse.
Yellow
Di-Chromate
15
20
30
A 30 AMP FUSE SHOULD NEVER BE USED IN
PLACE OF A 15 OR 20 AMP FUSE.
PTO SWITCH CHANGE
The new PTO Switch will have 8 terminals instead of 7 terminals.
The switch with 8 terminals can be used for
product made before 2001.
Part numbers for the new and old switches are
on the page 5 electrical parts reference.
There will be a new 175567 snap-in Ignition
Switch for tractors without headlights.
CG
F
H
B
E
A
D
PTO SWITCH
OFF
CIRCUITPOSITION
C + G, B + H
C + F, B + E, A + DON
5
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Diagnosis of Starter Solenoids
• Remove the red cable from the engine starter motor before testing.
• Place digital meter selector on D.C. Voltage scale that includes 13 Volts.
Step # 1.
12.6
1. Place meter probes on battery terminals. If the
reading is 12.2 VDC or more, proceed to the next
step. If the reading is below 12.2 VDC, charge or
replace the battery with one that has at least
12.2 V DC.
Step # 2.
(-)
(+)
A
1. Connect negative (black) meter lead to the battery
negative (-) terminal.
2. Connect the positive (red) meter lead to the ‘hot’
terminal of the solenoid.
3. Note the voltage reading.
Step # 3.
1. Keep the meter selector in the same position and
the negative meter lead connected to the battery
negative terminal.
2. Connect the positive (red) meter lead to the end of
the cable normally connected to the starter motor.
3. Engage the parking brake and turn the ignition
switch to the “START” position.
4. Note the voltage reading.
5. If the voltage drop is more than 0.50 VDC between
the two noted readings, the solenoid or the starter
cable is suspect. Replace the solenoid.
6. Re-install the red cable to the starter motor.
If the solenoid checks acceptable and the starter
does not crank, check for clean tight battery
connections and check the grounds for the
battery and the engine.
A
12.4
(-)
B
B
(+)
6
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The 0510 Automatic Transmission
from HYDRO-GEAR for Lawn Tractors
Oil should NOT be checked unless there is a complaint about the operation of the transmission.
There is a gold colored plug in the top of the transmission. Clean the underside of the frame and the
top of the transmission before checking the oil level. Contamination cannot be allowed to get into the
transmission. When the plug is removed, a 6 inch metal scale can be used to check the oil level.
When the transmission is cold, the oil level should be from .50 to 1.25 inches from the top of the
casting. 20W50 engine oil can be added to the level of the bottom thread for the oil plug. The oil
never needs to be changed for maintenance.
The 0510 transmission has an expansion tank. This allows for oil to expand into the tank
when the transmission is hot, and as the oil cools it is drawn back inside the transmission.
The expansion tank will be silver-gray in color and should not be opened.
If you are working on a tractor where the operator experiences transmission complaints:
• Check to see that the brake return spring is in position.
• Check the movement of the by pass valve and the freewheel control rod.
• Check the brake adjustments, if adjusted too tight, the transmission can overheat.
1-9/16"
Brake Rod Spring Adjustment Brake Disc / Puck Clearance
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NEUTRAL ADJUSTMENT FOR LAWN TRACTORS
WITH LEVER CONTROL
1. Place the tractor on a smooth paved level surface.
2. Loosen Adjustment Bolt in front of the right rear wheel, and lightly tighten using a 1/2"
wrench.
3. Start Engine and move Lever until tractor does not move forward or backward.
Hold Control Lever in that position and do not move. Turn the engine off.
4. While holding the Control Lever to keep it from moving, loosen theAdjustment Bolt . Move the
Control Lever to the position indicated for Neutral on the fender. Tighten Adjustment
Bolt securely.
FINE TUNE THE NEUTRAL ADJUSTMENT ON AUTOMATIC DRIVE
1. Place the tractor on a smooth paved level surface.
2. Loosen the Adjustment Bolt using a 1/2" wrench. If the tractor is creeping forward, move the
Control Lever forward 1/4 to 1/2 inch. Move the Control Lever rearward 1/4 to 1/2 inch if the
tractor is creeping backwards. Tighten the Adjustment Bolt securely.
3. Start engine and test from both forward and reverse.
4. If tractor still creeps, repeat step # 2 until satisfied.
NOTE: If additional clearance is needed to get to adjustment bolt, move mower deck height to
the lowest position.
9
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RETURN TO NEUTRAL ADJUSTMENT Lawn Tractor
Hydro Gear 0510 Automatic Transmission
with Footpedal Control
WARNING: Potential for Serious Injury
Certain procedures require the engine to be operated and the tractor is raised off the ground.
To prevent possible injury to the technician or bystander, insure the tractor is properly
secured.
The return to neutral mechanism on the transmission is designed to go to the neutral position after
the operator’s foot is removed from the foot pedals.
Use illustration at the bottom of page.
1. Confirm the freewheel rod at the back of the tractor is in the position for the transaxle to move the
tractor. Raise the rear tires of the tractor off the ground to allow free rotation.
2. Remove the tractor footpedal linkage from the transmission control arm. NOTE: It may be neces-
sary to remove the drawbar plate or the right rear wheel to remove the tractor footpedal
linkage.
3. Start the engine and raise the throttle to full speed.
4. Check for axle rotation. If the axles do not rotate, go to step 5. If the axles do rotate, go to
step 6.
5. Stop the engine. Reattach the footpedal linkage then recheck using steps 3 and 4. If the axles
do not turn, the adjustment is completed. Stop engine.
6. Note the direction of rear axle rotation of the right rear axle. Stop the engine. Loosen the adjusting puck screw until the puck can be rotated. Rotate the puck in the opposite direction of the
wheel rotation in 5 degree increments. Tighten the adjusting puck screw to 250 to 320 inch
pounds. Recheck using steps 3 and 4. Stop the engine. Continue to adjust the puck and test
until the rear axles do not rotate. Reattach the footpedal linkage then recheck using steps 3 and
4. If the axles do not turn, the adjustment is completed. Stop engine.
WARNING: Do not attempt to make
any adjustments with the engine running.
Use extreme caution while inspecting the
vehicle linkage.
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