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Y2K
User Manual
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MTD Y2K User Manual

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Y2K MTD/White
Technical Seminar
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FOREWORD
This Service Update Book is intended for Authorized Dealers who are familiar with outdoor power equipment. It is necessary, and good shop practice, that your service area be equipped with proper tools and the mechanics be supplied with the latest information available. The information in this handbook and a properly equipped shop will aid in making necessary repairs as simple as possible in a complete and satisfactory manner.
The Technical Service Handbook Form Number 770-8640M, again will suggest methods of repair on current products. It is intended to supplement the Technical Service Update Book.
All repair procedures illustrated in this update book are suggested methods of repair. With the aid of the informa­tion in this handbook, the technician should be able to repair or replace parts as necessary to correct most service problems. The service technician can also diagnose a problem more easily with a better knowledge of potential problems. Alternate methods of repair are acceptable but not encouraged. Alternate methods, in come cases, may be more time consuming and may result in a dealer performing unnecessary steps to repair a unit. The more you familiarize yourself with potential service problems, the more efficient your operation will become.
We recommend you keep this Service Update Book in your shop for future reference.
All rights reserved
Copyright © 1999 by MTD PRODUCTS INC
Acknowledgements
We would like to thank Briggs and Stratton for continuing (Partnership In Training and Education).
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MTD Y2K Table of Contents
INTRODUCTION TO MTD/WHITE OUTDOOR Y2K..........................................................................Section 1
Service Publications Available ...................................................................................................................1-1
Warranty Information .................................................................................................................................1-3
Lubrication Chart........................................................................................................................................1-9
MTD Quick Reference Guide...................................................................................................................1-11
Yardman Specifications ...........................................................................................................................1-15
White Outdoor Specifications...................................................................................................................1-18
FRONT WHEEL DRIVE SELF-PROPELLED LAWN MOWERS .......................................................Section 2
Removal and Replacement of the Drive Belt .............................................................................................2-1
Removal of the Front Wheel Drive Assembly ............................................................................................2-2
Front Height Adjustment Disassembly.......................................................................................................2-3
Bearing Sleeve Removal and Assembly....................................................................................................2-3
Front Height Adjustment Reassembly .......................................................................................................2-4
YARD BUG .........................................................................................................................................Section 3
Deck Leveling ............................................................................................................................................3-1
Brake Adjustment.......................................................................................................................................3-3
Blade Brake/PTO Adjustment ....................................................................................................................3-5
Speed Control Pedal Adjustment...............................................................................................................3-6
Steering Adjustment...................................................................................................................................3-9
Removal and Installation of the Deck Belt ...............................................................................................3-10
Removal and Installation of the Mowing Deck Assembly ........................................................................3-11
Removal and Replacement of the Drive Belts .........................................................................................3-13
Transmission Removal and Installation ...................................................................................................3-15
Transmission Disassembly ......................................................................................................................3-17
Transmission Reassembly.......................................................................................................................3-19
Electrical (Start Circuit) ............................................................................................................................3-22
Electrical (Off / Safety Circuit)..................................................................................................................3-25
Electrical Diagram....................................................................................................................................3-30
VARIABLE SPEED DRIVE.................................................................................................................Section 4
Steering Adjustments.................................................................................................................................4-1
Autodrive Pedal Adjustment.......................................................................................................................4-2
Brake Adjustments.....................................................................................................................................4-3
Leveling the Cutting Deck ..........................................................................................................................4-3
Deck Belt Removal and Installation ...........................................................................................................4-6
Cutting Deck Removal ...............................................................................................................................4-6
Drive Belt Removal and Reinstallation.......................................................................................................4-7
Transmission Removal and Installation ...................................................................................................4-10
Transmission Disassembly and Reassembly ..........................................................................................4-11
Electrical Section .....................................................................................................................................4-14
Electrical Diagram....................................................................................................................................4-22
HYDROSTATIC LT FOOT CONTROL ...............................................................................................Section 5
Drive Belt Removal ....................................................................................................................................5-1
Hydrostatic Transmission Removal ...........................................................................................................5-3
HYDROSTATIC GT FOOT CONTROL ..............................................................................................Section 6
Hydrostatic Transmission Removal and Installation ..................................................................................6-1
Z SERIES TRACTOR .........................................................................................................................Section 7
Z Series Neutral / Steering Adjustment......................................................................................................7-1
Removal of the ZTT Transmission From the Tractor .................................................................................7-6
Transmission Disassembly ......................................................................................................................7-11
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CHORE PERFORMERS.....................................................................................................................Section 8
Lawn Vacuum ............................................................................................................................................8-1
Two Stage Pump .......................................................................................................................................8-4
Log Splitter Pump User’s Guide.................................................................................................................8-4
Log Splitter Troubleshooting ......................................................................................................................8-7
ATTACHMENTS.................................................................................................................................Section 9
Grass Collectors — OEM-190-601, OEM-190-602, OEM-190-821 ...........................................................9-1
Front Bumper — OEM-190-603.................................................................................................................9-3
Tracpac — OEM-190-604..........................................................................................................................9-4
42" Dozer Blade — OEM-190-620 ............................................................................................................9-5
Adjustments ...............................................................................................................................................9-7
40" Snow Thrower — OEM-190-621 .........................................................................................................9-8
46" Dozer Blade — OEM-190-822...........................................................................................................9-13
SNOW THROWER ...........................................................................................................................Section 10
1999-2000 Snow Thrower Overview........................................................................................................10-1
4-Wheel Drive Snowthrower ....................................................................................................................10-2
SERVICE KITS .................................................................................................................................Section 11
MTD Y2K Table of Contents (continued)
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SERVICE PUBLICATIONS AVAILABLE
Please Order By Description (Include Year) and Part Number.
Description Form No. Unit Price
2000 MTD Microfiche - Spring/Summer 770-9442 $ 6.95 2000 MTD Microfiche - Fall/Winter 770-9441 $ 3.25 1999 MTD Microfiche - Spring/Summer 770-9438 $ 6.95 1999 MTD Microfiche - Fall/Winter 770-9435 $ 3.25 1998 MTD Microfiche - Spring/Summer 770-9432 $ 6.95 1998 MTD Microfiche - Fall/Winter 770-9427 $ 3.25 1997 MTD Microfiche - Spring/Summer 770-9496 $ 6.95 1997 MTD Microfiche - Fall/Winter 770-9497 $ 3.25 1996 MTD Microfiche - Spring/Summer 770-9482 $ 6.95 1996 MTD Microfiche - Fall/Winter 770-9481 $ 3.25 1995 MTD Microfiche - Spring/Summer 770-9471 $ 6.95 1995 MTD Microfiche - Fall/Winter 770-9470 $ 3.25 1994 MTD Microfiche - Spring/Summer 770-9466 $ 6.95 1994 MTD Microfiche - Fall/Winter 770-9465 $ 3.25 1993 MTD Microfiche - Spring/Summer 770-8291 $ 6.95 1993 MTD Microfiche - Fall/Winter 770-8290 $ 3.25 1992 MTD Microfiche - Spring/Summer 770-7981 $ 6.95 1992 MTD Microfiche - Fall/Winter 770-7980 $ 3.25 1991 MTD Microfiche - Spring/Summer 770-7606 $ 6.95 1991 MTD Microfiche - Fall/Winter 770-7607 $ 3.25 1990 MTD Microfiche 770-7228 $ 8.95 1989 MTD Microfiche 770-6811 $ 8.95 1988 MTD Microfiche 770-6503 $ 8.95 1987 MTD Microfiche 770-6083 $ 8.95 1986 MTD Microfiche 770-5170 $ 8.95 1985 MTD Microfiche 770-4106 $ 8.95 1984 MTD Microfiche 770-3357 $ 8.95 1983 MTD Microfiche 770-2662 $ 8.95 1982 MTD Microfiche 770-2200 $ 8.95 1981 MTD Microfiche 770-1155 $ 8.95 1980 MTD Microfiche 770-0273 $ 7.50 1979 MTD Microfiche 770-8912 $ 7.50 1978 MTD Microfiche 770-8122 $ 7.50 1977 MTD Microfiche 770-9104 $ 6.00 1976 MTD Microfiche 770-9103 $ 6.00 1975 MTD Microfiche 770-9102 $ 6.00 1974 MTD Microfiche 770-9101 $ 5.00
MTD Microfiche Set—Current 10 Years 770-9407 $58.95 MTD Microfiche Set—1991 thru 1995 770-9404 $29.95 MTD Microfiche Set—1986 thru 1990 770-9403 $29.95 MTD Microfiche Set—1981 thru 1985 770-9402 $29.95 MTD Microfiche Set—1975 thru 1980 770-9401 $29.95 MTD Microfiche Set—1964 thru 1974 770-7014 $30.00
AIRCAP Microfiche Set—thru 1990 706-15271 $20.00 General Power Microfiche Set—thru 1995 770-9412 $89.95 General Power Microfiche—1995 Only 770-9485 $ 9.95
1992 Yard-Man Microfiche
-
Spring/Summer 770-7985 $ 4.25
1992 Yard-Man Microfiche
-
Fall/Winter 770-7984 $ 2.25 1991 Yard-Man Microfiche - Spring/Summer 770-7613 $ 4.25 1991 Yard-Man Microfiche - Fall/Winter 770-7612 $ 2.25 1990 Yard-Man Microfiche 770-7231 $ 6.25 1989 Yard-Man Microfiche 770-6814 $ 6.25 1988 Yard-Man Microfiche 770-6505 $ 6.25 1987 Yard-Man Microfiche 770-6087 $ 6.25 1986 Yard-Man Microfiche 770-5175 $ 6.25 1985 Yard-Man Microfiche 770-4107 $ 6.25 1984 Yard-Man Microfiche 770-3356 $ 6.25 1983 Yard-Man Microfiche 770-2663 $ 6.25 1982 Yard-Man Microfiche 770-2203 $ 6.00 1981 Yard-Man Microfiche 770-1158 $ 6.00 1980 Yard-Man Microfiche 770-0272 $ 5.00 1979 Yard-Man Microfiche 770-8913 $ 5.00 1978 Yard-Man Microfiche 770-8199 $ 5.00 1977 Yard-Man Microfiche 770-7391 $ 3.50 1976 Yard-Man Microfiche 770-9105 $ 3.50 1975 & Prior Yard-Man Microfiche 770-9106 $14.00
Yard-Man Microfiche Set - 1983 thru 1992
770-9405 $29.95
Yard-Man Microfiche Set - 1982 and Prior
770-9406 $29.95
S E T S
A V A
I L A B L E
B E L O
W
MICROFICHE
S E T S
A V A
I L A B L E
B E L O
W
Description Form No. Unit Price
2000 MTD Parts Price Book 770-8855Q $15.00
MUST HAVE SERVICE MANUAL 770-8640M $29.95
2000 Service Update Seminar Book 770-8877Q $19.50
1999 Service Update Seminar Book 770-8877P $12.50
Warranty Claim Forms 770-7601H $5 per 100
Job Estimating Guide 770-7738P $ 3.00
Service Publications Order Forms 770-8633 N/C Video Tapes:
1996 Single Speed Transmission 770-9479 $14.95 1996 Two Speed Transmission 770-9480 $14.95 Special “Five-in-One”* 770-9475 $14.95 1997 Two Speed 770-0413M $14.95 Z Series Tractor Transmission and
Adjustment 770-0414M $14.95
*Contains: Trouble shooting: batteries & charging systems,
electrical (riders & tractors), hydrostatic transaxles plus neutral adjustment, 410/420 tiller chain cases, and log splitter test procedures.
MISCELLANEOUS
Description Form No. Unit Price
1999 MTD Master Book 770-99 $19.95 1998 MTD Master Book 770-98 $19.95 1997 MTD Master Book 770-97 $19.95 1996 MTD Master Book 770-96 $19.95 1995 MTD Master Book 770-95 $19.95 1994 MTD Master Book 770-94 $19.95 1993 MTD Master Book 770-8294 $17.50 1992 MTD Master Book 770-7986 $17.50 1991 MTD Master Book 770-7610 $17.50 1990 MTD Master Book 770-7232 $17.50 1989 MTD Master Book 770-6815 $17.50 1988 MTD Master Book 770-6506 $16.50 1987 MTD Master Book 770-6084 $16.50 1986 MTD Master Book 770-5171 $16.50
AIRCAP Master Book 706-15272 $34.50
(thru 1990)
General Power 770-0265K $19.95
Master Book (1995)
1992 Yard-Man Master Book 770-7988 $16.50 1991 Yard-Man Master Book 770-7620 $16.50 1990 Yard-Man Master Book 770-7234 $15.50 1989 Yard-Man Master Book 770-6818 $15.50 1988 Yard-Man Master Book 770-6508 $15.50 1987 Yard-Man Master Book 770-6088 $15.50 1986 Yard-Man Master Book 770-5174 $15.50 1985 Yard-Man Master Book 770-4102 $15.50 1984 Yard-Man Master Book 770-3358 $15.00 1983 Yard-Man Master Book 770-2665 $15.00 1982 Yard-Man Master Book 770-2204 $15.00 1981 Yard-Man Master Book 770-1159 $15.00 1980 Yard-Man Master Book 770-0270 $10.50 1979 Yard-Man Master Book 770-8915 $10.50
MASTER BOOKS
NOTE: Ohio Residents—When Ordering, Add 5.5% Sales Tax or Provide a Valid Sales Tax Exemption Certificate. Price subject to change without notice.
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SERVICE PUBLICATIONS AVAILABLE
Please Order By Description (Include Year) and Part Number.
Description Form No. Unit Price
White Microfiche Set—Current 10 Years 770-9409 $ 34.95
(Included in New Dealer Kits) White Microfiche Set—1991 to 1995 770-9413 $ 21.95 White Microfiche Set—1986 to 1990 770-9411 $ 14.95 White Microfiche Set—1980 to 1985 770-9410 $ 6.25 White Microfiche Set—1979 and Prior 770-8659 $ 8.00
2000 White Spring/Summer Microfiche 770-9444 $ 4.50 2000 White Fall/Winter Microfiche 770-9443 $ 2.25 1999 White Spring/Summer Microfiche 770-9440 $ 4.50 1999 White Fall/Winter Microfiche 770-9437 $ 2.25 1998 White Fall/Winter Microfiche 770-9429 $ 2.25 1998 White Spring/Summer Microfiche 770-9433 $ 4.50 1997 White Microfiche Spring/Summer Microfiche 770-9498 $ 4.50 1997 White Microfiche Fall/Winter Microfiche 770-9499 $ 2.25 1996 White Microfiche Spring/Summer Microfiche 770-9484 $ 4.50 1996 White Microfiche Fall/Winter Microfiche 770-9483 $ 2.25 1995 White Microfiche Spring/Summer Microfiche 770-9473 $ 4.50 1995 White Microfiche Fall/Winter Microfiche 770-9472 $ 2.25 1994 White Microfiche Spring/Summer Microfiche 770-9468 $ 4.50 1994 White Microfiche Fall/Winter Microfiche 770-9467 $ 2.25 1993 White Microfiche Spring/Summer Microfiche 770-8293 $ 4.50 1993 White Microfiche Fall/Winter Microfiche 770-8292 $ 2.25 1992 White Microfiche Spring/Summer Microfiche 770-7983 $ 4.50 1992 White Microfiche Fall/Winter Microfiche 770-7982 $ 2.25 1991 White Microfiche Spring/Summer Microfiche 770-7608 $ 4.50 1991 White Microfiche Fall/Winter Microfiche 770-7609 $ 2.25 1990 White Microfiche Spring/Summer Microfiche 770-7230 $ 4.50 1990 White Microfiche Fall/Winter Microfiche 770-7229 $ 2.25 1989 White Microfiche Spring/Summer Microfiche 770-6813 $ 4.50 1989 White Microfiche Fall/Winter Microfiche 770-6812 $ 2.00 1988 White Microfiche Microfiche 770-6504 $ 2.50 1987 White Microfiche Microfiche 770-6085 $ 2.50 1986 White Microfiche Microfiche 770-5173 $ 1.50 1985 White Microfiche Microfiche 770-4108 $ 1.50 1984 White Microfiche Microfiche 770-3493 $ 1.50 1983 White Microfiche Microfiche 770-3061 $ 1.00 1982 White Microfiche Microfiche 770-3060 $ 1.00 1981 White Microfiche Microfiche 770-3059 $ 1.00 1980 White Microfiche Microfiche 770-3058 $ 1.00
MICROFICHE
Description Form No. Unit Price
1999 White Master Books 770-99W $ 16.50 1998 White Master Books 770-98W $ 16.50 1997 White Master Books 770-97W $ 16.50 1996 White Master Books 770-96W $ 16.50 1995 White Master Books 770-95W $ 16.50 1994 White Master Books 770-94W $ 16.50 1993 White Master Books 770-8295 $ 16.50 1992 White Master Books 770-7987 $ 16.50 1991 White Master Books 770-7611 $ 16.50 1990 White Master Books 770-7233 $ 14.50 1989 White Master Books 770-6817 $ 12.95 1988 White Master Books 770-6554 $ 12.50 1987 White Master Books 770-6086 $ 12.50 1986 White Master Books 770-5172 $ 9.00 1985 White Master Books 770-4103 $ 8.50 1984 White Master Books 770-3930A $ 8.50 White Binder (4"-6" Expandable) 785-0570 $ 6.00
MASTER BOOKS
NOTE: Ohio Residents—When Ordering, Add 5.5% Sales Tax or Provide a Valid Sales Tax Exemption Certificate. Price subject to change without notice.
Description Form No. Unit Price
Repair Parts Cross Reference 770-3064/ $ 2.50
770-3174
Warranty Claim Forms 770-7601H $ 5.00
per 100
Service Parts Order Form 770-6016 N/C
Job Estimating Guide 770-7738P $ 3.00
MISCELLANEOUS
Description Form No. Unit Price
MUST HAVE SERVICE MANUAL 770-8640M $29.95 1999 Service Update Seminar Book 770-8877P $12.50 2000 Service Update Seminar Book 770-8877Q $19.50
SERVICE HANDBOOKS
Description Form No. Unit Price
Video Tapes: Single Speed Transmission 770-9479 $14.95 1996 Two Speed Transmission 770-9480 $14.95 Special “Five-in-One”* 770-9475 $14.95 1997 Two Speed 770-0413M $14.95 Z Series Tractor Transmission and
Adjustment 770-0414M $14.95
*Contains: Trouble shooting: batteries & charging systems,
electrical (riders & tractors), hydrostatic transaxles plus neutral adjustment, 410/420 tiller chain cases, and log splitter test procedures.
SERVICE VIDEO TAPES
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For TWO YEARS from the date of retail purchase within the United States of America, its possessions and territories, MTD PRODUCTS INC will, at its option, repair or replace, for the original purchaser, free of charge, any part or parts found to be defective in material or workmanship. This warranty covers units which have been operated in accordance with the operating instructions furnished with the unit, and which have not been subject to misuse, abuse, com­mercial use, neglect, accident, improper maintenance or alteration.
Normal wear parts or components thereof are subject to separate terms as noted below in the "No Fault ninety Day Consumer Warranty" clause.
All normal wear part failures will be covered on this product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear parts failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear parts are defined as batteries*, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, rubber auger spirals, shave plates and tires.
How to obtain service: Warranty service is avail­able, with proof of purchase, through your local autho­rized service dealer. To locate the dealer in your area, please check the yellow pages or contact the Customer Service Department of MTD PRODUCTS INC, P.O. Box 368022, Cleveland, Ohio 44136-9722. Phone 1-800-800-7310. The return of a complete unit will not be accepted by the factory unless prior written permission has been extended by the Customer Service Department of MTD PRODUCTS INC.
Transportation charges: Transportation charges for the movement of any power equipment unit or attach­ment are the responsibility of the purchaser.
WARRANTY AND SERVICE POLICY
MTD SERVICE CENTERS
PURPOSE
The purpose of warranty is to protect the customer from defects in materials and workmanship, defects which are not detected at the time of manufacture. Warranty does not imply, state or provide for the unlimited and unrestricted replacement of parts. The customer is responsible for their use and maintenance of the unit, and is responsible for providing adequate proof of purchase to substantiate any warranty claim. The manufacturer cannot and will not assume responsibility for conditions over which it has no control.
MTD MANUFACTURER'S LIMITED WARRANTY
Units exported out of the United States: MTD
PRODUCTS INC does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through MTD PRODUCTS INC's autho­rized channels of export distribution
Other Warranties:
1. The engine or component parts thereof carry separate warranties from their manufacturers. Please refer to the applicable manufacturer's warranty on these items.
2. *Batteries are covered by a 90 day replacement warranty.
3. Log splitter pumps, valves and cylinders, or component parts thereof are covered by a one year warranty.
4. All other warranties, express or implied, includ­ing any implied warranty of merchantability or fitness for a particular purpose, are hereby expressly disclaimed in their entirety.
5. The provisions as set forth in this warranty pro-
vide the sole and exclusive remedy of MTD PRODUCTS INC's obligations arising from the sales of its products. MTD PRODUCTS INC will not be liable for incidental or consequential loss or damage.
How state law relates to this warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Certain disclaimers are not allowed in some states and therefore they may not apply to you under all cir­cumstances.
NOTE: This warranty does not cover routine mainte­nance items such as lubricants, filters, blade sharpen­ing and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments. Nor does this warranty cover normal deterioration of the exterior finish due to use or exposure.
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OTHER WARRANTIES
The ENGINE is covered by a warranty extended by the engine manufacturer, which may include Briggs & Stratton Corporation, Tecumseh Products Company, Kohler Company or Onan Corporation. Any and all claims for engine or engine related components must be handled through the respective manufacturer's authorized service repre­sentative.
HYDROSTATIC TRANSMISSIONS manufactured by Hydro-Gear carry a two year limited warranty and are to be handled by authorized Hydro-Gear service representatives. Replacement parts and technical assistance can be obtained from the Hydro-Gear Central Distributor. MTD PRODUCTS INC is not responsible for processing these warranty claims nor processing returned units.
PEERLESS COMPONENTS are covered by Tecumseh Products Company. Any claims against this warranty will be handled directly by an authorized service center for Tecumseh Products.
CLAIMS Claims against MTD's warranty may consist of any of the following:
1. Replacement of missing parts on new equipment by an authorized servicing dealer.
2. Replacement of defective parts during the warranty period by an authorized servicing dealer.
3. Repair of defects during the warranty period by an authorized servicing dealer.
Claims against MTD's warranty may include:
1. Reasonable labor charges which are guided by posted MTD policy.
2. Parts necessary to complete repairs at the servicing firm's cost plus a percentage of dealer cost.
3. "NO FAULT" NINETY DAY CONSUMER WARRANTY**. All normal wear part failures will be covered on MTD products for a period of 90 days regardless of cause. After 90 days but within the two year period, normal wear part failures will be covered if caused by defects in material or workmanship of other compo­nent parts. Normal wear parts are defined as batteries, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, rubber auger spirals, shave plates and tires. **PLEASE
NOTE: This is not a "blank check" repair clause. This particular policy covers normal wear parts only!
4. Batteries on riding equipment are covered by a ninety (90) day replacement warranty. Batteries on walk behind mowers are covered for one year.
Claims against MTD's warranty will not include:
1. Repairs which become necessary because of:
• Misuse or abuse
• Accident
• Neglect
• Lack of correct maintenance
• Damage in transit
• Normal wear
• Incorrect set up of complete units or attachments by a dealer or consumer
• Damage from stale gas or gas that contains water or other debris
2. Units used commercially
3. Transportation charges
4. Normal maintenance such as tune-ups, carburetor and mechanical adjustments, oil changes, etc.
5. Service call or travel time charges
6. Telephone calls
7. Installation of attachments or accessories
8. Customer set up of a unit or attachment
The following information will be required on ALL warranty claims:
1. Authorized service dealer number
2. Model number and manufacturing code/serial number of unit
3. Date of purchase
4. Date of failure and repair
5. Description of failure and work performed
6. Parts and labor time required to complete repair, including type of part and quantity used
7. Owners name and address
• Each warranty claim must at minimum include the above information to be processed.
• If the serial number indicates the unit is out of warranty, attach a copy of the owner's original proof of purchase to the warranty claim.
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Completing the Claim Report:
Top of Claim Report:
MANUFACTURER: MTD, Yard-Man, etc PURCHASE DATE: DATE FAILED: REPAIR DATE: When purchased When unit failed When unit repaired
Box No. 1:
OWNER'S NAME: Doe, John STREET ADDRESS: 1 Any Street CITY/STATE: Any town, Ohio ZIP CODE:11111 OWNER'S SIGNATURE: _____________ PHONE: (000) 000-0000
Box No. 2:
EQUIPMENT MODEL NUMBER:
11 digit alpha-numeric number
CODE: 11 digit serial number or manufacturing date code ENGINE/TRANS MODEL NO.: Only if component being repaired TYPE OR SPEC. NO.: See previous TYPE OF EQUIPMENT: Rider, push, tiller, etc. HOURS USED: How many HOW USED: Residential, commercial, etc.
Box No. 3:
DISTRIBUTOR: Where parts for repair were obtained CITY/STATE: Of distributor ZIP CODE: Of distributor SIGNATURE: Not needed
WARRANTY CLAIM SUBMISSION:
MTD Products uses the Outdoor Power Equipment Warranty Claim Report:
Box No. 4:
UNIT PURCHASED FROM: Where was unit purchased STREET ADDRESS: Of retailer selling unit CITY/STATE: Of retailer selling unit ZIP CODE: Of retailer selling unit
Box No. 5:
PROBABLE CAUSE OF FAILURE: What specifically happened to cause the damage to the unit. Be specific here ("defective" is not sufficient). E.G. The shift bracket in the transmission was bent, causing the gears to strip and break the casting.
Box No. 6:
WORK PERFORMED: What was necessary for the repair. E.G. Open casing, replace shift bracket and gears, replace casing.
Box No. 7:
WARRANTY CREDIT: For factory use only
Box No. 8:
PART NUMBER: Must be an OEM Part number DESCRIPTION: Of part QTY: Number of part used PRICE: What was paid for the part TOTAL: Total amount used for the specific part (e.g. 2
parts @ $1.00 per = $2.00) HOURS: How much time to fix that specific part FACTORY USE: For factory use only
Box No. 9:
A,B,C,D: For factory use only
Box No. 10:
WARRANTY PERFORMED BY: Dealer performing the repair FIRM NAME: ADDRESS: CITY: STATE: ZIP CODE: PHONE: SIGNED:
Box No. 11:
AUTHORIZED SERVICE NO.: This is your designated six-digit "S" number supplied by MTD for authorized service dealers
SMALL CHECK BOX IN LOWER LEFT HAND CORNER: Check if more claim forms are needed
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PROCESSING:
• Most warranty claims are processed directly by the factory.
• Claims received which are missing information will be returned to the repairing service center.
• All claims must be filed within thirty (30) days after service is completed.
• MTD reserves the right to review any major repairs BEFORE work is performed. A major repair is considered any repair where the cost of repair is excessive in relation to the value of the unit. Authorization for major repairs is extended by the MTD Service Department or the authorized Central Service Distributor.
• Any claim judged to be excessive may be adjusted by MTD. The MTD "Job Estimating Guide" provides a rule of thumb time allowance for most standard repairs. PLEASE NOTE that upon receipt of an adequate explana­tion MTD WILL consider any and all extenuating circumstances which may apply on a warranty claim.
• Any claims not in compliance with the above will not be accepted.
• All parts sold or used for MTD warranty repairs MUST be genuine MTD original equipment parts.
• PLEASE MAIL ALL CLAIMS NOT INVOLVING RETURN PARTS TO:
MTD PRODUCTS INC P.O. Box 368022 Cleveland, Ohio 44136-9722 ATTENTION: WARRANTY
WARRANTY PARTS RETURN POLICY
Parts replaced under warranty must be held by the servicing firm for a period of thirty (30) days after the claim is paid. MTD reserves the right to request the return of any part replaced under warranty for inspection. If inspection is required a letter will be sent to the dealer explaining return shipping procedures.
1. Differentials
2. Clutches
3. Transaxles (upon request)
4. PTO Assemblies
5. Chain and Gear case assemblies (current production year only)
6. Hydrostatic valves
7. Hydrostatic pumps
8. Hydraulic cylinders (ONLY when non-repairable)
9. Electric motors (warranty period units only)
When returning a part for warranty credit and/or inspection, a COPY of the original WARRANTY CLAIM should be placed in a plastic bag and included with the parts. If more than one part is being returned, attach each claim copy to the appropriate part. Any part returned to MTD should be shipped via the most cost effective method. Freight charges for these parts are reimbursed to the repairing dealer. Documentation of these freight charges should be included with your warranty claim.
Each component that is returned is disassembled and inspected for failure mode. This information is crucial in the process of continuous improvement.
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Transmission Warranty Process
MTD Service Centers
1
Dealer inspects unit
Determines unit should be replaced
under warranty
2
Dealer calls parts distributor for
like-kind exchange after providing necessary information
3
Replacement unit sent
4
Dealer submits copy of warranty claim form to distributor
which includes ALL necessary information*
5
Dealer submits properly completed original warranty claim
to MTD Warranty Department for processing and
normal reimbursement
6
Dealer returns defective unit to MTD upon
receipt of a return letter
EXPLANATION OF PROCESS STEPS:
1. The dealer must make a thorough inspection using specific diagnostic techniques to determine whether unit must be replaced.
2. The Central Distributor will gather the claim number from the dealer and attach it to the replacement order. Each Central is responsible for maintaining an available supply of units to be used for warranty repairs.
3. Units will be shipped immediately to maintain service levels.
4. The dealer MUST submit a copy of the properly completed warranty claim form to the Central Distributor. Each Central will need this information so that Wegman Service can create a replenishment order. Any copy of a claim form received without COMPLETE information will be returned to the Central without a re-order placed.
5. The dealer will submit the properly completed warranty claim form to MTD per the standard warranty procedure. Claims received with incomplete information will be returned unpaid.
6. Upon receipt of a return letter, the defective unit must be returned to MTD. Shipping charges are reimbursed to the repairing dealer. Defective parts must be retained for a period of 30 days from the receipt of payment for the claim.
It is extremely important to file these claims accurately and immediately. Warranty service should not be an
expense to your Service Center. It should be just another means of payment for a normal repair.
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MANUFACTURER’S
LIMITED WARRANTY
The limited warranty set forth below is given by MTD PRODUCTS INC (“MTD”) with respect to new merchandise purchased and used in the United States, its possessions and territories.
MTD warrants this product against defects in material and workmanship for a period of two (2) years commencing on the date of original purchase and will, at its option, repair or replace, free of charge, any part found to be defective in material or workmanship. This limited warranty shall only apply if this product has been operated and maintained in accordance with the Operator’s Manual furnished with the product, and has not been subject to misuse, abuse, com­mercial use, neglect, accident, improper maintenance, alteration, vandalism, theft, fire, water or damage because of other peril or natural disaster. Damage resulting from the installation or use of any accessory or attachment not approved by MTD Products Inc. for use with the product(s) covered by this manual will void your warranty as to any resulting damages.
Normal wear parts or components thereof are subject to separate terms as follows: All normal wear part or compo­nent failures will be covered on the product for a period of 90 days regardless of cause. After 90 days, but within the two year period, normal wear part failures will be covered ONLY IF caused by defects in material or workmanship of OTHER component parts. Normal wear parts and compo­nents include, but are not limited to, belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires. Batteries are covered by a 90-day limited replacement warranty.
HOW TO OBTAIN SERVICE: Warranty service is available, WITH PROOF OF PURCHASE THROUGH YOUR LOCAL AUTHORIZED SERVICE DEALER. To locate the dealer in your area, please check for a listing in the Yellow Pages or contact the Customer Service Department of MTD PROD­UCTS INC by calling 1-800-800-7310 or writing to P.O. Box 368022, Cleveland, Ohio 44136-9722.
This limited warranty does not provide coverage in the following cases:
a. The engine or component parts thereof. These items
carry a separate manufacturer’s warranty. Please refer to the applicable manufacturer’s warranty on these items.
b. Log splitter pumps, valves and cylinders have a sepa-
rate one year warranty.
c. Routine maintenance items such as lubricants, filters,
blade sharpening and tune-ups, or adjustments such as brake adjustments, clutch adjustments or deck adjustments; and normal deterioration of the exterior finish due to use or exposure.
d. MTD does not extend any warranty for products sold
or exported outside of the United States of America, its possessions and territories, except those sold through MTD’s authorized channels of export distribu- tion.
No implied warranty, including any implied warranty of merchantability or fitness for a particular purpose, applies after the applicable period of express written warranty above as to the parts as identified. No other express warranty or guaranty, whether written or oral, except as mentioned above, given by any person or entity, including a dealer or retailer, with respect to any product shall bind MTD. During the period of the War­ranty, the exclusive remedy is repair or replacement of the product as set forth above. (Some states do not
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.)
The provisions as set forth in this Warranty provide the sole and exclusive remedy arising from the sales. MTD shall not be liable for incidental or consequential loss or damages including, without limitation, expenses incurred for substitute or replacement lawn care ser­vices, for transportation or for related expenses, or for rental expenses to temporarily replace a warranted product. (Some states do not allow the exclusion or limita-
tion of incidental or consequential damages, so the above exclusion or limitation may not apply to you.)
In no event shall recovery of any kind be greater than the amount of the purchase price of the product sold. Alteration of the safety features of the product shall void this War­ranty. You assume the risk and liability for loss, damage, or injury to you and your property and/or to others and their property arising out of the use or misuse or inability to use the product.
This limited warranty shall not extend to anyone other than the original purchaser, original lessee or the person for whom it was purchased as a gift.
How State Law Relates to this Warranty: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
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For TWO YEARS from the date of retail purchase within the United States of America, its possessions and territories, MTD PRODUCTS INC will, at its option, repair or replace, for the original purchaser, free of charge, any part or parts found to be defective in material or workmanship. This warranty covers units which have been operated and maintained in accordance with the operating instructions furnished with the unit, and which have not been subject to mis­use, abuse, neglect, accident, improper maintenance or alteration.
NORMAL WEAR PARTS or components thereof are subject to separate terms as noted below in the “No Fault Ninety Day Consumer Warranty” clause. Commercial use is subject to the terms listed above, and is covered for a period of 90 days from the date of purchase.
TWO YEAR CONSUMER WARRANTY ON NORMAL WEAR PARTS WITH NINETY DAY NO FAULT PRO­TECTION: All normal wear parts failures will be cov­ered on this product for a period of 90 days regard­less of cause. After 90 days, but within the two year period, normal wear parts failures will be covered if caused by defects in material or workmanship. Normal wear parts are defined as belts, blades, blade adapters, grass bags, rider deck wheels, seats, snow thrower skid shoes, shave plates and tires.
HOW TO OBTAIN SERVICE: Warranty service is available, with proof of purchase, through your local authorized service dealer. To locate the dealer in your area, please check the yellow pages or contact the Customer Service Department of MTD PRODUCTS INC, P O Box 361131, Cleveland, Ohio 44136-0019. Phone (330) 225-8883. The return of a complete unit will not be accepted by the factory unless prior written permission has been extended by the Service Department of MTD PRODUCTS INC.
TRANSPORTATION CHARGES: Transportation charges for the movement of any power equipment unit or attachment are the responsibility of the pur­chaser. Transportation charges for any parts submit­ted for replacement under this warranty must be paid by the purchaser unless such return is requested by MTD PRODUCTS INC.
UNITS EXPORTED OUT OF THE UNITED STATES: MTD PRODUCTS INC does not extend any warranty for products sold or exported outside of the United States of America, its possessions and territories, except those sold through MTD PRODUCTS INC’s authorized channels of export distribution.
OTHER WARRANTIES:
1. The engine or component parts thereof carry sep­arate warranties from their manufacturers. Please refer to the applicable manufacturer’s warranty on these items.
2. Batteries are covered by a 90-day replacement warranty.
3. Log splitter pumps, valves and cylinders or com­ponent parts thereof are covered by a one year warranty.
4. All other warranties, express or implied, including any implied warranty of merchantability or fitness for a particular purpose, are hereby expressly dis­claimed in their entirety.
5. The provisions as set forth in this warranty pro­vide the sole and exclusive remedy of MTD PRODUCTS INC’s obligations arising from the sales of its products. MTD PRODUCTS INC will not be liable for incidental or consequential loss or damage.
HOW STATE LAW RELATES TO THIS WARRANTY: This limited warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Certain disclaimers are not allowed in some states and therefore they may not apply to you under all circumstances.
NOTE: This warranty does not cover set-up, routine maintenance items such as lubricants, filters, blade sharpening and tune-ups, or adjustments such as brake adjustments. Nor does this warranty cover nor­mal deterioration of the exterior finish due to use or exposure.
MANUFACTURER’S LIMITED WARRANTY FOR:
1
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Lubrication Chart for Yard Machines and Yard-Man
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Lubrication Chart for Yard Machines and Yard-Man
(continued)
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Quick Reference Guide
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Quick Reference Guide
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Quick Reference Guide
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Quick Reference Guide
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Yardman Specifications
Lawn Tractors
Yard Bug™
Model A604F D604G X604G U604H D674G X694G 325
Specifications subject to change without notice.
Walk-Behind Mowers
Model E999M 999L 979L 559K 519C 106C
Specifications subject to change without notice.
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Yardman Specifications
1
Garden Tractors
Model U804H W804H V804P Z804P U844H 999
Specifications subject to change without notice.
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Yardman Specifications
TILLER CHIPPER/SHREDDER/VACS
EDGER
Model 458B Model 103A 203B
MODEL 564A
Specifications subject to change without notice.
Specifications subject to change without notice.
Specifications subject to change without notice.
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White Outdoor Specifications
Specifications subject to change without notice.
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White Outdooor Specifications
Specifications subject to change without notice.
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White Outdoor Specifications
1
Specifications subject to change without notice.
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White Outdoor Specifications
Specifications subject to change without notice.
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White Outdoor Specifications
Specifications subject to change without notice.
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White Outdoor Specifications
Specifications subject to change without notice.
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2 - 1
1. Remove both of the transmission cover screws with a 1/4" socket. See figure 1.
2. Push the sides of the transmission cover in, releasing the locking tabs from the height adjusters.
NOTE: You may need to use a flat head screw driver to apply pressure inward during cover removal.
3. Using a 7/16 socket and a 7/16 wrench, remove the idler and belt keeper from the unit. See figure
2.
NOTE: The belt is free from the transmission at this point.
Removal and Replacement of the Drive Belt
FIGURE 1.
FIGURE 2.
FIGURE 3.
Screw
Screw
Transmission
Cover
Transmission
Pulley
Belleville
Washer
Belt Keeper
Nut
Idler
Blade
Adapter
Blade Bolt
Bell
Washer
Drive
Pulley
Belt Keeper
Blade
4. Lift up on the front of the unit and tilt the machine towards the handlebars.
5. Remove the blade bolt and bell washer from the blade assembly using a 5/8 socket. See figure 3.
NOTE: The blade, blade adapter, and the drive pulley will come off of the crank shaft as one assembly.
6. Remove the belt from the unit.
REINSTALL THE BELT IN THE REVERSE ORDER.
SECTION 2
FRONT WHEEL DRIVE SELF-
PROPELLED LAWN MOWERS
2
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Front Wheel Drive Self-Propel
1. Lift up on the front of the unit and tilt the machine towards the handlebars. Secure the unit in this position.
NOTE: A 2x4 on end works well for this.
2. Remove the hubcaps, hairpins and washers. See figure 1.
NOTE: The washers on this unit are on the out­side of the wheels.
3. Remove the wheels, drive gears marked with “R” or “L” for right and left, the dowel pins and dust covers. See figure 1.
NOTE: The dust covers are being held on by the wheel hubs. There are no washers on the inside of the wheels.
Removal of the Front Wheel Drive Assembly
FIGURE 1.
FIGURE 2.
FIGURE 3.
Dowel
Pins
Dust Cover
Dust
Cover
Drive
Gear
Drive
Gear
Wheel
Wheel
Washer
Washer
Hairpins
Hub Caps
Drive
Cable
Cable
Lock Tabs
Cable Idler
Bracket
Hole for
T-27 Torx
Z Fitting
Idler
Bracket
Assembly
Pivot Plate
Assembly
Wheel
Axle
Height
Adjustment
Lever
DD Washer
Snap Ring
Belleville
Washers
Hex Cap
Screws
4. Remove the drive cable from the cable idler bracket by squeezing the cable lock tabs in and pulling the “Z” fitting from the idler arm. See figure
2.
5. Remove the cable bracket screw with a T-27 torx. This will allow the transmission to pivot freely.
6. Remove both hex cap screws and hex nuts from the left height adjuster using a 9/16 socket and wrench. Take note of which way the bell washers face. The cup side faces the deck. See figure 3.
NOTE: As you pull the right height adjustment away, the transmission assembly will come with it.
REINSTALL THE TRANSMISSION ASSEMBLY IN THE REVERSE ORDER.
FRONT DRIVE ASSEMBLY
FIGURE 4.
Upper Housing
Thrust
Washers
Cable Idler
Bracket
Output Shaft
Input
Pinion
Lower
Housing
Extension
Spring
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CAUTION: The height adjustment assembly is spring
loaded with a wave washer!!!
1. Remove the snap ring, DD washer, height adjust­ment lever and pivot plate. See figure 1.
NOTE: The wheel axle is mounted to the pivot plate, not to the adjustment lever.
Front Height Adjustment
Disassembly
FIGURE 1.
Pivot Plate
Assembly
Wheel
Axle
Height
Adjustment
Lever
DD Washer
Snap Ring
Belleville
Washers
Hex Cap
Screws
2. Remove the bearing retainer, bearing sleeve, bearing support, and wave washer from the height adjustment plate. See figure 2.
NOTE: These are all pressed together at this time.
3. Remove the wave washer from the bearing support.
4. The bearing assembly (retainer, sleeve, and support) can now be disassembled.
FIGURE 2.
Bearing
Retainer
Bearing
Sleeve
Bearing
Support
Height Adj.
Plate
Pivot Plate
Assembly
Height
Adjustment
Lever
DD Washer
Snap
Ring
Wave
Washer
1. Open the jaws of a vice to allow the bearing support to fall into the center, stopping the retainer lip on the top surface of the jaws.
2. Tap the bearing sleeve face with a brass hammer, and the assembly will come apart.
NOTE: The bearing sleeve has an indicator pin on it that locks the bearing in place. This ensures that the bearing does not spin on the axle shaft.
3. Replace the bearing sleeve.
NOTE: Make sure the indicator pin is in the detent of the bearing support.
4. Put the bearing support, new bearing sleeve, and the bearing retainer in the correct sequence.
5. Find a socket that will fit over the center raised bearing retainer area, yet fit flush on the outer perimeter of the bearing retainer. See figure 1.
6. Open the jaws of a vice to allow the bearing sup­port to fall into the center, stopping at the bearing support lip on the top surface of the jaws.
7. Place the socket over the bearing retainer perimeter and tap the bearing assembly until the bearing sleeve is firmly in place. See figure 1.
Bearing Sleeve Removal
and Assembly
FIGURE 1.
Bearing
Retainer
Socket
Bearing
Sleeve
Retainer
Lip
Bearing
Support Lip
Front Wheel Drive Self-Propel
2
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Front Wheel Drive Self-Propel
1. Place the wave washer on the bearing support.
2. Place the bearing support and the wave washer into the height adjustment plate.
NOTE: The wave washer goes between the bear­ing support and the height adjustment plate on the inside.
3. Place the pivot plate, lever, and the DD washer on next.
4. With a pair of retainer ring pliers, place the retain­ing ring on the bearing support.
NOTE: The retaining ring will not be in the grove at this time. The retaining ring needs to be installed with the squared edge facing the wheel.
Front Height Adjustment Reassembly
FIGURE 1.
Retaining
Ring
Bearing
Retainer
5. Using two 1" sockets, one on the bearing retainer side and one on the retaining ring side, put the assembly into a vice. See figure 1.
NOTE: If you have a 1" ID washer, use it on the retaining ring side for support and remove it when finished.
6. Compress the assembly until the retaining ring snaps itself into place.
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INITIAL PREPARATION:
IMPORTANT: Prior to leveling the mowing deck,
perform the following steps:
1). Check the tire pressure. All tires will be approxi­mately 12 PSI.
2). Place the rider on a level surface.
3). Depress and lock the parking brake.
4). Raise the hood and remove the grass bag assembly and discharge chute.
5). Remove the spark plug wire from the spark plug and lower the hood.
6). Raise the cutting height adjustment lever to the highest position.
7). Locate both lower "T" links and extension springs that secure the rear deck hangers to the pivot link assemblies.
8). Make certain the lower "T" links are mounted to the rider correctly. See figure 1.
Deck Leveling
FIGURE 1.
FRONT TO REAR LEVELING ADJUSTMENT:
IMPORTANT: The front of the mowing deck will
be between 1/4 and 3/8" lower in the front than the rear of the deck.
1). Using a work glove or rag, rotate the mowing blade until it is parallel with the rider frame. See figure 2.
FIGURE 2.
2). Depress and lock the deck pedal assembly.
3). Measure the front blade tip to ground.
4). Measure the rear blade tip to ground.
5). The front blade tip will be 1/4 to 3/8" lower than the rear blade tip. If not, perform the following adjustments:
6). Loosen both jam nuts that are directly on top of the center deck ferrules using a 3/4" wrench. See figure 3.
FIGURE 3.
Top Jam Nut
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SECTION 3
YARD BUG
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YARD BUG
FIGURE 4.
8). Raise or lower the mowing deck assembly by tightening or loosening the jam nuts that are directly on top of the center deck ferrules, until the proper measurement (front to back) has been achieved. Refer to figure 3.
9). Tighten both middle jam nuts that are directly below the center deck ferrules using a 3/4" wrench.
10). Release the deck pedal assembly
SIDE TO SIDE LEVELING ADJUSTMENT:
1). Using a work glove or rag, rotate the mowing blade until it is perpendicular to the rider frame. See figure 5.
FIGURE 5.
7). Loosen the middle jam nuts that are directly below the center deck ferrules until they bottom out on top of the mowing deck jam nuts using a 3/4" wrench. See figure 4.
Middle
Jam Nut
2). Depress and lock the deck pedal assembly.
3). Measure the right blade tip to ground.
4). Measure the left blade tip to ground.
5). The right blade tip will be equal to the left blade tip. If not, perform the following steps:
6). Loosen both jam nuts that are directly on top of the center deck ferrules using a 3/4" wrench. Refer to figure 3.
7). Loosen the middle jam nuts that are directly below the center deck ferrules until they bottom out on top of the mowing deck jam nuts using a 3/4" wrench. Refer to figure 4.
8). Identify which side of the mowing deck needs to be raised or lowered to achieve the correct mea­surements.
9). Locate and adjust the jam nuts that are directly on top of the center ferrules until the deck is leveled out. Refer to figure 3.
REMEMBER: The front to back adjustment will be altered if both jam nuts are altered.
10). Tighten both middle jam nuts that are directly below the center deck ferrules using a 3/4" wrench.
11). Release the deck pedal assembly.
12). Reconnect the spark plug wire to the spark plug.
13). Reinstall the discharge chute and grass bag assembly.
14). Lower the hood and test for a level cut.
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YARD BUG
TESTING THE BRAKES:
1). Release the parking brake and place the rider in neutral.
2). Depress the brake pedal and try to roll the rider.
NOTE: If the tractor moves, perform the following steps:
BRAKE ADJUSTMENT AT THE TRANSMISSION:
1). Standing on the right side of the rider, locate the brake cable under the front housing.
2). Follow the brake cable forward to the front chan­nel assembly. See figure 1.
Brake Adjustment
FIGURE 1.
FIGURE 2.
Brake Cable
Front Channel
Assembly
Rear Jam Nut
3). Locate and loosen the brake cable adjustment jam nuts using two 1/2" wrenches.
4). By hand, loosen the rear jam nut (closest to the deck) until it bottoms out on the threaded cable end.
5). Slide the brake cable forward until the rear jam nut is flush with the back side of the front channel assembly.
6). By hand, tighten the front jam nut to the front of the front channel assembly. See figure 2.
Front
Jam Nut
FIGURE 3.
7). Tighten both jam nuts using two 1/2" wrenches.
8). Locate the locking hex nut that secures the brake actuation arm to the brake assembly on the transmission. See figure 3.
9). Loosen (DO NOT REMOVE) the locking hex nut using a 1/2" wrench. See figure 3.
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YARD BUG
FIGURE 4.
10). Slide an .011" feeler gauge between the brake disc and the brake puck. See figure 4.
11). Tighten the locking hex nut until the .011" feeler gauge is snug. See figure 4.
12). Remove the .011" feeler gauge.
13). Test for proper brake adjustment using the TESTING THE BRAKES section.
PERIODIC BRAKE ADJUSTMENT:
1). Lock the parking brake and turn the ignition key off.
2). Pivot the hood up and remove the spark plug wire from the spark plug.
3). Lower the hood.
4). From the right side of the rider, locate the brake cable under the front housing.
5). Follow the brake cable forward to the front channel assembly.
6). Locate and loosen the brake cable adjustment jam nuts using two 1/2" wrenches. Refer to figures 1 and 2.
7). Loosen the front jam nut several turns.
8). Grasp the brake cable with your left hand from the rear of the front channel assembly and gently pull rearward.
9). Tighten the rear jam nut (clockwise) one complete rotation at a time using a 1/2" wrench. Between rotation, try to roll the rider. Refer to figure 1.
10). When the rider no longer rolls, hand tighten the front jam nut to the front of the front channel assembly. Refer to figure 2.
11). Tighten both jam nuts using two 1/2" wrenches.
12). Unlock the parking brake and roll the rider several feet on flat ground to make certain the brakes are not too tight.
13). Repeat the TESTING THE BRAKES section and make certain all hardware is secure.
14). Pivot the hood up, reconnect the spark plug wire, and pivot the hood down.
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YARD BUG
3). Remove the spark plug wire from the spark plug.
4). Depress the blade engagement pedal 3/4" from the starting position. See figure 2.
NOTE: Use a tape measure from the original starting point of the engagement pedal.
FIGURE 2.
5). Take hold of the deck engagement belt and try to pull it forward or backward. See figure 3.
FIGURE 3.
NOTE: If the belt is slipping through the deck
pulley and engagement flat idler, perform the fol­lowing steps:
6). Release the blade engagement pedal.
7). Locate and loosen the hex jam nuts that secure the threaded end of the deck cable to the deck cable bracket using two 1/2" wrenches. See figure 4.
FIGURE 4.
8). Adjust the deck cable to the proper specifications and secure the hex jam nuts using two 1/2" wrenches.
9). Test the blade engagement pedal for proper adjustment by performing steps 4 and 5.
NOTE: Make certain the deck belt has a maxi­mum deflection of 1/2" off center when the blade engagement pedal is fully depress.
3/4"
•
•
Pull
IMPORTANT: The deck belt will begin to engage
when the blade engagement pedal is depressed 3/4" from the original starting position.
1). Lower the mowing deck to the lowest cutting position.
2). Raise the hood and remove the grass bag assembly. See figure 1.
Blade Brake/ PTO Adjustment
FIGURE 1.
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YARD BUG
Speed Control Pedal Adjustment
INITIAL SPEED CONTROL PEDAL ADJUSTMENT WITH NEW BELTS:
NOTE: This section is performed with new belts ONLY.
1). Lock the parking brake and turn the ignition key "OFF".
2). Pivot the hood up and remove the spark plug wire from the spark plug.
3). Lower the hood.
4). From the right side of the rider, locate the variable drive cable under the front housing.
5). Follow the variable drive cable forward to the front channel assembly.
6). Locate and loosen the variable drive cable adjustment jam nuts using two 1/2" wrenches. See figures 1 and 2.
7). By hand, loosen the rear jam nut (closest to the deck) until it bottoms out on the threaded cable end. See figure 1.
8). By hand, tighten the front jam nut until the threaded cable end is exposed 3/4 to 7/8" past the front face of the front jam nut. See figure 2.
9). By hand, tighten the rear jam nut (clockwise) until it is snug up against the rear of the front channel assembly. See figure 1.
10). Tighten both jam nuts using two 1/2" wrenches.
11). Release the parking brake.
12). Apply 10 pounds of force to the variable pedal assembly with a fish scale. See figure 3.
FIGURE 1.
FIGURE 2.
Rear Jam Nut
Variable
Drive Cable
3/4" to 7/8"
Front
Jam Nut
FIGURE 3.
10 lbs.
13). From the back of the rider, locate the oval frame extrusion directly behind the engine.
14). Looking down through the oval extrusion, locate the head of the weld pin (belt keeper) on the idler bracket assembly.
15). With a partner applying 10 pounds of force to the variable pedal assembly, measure the distance between the edge of the weld pin head and the right inside edge of the oval extrusion. –The measurement will be between 1.60" and
1.65". See figure 4.
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YARD BUG
IF ADDITIONAL SPEED CONTROL ADJUSTMENT IS NEEDED, PERFORM THE FOLLOWING STEPS:
IMPORTANT: DO NOT perform adjustment
while the rider is running.
NOTE: Inspect both variable drive belts before performing this adjustment.
1). Place the rider on level ground and make certain the parking brake is NOT applied.
2). Raise the hood, remove one of the wiring harness female connectors from the seat switch, and lower the hood. See figure 5.
FIGURE 4.
3). Raise the rear wheels of the rider off the ground.
4). From the right side of the rider, locate the variable drive cable under the front housing.
5). Follow the variable drive cable forward to the front channel assembly.
6). Locate and loosen the variable drive cable adjustment jam nuts using two 1/2" wrenches. Refer to figures 1 and 2.
FIGURE 5.
7). By hand, loosen the front jam nut several full turns. See figure 6.
1.60" to 1.65"
•
•
Female
Connector
FIGURE 6.
8). Mark a line at any point on the back face of the rear jam nut. See figure 7.
FIGURE 7.
9). Grasp the variable drive cable with your left hand from the rear of the front channel assembly and gently pull rearward.
10). Looking at the line that was marked on the rear jam nut, tighten the rear jam nut 1 complete rota­tion (clockwise) using a 1/2" wrench.
11). "START" the rider.
12). Place the shift lever in the forward position.
13). Make certain the variable drive pedal is fully released.
Front Jam Nut
Mark Rear
Jam Nut
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YARD BUG
FIGURE 9.
FIGURE 10.
17). Tighten both jam nuts using two 1/2" wrenches.
18). "START" the rider.
19). Depress and release the variable pedal assem­bly several times.
20). Fully release the variable pedal assembly and make certain the rear wheels are not trying to rotate.
NOTE: If the rear wheels try to move at all, shut the rider "OFF" and back the rear jam nut off 1 full rotation.
21). IMPORTANT: Raise the hood, connect the wiring harness female connector (removed earlier) to the seat switch, and lower the hood.
TEST RUN AND ADJUST IF NECESSARY.
14). Look at the rear tire assemblies and check for motion.
NOTE: If any motion is present, shut "OFF" the rider and proceed to step 15.
NOTE: If there is NO motion, shut "OFF" the rider and repeat steps 9 through 14.
15). Looking at the line that was marked on the rear jam nut, loosen the rear jam nut 2 complete rota­tions using a 1/2" wrench. See figure 8.
FIGURE 8.
Mark Rear
Jam Nut
16). By hand, tighten the front jam nut to the front of the front channel assembly. See figure 9.
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YARD BUG
Steering Adjustment
IMPORTANT: The front tires should have a
"TOE-IN" between 1/16" and 5/16" to allow the unit to track properly.
1). Check the tire pressure in the front tires and make certain that they are at approximately 12 PSI.
2). Place the unit on level ground.
3). Place the steering wheel in the straight forward position. See figure 1.
NOTE: Make certain the tires are running parallel with the frame.
FIGURE 1.
4). In front of the axle, measure the distance hori­zontally from the inside of the left rim, to the inside of the right rim. See figure 2.
FIGURE 2.
5). From behind the axle, measure the distance hori­zontally from the inside of the left rim, to the inside of the right rim.
6). The measurement taken in front of the axle should be between 1/16" and 5/16" less than the measurement taken behind the axle. If not, per­form the following steps:
FIGURE 3.
Right
Ball Joint
Steering
Segment
7). Remove the hex nut securing the right ball joint to the steering segment gear using a 1/2" and a 9/16 wrench.
NOTE: Do not lose the lock washer. See figure
3.
8). Remove the hex nut securing the left ball joint to the steering segment gear using a 1/2" and a 9/16 wrench.
NOTE: Do not lose the lock washer.
9). Remove both ball joints from both tie rods using a 1/2" wrench.
10). Place the left and right tire assemblies in the straight forward position.
11). Set the toe-in for the rim assemblies to the proper measurements as described in steps 4, 5, and 6.
12). Thread the right hand ball joint onto the right hand tie rod until the mounting hole in the steer­ing segment gear lines up with the ball joint stud.
NOTE: Count the number of turns the ball joint rotates onto the tie rod. The number of rotations will be equal to the left side.
13). Secure the right hand ball joint to the steering segment gear with the hex nut removed earlier using a 1/2" and a 9/16 wrench.
NOTE: Make certain the lock washer is between the ball joint and the steering segment gear.
14). Install the left hand ball joint to the tie rod and steering segment gear performing steps 12 and
13. NOTE: Make certain the same number of rota-
tions are used for the left ball joint as the right ball joint.
IMPORTANT: Test the steering assembly for excessive tolerances. Make certain all the hard­ware is secure.
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1). Lower the deck to the lowest cutting position.
2). Raise the hood and remove the grass bag assembly and discharge chute. See figure 1.
7). Release the deck pedal assembly.
8). Loosen the hex nut that secures the flat idler pulley to the idler bracket using a 9/16 wrench and a 9/16 socket. See figure 3.
Removal and Installation of the Deck Belt
FIGURE 1.
3). Fully depress the deck pedal assembly and lock it down.
4). Remove both hex washer self tapping screws from the deck belt cover using a 1/2" socket.
5). Remove the top hex nut and lock washer from the idler bracket pivot screw using a 1/2" socket.
6). Remove the deck belt cover from the deck assembly. See figure 2.
NOTE: The deck belt must be engaged during deck belt cover installation. The belt keeper pin must not interfere with the deck belt.
FIGURE 2.
FIGURE 3.
9). Raise the cutting deck to the highest cutting posi­tion.
10). Remove the deck belt from the flat idler pulley and the deck spindle pulley. See figure 4.
FIGURE 4.
11). Remove the self tapping washer head hex screw that secures the left side of the half circle belt keeper to the frame using a 3/8 socket. See figure 5.
NOTE: The self tapping washer head hex screw is directly to the right of the front transmission support bracket.
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12). Loosen the hex nut and lock washer that secures the right side of the half circle belt keeper to the frame using a 7/16 socket and a 6" extension. See figure 6.
NOTE: You must come in from the rear of the rider to access the hex nut and lock washer.
FIGURE 5. FIGURE 6.
13). Remove the deck belt from the rider.
REINSTALL THE NEW DECK BELT IN THE REVERSE ORDER.
Self Tapping Screw
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NOTE: Prior to deck removal, perform deck belt
removal.
1). Locate and loosen the hex jam nuts that secure the threaded end of the deck cable to the deck cable bracket using two 1/2" wrenches. See figure 1.
Removal and Installation of the Mowing Deck Assembly
FIGURE 1.
2). Remove the cotter pin and flat washer that secures the deck cable eyelit to the brake brack­et pin.
3). Remove the deck cable eyelit from the brake bracket pin. See figure 2.
FIGURE 2.
Eyelit
Cotter Pin
Flat
Washer
Hex Nut
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4). Remove both front deck extension springs from the front channel assembly. See figure 3.
NOTE: The use of a 2 foot piece of recoil rope can be used for spring removal.
FIGURE 3.
5). Remove both of the clevis pins, flat washers, and hairpin clips that secure the deck stabilizer brack­et to the front channel assembly. See figure 4.
FIGURE 4.
6). Remove both hairpin clips that secure the center deck ferrules to the lift link assembly. See figure 5.
Hairpin
Washer
Clevis
Pin
FIGURE 5.
Hairpin
Hairpin
NOTE: Both center deck ferrules are secured to
the lift link assembly from the left. Also, there are two flat washers between the ferrules and the lift link assembly. See figure 6.
FIGURE 6.
7). Remove both small hairpin clips and flat washers that secure the rear deck support pins to the lower "T" links. See figure 7.
Flat Washer
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FIGURE 7.
8). Remove the mowing deck assembly.
INSTALL THE MOWING DECK ASSEMBLY IN THE REVERSE ORDER ABOVE.
Hairpin
Flat Washer
FIGURE 1.
NOTE: The upper and lower drive belts are
identical.
LOWER DRIVE BELT:
1). From behind the rider, pull the spring loaded "V" idler towards the right frame rail and release the lower drive belt downward. See figure 1.
2). Slowly release the "V" idler to the left frame rail.
3). Roll the lower drive belt down and off of the variable-speed pulley assembly. See figure 2.
Removal and Replacement of the Drive Belts
Pull
FIGURE 2.
4). Take hold of the lower drive belt and push it forward, up, and off of the transmission pulley. Pull it back towards the rear of the rider.
INSTALL THE LOWER DRIVE BELT IN THE REVERSE ORDER ABOVE.
Variable
Speed Pulley
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UPPER DRIVE BELT:
NOTE: Prior to removing the upper drive belt, it
is necessary to remove the lower drive belt. See figure 3.
FIGURE 3.
1). Remove the hex screw and lock washer that secures the engine pulley to the engine crankshaft using a 5/8 socket. See figure 4.
FIGURE 4.
2). Slowly lower the engine pulley until the lower pulley is clear of the half circle belt keeper. See figure 5.
FIGURE 5.
NOTE: The drive belt must be moved to the right
to keep it from catching the top of the transmis­sion pulley.
3). Remove the deck belt from the lower engine pulley.
4). Push up on the upper drive belt and roll it off of the upper engine pulley.
5). Lower the engine pulley from the rider. See figure 6.
NOTE: Make certain that the square key is in the crankshaft during reassembly.
FIGURE 6.
6). Remove the upper drive belt from idler pulleys on the idler bracket and the crankshaft.
7). Roll the upper drive belt down and out of the variable-speed pulley assembly.
INSTALL THE UPPER DRIVE BELT IN THE REVERSE ORDER ABOVE.
Keyway
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Transmission Removal and Installation
NOTE: Prior to transmission removal, perform
lower drive belt removal.
1). Raise the hood up and remove the grass bag assembly.
2). Lower the cutting height adjustment lever to the lowest position. See figure 1.
FIGURE 1.
3). Raise the rear wheels off the ground. See figure
2.
FIGURE 2.
4). Remove both hub caps from the rear wheel assemblies using a flat blade screw driver.
5). Remove the hex screws and bell washers that secure the rear wheel assemblies to the trans­mission axles using a 1/2" socket and a 6" exten­sion.
6). Remove the rear wheel assemblies from the rider.
NOTE: Make certain the rear axles are greased during reassembly. See figure 3.
FIGURE 3.
7). Remove both hex washer head self tapping screws that secure the transmission support bracket to the transmission using a 3/8 socket. See figure 4.
NOTE: Torque the hex washer head self tapping screws between 90 and110 in-lbs. during installation.
FIGURE 4.
Self Tapping
Screws
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8). Remove the hex nut and lock washer from the shift lever cap screw using two 1/2" wrenches. See figure 5.
FIGURE 5.
NOTE: During reinstallation remove the cotter
pin securing the shift lever assembly to the trans­mission. Secure the shift lever assembly to the frame before reinstalling the transmission. See figure 6.
FIGURE 7.
9). Loosen (DO NOT REMOVE) the locking hex nut that secures the brake actuation arm to the brake assembly using a 1/2" wrench. See figure 7.
FIGURE 6.
NOTE: Perform the BRAKE ADJUSTMENT sec-
tion during reassembly.
10). Pull the brake actuation arm forward and remove the brake cable spring from the brake actuation arm. See figure 8.
FIGURE 8.
Locking Hex Nut
11). Remove all four self tapping hex screws that secure the transmission to the frame using a 1/2" socket.
12). Slide the transmission slowly to the rear and remove the shift cable "Z" fittings from the shift lever. See figure 9.
1/2" Wrenches
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13). Remove the transmission from the rider.
INSTALL THE TRANSMISSION IN THE REVERSE ORDER ABOVE.
FIGURE 9.
“Z” Fitting
“Z” Fitting
Transmission Disassembly
1). Set the transmission on a work bench with the transmission pulley facing up.
2). Remove the cotter pin securing the shift lever to the shift fork assembly using needle nose pliers. See figure 1.
FIGURE 1.
3). Place a "C" clamp over the transmission pulley and tighten it down on the flat area of the pulley.
4). Rotate the "C" clamp until it rests up against the upper transmission housing.
5). Loosen the hex jam nut securing the transmis­sion pulley to the input shaft using a 7/8 socket.
6). Remove the hex jam nut, belleville washer, and transmission pulley from the input shaft. See figure 2.
FIGURE 2.
Cotter Pin
7). Loosen and remove all of the hex washer head self tapping screws that secure the upper and lower transmission housings together using a 3/8 socket.
NOTE: The two longest hex washer head self tapping screws secure the brake area.
8). Remove the upper transmission housing. See figure 3.
FIGURE 3.
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FIGURE 4.
NOTE: The transmission assembly has been
cleaned out for clarity. See figure 4.
FIGURE 5.
12). Disassemble and inspect all components of the upper drive shaft assembly. See figure 6.
FIGURE 6.
13). Place the upper transmission housing flat on the bench with the input shaft facing up.
14). Remove the wire ring, "E"-clip, and flat washer from the input shaft.
NOTE: There may be an additional shim washer on the input shaft to alleviate excessive toler­ances.
15). Lift the upper transmission housing and remove the input shaft.
16). Remove the thrust washer from the input shaft.
17). The input pinion can be separated from the input shaft by removing the retaining ring. See figure
7.
FIGURE 7.
18). Clean all components of the transmission assembly.
9). Remove the differential assembly. See figure 5.
10). Remove the shift fork, detent ball, and spring. See figure 5.
11). Remove the upper drive shaft assembly. See figure 5.
Differential
Assembly
Shift Fork
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Transmission Reassembly
1). Inspect the needle bearings in the upper trans­mission housing.
2). Inspect the input shaft and pinion.
3). Apply never seez to the input shaft.
4). Slide the thrust washer over the input shaft.
5). Slide the input shaft up through the needle bear­ings in the upper transmission housing.
6). Slide the flat washer over the input shaft.
7). Install the "E" ring and wire ring on to the input shaft.
8). Make certain the input shaft does not have excessive tolerance by placing two feeler gauges between the flat washer and the upper transmis­sion housing. See figure 1.
NOTE: The tolerance will be between .006" and .015". If not, place shim washers between the flat washer and the upper transmission housing.
9). Rotate the upper transmission housing 180 degrees and set it on the bench with the input pinion facing up.
10). Inspect all components of the upper drive shaft assembly.
11). Apply never seez to the drive shaft.
12). Grasp the short end of the drive shaft with your right hand.
13). Slide the thrust washer, bevel gear with large inner diameter hole, clutch collar, bevel gear with small inner diameter hole, flat washer, and short flange bearing over the long end of the drive shaft. See figure 2.
FIGURE 1.
FIGURE 2.
14). Holding the assembly in your left hand, slide the flat washer, long flange bearing, and brake disc over the short end of the drive shaft.
NOTE: There may be additional shim washers on the shaft assembly to alleviate excessive tol­erances.
15). Set the upper drive shaft assembly into the upper transmission housing. See figure 3.
FIGURE 3.
16). Make certain both bushings are seated correctly in the upper housing and the bevel gears have meshed properly with the input pinion.
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17). Make certain the upper drive shaft assembly is within tolerance by placing two feeler gauges between the flat washer and the bushing behind each bevel gear. See figures 4 and 5.
NOTE: The tolerance will be between .006" and .015" on both sides. If not, place a shim washer between the flat washer and the bushing on the side that is out of tolerance.
FIGURE 4.
FIGURE 5.
18). Place a dab of grease on the puck plate and brake puck before installing it into the brake yoke assembly.
19). Install the puck plate and brake puck into the brake yoke assembly.
20). Secure the brake yoke assembly to the lower transmission housing using a 3/8 socket.
NOTE: Torque both hex washer head self tap­ping screws between 90 and 110 in.-lbs.
21). Set the upper drive shaft assembly into the lower transmission housing.
22). Make certain both bushings are seated correctly in the lower housing.
23). Inspect the oil seals and sleeve bearings on the differential assembly.
24). Grease both axle shafts of the differential assem­bly.
25). Place the differential assembly into the lower transmission housing. See figure 6.
NOTE: Make certain the oil seals and sleeve bearings are seated properly in the lower hous­ing.
FIGURE 6.
26). Fully grease the transmission. See figure 7.
FIGURE 7.
Sleeve Bearings
Sleeve Bearing
Oil
Seal
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27). Place the detent spring and ball into the lower transmission housing.
28). Never seez the shift fork assembly and install it into the shift collar.
29). Place the upper transmission housing over the lower housing and rotate the input shaft, making certain the bevel gears mesh correctly with the input pinion. See figure 8.
FIGURE 8.
30). Install and hand tighten all of the hex washer head self tapping screws that secure the upper and lower transmission housings together.
NOTE: Make certain the two longest self tapping screws are securing the brake area.
31). Torque all hex washer head self tapping screws between 90 and 110 in.-lbs.
32). Install the transmission pulley, belleville washer, and hex jam nut onto the input shaft.
33). Place a "C" clamp over the transmission pulley and tighten it down on the flat area of the pulley.
34). Rotate the "C" clamp until it rests up against the upper transmission housing.
35). Torque the hex jam nut on the input shaft between 300-400 in.-lbs.
36). Secure the shift lever to the shift fork assembly using the cotter pin removed in disassembly.
37). Test operations.
Input Pinion
Bevel Gears
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IMPORTANT: This section is used for electrical
training. Even though some of the subsections are called out, this section is meant to be per­formed inclusively. If you are working on a spe­cific section, make certain all devices are in the proper modes (switches, relays, and etc...)
NOTE: A multimeter is a must for this section. If any of the following tests do not match, repair that portion of the system.
GENERAL CONTINUITY:
1). Turn the ignition key to the "OFF" position.
2). Place the multimeter in the OHM'S mode until instructed to change modes. See figure 1.
Electrical (Start Circuit)
FIGURE 1.
3). Place one probe on the negative battery termi­nal. Place the second probe on the frame bolt. –There will be CONTINUITY. See figure 2.
FIGURE 2.
Negative Terminal
Frame
Bolt
4). Place one probe on the positive battery terminal. Place the second probe on the inlet post of the solenoid. –There will be CONTINUITY. See figure 3.
FIGURE 3.
Positive Terminal
Inlet Post
of Solenoid
5). Place one probe on the negative battery termi­nal. Place the second probe on the engine block. –There will be CONTINUITY.
6). Place one probe on the outlet post of the solenoid. Place the second probe on the starter post. –There will be CONTINUITY. See figure 4.
FIGURE 4.
Outlet
Post
Starter Post
7). Place one probe on the negative battery termi­nal. Place the second probe on the solenoid base. –There will be CONTINUITY.
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FIGURE 5.
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IGNITION SWITCH:
8). Locate the ignition switch and remove the wiring harness connector. See figure 5.
9). Locate and identify all ignition switch terminals.
L–Alternator, S–Start, M–Magneto, G–Ground, B–Battery.
10). Locate and identify all wires coming into the wiring harness connector at the ignition switch.
Green–Ground, Red–Battery, Yellow–Magneto, Red/White–Alternator, Orange/Black–Start.
11). Place one probe on any frame bolt. Place the second probe on the ground (green) wire of the ignition switch connector. –There will be CONTINUITY. See figure 6.
FIGURE 6.
FUSE:
12). Locate and remove the fuse from the fuse con­nector. See figure 7.
FIGURE 7.
Frame
Bolt
Group
(Green) Wire
Fuse
13). Place one probe on one male terminal of the fuse. Place the second probe on the second male terminal of the fuse. –There will be CONTINUITY.
14). Place the fuse back into the fuse holder.
15). Place one probe on the inlet post of the solenoid. Place the second probe on the battery (red) wire of the ignition switch connector. –There will be CONTINUITY. See figure 8.
FIGURE 8.
Inlet Post
Battery
(Red) Wire
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16). Place the multimeter in the D.C. VOLTS mode.
17). Place the red probe on the positive battery (red) wire and the black probe on the ground (green) wire of the ignition switch connector. –There will be 12 VOLTS. See figure 9.
FIGURE 9.
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18). Place the multimeter in the OHM's mode.
19). Place one probe on the "B" terminal and the second probe on the "S" terminal of the ignition switch. –There will be NO CONTINUITY.
20). Turn the ignition key to the "START" (spring loaded) position. –There will be CONTINUITY.
NOTE: Turn the ignition key back to the "OFF" position after completion.
21). DO NOT reconnect the wiring harness to the ignition switch.
BRAKE SWITCH:
22). Locate the brake switch. See figure 10.
23). Identify the NC (normally closed) terminals of the brake switch.
24). Place one probe on one NC (yellow) terminal and the second probe on the second NC (yellow) terminal of the brake switch. –There will be CONTINUITY. See figure 11.
25). Depress the plunger on the brake switch. –There will be NO CONTINUITY. See figure 11.
FIGURE 10.
Brake Switch
FIGURE 11.
Pull Brake to
Depress Plunger
26). Release the plunger and place the probes on the NO (normally open– orange) terminals. –There will be NO CONTINUITY.
27). Depress the plunger on the brake switch. –There will be CONTINUITY.
PTO SWITCH:
28). Locate the PTO switch.
29). Identify the NC (normally closed) terminals of the PTO switch. See figure 12.
FIGURE 12.
PTO
Switch
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30). Place one probe on one NC (yellow) terminal and the second probe on the second NC (yellow) terminal of the PTO switch. –There will be CONTINUITY.
31). Depress the plunger on the PTO switch. –There will be NO CONTINUITY.
32). Release the plunger and place the probes on the NO (normally open– orange) terminals. –There will be NO CONTINUITY.
33). Depress the plunger on the PTO switch. –There will be CONTINUITY.
SOLENOID:
34). Locate and remove the orange– female connec­tor wire that is connected to the male actuation terminal of the solenoid.
35). Lock the parking brake down.
36). Make certain the deck engagement pedal is fully disengaged (UP) and depressing the plunger on the PTO switch all the way.
37). P lace one probe of the multimeter on the orange/black wire of the wiring harness ignition connector. Place the second probe on the female connector of the orange wire that was discon­nected from the male actuation terminal of the solenoid. –There will be CONTINUITY.
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38). Place one probe on the base (steel portion) and the second probe on the male actuation terminal of the solenoid. –There will be approximately 5 OHM'S at room temperature.
NOTE: The OHM's reading will rise or fall slightly depending on the current temperature.
39). Reconnect the orange wire– female connector to the male actuation terminal of the solenoid.
40). Reconnect the wiring harness ignition connector to the ignition switch.
41). Disconnect the thick red wire (solenoid to starter) from the outlet post of the solenoid using a 7/16" wrench.
42). Place one probe on the inlet post and one probe on the outlet post of the solenoid. –There will be NO CONTINUITY.
43). Turn the ignition key to the "START" (spring loaded) position. –There will be CONTINUITY.
NOTE: Turn the ignition key to the "OFF" posi­tion after completion.
44). Reconnect the thick red wire (solenoid to starter) to the outlet post of the solenoid using a 7/16" wrench.
45). Make certain all connections are secure and test the starting circuit.
IMPORTANT: This section is used for electrical training. Even though some of the subsections are called out, this section is meant to be performed inclusively. If you are working on a specific section, make certain all devices are in the proper modes (switches, relays, and etc...)
NOTE: A multimeter is a must for this section. If any of the following tests do not match, repair that portion of the system.
IGNITION SWITCH:
1). Turn the ignition key to the "OFF" position.
2). Locate the ignition switch and remove the wiring harness connector. See figure 1.
Electrical (Off / Safety Circuit)
FIGURE 1.
3
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3). Locate and identify all ignition switch terminals.
L—Alternator, S–Start, M–Magneto, G–Ground, B–Battery.
4). Locate and identify all wires coming into the wiring harness connector at the ignition switch.
Green–Ground, Red–Battery, Yellow–Magneto, Red/White–Alternator, Orange/Black–Start.
5). Place the multimeter in the OHM's mode until instructed to change modes. See figure 2.
FIGURE 2.
6). Place one probe on any frame bolt. Place the second probe on the ground (green) wire of the ignition switch connector. –There will be CONTINUITY. See figure 3.
FIGURE 3.
Frame
Bolt
Ground (Green)
Wire
7). Place one probe on the "G" terminal and one probe on the "M" terminal of the ignition switch. –There will be CONTINUITY.
MAGNETO:
8). Locate the magneto (yellow) wire coming off of the engine.
9). Disconnect the magneto (yellow) wire from the magneto harness wire at the connector.
10). Place one probe of the multimeter into the wiring harness magneto (yellow) wire connector. Place the second probe on the magneto (yellow) wire of the ignition switch connector. –There will be CONTINUITY. See figure 4.
FIGURE 4.
Magneto
(Yellow) Wire
Magneto
(Yellow)
Wire
11). Reconnect the magneto (yellow) wire to the mag­neto harness wire.
12). DO NOT reconnect the wiring harness connector to the ignition switch.
PTO SWITCH:
13). Locate the PTO switch and remove the wiring harness connector. See figure 5.
FIGURE 5.
PTO
Switch
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14). Identify the NC (normally closed) terminals of the PTO switch.
15). Place one probe on one NC terminal and the second probe on the second NC terminal of the PTO switch. –There will be CONTINUITY.
16). Depress the plunger on the PTO switch. –There will be NO CONTINUITY.
17). Release the plunger and place the probes on the NO (normally open) terminals. –There will be NO CONTINUITY.
18). Depress the plunger on the PTO switch. –There will be CONTINUITY.
19). Reconnect the wiring harness connector to the PTO switch.
REVERSE SWITCH:
20). Locate the reverse switch and disconnect the yellow/black wire and connector. See figure 6.
FIGURE 6.
Reverse Switch
21). Make certain the unit is off. Engage and lock down the cutting deck engagement pedal.
22). Place one probe of the multimeter into the yellow/black wire connector off of the reverse switch. Place the second probe on the magneto (yellow) wire of the ignition switch connector. –There will be CONTINUITY. See figure 7.
RELAY CONNECTOR–(PTO switch):
23). Locate the relay connector with the yellow/black wire running into it. See figure 8.
FIGURE 7.
FIGURE 8.
24). Place one probe on the yellow/black wire going into the relay connector. Place the second probe on the magneto (yellow) wire of the ignition switch connector. –There will be CONTINUITY.
BRAKE SWITCH:
25). Locate the brake switch and remove the wiring harness connector. See figure 9.
Magneto
(Yellow)
Wire
Reverse
Switch
Relay
Connectors
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FIGURE 9.
26). Identify the NC (normally closed) terminals of the brake switch.
27). Place one probe on one NC terminal. Place the second probe on the second NC terminal of the brake switch. –There will be CONTINUITY.
28). Depress the plunger on the brake switch. –There will be NO CONTINUITY. See figure 10.
Brake
Switch
FIGURE 10.
Pull Brake to
Depress Plunger
29). Release the plunger and place the probes on the NO (normally open) terminals. –There will be NO CONTINUITY.
30). Depress the plunger on the brake switch. –There will be CONTINUITY.
31). Reconnect the wiring harness connector on the he brake switch.
32). Make certain the brake pedal is fully released (up).
RELAY CONNECTOR– (brake switch):
33). Locate the relay connector with the yellow/white wire running into it. See figure 11.
34). Place one probe on the yellow/white wire going into the relay connector. Place the second probe on the magneto (yellow) wire of the ignition switch connector. –There will be CONTINUITY.
35). Place one probe on any frame bolt. Touch the second probe to the ground (green) wires com­ing into both relays (all four positions). –There will be CONTINUITY. See figure 12.
FIGURE 11.
FIGURE 12.
Relay
Connectors
Ground
(Green) Wire
Frame
Bolt
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FIGURE 13.
36). Turn the ignition key to the "ON" position.
37). Place one probe on the "B" terminal and one probe on the "L" terminal of the ignition switch. –There will be CONTINUITY.
SEAT SWITCH:
38). Locate the seat switch and remove both female harness connectors. See figure 13.
39). Place one probe on one male terminal and the second probe on the second male terminal of the seat switch. –There will be CONTINUITY.
40). Push the seat cushion in and activate the seat switch. –There will be NO CONTINUITY.
41). Reconnect both female harness connectors to the seat switch.
42). Locate the red wires coming into both relay con­nectors.
43). Place one probe on the alternator (red/white) wire of the ignition switch connector. Touch the second probe on the red wires coming into both relay connectors. –There will be CONTINUITY.
ALTERNATOR:
44). Locate and disconnect the alternator (red) wire from the harness (red/white) wire connector at the engine.
45). Place one probe in the round (red/white) alterna­tor connector on the harness. Place the second probe on the alternator (red/white) wire of the ignition switch connector. –There will be CONTINUITY.
46). Reconnect the alternator (red) wire to the har­ness (red/white) wire connector at the engine.
47). Reconnect the ignition switch wiring harness connector to the ignition switch.
Female
Connectors
RELAYS:
48). Remove both relays from the wiring harness relay connectors.
49). Locate and identify all terminals on the relays using the wiring diagram on the side of the relays.
50). Place one probe on terminal 3. Place the second probe on terminal 4. –There will be CONTINUITY.
51). Place one probe on terminal 3. Place the second probe on terminal 5. –There will be NO CONTINUITY.
52). Place on e probe on terminal 1. Place the second probe on terminal 2. –There will be app. 82 OHM's at room tempera- ture.
NOTE: The OHM's reading will rise or fall depending on the temperature of the relay.
53). Place a red jumper wire on the positive terminal of a battery. Place a black jumper wire on the negative terminal of a battery.
54). Attach the red jumper wire to terminal 2 of the relay. Attach the black jumper wire to terminal 1 of the relay. –There will be one CLICK.
55). Leave the relay attached to the battery. Place one probe on terminal 3. Place the second probe on terminal 4. –There will be NO CONTINUITY.
56). Leave the relay attached to the battery. Place one probe on terminal 3. Place the second probe on terminal 5. –There will be CONTINUITY.
57). Disconnect the relay from the battery. Repeat steps 50 through 56 for the second relay.
58). Place the multimeter into the D.C. VOLTS mode.
59). Locate and identify the red and green wires that come into the relay connectors at relay terminal positions 1 and 2.
60). Make certain the ignition key is "ON"
61). Place the red probe on the red wire and the black probe on the green wire of the relay con­nector. –There will be 12 VOLTS.
NOTE: Repeat this step for the second relay connector.
62). Turn the ignition key to the "OFF" position.
63). Reconnect the relays to the wiring harness relay connectors.
64). Make certain all wiring harness connections are secure and test the OFF/SAFETY CIRCUIT.
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3 - 30
Electrical Drawing
YARD BUG
YARD BUG
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Steering Adjustments
IMPORTANT: The front tires will have a "TOE-
IN" between 1/16" and 5/16" to allow the unit to track properly.
1). Check the tire pressure in the front tires and make certain that they are at approximately 14 PSI.
2). Place the unit on level ground.
3). Place the steering wheel in the straight forward position.
4). Lower the deck lift lever to the lowest position.
5). Line up the centering hole in the steering gear with the centering hole in the support plate, and insert a 1/4" Phillips screw driver up through both. See figure 1.
6). In front of the axle, measure the distance hori­zontally from the inside of the left rim to the inside of the right rim. See figure 2.
FIGURE 1.
7). From behind the axle, measure the distance hori­zontally from the inside of the left rim to the inside of the right rim.
8). The measurement taken in front of the axle should be between 1/16" and 5/16" less than the measurement taken behind the axle. If not, per­form the following steps:
9). Loosen the jam nut at the rear of the right ball joint that secures the ball joint to the drag link using a 1/2" wrench and an 11/16" wrench. See figure 3.
FIGURE 2.
FIGURE 3.
10). Remove the hex nut and lock washer that secures the right ball joint to the right axle assembly using a 1/2" wrench and a 9/16 wrench.
11). Remove the right hand ball joint from the right hand drag link.
12). Remove the left hand ball joint performing steps 9, 10, and 11 above.
13). Place the left and right tire assemblies in the straight forward position.
14). Set the toe-in for the rim assemblies to the prop­er measurements as described in steps 6, 7, and 8 above.
15). Thread the right hand ball joint onto the right hand drag link until the mounting hole in the right hand axle assembly lines up with the ball joint.
NOTE: Count the number of turns the ball joint was rotated onto the drag link. This number should be equal for the left side as well.
Centering
Hole
Jam Nut
4 - 1
SECTION 4
VARIABLE SPEED DRIVE
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Variable Speed Drive
16). Secure the right hand ball joint to the right hand axle assembly with the lock washer and nut removed earlier, using a 1/2" wrench and a 9/16 socket.
17). Secure the right hand ball joint jam nut to the right hand drag link using a 1/2" wrench and an 11/16 wrench.
FIGURE 1.
IMPORTANT: The AutoDrive pedal is properly
adjusted when the hole found in the double-idler bracket has approximately 1-3/8" of travel with ten pounds of pressure applied to the AutoDrive pedal. See figures 1 and 2.
Autodrive Pedal Adjustment
1). Locate the speed control assembly on the underside of the steering support bracket.
2). Remove both hairpin clips from the main pin on the speed control assembly. See figure 3.
10 Lbs.
Double Idler
Bracket
1-3/8"
FIGURE 2.
FIGURE 3.
NOTE: Be careful not to lose the small flat
washers found on the main pin.
NOTE: Make certain both hairpins are put back in from the top of the main pin during reassem­bly.
3). Remove the AutoDrive pedal return spring.
4). Using two 9/16" wrenches, remove the main pin from the speed control assembly.
5). Thread the idler adjustment rod inward or out­ward until the proper adjustment has been achieved.
REASSEMBLE THE AUTODRIVE PEDAL IN THE REVERSE ORDER ABOVE.
Main Pin
Hairpin
Clips
4 - 2
18). Install the left hand ball joint using steps 15, 16, and 17.
NOTE: Make certain the same amount of rota­tions are used on the left ball joint as the right ball joint.
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Variable Speed Drive
Brake Adjustments
IMPORTANT: Make certain the tractor comes to
a complete stop when the brake pedal is depressed. Also, make certain the rear wheels do not roll when the parking brake has been applied. If motion continues, perform the follow­ing steps:
1). Locate the hex nut that secures the brake assembly.
2). Loosen (DO NOT REMOVE) the hex nut using a 1/2" wrench.
3). Slide an .011" feeler gauge between the brake disc and the brake puck. See figure 1.
FIGURE 1.
4). Tighten the hex nut that secures the brake assembly.
5). Remove the .011" feeler gauge from the brake assembly.
6). Test for proper adjustments.
Hex Nut
Feeler Gauge
Leveling the Cutting Deck
NOTE: Prior to leveling the mowing deck, per-
form the following steps:
1). Check the tire pressure. The front tires will be approximately 14 PSI, and the rear tires will be approximately 10 PSI.
2). Place the tractor on a level surface.
3). Depress and lock the parking brake.
4). Raise the deck lift lever to the highest position.
FRONT TO REAR ADJUSTMENT:
IMPORTANT: The front of the deck will be
between 1/4" to 3/8" lower in the front than the rear of the deck.
1). Using a work glove or rag, rotate the blades until they are parallel with the tractor frame. See figures 1 and 2.
FIGURE 1.
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Variable Speed Drive
2). Measure the front blade tips to ground.
3). Measure the rear blade tips to ground.
4). Make certain the front blade tips are 1/4" to 3/8" lower in the front than the rear blade tips.
FIGURE 2.
FIGURE 3.
NOTE: If an adjustment is needed, perform the
following steps:
5). Loosen both two jam nuts on the rear side of the deck stabilizer bracket using a 3/4" wrench. See figure 3.
FIGURE 4.
Rear
Front
Jam Nuts
6). Locate both lock hex nuts on the front side of the deck stabilizer bracket. See figure 4.
Lock Nuts
7). Tighten both lock hex nuts to raise the front of the deck or loosen both lock hex nuts to lower the front of the deck using a 3/4" wrench.
8). Retighten both jam nuts on the rear side of the deck stabilizer when the proper adjustment has been achieved.
SIDE TO SIDE ADJUSTMENT:
IMPORTANT: The cutting deck must be even
side to side.
1). Using a work glove or rag, rotate the blades until they are cutting edge tip to cutting edge tip (perpendicular) to the tractor. See figure 5.
FIGURE 5.
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Variable Speed Drive
FIGURE 6.
2). Measure the outer blade tips to ground. Both measurements taken should be equal. See figure
6.
FIGURE 7.
4). Rotate the 3/4" deck adjustment gear right or left until the deck is level side to side and both blade tips to ground are equal in measurement.
5). Retighten the hex cap screw on the left deck hanger using a 1/2" and 3/4" wrench when the proper adjustment has been achieved.
FIGURE 8.
NOTE: If an adjustment is needed, perform the
following steps:
3). Loosen (DO NOT REMOVE) the hex cap screw on the left deck hanger bracket using a 1/2" and a 3/4" wrench. See figure 7.
Side
Equal
Side
Hex Cap
Screw
NEW ADJUSTMENT DESIGN
Adjustment
Gear
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Variable Speed Drive
Deck Belt Removal and Installation
42" CUTTING DECK:
1). Lower the deck to the lowest position.
2). Pull the PTO idler pulley and bracket towards the discharge chute, relieving belt tension. See figure 1.
FIGURE 1.
3). Remove the deck belt from the electric PTO clutch on the engine.
4). Remove the self tapping screws securing the spindle belt covers. See figure 2.
FIGURE 2.
5). Remove the spindle belt covers.
6). Remove the PTO deck belt.
REINSTALL THE NEW BELT IN THE REVERSE ORDER ABOVE.
46" CUTTING DECK: LOWER BELT:
1). Pull the lower deck belt flat idler and idler bracket towards the left side of the tractor, relieving the belt tension. See figure 1.
2). Remove the lower deck belt.
REINSTALL THE NEW BELT IN THE REVERSE ORDER ABOVE.
Electric
PTO
Clutch
Idler
Pull
Screws
Cutting Deck Removal
1). Lower the lift lever to the lowest setting.
2). Pull the PTO idler pulley and bracket towards the side discharge chute. See figure 1.
FIGURE 1.
Idler
Pull
Electric
PTO
Clutch
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Variable Speed Drive
FIGURE 2.
5). Pivot the deck support pins to the rear.
6). Raise the lift lever to the highest setting. This will raise the lift arms up and out of the way of the deck assembly.
7). Slide the cutting deck forward and release the front deck hangers off of the front stabilizer rod. DO NOT DROP the deck to the ground. See figure 3.
FIGURE 3.
8). Slide the deck towards the side discharge chute and remove it from the tractor.
CAUTION: Remove the deck stabilizer assembly from the tractor prior to moving the unit.
3). Remove the deck belt from the lower pulley on the engine.
NOTE: The 46" decks have an upper and a lower belt. The upper belt is removed for cutting deck removal.
4). Pull the rear deck support pins outward from the deck lift arms. See figure 2.
Deck Support
Pin
Lift
Arm
Front
Stabilizer
Rod
Drive Belt Removal and Reinstallation
TRANSMISSION BELT REMOVAL AND INSTALLATION: UPPER BELT:
1). Raise the seat of the tractor and disconnect the battery cables from the battery. Remove the negative cable first. See figure 1.
FIGURE 1.
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Variable Speed Drive
2). Remove the battery strap, battery, and the battery tray from the tractor. See figure 2.
FIGURE 2.
3). Raise the deck lift lever to the highest position.
4). Pull the transmission idler pulley towards the transmission and release the upper drive belt. See figure 3.
FIGURE 3.
5). Slowly release the idler pulley.
6). Remove the upper drive belt from the transmis­sion pulley and the variable-speed pulley. See figure 4.
NOTE: Slowly roll the drive belt off of the variable-speed pulley.
FIGURE 4.
Upper Drive
Belt
Pull
Upper Drive
Belt
VARIABLE-SPEED BELT REMOVAL AND REINSTALLATION: LOWER BELT:
IMPORTANT: Prior to lower variable speed belt
removal, perform cutting deck removal and upper drive belt removal.
1). Remove the hex bolt and lock nut securing the variable-speed pulley to the transmission using a 9/16 socket and a 9/16 wrench. See figure 5.
FIGURE 5.
9/16"
Wrench
9/16"
Socket
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Variable Speed Drive
2). Raise the variable speed pulley and roll the lower drive belt off.
3). Remove the variable-speed pulley from the trac­tor through the battery box opening.
4). Disconnect the wiring harness female connector from the reverse safety switch.
5). Loosen (DO NOT REMOVE) the flat moving idler on the double-idler bracket. See figure 6.
FIGURE 6.
6). Remove the variable-speed belt from the double idler pulley assembly.
7). Cut and remove the zip tie securing the PTO clutch wires to the wiring harness.
NOTE: Make certain a new zip tie is reinstalled during reassembly.
8). Carefully disconnect the wiring harness connec­tor from the electric PTO clutch assembly. See figure 7.
FIGURE 7.
NOTE: During reassembly, make certain the
PTO clutch wires are routed inside the right hand drag link.
9). Remove the hex bolt that secures the electric PTO clutch to the engine crank shaft using a 5/8 socket.
NOTE 1: Some units have a washer that rests on top of the electric PTO clutch, make certain it is in place during reassembly.
NOTE 2: Torque the hex bolt to 38 to 50 foot­pounds during reassembly.
NOTE 3: Make certain that the clutch retaining pin is in the electric PTO clutch bracket during reassembly.
10). Slowly lower the engine drive pulley and remove the variable-speed belt. See figure 8.
Wiring
Harness
Connector
Zip Tie
FIGURE 8.
Variable
Speed Belt
Engine
Pulley
NOTE: Carefully set the engine drive pulley
aside, making certain the 1/4" squared key remains in place.
11). Remove the variable-speed belt from the tractor.
REINSTALL THE VARIABLE-SPEED BELT IN THE REVERSE ORDER ABOVE.
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Variable Speed Drive
Transmission Removal and Installation
NOTE: Prior to performing transmission removal
and installation, it is necessary to remove the upper drive belt.
1). Remove both rear hub caps from the rear wheel assemblies.
2). Loosen both hex cap screws securing the rear wheel assemblies to the axles.
3). Raise the rear of the tractor off the ground.
4). Remove both center hex cap screws and bell washers from the rear wheel assemblies.
5). Remove both rear wheel assemblies from the tractor.
6). Disconnect the reverse safety switch. See figure
1.
FIGURE 1.
7). Remove the hair pin that secures the shift link­age to the shift fork and set the shift linkage aside. See figure 2.
FIGURE 2.
Reverse Safety Switch
Hairpin
8). Remove both of the self tapping screws that secure the transmission to the front torque brack­et using a 3/8 socket. See figure 3.
FIGURE 3.
9). Support the bottom of the transaxle.
10). Remove all four hex bolts and lock nuts securing the transmission to the frame using a 1/2" socket and a 1/2" wrench. See figure 4.
FIGURE 4.
11). Remove both transmission mounting brackets from the top of the frame.
12). Remove the hex bolt and lock nut securing the variable-speed pulley to the transmission using a 9/16 socket and a 9/16 wrench.
13). Remove the locking hex nut from the brake actu­ation arm on the transmission. See figure 5.
NOTE: During reassembly, perform the brake adjustment section.
Transmission
Mounting
Bracket
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Variable Speed Drive
FIGURE 5.
15). Pivot the anti-rotation bracket down and relieve the spring tension on the brake actuation arm.
16). Remove the flat washer from the actuation arm stud of the brake assembly.
17). Remove the brake spring from the brake actua­tion arm. See figure 5.
FIGURE 6.
NOTE: The variable-speed pulley will be hanging
by the drive belt at this time. Set it aside after removal of the transmission.
INSTALL THE TRANSMISSION IN THE REVERSE ORDER ABOVE.
Hex Nut
Anti-Rotation
Bracket
Hex
Screw
Brake
Spring
Transmission Disassembly and Reassembly
1). Remove the hex nut and bell washer that secures the transmission pulley to the input shaft using an 11/16 socket.
2). Remove the transmission pulley from the input shaft.
3). Remove all the self tapping screws that secure the two transmission case halves together using a 3/8 socket. See figure 1.
NOTE: The two long self tapping screws secure the brake area.
FIGURE 1.
Long
Screws
4 - 11
14). Loosen (DO NOT REMOVE) the hex washer head self-tapping screw that secures the anti­rotation bracket to the brake assembly using 3/8 wrench. See figure 5.
18). Slowly lower the transmission from the tractor. See figure 6.
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Variable Speed Drive
FIGURE 2.
10). Reassemble the lower drive shaft assembly (ONLY) and place it into the lower transmission housing. Secure the lower drive shaft in place with both self tapping screws using a 3/8 socket and a 6" extension.
11). Place two feeler gauges between the reverse spur gear and the flat washer shim. See figure 3.
NOTE: Make certain the tolerance is between .007" and .015".
4). Separate the upper transmission housing from the lower transmission housing and set it aside.
5). Remove the differential axle assembly from the lower housing.
6). Remove the shift fork assembly, detent ball and spring.
7). Remove both self tapping screws securing the lower drive shaft to the lower transmission hous­ing using a 3/8 socket and a 6" extension.
8). Remove the upper and lower drive shaft assem­blies as one unit from the lower transmission housing.
9). Remove and inspect all components of the upper and lower drive shafts. See figure 2.
Flange
Bearing
Shims
Shims
.031 Flat
Washer
Upper
Drive Shaft
20T Spur Gear
Lower Drive
Shaft
#420 x
22L
Flat
Washer
Flat Washer
10T
Sprocket
Screw
Screw
Coupling
29T Spur
Gear
Clutch Collar
42T Bevel Gear
Flat
Washer
Shim
Flange
Bearing
FIGURE 3.
12). Remove the lower shaft assembly from the lower transmission housing using a 3/8 socket and a 6" extension.
13). Reassemble the upper drive shaft assembly (ONLY) and place it into the lower transmission housing. Make certain the bushing detents are sitting firmly into the housing.
14). Place two feeler gauges between the chain sprocket and the flat washer shim. See figure 4.
NOTE: Make certain the tolerance is between .007" and .015".
FIGURE 4.
15). Place two feeler gauges between the gear on the upper drive shaft and the flat washer shim. See figure 5.
NOTE: Make certain the tolerance is between .007" and .015".
Remove
Spur Gear
Chain
Sprocket
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Variable Speed Drive
FIGURE 5.
16). Place two feeler gauges between the top of the upper housing and the flat washer on the input shaft. See figure 6.
NOTE: Make certain the tolerance is between .007" and .015".
FIGURE 6.
Upper
Drive Shaft
Gear
Flat
Washer
17). Lubricate all shafts with Never Seez and reassemble the components of the transmission in the lower housing.
18). Fill the transmission with 20 ounces of grease, part #737-0148.
19). Place the upper transmission housing over the lower housing and secure them together with the self tapping screws removed earlier, using a 3/8 socket. See figure 7.
FIGURE 7.
IMPORTANT: Remember to install the two
longest self tapping screws in the brake assem­bly area.
20). Torque all perimeter case halve self tapping screws between 90 and 110 inch-pounds using a 3/8 socket and a torque wrench. See figure 8.
FIGURE 8.
REASSEMBLE ALL COMPONENTS IN THE REVERSE ORDER ABOVE.
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Variable Speed Drive
Electrical Section
NOTE: A multimeter is a must for this section. If
any of the following tests do not match, repair that portion of the system.
BRAKE SWITCH:
IMPORTANT: The fuel tank has been removed
for clarity.
1). Locate and remove the brake safety interlock switch from the metal frame tab. See figure 1.
NOTE: The brake switch has a center locking tab that must be dislodged from the metal frame tab.
2). Pull the wiring harness connector and brake switch forward and slide it toward the right frame rail. See figures 2 and 3.
FIGURE 1.
FIGURE 2.
3). Remove the brake safety switch from the wiring harness connector. See figure 3.
FIGURE 3.
4). Place the multimeter in the OHM's mode.
5). Place both probes of the multimeter on the NC (normally closed) terminals and test for continuity. –There will be CONTINUITY. See figure 4.
Brake Switch
Metal Frame Tab
FIGURE 4.
6). Place both probes on the NO (normally open) terminals and test for continuity. –There will be NO CONTINUITY. See figure 5.
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Variable Speed Drive
FIGURE 5.
7). Depress the plunger and perform steps 5 and 6.
NOTE: The NC (normally closed) terminals will not have continuity. The NO (normally open) terminals will have continuity.
SEAT SAFETY SWITCH:
NOTE: The seat safety switch is mounted direct-
ly below the left seat compression spring assem­bly.
1). Raise the seat.
2). Remove the negative and positive battery cables from the battery.
NOTE: For safety, remove the negative terminal first.
3). Remove the battery strap, battery, and battery tray from the tractor.
4). Reach in through the battery opening and squeeze the locking clips together on the seat switch. See figure 8.
5). Remove the seat switch from the frame holding bracket. See figure 6.
FIGURE 6.
6). Disconnect the wiring harness connector from the seat switch. See figure 7.
FIGURE 7.
7). Set the seat safety switch on a flat surface. This is the at rest position. See figure 8.
FIGURE 8.
8). Place the multimeter in the OHM's mode.
9). Place both probes of the multimeter on the lower NC (normally closed) terminals and test for con­tinuity. –There will be CONTINUITY. See figure 9.
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Variable Speed Drive
FIGURE 10.
11). Depress the plunger and perform steps 9 and 10.
NOTE: Both sets of NC terminals will not have continuity.
ELECTRIC PTO SWITCH:
IMPORTANT: The electric PTO switch is three
small switches bundled into one. The PTO switch consists of nine total terminal positions (three sets of three terminals) on the back side. Seven of these terminals have male spades. Two termi­nals do not have male spades because they are not used in our applications.
NOTE: Remove all four self tapping screws securing the fuel tank to the dash panel using a 1/2" socket. Lower the fuel tank out of the way.
1). Locate and remove the PTO switch and wiring harness connector. See figure 11.
FIGURE 11.FIGURE 9.
10). Place both probes on the second set of upper NC (normally closed) terminals. –There will be CONTINUITY. See figure 10.
PTO
Switch
2). Remove the wiring harness connector from the PTO switch.
3). Make certain the PTO switch is in the OFF (closed) position.
4). Looking at the back side of the PTO switch, find the male terminals that are nearest the steering column. There will be a terminal on each side and no terminal in the center... XOX.
5). Using an ohm meter, place the test probes on the outer two terminals. This is the start circuit. –There will be CONTINUITY. See figure 12.
FIGURE 12.
6). Pull the PTO switch to the ON position. –There will be NO CONTINUITY. See figure 13.
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Variable Speed Drive
FIGURE 13.
7). Push the PTO switch back to the OFF position and check the two right terminals...OXX in the middle. –There will be NO CONTINUITY. See figure 14.
FIGURE 14.
8). Pull the PTO switch to the ON position. –There will be CONTINUITY. See figure 15.
FIGURE 15.
9). Push the PTO switch back to the OFF position and check the outer two terminals in the last set of three...XXX. –There will be CONTINUITY. See figure 16.
FIGURE 16.
10). Pull the PTO switch to the ON position. –There will be NO CONTINUITY.
11). Push the PTO switch back to the OFF position and check the two right terminals for continuity...XXX. –There will be NO CONTINUITY.
12). Pull the PTO switch to the ON position. –There will be CONTINUITY. See figure 17.
FIGURE 17.
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Variable Speed Drive
NOTE: If any of the above tests do not match,
the electric PTO switch is defective. Recheck the PTO switch to make certain that it is defective.
IGNITION SWITCH:
NOTE: Remove all four self tapping screws
securing the fuel tank to the dash panel using a 1/2" socket. Lower the fuel tank out of the way.
Terminal Codes:
G= Ground S=Start M=Magneto L=Lights B=Battery A1=Alternator A2=Alternator–Lights
NOTE: A multimeter is a must for this section. If any of the following tests do not match, repair that portion of the system.
1). From behind the dash panel, locate the ignition switch and wiring harness connector. See figure
18.
2). Remove the wiring harness connector from the ignition switch. See figure 19.
3). Make certain the multimeter is working properly. Hold both test probes apart and check the meter display. –There will be an O.L. (open line) reading. See figure 19.
FIGURE 18.
4). Turn the key to the ON position. Place the test probes on the B and A1 terminals. –There will be CONTINUITY. See figure 20.
FIGURE 19
Ignition Switch
5). Turn the key to the OFF position. –There will be NO CONTINUITY.
6). Leave the key in the OFF position. Place the test probes on the M and G terminals. –There will be CONTINUITY. See figure 21.
FIGURE 20.
Battery
Position
A1 Position
FIGURE 21.
Ground
Magneto
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Variable Speed Drive
7). Turn the key to the ON position. –There will be NO CONTINUITY.
8). Leave the key in the ON position. Place the test probes on the B and S terminals. –There will be NO CONTINUITY.
9). Turn the key to the START (spring loaded) position. –There will be CONTINUITY. See figure 22.
10). Leave the key in the ON position. Place the test probes on the B and A1 terminals. –There will be CONTINUITY. See figure 23.
FIGURE 22.
11). Turn the key to the (spring loaded) START position. –There will be CONTINUITY.
12). Turn the key to the LIGHTS position. Place the test probes on the L and A2 terminals. –There will be CONTINUITY. See figure 24.
FIGURE 23.
Start
Battery
A1
B
FIGURE 24.
13). Turn the key to the OFF position. –There will be NO CONTINUITY.
NOTE: The ignition switch can be removed by depressing the upper and lower tabs.
ELECTRIC PTO RELAY:
NOTE: Remove all four self tapping screws
securing the fuel tank to the dash panel using a 1/2" socket. Lower the fuel tank out of the way.
1). Locate the electric PTO relay and wiring har­ness. See figure 25.
FIGURE 25.
Lights
A2
Electric
PTO Relay
2). Remove the PTO relay from the wiring harness connector. See figure 26.
NOTE: The relay circuitry is on the front of the relay.
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Variable Speed Drive
FIGURE 26.
3). Place the relay on a flat surface and identify the corresponding male terminals. See figure 27.
NOTE: The male terminals are labeled at the base of the relay.
FIGURE 27.
3
5
2
1
4
5). Place the test probes on terminals 3 and 4. –There will be CONTINUITY. See figure 29.
FIGURE 29.
4). Using an ohm meter, place the test probes on terminals 1 and 2. –Depending on the temperature, the ohms read­ing should be approximately 82 ohms. See figure
28.
FIGURE 28.
2
1
4
3
6). Locate a 12 volt battery and hook up a positive and negative jumper wire.
7). Place the positive jumper wire on terminal 1 and a negative jumper wire on terminal 2 of the relay. The relay will activate. –There will be NO CONTINUITY on terminals 3 and 4.
9). Leave the battery hooked up to terminals 1 and
2.
10). Place the test probes on terminals 3 and 5. –There will be CONTINUITY.
11). Remove the positive and negative jumper wires from the relay. –There will be NO CONTINUITY on terminals 3 and 5. See figure 30.
4 - 20
FIGURE 30.
5
3
NOTE: If any of the above tests do not match,
the relay is defective. Recheck the relay to make certain that it is defective.
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4 - 21
Variable Speed Drive
Electrical Drawing
4
VARIABLE SPEED DRIVE
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4 - 22
NOTE
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1. Coming in from below the left foot board, locate the stationary “V” idler.
2. Grasp the left frame rail and “V” belt on both sides of the “V” idler.
3. Squeeze both hands and release the “V” belt from the “V” idler.
4. Release the “V” belt slowly. See figure 1.
7. Roll the “V” belt out of both the “V” idler and the flat idler on the double idler bracket assembly. See figure 3.
Drive Belt Removal
5 - 1
FIGURE 4.
FIGURE 3.
FIGURE 2.
FIGURE 1.
5. Push forward lightly on the double idler bracket assembly and remove the extension spring from the fixed frame bolt.
6. Remove the extension spring from the double idler bracket assembly and set it aside. See figure 2.
8. Grasp the electric PTO clutch and remove the hex bolt securing it to the crank shaft using a 5/8 socket. See figure 4.
Stationary
“V” Idler
“V” Belt
Double
Idler
Bracket
Extension
Spring
“V” Belt
Flat
Idler
“V” Idler
PTO
Clutch
SECTION 5
HYDROSTATIC LT FOOT
CONTROL
5
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5 - 2
Hydrostatic LT Foot Control
9. Set the hex bolt and hardware aside.
NOTE: The order of the hardware is as follows: hex bolt, lock washer, spacer, and stepped spacer. See figure 5.
FIGURE 7.
FIGURE 6.
FIGURE 5.
10. Slowly lower the electric PTO and secure it.
NOTE: Make certain the electric PTO is NOT hanging on the harness wires.
11. Grasp the drive pulley and pull downward until the “V” belt is clear of the belt keepers at the engine. See figure 6.
12. Roll the drive belt off of the drive pulley at the engine and set the drive pulley aside.
NOTE: The drive pulley goes on the crank­shaft thin side up, and has a separate key.
13. Pull the “V” belt down and to the back side of the crankshaft.
14. Pull the “V” belt rearward towards the hydro­static transmission.
15. Remove the “V” belt from around the hydro­static drive pulley. See figure 7.
NOTE: The fins on the hydrostatic fan are slightly flexible and can be bent down cautiously to remove the “V” belt.
INSTALL THE DRIVE BELT IN THE REVERSE ORDER ABOVE.
Engine
Pulley
Stepped
Spacer
Spacer
Lock
Washer
Hex Bolt
Belt Keeper
“V” Belt
Hydrostatic
Drive Pulley
“V” Belt
Fins
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Hydrostatic LT Foot Control
1. Raise the rear wheels off the ground.
2. Support the hydrostatic transmission from below.
3. Remove both hex bolts and belleville washers securing the rear wheel assemblies to the rear axles using a 1/2" socket and extension. See figure 1.
10. Coming in from below the left foot board, locate the stationary "V" idler.
11. Grasp the left frame rail and "V" belt on both sides of the "V" idler. See figure 4.
Hydrostatic Transmission Removal
FIGURE 1.
FIGURE 2.
FIGURE 3.
FIGURE 4.
4. Remove the rear wheel assemblies.
5. Raise the seat.
6. Remove the battery cables from the battery termi­nals using a 7/16 wrench.
7. Remove the battery and battery tray from the tractor. See figure 2.
8. Remove all three self tapping screws securing the hydrostatic fan to the hydrostatic drive pulley using a 5/16 socket.
9. Remove the hydrostatic fan. See figure 3.
5 - 3
Rear
Axle
Battery
Screws
Screw
Fan
Frame Rail
“V” Idler
“V” Belt
5
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Hydrostatic LT Foot Control
FIGURE 5.
FIGURE 7.
FIGURE 6.
FIGURE 8.
14. Roll the "V" belt off of the hydrostatic drive pulley. See figure 7.
15. Remove the hairpin securing the hydrostatic foot control rod ferrule and reverse safety bracket to the neutral return plate. See figure 8.
NOTE: Make certain the small extension spring is properly installed during reinstallation.
5 - 4
Frame Rail
“V” Idler
“V” Belt
Hydrostatic
Drive Pulley
Neutral
Return Link
Ground
Wire
Hairpin
FIGURE 9.
Neutral
Return Spring
16. Remove the self tapping screw securing the ground wire to the neutral return link. See figure 9.
12. Squeeze both hands and release the "V" belt from the "V" idler. See figure 5.
13. Release the "V" belt slowly. See figure 6.
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Hydrostatic LT Foot Control
18. Remove the hydrostatic relief spring from the hydrostatic bypass linkage and set it aside. See figure 11.
19. Remove the brake extension spring from the brake rod using a pair of vice grips. See figure 12.
NOTE: Insert the brake extension spring into the brake rod before installing the hydro­static transmission.
FIGURE 12.
FIGURE 11.
FIGURE 10.
20. Remove both self tapping screws securing the front of the hydrostatic transmission to the front hydrostatic support bracket using 1/2" socket. See figure 13.
FIGURE 13.
21. Secure the front of the hydrostatic transmission to make certain it does not tip forward during lowering.
5 - 5
Frame
Bolt
Hydrostatic
Bypass
Linkage
Relief
Spring
Screws
Hydrostatic
Support Bracket
Brake
Extension
Spring
5
17. Remove the neutral return spring from the frame bolt using a piece of recoil rope. See figure 10.
NOTE: An assistant may be necessary during reinstallation to guide the extension spring back onto the frame bolt. See figure 9 and 10.
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Hydrostatic LT Foot Control
23. Secure the tractor frame. See figure 15.
REINSTALL THE HYDROSTATIC TRANSMISSION IN THE REVERSE ORDER ABOVE.
FIGURE 14.
FIGURE 15.
FIGURE 16.
5 - 6
22. Remove all four hex bolts and lock nuts securing the hydrostatic transmission to the frame rails using a 1/2" socket and a 1/2" wrench. See figure 14.
Bolts
Lock Nuts
24. Slowly lower the hydrostatic transmission from the tractor. See figure 16.
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FIGURE 3.
FIGURE 2.
FIGURE 1.
1. Raise the rear wheels off the ground
2. Support the bottom of the hydrostatic transmis­sion.
3. Remove the center hub caps
4. Remove the lug nuts securing the rear wheel assemblies to the rear axle hubs using a 3/4" socket and extension.
5. Remove the rear wheel assemblies.
6. Raise the seat.
7. Remove the battery cables from the battery terminals using a 7/16 wrench.
8. Remove the battery and battery tray from the tractor.
9. Remove all three self tapping screws securing the hydrostatic fan to the hydrostatic drive pulley using a 5/16 socket. See figure 1.
16. Remove the self tapping screw securing the ground wire to the neutral return plate using a 3/8 socket.
17. Remove the hairpin securing the hydrostatic foot control rod ferrule and reverse safety bracket to the neutral return plate.
NOTE: Make certain the small extension spring is properly installed during reinstallation. See figure 2 and 3.
Hydrostatic Transmission Removal and Installation
10. Remove the hydrostatic fan.
11. Coming in from below the left foot board, locate the stationary "V" idler.
12. Grasp the left frame rail and "V" belt on both sides of the "V" idler.
13. Squeeze both hands and release the "V" belt from the "V" idler.
14. Release the "V" belt slowly.
15. Roll the "V" belt off of the hydrostatic drive pulley.
18. Set the reverse safety bracket aside.
6 - 1
Screws
Screw
Fan
Hydrostatic
Control Rod
Hairpin
Extension Spring
Hydrostatic
Control Rod
Hairpin
SECTION 6
HYDROSTATIC GT FOOT
CONTROL
6
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Hydrostatic GT Foot Control
FIGURE 4.
FIGURE 7.
FIGURE 8.
FIGURE 5.
FIGURE 6.
21. Snip the zip tie that secures the hydrostatic vent tube to the frame. See figure 6.
NOTE: Make certain the hydrostatic vent tube is zip tied back into place during reinstallation. See figure 6.
22. Remove both self tapping screws securing the front of the hydrostatic transmission to the front hydrostatic support bracket using 1/2" socket. See figure 7.
23. Secure the front of the hydrostatic transmission to make certain it does not tip forward during lower­ing.
24. Remove all four of the hex bolts and lock nuts securing the hydrostatic transmission to the side transmission support brackets using a 1/2" socket and a 1/2" wrench. See figure 8.
6 - 2
Hairpin
Relief Lever
Hairpin
Zip Tie
Vent
Tube
Screws
Transmission
Support
Brackets
Bolts
Lock Nuts
19. Remove the hairpin securing the hydrostatic relief lever to the hydrostatic transmission. See figures 4 and 5.
20. Set the hydrostatic relief lever aside. See figures 4 and 5.
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Hydrostatic GT Foot Control
26. Secure the tractor frame.
27. Slowly lower the hydrostatic transmission from the tractor. See figure 10.
REINSTALL THE HYDROSTATIC IN THE REVERSE ORDER ABOVE.
FIGURE 9.
FIGURE 10.
6 - 3
Brake
Rod
Brake Extension
Spring
6
25. Remove the brake extension spring from the brake rod using a pair of vice grips.
NOTE: The hydrostatic transmission can be tilted to assist brake spring removal. See figure 9.
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6 - 4
NOTES
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7 - 1
FIGURE 4.
FIGURE 3.
FIGURE 1.
FIGURE 2.
1. Park the unit on flat, level ground.
2. Remove the ignition key.
3. Pull outward and detach the base of the control bellow from the bellow retaining bracket.
4. Slide the control bellow upward (towards the drive control handles. See figure 1.
5. Remove the carriage bolt and flange lock nut securing each drive control handle to the upper left and right bellcrank assemblies using a 1/2" socket. See figure 2.
Z Series Neutral / Steering Adjustment
6. Remove both of the drive control handles and the control bellow, and set them aside.
7. Remove all four hex washer head screws secur­ing the bellow retainer bracket to the top of the support tower using a 3/8 socket. See figure 3.
NOTE: Pivot both upper bellcrank assemblies rearward to allow full clearance between the safety switches and the push pins.
8. Pull straight up on the console assembly and remove it from the rider.
9. Remove both safety switches from their respec­tive holders by squeezing the retaining clips in and pushing upward until they are clear of the securing brackets. See figure 4.
Control
Handle
Flange
Lock Nut
Control
Handle
Bell
Crank
Screws
Screws
Bellow Retainer
Bracket
Bellow
Safety Switch
7
SECTION 7
Z SERIES TRACTOR
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7 - 2
Z Series
10. Remove the hex cap screw and flange lock nut securing each control rod assembly to the upper left and right bellcrank assemblies using a 9/16 socket and 9/16 wrench. See figure 5.
NOTE: The damper cylinders will remain secured to the support tower assembly.
11. Remove the hex cap screw and flange lock nut securing each control rod assembly to the lower left and right bellcrank assemblies using a 9/16 socket and a 9/16 wrench. See figure 6.
FIGURE 8.
FIGURE 7.
FIGURE 6.
FIGURE 5.
15. Remove the rear fender assembly and set it aside.
16. Remove all four hex bolts securing the rear of the foot board body to the center frame rails using a 1/2" socket. See figure 8.
14. Remove all four hex bolts securing the seat plat­form to the upper frame rails using a 9/16 socket. See figure 7.
NOTE: The damper cylinders will remain secured to the control rod assemblies.
12. Raise the seat.
13. Disconnect the wiring harness connector from the seat switch and push it down through the seat platform.
Screw
Screw
Flange
Lock Nut
Flange
Lock
Nut
Control
Rods
Lock Nuts
Screws
Control Rod
Control
Rod
Bolts
Seat Platform
Frame Rail
Bolts
Foot Board
Body
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7 - 3
Z Series
FIGURE 12.
FIGURE 11.
FIGURE 10.
FIGURE 9.
18. Remove the hex flange lock nut and carriage bolt securing the parking brake retaining rod bracket to the support tower assembly using a 7/16 sock­et. See figure 10.
17. Remove both front shoulder bolts securing the front of the foot board body to the front frame assembly using a 15/16 socket. See figure 9.
NOTE: This is the set position for neutral.
20. Insert a 1/4" by 7" dowel pin or equivalent through the upper alignment hole of the support tower, through the upper left and right bellcrank assem­blies, and out the opposite side of the support tower. See figure 12.
19. Remove both hex flange lock nuts and carriage bolts securing the brake pedal to the brake arm assembly using a 9/16 socket. See figure 11.
Shoulder
Bolt
Shoulder
Bolt
Front Foot
Board Body
Retaining
Bracket
Lock
Nut
Lock Nuts
Dowel Pin
7
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7 - 4
Z Series
FIGURE 16.
FIGURE 15.
FIGURE 14.
FIGURE 13.
25. Tighten all four hex jam nuts that maintain all the alignaball positions on the control rod assemblies using two 9/16 wrenches.
26. Raise the rear of the rider until the rear wheel assemblies are off the ground, and secure it with jack stands. See figure 16.
NOTE: This is the set position for neutral.
22. With the damper cylinders secured, loosen all four hex jam nuts that maintain the alignaball positions on the control rod assemblies using a 9/16 wrench. See figure 14.
23. With the damper cylinders secured, adjust all four alignaballs until the hex cap screws (removed earlier) slip into the upper and lower bellcrank assemblies with little effort.
Dowel
Pin
Alignaballs
Jam
Nuts
Control
Rods
Flange
Lock Nuts
Screw
Screw
21. Raise the front of the foot board body high enough to insert a 1/4" by 7" dowel pin or equiva­lent through the lower alignment hole of the sup­port tower, through the lower left and right bell­crank assemblies, and out the opposite side of the support tower. See figure 13.
24. Secure the alignaballs and hex cap screws to the bellcrank assemblies with the flange lock nuts removed earlier using a 9/16 socket and a 9/16 wrench. See figure 15.
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7 - 5
Z Series
FIGURE 19.
FIGURE 18.
FIGURE 17.
28. Loosen all four hex jam nuts that maintain the alignaball positions on the hydrostatic control rods using two 9/16 wrenches. See figure 18.
NOTE: The rotation of the hydrostatic control rod will increase or decrease the length between the alignaballs on each hydrostatic control rod. The pump end is left handed, and the tower end is right handed.
33. Tighten all four hex jam nuts that maintain all the alignaball positions on the hydrostatic control rods using a 9/16 wrench. See figures 17 and 18.
NOTE: Make certain the hydrostatic control rods do not rotate while securing the jam nuts.
34. Shut the rider off and remove the 1/4" by 7" dowel pins from the upper and lower alignment holes in the support tower.
35. Depress the brake pedal, start the rider, and adjust the throttle to full.
36. Release the brake pedal and check the rear wheel assemblies for motion.
NOTE: If there is motion, insert the 1/4" by 7" dowel pin and repeat steps 27 through 35.
37. If a state of no motion has been achieved, shut the rider off.
38. Raise the rear of the rider and remove the jack stands.
39. Lower the rear of the rider to the ground.
REASSEMBLE THE RIDER IN THE REVERSE ORDER ABOVE.
29. Make certain the PTO is in the OFF position.
30. Depress the brake pedal, start the rider, and adjust the throttle to full.
31. Release the brake.
32. Rotate the hydrostatic control rods clockwise or counter-clockwise until the rear wheel assemblies come to a complete stop. See figure 19.
Hydrostatic
Control Rods
Jam Nut
Jam Nut
Control
Rods
7
27. Locate the hydrostatic control rods that run from the lower bellcrank assemblies to the hydrostat­ics. See figure 17.
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7 - 6
NOTES
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