Sabre 1338 Gear, 1538 Hydro, 15538 Hydro, 1538 Gear, 1546 Gear Technical Manual

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Sabre Lawn Tractor

38–Inch and 46–Inch (96 cm and 117 cm)

Models: 1338 Gear

1538 Gear 1538 Hydro 15538 Gear

15538 Hydro

1546 Gear 1638 Hydro 1646 Gear 1646 Hydro

Technical Manual

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John Deere Consumer Products Group

TM–GX10131 (Mar–97)

LITHO IN U.S.A. (New)

Page 2

This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows:

INTRODUCTION

Safety

Specifications and Information

• Table of Contents

• Specifications

• Component Location

• System Schematic

• Theory of Operation

• Troubleshooting Chart

• Diagnostics

• Tests & Adjustments

• Repair

Note: Depending on the particular section or system

being covered, not all of the above groups may be used.

Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered.

We appreciate your input on this manual. If you find any errors, or want to comment on the layout of the manual, please mail your comments back to us.

Engine

Electrical

Gear Power Train

Hydrostatic Power Train

All information, illustrations and

specifications in this manual are based on

the latest information available at the time of

publication. The right is reserved to make

changes at any time without notice.

Deere & Co.

John Deere Worldwide Lawn and

Grounds Care Division

Power Products Group

P.O. Box 7047

Charlotte, NC 28241

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1997

Steering

Attachments

Miscellaneous

Service Information Bulletins

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SAFETY

HANDLE FLUIDS SAFELY-AVOID FIRES

• BE PREPARED FOR EMERGENCIES

HANDLE CHEMICAL PRODUCTS SAFELY

TS1133

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used include such items as lubricants, coolants, paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

• DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste includes oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center.

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SAFETY

USE CARE IN HANDLING AND SERVICING BATTERIES

• PREVENT BATTERY EXPLOSIONS

• Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

• Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

• PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

• Avoid acid burns by:

1. Wearing eye protection and rubber gloves.

2. Avoiding breathing fumes from electrolyte.

3. Avoiding tipping battery.

4. Use proper jump start procedure.

USE SAFE SERVICE PROCEDURES

• WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.

• SERVICE MACHINES SAFELY

Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

• If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda to help neutralize the acid.

3. Flush your eyes with water for 10–15 minutes.

4. Get medical attention immediately.

• If acid is swallowed:

1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

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• USE PROPER TOOLS

Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

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SAFETY

• PARK MACHINE SAFELY

1. Depress brake pedal fully.

2. Move park lever into lock position.

3. Check that shift lever has returned to neutral.

4. Make sure blade drive lever is pulled back fully.

5. Move throttle lever to SLOW IDLE position and allow engine to idle for approximately 30 seconds before turning key switch to OFF position. Remove the ignition key to prevent accidental starting.

• Before working on the machine:

1. Lower all equipment to the ground.

2. Stop the engine and remove the key.

3. Disconnect the battery ground strap.

4. Hang a “DO NOT OPERATE” tag in operator station.

• WORK IN CLEAN AREA

• Before starting a job

1. Clean work area and machine:

2. Have all the necessary tools to do your job

3. Have the right parts on hand.

4. Read all instructions thoroughly; do not attempt shortcuts.

• ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

• WORK IN VENTILATED AREA

• SUPPORT MACHINE PROPERLY AND USE

PROPER LIFTING EQUIPMENT

TS229

If you must work on a lifted machine or attachment, securely support the machine or attachment with jack stands rated to support the lifted load.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

Lifting heavy components incorrectly can cause severe personal injury or machine damage. Follow recommended procedure for removal and installation of components in the manual.

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

WARNING: California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline engine exhaust from this product contains chemicals known to the State Of California to cause cancer, birth defects, or other reproductive harm.

• REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

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SAFETY

• AVOID HARMFUL ASBESTOS DUST

Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.

• SERVICE TIRES SAFELY

REPLACE DECALS

Replace missing or damaged Decals. See the machine operator's manual for correct safety sign placement.

LIVE WITH SAFETY

Explosive separation of a tire and rim parts can cause serious injury or death.

Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

• Check wheels for low pressure, cuts, bubbles, damaged rims or missing retaining hardware.

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

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SAFETY

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SPECIFICATIONS & INFORMATION CONTENTS

CONTENTS

Page

SPECIFICATIONS & INFORMATION

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

UNIFIED INCH TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TRACTOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GEAR TRANSAXLE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

HYDROSTATIC TRANSMISSION SERIAL NUMBER — K55. . . . . . . . . . . . . . . . . . 10

HYDROSTATIC TRANSMISSION SERIAL NUMBER — K51. . . . . . . . . . . . . . . . . . 10

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SPECIFICATIONS SPECIFICATIONS & INFORMATION

SPECIFICATIONS

Engine:

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs and Stratton

Style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical Shaft

Models:

13 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28M707

15 Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28N700

16 Horsepower (Cast Iron Sleeve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Q777

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, Air Cooled, Single Cylinder, 4-Cycle

Crankcase Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pints

Oil: Warm Climate (Above 40°F) . . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 30W

Cold Climate (Below 40°F). . . . . . . . . . . . . . . . . . . . . . . .SE, SF, SG, SAE 10W30

Electrical:

Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetron

Magneto Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 -0.35 mm (0.010 - 0.014 in.)

Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit (AC/DC)

Charging Capacity. . . . . . . . . . . . . . . . 2-4 amps, 14 volts DC@3600 rpm (Unregulated)

Spark Plugs

13 Hp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TY6129 (Champion RJ-19 LM)

15 & 16 Hp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC)

Spark Plug Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BCI Group, U1

Battery Cranking Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps at 0° C (32° F)

Battery Cold Cranking Amps. . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps at 0° C (32° F)

Battery Specific Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Above 1.225 Points

Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive

Fuel Shut-Off Solenoid (16 H.P. Only). . . . . Replaceable (Below Carburetor Float Bowl)

Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1156, 12 Volt

Magneto Ignition

Fuel/Air System:

Carburetor Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Carburetor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Draft

Throttle/Choke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unitized Control Linkage

Carburetor Fuel Shut-Off Solenoid ( Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric

Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity Flow

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable Inline type

Fuel Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded (87 Octane Minimum)

Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 L (1.25 gal)

Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Element with Foam Pre-cleaner

Muffler Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Backfire

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SPECIFICATIONS & INFORMATION SPECIFICATIONS

Power Train—K55 Transmission:

Gear Transaxle—

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spicer Heavy-Duty 4360 Transaxle

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Five-Speed/Linear Shift

Domestic Ground Speeds (at FAST idle—3350 rpm) and Gear Ratios:

1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 km/hr (1.5 mph)—61.67:1

2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 km/hr (2.0 mph)—46.67:1

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 km/hr (3.1 mph)—30.00:1

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 km/hr (4.0 mph)—23.48:1

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 km/hr (5.0 mph)—18.46:1

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 km/hr (2.3 mph)—40.00:1

Brake Type . . . . . . . . . . . . . . . . . .Single, External Brake Disc With Dual Friction Pucks

Lubrication—Input Shaft Needle Bearings . . . . . . . . . . . . . . . . . . Multi-Purpose Grease

Lubrication—Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose Grease

Capacity—Transaxle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.64 kg (1.406 lbs)

Hydro Transaxle—

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tuff Torq

K55 Transaxle

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic

Ground Speeds (at FAST idle—3350 rpm):

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.66 km/hr (0—5.38 mph)

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—4.24 km/hr (0—2.62 mph)

Brake Type . . . . . . . . . . . . . . . . . . . . . . Single, External Disc Brake With Friction Pucks

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD

Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (3.4 pt)

Power Train—K51 Transmission:

Gear Transaxle—

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dana

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spicer K51 Transaxle

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Five-Speed/Linear Shift

Domestic Ground Speeds (at FAST idle—2950 rpm) and Gear Ratios:

1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 km/hr (1.5 mph)

2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 km/hr (2.0 mph)

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 km/hr (3.1 mph)

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 km/hr (4.0 mph)

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 km/hr (5.0 mph)

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 km/hr (2.3 mph)

Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Internal Brake Disc

Lubrication—Input Shaft Needle Bearings . . . . . . . . . . . . . . . . . . Multi-Purpose Grease

Lubrication—Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose Grease

Capacity—Transaxle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 kg (5.07 lbs)

Hydro Transaxle—

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kanzaki

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tuff Torq

K51 Transaxle

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic

Ground Speeds (at FAST idle—2950 rpm):

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—8.5 km/hr (0—5.3 mph)

Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0—5.3 km/hr (0—3.3 mph)

Brake Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, Internal Disc Brake

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD

Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (2.4 qt)

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SPECIFICATIONS SPECIFICATIONS & INFORMATION

Traction Drive Belt:

Gear—

New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2660±8 mm (104.7±0.3 in.)

Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2631 mm (103.6 in.)

Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2710 mm (106.7 in.)

Hydro—K55 Transmission

New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485±8 mm (97.8±0.3 in.)

Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2477 mm (97.5 in.)

Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2530 mm (99.6 in.)

Hydro—K51 Transmission

New Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400±8 mm (94.5±0.3 in.)

Minimum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2392 mm (94.2 in.)

Maximum Effective Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2424 mm (94.9 in.)

Mower Deck Drive Belt

38-Inch Deck—

Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425±10 mm (95.5±0.4 in.)

46-Inch Deck—

Actual effective length . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3492±10 mm (137.5±0.4 in.)

Mower Deck:

38-Inch Mower Deck—

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary—Dual Spindles (Non-Serviceable)

Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel

Cutting Blade. . . . . . . . . . . . . . . . . . . . . . . . . Two—76 x 5 x 496 mm (3 x 0.2 x 19.5 in.)

Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30±5° Angle

Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40±3 mm (1.57±0.12 in.)

Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 965 mm (38 in.)

Overall Width (w/o discharge chute) . . . . . . . . . . . . . . . . . . . . . . . . . 1026 mm (40.4 in.)

Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler)

Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None—Sealed Bearings

Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Operator’s Station

Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven: 31.8—89 mm (1.25—3.5 in.)

46-Inch Mower Deck—

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotary—Triple Spindles (Non-Serviceable)

Material Type. . . . . . . . . . . . . . . . . . .Stamped 2.5 mm (0.098 in.) Nominal Gauge Steel

Cutting Blade. . . . . . . . . . . . . . . . . . . . . . Three—50.8 x 5 x 407.4 mm (2 x 0.2 x 16 in.)

Blade Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30±5° Angle

Blade Wing Lift/Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3±3 mm (0.8±0.12 in.)

Overall Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1168.4 mm (46 in.)

Overall Width (W/O Discharge Chute) . . . . . . . . . . . . . . . . . . . . . . . 1308 mm (51.5 in.)

Drive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single V-Belt (With Spring Tension Idler)

Spindle Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None—Sealed Bearings

Lift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Operator’s Station

Cutting Settings. . . . . . . . . . . . . . . . . . . . . . . Seven: 31.75 mm—89 mm (1.25—3.5 in.)

Chassis:

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1135 mm (44.69 in.)

Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524 mm (60 in.)

Overall Width (W/O Mower Deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . 908 mm (35.75 in.)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 980 mm (38.6 in.)

Average Overall Weight 38 inch (With Mower Deck, No Fuel) . . . . . 195.05 kg (430 lbs)

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Page 12

SPECIFICATIONS & INFORMATION SPECIFICATIONS

Average Overall Weight 46 inch (With Mower Deck, No Fuel) . . . . . 204.12 kg (450 lbs)

Hitch Capacity—

Export:

Horizontal Pull Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 kg (56 lbs)

Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 kg (15 lbs)

Domestic:

Trailer Load Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 kg (300 lbs)

Trailer Tongue Weight Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6 kg (50 lbs)

Steering:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual—Pinion/Sector

Axle Pivot Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shim Adjustable

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose Grease

Lubrication Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 hrs (Maximum)

Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) — Non-Adjustable

Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584 mm (23 in.)

Wheels:

Size—

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.0 x 4.50

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.0 x 6.18

Tires:

Size—

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 x 6.50—6 NHS (2 Ply)

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 x 9.50—8 NHS (2 Ply)

Pressure—

Front (with mower deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)

Rear (with mower deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)

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Page 13

UNIFIED INCH TORQUE VALUES SPECIFICATIONS & INFORMATION

UNIFIED INCH TORQUE VALUES

SAE Grade and Head Markings

SAE Grade and Nut Markings

Size

1/4

5/16

3/8

7/16

1/2

Grade 1

LubricatedaDry

No Marks

1 or 2

Grade 2

LubricatedaDry

5.1

5.2

Grade 5, 5.1 or 5.2 Grade 8 or 8.2

LubricatedaDry

8.2

Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

3.8 2.8 4.7 3.5 6 4.4 7.5 5.5 9.5 712913.5 10 17 12.5

7.7 5.7 9.8 7.2 12 9 15.5 11.5 19.5 14.5 25 18.5 28 20.5 35 26

13.5 10 17.5 13 22 16 27.5 20 35 26 44 32.5 49 36 63 46

22 16 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74

34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115

9/16

5/8

3/4

7/8

1-1/8

1-1/4

1-3/8

1-1/2

48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165

67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225

120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400

190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640

285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960

400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350

570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920

750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500

990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head.

Tighten toothed or serrated-type lock nuts to the full torque value.

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

“Dry” means plain or zinc plated without any lubrication.

Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6 in.) long. Grade 1 applies for hex cap screws over

152 mm (6 in.) long, and for all other types of bolts and screws of any length.

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Page 14

SPECIFICATIONS & INFORMATION METRIC TORQUE VALUES

METRIC TORQUE VALUES

Property Class and Head Markings

Property Class and Nut Markings

4.8

510

8.8

9.8

10.9

12.9

Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

LubricatedaDry

Size

LubricatedaDry

Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft Nm lb-ft

4.7 3.5 6 4.4 9 6.6 11.5 8.5 13 9.5 16.5 12.5 15.5 11.5 19.5 14.5

11.5 8.5 14.5 10.7 22 16 28 20.5 32 23.5 40 29.5 37 27.5 47 35

M10

23 17 29 21 43 32 55 40 63 46 80 59 75 55 95 70

M12

40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120

12.9

M14

63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190

M16

100 74 125 92 190 140 240 175 275 200 350 225 320 235 400 300

M18

135 100 175 125 265 195 330 245 375 275 475 350 440 325 560 410

M20

190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580

M22

265 195 330 245 510 375 650 480 725 535 920 680 850 625 108 800

M24

330 245 425 315 650 480 820 600 920 680 115 850 108 800 135 100

M27

490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 200 1500

M30

660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1700 2700 2000

M33

900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730

M36

1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.

Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

“Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

“Dry” means plain or zinc plated without any lubrication.

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Page 15

GASOLINE SPECIFICATIONS SPECIFICATIONS & INFORMATION

GASOLINE SPECIFICATIONS

CAUTION

Handle fuel with care, it is highly flammable. DO NOT refuel machine:

• Indoors. Always fill fuel tank outdoors.

• While you smoke.

• When machine is near and open flame or

sparks.

• When engine is running. STOP engine.

• When engine is hot. Allow it to cool.

Help prevent fires:

• Fill fuel tank only to bottom of filler neck.

• Clean oil, grease and dirt from machine.

• Clean up spilled fuel immediately.

• Do not store machine with fuel in tank in a

building where fumes may reach an open flame or spark.

To prevent fire and explosion caused by static electric discharge while you fill tank:

• Use approved, non-metal fuel container.

• When using a funnel, MAKE SURE it is

PLASTIC.

• Avoid using a funnel which has a metal screen or filter.

LUBRICANT SPECIFICATIONS

ENGINE OIL

Use oil viscosity based on the expected air temperature range during the period between oil changes.

The following oil is preferred:

• 10W30

IMPORTANT: To avoid engine damage:

• DO NOT mix oil with gasoline

• Use only clean oil and fuel

• Use clean approved containers and funnels.

• Store oil and fuel in an area protected from dust,

moisture and other contamination.

Unleaded fuel is recommended because it burns cleaner and leaves less unburned deposits in engine combustion chamber. Regular unleaded gasoline with an anti-knock index of 85 octane or higher may be used. Use of gasohol is acceptable as long as the ethyl alcohol blend does not exceed 11 percent. Do not use gasoline that contains Methanol.

Fill fuel tank at end of each day's operation. Fill only to bottom of filler neck.

GASOLINE STORAGE

Keep fuel in a clean container in a protected area. Do not use deicers to remove water from fuel. Do not depend on fuel filters to remove water.

If possible, install a water separator at the storage tank outlet.

IMPORTANT: Keep all dirt, scale, water or other

foreign material out of fuel.

If mower is stored for the winter, add gasoline storage stabilizer to the fuel. Follow directions on can.

Other oils may be used if they meet one of the following:

• API Service Classification SG

• API Service Classification SF

• CCMC Specification G4

Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

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Page 16

SPECIFICATIONS & INFORMATION LUBRICANT SPECIFICATIONS

GREASE

Use grease based on the expected air temperature range during the service interval.

The following greases are preferred:

• MOLY HIGH TEMPERATURE EP GREASE

• HIGH TEMPERATURE EP GREASE

• MULTI-PURPOSE GREASE

SYNTHETIC LUBRICANTS

Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this group.

The recommended temperature limits and service or oil change intervals should be maintained as shown in the operator’s manual.

Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additive in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

OIL FILTERS

Filtration of oils is critical to proper lubrication. Always change filters regularly.

Use filters meeting John Deere performance specification.

LUBRICANT STORAGE

Other greases may be used if they meet one of the following:

• SAE Multipurpose EP Grease with a maximum of 5% molybdenum disulfide.

• SAE Multipurpose EP Grease

Greases meeting Military Specification MIL-G-10924F may be used as arctic grease.

ALTERNATIVE LUBRICANTS

Conditions in certain geographical areas outside the United States and Canada may require different lubricant recommendations than these printed in this manual or the operator's manual. Consult with your John Deere Dealer, or Sales Branch to obtain the alternative lubricant recommendations.

This machine can operate at top efficiency only if clean lubricants are used.

Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides.

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Page 17

SERIAL NUMBER LOCATIONS SPECIFICATIONS & INFORMATION

SERIAL NUMBER LOCATIONS

When working on machines or components that are covered by warranty, it is IMPORTANT that you include the tractor identification number and serial numbers on the warranty claim form.

The location of tractor identification number and component serial numbers are shown below.

the component

TRACTOR IDENTIFICATION NUMBER

GEAR TRANSAXLE SERIAL NUMBER

Gear transaxle serial number sticker (C) is on rear of housing.

HYDROSTATIC TRANSMISSION SERIAL NUMBER — K55

Tractor identification number plate (A) is located on the rear of frame or under seat.

ENGINE SERIAL NUMBER

Serial number (D) is stamped into top of upper case half. It is only accessible with hydro removed.

HYDROSTATIC TRANSMISSION SERIAL NUMBER — K51

Tractor engine serial number sticker (B) is located on fan shroud.

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Serial number (E) is located on a bar coded label located on the right rear side of the transaxle.

Page 18

ENGINE CONTENTS

CONTENTS

Page

ENGINE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE EQUIPMENT AND TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

OTHER MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ENGINE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

The engines used on Sabre products are warranted by the manufacturer - Briggs & Stratton Corporation.

Please refer to the Owners Manual supplied with your machine for applicable Briggs & Stratton Owners Warranty Policy.

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CONTENTS CONTINUED ENGINE

Page

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Page 20

SPECIFICATIONS ENGINE

SPECIFICATIONS

NOTE: Engine service specifications and procedures are available from

your local Briggs & Stratton dealer or by writing:

BRIGGS & STRATTON CORPORATION

Milwaukee, WI. 53201

For Parts Request:

13HP . . . . . . . . . .Illustrated Parts List Diamond Plus Model Series 28M700 to 28M799

15HP . . . . . . . . . . Illustrated Parts List Diamond Plus Model Series 28N700 to 28N788

16HP . . . . . . . . . . . . . Illustrated Parts List Vanguard Model Series 28Q700 to 28Q799

For Repair Manual Request:

13 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines

15 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines

16 Horsepower. . . . . . . . . . . . . REPAIR MANUAL For Single Cylinder 4-Cycle Engines

SERVICE EQUIPMENT AND TOOLS

Please refer to appropriate Briggs & Stratton Repair Manual, see above, for specific tools required to service the particular engine in your mower.

OTHER MATERIALS

Name Use

RTV Silicone Sealant Seal valve cover.

Prussian Blue Compound Check valve seat contact.

Valve Lap Compound Lap valves.

SCOTCH-BRITE® Pad Clean cylinder head.

Zinc Oxide/Wood Alcohol Check block for cracks.

SCOTCH-BRITE® is a trademark of the 3M Company.

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Page 21

ENGINE REPAIR

REPAIR

ENGINE REMOVAL

1. Turn all switches OFF and disconnect battery negative ( - ) cable.

2. Raise hood. Disconnect light harness on right side

of hood. Lower hood to approximately 3/4 open and slide off bracket.

Capscrews And Nut

Heat Shield

Capscrews

CAUTION

Gasoline is explosive. Do not expose to flame or spark. Serious injury can result. Store in a properly marked, safe container. Wipe-up any spills IMMEDIATELY.

7. Disconnect hose clamp (E) and slide fuel line off of hose barb on carburetor.

8. Disconnect wires from starter terminal (F).

3. Remove two capscrews securing heat shield to frame. Remove capscrew and nut on side of heat shield. Remove heat shield.

4. Disconnect fuel shutoff solenoid wire (A)(16 horsepower only).

5. Turn fuel shutoff valve (B) (early models only) to OFF position or pinch closed fuel hose to carburetor.

6. Loosen clamp (C) to disconnect throttle cable (D).

NOTE: Ground terminal (G) will be disconnected when

engine mounting bolt is removed.

9. Disconnect two (2) harness connectors (H).

10. Remove traction drive belt and mower drive belt.

11. Remove capscrew securing pulley assembly to engine output shaft. Remove pulley assembly.

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Page 22

REPAIR ENGINE

Ground Wire

Capscrews

Nuts

12. Remove four cap screws. Remove engine.

ENGINE INSTALLATION

1. Install engine in mower frame.

Ground Wire

2. Put ground lead connector on top of front right hand engine mounting flange, and insert capscrew through connector, engine, and frame.

3. Install lower engine ground connector on capscrew installed in step 2, and secure with washer and nut.

4. Install other three capscrews, washers, and nuts. Torque to 32 N•m (24 lb-ft).

5. If muffler was removed inspect muffler flange for flatness. Install muffler with new gasket. Torque mounting bolts to 24•m (18 lb-ft).

Capscrews And Nut

Heat Shield

Capscrews

6. Install heat shield. Secure with two capscrews to front frame mounting brackets. Install capscrew and nut on side of heat shield.

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Page 23

ENGINE REPAIR

Capscrew

10. Connect and adjust throttle cable (C) to obtain full

7. Install engine output shaft key and pulley assembly. Secure with washer, lock washer and capscrew. Torque to 75 N•m (55 lb-ft).

throttle and choke when lever is full forward, and idle when lever is rearward.

11. Connect fuel solenoid wire (N) (16 horsepower only), and fuel line and clamp (E).

12. Open fuel shutoff valve (B) (early models only), or remove clamp from fuel line.

8. Connect wires to starter terminal (F).

9. Connect two (2) harness connectors (H).

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Page 24

ELECTRICAL CONTENTS

CONTENTS

Page

ELECTRICAL

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

READING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WIRE COLOR ABBREVIATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WIRE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . 9

CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS . . . . . . . . . . . . 10

IGNITION & SEAT SWITCH CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 12

IGNITION CIRCUIT TEST POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CHARGING & HEADLIGHT CIRCUIT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . 16

CHARGING CIRCUIT DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

HEADLIGHTS CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

CHARGE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DC AMPERAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

AC VOLTAGE OUTPUT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

STARTER AMP DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SEAT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

BRAKE SWITCH / BLADE DRIVE SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 24

BRAKE SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

IGNITION SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GROUND CIRCUIT TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

IGNITION SWITCH REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SEAT SWITCH REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

STARTER SOLENOID REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 28

2/11/97 4 - 1

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CONTENTS CONTINUED ELECTRICAL

Page

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Page 26

SPECIFICATIONS ELECTRICAL

SPECIFICATIONS

Battery:

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

BCI group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .U-1

Cold Cranking Amps at 0 Reserve Capacity At 0

Specific Gravity (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.225 points

Electrolyte Quantity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)

Ignition:

Primary Coil Resistance

One direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1000 Ohms

Other Direction (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 K Ohms

Secondary (Plug Wire And Core) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 - 10.85 K Ohms

Air gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.2 - 0.3 mm (0.008 - 0.012 in.)

Spark Plug:

Type:

13 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TY6129 (Champion RJ-19 LM)

15 and 16 HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M78543 (Champion RC-12 YC)

Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N•m (221 lb-in.)

C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 amps

C (32°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 amps

Starter:

Starter Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bendix Inertia Drive

Amp draw

Loaded (Engaging Engine) . . . . . . . . . . . . . . . . . . . . . . .180 amps at 225 engine rpm

Stator:

Stator size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 amp

Unregulated Output At 3600 Rpm (No Lamps Attached):

AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 volts AC

DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 amps DC

Headlight Bulbs:

Headlight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type 1073, 12 Volt, 23 Watt

3/5/97 4 - 3

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Page 27

ELECTRICAL THEORY OF OPERATION

THEORY OF OPERATION

GENERAL INFORMATION

The theory of operation stories divide the electrical system into individual circuits by function. Each circuit is isolated from the main wiring schematic and only shows the components that are used in it. The story contains information on function, operating conditions, and theory of operation. The circuit schematics are drawn with the components in the operating position, with the power, or battery positive, into them across the top and the ground, or battery negative, across the bottom.

DIAGNOSTIC INFORMATION

The diagnostic procedures is used to test the complete circuit regardless of the problem or complaint. Select a symptom or system from the quick check or troubleshooting chart and follow the test procedures under that heading.

The diagnostic procedure lists:

• Test conditions

• Test sequence

• Test location

• Normal reading

• Check or test to perform if reading is not normal

When performing the test or check, be sure to set your machine up to the test conditions listed and follow the sequence carefully. The middle “NORMAL” column gives the reading or condition that should be obtained when performing the test or check. If the results of the test or check are not normal, perform the test, check, or adjustment listed in the third “IF NOT NORMAL” column to repair the malfunction. The detailed tests or adjustments referred to in the “IF NOT NORMAL” column are located at the end of that group. The system diagram that accompanies each test procedure is drawn to resemble machine components. The key number on the art matches the number in the “TEST LOCATION” column and the leader line points to the exact point the test is to be made.

WIRE COLOR ABBREVIATION CHART

Blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black

Blu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue

Brn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown

Grn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green

Gry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray

Org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orange

Pnk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink

Pur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purple

Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red

Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tan

Wht. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White

Yel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yellow

Blk/Wht. . . . . . . . . . . . . . . . . . . . . . . . . .Black/White

Blu/Wht. . . . . . . . . . . . . . . . . . . . . . . . . . Blue/White

Brn/Wht . . . . . . . . . . . . . . . . . . . . . . . . Brown/White

Brn/Yel . . . . . . . . . . . . . . . . . . . . . . . . Brown/Yellow

Dk Blu. . . . . . . . . . . . . . . . . . . . . . . . . . . . Dark Blue

Dk Brn/Lt Grn . . . . . . . . . . Dark Brown/Light Green

Dk Brn/Red. . . . . . . . . . . . . . . . . . Dark Brown/Red

Dk Brn/Yel . . . . . . . . . . . . . . . . . Dark Brown/Yellow

Dk Grn . . . . . . . . . . . . . . . . . . . . . . . . . Dark Green

Lt Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Blue

Lt Grn . . . . . . . . . . . . . . . . . . . . . . . . . . Light Green

Org/Wht . . . . . . . . . . . . . . . . . . . . . . . Orange/White

Pnk/Blk . . . . . . . . . . . . . . . . . . . . . . . . . . Pink/Black

READING SCHEMATICS

The schematic is made up of individual circuits laid out in a sequence of related functions. Current flow is generally from top to bottom through each circuit and component. All components are shown in the OFF position. The diagram does not list connector information unless needed to avoid confusion.

Each component is shown by a symbol and name. The identification code contains a device identifying letter and number.

The circuit number and wire color of the wires are shown directly next to the wire path.

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Pur/Wht . . . . . . . . . . . . . . . . . . . . . . . . Purple/White

Red/Blk. . . . . . . . . . . . . . . . . . . . . . . . . . . Red/Black

Red/Wht . . . . . . . . . . . . . . . . . . . . . . . . . . Red/White

Wht/Blk. . . . . . . . . . . . . . . . . . . . . . . . . .White/Black

Wht/Red . . . . . . . . . . . . . . . . . . . . . . . . . . White/Red

Yel/Blk . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Black

Yel/Red. . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/Red

Yel/Wht . . . . . . . . . . . . . . . . . . . . . . . . . Yellow/White

Page 28

ELECTRICAL SCHEMATIC ELECTRICAL

ELECTRICAL SCHEMATIC

120 BLK

ENGINE

CONNECTOR

SPARK

PLUG

HEADLAMP

HARNESS

HEADLIGHTS

CONNECTOR

940 WHT

0 = OFF

1 = ON

942 WHT

705 PUR/WHT

941 WHT

941A WHT

0 = OFF

1 = ON

SWITCH

IGNITION

SWITCH

BRAKE

IGNITION

MODULE

COIL

WHT/BLK

945 WHT/BLK

946A

0 1

BLADE

DRIVE

SWITCH

700 PUR

0 = OFF

1 = RUN02 = START

2 1

0,1

946 WHT/BLK

SEAT

710 PUR

0 = OFF SEAT

1 = ON SEAT

100 BLK

SWITCH

110 BLK

200 RED

451 YEL/WHT

220 RED/BLK

201 RED

RED/WHT

202

15A

FUSE

201 RED

START

SOLENOID

ENGINE

CONNECTOR

401 YEL

DIODE

RED

BATTERY

FUEL

SHUT-OFF

SOLENOID

STARTER

MOTOR

(16 HP ONLY)

STATOR

710 PUR

105 BLK

FRAME GROUND

3/5/97 4 - 5

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Page 29

WIRE HARNESS ELECTRICAL

WIRE HARNESS

945 WHT

942 WHT/BLK

705 PUR

710 PUR/WHT

451 YEL/WHT

BLADE

DRIVE

SWITCH

ENGINE

220RED/BLK

BATTERY

GROUND

CONNECTOR

8mm (5/16") Eyelet

100

110

105

401YEL

FUEL SOLENOID

945

946

946A

940 WHT

941

941A

940

942

202RED/WHT

ENGINE GROUND

HEADLIGHTS

8mm (5/16") Eyelet

451YEL/WHT

201 RED

120 BLK

946A WHT/BLK

700 PUR

941A WHT

705PUR/WHT

BRAKE SWITCH

Eyelet

8mm (5/16")

BATTERY POSITIVE

SOLENOID

POSITIVE

1 2

220

202

200

100 BLK

401YEL

IGNITION SWITCH

SOLENOID

GROUND

200 RED

15 AMP FUSE

& HOLDER

946 WHT/BLK

SEAT SWITCH

110 BLK

HEADLIGHT

WIRE HARNESS

4 - 6 3/5/97

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700 PUR

941 WHT

Page 30

COMPONENT LOCATION ELECTRICAL

COMPONENT LOCATION

Headlights

Spark Plug

Starter Motor

Fuel Shut-Off Solenoid

Seat Switch

Ignition Switch

Blade

Drive

Switch

Brake

Switch

Starter Solenoid

Battery

3/5/97 4 - 7

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Page 31

TROUBLESHOOTING ELECTRICAL

TROUBLESHOOTING

Problem or Symptom

Check or Solution

Engine will not crank.

Engine cranks—will not start.

Engine starts hard or will not

stay running.

Engine misses or runs rough.

Weak or no spark.

Engine will not shut off.

Battery goes dead,

discharges or overcharges.

Headlights do not light or will

not shut off.

Fuel shut-off solenoid will

not open (16 hp only)

Fuel shut-off solenoid will

not close (16 hp only)

Engine dies when brake lever

is released.

Engine dies when blade lever

is engaged.

See Cranking Circuit Diagnosis ● ● ●●

See Ground Circuit Tests ●● ● ●● ●●● ●●

Test battery and connections.

See Ignition Circuit Tests

See Charging Circuit Tests

See Starter Solenoid Test ●

See Seat Switch Tests ● ● ●●

See headlight circuit test points.

See fuel shut-off solenoid circuit test points (16 hp only)

Check for short circuit. ●● ● ●● ●●●●●●

Check for high resistance or open circuit.

Check for correct spark plug and spark plug gap.

Check strength of flywheel ignition module magnet and/or flywheel stator magnets.

See fuel and air system tests and adjustments.

Check for stator shorted to ground

Check seat switch connector is plugged in and interlock spring inside connector is good

● ●●●

● ●●●● ●●

● ● ●●

●

● ● ●●

●● ● ●● ●●●●●●

● ●●●

● ●●● ●

● ●●

● ●

●●

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Page 32

DIAGNOSTICS ELECTRICAL

DIAGNOSTICS

CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT OPERATION

Function:

The cranking system is used to energize the starting motor.

Operating Conditions:

In order to crank the engine; the blade drive lever must be disengaged (blade switch plunger depressed), the brake pedal must be depressed (brake switch plunger depressed), and the ignition switch must be in the start position. The operator does not have to be on the seat to crank the engine if the above conditions are met.

Theory of Operation:

The starting motor has a separate starter solenoid, located under the operator’s seat. Current flows from the battery positive terminal to the starter solenoid secondary terminal, plug in fuse, and ignition switch. With the ignition switch in the start position, current flows from the ignition switch, to the blade drive switch, brake switch, and to the starter solenoid primary terminal, energizing the pull-in windings of the solenoid and engaging the starter.

201 RED

200 RED

The 16 HP fuel shut-off solenoid is also energized by the ignition switch and allows fuel to flow to the carburetor.

The blade drive switch is located under the left side of the mower frame, at the end of the blade drive lever shaft. It is used to prevent the engine from cranking if the blade drive is engaged. With the blade drive lever disengaged, (blade drive switch plunger depressed), current flows through the 705 Pur/Wht wire to the brake switch.

The brake switch is located under the right side of the mower frame, in front of the brake pedal bell crank. When the park brake is engaged, the bell crank depresses the brake switch plunger and the switch is closed, energizing the starter solenoid primary coil. The starter solenoid plunger is pulled in by the primary coil, closing the secondary terminals and supplying high battery current to the starter motor. The spinning of the starter motor extends the starter bendix drive into the engine flywheel, turning over the engine until the ignition circuit fires. Once the engine starts, the operator releases the ignition switch to run position. The current flow to the starter solenoid primary coil is stopped, releasing the starter solenoid plunger, and cutting off the high battery current to the starter motor.

STARTER SOLENOID

BATTERY

STARTER

BLK

MOTOR

FRAME GROUND

RED

105 BLK

PLUG-IN

FUSE

IGNITION SWITCH

0=OFF 1=ON

700 PUR

710 PUR

401 YEL

705 PUR/WHT

BLADE DRIVE SWITCH

BRAKE

SWITCH

0=OFF 1=RUN

012

2=START

FUEL SHUT-OFF SOLENOID

0=OFF 1=ON

GROUND POWER CONTROL

3/5/97 4 - 9

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Page 33

DIAGNOSTICS ELECTRICAL

CRANKING & FUEL SHUTOFF SOLENOID CIRCUIT DIAGNOSIS

Test Conditions:

• Ignition switch in OFF position • Meter positive (+) lead on numbered test point

Test/Check Point Normal If Not Normal

1. Battery positive terminal 11.8-13.2 volts Test battery

2. Starter solenoid front cable terminal Battery voltage Check positive battery cable

3. Plug in fuse under operator’s seat Battery voltage Check fuse and red/wht ignition wires

4. Ignition switch terminal red wire Battery voltage Check red ignition wires

Test Conditions:

NOTE: Perform the tests below one at a time, allowing the starter to cool between tests. Do not allow the starter

to crank for more that 15 seconds, and allow 30 seconds for starter windings to cool. If starter mechanism is not turning, windings may still be conducting current and heating up. Disconnect starter cable from starter (and isolate cable terminal) if cranking circuit or fuel shutoff solenoid (and not starter) is being tested.

Test/Check Point Normal If Not Normal

5. Ignition switch terminal purple wire Battery voltage Replace ignition switch

• Meter negative (—) lead on battery negative (—) terminal

• Blade Drive OFF • Transmission in neutral

• Park brake engaged • Ignition switch in START position

6. Blade Drive Switch purple wire Battery voltage Test purple wire back to ignition switch

7. Blade Drive Switch purple/white wire Battery voltage Check Blade Drive Switch and lever

8. Park brake switch purple/white wire Battery voltage Test purple/white wire back to blade switch

9. Park brake switch purple wire Battery voltage Check park brake switch and lever

10. Starter solenoid purple wire Battery voltage Test purple wire back to park brake switch

11. Starter solenoid ground terminal (black wire)

12. Starter solenoid battery terminal (red wire, rear terminal)

13. Starter solenoid starter terminal (red wire, front terminal)

14. Starting motor Battery voltage Clean battery terminals.

Fuel Shutoff Solenoid Test: (16 hp only)

15. Ignition switch yellow wire Battery voltage Replace ignition switch

16. Fuel shut-off solenoid yellow wire Battery voltage Check yellow wire back to ignition switch

17. Fuel shut-off solenoid black wire Greater than 0 volts

Greater than 0 volts Less than 0.2 volts

Battery voltage Clean terminals at battery and solenoid

Battery voltage Clean battery terminals.

(Ignition Switch In Start Position)

Less than 0.2 volts

Greater than 0.2 volts solenoid ground circuit black wire.

volts - replace solenoid

Test red battery wire for shorts or breaks.

Replace starter solenoid

Check red wire back to solenoid. Test starter (see engine manual)

Greater than 0.2 volts

volts: replace fuel shut-off solenoid

- check starter

: check engine ground

4 - 10 3/5/97

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Page 34

DIAGNOSTICS ELECTRICAL

Blk

IGNITION SWITCH

Red

700 PUR

BATTERY

941 WHT

200 RED

401 YEL

100 Black

705 PUR/WHT

700 PUR

710 PUR

15A Fuse

BRAKE SWITCH

BLADE DRIVE SWITCH

STARTER

Red

FUEL SHUTOFF SOLENOID

201 RED

401 YEL

BLK

STARTER RELAY (SOLENOID)

710 PUR

202 RED/WHT

105 BLK

3/5/97 4 - 11

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Page 35

ELECTRICAL DIAGNOSTICS

IGNITION & SEAT SWITCH CIRCUIT OPERATION

Function:

To create a spark that ignites the fuel/air mixture in the engine. The ignition coil and module will produce a spark at the spark plug unless the ignition & seat switch circuit of the tractor chassis wiring acts to ground the coil primary and stop the engine.

This circuit is used as a safety interlock to prevent the engine from starting, or to stop the engine while running, if the operator attempts to use unsafe actions. This circuit is independent of the cranking circuit, but shares some components.

Operating Conditions:

To produce a spark the following conditions must be met:

• The ignition switch must be in the start or run position.

• The blade drive lever must be disengaged (back) if the operator is off the operator’s seat.

• The park brake switch must be engaged (brake applied) if the operator is off the operator’s seat.

Once the engine is running, the operator must be ON the seat to release the brake pedal, or engage the Blade Drive, or the ignition module will be grounded and the engine will stop.

Theory of Operation:

The ignition system is an electronic magneto design. Ignition timing is controlled by the ignition module and is NOT ADJUSTABLE.

Battery current is always present at ignition switch terminal “B”. When the fuel shut-off solenoid (16 Horsepower engine only) is installed, it becomes energized when the ignition switch is in either START or RUN position, via ignition switch terminal “A”, unseating the plunger and allowing fuel flow into the venturi of the carburetor. When the ignition switch is turned OFF, current flow is broken and internal spring force closes the solenoid plunger, stopping fuel flow.

As the electric starter turns the flywheel, a magnet in the flywheel produces current in the primary coil of the ignition module by electromagnetic induction. When the primary current builds to its highest level, the ignition module induces high voltage current into the secondary coil. This high voltage current then flows to the spark plug and jumps the spark plug gap and creates a spark that ignites the fuel/air mixture, causing the engine to start and run.

The ignition module will stop producing current to the spark plug if the 940 White wire from the coil is allowed to ground to the mower chassis. The engine is shut off by grounding the ignition module in one of two ways:

1. Through the ignition switch when key is moved to OFF position.

2. Through the brake switch, or blade drive switch, if the operator tries to get OFF the seat with the blade drive ENGAGED or the park brake NOT ENGAGED.

When the brake pedal is RELEASED, the brake switch creates a path for the ignition module to the seat switch. When the operator is OFF the seat, the seat switch (normally closed) completes the path to ground for the ignition module current, preventing high current induction into the secondary coil which prevents the spark plug from firing, killing the engine.

The blade drive switch is in parallel with the blade switch, and will also ground the ignition module when the blade drive is engaged with no operator on the machine, killing the engine.

The blade drive and brake switches are also used to prevent the engine from cranking if the blade drive lever is ENGAGED or park Brake is NOT ENGAGED when ignition switch is moved to START. (See Cranking Circuit Operation Section)

The operator’s seat switch has an interlock built into it’s connector which prevents the mower from being used with the seat switch disconnected. An internal spring will short the two cavity connectors together when disconnected from the seat switch. This has the effect of grounding the ignition module when the blade drive lever is engaged or the brake pedal is released, stalling the engine.

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Page 36

DIAGNOSTICS ELECTRICAL

RED

STARTER SOLENOID

BATTERY

BLACK

RED

201 Orange

401

YELLOW

FUEL SHUT-OFF SOLENOID (OPTIONAL)

100

BLACK

200 RED

401 YELLOW

BLADE DRIVE SWITCH

0=OFF 1=ON

SEAT SWITCH

0=OFF 1=ON

946 WHITE/ BLACK

945 WHITE/BLACK

942 WHITE

941 WHITE

KEY SWITCH

941 WHITE

942 WHITE

BRAKE SWITCH

940 WHITE

0=OFF 1=RUN 2=START

940 WHITE

0=OFF 1=ON

ENGINE

CONNECTOR

FRAME GROUND

GROUND POWER CONTROL

100 BLACK

110 BLACK

COIL

E1 SPARK PLUG

IGNITION MODULE

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Page 37

DIAGNOSTICS ELECTRICAL

IGNITION CIRCUIT TEST POINTS

When diagnosing an ignition problem, isolate magneto circuit from ground circuit by separating engine connector. If engine will not start check magneto circuit first and then check ground circuit. If engine will not shut off, check ground circuit. Remember engine is stopped by grounding ignition coil through either key switch, seat switch or the brake switch and PTO switch.

Test Conditions:

• Ignition switch in run position • Park Brake engaged • Blade Drive Lever disengaged

• Meter positive (+) lead on

numbered test point

Test/Check Point Normal If Not Normal

1. Engine connector 940 white wire (wiring harness side of connector)

Test Conditions:

• Park brake disengaged • Seat switch depressed

Test/Check Point Normal If Not Normal

2. Engine connector 940 white wire

• Meter negative (—) lead on engine ground

Infinite resistance Check that blade drive switch

Infinite resistance Check that brake switch is being

Infinite resistance Check for shorted 940, 941, 942,

Infinite resistance Check for faulty ignition switch

Infinite resistance Check for shorted 945/946 white/

• Engine connector disconnected

plunger is being fully depressed by blade drive lever

fully depressed by brake arm

white wires to chassis

(internal short)

black wires

Check for faulty seat switch

Test Conditions:

• Key switch in off position • Seat switch released • Brake switch released

Test/Check Point Normal If Not Normal

3. Engine connector 940 white wire

Maximum 0.1 ohms Check for open 940/941/942 white

wires

Check for open 100/110 black wires

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Page 38

DIAGNOSTICS ELECTRICAL

940

White

940

White

942

White

White/Black

945

Engine

Connector

110

Black

Seat Switch

945

White/Black

946

White/Black

Brake Switch

Key Switch

3/5/97 4 - 15

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White

941

100

Black

942

White

940

White

942

White

945

White/Black

Blade Drive Switch

Page 39

ELECTRICAL DIAGNOSTICS

CHARGING & HEADLIGHT CIRCUIT OPERATION

Function:

To maintain battery voltage between 11.8 and 13.2.

Operating Conditions:

The engine must be running for the charging system to operate. Headlights are on only when the engine is running.

451 YEL/WHT

Theory of Operation:

The charging system is of the permanent magnet and stator design. Magnets imbedded into the crankshaft flywheel pass a multi-pole stator mounted under the flywheel, inducing alternating current into the stator coils. Alternating current is routed to the headlamp bulbs anytime the engine is running through the 451 Yel/Wht wire. One half of the stator output current is rectified by an in-line diode in the 220 Red/Blk circuit, and used to charge the battery. Charging output is unregulated.

HEADLIGHTS

220 RED

200 RED

BATTERY

BLACK

201 RED

CONNECTOR

ENGINE

DIODE

STARTER SOLENOID

15 A FUSE

201 RED

120 BLACK

IGNITION SWITCH

0=OFF 1=RUN 2=START

012

W1 FRAME GROUND

4 - 16 3/5/97

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STATOR

GROUND POWER

Page 40

DIAGNOSTICS ELECTRICAL

CHARGING CIRCUIT DIAGNOSIS

Test Conditions:

• Brake engaged, blade drive lever disengaged • Engine running at fast idle (3600 rpm)

• Engine connector disconnected • Meter negative (–) lead on battery negative (–) terminal

• Ignition switch in run position • Meter positive (+) lead on numbered test point

NOTE: Be sure to set multimeter to read AC or DC voltage or amperage as test requires:

Test/Check Point Normal If Not Normal

1. Engine connector 451 Yel/Blk wire

2. Engine connector 220 Red/Blk wire

3. Headlamps Remain on with engine running Go to step 4

4. Headlamp connector 451 Yel/ Wht connector at engine cover

Test Conditions:

• Meter negative (—) lead grounded to engine frame • Stop engine

• Meter positive (+) lead on numbered test point • Disconnect engine connector

Test/Check Point Normal If Not Normal

5. Engine connector wires:

Red Wire Black wire

Unregulated voltage 14 VAC See Briggs & Stratton engine

manual for charging system repair

2–4 Amps DC See Briggs & Stratton engine

manual for charging system repair

11.8-13.2 DC voltage Check headlamp bulbs

Infinite resistance from wire to ground Infinite resistance from wire to wire

See Briggs & Stratton engine manual for charging system repair

Check stator for short to ground Check stator for internal short See Briggs & Stratton manual

Test Conditions:

• Reconnect engine connector • Start engine • Multimeter negative to ground

Test/Check Point

6. Plug in fuse 11.8-13.2 DC volts (both sides of fuse) Check 220 Red/Blk circuit

7. Red wire at ignition switch 11.8-13.2 DC volts Check 220 Red circuit

8. Battery positive terminal 11.8-13.2 DC volts Check 201 Red Battery Positive

3/5/97 4 - 17

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lead and terminal connector

Page 41

DIAGNOSTICS ELECTRICAL

HEADLIGHTS CIRCUIT DIAGNOSIS

Test Conditions:

• Park brake engaged, blade drive disengaged • Engine running at fast idle

• Meter negative (—) lead on battery negative (—)

terminal

NOTE: But sure to set multi-meter to measure AC or DC voltage or amperage as required by test:

Test/Check Point Normal If Not Normal

1. Headlamps Bulbs are lit whenever engine is running

2. Yellow/White wire at

headlamp socket connector

3. Yellow/White wire at

connector at engine cover hinge.

Test Conditions:

• Stop engine

Test/Check Point

4. Remove engine connector

and test for voltage at Red wire from engine. See Charging Circuit Diagnosis Section in this manual

12—14 Volts AC. Test ground circuit

12—14 Volts AC. Replace headlamp harness under engine cover

12—14 Volts AC See Briggs & Stratton engine

• Meter positive (+) lead on numbered test point

Check for burned out bulbs

Go to step 3

Go to step 4

manual for service and repair

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Page 42

DIAGNOSTICS ELECTRICAL

Yel/Wht

Headlight Harness

120 Black

451Yel/Wht

Red

TO ENGINE

451

Yellow/White

TO CHASSIS

220

Red/Black

451 YEL/WHT

120 Black

Engine

Connector

Black

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Headlight Harness

Page 43

ELECTRICAL TESTS AND ADJUSTMENTS

TESTS AND ADJUSTMENTS

BATTERY TEST

Reason:

To check condition of battery and determine battery voltage.

Equipment:

• Hydrometer

• Voltmeter or Battery Tester

• All cells more than 1.225 with less than 50 point

variation, load test battery.

• More than 50 point variation: replace battery.

CHARGE BATTERY

Reason:

To increase battery charge after battery has been discharged.

Equipment:

• Battery charger (variable rate)

Procedure:

1. Clean battery terminals and top of battery.

2. Inspect battery terminals and case for breakage or cracks.

3. Check electrolyte level in each battery cell. Add clean, soft water as needed. If water was added, charge battery for 20 minutes at 10 amps.

4. Remove surface charge by placing a small load on the battery for 15 seconds.

5. Check specific gravity of each cell with a hydrometer.

6. Check battery voltage with voltmeter or Battery Tester.

Specifications:

Minimum specific gravity

. . . . . . . . . 1.225 with less than 50 point variation

Minimum battery voltage. . . . . . . . . . . . . . 12.4 volts

Results:

• Battery voltage less than 12.4 VDC, charge battery.

• Battery voltage more than 12.4 VDC, test specific

gravity.

• All cells less than 1.175, charge battery at 10 amp rate.

• All cells less than 1.225 with less than 50 point variation, charge battery at 10 amp rate.

Procedure:

NOTE: See BATTERY TEST in this group before

charging battery.

1. Connect variable rate charger to battery.

NOTE: Maximum charge time at boost setting is 10

minutes. Allow additional 5 minutes for each 10 degrees below 70 degrees F.

2. Start charger at slow rate. Increase charge rate one setting at a time. Check charger ammeter after 1 minute at each setting. Maintain 10 amp charge rate. Use boost setting as necessary.

3. Check if battery is accepting a 10 amp charge after 10 minutes at boost setting.

Battery will not accept 10 amp charge after 10

minutes at boost setting: replace battery.

Battery is accepting 10 amp charge after 10 minutes

at boost setting, and battery did not need water: go to steps 6 and 7.

Battery is accepting 10 amp charge after 10 minutes

at boost setting, but battery did need water or all cells were below 1.175: go to steps 4 and 5.

4. Set charger at 15-25 amps.

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Page 44

TESTS AND ADJUSTMENTS ELECTRICAL

IMPORTANT: Decrease charge rate if battery gases

or bubbles excessively or becomes too warm to touch.

5. Check specific gravity after 30 minutes (60 minutes for maintenance-free battery).

More than 50 point variation between cells: replace

battery.

Less than 50 point variation between cells: go to

steps 6 and 7.

NOTE: If battery was discharged at slow or unknown

rate, charge at 10–15 amps for 6–12 hours. (Maintenance-free battery: 12–24 hours.)

If battery was discharged at fast rate, charge at 20–25 amps for 2–4 hours. (Maintenance-free battery: 4–8 hours.)

6. Continue charging battery until specific gravity is

1.230-1.265 points.

7. Load test battery.

BATTERY LOAD TEST

Reason:

To check condition of battery under load.

Procedure:

1. Turn load knob of tester clockwise until amperage reading (A) is equal to:

a.Cold cranking amperage rating (use blue scale).

— OR —

b.Three times ampere hour rating (use black scale).

2. Hold for 15 seconds and turn load knob of tester off.

3. Repeat procedure steps 1 and 2 from above and read condition of battery at DC Volts scale (B).

Results:

• If the battery does not pass the test and has not been charged, charge battery and retest.

• If the battery does not pass the test and has been charged, replace the battery.

DC AMPERAGE OUTPUT TEST

Reason:

To determine direct current amperage output of the engine.

Equipment:

• Multimeter

Equipment:

• Battery Tester

Connections:

1. Turn load knob (C) of tester counter-clockwise to off.

2. Connect tester positive cable (D) to battery positive terminal.

3. Connect tester negative cable (E) to battery negative terminal.

Red Wire

Connections:

1. Remove surface charge from battery by cranking engine for 15 seconds.

2. Set multimeter to read DC amperage

3. Disconnect engine connector (A).

4. Connect red multimeter red lead to red wire from engine connector at terminal (B).

5. Connect black multimeter lead to chassis ground.

Procedure:

1. Start and run engine at 3600 rpm while watching multimeter.

Specifications:

DC Amperage (Max) . . . . . . . . . . . . . . . . . . . . 2 Amps

Results:

• If engine fails to produce DC amperage, see the Briggs & Stratton service manual for repair information.

3/5/97 4 - 21

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Page 45

ELECTRICAL TESTS AND ADJUSTMENTS

AC VOLTAGE OUTPUT TEST

Reason:

To measure engine alternating current voltage output to determine stator condition.

Equipment:

• Multimeter

Black Wire

Connections:

1. Disconnect engine connector (A).

2. Set multimeter to read AC voltage.

3. Connect red multimeter lead to black wire from engine connector at terminal (B).

4. Connect black multimeter lead to chassis ground.

Procedure:

1. Start and run engine at 3600 rpm while watching multimeter.

STARTER SOLENOID TEST

Reason:

To determine if starter solenoid or starter is defective.

Equipment:

• Jumper wire

Connections:

1. Put transaxle in neutral. Move key switch to off position.

2. Engage park brake.

3. Disconnect and ground spark plug lead.

4. Disconnect purple wire from small starter solenoid engagement terminals (A).

Specifications:

AC Voltage Output (3600 rpm):. . . . . . . . . . . 14 Volts

Results:

• If reading is less than specifications, see Briggs & Stratton service manual for electrical system repair.

Procedure:

1. Connect jumper wire to positive battery terminal and briefly jump to bare small starter solenoid engagement terminal (A).

Results:

• Starter runs: solenoid is good, check circuit wiring.

• Starter does not run: go to step 2.

2. Connect jumper wire between starter solenoid large terminals (B and C).

Results:

• Starter runs: Replace solenoid.

• Starter does not run: Check battery cables then

replace starter.

4 - 22 3/5/97

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Page 46

TESTS AND ADJUSTMENTS ELECTRICAL

STARTER AMP DRAW TEST

Reason:

To determine the amperage required to crank the engine and check starter motor operation under load.

Equipment:

• Battery Tester

• Photo Tachometer

Connections:

1. Put transaxle in neutral. Engage park brake.

2. Test system ground connections and battery.

3. Turn knob (A) of tester counter-clockwise to off.

4. Connect red clamp of battery tester to positive terminal of battery and black clamp of tester to negative terminal of battery.

5. Install tachometer reflective tape on flywheel screen.

6. Remove spark plug high tension lead and ground to engine.

Procedure:

1. Crank engine and read voltage on DC voltage scale of battery tester and check engine rpm.

2. Turn key switch to off position.

IMPORTANT: Perform the following procedure

within 15 seconds to prevent electrical damage to components.

SEAT SWITCH TEST

Reason:

To ensure proper operation of seat switch.

Equipment:

• Ohmmeter

Procedure:

1. Park machine on level surface and turn key switch OFF.

2. Shift lever in NEUTRAL and park brake LOCKED.

3. Disconnect harness connector from seat switch.

4. Check continuity across switch terminals (A) and (B).

Results:

• There should BE continuity between terminals (A and B) when seat is RELEASED,

• There should NOT BE continuity between terminals (A and B) when plunger is DEPRESSED.

• If continuity is NOT correct, replace switch.

3. Turn knob of battery tester clockwise until the DC voltage is the same as when cranking.

4. Read DC amperage on battery tester.

5. Turn load knob fully counterclockwise.

Specifications:

Maximum starter amp draw

. . . . . . . . . . . . . . . . . . . . . . . . 180 amps at 225 rpm

Results:

• If amperage is above specification, or rpm is low, check starter for binding or damaged.

• If starter is good, check internal engine, traction or PTO drive for binding or damage.

3/5/97 4 - 23

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NOTE: The seat switch connector has an interlock

spring which shorts the 3 wires together when removed from seat switch terminals. Check that spring mechanism is releasing properly when center tab is depressed.

Page 47

ELECTRICAL TESTS AND ADJUSTMENTS

BRAKE SWITCH / BLADE DRIVE SWITCH TEST

Reason:

To make sure the brake pedal switch and blade drive switch operate properly.

Equipment:

• Ohmmeter

Procedure:

1. Park machine on level surface and turn ignition switch OFF.

2. Shift lever in NEUTRAL and park brake LOCKED.

3. Blade drive DISENGAGED.

4. Locate switch being tested as follows:

Brake switch is located under right side frame at brake pedal bellcrank.

Blade drive switch is located under left side frame at bottom of blade drive lever actuating arm.

5. Disconnect harness connector from switch being tested.

6. Check continuity as follows using terminals shown above.

• there should BE continuity between terminals (B and C) when plunger is RELEASED,

• there should NOT BE continuity between terminals (B and C) when plunger is DEPRESSED.

• there should NOT BE continuity between terminals (A and D) when plunger is RELEASED,

BRAKE SWITCH ADJUSTMENT

Reason:

To ensure proper that engine starts only when brake fully applied.

Procedure:

1. Depress brake pedal and set park brake.

2. Check condition of both mounting rivets (C). If not tight, damaged, or improperly installed, they could affect adjustment and function of start and safety circuits. If rivets are bad, go to Step 3; if rivets are good, go to Step 4.

3. Disconnect harness connector and remove switch assembly to bench vise. Remove rivets, as necessary, using a 4.76 mm (3/16 in.) drill bit and replace with 4.75 x 14.61 mm (0.187 x 0.575 in.) aluminum pop rivets (M67899). Loosely install switch and solidly connect harness connector.

4. Loosen switch bracket hardware (B).

5. Move switch until plunger (A) is about 3 mm (1/8 in.) from bottoming.

6. Check that switch does not bottom when brake pedal fully depressed. Increase clearance if needed.

7. Tighten bracket hardware.

8. Check switch operation.

• Engine should NOT turn over or start when brake pedal is not depressed.

• Engine should turn over and start when brake pedal is fully depressed.

• If operation is not correct, test switch.

• there should BE continuity between terminals (A

and D) when plunger is DEPRESSED.

Results:

• If continuity is NOT correct, replace switch.

4 - 24 3/5/97

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Page 48

TESTS AND ADJUSTMENTS ELECTRICAL

IGNITION SWITCH TEST

Reason:

To verify ignition switch functions are operating properly.

Equipment:

• Ohmmeter or Continuity Tester

Procedure:

1. Park machine on level surface and turn ignition switch OFF.

2. Shift lever in NEUTRAL and park brake LOCKED.

3. Remove ignition switch cover (see Repair Section page 27 for Ignition Switch Removal & Installation)

4. Disconnect ignition switch connector.

NOTE: Ignition switch terminals are identified to

coincide with electrical schematic designations.

5. Use an ohmmeter to test ignition switch continuity in OFF, RUN, and START positions.

Ignition Switch Continuity

Switch Position Terminal Continuity

OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (G and M)

RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A and B)

START . . . . . . . . . . . . . . . . . . . . . . . (A and B and ST)

Results:

• If any continuity is NOT correct, replace ignition switch.

3/5/97 4 - 25

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Page 49

ELECTRICAL TESTS AND ADJUSTMENTS

GROUND CIRCUIT TESTS

Reason:

To check for opens, loose terminal wire crimps, poor connections, or corrosion in the ground circuit. The voltmeter method checks ground connections under load.

Equipment:

• Ohmmeter or voltmeter

GROUND

Chassis Ground

points. If a problem is indicated, disconnect the wiring harness connector to isolate the wire or component and check resistance again. Maximum allowable resistance in the circuit is 0.1 ohms. Check both sides of connectors closely as disconnecting and connecting may temporarily solve problem.

VOLTMETER METHOD:

1. Put transmission in neutral. Engage park brake. Put blade drive switch in disengaged position. Turn ignition switch to on position.

2. Connect voltmeter negative (black) lead to negative terminal of battery.

3. Put meter positive (red) lead on ground terminal of component to be tested. Be sure the component circuit is activated (key on, switches closed) so voltage will be present at the component. Record voltage. Voltage must be greater than 0 but less than 1 volt. Some components will have a very small voltage reading on the ground side and still be operating correctly.

Results:

• If resistance is above 0.1 ohms, check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit.

• If voltage is 0, the component is open.

• If voltage is greater than 1 volt, the ground circuit is

bad. Check for open wiring, loose terminal wire crimps, poor connections, or corrosion in the ground circuit.

GROUND

Engine Ground

Procedure:

OHMMETER METHOD:

1. Turn ignition switch to off position. Engage park brake.

2. Connect ohmmeter negative (black) lead to negative terminal of battery. Put meter positive (red) lead on negative terminal of battery and record reading.

3. Put meter red lead on ground terminal of circuit or component to be tested that is closest to the battery negative terminal. Resistance reading must be very close to or the same as the battery negative terminal reading. Work backwards from the battery on the ground side of the problem circuit until the resistance reading increases above

0.1 ohms. The problem is between the last two test

4 - 26 3/5/97

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Page 50

REPAIR ELECTRICAL

REPAIR

IGNITION SWITCH REMOVAL & INSTALLATION

1. Remove rear retaining screws (A) and Bracket (B).

NOTE: Front bracket (F) does not have to be removed.

SEAT SWITCH REMOVAL & INSTALLATION

NOTE: Seat switch connector has an internal spring

which will short cavities of connector together when it is disconnected from seat switch. This prevents operator from defeating seat switch by leaving connector disconnected.

1. Tilt seat forward.

2. Disconnect connector (A).

3. Rotate switch assembly (B) counterclockwise to remove switch from seat pan.

2. Remove ignition switch connector (C).

3. Check and/or replace ignition switch as required.

4. Install new switch and replace cover by inserting lugs (D) into slots (E). Secure from underside of tractor fender with two screws (A) and bracket (B). DO NOT overtighten screws, they are threaded into plastic.

4. Depress tabs (D) of cover and remove.

5. Unsnap switch (C) from housing.

6. Assemble in reverse order of disassembly.

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Page 51

ELECTRICAL REPAIR

STARTER SOLENOID REMOVAL & INSTALLATION

Procedure:

1. Park machine on level surface, park brake ON, engine OFF.

2. Lift seat and remove negative battery cable from battery terminal.

3. Remove positive battery cable from battery terminal.

4. Remove battery hold-down (rubber strap) from frame, and lift battery from tractor.

5. Starter solenoid is located under operator’s seat in front of battery.

710 Purple To Brake Switch

105 Black To Ground

201 Red To Battery

201 Red To Fuse

201 Red To Starter

6. Follow wiring above to remove and replace solenoid from frame.

7. When connecting battery, always connect positive cable to battery terminal first, and negative cable last.

4 - 28 3/5/97

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Page 52

CONTENTS GEAR POWER TRAIN

CONTENTS

Page

GEAR POWER TRAIN

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE PART KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TRANSAXLE COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TRACTION DRIVE SYSTEM COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . . 8

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TRACTION DRIVE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TRANSAXLE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

BRAKE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CLUTCH/BRAKE LINKAGE &TRACTION DRIVE ADJUSTMENT . . . . . . . . . . . . . . 15

SHIFT LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TRACTION DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TRACTION DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

TRACTION DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

TRACTION DRIVE SYSTEM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SHIFT LINKAGE REMOVAL & INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

TRANSAXLE REMOVAL & INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

TRANSAXLE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

INTERMEDIATE SHAFT & DRIVE SHAFT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . 29

TRANSAXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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GEAR POWER TRAIN CONTENTS CONTINUED

5 - 2 3/5/97

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Page 54

SPECIFICATIONS GEAR POWER TRAIN

SPECIFICATIONS

Dimensions:

Overall Axle Width (End-To-End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.4 mm (29 in.)

Overall Case Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432.5 mm (17. in.)

Overall Case Length (Front-To-Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 mm (11 in.)

Overall Height (Top Of Input Shaft-To-Bottom Case) . . . . . . . . . . . . . 183.4 mm (7.2 in.)

Overall Case Height (Top Case-To-Bottom Case). . . . . . . . . . . . . . . . . 154.2 mm (6 in.)

Gear Teeth:

Bevel Pinion Gear (Input Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Drive Shaft:

Bevel Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Drive Sprocket Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Intermediate Shaft:

Drive Sprocket Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1st Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Combination Gear (Idler Shaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 and 35

Differential Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Differential Miter Bevel Gears (Axle Shafts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Differential Miter Bevel Gears (Cross Shaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Drive Belt:

Effective Length

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2660 (104.725 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2631 mm (103.6 in.)

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2710 mm (106 in.)

Top Width

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7 mm (0.500 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 mm (0.43 in.)

Depth

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 mm (0.31 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.)

Lubrication:

Grease Type, (Case). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Purpose EP

Capacity (Grease). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638 gms (1.4 lbs)

Overall Weight (With Grease). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.2 kg (31.3 lbs)

Rear Axle Loading:

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 lbs.

2/12/97 5 - 3

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Page 55

GEAR POWER TRAIN SPECIFICATIONS

Gear Ratios:

1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.67:1

2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.67:1

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.00:1

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.48:1

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.71:1

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00:1

Ground Speeds:

1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20 km/hr (1.37 mph)

2nd Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.91 km/hr (1.81 mph)

3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.54 km/hr (2.82 mph)

4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.79 km/hr (3.60 mph)

5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.66 km/hr (5.38 mph)

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 km/hr (2.11 mph)

TORQUE SPECIFICATIONS

Brake Assembly Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . .20 N•m (15 lb-ft.)

Clutch Bellcrank Mounting Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . 34 N•m (25 lb-ft.)

Detent Ball and Spring Set Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flush Only

Gear Shift Lever Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 N•m (11 lb-ft.)

Hanger Bracket to Frame Cap Screws (Front) . . . . . . . . . . . . . . . . . . .27 N•m (20 lb-ft.)

PTO Clutch to Crankshaft Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . 75 N•m (55 lb-ft)

Front Hanger capscrews to frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 N•m (22 lb-ft.)

Front Transaxle Cap Screws To Hangers . . . . . . . . . . . . . . . . . . . . . . .27 N•m (20 lb-ft.)

ReAr Axle Cap Screws & Nuts To Frame . . . . . . . . . . . . . . . . . . . . . . .30 N•m (22 lb-ft.)

ShIft Linkage Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (11 lb-ft.)

OTHER MATERIALS

Form-In-Place Gasket Silicone Sealant Never-Seez

—PT506 or PT569

SERVICE PART KITS

Brake Friction Puck Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119620

Clutch Keys Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119611

Combination Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119607

Detent Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119619

Differential Miter Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119612

Differential Ring Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119879

Drive Chain and Sprocket Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119613

Drive Shaft Assembly Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119610

Input Shaft Assembly Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119602

Input Shaft Assembly Shim Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119603

Pinion and Gear Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119606

Transaxle Assembly Kit (Complete) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AM121563

Right Hand Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AM122525

Left Hand Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AM122524

Gear Set Assembly Kit 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119614

Gear Set Assembly Kit 2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119615

Gear Set Assembly Kit 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119616

Gear Set Assembly Kit 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM119617

Gear Set Assembly Kit 5th). . . . . . . . . . . . . . . . . .Use Parts Manual For Specific Model

5 - 4 2/12/97

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Page 56

TROUBLESHOOTING GEAR POWER TRAIN

TROUBLESHOOTING

Problem or

Symptom

Check or Solution

Belt jumping off or

slapping

Lack of drive in one

or both directions

Loses power under

load, belt slips, or

erratic drive

Jerky or aggressive

engagement

Cannot get all

forward gears

Cannot get reverse

gear

Jumps out of gear

or must hold into

Shifts hard

Noisy operation

Leaking grease

Brakes will not

stop tractor

Park brake will not

hold

Belt sheaves, idlers, & guides loose, out of adjustment, worn, or damaged

●● ●● ●

Belt worn, frayed, glazed, or stretched—replace belt

Clutch/brake pedal linkage out of adjustment

Clutch/brake components worn, bent, or broken— replace and adjust

Shift lever and linkage bent, worn, out of adjustment, or broken— replace or adjust properly

Input sheave, input shaft, and axle keys or keyways worn or damaged— replace

Internal transaxle components worn, stripped, or broken

Transaxle case halves worn or broken—replace

Incorrect type or volume of lubricant used—replace with correct type and volume

●● ●● ●

●● ●● ●● ●●

●● ●●●●●●● ●●

●●●●

● ●● ● ●●

●● ●●●●●●● ●●

●● ●●●● ● ●●

●● ●●●●●●●●

Intermediate shifter/brake shaft or axle seals worn or damaged—replace seals

Transaxle cap screws loose or case holes stripped

Poor application of sealant on transaxle case halves

Incorrect type sealant— replace with proper sealant

2/12/97 5 - 5

www.servicemanualall.com

● ● ●●●●●●

●

Page 57

GEAR POWER TRAIN COMPONENT LOCATION

COMPONENT LOCATION

1. Flange bearing 45. Spacer

2. Shim 46. Drive chain drive sprocket (9 teeth)

3. Spur gear (14 teeth) 47. Drive shaft bevel gear (42 teeth)

4. Shift collar 48. Shim

5. Shift key (4 used) 49. Drive shaft

6. Shifter Fork 50. Drive shaft 1st gear (12 teeth)

7. Intermediate shifter/brake shaft 51. Drive shaft 2nd gear (15 teeth)

8. Woodruff key 52. Drive shaft 3rd gear (20 teeth)

9. Upper case housing 53. Drive shaft 4th gear (23 teeth)

10. O-ring seal (2 used) 54. Drive shaft 5th gear (28 teeth)

11. Screw (2 used) 55. Spacer

12. Detent ball (2 used) 56. Washer

13. Detent spring (2 used) 57. Flange bearing

14. Set screw (2 used) Flush Only 58. Square-cut rubber ring

15. Shifter shaft rubber boot 59. Left axle shaft

16. Screw (14 used) 60. Washer (0.758x1.25x0.031 in.)

17. Retaining ring 61. Washer (0.758x1.25x0.031 in.)

18. Drive chain large sprocket /reverse gear (18 teeth) 62. Differential bevel gear (15 teeth)

19. Spacer 63. Retaining ring

20. Intermediate shaft 1st gear (37 teeth) 64. Differential ring gear (32 teeth

21. Intermediate shaft 2nd gear (35 teeth) 65. Differential bevel gear (15 teeth)

22. Intermediate shaft 3rd gear (30 teeth) 66. Retaining ring

23. Intermediate shaft 4th gear (27 teeth) 67. Differential bevel gear (15 teeth)

24. Intermediate shaft 5th gear (22 teeth) 68. Shim

25. Spacer w/internal keys 69. Shim

26. Washer 70. Right axle shaft

27. Flange bearing 71. Square-cut rubber ring

28. Square-cut rubber seal (open lip to inside) 72. Differential cross shaft

29. Drive chain (24 pitches) 73. Differential bevel gear (15 teeth)

30. Retaining ring 74. Lower case housing

31. Shim 75. Thin friction puck

32. Needle bearing (2 used) 76. Brake disc

33. Washer (2 used) 77. Thick friction puck

34. Input shaft 78. Friction puck striker plate

35. Bevel pinion gear (14 teeth) 79. Brake housing

36. Woodruff key 80. Brake lever

37. Retaining ring 81. Washer

38. Washer 82. Lever stop bracket

39. Spacer 83. Cap screw (5/16x1.44.)

40. Washer 84. Lock nut (5/16)

41. Idler gear (12 & 35 teeth) 85. Lever Stop bushing

42. Shim 86. Actuator dowel pin (2 used)

43. Idler shaft 87. Washer

44. Flange bearing 88. Cap screw (5/16x2.25)

5 - 6 2/12/97

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Page 58

COMPONENT LOCATION GEAR POWER TRAIN

TRANSAXLE COMPONENT LOCATION

Flush Only

10 N•m

(88 lb-in.)

10 N•m (88 lb-in.)

Shims (42 and 48) are critical when any gears or case halves are being replaced.

Use Form-In-Place Gasket Silicone Sealant to seal housing halves.

2/12/97 5 - 7

www.servicemanualall.com

22 N•m

(190 lb-in.)

22 N•m

(190 lb-in.)

Page 59

GEAR POWER TRAIN COMPONENT LOCATION

TRACTION DRIVE SYSTEM COMPONENT LOCATION

1. Frame weldment—idler adjustment

2. Carriage bolt (M8x45)

3. Clutch bellcrank bracket

4. Bushing

5. Cap screw

6. Clutch assist spring assembly

7. Carriage bolt (M8x45)

8. Clutch cross shaft

9. Park lever

10. Idler

11. Carriage bolt (M8x50)

12. Clutch spring

13. Washer (2 used)

14. Belt guide

15. Flange nut (M8)

16. Crankshaft drive sheave

17. Foot pad

18. Cap screw (M8x35)

19. Bellcrank

20. Drive belt

21. Clutch/brake pedal

22. Flange lock nut (M8)

23. Cotter pin

24. Washer

25. Clutch sheave

26. Park locking rod tension spring

27. Flange nut (M6)

28. Park locking rod

29. Flange nut (M8)

30. Rolled pin (M4x20)

31. Safety wire

32. Washer

33. Brake rod compression spring

34. Brake compression spring strap

35. Flange nut (M8)

36. Adjustable idler

37. Belt guide

38. Flange nut (M8)

39. Cotter pin

40. Belt guide

41. Flange nut (M8)

42. Brake rod

43. Cotter pin

44. Washer

45. Brake lever

46. Brake rod return spring

47. Flange nut (M6)

48. Belt guide

49. Transaxle drive sheave

50. Snap ring

51. Lock nut (M8)

52. Cap screw (M8x30)

53. Special patch lock cap screw

54. Lock washer (1/4 in.)

55. Washer

56. Cap screw (M8x30)

57. Shift knob

58. Shift lever

59. Right shift lever mounting bracket

60. Lock nut (M8)

61. Special square hole washer

62. Shift arm

63. Lock nut (M8)

64. Universal shift link

65. Lock nut (M8)

66. Left shift lever mounting bracket

5 - 8 2/12/97

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Page 60

COMPONENT LOCATION GEAR POWER TRAIN

TRACTION DRIVE SYSTEM COMPONENT LOCATION

28 29

SHIFT LINKAGE SYSTEM COMPONENT LOCATION

4445

2/12/97 5 - 9

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Page 61

GEAR POWER TRAIN THEORY OF OPERATION

THEORY OF OPERATION

TRACTION DRIVE SYSTEM OPERATION

A. Clutch Pedal E. Tensioning Sheave B. Engine Drive Sheave F. Bellcrank Assembly C. Tensioning Spring G. Actuating Spring Assembly D. Clutch Shaft H. Transaxle Drive Sheave

Function:

The belt traction drive transfers power from the engine to the 5-speed transaxle. The clutch pedal controls the belt traction drive, and allows the transaxle to be shifted through it’s five speed range.

With engine running and clutch engaged (clutch pedal (A) released), the engine drive sheave (B) pulls the drive belt and transmits power to the transaxle drive sheave (H). As clutch/brake pedal (A) is depressed by the operator, clutch shaft (D) pulls the clutch actuating spring assembly (G) forward. Initial movement of the pedal compresses the spring in the actuating spring assembly (G) and, once compressed, pivots the bellcrank assembly (F). As the bellcrank assembly pivots, the tensioning sheave (E) moves rearward, releasing drive belt tension. This allows the engine

drive sheave to rotate without transferring any power through the slackened drive belt.

As the bellcrank pivots rearward, belt tensioning spring (C) is stretched, building additional tension in the spring. As the operator begins to ease-up on the clutch/brake pedal (A), tensioning spring (C) pulls the bellcrank tensioning sheave (E) into the drive belt, causing the belt to tighten and seat in the grooves of the transaxle drive sheave (H) and the engine drive sheave (B). This interaction of components results in turning the transaxle drive sheave rapidly in a clockwise direction, transferring power from the engine to the 5-speed transaxle.

5 - 10 2/12/97

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Page 62

THEORY OF OPERATION GEAR POWER TRAIN

TRANSAXLE OPERATION

Function:

The transaxle transmits power from the engine to the drive axles and rear wheels, and provides gear selection of five forward speeds, one reverse, and neutral.

A. Input Pinion Gear B. Intermediate Gears C. Drive Shaft D. Forward Drive Gears E. Cross Shaft Bevel Gears F. Idler Shaft G. Spur Gear H. Shift Fork

Forward Gears:

With engine running and clutch engaged, the transaxle drive sheave, input shaft, and input pinion gear (A), are driven by the engine and traction drive belt.

The input pinion gear (A), which is splined to the input shaft and retained by a snap ring, drives the beveled drive gear (L). The beveled drive gear turns the drive shaft (C), and the five forward drive gears (D).

A forward gear is selected when the operator moves the shift lever. The shift linkage moves the shift fork (H), shift collar (O), and shift keys (I) into one of the five intermediate gears (B). The selected gear is keyed to the intermediate shaft (J). Power is transferred by the intermediate gear (B) on the right side of the intermediate shaft, to the splined spur gear (G) on the left side of the shaft.

The spur gear (G) drives the idler gear (N), splined to the idler shaft (F), which transfers power into the differential ring gear (M). Power is transferred by the

I. Shift Keys J. Intermediate Shaft K. Drive Axles L. Beveled Drive Gear M. Differential Ring Gear N. Idler Gear O. Shift Collar

cross shaft and bevel gears (E) to both drive axles (K) out to the wheels and tires. The keyed drive wheels are retained by an E-Ring.

Reverse Gears:

With engine running and clutch engaged, the transaxle drive sheave, input shaft, and input pinion gear (A), are driven by the engine and traction drive belt.

Power is transferred to the bevel drive gear (L), and drive shaft (C), which drives the small drive chain sprocket (U), the drive chain (T), and the large drive chain sprocket (S) on the intermediate shaft (J).

When the operator shifts into reverse, the shift fork (H), shift collar (O), and shift keys (I) become keyed to the large drive chain sprocket (S). The large drive chain sprocket (S) turns the intermediate shaft (J) and the spur gear (G). The idler shaft (F) and idler gear (N) are driven by the spur gear in reverse, which turn the differential, drive axles, and drive wheels in reverse.

Neutral:

When the operator moves the shift lever into neutral position, the shifter fork (H) places the shift keys (I) under the free-floating spacer (R), allowing no power to be transmitted into the intermediate shaft (D), which also allows neutral to be maintained with clutch pedal released and engine running.

2/12/97 5 - 11

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Page 63

GEAR POWER TRAIN THEORY OF OPERATION

BRAKE SYSTEM OPERATION

A. Clutch/Brake Pedal E. Adjustable Idler Assembly B. Clutch Cross Shaft and Bellcrank F. Transaxle Drive (Input) Sheave C. Clutch Actuating Spring Assembly G. Brake Rod Assembly D. Clutch Bellcrank and Tensioning Idler Assembly H. Clutch Tensioning Spring

Function:

The brake system allows the operator to slow down, stop, or lock the tractor into park position.

There is a small segment of pedal travel (P) that briefly allows the tractor to free-wheel so the operator can shift-on-the-go before the brake starts to engage. This segment can be adjusted to allow more overlap

between clutch and brake functions, if desired.

Theory of Operation:

NOTE: Clutch/brake pedal has approximately 127 mm

(5 in.) of travel, and operates as follows:

Transaxle Brake Assembly

The first movement of the clutch/brake pedal (N) is used for taking-up freeplay in the linkage and the beginning of compressing the clutch actuating spring assembly (C).

The next segment of pedal travel (O) is fully compressing the clutch actuating spring assembly (C), and pulling the clutch bellcrank and idler assembly (D) fully rearward, overcoming the belt tensioning spring (H) and fully disengaging the traction drive system.

As the pedal is released, belt tensioning spring (H) pulls the clutch bellcrank and tensioning idler assembly (D) forward into the belt, tensioning the belt and fully engaging the traction drive system.

5 - 12 2/12/97

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The last segment of travel (Q) fully engages the brake system. The brake lever (S), with the bottom cam surface contour (I), pushes the two dowel pins (J) against the striker plate (K). The striker plate forces the thicker, outer friction puck (L) against the brake disc (H). The two friction pucks (L and M) become compressed against both sides of the brake disc (R). The brake disc is keyed to the end of the intermediate shifter/brake shaft (not shown). When the compression force of the friction pucks is great enough to stop the brake disc rotation, the transaxle and wheels stop turning. This works in conjunction with the clutching system.

With the clutch/brake pedal (A) fully depressed and the traction drive system disengaged (fully clutched), the park brake lever assembly (not shown) can be engaged, locking the clutch/brake pedal linkage and the brake disc in the park position.

Page 64

DIAGNOSIS GEAR POWER TRAIN

DIAGNOSIS

Test Conditions:

• Mower on level surface

• Mower deck removed

• Engine OFF

Test/Check Point Normal If Not Normal

1. Inspect traction drive belt. Belt in good condition, not glazed, split,

2. Inspect engine and transaxle sheaves, idlers and idler bearings, and belt guides.

3. Test drive mower up 17° slope in first, second, third and reverse gears.

4. Shift linkage adjustment. Linkage shifts smoothly, obtains all

5. Inspect exterior of transaxle housing.

• Front wheels blocked

• Rear wheels raised off ground with axle housings on jack stands.

• Park brake ON

unraveled, or stretched. Minimum width 11 mm (0.43 in.).

Sheaves, idlers and guides in good condition.

Guides installed, properly adjusted and tight.

Mower pulls up slope with no clutch slippage (traction drive belt adjusted properly).

gears & neutral (See shift linkage adjustment section for test)

No cracks, leaks, or loose hardware. Repair or replace as necessary. If

Replace traction drive belt See Repair section for removal/ installation instructions

Replace any loose, worn, or damaged components. (See Repair section for removal/ installation instructions)

Adjust traction drive belt rear idler (See clutch actuating spring adjustment)

Adjust linkage. (See shift linkage adjustment section for procedure)

case seal is leaking, reseal case

6. Perform brake test (See tests and adjustments)

7. Inspect brake pads & disk Pads and disks not worn beyond

8. Inspect brake linkage Brake spring adjustment is 7.5-8 mm

9. Inspect rear tires Tire pressures are equal Adjust air pressure.

10. Inspect rear wheels Wheels not bent or out of round. Replace wheels.

11. Remove rear wheels and inspect axles.

Test Conditions:

• Mower on level surface

• Front wheels blocked

• Park brake OFF

1. Depress clutch pedal and shift into all 5 speeds and reverse

Mower holds on 17° slope, and stops in

0.9-1.5 M (3-5 ft) or less.

specifications. Disc not rubbing on transaxle case.

(0.30-0.32 in.)(See tests & adjustments section)

Tire outside diameters are equal Match tires for same size.

Keys, keyways and E-rings in good shape and seated correctly.

• Rear wheels raised off ground with axle housings on jack stands.

• Operator on seat, engine running at operating temperature.

Rear wheels remain still with no axle rotation (Clutch pedal down)

Go to step 7 and 8

Replace pad & disk as needed. If disk is rubbing case, rebuild transaxle

Adjust brakes (See tests & adjustments section)

Repair or replace as needed.

Adjust clutch actuating spring.

2. Shift transaxle through gears, using clutch to shift

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Shifts smoothly, and obtains all forward and reverse gears (both rear wheels are being driven)

Adjust shift linkage If still no drive, check transaxle drive sheave shaft key, or remove transaxle for internal inspection.

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TESTS AND ADJUSTMENTS GEAR POWER TRAIN

TESTS AND ADJUSTMENTS

CLUTCH/BRAKE LINKAGE &TRACTION DRIVE ADJUSTMENT

Reason:

To ensure clutch/brake pedal linkage and traction drive system maintains traction in all three lower gears up a 17° slope. Also, to ensure it disengages traction drive belt, engages brake to slow down or stop tractor within a specified distance, and holds tractor stationary in PARK position on a 17° slope or less.

Procedure:

NOTE: This is a four part test and adjustment

procedure:

1. Test drive on 17° slope,

2. Brake spring adjustment,

3. Clutch spring adjustment,

4. Repeat test drive on 17° slope.

TRACTION BELT DRIVE TEST

DO NOT engage clutch/brake pedal too aggressively or tractor may tip over backwards. It is recommended that you install the mower deck before performing the test drive on a 17° slope.

CAUTION

2. Look for a steady pull in all three lower gears up the slope.

3. If traction test fails in any or all of the three lower gears, the belt tension must be adjusted.

17°

BRAKE TEST

1. Drive or push tractor onto a 17° slope and lock clutch/brake pedal in PARK position.

2. Park brake must hold tractor stationary on slope and tractor must not roll downward once park brake is set.

3. Drive tractor on dry pavement in a safe, open, and level area at fast idle in high gear. Apply a “panic stop” force (no more than 50 pounds of force) to brake pedal—tractor must stop within 0.9—1.5 M (3—5 ft) and both wheels should lock-up, leaving skid marks on pavement.

4. Repeat Steps 4—6 for reverse.

5. If any test fails, the clutch and brake linkages must be adjusted or components replaced.

IMPORTANT: Anytime the brake or clutch spring

need to be adjusted, both must be examined to ensure desired results will be obtained.

17°

1. T est drive tractor to see if traction drive system pulls tractor up a 17° slope in all three lower gears.

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NOTE: These adjustment procedures can be

performed with tractor on the floor; however, you may want to safely raise the tractor for easier access. If you do, remove the battery to avoid spilling any electrolyte solution.

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GEAR POWER TRAIN TESTS AND ADJUSTMENTS

BRAKE SPRING ADJUSTMENT—

4. Measure distance between end of compression spring bracket (C) and front edge of brake rod stop tabs (D).

• If distance is less than 2 mm (0.08 in.)—

Contact Points

1. First check for brake disc contacting the case (1) and/or brake lever contacting its mounting bracket (2), top or bottom. If so, replace friction pucks and disc before making any adjustments.

5. Tighten lock nut (E) until distance between end of compression spring bracket (C) and front edge of brake rod stop tabs (D) is 7.5—8 mm (0.30—0.32

in.)

6. Once above measurement is obtained, cycle clutch/ brake pedal.

7. Remeasure distance, it should be the same. This brake setting should hold the tractor stationary on a 17° slope.

If distance is greater than 8 mm (0.32 in.)—

8. With park brake set, gradually loosen lock nut (E) until distance of 7.5—8 mm (0.30—0.32 in.) is obtained.

9. Cycle park brake and measure distance again (see Step 7).

10. If tractor fails either brake test, inspect brake assembly components, replace as necessary, and repeat all adjustment procedures and drive tests.

2. Remove the mower deck.

3. Depress clutch/brake pedal (A) and lock park brake lever (B) into PARK position from operator’s station.

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CLUTCH ACTUATING SPRING ADJUSTMENT

IMPORTANT: Anytime the brake or clutch spring

need to be adjusted, both must be examined to ensure desired results will be obtained.

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TESTS AND ADJUSTMENTS GEAR POWER TRAIN

• shortening the clutch spring causes decreased drive traction and aggressiveness.

SHIFT LINKAGE ADJUSTMENT

1. Unlock park brake and release pedal (A).

2. Measure clutch actuating spring length (B). Measurement should be 42—45 mm (1.65—

1.77in.). Clutch actuating spring length is adjusted by sliding rear idler sheave (C) on it’s slotted mounting bracket, as follows:

3. Depress brake/clutch pedal (A) and lock park brake.

4. Remove belt guide (D) to access idler sheave mounting nut (E). Loosen mounting nut and adjust idler as follows:

• If spring length is less than 42 mm (1.65 in.), slide idler rearward.

• If spring length is greater than 45 mm (1.77 in.), slide idler forward.

5. Tighten idler nut (E).

6. Cycle pedal in and out two or three times measuring clutch spring length each time. Measurement must fall within 42—45 mm (1.65—1.77 in.) each time. If not, continue to adjust rear idler slightly until it does.

7. Install belt guide (D). This clutch spring setting should provide proper belt tension to pull tractor up a 17° slope in all three lower gears.

8. Install battery, if removed.

Reason:

To ensure shift lever obtains all shift positions and that neutral position does not allow transaxle to rotate.

Conditions:

• Remove deck

• Safely raise rear wheels 51 mm (2 in.) off ground

and block front wheels (front and rear).

• Shift lever in neutral.

• Park brake off.

Procedure:

1. Check that shift linkage hardware (A and B) is in good condition and tight.

2. Start and run engine at fast idle.

3. Check that transaxle does not rotate while shift lever (D) is in neutral position (C), and clutch/brake pedal released.

REPEAT TEST DRIVE

1. Repeat test drive in at beginning of this section.

2. If tractor fails either brake test, inspect brake assembly components, replace as necessary, and repeat all adjustment procedures and drive tests.

3. If belt is not excessively worn, make small adjustments to idler sheave to obtain proper response in traction drive system as follows:

• lengthening the clutch spring causes increased drive traction and aggressiveness

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4. If transaxle rotates, move shift lever (D) slightly until transaxle shift lever clicks firmly into it’s neutral detent. (This may occur while shift lever (D) is in the reverse or first gear range of shift gate).

5. Stop engine.

6. Raise seat and loosen left side lock nut (E) holding shift linkage bracket to frame. (Left wheel removed for clarity purposes only). Slide shift linkage bracket (F) forward or rearward in slots (G) until shift lever is centered in neutral shift gate. Tighten lock nut (E).

Results:

• Test drive tractor to ensure all forward and reverse gears are obtained and that tractor does not move when shifter is in neutral position.

• If adjustments are not satisfactory, repeat procedure until proper results are obtained.

• If adjustments are still not satisfactory, internal transaxle repair is needed.

REPAIR

TRACTION DRIVE BELT REMOVAL

NOTE: If drive belt is in good condition, it does not

need to be removed when removing transaxle. Engage park brake and remove belt from transaxle drive sheave.

1. Park mower on level surface.

2. Remove mower deck.

3. Safely raise and block tractor to gain easy access to underside of frame.

NOTE: If mower is to be raised at an angle, remove

battery from frame before jacking.

7. If left side bracket adjustment (Step 6) does not allow enough shift lever movement to center shift lever in neutral gate, loosen three mounting brackets (I) holding shift quadrant (H) to fender.

8. Adjust quadrant forward or rearward until shift lever is centered in the neutral gate.

9. Tighten mounting brackets (I). Restart engine and move shift lever through all gears (using clutch to shift). Re-check for axle rotation in neutral (steps 2 through 4 this section).

10. Lower tractor to surface and remove blocks.

Steering Arm

Steering Link

Spindle Shaft

4. Remove cotter key and washer holding steering link to right front spindle shaft.

5. Rotate steering link to align tabs on link with slots in steering arm. Remove link from arm.

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12. Remove belt from transaxle drive sheave, and pull through transaxle belt guide.

6. Depress and lock brake pedal (A) with park brake lever.

7. Remove front idler belt guide and sheave (B).

8. Remove clutch bellcrank belt guide (C).

9. Remove adjustable idler belt guide (D).

10. Remove park lever (E).

Mower drive lever return spring is under tension and located inside frame. Use pliers or spring puller tool to remove spring. Protect your eyes and face from the possibility of spring being released at high speed.

11. Remove mower drive lever return spring (F)

CAUTION

13. Pull belt from around engine drive sheave (G), and past front belt guide (H). Pull belt under belt guide and around steering arm (I).

14. Rotate mower drive lever to allow belt to pass between lever (J) and switch (K).

15. Remove belt from clutch bellcrank and idler sheave, and remove belt from mower.

TRACTION DRIVE BELT INSPECTION

1. Examine belt to determine if it is worn, stretched, cracked, frayed, or damaged beyond the point of continued use.

2. Measure and compare removed belt to the following:

New Belt Dimensions:

Length. . . . . . . . . . . . . . . 2660±8 mm (104.7±0.3 in.)

Minimum length . . . . . . . . . . . 2631 mm (103.6 in.)

Maximum length. . . . . . . . . . . 2710 mm (106.7 in.)

Top width . . . . . . . . . . . . . . . . . . 12.7 mm (0.500 in.)

Minimum top width . . . . . . . . . . . 11 mm (0.43 in.)

Depth . . . . . . . . . . . . . . . . . . . . . 7.874 mm (0.31 in.)

Minimum depth. . . . . . . . . . . . . . . . 7 mm (0.28 in.)

3. Replace belt if any of above dimensions are not found.

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TRACTION DRIVE BELT INSTALLATION

1. Install end of drive belt under belt guide (H), and pull belt up between guide (H) and sheave (G). Pull belt over large sheave (G) and down into small sheave.

2. Route belt between mower drive lever (J) and switch (K), and around steering arm (I).

5. Install drive belt through rear belt guide (A) and over transaxle drive sheave (B).

6. Install belt guides on clutch sheave and adjustable idler.

7. Install park brake lever and mower drive lever return spring.

8. Release park brake and check that belt is seated in grooves of all sheaves and idlers.

9. Perform Clutch/Brake Pedal Linkage Adjustments, shown earlier in this section.

TRACTION DRIVE SYSTEM REMOVAL

1. Remove mower deck.

2. Block mower wheels securely at front and rear.

3. Engage park brake.

4. Remove traction drive belt from transaxle sheave.

5. Disengage park brake.

3. Route drive belt over the top of clutch cross shaft (A) and park brake locking rod (B).

4. Route through clutch sheave (C) and adjustable idler (D) as shown

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Clutch tension spring is capable of causing extreme injury if allowed to be released quickly from mower frame. Protect your face, eyes and hands before releasing spring.

6. Thread one end of a three foot long piece of starter rope under the front hook of clutch tension spring (C). Pull rope half way through spring until ends meet, and wrap ends around a bar several times to make a temporary handle. Pull handle until spring hook is free from frame, and release tension from spring. Tension is now off traction drive system and it may be worked on safely.

7. Remove clutch actuating spring (D) from clutch bellcrank (E) and cross shaft (F).

CAUTION

8. Remove clutch/brake pedal by removing mounting nut (G) and pulling pedal through frame.

9. Remove brake bracket from bellcrank by removing cotter key and washer (H).

10. Remove bellcrank from clutch shaft by removing safety wire (I) securing roll pin, then driving out roll pin (J) and removing bellcrank.

11. Remove two bolts and nuts through retainer plate holding left end of clutch shaft, and remove shaft from frame.

12. Remove nut (K) holding parking brake lock lever to parking brake locking rod.

13. Remove spring from frame to parking brake locking rod and slide rod out of frame.

14. Bellcrank assembly is held to frame with one bolt and bushing.

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SHIFT LINKAGE REMOVAL & INSTALLATION

1. Remove battery.

2. Block rear of tractor off ground. Remove left drive wheel.

3. Remove shift knob (G).

4. Remove lock nuts (M and O) to remove shift link (N).

5. Remove lock nuts (A and I) and cap screws (B and F).

6. Adjust mounting brackets (J and P) so shift rod (H) can be removed from the left side of the frame. You will have to “snake” the shift rod from the tractor.

7. Remove cap screw (C) to remove shift lever (L) and washers (D, E, and K).

8. Replace necessary components.

9. Install shift linkage in reverse order of removal.

10. Tighten shift lever cap screw and lock nuts to specifications shown.

15 N•m (11 lb-ft.)

16 N•m (12 lb-ft.)

15 N•m (11 lb-ft.)

A–Lock Nut G–Shifter Knob M–Lock Nut B–Cap Screw H–Shift Rod N–Shift Link C–Shift Lever Cap Screw I–Lock Nut O–Lock Nut D–Lock Washer J–Right-Hand Bracket P–Left-Hand Bracket E–Washer K–Special Square-Hole Washer F–Cap Screw L–Shift Lever

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TRANSAXLE REMOVAL & INSTALLATION

1. Raise mower off ground and support with jackstands under frame and not transaxle case.

2. Remove rear wheels.

3. Disconnect shift linkage (B) from shift arm (C).

4. Remove traction drive belt (A).

Hint: Lock park brake to loosen belt. Release park brake after removal.

7. Support transaxle with jack stands or have a helper hold transaxle in place while you remove hardware.

8. Remove front cap screws (F) and rear hardware (G).

9. Carefully remove transaxle to workbench.

10. Install transaxle in reverse order of removal.

11. Tighten mounting hardware to the following specifications:

Front Hanger capscrews

to frame. . . . . . . . . . . . . . . . . . . . 30 N•m (22 lb-ft.)

Front transaxle cap screws

to hangers. . . . . . . . . . . . . . . . . . 27 N•m (20 lb-ft.)

Rear axle cap screws

& nuts to frame. . . . . . . . . . . . . . 30 N•m (22 lb-ft.)

Shift linkage lock nut. . . . . . . . . . . 15 N•m (11 lb-ft.)

12. Install traction drive belt (A).

13. Install drive wheels.

14. Lower tractor to ground.

TRANSAXLE DISASSEMBLY

IMPORTANT: Maintain absolute cleanliness when

working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly.

5. Disconnect clutch/brake rod return spring (D).

6. Remove cotter pin (H) and disconnect clutch/brake rod (E) from brake lever (I).

IMPORTANT: Pay close attention to the order and

orientation of all components inside the transaxle. Ta g and label parts, if necessary. This will aid assembly and prevent transaxle damage

Remove Drive Sheave/Shift Arm:

1. Remove drive sheave snap ring (C).

2. Remove drive sheave (B).

3. Remove shift arm lock nut (D), lock washer, and flat washer.

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4. Remove shift arm (A), and square-hole flat washer from transaxle shifter shaft

Remove Shifter Detent Assembly:

1. Remove shifter shaft rubber boot (E).

2. Remove both set screws (H) and detent springs (G).

IMPORTANT: DO NOT drop or lose detent balls.

3. Use a magnet or place a shop cloth over holes and turn transaxle upside-down to catch both detent balls (F) in cloth.

4. Inspect detent balls and springs for wear or damage. Replace components as necessary. Do not install springs or detent balls until final assembly.

Remove Brake Assembly:

1. Remove brake assembly by removing two outer capscrews (D) holding caliper to transaxle.

2. It is recommended that inside (thin) brake pad (A), and outside (thick) brake pad (C), and brake disc (B), all be replaced when transaxle is disassembled.

3. Inspect remaining components for wear or damage. Replace components as necessary, but do not install this assembly until transaxle has been completely assembled.

Separate Transaxle Housing Case Halves:

IMPORTANT: Maintain absolute cleanliness when

working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly.

Contact Points

IMPORTANT: Before removal, inspect brake

components for wear. Check that brake disc is not contacting transaxle case (1), brake lever is not contacting its mounting bracket (2) (top or bottom). If so, all worn components must be replaced.

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Input Shaft & Pinion Gear Inspection:

1. Remove brake assembly (A) (see previous procedure). Remove sixteen transaxle housing socket head screws (B).

Upper Case

Lower Case

Half

1. Visually check overall condition of assembly, including the key and keyway, and the drive sheave hub keyway.

2. Check condition of pinion gear (D) - look for wear, pitting, broken teeth, etc.

3. Grasp the input shaft and try to rock it left or right inside case housing. If movement is noticeable, replace needle bearing (B and C).

4. Use a feeler gauge to measure clearance between pinion gear (D) and snap ring (E):

Clearance . . . . . . . . . . .0.127 mm (0.005 in.) or less.

5. If clearance is excessive, shim thickness (A) needs to be changed or worn components must be replaced.

2. Carefully separate transaxle housing case. Remove upper case from lower case assembly.

3. Inspect overall condition of transaxle without removing any components. Visually target worn or damaged parts for replacement.

4. Remove most of the grease without removing any components.

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Input Shaft/Pinion Gear Disassembly:

1. Remove snap ring (E), bevel pinion gear (D), small washer (F), and large washer (G) from input shaft (K) inside upper case half.

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GEAR POWER TRAIN REPAIR

Bearing Inside

Diameter . . . . . 15.89–15.92 mm (0.625–0.627 in.)

6. Replace both bearings by carefully pressing them

from case bore without damaging bore.

7. Pack area between bearing with Multi-Purpose EP Grease.

8. Clean and inspect bore. If scratched or deformed, replace upper case half.

2. Turn upper case half so input shaft is facing up.

3. Remove woodruff key (J), E-ring (I), shim washer (H), and input shaft (K).

Assemble Input Shaft/Pinion Gear Assembly:

A G

IMPORTANT: DO NOT scratch or deform upper

case half bore when installing needle bearings.

IMPORTANT: DO NOT scratch or deform upper

case half bore when removing needle bearings.

4. Visually inspect condition of needle bearings, upper bearing (J) and lower bearing (K). If needles are discolored, spalled, scratched, missing, broken, etc. replace bearings.

5. Measure inside diameters of each bearing:

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1. Pack needle bearings (A and B) with Multi-Purpose EP Grease before installing.

2. Install lower needle bearing (B) with flat side of bearing (with lettering) toward inside of case. Press lower needle bearing in case bore with a maximum recess of 0.76 mm (0.030 in.) (H) from case surface.

3. Install upper needle bearing (A) with flat side of bearing (with lettering) toward outside of case. Press lower needle bearing flush with surface of case bore. A maximum recess of 0.76 mm (0.030 in.) from case surface is also acceptable.

4. Pack cavities (G and H) with Multi-Purpose EP grease before installing input shaft.

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Shifter Disassembly:

5. Install input shaft (E) (with keyway on outside of case), large washer (I), small washer (J), bevel pinion gear (K), and snap ring (L).

1. Lift shifter shaft (B) from lower case half mounting hole (C) and groove of shift collar (D).

6. Turn upper case half over.

7. Install a shim washer (C) (from Shim Kit) of the proper thickness that allows enough clearance for E-ring (D) to be installed.

8. Turn upper case half over and measure air gap between snap ring (L) and bevel pinion gear (K):

Clearance . . . . . . . . . . .0.127 mm (0.005 in.) or less.

9. If clearance is excessive, shim thickness (C) needs to be changed.

10. Install woodruff key (F) in shaft keyway.

2. Clean shifter assembly and inspect condition of detent holes (A), shift pins (E), shaft (B), lower case mounting hole (C), and shift collar (D).

3. Replace any worn or damaged parts of shifter assembly , rubber boot, detent balls, detent springs, or set screws.

4. If lower case mounting hole (C) is worn or damaged, replace the case half.

5. If shift collar (D) is worn or damaged, replace it when intermediate shaft assembly is disassembled.

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Idler Gear Inspection:

1. Visually check overall condition of assembly, including shaft and bushings, gears for wear, pitting, broken teeth, etc.

2. Use a feeler gauge to measure clearance (A) between end surface of combination gear and side surface of case half:

Clearance . . . . . . 0.33—0.63 mm (0.013 —0.025 in.),

3. If clearance is excessive worn and/or damaged components need to be replaced.

3. Separate and inspect idler components:

• Washers (B and D) should be 0.632 x 1.00 x 0.026 in., not scored nor discolored (burnt).

• Spacer (C) should be 0.630 x 1.00 x 0.169 in., not scored nor discolored (burnt).

• Narrow combination gear (E) should have 35 good teeth and wide combination gear (F) should have 12 good teeth, not scored nor discolored (burnt).

• Idler shaft (G) should be smooth and not scored, pitted, nor discolored (burnt).

• Shim washer(s) (H) should be 0.632x1.00 and range in thickness from 0.010 to 0.082 in.

G H

Idler Gear Disassembly:

1. Lift idler gear assembly (A) from lower case half.

2. Clean components and disassemble.

• Inside bearing (I) and outside bearing (K), (which

are press fit), should not be scored nor discolored (burnt);

NOTE: Replacement gear and needle bearings and a

new shaft are also recommended whenever new gear is ordered.

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4. Inspect lower and upper case halves idler shaft bearing surfaces (L) for excessive scoring or wear. Replace case halves as necessary.

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INTERMEDIATE SHAFT & DRIVE SHAFT REPAIR

Exploded View

B D

Intermediate & Drive Shaft Inspection:

1. Inspect overall condition of intermediate shaft and drive shaft assemblies, including gears for wear, pitting, broken teeth, etc.

2. For the drive shaft assembly (I), use a feeler gauge to measure clearance (G) between side surface of small gear (F) and side surface of shim washer (H):

3. For the intermediate shaft assembly (E), use a feeler gauge to measure clearance (C) between end surface of flange bearing (D) and washer (B):

Clearance (G) . . . . . . . . . . . . . . . . . . . . . 0—0.20 mm

(0—0.008 in.)

Clearance (C) . . . . . . . . . . . . . . . . . . . . . 0—0.25 mm

(0—0.010 in.)

4. If either or both clearance measurements are in excess of specifications shim washers (A) or (H) need to be added or worn components need to be replaced.

Intermediate & Drive Shaft Disassembly:

1. Lift both drive (I) and intermediate (E) shaft assemblies from transaxle case together.

2. Carefully remove drive shaft assembly components (bottom row of exploded view) from drive shaft (I). Be sure to remember each components orientation to its neighbor and to the drive shaft. Mark the same side of each component to aid reassembly.

3. Clean components individually once disassembled.

4. Inspect each component closely for wear, scoring, cracks, chips, and broken teeth or splines.

5. Repeat steps 2 through 4 for the intermediate shaft (E) and its components (top two rows of exploded view).

6. Replace components as necessary.

IMPORTANT: Remember gear sets are a matched

set and both must be replaced, even if only one gear in the set is damaged.

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Differential/Axle Shaft Inspection:

Left-Hand Short Axle

Right-Hand Long Axle

1. Visually check overall condition of assembly.

2. Use a feeler gauge to measure clearance (A) between side surface of shim washer and side surface of lower case:

Clearance . . . . . . 0.18—0.38 mm (0.007—0.015 in.),

3. If clearance is excessive, worn or damaged components must be replaced.

2. Carefully remove axle shaft assembly components from ring gear (G). Be sure to remember each components orientation to its neighbor and to the ring gear (G). Mark the same side of each component to aid reassembly.

3. Clean components individually once disassembled, be sure to remove all sealant material from upper and lower case halves.

4. Inspect each component (especially both upper and lower case halves) closely for wear, scoring, cracks, chips, or discoloration (burnt). Replace components as necessary.

5. Replace seals (I and F) every time transaxle housing has been separated.

TRANSAXLE ASSEMBLY

IMPORTANT: Maintain absolute cleanliness when

working on transaxle. The close tolerances in this unit will not tolerate ANY dirt. Use only clean fresh multipurpose EP grease during assembly.

IMPORTANT: Coat all mating surfaces, except seal

surfaces, with SAE 30 weight oil before assembly. Pay close attention to proper order and orientation of all components. Use a calliper to identify the correct shim, spacer, or washers are installed correctly.

Differential/Axle Shaft Assembly:

Differential/Axle Shafts Disassembly:

1. Put inward pressure on both axles (D and E) as you lift differential assembly (F) from lower case.

1. Assemble left-hand, short axle (A) as shown with splined, beveled gear facing the ring gear.

2. Assemble right-hand, long axle (D) as shown with splined, beveled gear facing the ring gear and shim washers (B) assembled in combination of thicknesses to obtain specified air gap (see Inspect Differential/Axle Shafts Assembly).

3. Assemble internal shaft (C) as shown with beveled gears facing each other.

4. Install internal shaft assembly in slots of ring gear and push beveled gears away from each other so they are ready to mesh with both axle beveled gears.

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5. Install axle shafts so beveled gears (E) mesh with differential internal shaft beveled gears.

6. Keep inward pressure on both axles as you install differential assembly in lower case housing.

7. Measure air gap between shim washers (F) and side of housing (H). If air gap meets specification (see Inspect Differential/Axle Shafts Assembly), go to next step. If air gap does not meet specification, remove right axle shaft and add other shim washer combinations until air gap in within specification.

8. Carefully install new axle shaft seals (G and I) and seat them in their lower case housing grooves.

Assemble Drive/Intermediate Shaft Assemblies:

4. Install remaining intermediate shaft components in their proper order and orientation (reference top two rows of components in exploded view at the beginning of this section).

1. Install retaining ring (C) in intermediate shaft groove.

2. Install four keys in grooves of intermediate shaft and hold them so internal shift collar anchors (A) will seat in internal groove of collar (B) as it is installed on the shaft.

3. Slide shift collar and keys against retaining ring (C) and compress locking ramps/lugs (D) to clear retaining ring.

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5. Install drive shaft components one at a time from left-to-right (reference bottom row of components in photo M42335 at the bottom of this page). Long flange of small sprocket (J) faces bevel drive gear.

6. Shim washer(s) (E) for intermediate shaft (F) are found in Shim Kit.

7. Shim washer(s) (H) for drive shaft (I) are found in Shim Kit.

8. Install new intermediate shaft seal (G) with open lip facing inside.

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GEAR POWER TRAIN REPAIR

• Washers (A and C) should be 0.632 x 1.00 x 0.026 in.,

• Spacer (B) should be 0.630 x 1.00 x 0.169 in.,

• Narrow combination gear (D) should have 35 good

teeth and wide combination gear (E) should have 12 good teeth,

• Idler shaft (F) should be smooth, not scored, worn, or pitted,

• Shim washer(s) (G) are found in Shim Kit.

9. Measure air gaps (K and N)—(see Inspect Drive/ Intermediate Shaft Assemblies). Make any changes in shim washer (M) thicknesses from Shim Kit and shim washer (J) thicknesses from Shim Kit to obtain proper air gaps.

10. When proper air gap is obtained, gears should drag slightly against feeler gauge.

2. Install idler combination gear assembly (H) into lower case half.

3. Measure air gap (J) between shim washer (I) and face of case (K) (see Inspect Idler Combination Gear Assembly).

4. When proper air gap is obtained, assembly should drag slightly against feeler gauge.

Assembly Transaxle Housing Case Halves:

11. Apply Never-Seez® to top surface (O) of shifter plate and contact portions of shifter shaft (P) and (Q) with upper and lower case halves.

12. Install shifter fork assembly.

Assemble Idler Combination Gear Assembly:

1. Install components on idler shaft in order shown:

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F G

Lower Case

Half

Upper Case

Half

Page 84

REPAIR GEAR POWER TRAIN

1. Pack upper case beveled pinion gear and lower case housing assembly with 638 g (1.406 lbs) of Multi-Purpose EP grease.

2. Apply Form-In-Place Gasket Silicone Sealant to lower case.

3. BE SURE sealant DOES NOT contact any gear, shaft, or bearing surfaces.

4. Align lower and upper case halves together, be sure shaft seals are seated correctly and you may

have to turn input shaft (D) slightly to insure beveled pinon gear meshes with beveled drive gear.

5. Install 14 outside socket head screws (A) and two center socket head screws (B) with new rubber seals (C).

6. Tighten screws to 10 N•m (88 lb-in.).

Install Shifter Detent Assembly:

Install Brake Assembly:

E F

1. Install woodruff key (D) into shaft keyway (A).

2. Install thinner friction puck (B) in lower case puck recess (S).

3. Install brake disc (C) with hub outward.

4. Install spacer (O) over left lip (P) of mounting bracket.

5. Install long cap screw (M) and washer (N) in left mounting bracket hole.

6. Install brake lever (H), washer (I), bent bracket (J), and lock nut (L) on mounting bracket center stud.

7. Install short cap screw (K) in right mounting bracket hole (G).

8. Install dowel pins (F) inside two center mounting bracket holes (Q).

9. Install striker plate (R) and thick friction puck (E) in backside recess of mounting bracket.

IMPORTANT: DO NOT drop or lose detent balls.

1. Install shifter shaft rubber boot (B).

2. Coat detent balls (C) and springs (D) with Never-Seez and install in case bores.

3. Install and tighten set screws (A) until they are flush with top of mounting hole surface.

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Page 85

GEAR POWER TRAIN REPAIR

1. Install complete brake assembly to transaxle.

2. Tighten cap screws (K and M) to 20 N•m (160 lb-in.).

3. Tighten lock nut (L) to specification until there is a 10 mm (0.39 in.) clearance between thick friction puck and brake disc.

Install Drive Sheave and Shift Arm:

1. Install woodruff key (C) in input shaft (E).

2. Install drive sheave (D) and fasten with snap ring (F).

3. Install shift arm (A). Tighten cap screw (B) to 16 N•m (140 lb-in.).

NOTE: Be sure when installing that special square

hole washer and shift arm are seated properly over square end of shifter shaft.

Install Transaxle:

See “TRANSAXLE REMOVAL & INSTALLATION” on page 23.

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Page 86

CONTENTS CONTINUED HYDROSTATIC POWER TRAIN

Page

HYDROSTATIC POWER TRAIN

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

REPAIR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

OTHER MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMPONENT LOCATION—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMPONENT LOCATION—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

COMPONENT LOCATION—K51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

COMPONENT LOCATION—K51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TRACTION DRIVE SYSTEM COMPONENT LOCATION. . . . . . . . . . . . . . . . . . . . . 10

PEDAL LINKAGE ASSEMBLY COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . 11

SHIFT LINKAGE COMPONENT LOCATION—K–55 TRANSAXLE . . . . . . . . . . . . . 12

SHIFT LINKAGE COMPONENT LOCATION—K–51 TRANSAXLE . . . . . . . . . . . . . 13

THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TRACTION DRIVE BELT SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION. . . . . . . . . . . . . . . . . . 14

BRAKE/NEUTRAL RETURN PEDAL COMPONENT LOCATION & OPERATION. . 16

TRANSPORT (FREE-WHEEL) SYSTEM OPERATION—K55 . . . . . . . . . . . . . . . . . 19

TRANSPORT (FREE-WHEEL) SYSTEM OPERATION—K51 . . . . . . . . . . . . . . . . . 20

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSIS—K55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIAGNOSIS —K51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TESTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

TRACTION DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DRIVE BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TRANSPORT (FREE-WHEEL) VALVE ADJUSTMENT—K55 . . . . . . . . . . . . . . . . . 31

SHIFT LINKAGE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

BELLCRANK SPRING TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 32

BRAKE SPRING ADJUSTMENT—K55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

BRAKE SPRING ADJUSTMENT—K51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

NOTE: INSPECTION, DISASSEMBLY, AND REPAIR INSTRUCTIONS

SHOWN IN THIS MANUAL ARE FOR OUT-OF-WARRANTY REPAIRS ONLY.

This transaxle is warranted for 2 years (residential-homeowner application) or 90 days (commercial application). Should an internal defect result in a transaxle failure within the warranty period, John Deere will replace the transaxle assembly.

NOTE: If internal hydro component parts are suspected (after

performing all SERVICE DEPARTMENT FOR AUTHORIZATION TO REPLACE TRANSAXLE ASSEMBLY.

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external checks and adjustments) CALL SABRE

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HYDROSTATIC POWER TRAIN CONTENTS CONTINUED

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

TRACTION DRIVE BELT REMOVAL—K55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TRACTION DRIVE BELT REMOVAL—K51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

TRACTION DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

TRACTION DRIVE BELT INSTALLATION – K55 . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TRACTION DRIVE BELT INSTALLATION—K51. . . . . . . . . . . . . . . . . . . . . . . . . . . 38

TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/INSPECTION/INSTAL-

LATION—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION—K55. . . . . . . . . 40

TRANSAXLE REMOVAL AND INSTALLATION—K55 . . . . . . . . . . . . . . . . . . . . . . 41

TRANSAXLE DISASSEMBLY—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

TRANSAXLE ASSEMBLY—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

TRANSAXLE INSTALLATION—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

TRANSAXLE BLEED PROCEDURE—K55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

TRACTION DRIVE BELT TENSIONING SYSTEM REMOVAL/INSPECTION/INSTAL-

LATION—K51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

POWER TRAIN LINKAGE SYSTEM REMOVAL/INSTALLATION—K51. . . . . . . . . 57

TRANSAXLE REMOVAL AND INSTALLATION—K51 . . . . . . . . . . . . . . . . . . . . . . 58

TRANSAXLE EXTERNAL COMPONENTS REMOVAL—K51. . . . . . . . . . . . . . . . . 59

TRANSAXLE INSTALLATION—K51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Page 88

SPECIFICATIONS HYDROSTATIC POWER TRAIN

SPECIFICATIONS

Gear Teeth: K–55 K–51

Spur Gear (drive shaft) . . . . . . . . . . . . . . . . 6 teeth 12 teeth

Differential Ring Gear . . . . . . . . . . . . . . . . . 98 teeth 53 teeth

Differential Bevel Pinion Gears

Cross shaft . . . . . . . . . . . . . . . . . . . . . . . 10 teeth 10 teeth

Axle shafts) . . . . . . . . . . . . . . . . . . . . . . . 16 teeth 16 teeth

Drive Belt: K–55 K–51

Effective Length

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2485 mm (97.8 in.) 2400 mm (94.5 in.)

Top Width

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11 mm (0.52 in.) 12.7 mm (0.50 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (0.39 in.) 10 mm (0.39 in.)

Bottom Width

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.93 mm (0.31 in.) 7.63 mm (0.30 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.24 in.) 6 mm (0.24 in.)

Depth

New. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46 mm (0.37 in.) 8.89 mm (0.35 in.)

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . 7 mm (0.28 in.) 7 mm (0.28 in.)

Lubrication: K–55 K–51

Oil Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10W30 Engine Oil, Class CD Factory Sealed

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L (1.7 qt) Factory Sealed

Gear Ratios: K–55 K–51

Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3:1 28.2:1

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3:1 28.2:1

Ground Speeds: K–55 K–51

Domestic—Forward . . . . . . . . . . . . . . . . . . 0–8.66 km/hr (0–5.38 mph) 0–8.5 kph (0–5.3 mph)

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–4.24 km/hr (0–2.62 mph) 0–5.3 kph (0–3.3 mph)

Export—Forward. . . . . . . . . . . . . . . . . . . . . 0–7.75 km/hr (0–4.82 mph) 0–8.5 kph (0–5.3 mph)

Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–3.80 km/hr (0–2.36 mph) 0–5.3 kph (0–3.3 mph)

Output Torque Rating: K–55 K–51

Rated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) 231 N•m (170.4 lb-ft)

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . 680 N•m (506 lb-ft) 805 N•m (594 lb-ft)

Brake Torque Rating: K–55 K–51

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . 196 N•m (145 lb-ft) at 245 N (55 lbs) Brake Arm Force

Rear Axle Loading: K–55 K–51

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . 240 kgs (528 lbs) 240 kgs (528 lbs)

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Page 89

HYDROSTATIC POWER TRAIN SPECIFICATIONS

REPAIR SPECIFICATIONS

Transaxle Components Wear Tolerances: K–55 K–51

Pump (Input) Shaft

Wear Limit. . . . . . . . . . . . . . . . . . . . . . .Visual Check N/A

Motor (Drive) Shaft

Wear Limit. . . . . . . . . . . . . . . . . . . . . . .Visual Check N/A

Axle Shaft Thrust Washers

Wear Limit. . . . . . . . . . . . . . . . . . . . . . .Visual Check N/A

Pump Plate

Wear Limit. . . . . . . . . . . . . . . . . . . . . . .Visual Check N/A

Motor Plate

Wear Limit. . . . . . . . . . . . . . . . . . . . . . .Visual Check N/A

Pump Swashplate Upper Case

Thrust Bushings Minimum. . . . . . . . . . . . 1.3 mm (0.051 in.) N/A

Pump Swashplate Bushing

Wear Limit. . . . . . . . . . . . . . . . . . . . . . . . Visual Check N/A

Pump Swashplate-To- Shifter Blocks

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.0059 in.) N/A

Axle Shaft-To-Upper Case Bushing

Maximum. . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (0.02 in.) N/A

Differential Cross-Shaft-To-Bevel

Pinion Gears Maximum. . . . . . . . . . . . . . 0.5 mm (0.02 in.) N/A

Brake Components Wear Tolerances: K–55 K–51

Brake Disc (Minimum). . . . . . . . . . . . . . . . . .2.5 mm (0.1 in.) N/A

Brake Puck (Minimum) . . . . . . . . . . . . . . . . .8 mm (0.32 in.) N/A

Brake Lever

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . .25 mm (1 in.) N/A

Degrees Forward from Vertical . . . . . . . . .30° 20°

Travel Maximum . . . . . . . . . . . . . . . . . . . .30° 30°

TORQUE SPECIFICATIONS K–55 K–51

Brake Lever Bracket Cap Screws. . . . . . . . 55 N•m (40 lb-ft.) 55 N•m (40 lb-ft.)

Case Cap Screws

New Case . . . . . . . . . . . . . . . . . . . . . . . . 30 N•m (264 lb-in.) 30 N•m (264 lb-in.)

Used Case. . . . . . . . . . . . . . . . . . . . . . . . 27 N•m (243 lb-in.) 27 N•m (243 lb-in.)

Center Block Cap Screws. . . . . . . . . . . . . . 55 N•m (40 lb-ft.) N/A

Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N•m (168 lb-in.) N/A

Pump Port Connector . . . . . . . . . . . . . . . . . 24 N•m (217 lb-in.) N/A

Pump Port Connector Pipe Plug . . . . . . . . . 8 N•m (72 lb-in.) N/A

Pump Port Plug. . . . . . . . . . . . . . . . . . . . . . 24 N•m (217 lb-in.) N/A

Reservoir Cover Cap Screws . . . . . . . . . . . 29 N•m (260 lb-in.) N/A

6 - 4 2/12/97

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Page 90

SPECIFICATIONS HYDROSTATIC POWER TRAIN

OTHER MATERIALS

Transaxle Housing Case Half Sealant: K–55 K–51

Form-In-Place Silicone N/A Gasket Sealant

Pump Connector Pipe Plug Sealant: K–55 K–51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe Sealant With Teflon® N/A

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approved Teflon® Sealant Tape N/A

Lubrication: K–55 K–51

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-W-30 Class-CD Factory Sealed

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Page 91

HYDROSTATIC POWER TRAIN COMPONENT LOCATION

COMPONENT LOCATION COMPONENT LOCATION—K55

1. Axle Shaft/Wheel Key (2 used) 49. Spacer (M10x20x20)

2. Left Axle Shaft 50. Cap Screw (M10x60) (3 used)

3. Left Axle Shaft Seal 51. Pump Filter

4. Left Axle Shaft Bushing 52. Motor Plate Dowel Pin (2 used)

5. Upper Case Housing 53. Pump Plate

6. O-Ring 54. Rolled Pins (M12x22) (2 used)

7. Fill Cap 55. Pump and Motor Center Block

8. Snap Ring 56. Motor Plate

9. Input Shaft Seal 57. Motor Cylinder Block

10. Snap Ring 58. Motor Piston Spring (5 used)

11. Ball Bearing 59. Motor Piston Washer (5 used)

12. Snap Ring 60. Motor Piston (5 used)

13. Cap Screw (M8x20) (4 used) 61. Motor Swashplate Bearing

14. Vent Valve Cap 62. Motor Fixed Swashplate Housing

15. Vent Valve 63. Spring

16. Reservoir Cover 64. Snap Ring

17. Brake Friction Puck Shims 65. Ball Bearing

18. Brake Friction Puck 66. Motor Output Shaft (6 teeth)

19. Brake Disc (splined) 67. Ball Bearing

20. Brake Lever 68. Silicone Sealant

21. Cap Screw (M10x45) (2 used) 69. Debris Magnet

22. Brake Lever Mounting Bracket 70. Magnet Seal

23. Right Axle Shaft Bushing 71. Motor Output Shaft Seal

24. Right Axle Shaft Seal 72. RH Axle Bushing

25. Right Axle Shaft 73. LH Axle Bushing

26. Shifter Shaft O-Ring 74. Lower Case Housing

27. Shift Block (2 used) 75. O-Ring

28. Shifter Shaft 76. Drain Plug

29. Left Axle Shaft Thrust Washer 77. Cap Screw (Self-Tapping) (M8x30) (17 used)

30. Left Axle Shaft C-Ring Retainer 78. O-Ring

31. Left Axle Shaft Differential Bevel Pinion Gear (16 teeth) 79. Bleed Port Connector

32. Differential Ring Gear (98 teeth) 80. Pipe Plug

33. Differential Cross Shaft Block 81. O-Ring

34. Differential Cross Shaft Bevel Gear (10 teeth) 82. O-Ring

35. Right Axle Shaft Differential Bevel Pinion Gear (16 teeth) 83. Pump Port Plug

36. Right Axle Shaft C-Ring Retainer 84. O-Ring

37. Right Axle Shaft Thrust Washer 85. Transport Bypass Valve Actuating Pin

38. Differential Cross Shaft Bevel Gear (10 teeth) 86. Transport Bypass Valve Actuating Bracket

39. Pump Swashplate Upper Case Thrust Bushing (2 used) 87. E-Ring

40. Pump Swashplate 88. Transport Bypass Valve Push Pin (2 used)

41. Pump Swashplate Bushing 89. Transport Bypass Valve Spring (2 used)

42. Pump Swashplate Bearing 90. Transport Bypass Valve Push Pin Guide (2 used)

43. Pump Input Shaft 91. Transport Bypass Valve Body (2 used)

44. Pump Piston (5 used) 92. O-Ring (2 used)

45. Pump Piston Washer (5 used) 93. Ball (2 used)

46. Pump Piston Spring (5 used) 94. Ball Holder (2 used)

47. Pump Cylinder Block 95. Spring (2 used)

48. Pump Plate Dowel Pin (2 used) 96. Spring Holder (2 used)

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Page 92

COMPONENT LOCATION HYDROSTATIC POWER TRAIN

COMPONENT LOCATION—K55

27 N•m (20 lb-ft.)

40 N•m

(30 lb-ft.)

New Case: 31 N•m (278 lb-in.)

Used Case: 27 N•m (243 lb-in.)

57 N•m (42 lb-ft.)

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19 N•m (168 lb-in.)

24 N•m (217 lb-in.)

8 N•m (72 lb-in.)

Page 93

HYDROSTATIC POWER TRAIN COMPONENT LOCATION

COMPONENT LOCATION—K51

1. Knob

2. 1/4X20 Hex Jam Nut

3. Rod

4. E-Ring

5. M6X30 Bolt

6. Snap Ring

7. Spacer

8. Sheave

9. Fan

10. Flnage Lock Nut

11. Lock Nut

12. Screw

13. Screw

14. Strap

15. Push Nut

16. Screw (R.H. Side) Screw (L.H. Side Not Shown)

17. Transmission Assembly

6 - 8 2/12/97

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Page 94

COMPONENT LOCATION HYDROSTATIC POWER TRAIN

COMPONENT LOCATION—K51

New Case: 27.4-31.4 N•m (20-23 lb-ft.)

Used Case: 22.5-27.4 N•m (16-20 lb-ft.)

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Page 95

HYDROSTATIC POWER TRAIN COMPONENT LOCATION

TRACTION DRIVE SYSTEM COMPONENT LOCATION

K–55 TRANSAXLE

K–51 TRANSAXLE

1. Transaxle Drive Sheave (K55)

2. Transaxle Drive Sheave (K51)

3. Arm (K55)

4. Arm (K51)

5. Bolt M8 x 45

6. Spring

7. Bushing

8. Cap Screw

9. Bolt (K51)

10. Spacer (K51)

11. Flange Nut M8

12. Lock Washer

13. Cap Screw

14. Sheave, Engine

15. Bolt M8 x 45

16. Idler

17. Idler

18. Idler (K51)

6 - 10 2/12/97

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Page 96

COMPONENT LOCATION HYDROSTATIC POWER TRAIN

PEDAL LINKAGE ASSEMBLY COMPONENT LOCATION

K–55 TRANSAXLE

K–51 TRANSAXLE

1. Neutral Switch

2. Lock Nut, 9.525mm

3. Pivot

4. Nut, 3/8 in.

5. Rod

6. Washer

7. Cotter Pin

8. Brake Rod Return Spring

9. Brake Spring Strap

10. Brake Compression Spring

11. Washer

12. Park Brake Lever

13. Extension Spring

14. Flange Nut

15. Rod, Parking Brake

16. Cap Screw, M8x35 (K55)

17. Lock Nut M8 (K55)

18. Brake Pedal (K55)

19. Pad

20. Shaft, Brake (K51)

21. Strap, Return to Neutral

22. Screw, M8x20 (K51)

23. Bracket (K51)

24. Lock Nut, M8 (K51)

2/12/97 6 - 11

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Page 97

HYDROSTATIC POWER TRAIN COMPONENT LOCATION

SHIFT LINKAGE COMPONENT LOCATION—K–55 TRANSAXLE

1. Cap Screw (M6x20)

2. Shift Arm

3. Lock Nut (M6)

4. Lock Nut (M10)

5. Flange Nut (M8)

6. Return-To-Neutral Strap

7. Shift Knob

8. Neutral Return Bushing

9. Rolled Pin (M4x20)

10. Shift Lever

11. Shift Lever Neutral Return

Spring

12. Spacer

13. Support Strap

14. Shoulder Bolt

15. Cap Screw (M10x25)

16. Cap Screw (M8x25)

17. Spacer

18. Flange Nut (M8)

19. Lock Nut (5/16-24 UNF 3B)

20. Shift Link Ball Joint Assembly

21. Flange Nut (M8)

22. Mounting Stud (M10x76.5-Top/ M8x40-Bottom)

23. Shift/Return-To-Neutral Bracket

24. Flange Nut (M8)

25. Lock Nut (5/16-24 UNF 3B)

26. Woodruff Key (5/32x5/8 in.)

27. Anchored Washer

28. Friction Disc

29. Bellcrank

30. Friction Disc

31. Anchored Washer

32. Shift Link

33. Tensioning Spring

34. Snap Ring

6 - 12 2/12/97

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Page 98

COMPONENT LOCATION HYDROSTATIC POWER TRAIN

SHIFT LINKAGE COMPONENT LOCATION—K–51 TRANSAXLE

1. Torsion Spring

2. Spring Pin (4 x 20 mm)

3. Gearshift Lever

4. Knob

5. Lock Nut

6. Strap

7. Roller

8. Bracket

9. Ball Joint

10. Stud, Adjusting

11. Nut, (5/16”)

12. Ball Joint

13. Bushing

14. Shoulder Bolt

15. Screw M10 x x25

16. Screw M8 x 25

17. Support

18. Lock Nut (5/16-24 UNF 3B)

19. Spacer

20. Flange Nut, M8

21. Flange Nut, M10

2/12/97 6 - 13

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Page 99

HYDROSTATIC POWER TRAIN THEORY OF OPERATION

THEORY OF OPERATION

In this group the Sabre hydrostatic power train is separated into the following systems:

• Traction Drive Belt System

• Transaxle and Shift Linkage System

• Brake/Neutral Return Pedal System

• Transport (Free-Wheeling) System

TRACTION DRIVE BELT SYSTEM OPERATION

Function:

The traction drive belt transfers power from the engine to the input pulley of the hydrostatic transaxle.

Major Components:

• Foot pedal and brake linkage

• Engine drive sheave

• Traction drive belt

• Tensioning idler assembly

• Tensioning spring

• Adjusting idler assembly

• Transaxle drive sheave

Theory of Operation:

TRANSAXLE AND SHIFT LINKAGE SYSTEM OPERATION

Function:

The function of the transaxle is to transfer power from the traction drive belt system (driven by the engine), to the rear wheels, and allow the operator to select ground speed and direction.

The drive belt turns the transaxle input pulley, and drives the transaxle’s hydrostatic pump. When the hydrostatic drive is in neutral, no pressure is built up in the pump. When the operator pushes the hydrostatic drive lever forward, the shift linkage tilts the swash plate, inside the transaxle, off center, and the pump pistons build pressure which drives the hydrostatic motor. The motor drives the rear axle and wheels through the differential assembly.

The transaxle provides infinite ground speed selections up to 5 mph in forward and up to 2.6 mph in reverse.

Major Components:

• Transaxle input pulley and fan

• Pump (input) shaft and cylinder block assembly

• Shift linkage and pump swashplate assembly

• Center block assembly

• Motor cylinder block assembly and drive shaft

• Differential assembly and axle shafts

• Wheels and tires.

Theory of Operation:

(D) Used with

K-51 Only

The traction drive belt (A) is driven by the upper pulley of the engine drive sheave (B). The traction belt then transmits engine power to the input pulley of the hydrostatic transaxle (C). On the K-51 transaxle only, an additional idler pulley (D) is used between the engine sheave and the transaxle. The traction drive belt is tensioned by the tension idler (E), which is mounted on a spring loaded bracket (F). The tension spring (G) runs forward and hooks to the frame. When the traction drive belt stretches beyond the range of the spring loaded tension idler, an adjustable idler (H) can be moved in slots on the frame, allowing the tension idler to move back into range.

Neutral:

When the engine is running, the traction drive belt (A) turns the transaxle input pulley (C), cooling fan, and input shaft. The input shaft turns the hydrostatic pump input shaft and pump body, inside the transaxle.

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Page 100

THEORY OF OPERATION HYDROSTATIC POWER TRAIN

R.H. Frame Rail Removed For Clarity

Shaft

On the K-51 transaxle, the turnbuckle link (M) moves

the transaxle shift lever (P). The shift lever turns the transaxle shifter shaft.

When the hydrostatic drive lever (I), is in the neutral position (J), the shift bracket (K) is centered in it’s mounting bracket (L), and the turnbuckle link (M) is centered in the slot on the right side frame.

On the K-55 transaxle, the turnbuckle link (M) moves the bellcrank (N), link strap (O), and transaxle shift lever (P). The shift lever turns the transaxle shifter shaft.

K55

When in neutral, the shift linkage holds the shifter shaft (J) and the variable-angle pump swashplate (O) in the neutral position. While in neutral (level) position, the pump cylinder block (N) rotates with the pump (input) shaft but does not pump any oil into the motor half of the center block (P) because the pump pistons are not moving up and down as they rotate. Therefore, the motor cylinder block (Q) does not turn nor do the motor (output) shaft (M), differential assembly (L), or drive axles (K and R).

2/12/97 6 - 15

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