Simplicity Broadmotor Series, AGCO Allis 1600 Series, Massey Ferguson 2600 Series Service & Repair Manual
Not for Reproduction
Service & Repair Manual Broadmoor Series
MANUFACTURING, INC.
500 N Spring Street / PO Box 997
Port Washington, WI 53074-0997 USA
© Copyright 2001 Simplicity Manufacturing, Inc.
All Rights Reserved. Printed in USA.
Rev 4/2001
TP 500-2493-00-BM-SMA
Repair Manual Contents
This manual is divided into the sections listed below.
Please click hyperlink to access the specific contents of that section.
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 — 1-14
2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 — 2-4
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 — 3-12
4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 — 4-8
5 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 — 5-6
6 Common Service Procedures . . . . . . . . . . . . . . . . . . . 6-1 — 6-10
7 Electrical System Service. . . . . . . . . . . . . . . . . . . . . . . 7-1 — 7-34
8 Steering & Front Wheel Repair. . . . . . . . . . . . . . . . . . 8-1 — 8-14
9 Drive Controls Service. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 — 9-8
10 Hand Controls Service. . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 — 10-6
11 Transmission Removal & Installation. . . . . . . . . . . . 11-1 — 11-8
12 Transmission Tear Down . . . . . . . . . . . . . . . . . . . . . . . 12-1 — 12-16
14 Seat Deck & Fuel Tank Service. . . . . . . . . . . . . . . . . . 14-1 — 14-8
15 PTO Clutch Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 — 15-6
16 Mower Deck Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 — 16-22
13 Hood & Dashboard Service . . . . . . . . . . . . . . . . . . . . . 13-1 — 13-8
Not for Reproduction
1 - 1
1 General Information
Table of Contents
SECTION CONTENTS
Models Covered
Models & Identification................................................................. 1-2
Introduction
Introduction .................................................................................. 1-3
Manual Content ........................................................................... 1-3
Safety Rules
Safety Rules - General Operation................................................ 1-4
Safety Rules - Service And Maintenance .................................... 1-6
General Repair Information
Bearings & Bushings ................................................................... 1-9
Belts & Pulleys............................................................................. 1-9
Electrical Parts............................................................................. 1-9
Fasteners & Hardware............................................................... 1-10
Genuine Replacement Parts...................................................... 1-10
Hydraulic Parts .......................................................................... 1-10
Paint........................................................................................... 1-10
Required Tools & Equipment..................................................... 1-10
Systems Checks ........................................................................ 1-10
Torque Specifications ................................................................ 1-11
Specifications..............................................................................1-12
SECTION 1. GENERAL INFORMATION
Not for Reproduction
1 General Information
Models Covered In This Manual
1 - 2
1693052 Broadmoor, 14HP Hydro
1693054 Broadmoor, 16HP Hydro
1693056 Broadmoor, 16HP V Hydro
1693058 1614H, 14HP Hydro
1693060 1616H, 16HP Hydro
1693062 1616VH, 16HP V-Twin Hydro
1693064 2616H, 16HP Hydro
1693066 2616VH, 16HP V-Twin Hydro
1693068 Broadmoor, 14HP Hydro (Export)
1693070 Broadmoor, 16HP Hydro (Export)
1693072 Broadmoor, 16HP V Hydro (Export)
1693275 Broadmoor, 18HP V Hydro
1693277 1618H, 18HP V-Twin Hydro
1693279 2618H, 18HP V-Twin Hydro
1693281 Broadmoor, 18HP V Hydro (Export)
1693351 Broadmoor, 14HP Hydro
1693353 Broadmoor, 16HP Hydro
1693355 Broadmoor, 16HP V Hydro
1693358 Broadmoor, 14HP Hydro (Export)
1693360 Broadmoor, 16HP Hydro (Export)
1693362 Broadmoor, 16HP V Hydro (Export)
1693365 1614H, 14HP Hydro
1693367 1616H, 16HP Hydro
1693369 1616VH, 16HP V-Twin Hydro
1693372 2615H, 16HP Hydro
1693374 2616VH, 16HP V-Twin Hydro
1693580 Broadmoor, 16HP Hydro
1693592 Broadmoor, 16HP V Hydro
1693594 Broadmoor, 16HP V Hydro (Export)
1693596 1615H, 16HP Hydro
1693598 2616H, 16HP Hydro
1693600 Broadmoor, 18HP V Hydro
1693602 1618H, 18HP V-Twin Hydro
1693604 2618H, 18HP V-Twin Hydro
1693613 Broadmoor, 18HP V Hydro (Export)
1693617 1616VH, 16HP V-Twin Hydro
1693622 2616VH, 16HP V-Twin Hydro
1693662 Broadmoor, 16HP Hydro (Export)
1693817 Broadmoor, 16HP V Hydro
1693819 Broadmoor, 16HP V Hydro (Export)
1693821 1616VH, 16HP V-Twin Hydro
1693823 2616VH, 16HP V-Twin Hydro
Tractors
Mower Decks
1692682 38” Mower Deck
1692682 38” Mower Deck
1692683 38” Mower Deck
1692683 38” Mower Deck
1692683 38” Mower Deck
1692683 38” Mower Deck
1692684 44” Mower Deck
1692684 44” Mower Deck
1692685 44” Mower Deck
1692685 44” Mower Deck
1692685 44” Mower Deck
1692685 44” Mower Deck
1693170 38” Mower Deck (Export)
1693170 38” Mower Deck (Export)
1693171 44” Mower Deck (Export)
1693171 44” Mower Deck (Export)
1693267 50” Mower Deck
1693267 50” Mower Deck
1693283 50” Mower Deck (Export)
1693283 50” Mower Deck (Export)
1693284 50” Mower Deck
1693284 50” Mower Deck
1693284 50” Mower Deck
1693284 50” Mower Deck
Mower Deck
Identification Tag
Tractor
Identification Tag
IDENTIFICATION TAG LOCATIONS
AMERICAN MODELS
CE MODELS
SSAAMMPPLLEE
SSAAMMPPLLEE
MODELS COVERED &
IDENTIFICATION NUMBERS
This manual contains service information for the
models listed below. Consult the Identification
Tag located on the tractor frame for the manufacturer’s identification number and serial number.
Always use the manufacturer’s identification number and serial number when ordering parts or documentation. Attachments are not covered in this
manual. Refer to the attachment operator’s manual or authorized dealer for service information.
Transmissions are identified by identification number tags located on the transmission casing.
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1 - 3
1 General Information
Introduction
INTRODUCTION
This manual is divided into sixteen major sections of service information required for the models specified.
These sections are:
1. General Information
2. Troubleshooting
3. Maintenance
4. Adjustments
5. Belt Replacement
6. Common Service Procedures
7. Electrical System Service
8. Steering & Front Wheel Repair
9. Drive Controls Service
10. Hand Controls Service
11. Transmission Removal & Installation
12. Transmission Tear Down
13. Hood and Dashboard Service
14. Seat Deck & Fuel Tank Service
15. PTO Clutch Service
16. Mower Deck Repair
Since part numbers are subject to change and may vary
by model year and manufacturing number, all parts in
this manual are referred to by general description.
Specific part number information may be found in the
respective Parts Manual for the unit being serviced.
Always use the manufacturing number that appears on
the Identification Tag of the unit you are servicing to
identify component part numbers.
MANUAL CONTENT
This manual is intended primarily for use by dealer service personnel as a technical reference manual or as a
compliment to normal service training.
While the information in this manual has been developed
to permit mechanics and service technicians to perform
most service procedures quickly and effectively, it is
assumed that those using this manual will have some
outdoor power equipment service experience or other
basic power equipment service training with similar types
of products.
In addition, it is assumed that all those performing service on these units are familiar with the general principles of operation of these units, and understand all operating controls, safety instructions, and normal handling
precautions for servicing large, high horsepower riding
tractors and mowers.
Engine information is available from the appropriate
engine manufacturer in a separate service manual.
General engine information and basic engine troubleshooting information is provided, but is intended for
general guidance only. The engine manufacturer’s manual should be always be consulted first before making
any major adjustments, part changes, or other major
repairs.
This manual includes all relevant service information for
model years 1990 through 1995, and whenever necessary, includes inset illustrations or other references to
help identify previous part designs and alternative service procedures.
The service techniques in this manual also assume that
the person providing service has access to a standard
assortment of mechanic’s hand tools, and approaches
most disassembly and repair procedures with availability
of these basic tools in mind. Whenever specialized or
custom tools are available to save time, reduce effort, or
improve overall service efficiency, the most effective safe
repair method available should be utilized.
Not for Reproduction
1 General Information
Safety Rules
1 - 4
GENERAL OPERATION
• Read, understand, and follow all instructions in the manual and on
the unit before starting.
• Only allow responsible adults, who are familiar with the instructions, to operate the unit (local regulations can restrict operator
age).
• Clear the area of objects such as rocks, toys, wire, etc., which
could be picked up and thrown by the blade(s).
• Be sure the area is clear of other people before mowing. Stop unit
if anyone enters the area.
• Never carry passengers.
• Do not mow in reverse unless absolutely necessary. Always look
down and behind before and while travelling in reverse.
• Be aware of the mower discharge direction and do not point it at
anyone. Do not operate the mower without either the entire grass
catcher or the deflector in place.
• Slow down before turning.
• Never leave a running unit unattended. Always disengage the
PTO, set parking brake, stop engine, and remove keys before dismounting.
• Turn off the PTO switch to disengage the blades when not mowing.
• Stop engine before removing grass catcher or unclogging chute.
• Mow only in daylight or good artificial light.
• Do not operate the unit while under the influence of alcohol or
drugs.
• Watch for traffic when operating near or crossing roadways.
• Use extra care when loading or unloading the unit into a trailer or
truck.
• Data indicates that operators, age 60 years and above, are
involved in a large percentage of riding mower-related injuries.
These operators should evaluate their ability to operate the riding
mower safely enough to protect themselves and others from injury.
• Keep in mind the operator is responsible for accidents occurring to
other people or property.
• All drivers should seek and obtain professional and practical
instruction.
• Always wear substantial footwear and trousers. Never operate
when barefoot or wearing sandals.
• Before using, always visually check that the blades and blade hardware are present, in-tact, and secure. Replace worn or damaged
parts.
• Never operate the machine with defective guards, or without safety
protective devises in place.
• Disengage attachments before: refuelling, removing an attachment,
making adjustments (unless the adjustment can be made from the
operator’s position).
• When the machine is parked, stored, or left unattended, lower the
cutting means unless a positive mechanical lock is used.
• Follow the manufacturer’s recommendation for wheel weights or
counterweights.
SLOPE OPERATION
Slopes are a major factor related to loss-of-control and tip-over accidents,
which can result in severe injury or death. All slopes require extra caution.
If you cannot back up the slope or if you feel uneasy on it, do not operate
on it.
Control of a ride-on machine sliding on a slope will not be regained by the
application of the brake. The main reasons for loss of control are: insufficient tire grip on the ground, speed too fast, inadequate braking, the type
of machine is unsuitable for it’s task, lack of awareness of the ground conditions, incorrect hitching and load distribution.
Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control
of unit, severe personal injury or death to you, or bystanders, or damage to property or equipment.
This mowing deck is capable of amputating hands and feet and throwing objects.
The triangle in text signifies important cautions or warnings which must be followed.
WARNING
Never operate on slopes greater than 17.6 percent
(10°) which is a rise of 3-1/2 feet (106 cm) vertically in
20 feet (607 cm) horizontally.
When operating on slopes use additional wheel
weights or counterweights. See your dealer to
determine which weights are available and
appropriate for your unit.
Select slow ground speed before driving onto slope.
In addition to front and rear weights, use extra caution
when operating on slopes with rear-mounted grass
catcher.
Mow UP and DOWN the slope, never across the
face, use caution when changing directions and DO
NOT START OR STOP ON SLOPE.
Do
• See your authorized dealer for recommendations of wheel weights
or counterweights to improve stability.
• Mow up and down slopes, not across.
• Remove obstacles such as rocks, tree limbs, etc.
• Watch for holes, ruts, or bumps. Uneven terrain could overturn the
unit. Tall grass can hide obstacles.
• Use slow speed. Tires may lose traction on slopes even through
the brakes are functioning properly. Choose a low gear so that you
will not have to stop or change speeds while on the slope.
• Use extra care with grass catchers or other attachments. These
can change the stability of the unit.
• Keep all movement on the slopes slow and gradual. Do not make
sudden changes in speed or direction.
• Always keep unit in gear especially when traveling downhill. When
clutching, release clutch slowly.
Do Not
• Do not start or stop on a slope. If tires lose traction, disengage the
blade(s) and proceed slowly straight down the slope.
• Do not turn on slopes unless necessary, and then, turn slowly and
gradually downhill, if possible.
• Do not mow near drop-offs, ditches, or embankments. The mower
could suddenly turn over if a wheel is over the edge of a cliff or
ditch, or if an edge caves in.
• Do not mow on wet grass. Reduced traction could cause sliding.
• Do not try to stabilize the unit by putting your foot on the ground.
• Do not use grass catchers on steep slopes.
• Do not mow slopes you cannot back up.
• Do not shift to neutral and coast down hill.
TP 600-2459-00-XX-SMA
Not for Reproduction
1 - 5
1 General Information
Safety Rules
Slope Operation Continued
Children
Tragic accidents can occur if the operator is not alert to the presence of
children. Children are often attracted to the unit and the mowing activity.
Never assume that children will remain where you last saw them.
• Keep children out of the mowing area and under the watchful care
of another responsible adult.
• Be alert and turn unit off if children enter the area.
• Before and during reverse operation, look behind and down for
small children.
• Never carry children. They may fall off and be seriously injured or
interfere with safe unit operation.
• Never allow children to operate the unit.
• Use extra care when approaching blind corners, shrubs, trees, or
other objects that may obscure vision.
TOWING
• Never allow children or others in or on towed equipment.
• Tow only with a machine that has a hitch designed for towing. Do
not attach towed equipment except at the hitch point.
• Follow the manufacturer’s recommendations for weight limit for
towed equipment and towing on slopes.
• On slopes, the weight of the towed equipment may cause loss of
traction and loss of control.
• Travel slowly and allow extra distance to stop.
• Do not shift to neutral and coast down hill.
TRANSPORTING AND STORAGE
• Always observe safe refueling and fuel handling practices when
refueling the tractor after transportation or storage.
• Always follow the engine manual instructions for storage preparations before storing the tractor for both short and long term periods.
• Always follow the engine manual instructions for proper start-up
procedures when returning the unit to service.
• Never store the unit or fuel container inside where there is an open
flame or pilot light, such as in a water heater. Allow unit to cool
before storing.
EMISSIONS
• Engine exhaust from this product contains chemicals known, in
certain quantities, to cause cancer, birth defects, or other reproductive harm.
• Look for the relevant Emissions Durability Period and Air Index
information on the engine emissions label.
WARNING
When transporting this tractor on an open trailer,
make sure unit is facing forward, toward the direction
of travel. If tractor is facing backward, wind lift could
cause damage to the hood.
SERVICE AND MAINTENANCE
• Use extra care in handling gasoline and other fuels. They are flammable and vapors are explosive.
a) Use only an approved container.
b) Never remove gas cap or add fuel with the
engine running. Allow engine to cool before refueling. Do not
smoke.
c) Never refuel the unit indoors.
• If fuel is spilled, do not attempt to start the engine but move the
machine away from the area of spillage and avoid creating any
source of ignition until fuel vapors have dissipated.
• Replace all fuel tank caps and fuel container caps securely.
• Never fill containers inside a vehicle or on a truck bed with a plastic
bed liner. Always place containers on the ground away from your
vehicle before filling.
• Remove gas-powered equipment from the truck or trailer and refuel
it on the ground. If this is not possible, then refuel such equipment
on a trailer with a portable container, rather than from a gasoline
dispenser nozzle.
• Keep nozzle in contact with the rim of the fuel tank or container
opening at all times until fueling is complete. Do not use a nozzle
lock-open device.
• If fuel is spilled on clothing, change clothing immediately.
• Maintain or replace safety and instruction labels as necessary.
• Never run a unit in an enclosed area.
• Keep nuts and bolts, especially blade attachment bolts, tight and
keep equipment in good condition.
• Never tamper with safety devices. Check their proper operation
regularly and make necessary repairs if they are not functioning
properly.
• Keep unit free of grass, leaves, or other debris build-up. Clean up
oil or fuel spillage.
• Stop and inspect the equipment if you strike an object. Repair, if
necessary, before restarting.
• Never make adjustments or repairs with the engine running unless
specified otherwise in the engine manufacturer’s manual.
• Grass catcher components are subject to wear, damage, and deterioration, which could expose moving parts or allow objects to be
thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.
• Mower blades are sharp and can cut. Wrap the blade(s) or wear
gloves, and use extra caution when servicing them.
• Check brake operation frequently. Adjust and service as required.
• Use only factory authorized replacement parts when making
repairs.
• Always comply with factory specifications on all settings and
adjustments.
• Only authorized service locations should be utilized for major service and repair requirements.
• Never attempt to make major repairs on this unit unless you have
been properly trained. Improper service procedures can result in
hazardous operation, equipment damage and voiding of manufacturer’s warranty.
• On multiple blade mowers, take care as rotating one blade can
cause other blades to rotate.
• Do not change engine governor settings or over-speed the engine.
Operating the engine at excessive speed can increase the hazard
of personal injury.
• Disengage drive attachments, stop the engine, remove the key,
and disconnect the spark plug wire(s) before: clearing attachment
blockages and chutes, performing service work, striking an object,
or if the unit vibrates abnormally. After striking an object, inspect
the machine for damage and make repairs before restarting and
operating the equipment.
• Never place hands near the hydro pump cooling fan when the tractor is running. Cooling fan is located on top of the transaxle
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1 General Information
Safety Rules
1 - 6
SERVICE AND MAINTENANCE
The service information provided in this manual is intended to provide you with the knowledge required to perform
a wide range of service procedures on the listed equipment.
While appropriate safety reminders and safety warnings
have been included here and elsewhere in this manual to
help promote the use of safe service techniques, you
must also observe all appropriate shop safety rules
whenever performing these procedures.
No single manual, including this one, can include every
possible warning or safety instruction necessary to guarantee complete safety - you must apply your common
sense and knowledge of shop and power equipment
safety whenever performing service, whenever working
around others who are operating, servicing, or handling
equipment, and whenever you are present in a work
environment where hand or power tools, shop equipment, or outdoor power equipment may be present.
This includes taking the necessary safety precautions to
help ensure a safe workplace, exercising reasonable
care to avoid unsafe acts, and being alert for potential
hazards as you move about the workplace or engage in
various service activities.
If you encounter a service situation involving the use of
an unfamiliar tool, procedure, or part, and rereading the
appropriate section of this manual does not provide the
information you want, contact your Simplicity dealer
before proceeding. Never attempt a repair that you’re
not sure about, since help is usually never more than just
a phone call away.
Practicing safe service procedures not only helps protect
you and those you work around, it also contributes to
providing safe, reliable equipment .
Personal Protective Equipment
• Wear protective safety glasses whenever using hand
or power tools, shop equipment, and whenever working under power equipment to protect your eyes from
falling debris and small parts.
• Wear safety goggles or full face protection when handling battery electrolyte fluid, or when performing
grinding or sharpening operations that produce
sparks or flying debris. Extensive grinding may
require the use of protective sleeves and an apron.
• Wear work gloves when handling sharp surfaces
such as mower blades, or when working around
sharp edges. Never wear gloves that are loose fitting
or that have tie straps, as these could cause your
hands to get caught by rotating parts, resulting in
serious injury. Chemical-resistant Rubber gloves are
recommended when handling or pouring battery electrolyte.
• Steel-toe safety shoes are highly recommended to
protect feet from falling tools, heavy parts, and other
shop equipment.
Fuel Handling Safety
• Always use extra care when handling gasoline gasoline is highly flammable, and gasoline vapors
are explosive as well as toxic if inhaled.
• Never store fuel indoors, or refuel a unit indoors.
Gasoline vapors can easily travel unseen to distant
sources of ignition such as pilot lights or open flames
on water heaters, furnaces, stoves, or other gas
operated appliances, sparks from electric motors or
other electrically-operated tools and equipment, welding equipment, grinders, or burning smoking materials. Contact with these or any other sources of ignition will cause an explosion and/or fire, serious personal injury, and damage to property and equipment.
• Never transfer gasoline from one container to another
unless the containers are connected by an approved
grounding strap. Hand or power operated transfer
pumps can generate a static charge of electricity,
causing dangerous sparking and ignition of fuel or
fuel vapors. Always follow the pump manufacturer’s
safety and operating instructions.
• Use only approved containers for fuel, and always
handle the container with extreme care to avoid
spillage or leaking of explosive vapors.
• Never smoke or allow others in the area to smoke
while refilling the fuel tank, or when handling gasoline cans. Make sure any smoking materials that had
been in use in the area are fully extinguished before
opening a fuel can or starting refueling .
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1 - 7
1 General Information
Safety Rules
Exhaust Gas Safety
• Internal combustion engines produce and exhaust
Carbon Monoxide (CO), an odorless, colorless, gas
that causes dizziness, nausea, flu-like symptoms,
unconsciousness, or even brain damage or death, if
breathed for prolonged periods.
• If exposed to Carbon Monoxide gas, get to a fresh air
source immediately and seek medical attention. CO
can build up in your blood, and can cause lingering
symptoms or permanent damage if left untreated.
• Operate the unit outdoors or in a well ventilated area,
or pipe exhaust gases out of the work area to an outside location where the exhaust can be dissipated
safely away from doors, windows, air conditioners, or
other potential sources of outside-air intake that could
permit reentry of hazardous fumes.
• Never enter an enclosed area where an engine has
been running and exhaust gases have been allowed
to collect. Open adjacent windows or doors first to
permit outside air to ventilate the area, and allow sufficient time for a complete air exchange to occur.
Battery/Electrolyte Safety
• Lead-Acid batteries use an electrolyte containing sulphuric acid, a highly corrosive liquid that can cause
severe chemical burns if allowed to come into contact
with skin, or blindness if allowed to contact your eyes.
Always wear approved eye goggles or a full face
shield and protective gloves when handling electrolyte or filling the battery.
• Lead-acid batteries also produce hydrogen, a colorless, highly explosive gas that can be easily ignited
by a single spark. Charging the battery incorrectly or
hooking up jumper cables improperly can cause
sparking, and must be avoided. Always follow recommended battery charging and jumper cable procedures.
• When removing or installing battery cables, disconnect the negative cable FIRST, and reconnect it
LAST. If not done in this order, the positive terminal
could be accidentally shorted to the frame by a tool,
creating a dangerous spark that can ignite nearby
fuel vapors or escaping hydrogen gas from the battery.
• Keep battery securely fastened in position with vent
tube directed down and out of battery compartment.
Replace battery if electrolyte leakage occurs. Make
sure the battery vent tube is properly installed, and is
not plugged with clippings or other debris. Replace
the vent tube if cracked, damaged, or missing from
unit.
• Old batteries should be disposed of by recycling.
Electrical System Safety
• Loose connectors, worn wires, damaged wire insulation, and loose termination hardware can cause
sparks, short-circuits, and erratic equipment operation. Always check wiring for damage, and make
appropriate repairs before placing unit back into operation.
• Use care when working around exposed terminals to
prevent short-circuiting the electrical system.
Sparking, electric shocks, and damage to the system
may result from accidental contact between terminals
and metal hand tools.
Elevating Unit Safely
• Always support unit on approved jack stands when
working on an elevated unit, and keep unit from
rolling by engaging parking brake and placing wheel
chocks behind wheels still on floor or work table.
• Secure unit to work-surface of scissor-lift worktables
or other powered lift tables in accordance with the
manufacturer’s instructions. Unsecured units may
roll unexpectedly while work is being done, causing
injuries.
• Never work under an elevated unit unless it is properly supported by jack stands, locked from rolling with
wheel chocks or equivalent, and you can quickly
escape from under the unit in an emergency using a
rolling device such as a mechanic’s creeper.
• Always protect your eyes from falling debris or small
parts by wearing approved safety glasses or goggles.
• Remove the ignition key and disconnect the spark
plug wires before working under a unit. Accidental or
inadvertent starting could result in serious injuries.
Proper Tool Use
• Use power and hand tools only for the use that they
were designed. Never alter or modify tools, or improvise using tools that are not suitable for the job at
hand.
• Keep all hand and power tools in good repair, and put
them away when done to avoid cluttering the work
area. Use extra care when using corded tools
around moving or rotating parts such as belts and
pulleys, since the cord could get caught and suddenly
pull the tool, or you, into the area of moving parts.
• Always check the unit to ensure that all hand and
power tools and tool attachments have been
removed from the unit after use. Small tools and tool
attachments left on the equipment can fall into the
cutting path when the unit is placed into service, and
become a hazard to bystanders if struck by mower
blades.
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1 General Information
Safety Rules
1 - 8
Work Area Safety
• Always keep the work area clear of clutter from discarded parts, and debris from parts boxes or packaging materials. Small parts, hardware items, and other
debris or refuse left lying around can become slip,
trip, and fall hazards if not removed and discarded of
properly.
• Always observe general shop safety rules for housekeeping, and tend to oil spills and other spilled fluids
promptly to prevent slip and fall injuries.
• Allow sufficient work area around the equipment you
are working on to permit comfortable working positions. Never put yourself in a position that would prevent you from escaping quickly in the event of emergencies such as sudden shifts in equipment position,
fire, or other situations requiring an immediate reaction on your part.
Compressed Air Safety
• Always use care when using compressed air to blow
dirt and debris off equipment - always direct the air
blast away from yourself and others in the area, and
protect your eyes with safety glasses to prevent injury
from particles that may blow back toward your face.
• Never use high pressure air directly against your skin
to clean dirt and debris - the air pressure could actually force foreign material or fluids into your skin,
causing serious injuries.
• Use care when filling tires - lawn and garden tractors
utilize low pressure tires, and over-pressurization is
hazardous to you and anyone who operates the
equipment with improper tire pressures. Always consult the air pressure recommendations for the unit
involved before adding additional air to the tires.
Grease & Lubricant Safety
• Normal service and maintenance involves the use of
oils and greases that could present a fire hazard if
not handled properly. Always dispose of oily rags
properly to prevent fires caused by spontaneous
combustion.
• Spilled lubricants pose dangerous slip hazards and
must be taken care of immediately. Wipe up spills
carefully, or use absorbent materials to soak up
spilled fluids. Always dispose of rags, paper towels,
and other saturated absorbents properly.
• Store oils and greases away from flame or other ignition sources. Petroleum-based fluids can be ignited
by smoking materials and sparks - always treat oils
and greases as potentially flammable materials.
Always cap oil and grease containers when done
using, and store or dispose of properly.
General Servicing Safety
• Always check safety devices and switches for proper
operation - never alter these devices or make temporary or makeshift repairs. Use only factory-authorized parts and procedures, and check newlyinstalled parts for proper operation.
• Make sure all hardware items are properly tightened,
especially blade attachment bolts. Replace any hardware that appears damaged.
• Check brake operation, and adjust or repair as
required. Always comply with factory specifications
on settings and adjustments.
• Check grass catcher components for wear, damage,
or deterioration, and replace with factory authorized
parts if necessary.
• Always make repairs using factory authorized
replacement parts only. Using parts that don’t meet
factory specifications can result in sudden or premature failures, poor or erratic equipment performance,
and potential safety hazards to operators and
bystanders.
• Always comply with factory specifications on settings
and adjustments when installing new parts, making
repairs, or performing routine service procedures.
• Always test repairs before releasing units to customers, paying special attention to any items that are
safety-related. Correct any problems noted, and recheck to ensure that the problems have been fully
remedied.
• Make sure all safety and operating instruction decals
are legible, properly located, and securely attached.
Replace any decals that can’t be read or are in danger of falling off.
• Always advise equipment owners of any potential
operating or safety problems that may be arising due
to anticipated wear, and request that the owner
address the problem before a hazard develops.
• Never allow a unit to be placed back into service if a
serious safety or operating problem is evident.
Advise the owner of the problem and the possible
hazards associated with the problem, and request
permission to correct the deficiencies.
• Use extreme care when working on older models that
do not have all of the latest safety devices and
switches. Disengage the PTO and transmission
before starting the unit, or commencing repairs.
• Always use care when removing or installing parts to
prevent damage from dropping or rough handling.
Support heavy parts properly to prevent damage or
personal injury to yourself and others.
Not for Reproduction
1 - 9
1 General Information
Repair Information
GENERAL REPAIR INFORMATION
In addition to providing specific repair procedures for the
equipment listed at the beginning of this section, this
manual provides the following additional general instructions for dealing with repairs to various types of components.
This information is designed to help you deal more effectively with these components by providing basic service
knowledge and other useful tips.
Bearings & Bushings
Roller bearings, ball bearings, and bushings are used to
provide support to rotating shafts and other parts such as
gears, pulleys, and sprockets that are used to transmit
rotary motion. Over time, bearings and bushings may
require additional lubrication to transmit this rotary
motion with minimal friction, or may need replacement
due to normal operation and wear. Normal service for
bearings and bushings includes removal, cleaning,
inspection, lubrication, and replacement.
REMOVAL
Most bearings and bushings used on the listed equipment can be easily removed by following the appropriate
detailed procedures found throughout this manual. Care
should always be exercised to avoid scratching or damaging the bearing or bushing, the mounting shaft, and
surrounding components. Bearing or bushing removal is
usually necessary when excessive play or wobble is
noticed on the part it supports, when unusual noise or
vibration is apparent, or when a burning smell is present
at the bearing location.
CLEANING
Sealed bearings and bushings can be cleaned by careful
wiping with a cloth. Bearings with one-sided or removable shields and plain bushings can be cleaned by
immersion in safety solvent, and brushing with a part
cleaning brush. Oil-impregnated bushings, and bushings
made of nylon or other synthetic materials, can be
cleaned with safety solvents, or wiped clean, but should
not be immersed in solvent for periods longer than that
necessary to remove heavy or caked-on build-ups of
grease. All petroleum-based solvents are flammable, so
appropriate precautions regarding flames, sparks, and
other ignition sources should always be observed.
Gasoline should never be used because of its volatility
and its highly toxic nature.
INSPECTION
Once cleaned, bearings can be properly inspected for
wear, scratches, visible damage such as corrosion,
cracked seals or scorching, and rough, or noisy, operation. Bushings can be visually checked for scratches,
uneven wear, or other visual damage.
LUBRICATION
After passing inspection, bearings and bushings should
be lubricated in accordance with factory specifications,
and reinstalled according to the appropriate installation
instructions. New bearings and bushings must also be
properly lubricated before use. For optimal performance,
and as a practical preventive maintenance measure,
bearings and bushings used in pairs or multiple sets
should all be replaced at the same time.
Belts & Pulleys
Belts and pulleys transmit rotary motion from power
sources to work components, providing the force needed
to drive transmissions, operate mower decks, and power
various attachments. This continual use eventually
causes belts to wear out, and over time may also require
the replacement of pulleys and pulley bearings.
Belt wear and various types of damage are easily
checked by visual examination, which is covered in
greater detail elsewhere in this manual. Pulleys may
also be checked visually for wear or apparent damage,
but pulley bearings usually require removal, cleaning,
and inspection to determine if replacement is required.
Belt and pulley life can be optimized by making sure that
proper belt tension and alignment are observed when
belts are installed. Proper belt tension and alignment
should also be maintained by performing periodic checks
and adjustments. In addition, only factory authorized
replacement belts will minimize problems caused by
size, thermal instability, and variations in quality.
Electrical Parts
The electrical parts used on these units has been specifically engineered for outdoor power equipment, and is
designed to provide years of reliable operation. As with
all electrical components and systems, electrical contacts must be kept clean and dry, and all terminations
must be securely fastened or connected. Also, all electrical components, wiring, and connectors should be periodically inspected for corrosion, signs of excessive heat
build-up, or other damage that signals that it is time to
repair or replace the item.
Specific procedures for electrical troubleshooting and
most common repairs is covered in separate sections of
this manual.
Not for Reproduction
1 General Information
Repair Information
1 - 10
Fasteners & Hardware
All hardware and fasteners used in this equipment must
meet factory specifications for SAE grade, size, and
torque, and must be kept securely tightened. Locking
hardware that degrades with use should be replaced
when service is performed in affected areas. Always
observe factory specifications for torque, or consult the
torque chart for torque information.
Genuine Replacement Parts
Only factory authorized replacement parts should be
used when making repairs or performing routine maintenance. The use of parts that do not meet stringent factory specifications can cause poor performance, premature
failures, and lead to potential safety hazards. In addition,
the use of non-factory authorized replacement parts will
void your warranty.
Hydraulic Parts
Hydraulic parts are adversely affected by dirt and contamination, and care must be exercised when performing
service on these parts to prevent foreign material from
entering. Specific service information appears elsewhere in this manual, and all precautions and procedures must be followed when repairing or servicing these
parts.
Paint
The paint on outdoor power equipment provides for an
attractive appearance, as well as a barrier to corrosion
caused by exposure to moisture in the environment.
Scratches, abrasions, and other damage to painted surfaces should be repaired promptly to prevent the formation of rust and premature part failure. Factory supplied
paints are available that provide both an accurate color
match and superior corrosion resistance.
Required Tools & Equipment
All repairs in this manual can be accomplished with standard mechanic’s hand tools. The use of appropriate
power tools such as impact wrenches and power drivers
may aid in part removal and replacement, but care must
be exercised to avoid causing damage to components
from excessive tightening. Transmission service, steering service, tire and wheel service, and service to components located under the frame also requires the use of
a jack with suitable capacity, and jack stands to support
the unit being worked on.
Systems Checks
In addition to performing individual component service,
components affected by related parts changes should
also receive attention at the time service is performed.
Examples of this include part replacements that are part
of a safety device, electrical components, transmission
components, and pulleys that are part of the same power
delivery system. Giving attention to related parts will
help ensure that the parts most likely to be affected by
the wear of similar or nearby parts, or parts subjected to
the same amount of stress or wear, are given appropriate attention before a failure can occur.
Not for Reproduction
1 General Information
Torque Specifications
1 - 11
Torque Specification Chart
FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%)
Hardware
Grade
SAE Grade 2 SAE Grade 5 SAE Grade 8
Size Of in/lbs in/lbs in/lbs
Hardware ft/lbs Nm. ft/lbs Nm. ft/lbs Nm.
8-32 19 2.1 30 3.4 41 4.6
8-36 20 2.3 31 3.5 43 4.9
10-24 27 3.1 43 4.9 60 6.8
10-32 31 3.5 49 5.5 68 7.7
1/4-20 66 7.6 8 10.9 12 16.3
1/4-28 76 8.6 10 13.6 14 19.0
5/16-18 11 15.0 17 23.1 25 34.0
5/16-24 12 16.3 19 25.8 27 34.0
3/8-16 20 27.2 30 40.8 45 61.2
3/8-24 23 31.3 35 47.6 50 68.0
7/16-14 30 40.8 50 68.0 70 95.2
7/16-20 35 47.6 55 74.8 80 108.8
1/2-13 50 68.0 75 102.0 110 149.6
1/2-20 55 74.8 90 122.4 120 163.2
9/16-12 65 88.4 110 149.6 150 204.0
9/16-18 75 102.0 120 163.2 170 231.2
5/8-11 90 122.4 150 204.0 220 299.2
5/8-18 100 136 180 244.8 240 326.4
3/4-10 160 217.6 260 353.6 386 525.0
3/4-16 180 244.8 300 408.0 420 571.2
7/8-9 140 190.4 400 544.0 600 816.0
7/8-14 155 210.8 440 598.4 660 897.6
1-8 220 299.2 580 788.8 900 1,244.0
1-12 240 326.4 640 870.4 1,000 1,360.0
NOTES
1. These torque values are to be used for all hardware
excluding: locknuts, self-tapping screws, thread forming
screws, sheet metal screws and socket head setscrews.
2. Recommended seating torque values for locknuts:
a. for prevailing torque locknuts - use 65% of grade 5
torques.
b. for flange whizlock nuts and screws - use 135% of
grade 5 torques.
3. Unless otherwise noted on assembly drawings, all torque
values must meet this specification.
Hardware Identification & Torque Specifications
Common Hardware Types
3/8
5/16
1/4
1/2
DIA.
7/16
DIA.
Wrench & Fastener Size Guide
Standard Hardware Sizing
When a washer or nut is identified as 1/2”, this is the
Nominal size, meaning the inside diameter is 1/2 inch; if a
second number is present it represent the threads per inch
When bolt or capscrew is identified as 1/2 - 16 x 2”, this
means the Nominal size, or body diameter is 1/2 inch; the
second number represents the threads per inch (16 in this
example, and the final number is the body length of the
bolt or screw (in this example 2 inches long).
The guides and ruler furnished below are designed to
help you select the appropriate hardware and tools.
Not for Reproduction
Hex Head Capscrew
Washer
Carriage Bolt
1/4 3/4
1/4 3/4
0
Nut, 1/2”
1/2
1
1/2
Screw, 1/2 x 2
2
1/4 3/4
1/2
3
1/4 3/4
1/2
4
Body
Diameter
Body
Length
Lockwasher
Hex Nut
Inside
Diameter
No
Marks
1 General Information
Specifications
1 - 12
NOTE: Specifications are correct at time of printing and are subject to change without notice.
ENGINE
14 HP & 16 HP Briggs & Stratton Vanguard
Make Briggs & Stratton
Model Vanguard™ V-Twin
Horsepower 16 HP @ 3600 rpm
Cylinder 2
Bore 2.68 in (68 mm)
Stroke 2.60 in (66 mm)
Displacement 29.3 Cu. in (480 cc)
Construction Overhead Valve, Cast-Iron Sleeves,
Aluminum Crankcase
Electrical System 12 Volt, 16 amp Alternator Regulated Battery
Capacity 340 Cold Cranking amps, 41 Min. Reserve
Industrial Rated Starter Motor
Ignition Magnetron Electronic Ignition
Air Cleaner Ducted Paper Cartridge and Foam
Pre-cleaner
Lubrication Full Pressure Lube w/ Oil Filter
Oil Capacity 56 Oz. w/Filter (1.7 L)
Muffler Quiet Compact, Low Back Pressure
16 HP Briggs & Stratton V-Twin
Make Briggs & Stratton
Model Intek™ V-Twin
Horsepower 16 HP @ 3600 rpm
Cylinder 2
Bore 2.97 in (76 mm)
Stroke 2.89 in (73 mm)
Displacement 40.0 Cu. in (656 cc)
Construction Overhead Valve, Cast-Iron Sleeves,
Aluminum Crankcase
Electrical System 12 Volt, 9 amp Alternator Regulated Battery
Capacity 340 Cold Cranking amps, 41 Min. Reserve
Ignition High Energy Electronic Ignition
Air Cleaner Ducted Paper Cartridge and Foam
Pre-cleaner
Lubrication Full Pressure Lube w/ Oil Filter
Oil Capacity 4 Pints w/Filter (1.9 L)
Muffler Quiet Compact, Low Back Pressure
18 HP Briggs & Stratton Vanguard
Make Briggs & Stratton
Model Vanguard™ V-Twin
Horsepower 18 HP @ 3600 rpm
Cylinder 2
Bore 3.03 in (77 mm)
Stroke 2.64 in (67 mm)
Displacement 38 Cu. in (624 cc)
Construction Overhead Valve, Cast-Iron Sleeves,
Aluminum Crankcase
Electrical System 12 Volt, 16 amp Alternator Regulated Battery
Capacity 340 Cold Cranking amps, 41 Min. Reserve
Industrial Rated Starter Motor
Ignition Magnetron Electronic Ignition
Air Cleaner Ducted Paper Cartridge and Foam
Pre-cleaner
Lubrication Full Pressure Lube w/ Oil Filter
Oil Capacity 2 Quarts w/Filter (1.9 L)
Muffler Quiet Compact, Low Back Pressure
16 HP Kohler
Make Kohler
Model Command™ CV16S
Horsepower 16 HP @ 3600 rpm
Cylinder 1
Bore 3.55 in (90 mm)
Stroke 2.64 in (67 mm)
Displacement 26.0 Cu. in (426 cc)
Construction Overhead Valve, Cast-Iron Sleeve,
Aluminum Crankcase
Electrical System 12 Volt, 15 amp Alternator Regulated Battery
12 Volt, 340 Cold Cranking amps,
41 Min. Reserve Capacity
Ignition High Energy Electronic Ignition
Air Cleaner Ducted Paper Cartridge and Foam
Pre-cleaner
Lubrication Full Pressure Lube w/ Oil Filter
Oil Capacity 2 Quarts w/Filter (1.9 L)
Muffler Quiet Compact, Low Back Pressure
TRANSMISSION:
Type Tuff Torq K61
Hydrostatic
Pump Variable Displacement Axial Piston
Motor Fixed Displacement Reversible Axial Piston
Control Single Lever Foot Pedal, Free-Wheeling
Lever for Manual Tractor Movement
Hydraulic Fluid 10w 30 Premium Engine Oil
External Oil Reservoir
Speeds Forward: 0 - 5.6 MPH (0 - 9.0 km/h)
@ 3400 rpm Reverse: 0 - 3.2 MPH (0 - 4.8 km/h)
Differential Bevel Gear with Controlled Traction
Axle Shaft 1 in
Continuous Torque 188 ft. lbs.
Output
Drawbar Rating 251 lbs.
Maximum Weight 629 lbs.
on Axle
CHASSIS:
Frame Heavy Steel Channel - 10-12 Gauge
Power Take-Off Point: Front
Engine Mounting: Above Front Axle
Pivot Point Location: Front Axle
Rear Wheels Tire Size: 20 x 10.00-8 Turf Type
Pneumatic Inflation Pressure: 6-8 psi
(41-55 kPa)
Front Axle 1-3/4 in x 3 in 12 Ga. Fabricated Tube
Front Wheels Tire Size: 15 x 6.00-6
Pneumatic Inflation Pressure: 12-15 psi
(82-103 kPa)
Accessibility Hood Tips Forward
Seat Type: Bucket, High Back w/Quick Adjust,
Spring Suspension
Adjustable to Suit Different Size Operators
Turning Radius Inside Rear Tire: 16 in (40.6 cm)
Fuel Tank Material: Non-Corrosive Polyethylene
Fuel Tank Gauge Built Into Filler Cap
Capacity: 4 Gallons (15.1 L)
Not for Reproduction
1 - 13
1 General Information
Specifications
CONTROLS:
Steering 15" (38 cm) Steering Wheel
System: Gear and Sector, 1.25 turns Lock to
Lock
Clutch/ Location: Right Front
Brake Pedal Combination Clutch/Brake/Parking Brake
Pedal
Location Mower Lift Lever: Right Side
PTO Clutch: Electric, Dash Mounted
Hydrostatic Control-Single Lever Foot Pedal
Ignition Key Switch: On Lower Dash Panel
Throttle Lever On Dash Panel and Choke
Knob On Lower Dash Panel
Light Switch: On Dash Panel
Separate Indicator Lights for Safety
Interlock Switch: Operator Present,
PTO Disengaged,
Low Oil Pressure Warning Light, Hourmeter
DIMENSIONS:
Overall Length 70.25 in (178 cm)
Overall Width 35 in (88.9 cm)
Height To Top of Steering Wheel: 40 in (101.6 cm)
To Top of Engine Cover: 34 in (86.7 cm)
Wheel Base 50.75 in (129 cm)
Weight (apx..) Net: 424 lbs. (192 kg) w/o mower
536 lbs. (243 kg) w/mower
Shipping: 575 lbs. (261 kg) w/o mower
687 lbs. (312 kg) w/mower
Tractor Height
w/Snowcab 71.5 in (181 cm)
Tractor Length
w/Snowthrower est. 98 in (249 cm)
Tractor Length
w/Dozer Blade est. 94 in (239 cm)
50” MOWER: 12 GA.
Effective Cutting
Width 50 in Mower - 50 in (127 cm)
Overall Width
with Deflector 50 in Mower - 62 in (157.5 cm)
Weight 50 in Mower - 135 lbs. (61.4 kg)
Variable Cutting Ht. 1.0 - 3.6 in (3.2 to 8.0 cm)
Blade Arrangement Three Staggered Blades
Mower Drive V-Belt From Tractor Engine PTO Electric
Clutch
Spindle Bearings Lubricated and Sealed Ball Bearings
Lube Fitting Provided
44” MOWER: 12 GA.
Effective Cutting
Width 44 in Mower - 44 in (111.8 cm)
Overall Width
with Deflector 44 in Mower - 56 in (142.2 cm)
with Turbo 58" (147 cm)
Weight 44 in Mower - 112 lbs. (51 kg)
Variable Cutting Ht. 1.0 - 3.6 in (3.2 to 8.0 cm)
Blade Arrangement Three Staggered Blades
Mower Drive V-Belt From Tractor Engine PTO Electric
Clutch
Spindle Bearings Lubricated and Sealed Ball Bearings
Lube Fitting Provided
38” MOWER: 12 GA.
Effective Cutting
Width 38 in Mower - 38 in (96.5 cm)
Overall Width
with Deflector 38 in Mower - 49.5 in (125.7 cm)
with Turbo 38 in Mower - 51.5 in (131 cm)
Weight 38 in Mower - 100 lbs. (45 kg)
Variable Cutting Ht. 1.0 - 3.6 in (2.5 to 9.1 cm)
Blade Arrangement Two Blades
Mower Drive V-Belt From Tractor Engine PTO Electric
Clutch
Spindle Bearings Lubricated and Sealed Ball Bearings
Lube Fitting Provided
Not for Reproduction
1 General Information
Notes
1 - 14
Not for Reproduction
2 - 1
2 Troubleshooting
Table of Contents
SECTION CONTENTS
Troubleshooting
Troubleshooting the Tractor ......................................................... 2-2
Troubleshooting the Mower.......................................................... 2-3
SECTION 2. TROUBLESHOOTING
Not for Reproduction
2 Troubleshooting
Tractor Troubleshooting
2- 2
TROUBLESHOOTING
While normal care and regular maintenance will extend
the life of your equipment, prolonged or constant use
may eventually require that service be performed to
allow it to continue operating properly.
The troubleshooting guide below lists the most common
problems, their causes and remedies.
Troubleshooting the Tractor
PROBLEM CAUSE REMEDY
Engine will not turnover or start. 1. Brake pedal not depressed. Fully depress brake pedal.
2. PTO (electric clutch) switch Place in OFF position.
in ON position.
3. Out of fuel. If engine is hot, allow it to cool, then refill
the fuel tank.
4. Engine flooded. Push choke knob in (twin cylinder models)
or move throttle control out of CHOKE
position (single cylinder models).
5. Circuit breaker tripped. Wait one minute for automatic reset.
Replace if defective.
6. Battery terminals require See Battery Maintenance Section.
cleaning.
7. Battery discharged or dead. Recharge or replace.
8. Wiring loose or broken. Visually check wiring & replace broken or
frayed wires. Tighten loose connections.
9. Solenoid or starter motor faulty. See Electrical Troubleshooting Section.
10. Safety interlock switch or See Electrical Troubleshooting Section.
module faulty.
11. Spark plug(s) faulty, fouled Clean and gap or replace.
or incorrectly gapped. See engine manual.
12. Water in fuel. Drain fuel & refill with fresh fuel.
13. Gas is old or stale. Drain fuel & replace with fresh fuel.
Engine starts hard or runs poorly. 1. Fuel mixture too rich. Clean air filter. Check choke adjustment
(engine speed control).
2. Spark plug(s) faulty, fouled, or Clean and gap or replace.
incorrectly gapped. See engine manual.
Engine knocks. 1. Low oil level. Check/add oil as required.
2. Using wrong grade oil. See engine manual.
Excessive oil consumption. 1. Engine running too hot. Clean engine fins, blower screen and
air cleaner.
2. Using wrong weight oil. See engine manual.
3. Too much oil in crankcase. Drain excess oil.
Engine exhaust is black. 1. Dirty air filter. Replace air filter. See engine manual.
2. Choke closed. Open choke.
Engine runs, but tractor will 1. Ground speed control pedals Depress pedals.
not drive. not depressed.
2. Transmission release lever Move into drive position.
in “push” position.
3. Drive belt is broken. See Drive Belt Replacement.
4. Drive belt slips. See cause and remedy below.
5. Brake is not fully released. See Brake Adjustment.
WARNING
To avoid serious injury, perform maintenance on
the tractor or mower only when the engine is
stopped and the parking brake engaged.
Always remove the ignition key, disconnect the
spark plug wire and fasten it away from the plug
before beginning the maintenance, to prevent
accidental starting of the engine.
Not for Reproduction
2 - 3
2 Troubleshooting
Mower Troubleshooting
Tractor Troubleshooting Cont.
Tractor drive belt slips. 1. Brake is out of adjustment. See Adjustments Section.
2. Pulleys or belt greasy or oily. Clean as required.
3. Belt stretched or worn. Replace with new belt.
4. Idler pulley pivot bracket Remove idler pulley bracket, clean and lubricate.
“frozen” in declutched position.
Brake will not hold. 1. Brake is incorrectly adjusted. See Brake Adjustment.
2. Internal brake worn. See Transmission Teardown.
Tractor steers hard or 1. Steering linkage is loose. Check and tighten any loose connections.
handles poorly. See Steering Gear Adjustment.
2. Improper tire inflation. Check and correct.
3. Front wheel spindle Grease spindles. See Lubricating the
bearings dry. Tractor.
Drive belt does not stop when 1. Belt stops or belt tension See Adjustments Section.
clutch/brake pedal depressed. out of adjustment.
Troubleshooting the Mower
PROBLEM CAUSE REMEDY
Mower will not raise. 1. Lift link not properly attached Attach or repair.
or damaged.
Mower cut is uneven. 1. Mower not leveled properly. See Mower Adjustment.
2. Tractor tires not inflated See Maintenance Section.
equally or properly.
Mower cut is rough looking. 1. Engine speed too slow. Set to full throttle.
2. Ground speed too fast. Slow down.
3. Blades are dull. Sharpen or replace blades.
See Mower Blade Service.
4. Mower drive belt slipping Clean or replace belt as necessary.
because it is oily or worn.
5. Check PTO (Electric Clutch) See Adjustments Section.
Adjustment.
6. Blades not properly fastened See Servicing the Mower Blades.
to arbors.
Engine stalls easily with 1. Engine speed too slow. Set to full throttle.
mower engaged. 2. Ground speed too fast. Slow down.
3. Carburetor improperly adjusted. See Engine Manual.
4. Cutting height set too low. Cut tall grass at maximum cutting
height during first pass.
5. Discharge chute jamming Cut grass with discharge pointing toward
with cut grass. previously cut area.
Excessive mower vibration. 1. Blade mounting screws Tighten to 45-55 ft.lbs. (61-75 N.m.).
are loose.
2. Mower blades, arbors, Check and replace as necessary.
or pulleys are bent.
3. Mower blades are out Remove, sharpen, and balance blades.
of balance. See Servicing the Mower Blades.
4. Belt installed incorrectly. Reinstall Correctly.
Excessive belt wear or breakage. 1. Belt tension too tight. Adjust belt tension.
2. Bent or rough pulleys. Repair or replace.
3. Using incorrect belt. Replace with correct belt.
Mower drive belt slips 1. Idler pulley spring broken or not Repair or replace as needed.
or fails to drive. properly attached.
2. Belt stops out of adjustment. Check belt stops.
3. Mower drive belt broken. Replace drive belt.
Not for Reproduction
2 Troubleshooting
Notes
2- 4
Not for Reproduction
3 - 1
3 Maintenance
Table of Contents
SECTION CONTENTS
Storage
Temporary.....................................................................................3-2
Long Term.....................................................................................3-2
Starting After Long Term Storage .................................................3-2
Maintenance Schedule..........................................3-3
Checking Tire Pressures.......................................3-3
Check / Change Transmission Oil........................3-4
Accessing the Engine ...........................................3-5
Fuel Filter Replacement ........................................3-5
Oil & Filter Change ................................................3-5
Check / Change Air FIlter......................................3-5
Inspect & Replace Spark Plugs............................3-5
Lubrication .............................................................3-6
Lubricate Rear Axles.............................................3-7
Battery Maintenance
Check Battery Fluid.......................................................................3-8
Clean Battery and Cables .............................................................3-8
Servicing the Mower Blades.................................3-9
Perform Safety Checks
Functional Tests..........................................................................3-10
Dash Safety Lights Test ..............................................................3-10
Mower Blade Stopping Check.....................................................3-10
Seat Switch Connection ..............................................................3-10
Safety Interlock System Check ...................................................3-11
Blade Brake Check .....................................................................3-11
SECTION 3. MAINTENANCE
Not for Reproduction
3 Maintenance
Storage
3 - 2
WARNING
Never store the unit, with gasoline in engine or
fuel tank, in a heated shelter or in enclosed,
poorly ventilated enclosures. Gasoline fumes may
reach an open flame, spark or pilot light (such as
a furnace, water heater, clothes dryer, etc.) and
cause an explosion.
Handle gasoline carefully. It is highly flammable
and careless use could result in serious fire
damage to your person or property.
Drain fuel into an approved container outdoors
away from open flame or sparks.
STORAGE
Temporary Storage (30 Days Or Less)
Remember, the fuel tank will still contain some gasoline, so
never store the unit indoors or in any other area where fuel
vapor could travel to any ignition source. Fuel vapor is also
toxic if inhaled, so never store the unit in any structure used
for human or animal habitation.
Here is a checklist of things to do when storing your unit
temporarily or in between uses:
• Keep the unit in an area away from where children may
come into contact with it. If there’s any chance of unauthorized use, disconnect the spark plug wires.
• If the unit can’t be stored on a reasonably level surface,
chock the wheels.
• Clean all grass and dirt from the mower.
NOTE: If storing your tractor between winter snow removal
jobs in a cold area, we suggest that you fill the fuel tank at
the completion of each job to prevent water condensation in
the fuel tank. Wait for engine to cool before filling tank.
Long Term Storage (Longer Than 30 Days)
Before you store your unit for the off-season, read the
Maintenance and Storage instructions in the Safety Rules
section, then perform the following steps:
1. Drain crankcase oil and refill with a grade of oil that will
be required when unit is used again.
2. Prepare the mower deck for storage as follows:
a. Remove mower deck from the unit.
b. Clean underside of mower deck.
c. Coat all bare metal surfaces with paint or light coat
of oil to prevent rusting.
3. Clean external surfaces and engine.
4. Prepare engine for storage. See engine owner’s
manual.
5. Clean any dirt or grass from cylinder head cooling fins,
engine housing and air cleaner element.
6. Cover air cleaner and exhaust outlet tightly with plastic
or other waterproof material to keep out moisture, dirt
and insects.
7. Completely grease and oil unit as outlined in the Normal
Care section.
8. Clean up unit and apply paint or rust preventative to any
areas where paint is chipped or damaged.
9. Be sure the battery is filled to the proper level with water
and is fully charged. Battery life will be increased if it is
removed, put in a cool, dry place and fully charged
about once a month. If battery is left in unit, disconnect
the negative cable.
10. Drain fuel system completely or add a gasoline stabilizer
to the fuel system. If you have chosen to use a fuel stabilizer and have not drained the fuel system, follow all
safety instructions and storage precautions in this manual to prevent the possibility of fire from the ignition of
gasoline fumes. Remember, gasoline fumes can travel
to distant sources of ignition and ignite, causing risk of
explosion and fire.
NOTE: Gasoline, if permitted to stand unused for extended
periods (30 days or more), may develop gummy deposits
which can adversely affect the engine carburetor and cause
engine malfunction. To avoid this condition, add a gasoline
stabilizer to the fuel tank and run the engine a few minutes,
or drain all fuel from the unit before placing it in storage.
STARTING AFTER
LONG TERM STORAGE
Before starting the unit after it has been stored for a long
period of time, perform the following steps.
1. Remove any blocks from under the unit.
2. Install the battery if it was removed.
3. Unplug the exhaust outlet and air cleaner.
4. Fill the fuel tank with fresh gasoline. See engine
manual for recommendations.
5. See engine owner’s manual and follow all instructions
for preparing engine after storage.
6. Check crankcase oil level and add proper oil if
necessary. If any condensation has developed during
storage, drain crankcase oil and refill.
7. Inflate tires to proper pressure. Check fluid levels.
8. Start the engine and let it run slowly. DO NOT run at
high speed immediately after starting. Be sure to run
engine only outdoors or in well ventilated area.
Not for Reproduction
3 - 3
3 Maintenance
Schedule
MAINTENANCE SCHEDULE & PROCEDURES
The following schedule should be followed for normal care of your tractor and mower. You will need to keep a record
of your operating time. Determining operating time is easily accomplished by multiplying the time it takes to do one
job by the number of times you’ve done the job, or you can install the optional hour meter.
* See the engine manufacturer's owner's manual.
** Change original engine oil after first 5 hours of operation.
*** More often in hot (over 85° F: 30° C) weather or dusty operating conditions.
**** Perform service after the first 50 hours of operation, then every 250 hours.
Tire Pressure
Front 12-15 psi (83-104 kPa)
Rear 6-8 psi (41-55 kPa)
Figure 1. Checking Tire Pressure
CHECK TIRE PRESSURES
Tire Pressure should be checked periodically, and maintained at the levels shown in the chart. Note that these
pressures may differ slightly from the “Max Inflation”
stamped on the side-wall of the tires. The pressures
shown provide proper traction, improve cut quality, and
extend tire life.
Before Before Every Every Every Spring
SAFETY ITEMS First Use Each Use 5 Hours 25 Hours 100 Hours & Fall
Check Safety Interlock System ●●
Check Tractor Brakes ●●
Check Mower Blade Stopping Time ●●
Before Before Every Every Every Spring
NORMAL CARE ITEMS First Use Each Use 5 Hours 25 Hours 100 Hours & Fall
Check Tractor/Mower for loose hardware ●●●
Check Engine Air Filter *, *** ●●
Check Engine Oil Level * ●● ●
Change Engine Oil & Filter *, **, *** ●●
Lubricate Tractor & Mower *** ●●
Check Tire Pressure ●● ●
Check Transmission Fluid ●●
Change Transmission Fluid **** Every 250 Hours
Check/Adjust PTO Clutch **** Every 250 Hours
Check Fuel Filter ●●
Clean Battery & Cables ●●
Clean & Sharpen Mower Blades ●●
Inspect Spark Plug(s) * ●●
Lubricate Rear Axle Shafts Yearly
Not for Reproduction
3 Maintenance
Check / Change Transmission Oil
3 - 4
CHECK / CHANGE
TRANSMISSION OIL
The transmission oil should be checked before each use,
and changed at the intervals shown or if it has become
discolored from overheating or contamination.
Service Interval: After initial 50 Hrs, then every 250 Hrs.
Oil Capacity: Apx. 3.5 Quarts
Oil Type: SAE 10W-30 with a minimum API rating
of SG/CD.
Checking the Oil Level:
1. Locate the reservoir tank on the rear of the unit.
Observe the oil level. Oil should be up to the FULL
mark (see Figure 2). DO NOT OVERFILL. Empty
space is required for heat expansion.
2. If necessary, clean the area surrounding the reservoir
cap, remove the cap, and add oil.
Changing the Transmission Oil:
1. Drain hydrostatic system by removing drain plug (see
Figure 3). Drain oil into a suitable container.
2. Reinstall the drain plug.
3. Add oil a few ounces at a time until the reservoir is
filled to the FULL mark. DO NOT OVERFILL. Empty
space is required for heat expansion.
4. Run tractor for several minutes and recheck the
transmission oil level. If the transmission is excessively noisy or unresponsive, perform the purging
procedure found in the Service section.
FULL
Figure 2. Transmission Oil Reservoir
Full Mark
Figure 3. Transmission Drain Plugs
Do not allow dirt, water, or other debris to
enter the reservoir. Even a small amount of
dirt can irreparably damage the transmission
Drain
Plug
Not for Reproduction
3 - 5
3 Maintenance
Engine Service
Figure 5. Engine Compartment
-Kohler Single Cylinder Engine
A. Battery D Oil Fill/Dipstick
B. Oil Filter E. Fuel Filter (Not Shown
C. Air Filter F. Throttle/Choke Cable
D
C
B
A
E
F
ACCESSING THE ENGINE
To gain access to the engine, unhook the rubber straps
(Figure 4) and tip the hood forward.
NOTE: For engine service item locations see Figure
6 for models with Briggs & Stratton engines and
Figure 5 for models with Kohler engines
FUEL FILTER REPLACEMENT
The fuel filter (E, Figures 5 & 6) is located in the fuel line
between the fuel tank and the carburetor.
If filter is dirty or clogged, replace as follows:
1. Disconnect the negative battery cable.
2. Place a container below the filter to catch spilled fuel.
3. Using a pliers, open and slide hose clamps from fuel
filter.
4. Remove hoses from filter.
5. Install new filter in proper flow direction in fuel line.
6. Secure with hose clamps.
7. Reconnect the negative battery cable when finished.
D
C
B
A
E
G
F
Figure 6. Engine Compartment
- Briggs & Stratton Twin Cylinder Engines
A. Battery E. Fuel Filter
B. Oil Filter F. Throttle Cable
C. Air Filter G. Choke Cable
D Oil Fill/Dipstick
Figure 4. Engine Access
Undo Hood
Straps (Both
Sides) and Lift
Hood to access
Engine
D
C
B
A
E
OIL & FILTER CHANGE
Refer to engine manual for specific oil and filter recommendations and oil draining procedures.
CHECK / CHANGE AIR FILTER
Refer to the engine manual for specific air filter service
procedures.
INSPECT & REPLACE SPARK PLUGS
Refer to the engine manual for specific spark plug
replacement procedures.
Not for Reproduction
3 Maintenance
Lubrication
3 - 6
Figure 8. Lubricating the Tractor
LUBRICATION
Lubricate the unit at the locations shown in Figures 7-11
as well as the following lubrication points.
Grease:
• front axle pivot
• front axle grease fittings
• steering linkage
• foot pedal
• mower pivots
• mower arbors
• transmission idler assembly pivot
Use grease fittings when present. Disassemble parts
to apply grease to moving parts when grease fittings
are not present.
Not all greases are compatible. Simplicity Lithium
Grease is recommended, automotive-type lithium
grease may be used when this is not available.
Oil:
• hydro linkage
• seat adjustment assembly
• brake linkage
• frame pivot points
• mower deck height adjustment linkage
Generally, all moving metal parts should be oiled
where contact is made with other parts. Keep oil and
grease off belts and pulleys. Remember to wipe fittings and surfaces clean both before and after lubrication.
Figure 9. Brake Pedal Pivot Point
Figure 7. Lubricate Steering Linkage
Not for Reproduction
3 - 7
3 Maintenance
Lubricate Rear Axles
Figure 11. Mower Lubrication Points
Figure 10. Arbor Lubrication Points
LUBRICATE REAR AXLES
We recommend removing the rear wheels and lubricating the axle shafts yearly. This prevents the wheel from
seizing onto the axle shaft, making future service easier.
1. Remove the key and disconnect the spark plug
wire(s) while working on the unit.
2. Engage the parking brake and block the front wheels.
3. Using a jack or chain hoist positioned at the center of
the rear frame, carefully jack the unit up until the rear
tires are approximately 1" - 2" off the ground.
NOTE: For overall unit stability during service, do not
jack rear end higher than required for wheel removal.
4. Support the rear of the unit on jack stands positioned
under the rear frame (see Figure 12).
5. Remove the plastic hub cap (G, Figure 13).
6. Remove e-ring (F) using a screwdriver.
7. Remove the washers (D) and wheel (C).
NOTE: Your axle assembly may differ slightly from the
assembly pictured: washer (D, Figure 13) may be missing or doubled. This is adjusted on a tractor by tractor
basis during assembly to allow a small amount of axle
end-play.
8. Lubricate the axle shaft with anti-seize compound or
lithium grease.
9. See Figure 13 for assembly. Reinstall components in
reverse order of disassembly and lower the unit. Be
sure the key (H) is in place in the axle key-way.
Figure 12. Elevate the Rear End
Figure 13. Wheel and Axle Assembly
A. Washer E. Hub Cap Retainer
B. Spacer F. E-Ring
C. Wheel G. Hub Cap
D. Washer H. Key
A
B
C
D
E
F
G
H
Not for Reproduction
3 Maintenance
Battery Maintenance
3 - 8
BATTERY MAINTENANCE
Checking the Battery Fluid
Note: Does not apply to maintenance-free batteries.
1. Raise the hood to access battery.
2. Remove the battery filler cap (See Figure 14). Fluid
must be even with the split ring full mark. If not, add
distilled water.
3. Reinstall the filler cap.
Cleaning the Battery and Cables
1. Disconnect the cables from the battery, negative
cable first (B, Figure 14).
2. Remove the battery hold-down rods (C, Figure 14)
and battery clamp (D) and battery.
3. Clean the compartment with a solution of baking
soda and water.
4. Clean the battery terminals and cable ends with a
wire brush and battery terminal cleaner until shiny.
5. Reinstall the battery in the battery compartment, and
secure with the battery hold-down rods (C) and battery clamp (D).
6. Reattach the battery cables, positive cable first (see
A, Figure 14)
7. Coat the cable ends and battery terminals with petroleum jelly or non-conducting grease.
WARNING
Be careful when handling the battery. Avoid
spilling electrolyte. Keep flames and sparks away
from the battery.
When removing or installing battery cables,
disconnect the negative cable FIRST and reconnect
it LAST. If not done in this order, the positive
terminal can be shorted to the frame by a tool.
Figure 14. Battery
A. Positive Battery Terminal
B. Negative Battery Terminal
C. Hold Down Rod
D. Battery Clamp
Not for Reproduction
C
D
B
A
3 - 9
3 Maintenance
Mower Blade Service / Blade Brake Check
SERVICING THE MOWER BLADES
1. Remove mower from the tractor. See Mower
Installation & Removal.
2. Blades should be sharp and free of nicks and dents.
If not, sharpen blades as described in following steps.
3. To remove blade for sharpening, use a wood block to
hold blade while removing the blade mounting capscrew (Figure 15).
4. Use a file to sharpen blade to fine edge. Remove all
nicks and dents in blade edge. If blade is severely
damaged, it should be replaced.
5. Balance the blade as shown in Figure 16. Center the
blade’s hole on a nail lubricated with a drop of oil. A
balanced blade will remain level.
6. Reinstall each blade with the tabs pointing up toward
deck as shown in Figure 17. Secure with a capscrew,
spring washer and hex washer (be certain the hex
washer is aligned with the hex shaft). Use a wooden
block to prevent blade rotation and torque capscrews
to 45-55 ft.lbs. (61-75 N.m.).
WARNING
For your personal safety, do not handle the sharp
mower blades with bare hands. Careless or
improper handling of blades may result in serious
injury.
WARNING
For your personal safety, blade mounting
capscrews must each be installed with a hex
washer and spring washer, then securely
tightened. Torque blade mounting capscrew to
45 - 55 ft. lbs. (61 - 75 N.m.)
Figure 16. Balancing The Blade
Workbench
Nail
Figure 15. Removing the Blade
Figure 17. Installing The Blade
A. 4x4 Wood Block C. Spring Washer
B. Hex Washer D. Blade Bolt
4x4 Wood Block
Not for Reproduction
LOOSEN
B
A
TIGHTEN
C
D
3 Maintenance
Perform Safety Checks
3 - 10
PERFORM SAFETY CHECKS
Functional Tests
1. Check the tractor for loose bolts, screws, nuts, etc.
2. Start the engine and check all controls for proper
operation: ground speed control pedals, clutch/brake
pedal, parking brake, throttle and choke cables, electric PTO clutch, headlight switch, steering, attachment
lift, etc.
3. Stop the engine and check for fluid leaks: oil, gasoline, coolant, or transmission oil.
4. If any control fails to operate properly during testing or
seems to be out of adjustment, check and readjust it
according to the following Adjustments section.
Dash Safety Lights Test
Check the operation of the tractor controls and dash
safety lights. With an operator in seat and ignition switch
turned to ON (engine not running):
1. PTO Indicator Light (red) should go on and off with
operation of electric clutch switch.
2. The parking brake / cruise control lock light should go
on when the parking brake / cruise control is activated.
3. Headlight Indicator Light should go on when the
headlights are turned on.
4. Oil Pressure Indicator Light (red) should turn on and
should go out immediately after the engine starts.
Mower Blade Stopping Check
Mower blades and mower drive belt should come to a
complete stop within five seconds after the electric clutch
switch is turned off.
With the tractor in neutral, the electric clutch switch disengaged, and an operator in the seat, start the tractor
engine. Run the engine at full throttle. Engage the electric
PTO clutch switch and wait several seconds. Disengage
electric clutch switch and check the time it takes for the
mower drive belt to stop.
If the mower drive belt does not stop within five seconds,
adjust the PTO clutch according to the instructions in the
Electric Clutch Adjustment section.
Seat Switch Connection
Check that the seat switch (A, Figure 18) is connected to
the seat switch wire harness (B).
WARNING
Disengage the PTO, stop the engine, set the parking
brake, and wait for moving parts to stop before leaving operator's position for any reason.
If the tractor does not pass the test, do not operate tractor. Under no circumstance should you
attempt to defeat the purpose of the safety
system.
Figure 18. Seat Switch
A. Seat Switch B. Wiring Harness
A
B
Not for Reproduction
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