Simplicity AGCO Allis 500 Series, 169354, 169588, 169591, 169593 Service And Repair Manual
...
Repair Manual Contents
This manual is divided into the sections listed below.
Please see the first page of each section for the specific contents of that section.
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 — 1-16
2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 — 2-6
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 — 3-12
4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 — 4-10
5 Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 — 5-8
6 Common Service Procedures. . . . . . . . . . . . . . . . . . . 6-1 — 6-10
7 Electrical System Service. . . . . . . . . . . . . . . . . . . . . . . 7-1 — 7-30
8 Steering Component Service . . . . . . . . . . . . . . . . . . . 8-1 — 8-10
9 Drive Controls Service. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 — 9-16
10 Transmission Removal & Installation . . . . . . . . . . . 10-1 — 10-16
11 Transmission Tear-Down . . . . . . . . . . . . . . . . . . . . . . . 11-1 — 11-28
12 Hood Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . 12-1 — 12-4
13 Seat & Seat Deck Service. . . . . . . . . . . . . . . . . . . . . . . 13-1 — 13-6
14 PTO Clutch Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 — 14-4
16 Mower Deck Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 — 16-18
15 Miscellaneous Component Service . . . . . . . . . . . . . 15-1 — 15-4
1-1
1 General Information
Table of Contents
SECTION CONTENTS
Models Covered, Identification Numbers,
& Basic Configurations
Models, Identification, & Configurations ...................................... 1-2
Introduction
Introduction.................................................................................. 1-4
Manual Content ........................................................................... 1-4
Safety Rules
Safety Rules - General Operation................................................ 1-5
Safety Rules - Service And Maintenance .................................... 1-7
General Repair Information
Bearings & Bushings ................................................................. 1-10
Belts & Pulleys........................................................................... 1-10
Electrical Parts........................................................................... 1-10
Fasteners & Hardware............................................................... 1-11
Genuine Replacement Parts...................................................... 1-11
Paint........................................................................................... 1-11
Required Tools & Equipment..................................................... 1-11
Systems Checks........................................................................ 1-11
Specifications..............................................................................1-12
Torque Specifications ................................................................ 1-15
SECTION 1. GENERAL INFORMATION
1 General Information
Models Covered In This Manual
1-2
MODELS COVERED, IDENTIFICATION NUMBERS, AND
BASIC CONFIGURATIONS
Mower Deck
Identification Tag
Tractor
Identification Tag
TRACTOR & MOWER IDENTIFICATION TAG LOCATIONS
169XXXX
MFG
Simplicity Manufacturing, Inc.
Port Washington, WI 53074-0997 U.S.A.
SERIAL
XXXXX
When contacting your Authorized
Dealer for replacement parts, service,
or information YOU MUST HAVE
THESE NUMBERS.
This manual contains service information for the models
listed on the following page (and similar models produced after this manual’s printing). 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.
At the time of this printing Regent / 500 / 2500 series
tractors have been built with four basic powertrain configurations. These four basic types are referred to throughout this manual and denoted by their transmission.
When a service procedure is specific to a certain model,
that model will be identified as one of the groups listed at
right.
MODEL IDENTIFICATION
Hydro-Gear 0500 and 0650 Models are similar utilizing
the same brake linkage . Their engines and transmissions are also similar. Their primary difference is the
linkage used to connect the transmission to the foot
pedal.
Tuff Torq K-56 Models are radically different from
Hydro-Gear Models. Tuff Torq models can be easily recognized by their Kohler engine.
Peerless Models are distinct in that they are gear drive
and require clutching.
Hydro-Gear 0500 Models
Engine: Briggs and Stratton 14HP Vanguard
Transmission: Hydrostatic, Hydro-Gear 318-0500, or
Hydro-Gear 322-0500
Deck: 38” Twin Blade
Hydro-Gear 0650 Models
Engine: Briggs and Stratton 16HP Vanguard
Transmission: Hydrostatic, Hydro-Gear 322-0650
Deck: 44” Triple Blade
Tuff Torq K-56 Models
Engine Kohler Command 14HP & 16HP
Transmission: Hydrostatic, Tuff Torq K56
Deck: 38” Twin Blade and 44” Triple Blade
Peerless Models, “Gear Drive”
Engine: 14HP Kohler Command,
16HP Kohler Command,
15.5 HP Briggs & Stratton Diamond I/C,
14HP Briggs & Stratton Diamond I/C
Transmission: Gear Drive, Peerless MST-205-515 or
MST-205-515A
Deck: 38” Twin Blade and 44” Triple Blade
SSAAMMPPLLEE
1-3
1 General Information
Models Covered In This Manual
Mfg. No.
1692354 14HP Regent Hydro
1692588 514H, 14 HP Hydro
1692591 2514H, 14 HP Hydro
1692593 14HP Regent Gear
1692595 514G, 14 HP Gear
1692597 2514G, 14 HP Gear
1692599 14HP Regent Gear (Export)
1692601 14Hp Regent Hydro (Export)
1692760 16HP Regent Gear
1692762 16HP Regent Hydro
1692829 516G, 16 HP Gear
1692831 516H, 16 HP Hydro
1692835 2516H, 16 HP Hydro
1693100 2514G. 14HP Gear
1693102 2514H, 14HP Hydro
1693104 2516H, 16 HP Hydro
1693074 14HP Regent Gear
1693076 14HP Regent Gear (Export)
1693080 14HP Regent Hydro
1693082 14HP Regent Hydro (Export)
1693084 16HP Regent Gear
1693086 16HP Regent Gear (Export)
1693088 16HP Regent Hydro
1693090 16HP Regent Hydro(Export)
1693092 514G, 14 HP Gear
1693094 514H, 14HP Hydro
1693098 516H, 16HP Hydro
1693100 2514G, 14HP Gear
1693102 2514H, 14HP Hydro
1693104 2516H, 16HP Hydro
1693323 Regent, 14HP Gear
1693325 Regent, 14HP Hydro
1693327 Regent, 16HP Gear
1693329 Regent, 16HP Hydro
Tractors
Description
Description
Mower Decks
1692358 38” Mower Deck
1692589 38” Mower Deck
1692744 44” Mower Deck
1692851 44” Mower Deck
1693078 38” Mower Deck
Mfg. No.
1693331 Regent, 14HP Gear (Export)
1693333 Regent, 14HP Hydro (Export)
1693335 Regent, 16HP Gear (Export)
1693337 Regent, 16HP Hydro (Export)
1693339 514G, 14HP Gear
1693341 514H, 14HP Hydro
1693343 516H, 16HP Hydro
1693345 2514G, 14HP Gear
1693347 2514H, 14HP Hydro
1693349 2516H, 16HP Hydro
Sports Series Tractors
1692873 Packers Regent 14HP Hydro
1692957 Vikings Regent 14HP Hydro
1692959 Steelers Regent 14HP Hydro
1692961 Panthers Regent 14HP Hydro
1692963 Chiefs Regent 14HP Hydro
1692965 Colts Regent 14HP Hydro
1692967 Badgers Regent 14HP Hydro
1692969 Hawkeyes Regent 14HP Hydro
1692971 Wolverines Regent 14HP Hydro
1692973 Spartans Regent 14HP Hydro
1692975 Nittany Lions Regent 14HP Hydro
1693190 New England Patriots 14HP Regent
1693192 Packers Superbowl 14HP Regent
1693194 Dallas Cowboys 14HP Regent
1693196 New York Giants 14HP Regent
1693198 Tennessee Volunteers 14HP Regent
1693200 Indiana Hoosiers 14HP Regent
1693202 Ohio State Buckeyes 14HP Regent
1693212 Chicago Bears 14HP Regent
1693214 Detroit Lions 14HP Regent
1693216 Philadelphia Eagles 14HP Regent
Mfg. No.
Description
1693079 38” Mower Deck
1693169 44” Mower Deck (Export)
1693188 44” Mower Deck
1693189 44” Mower Deck
1693218 38” Mower Deck (Export)
Mfg. No.
Description
NOTE: This list is correct and complete at the time of
printing. Though your tractor may not appear on this list,
it may be covered in part or in full by this manual
1 General Information
Introduction
1-4
INTRODUCTION
This manual is divided into sixteen major sections of service information.
1. General Information
Contains general information such as models and manufacturing numbers, general repair instructions for components, and important safety instructions for operating and
servicing the units.
2. Troubleshooting
Provides troubleshooting information pertaining to unit
operation.
3. Maintenance
Contains basic service information for normal maintenance and off-season storage.
4. Adjustments
Contains basic service information and procedures for
adjustments.
5. Belt Replacement
Contains procedures for removing and installing belts.
6. Common Service Procedures
Contains common service procedures.
7. Electrical System Service
Contains electrical system component location, component replacement, and troubleshooting procedures.
8. Steering Component Service
Contains steering system component service procedures.
9. Drive Controls Service
Contains drive system component service procedures.
10. Transmission Removal & Installation
Contains procedures for removing and installing whole
transmission assemblies.
11. Transmission Tear-Down
Contains procedures for disassembling and reassembling transmissions.
12. Hood Assembly Service
Contains procedures for removing, disassembling, and
reassembling the hood and headlight bezel.
13. Seat & Seat Deck Service
Contains procedures for seat and seat deck service.
14. PTO Clutch Service
Covers removal and installation of the PTO clutch.
15. Miscellaneous Component Service
Covers removal of the throttle control, gas tank, and
other components not grouped in other sections.
16. Mower Deck Service
Covers common mower deck service procedures.
MANUAL CONTENT
This manual is intended primarily for use by dealer service personnel as a technical reference manual or as a
complement 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 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 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 1995 through 1998, 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.
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.
1-5
1 General Information
Safety Rules
Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of
tractor, severe personal injury or death to you, or bystanders, or damage to property or equipment. The
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.
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.
• 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.
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 mow it.
Do
• Follow manufacturer’s 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. Choose a low gear so that you will
not have to stop or shift 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.
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 catcher on steep slopes.
WARNING - SLOPE OPERATION
Never operate on slopes greater than 30 percent (16.7°)
which is a rise of three feet vertically in 10 feet horizontally. When operating on slopes that are greater than 15
percent (8.5°) but less than 30 percent use front counterweights and rear wheel weights (see your dealer). 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.
1 General Information
Safety Rules
1-6
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 when backing, 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.
TRANSPORTING AND STORAGE
• Always observe safe refueling and fuel handling practices when refueling the tractor after transportation,
service, or storage.
• Always follow the engine manual instructions for
storage preparations when preparing 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, gas furnace, or stove. Allow unit to cool
before storing. (“Cool” is defined as being cool
enough that all components can be touched: less
than 150 degrees Fahrenheit.)
GENERAL SAFETY
All WARNING, CAUTION, and instructional messages
appearing in decals on the tractor and mower being serviced must be carefully read and obeyed. Severe personal injury can result when these instructions are not
followed. The information is for your safety, as well as
those who operate the equipment, and it is important!
If any of these decals are lost or damaged, replace them
at once. See your Parts Manual for replacement information.
These labels are easily applied and will act as a constant
visual reminder to you, the operator, and others who may
use the equipment, to follow the safety instructions necessary for safe, effective operation.
1-7
1 General Information
Safety Rules
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,
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 .
1 General Information
Safety Rules
1-8
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
builds 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.
Safe Elevation Of Unit
• 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.
1-9
1 General Information
Safety Rules
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.
1 General Information
Repair Information
1-10
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 have been
specifically engineered for outdoor power equipment,
and are 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.
1-11
1 General Information
Repair Information
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.
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.
1 General Information
Specifications
1-12
14 HP Briggs & Stratton
Make: Briggs & Stratton - 4 cycle air cooled
Model & Type: See engine l.D. plate
Horsepower: 14 HP @ 3600 rpm (Eng. Mfg’s. Rating)
Cylinder: 1 horizontal
Bore & Stroke: 3.44 x 3.06 inches (87.3 x 77.7 mm)
Displacement: 28.4 cu. in. (465 cc)
Construction: Overhead valve, cast iron sleeves, aluminum
crankcase
Electrical: Vanguard - 12 volt 9 amp. alternator regulated
battery, 12 volt, 340 cranking amps, 41 minute
reserve capacity.
Diamond - unregulated 3 amp. DC charging
circuit.
Governor: Mechanical
Oil Capacity: 4.0 pints w/filter (1.9 L)
Ignition: Magnetron electronic
Charging: Diamond: Unregulated 3-amp DC,
Vanguard: Unregulated 9-amp DC
Air Cleaner: Ducted paper cartridge and foam pre-cleaner
Fuel Tank: High density polyurethane construction; 2 gal-
lons (7.57 liters) of “regular” grade leaded or
non-leaded gasoline.
Muffler Large, low back pressure, remote canister type
Starter: 12 volt electric gear drive
15.5 HP Briggs & Stratton
Make: Briggs & Stratton - 4 cycle air-cooled
Model & Type: Diamond I/C
Horsepower: 15.5 HP
Cylinder: 1 horizontal
Bore & Stroke: 3.44in.(87.3)mm
Displacement: 28.4cu.in.(465cc)
Construction: Overhead valve, Dura Bore Sleeves,
Aluminum Crankcase.
Electrical: 12 volt 9 amp, alternator
regulated battery, 12 volt, 340 cranking
amps, 41 minute reserve capacity.
Governor: Mechanical
Oil Capacity: 3 Pints w/Filter (1.4 L)
Ignition: Magnetron Electronic
Charging: Regulated 9 amp DC charging circuit
Air Cleaner: Tri-Clean
Fuel Tank: High Density polyurethane construction;
2 gallons (7.57 liters) of “regular” grade
leaded or non-leaded gasoline.
Muffler: Simplicity Custom Muffler
Starter: Electric
Specifications
ENGINE
16 HP Kohler Command
Make Kohler
Model Command CV16S
Horsepower 16 @ 3600 rpm
Cylinder 1 horizontal
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,
23 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 4.0 Pints w/Filter (1.9 L)
Fuel Tank Material: High-Density Polyethylene,
Transparent
Capacity: 2.0 Gallons (7.5 L)
Muffler Quiet Compact, Low Back Pressure
14 HP Kohler Command
Make Kohler
Model Command CV14S
Horsepower 14 @ 3600 rpm
Cylinder 1 horizontal
Bore 3.43 in (87 mm)
Stroke 2.64 in (67 mm)
Displacement 24.3 Cu. in (398 cc)
Construction Overhead Valve, Cast-Iron Sleeve,
Aluminum Crankcase
Electrical System 12 Volt, 15 amp. Alternator Regulated
Battery: 12 Volt, 340 Cold Cranking amps
23 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 4 Pints w/Filter (1.9 L)
Fuel Tank Material: High Density Polyethylene,
Transparent
Capacity: 2.0 Gallons (7.5 L)
Muffler Quiet Compact, Low Back Pressure
1-13
1 General Information
Specifications
16 HP Briggs & Stratton
Make: Briggs & Stratton - 4 cycle air cooled
Model & Type: Vanguard
Horsepower: 16 HP
Cylinder: 1 horizontal
Bore & Stroke: 3.44 in./87.3 MM (3.06 in./77.7 MM)
Displacement: 28.4 cu.in.(465cc)
Construction: Overhead valve, Cast Iron Sleeves,
Aluminum Crankcase.
Electrical: 12 volt 9 amp, alternator regulated battery,
12 volt, 340 cranking amps, 41 minute
reserve capacity.
Governor: Mechanical
Oil Capacity: 3.5 Pints w/Filter (1.7 L)
Ignition: Magnetron Electronic
Charging: Regulated 9 amp DC charging circuit
Air Cleaner: Dual Element
Fuel Tank: High Density polyurethane construction;
2 gallons (7.57 liters) of “regular” grade
leaded or non-leaded gasoline.
Muffler: Simplicity Custom Muffler
Starter: 12 volt electric gear drive
TRANSMISSION
Peerless (Gear Drive) Models
Type Peerless MST 205,
Spur Gear
Material Shaft: Hardened
Bearings: Needle Roller & Bushings
Lubrication EP 90 Oil
Speeds Five Forward, One Reverse
Speeds 1st: 1.0 MPH (1.6 km/h)
@ 3400 rpm 2nd: 2.0 MPH (3.2 km/h)
3rd: 3.0 MPH (4.8 km/h)
4th: 4.2 MPH (6.7 km/h)
5th: 4.7 MPH (7.5 km/h)
Rev: 1.4 MPH (2.2 km/h)
Differential Bevel Gear Type
Axle Shaft .75 in
Continuous Torque 225 ft. lbs.
Output
Drawbar Rating 16 HP: 300 lbs., 14 HP: 321 lbs.
Maximum Weight 525 lbs.
on Axle
Tuff Torq K-56 Hydro Models
Type Hydrostatic, Tuff Torq K56
Pump Variable Displacement Axial Piston
Motor Fixed Displacement Axial Piston
Control Single Pedal Foot Control
with Release Valve for Manually Pushing.
Hydraulic Fluid 10w 30 Premium Engine Oil
Speeds Forward: 0-5.6 MPH (9.0 km/h)
@ 3400 rpm Reverse: 0-3.0 MPH (4.6 km/h)
Differential Bevel Gear Type
Axle Shaft .75 in
Continuous Torque 170 ft. lbs.
Output
Drawbar Rating 227 lbs.
Maximum Weight 673 lbs.
on Axle
Hydro-Gear 0500 / 0650 Models
Type Hydrostatic, Hydro-Gear 318-0500, 322-0500,
or 322-0650
Pump Variable displacement axial piston
Motor Fixed displacement axial piston
Control Single Pedal Foot Control
with Release Valve for Manually Pushing.
Hydraulic Fluid 20W-50 Premium Engine Oil
Ground speeds Forward: 0-4.7 mph (7.5 km/h)
@ 3400 rpm: Reverse: 0-2.6 mph (4.1 km/h)
Differential: Bevel Gear Type
Axle Shaft: .75 in.
Continuous Torque 0500 Models: 135 ft. lbs.,
Output 0650 Models: 160 ft. lbs.
Drawbar Rating 0500 Models: 193 lbs., 0650 Modes: 213 lbs.
Maximum Weight 0500 Models: 500 lbs., 0650 Models: 540 lbs.
on Axle
1 General Information
Specifications
1-14
CONTROLS
Steering Full Circle Steering Wheel System, Gear and
Sector, 1.5 turns Lock to Lock.
Clutch/Brake Location Right Front
Pedal Combination Clutch/Brake Pedal
Parking Brake Foot / Hand Lock
Ground Speed Right side of seat deck
Shift Lever (Gear)
Ground Speed Right side foot rest
Foot Pedal (Hydro)
Throttle Control Combination Speed & Choke Control on left
side of dash board.
Key Switch Starter and Magneto ON/OFF Switch located
on Right side of seat deck
Mower Drive Electric Clutch PTO Switch located on right side
of seat deck
CHASSIS
Frame Heavy Gauge Steel Channel - 12/14 Gauge
Engine Mounting: Above Front Axle
Pivot Point Location: Rear Carrier
Rear Wheels Tire Size: 20 x 8-8 Turf Type or 18 x 8.50 -8
Inflation Pressure: 12-15 psi (82-103 kPa)
Front Wheels Tire Size: 15 x 6.00-6
Inflation Press.: 12-15 psi (82-103 kPa)
Bearings: Sintered Iron with Grease Fittings
Accessibility Hood Tips Forward for Engine,
Seat Tips Forward for Battery.
Seat High-Back, Quick Adjust, Spring Suspension
Turning Radius Inside Rear Tire: 14 in (36 cm)
Fuel Tank Material: Non-Corrosive Polyethylene
Capacity: 2 Gallons (7.5 L)
DIMENSIONS
Tractor
Overall Length 68 in (172 cm)
Overall Width 36 in (92 cm)
Height At Steering Wheel: 41 in (104 cm)
To Top of Engine Cover: 34 in (86 cm)
Wheel Base 50 in (127 cm)
Weight (Apx. Net) 371 lbs. (168 kg)
w/44 in mower 463 lbs. (210 kg)
Tractor Height
w/Snowcab est. 70 in (177 cm)
Tractor Length
w/Snowthrower est. 90 in (228 cm)
Tractor Length
w/Dozer Blade est. 86 in (218 cm)
44” Mower
Thickness 12 Ga.
Effective Cutting
Width 44 in Mower - 44 in (111.8 cm)
Overall Width
with Deflector 56 in (142.2 cm)
with Turbo 44 in Mower - 58in (147 cm)
Weight 107 lbs. (49 kg)
Cutting Height Variable: 1.5 to 3.9 in (3.8 to 10 cm)
Blade Arrangement Three Staggered Blades
Mower Drive V-Belt from Tractor PTO Electric Clutch
Spindle Bearings Sealed Ball Bearings - Lube Fitting Provided
38” Mower
Thickness Early Models: 14 Ga., Later Models: 12-Ga.
Effective Cutting
Width 38 in Mower - 38 in (97 cm)
Overall Width
with Deflector 49.5 in (126 cm)
with Turbo 38 in Mower - 51.5 in (131 cm)
Weight 81 lbs. (36.7 kg)
Cutting Height Variable Between 1.5 and 3.9 in (3.8 and 10 cm)
Blade Arrangement Two Staggered Blades
Mower Drive V-Belt from Tractor Engine PTO Electric Clutch
Spindle Bearings Sealed Ball Bearings - Lube Fitting Provided
1-15
1 General Information
Hardware Identification & Torque Specifications
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 - 13 x 2”, this
means the
Nominal size
, or
body diameter
is 1/2 inch; the
second number represents the
threads per inch
(13 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.
Hex Head Capscrew
Washer
Carriage Bolt
0
1/4 3/4
1/2
1
1/4 3/4
1/2
Nut, 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
1-16
1 General Information
Notes
2 - 1
2 Troubleshooting
Table of Contents
SECTION CONTENTS
Troubleshooting
Troubleshooting Chart.................................................................. 2-2
Troubleshooting Common Mowing Problems .............................. 2-4
SECTION 2. TROUBLESHOOTING
2 - 2
2 Troubleshooting
Troubleshooting Chart
WARNING
Before beginning any service work, turn the PTO
off,set the parking brake, turn the ignition switch
off, remove the key, disconnect the spark plug
wire, and disconnect the negative battery cable.
Never attempt to perform repairs while the engine
is running.
FAILURE TO COMPLY WITH THIS, AND OTHER,
SAFETY REQUIREMENTS CAN RESULT IN
SERIOUS PERSONAL INJURY.
TROUBLESHOOTING
The troubleshooting guide below lists some common
problems, their causes, and remedies.
See the repair information in the following sections for
instructions on how to perform most of these minor
repairs yourself. If you prefer, all of these procedures
can be performed for you by your local authorized dealer.
TROUBLESHOOTING THE TRACTOR
PROBLEM CAUSES REMEDIES SEE SECTION
Engine will not 1. Ground speed control lever Shift into neutral. N/A
turnover or start. not in neutral-start position.
2. PTO (electric clutch) switch Place in OFF position. N/A
in ON position.
3. Out of fuel. If engine is hot, allow it to cool, then refill 3
the fuel tank.
4. Engine flooded. Move throttle control out of CHOKE position N/A
5. Circuit breaker tripped. Wait one minute for automatic reset. 7
Replace if defective.
6. Battery terminals require Clean Battery. 3
cleaning.
7. Battery discharged or dead. Recharge or replace. 6
8. Wiring loose or broken. Visually check wiring & replace broken or 7
frayed wires. Tighten loose connections.
9. Solenoid or starter motor faulty. Repair or replace. 7
10.Safety interlock switch. Replace as needed. 7
11.Spark plug(s) faulty, fouled Clean and gap or replace. See Engine Manual
or incorrectly gapped.
12.Water in fuel. Drain fuel & refill with fresh fuel. N/A
13.Gas is old or stale. Drain fuel & replace with fresh fuel. N/A
14.Foot pedal not fully depressed. Depress pedal. N/A
Engine starts hard 1. Fuel mixture too rich. Clean air filter. See Engine Manual
or runs poorly. 2. Carburetor adjusted incorrectly. Adjust Carburetor. See Engine Manual
3. Spark plug(s) faulty, fouled, or Clean and gap or replace. See Engine Manual
incorrectly gapped.
Engine knocks. 1. Low oil level. Check/add oil as required. 3
2. Using wrong grade oil. See engine manual.
Excessive oil 1. Engine running too hot. Clean engine fins, blower screen and See Engine Manual
consumption. air cleaner.
2. Using wrong weight oil. See engine manual.
3. Too much oil in crankcase. Drain excessive oil. 3
Engine exhaust 1. Dirty air filter. Replace air filter. See Engine Manual
is black. 2. Throttle is in choke position. Move throttle out of CHOKE position. N/A
Engine runs, but 1. Ground speed control lever Shift in forward or reverse. N/A
tractor will not drive. in neutral.
2. Transmission release lever Move into “drive” position. N/A
in “push” position.
(Hydro models only)
3. Drive belt is broken. Replace Belt 5
4. Drive belt slips. Adjust clutch/brake, replace belt. 4, 5
5. Brake is not fully released. Adjust Brake. 4
2 - 3
2 Troubleshooting
Troubleshooting Chart
Tractor Troubleshooting Cont.
PROBLEM CAUSES REMEDIES SEE SECTION
Tractor drive 1. Pulleys or belt greasy or oily. Clean as required. N/A
belt slips. 2. Belt stretched or worn. Replace with correct belt. 5
3. Idler pulley pivot bracket Remove idler pulley, clean and lubricate. 3
“frozen” in declutched position.
Brake will 1. Brake is incorrectly adjusted. Adjust brake. 4
not hold. 2. Internal brake disc on Service as required. 4, 9
transaxle worn.
Tractor steers hard 1. Steering linkage is loose. Check and tighten any loose connections. 4, 8
or handles poorly. 2. Improper tire inflation. Check and correct. 3
3. Wheel bearings dry. Grease wheels and lubricate steering linkage 3
or steering linkage dry.
Drive belt does 1. Belt stops or belt tension Repair or adjust as needed. 4
not stop when clutch out of adjustment.
/brake is depressed.
TROUBLESHOOTING THE MOWER
PROBLEM CAUSES REMEDIES SEE SECTION
Mower will not raise. 1. Lift linkage sticking. Lubricate mower deck. 3
Mower cut is 1. Mower not leveled properly. Level mower deck. 3
uneven. 2. Tractor tires not inflated Check and inflate tires. 3
equally or properly.
Mower cut is rough 1. Engine speed too slow. Always mow at full throttle. N/A
looking. 2. Ground speed too fast. Slow down. N/A
3. Blades are dull. Sharpen or replace blades. 3, 6
4. Mower drive belt slipping Clean or replace belt as necessary. 5
because it is oily or worn.
5. Blades not properly fastened Tighten to 50-70 ft.lbs. (74 N.m.). 6
to arbors.
Engine stalls easily 1. Engine speed too slow. Always mow at full throttle. N/A
with mower 2. Ground speed too fast. Slow down. N/A
engaged. 3. Carburetor improperly adjusted. Adjust carburetor. See Engine Manual
4. Cutting height set too low. Cut tall grass at maximum cutting N/A
height during first pass.
5. Discharge chute jamming Cut grass with discharge pointing toward N/A
with cut grass. previously cut area.
Excessive mower 1. Blade mounting screws Tighten to 50-70 ft.lbs. (74 N.m.). 6
vibration. are loose.
2. Mower blades, arbors, Check and replace as necessary. 16
or pulleys are bent.
3. Mower blades are out Remove, sharpen, and balance blades. 3
of balance.
4. Belt installed incorrectly. Reinstall Correctly. 5
Excessive belt wear 1. Using incorrect belt. Replace with correct belt. 5
or breakage. 2. Bent or rough pulleys. Repair or replace. 16
Mower drive belt 1. Idler pulley spring broken or not Repair or replace as needed. 16
slips or fails properly attached.
to drive. 2. Belt stops out of adjustment. Check belt stops. 4, 16
3. Mower drive belt broken. Replace drive belt. 5
2 Troubleshooting
Mowing Troubleshooting Chart
2 - 4
Stepped Cutting
Stepped cutting is sharp ridges or uneven levels left in
the lawn surface. Stepped cutting is usually caused by
mower deck damage or mis-adjustment, or damage to
mower blades.
CAUSE SOLUTION SEE SECTION
Deck is not leveled correctly Level the deck correctly 4
Tires are not properly inflated Check and inflate the tires 3
Blades are damaged Replace the blades 6
Deck shell is damaged Repair or replace the deck 16
Mower spindle is bent or loose Repair or replace the spindle 16
Blades are installed incorrectly Reinstall the blades correctly 6
Stepped Cutting
Streaking
Streaking
Streaking is when thin strips of uncut grass are left
behind the mower. Streaking is usually caused by
operator error or poor blade maintenance.
CAUSE SOLUTION SEE SECTION
Blades are not sharp Sharpen your blades 3
Blades are worn down too far Replace your blades 6
Engine speed is too slow Always mow at full throttle N/A
Ground speed is too fast Slow down N/A
Deck is plugged with grass Clean out the mower N/A
Not overlapping cutting rows enough Overlap your cutting rows N/A
Not overlapping enough when turning When turning your effective cutting width N/A
decreases–overlap more when turning
TROUBLESHOOTING COMMON MOWING PROBLEMS
2 - 5
2 Troubleshooting
Mowing Troubleshooting Chart
Stingers
Stingers are sparse patches of uncut grass left behind
the mower. Stingers are usually caused by operator
error or poor blade maintenance.
CAUSE SOLUTION SEE SECTION
Blades are not sharp or are nicked Sharpen your blades 3
Blades are worn down too far Replace your blades 6
Engine speed is too slow Always mow at full throttle N/A
Ground speed is too fast Slow down N/A
Deck is plugged with grass Clean out the mower N/A
Uneven Cutting
Uneven cutting is waviness or smooth troughs in the
lawn surface. Uneven cutting is usually caused by
mower deck damage or mis-adjustment.
CAUSE SOLUTION SEE SECTION
Deck is not leveled correctly Level the deck correctly 4
Blades are dull or worn Sharpen or replace the blades 3, 6
Blades are damaged Replace the blades 6
Deck is clogged with grass clippings Clean out the deck N/A
Deck shell is damaged Repair or replace the deck 16
Mower spindle is bent or loose Repair or replace the spindle 16
Blades are installed incorrectly Reinstall the blades correctly 6
Scalping
Scalping is when the mower deck comes close to or hits
the ground. Scalping can be caused by the mower deck
mis-adjustment, unevenness in the lawn, or by mower
deck bouncing because the ground speed is too fast.
CAUSE SOLUTION SEE SECTION
Lawn is uneven or bumpy Roll or level the lawn N/A
Mower deck cutting height is set too low Raise the cutting height N/A
Ground speed is too fast Slow down N/A
Deck is not leveled correctly Correctly level the deck N/A
Tire pressure is low or uneven Check and inflate the tires 3
Uneven Cutting
Scalping
Stingers
2 Troubleshooting
Notes
2 - 6
3 - 1
3 Maintenance
Table of Contents
SECTION CONTENTS
Storage
Temporary Storage ...................................................................... 3-2
Long Term Storage ...................................................................... 3-2
Starting After Long Term Storage ................................................ 3-2
Maintenance Schedule
Maintenance Schedule................................................................. 3-3
Maintenance Procedures
Tire Pressure................................................................................ 3-3
Checking & Adding Gasoline ....................................................... 3-4
Engine Oil & Filter ........................................................................ 3-4
Check / Change Air Filter............................................................. 3-4
Replace Spark Plug ..................................................................... 3-4
Lubricate Rear Axles.................................................................... 3-5
Sharpen & Balance Mower Blades .............................................. 3-6
Tuff Torq K-56 Transmission Service........................................... 3-7
Hydro-Gear 0500 / 0650 Transmission Service........................... 3-7
Peerless Transmission Service.................................................... 3-7
Battery Maintenance
Check the Battery Fluid................................................................ 3-8
Cleaning the Battery and Cables ................................................. 3-8
Lubrication
Lubrication.................................................................................... 3-9
Safety Checks
Blade Brake Check .................................................................... 3-11
Safety Interlock System Checks ................................................ 3-11
SECTION 3. MAINTENANCE
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 charge 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.
3 - 3
3 Maintenance
Schedule / Tire Pressure
Tire Pressure
Front
12 - 15 psi (82 - 103 kPa)
Rear
10 - 12 psi (56 - 82 kPa)
MAINTENANCE PROCEDURES
MAINTENANCE SCHEDULE
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.
**** Tuff Torq K56 Models Only: Change transmission oil after the first 50 hours of operation, then every 250 hours.
Use SAE 10W-30 with a minimum API rating of CD.
*****Briggs & Stratton Models: Change oil & filter every 50 hours. Kohler Models: Change oil & filter every 100 hours.
See Before Before Every Every Every Spring
SAFETY ITEMS Page First Use Each Use 5 Hours 25 Hours 100 Hours & Fall
Check Safety Interlock System 3-11 ●●
Check Tractor Brakes — ●●
Check Mower Blade Stopping Time 3-11 ●●
See Before Before Every Every Every Spring
NORMAL CARE ITEMS Page First Use Each Use 5 Hours 25 Hours 100 Hours & Fall
Check Tractor/Mower for loose hardware — ●●●
Check Engine Air Filter 3-4* ● ***●
Check Engine Oil Level 3-4* ●●
Change Engine Oil & Filter** 3-4* See Notes: ***** ***
Lubricate Tractor & Mower 3-9 ● ***●
Check Tire Pressure 3-3 ●●
Change Trans. Oil (Tuff Torq K56 Only) 3-7 ****Every 250 Hours
Check Fuel Filter 3-4 ●
Clean Battery & Cables 3-8 ●
Sharpen & Balance Mower Blades 3-6 ●
Inspect / Replace Spark Plug 3-4* ●
Lubricate Rear Axle Shafts 3-5 ●
WARNING
Before beginning any service work, turn the PTO
off,set the parking brake, turn the ignition switch
off, remove the key, disconnect the spark plug
wire, and disconnect the negative battery cable.
Tire Pressure
Tire pressure should be checked periodically, and maintained at the levels shown in the chart at right. Note that
these pressures differ slightly from the “Max Inflation”
stamped on the side-wall of the tires. The pressures
shown in the chart provide proper traction, improved cut
quality, and extended tire life.
3 Maintenance
Engine Maintenance
3 - 4
Replacing the Fuel Filter
The fuel filter (C, Figure 1) is located in fuel line between
fuel tank and carburetor. If filter is dirty or clogged,
replace as follows. Place a container below filter to catch
spilled gasoline.
1. Using a pliers, open and slide hose clamps from fuel
filter.
2. Remove hoses from filter.
3. Install new filter in proper flow direction in fuel line.
Secure with hose clamps. See warning at beginning
of procedure.
Engine Oil & Filter
Refer to engine manual for specific oil and filter recommendations and oil draining procedures.
Engine oil level must be checked at regular intervals to
ensure that engine oil is maintained at a level that will
provide for adequate lubrication of internal components.
The engine oil filter should be changed in accordance
with the engine manufacturer’s recommendations, which
is generally every 50 hours of operation, or more frequently when operating conditions are hot (over 85°), or
dusty.
The oil filter removes abrasive particles and other contaminants from the oil, keeping it clean for maximum lubrication efficiency, and should only be replaced with the
type of filter recommended by the engine manufacturer.
Figure 1. Typical Engine Compartment
A. Oil Fill D. Air Filter
B. Gas Tank E. Spark Plug
C. Fuel Filter
B
A
D
E
C
Checking and Adding Gasoline
Raise the hood and check the fuel tank to be sure there
is enough gasoline to complete the job. To add gasoline,
remove the gas cap. Do not overfill. Leave room in the
tank for fuel expansion. Refer to your engine manual for
gasoline recommendations. Install and hand tighten the
gas cap.
CAUTION
Never use gasoline containing METHANOL, gasohol containing more than 10% ethanol, gasoline
additives, premium gasoline, or white gas because
engine/fuel system damage could result.
WARNING
Do not remove fuel filter when engine is hot, as
spilled gasoline may ignite. DO NOT spread hose
clamps further than necessary. Ensure clamps
grip hoses firmly over filter after installation.
Check / Change Air Filter
Refer to the engine manual for specific air filter service
intervals and procedures. Refer to Figure 1 for air filter
location.
The engine air filter filters out dust and dirt from the air
intake of the engine, and must be cleaned or replaced
every 25 hours of operation, or more frequently when
operating conditions are dusty.
Replace Spark Plug
Refer to the engine manual for specific spark plug service intervals and replacement procedures. Dirty, worn,
or fouled spark plugs may cause hard starting, rough
engine operation, or loss of power. Refer to Figure 1 for
spark plug location.
To remove the spark plug(s) from the engine for inspection or replacement:
1. Turn the ignition off and remove the key. Allow
engine to cool.
2. Raise the hood and locate the spark plug cable and
boot. Pull the boot off the spark plug.
3. Using a spark plug socket and socket wrench,
remove the spark plug from the engine by turning the
spark plug counter-clockwise.
4. Inspect, clean, re-gap, or replace the spark plug as
required.
5. Reinstall the spark plug. Thread the plug into the
cylinder head by hand, then tighten as instructed by
the engine manufacturer’s manual.
3 - 5
3 Maintenance
Lubricate Rear Axles
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 and makes future service easier.
Refer to Figures 2-7.
1. Remove the key and disconnect the spark plug wire
while working on the unit.
2. Elevate the rear of the unit. See Section 6.
3. Remove the plastic hub cap (H).
4. Remove e-ring (G) using a screwdriver.
5. Remove the washers (B, E), spacers (C), wheel (D),
and key (A).
NOTE: Your axle assembly may differ slightly from
the assembly pictured: washers 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.
6. Lubricate the axle shaft with anti-seize compound or
lithium grease.
7. Reinstall components in reverse order of disassembly
and lower the unit. Be sure the key (A) is in place in
the axle keyway.
A. Key E. Small Washer
B. Large Washer F. Hub Cap Retainer
C. Spacer G. E-Ring
D. Wheel H. Hub Cap
Figure 2. Regent, Tuff Torq K56 Models
A
C
D
H
G
B
B
Figure 4. Regent, Hydro-Gear 0500/0650 Models
A
C
D
H
G
B
Figure 3. 500/2500, Tuff Torq K56 Models
A
F
C
D
H
G
B
B
Figure 5. 500/2500, Hydro-Gear 0500/0650 Models
A
F
C
D
H
G
E
B
B
Figure 6. Regent, Peerless (Gear) Models
A
C
E
D
H
G
B
B
Figure 7. 500/2500, Peerless (Gear) Models
A
F
C
D
H
G
B
E
3 Maintenance
Sharpen & Balance Blades
3 - 6
Sharpen & Balance 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 8).
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 9. 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 10. 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 50-70 ft.lbs. (67-95 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
50 - 70 ft. lbs. (67 - 95 N.m.)
Figure 9. Balancing The Blade
Workbench
Nail
LOOSEN
Figure 8. Removing the Blade
A
D
C
B
TIGHTEN
Figure 10. Installing The Blade
A. 4x4 Wood Block C. Spring Washer
B. Hex Washer D. Blade Bolt
4x4 Wood Block
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