Simplicity LTH series, Massey Ferguson 2600 series, AGCO Allis 1600 series, Broadmoor series, LTG series Service Manual

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Service & Repair Manual Broadmoor Series

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MANUFACTURING, INC.

500 N Spring Street / PO Box 997 Port Washington, WI 53074-0997 USA

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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

Specifications..............................................................................1-11

Torque Specifications ................................................................ 1-13

SECTION 1. GENERAL INFORMATION

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Mfg. No.

1 General Information

Models Covered In This Manual

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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.

1691795 12.5LTH 1691807 16LTH 1691817 1613H 1691819 1616H 1691886 12.5LTH 1691888 1613H 1691891 12.5LTG 1691893 1613G 1692071 16LTH 1692073 12.5LTH 1692075 1616H 1692076 1613H 1692182 Broadmoor 1692184 1614H 1692261 Broadmoor 1692265 1613H 1692279 Broadmoor 1692281 1614H 1692283 Broadmoor

Tractors

Description

Mower Decks

1691704 38” Mower Deck 1691705 44” Mower Deck 1691815 38” Mower Deck 1691816 44” Mower Deck

Mfg. No.

Figure 1. Tractor & Mower Identification Tags

Mower Identification Tag (Typical Location)

Tractor Identification Tag (Typical Location)

1692285 1616H 1692287 Broadmoor 1692289 1615G 1692414 Broadmoor 1692416 Broadmoor 1692416 Broadmoor 1692418 Broadmoor 1692420 Broadmoor 1692430 1614VH 1692432 1614H 1692434 1615G 1692436 1616H 1692497 2614H 1692499 2616H 1692528 Broadmoor 1692530 1615H 1692609 Broadmoor 1692613 1615H

Mfg. No.

Description

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1 General Information

Introduction

INTRODUCTION

This manual is divided into eight major sections of service information required for the models specified. These sections are:

Section Title

1. General Information

2. Troubleshooting

3. Maintenance

4. Adjustments

5. Electrical

6. General Repair

7. Transmission Removal & Repair

8. Mower Deck repair

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. Electrical

Contains information and service procedures for troubleshooting and repairs of electrical systems.

6. General Repair

Covers disassembly, inspection, and repair of all major assembly groups except transmissions.

7. Transmission Removal & Repair

Covers removal, disassembly, inspection, and repair of Simplicity serviceable transmissions.

8. Deck Repair

Covers common mower deck service procedures.

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.

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1 General Information

Safety Rules

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Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of rider, 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.

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.

• 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 embank- ments. 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.

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1 General Information

Safety Rules

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.

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.

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Safety Rules

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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 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.

Elevation Of Unit Safety

• 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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Safety Rules

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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.

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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.

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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.

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Specifications

Capacity: 4 Gallons (15.1 L)

Muffler Quiet Compact, Low Back Pressure

15 HP Briggs & Stratton

Make Briggs & Stratton Model Vanguard Horsepower 15 HP @ 3600 rpm Cylinders 1 Bore 3.44 In. (87.3 mm) Stroke 3.06 In. (77.7 mm) Displacement 29.3 Cu. In. (480 cc) Construction Overhead Valve, Cast Iron Sleeves,

Aluminum Crankcase

Electrical 12 Volt, 9 Amp Alternator Regulated System Battery: 340 Cold Cranking Amps, 41 min.

Reserve Capacity, Industrial Rated Starter Motor

Ignition Magnetron Electronic Ignition Air Cleaner Ducted Paper Cartridge and Foam

Precleaner large 325 sq. in. Air Filtering System

Lubrication Splash Lube with Circulating Pump & Filter Oil Capacity 3.5 Pints w/Filter (1.6 L) Fuel Tank Material: Non-Corrosive Polyethylene

Fuel Tank Gauge Built Into Filler Cap Capacity: 4 Gallons (15.1 L)

Muffler Quiet Compact, Low Back Pressure

TRANSMISSION

Gear Models

Type Spur Gear Material Gear: Heat Treated

Shaft: Hardened and Ground Bearings: Needle Roller, Sealed Ball and Bushings

Lubrication Bentonite Grease Speeds Five Forward, One Reverse @ 3400 rpm 1st: 1.1 MPH (1.8 km/h)

2nd: 2.2 MPH (3.5 km/h) 3rd: 3.4 MPH (5.5 km/h) 4th: 4.2 MPH (6.8 km/h) 5th: 5.1 MPH (8.2 km/h) Reverse: 2.4 MPH (3.9 km/h)

Differential Spur Gear Type

Hydro Models

Type Hydrostatic Pump Variable Displacement Piston

Specifications

ENGINE

14 & 16 HP Briggs & Stratton

Make Briggs & Stratton Model Vanguard V-Twin Horsepower 14 & 16 HP @ 3600 rpm Cylinders 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 12 Volt, 16 Amp Alternator Regulated System Battery: 340 Cold Cranking Amps, 41 min.

Reserve Capacity, Industrial Rated Starter Motor

Ignition Magnetron Electronic Ignition Air Cleaner Ducted Paper Cartridge and Foam

Precleaner large 325 sq. in. Air Filtering System

Lubrication Full Pressure Lube w/Oil Filter Oil Capacity 3.5 Pints w/Filter (1.6 L) Fuel Tank Material: Non-Corrosive Polyethylene

Fuel Tank Gauge Built Into Filler Cap Capacity: 4 Gallons (15.1 L)

Muffler Quiet Compact, Low Back Pressure

14 HP Kohler

Make Kohler Model Command™ Horsepower 14 HP @ 3600 rpm Cylinders 1 Bore 3.43 In. (87 mm) Stroke 2.64 In. (67 mm) Displacement 24.3 Cu. In. (398 cc) Construction Overhead Valve, Cast Iron Sleeves,

Aluminum Crankcase

Electrical 12 Volt, 15 Amp Alternator Regulated System Battery: 340 Cold Cranking Amps, 41 min.

Reserve Capacity

Ignition High Energy Electronic Ignition Air Cleaner Ducted Paper Cartridge and Foam

Precleaner

Lubrication Full Pressure Lube w/Oil Filter Oil Capacity 4.0 Pints w/Filter (1.9 L) Fuel Tank Material: Non-Corrosive Polyethylene

Fuel Tank Gauge Built Into Filler Cap

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Specifications

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Motor Fixed Displacement Piston Hydraulic Fluid 3.5 Quarts (3.3 L) SAE 20W-50 Premium Control Single Lever Release

Lever for Manual Tractor Movement, Continuously Variable, Forward & Reverse, without Braking

Speeds Forward: 0-5.5 MPH (0-8 km/h) @ 3400 RPM Reverse: 0-1.7 MPH (0-2.7 km/h) Differential Automotive Type

CONTROLS

Steering Full Circle Steering Wheel System Gear

and Sector

Clutch/Brake Location Right Front Pedal Combination Clutch/Brake/Parking Brake

Pedal Standard Equipment

Location -Mower Lift Lever Right Side, Lower Dash

Tower

-PTO Clutch Electric, Dash Mounted

-Ground Speed Lever Dash Mounted

-Ignition Key Switch on dash panel

-Throttle Lever and Choke Lever on dash panel

-Light Switch on dash panel

-Separate Indicator Lights for Safety

-Interlock Switch Operator Present

-Transmission Neutral, PTO Disengaged

-Clutch/Brake Pedal Depressed

-Low Oil Pressure Warning Light

CHASSIS

Frame Heavy Gauge Steel Channel

Power Take-Off Point Front Engine Mounting Above Front Axle Pivot Point Location Front Axle

Rear Wheels Tire Size 20 x 8.00-10 Turf Type

Pneumatic Inflation Pressure 6-8 psi (41-55 kPa)

Front Wheels Tire Size 15 x 6.00-6

Pneumatic Inflation Pressure 12-15 psi (82-103 kPa)

Front Axle 1-3/4” x 3” 12 Ga. Fabricated Rectangular

Tube

Accessibility Hood Tips Forward Seat Type Bucket, High Back, Adjustable w/

Spring Suspension; Adjustable to Suit Different Size Operators

Turning Radius Inside Rear Tire 16 In. (40.6 cm)

DIMENSIONS

Tractor

Overall Length 67 In. (170.2 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 48 In. (121.9 cm) Weight Net: 455 lbs. (206 kg) (approx.) w/o Shipping: 575 lbs. (261 kg) mower

Mower - 38"

Effective Cutting Width 38 In. (96.5 cm) Overall Width with Deflector 49.5 In. (125.7 cm) Weight 100 lbs. (45 kg) Variable Cutting Ht. 1-3.6 in. (2.5 to 91 cm) Blade Arrangement Two Blades Mower Drive V-Belt From Tractor PTO Pulley Spindle Bearings Lubricated and Sealed Ball Bearings

Mower - 44"

Effective Cutting Width 44 In. (111.8 cm) Overall Width with Deflector 56 In. (142.2 cm) Weight 115 lbs. (52 kg) Variable Cutting Ht. 1-3.6 In. (2.5 to 91 cm) Blade Arrangement Three Staggered Blades Mower Drive V-Belt From Tractor PTO Pulley Spindle Bearings Lubricated and Sealed Ball Bearings

Page 15

1 General Information

Torque Specifications

1 - 13

SIZE SAE GRADE #2 SAE GRADE #5 SAE GRADE #8

in/lbs in/lbs

in/lbs

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

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.

TORQUE SPECIFICATIONS FOR

STANDARD MACHINE HARDWARE

(Tolerance ± 20%)

Page 16

1 General Information

Notes

1 - 14

Page 17

2 - 1

2 Troubleshooting

Table of Contents

SECTION CONTENTS

Troubleshooting

Troubleshooting the Tractor ......................................................... 2-2

Troubleshooting the Mower.......................................................... 2-3

SECTION 2. TROUBLESHOOTING

Page 18

2 Troubleshooting

Tractor Troubleshooting

2- 2

TROUBLESHOOTING

The troubleshooting guide below lists some common problems, their causes, and remedies.

See the repair information on 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.

WARNING

Never attempt to perform repairs while the engine is running.

Always turn the engine off and remove the key.

FAILURE TO COMPLY WITH THIS, AND OTHER, SAFETY REQUIREMENTS CAN RESULT IN SERIOUS PERSONAL INJURY.

TROUBLESHOOTING THE TRACTOR

Engine will not turnover or start. 1. Ground speed control lever Shift into neutral.

not in neutral-start position.

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 Electrical Troubleshooting 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. Repair or replace. See Electrical

Troubleshooting Section.

10. Safety interlock switch or Replace as needed. See Electrical module faulty. Troubleshooting Section.

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.

14. Foot pedal not depressed. Depress pedal.

Engine starts hard or runs poorly. 1. Fuel mixture too rich. Clean air filter. Check choke adjustment

(engine speed control).

2. Carburetor adjusted incorrectly. See engine manual.

3. 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 excessive oil.

Engine exhaust is black. 1. Dirty air filter. Replace air filter. See engine manual.

2. Engine speed control Change engine speed. is in choke position.

Engine runs, but tractor will 1. Ground speed control lever Shift in forward or reverse. not drive. in neutral.

2. Transmission release lever Move into drive position. in “push” position. (Hydro models only)

3. Belt is broken. See Drive Belt Replacement.

4. Drive belt slips. See problem and cause below.

5. Brake is not fully released. See Brake Adjustment.

Page 19

2 - 3

2 Troubleshooting

Mower Troubleshooting

Tractor Troubleshooting Cont.

Tractor drive belt slips. 1. Clutch is out of adjustment. See Adjustments Section.

2. Pulleys or belt greasy or oily. Clean as required.

3. Belt stretched or worn. Replace with correct belt.

4. Idler pulley pivot bracket Remove idler pulley, clean and lubricate. “frozen” in declutched position.

Brake will not hold. 1. Brake is incorrectly adjusted. See Brake Adjustment.

2. Internal brake disc on See Brake Adjustment and transaxle worn. Transmission Repair Sections.

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. Spindle bearings dry. Grease spindles. See Lubricating the

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

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 speed.

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 50-70 ft.lbs. (74 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.

Page 20

2 Troubleshooting

Notes

2- 4

Page 21

3 - 1

3 Maintenance

Table of Contents

SECTION CONTENTS

A. Storage

Temporary .............................................................................. 3-2

Long Term .............................................................................. 3-2

Starting After Storage ............................................................. 3-3

B. Preventive Maintenance Chart .................................. 3-3

C. Maintenance & Adjustments

Engine Oil Level ..................................................................... 3-4

Engine Oil Filter ...................................................................... 3-4

Engine Air Filter ...................................................................... 3-4

Fuel Filter ............................................................................... 3-5

Spark Plug .............................................................................. 3-6

Battery Maintenance .............................................................. 3-6

Mower Blade Service ............................................................. 3-7

Lubricating Tractor ................................................................. 3-8

Lubricating Mower .................................................................. 3-10

Tire Pressure .......................................................................... 3-10

SECTION 3. MAINTENANCE

Page 22

3- 2

3 Maintenance

Storage

WARNING

Never store a tractor, with gasoline in engine or fuel tank, in a heated shelter or in an enclosed, poorly ventilated enclosure. 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.

A. STORAGE

Temporary Storage

(30 Days Or Less)

Remember, the fuel tank will still contain some gasoline, so never store the tractor indoors where fuel vapor could travel to any ignition source. Fuel vapor is also toxic if inhaled, so never store the tractor in any structure used for human or animal habitation.

Here is a checklist of things to do when storing your tractor temporarily or in between uses:

• Do not store the tractor in an area where children may come into contact with it. If there is any chance of unauthorized use, remove the ignition key and keep it in a safe place.

• If the tractor cannot be stored on a reasonably level surface, block 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 the engine to cool before filling the tank.

Long Term Storage

(Longer Than 30 Days)

Before you store your tractor 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 tractor is used again.

2. Prepare the mower deck for storage as follows:

a. Remove mower deck from the tractor. (See

Operators Manual)

b. Clean underside of mower deck.

c. Coat all bare metal surface 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 tractor as outlined in the Lubrication section.

8. Clean up tractor 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. Do not allow the battery to freeze. If the battery is left in the tractor, disconnect the negative cable.

10. Drain the 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 or drain all fuel from the system before placing unit in storage.

11. Transport the tractor to a suitable, dry, indoor location. If the tractor is to be stored 6 months or longer, block the tractor up off the wheels to relieve weight and also to keep the tires off a damp floor. Protect tires from prolonged exposure to direct sunlight.

Page 23

3 - 3

3 Maintenance

Storage

Starting After Long Term Storage

Before starting the tractor after it has been stored for a long period of time, perform the following steps:

1. Remove the blocks from under the tractor.

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. Check crankcase oil level and add proper oil if necessary.

6. Inflate tires to proper pressure.

7. Check all fluid levels.

8. Start the engine and let it run slowly until warm. DO NOT run at high speed immediately after starting. Be sure to run engine only outdoors or in well ventilated areas.

B. PREVENTIVE MAINTENANCE CHART

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.

Safety Items Before Before Every Every Every 100 Spring

First Use Each Use 5 Hours 25 Hours Hours & Fall

Check safety interlock system. •• Check tractor brakes. •• Check mower blade stopping time. •After adjustment or service of electric PTO clutch •

Normal Care Items

Check tractor for loose hardware.

•••

Check engine oil level.

••• •

Check engine air filter. ***• Change engine oil & filter.** ***50 hrs ***• Lubricate tractor & mower. ***• Check fluid levels & tire pressure. •• **• Change transmission fluid. (hydro)**** Only if transaxle is serviced. Check fuel filter. • Clean battery & cables. • Clean/sharpen blades. • Inspect spark plug(s). •

* 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. **** Some transaxles are sealed units and do not require regular interval fluid changes.

Page 24

3- 4

3 Maintenance

Engine

C. MAINTENANCE & ADJUSTMENTS

ENGINE OIL LEVEL

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. Operating the engine with insufficient oil in the oil sump will cause engine components to wear prematurely, and prolonged use with low oil levels may cause engine overheating, permanent damage, and voiding of the engine manufacturer’s warranty.

In addition to following the engine manufacturer’s instructions for checking oil level, the recommendations for oil type and viscosity must also be followed. These recommendations vary based on the season during which the unit is being operated, and may require that the oil be changed to suit different operating conditions.

The location of the oil level indicator and oil fill tube are indicated in the engine manufacturer’s manual shipped with each unit. In general, the oil fill tube is marked with an oil can symbol or the word “OIL”, and is located next to the engine to permit easy access (See Figures 1 through 3).

The engine oil fill tube is usually also the location of the engine oil level dipstick, allowing oil level checks and filling to be performed using the same tube.

ENGINE OIL FILTER

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.

The oil filter is located at the base of the engine, and is removed by unscrewing the filter from the filter base using an oil filter wrench (See Figures 1 through 3).

ENGINE AIR FILTER

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.

Follow the engine manufacturer’s recommendations for removal, cleaning, and replacement. See Figures 1 through 3 for air filter locations.

Figure 1. Engine Compartment - 14 / 16HP

Briggs & Stratton Twin Cylinder Engine A. Battery B. Oil Filter C. Air Filter D Oil Fill/Dipstick E. Fuel Filter F. Throttle Cable G. Choke Cable

Figure 2. Engine Compartment - 14 HP Kohler Single Cylinder Engine A. Battery B. Oil Filter C. Air Filter D Oil Fill/Dipstick E. Fuel Filter F. Throttle/Choke Cable

Page 25

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3 Maintenance

Engine

Figure 3. Engine Compartment - 15 HP Briggs & Stratton Single Cylinder Engine A. Battery B. Oil Filter C. Air Filter D Oil Fill/Dipstick E. Fuel Filter F. Throttle Cable

FUEL FILTER

The fuel filter is located in the engine compartment and is installed in the rubber fuel line between the fuel tank and the fuel pump (See Figures 1 through 4). The fuel filter should be checked every 100 hours of operation, or sooner and replaced if it appears to be dirty or clogged.

A dirty or clogged filter may cause erratic engine operation, hard starting, or loss of power.

Before removing the hoses from the fuel filter, place a small container under the filter to catch the gasoline in the hoses and filter that will drain out as the filter is removed.

1. Squeeze the tabs on the hose clamps together using a pliers, and slide the clamps away from the fuel filter.

2. Note the fuel flow direction indicated on the filter, and remove the filter by pulling the hoses away from the filter with a twisting motion. Be prepared for fuel in the hoses and fuel filter to drain out as the hoses are disconnected, and catch the fuel in the container.

3. Observing the same fuel filter flow direction noted during removal, install the new fuel filter in the fuel line by sliding the hoses onto the filter.

4. Squeeze the tabs on the hose clamps together, and slide the clamps into place over the fuel filter tubes to secure the fuel lines to the fuel filter.

NOTE: The hose clamps must connect the fuel line hoses to the fuel filter securely to prevent fuel leakage and the possibility of engine compartment fire. Replace the hose clamps if they do not provide a secure, leakproof attachment to the fuel filter.

NOTE: Replace old, brittle, hard, or cracked fuel line.

Figure 4. Fuel Filter Location - Right Side Of Engine - Twin Cylinder Engine

Fuel Filter

DANGER

Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. Follow all precautions for the safe handling of gasoline when removing and installing the fuel filter. DO NOT spread hose clamps more than necessary. Replace clamps if they do not provide a secure, leak-proof attachment to the fuel filter when reinstalled.

Page 26

3- 6

3 Maintenance

Engine / Battery

BATTERY MAINTENANCE

Checking the Battery Fluid

1. Raise the hood.

2. Remove battery filler cap. Fluid must be even with split ring full mark. If not, add distilled water.

3. Reinstall filler cap.

Cleaning the Battery and Cables

1. Disconnect the cables from the battery, negative cable first (B, Figure 6).

2. Remove the battery clamp, then remove the battery.

3. Scrub the battery, cables and battery compartment with baking soda and water.

4. Clean the battery terminals and cable clamps with a wire brush and battery post terminal cleaner.

5. Reinstall battery and clamp.

6. Connect cables, positive cable first.

7. Coat battery cable clamps and battery terminals with a protective anti-corrosive coating such as grease or petroleum jelly.

Figure 6. Battery A. Positive Battery Terminal C. Hold Down Rod B. Negative Battery Terminal D. Battery Clamp

WARNING

Be careful when handling the battery. Avoid spilling electrolyte. Keep flames and sparks away from the battery.

WARNING

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.

SPARK PLUG

The spark plug(s) should be inspected at the regular intervals specified in the engine manufacturer’s owner’s manual and cleaned or replaced as required.

Dirty, worn, or fouled spark plugs may cause hard starting, rough engine operation, or loss of power, and may contribute to premature starter failure from excessive cranking of the engine.

The spark plug(s) can be found by looking for the thick black spark plug cable(s) at the engine head, and removing the spark plug boot(s) that connect(s) the cable to the spark plug.

The spark plug boot can be removed from the spark plug by pulling the boot away from the spark plug with a slight side-to-side motion.

To remove the spark plug(s) from the engine for inspection or replacement:

1. Turn the ignition off and remove the key.

2. Raise the hood.

3. Locate the spark plug cable and boot, and pull the boot off the spark plug (Figure 5).

4. Using a spark plug socket and socket wrench or equivalent spark plug removal tool, unscrew the spark plug from the engine by turning the spark plug counter-clockwise.

5. Inspect the spark plug in accordance with the engine manufacturer’s instructions, and clean, re-gap, or replace the spark plug as required.

6. When reinstalling the spark plug, start the plug into the engine by first turning it clockwise by hand to prevent cross-threading and possible damage to the spark plug port. Tighten as instructed in engine manufacturer’s manual.

Figure 5. Typical Spark Plug Location A. Spark Plug B. Spark Plug Cable & Boot

Page 27

3 - 7

3 Maintenance

Mower Blade Service

MOWER BLADE SERVICE

1. Remove mower from the tractor. See Operators Manual.

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 wooden block to hold blade while removing the blade mounting capscrew (Figure 7).

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 8. Center the blades’ 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 9. Secure with a capscrew (D), cup washer (C) and spline washer (B). Use a wooden block to prevent blade rotation and torque capscrews to 50-70 ft.lbs. (67-95 N.m.).

Figure 7. Removing The Blade

Figure 8. Balancing The Blade

Figure 9. Installing The Blade A. 4X4 Wooden Block C. Cup Washer B. Spline Washer D. Capscrew

TIGHTEN

WARNING

Blade mounting capscrews must each be installed with a cup washer and spline washer, then securely tightened. Torque blade mounting capscrew 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.

Page 28

3- 8

3 Maintenance

Lubrication

LUBRICATION

Lubricating the Tractor

Lubricate the tractor as shown in Figures 10 through

17. When a grease gun is shown, wipe the fitting clean, apply two or three pumps of lithium base automotive grease, and wipe off excess grease. When an oil can is shown, wipe the area clean, apply a few drops of SAE 30 weight oil, then wipe up drips or spills.

In general, linkage connections and other parts that have partial rotational or sliding movement (pedal pivot points, steering links, etc.) should be lubricated periodically with SAE 30 weight oil. Avoid applying excessive amounts of oil since this may cause a build-up of dirt and grass clippings around the lubricated area, making subsequent lubrication more difficult to accomplish.

Roller bearings, bushings, axles, rotating assemblies with grease fittings, and mechanisms with exposed gear teeth (steering gears) require periodic lubrication with lithium grease.

When grease fittings are present, a manual or pneumatic pressure-feed grease gun should be utilized to inject enough grease through the fitting to fully permeate the enclosed area containing the bearings or other moving parts.

Plain bushings, bearings, axles without grease fittings, and exposed gear teeth require the direct application of grease to all wear surfaces. Use a small, clean applicator brush or other means of applying and spreading the grease evenly.

Special care should be taken with ball and roller bearings to ensure that a liberal application of grease is applied to the bearing rollers or balls, and both inner and outer races or bearing and bearing cups.

Figure 10. Brake Pedal Pivot Point

Figure 12. Tractor Lubrication Points - Rear Half

(Gear Models)

Apply parking brake to lube idler pulley.

Lubricate With Grease

Figure 11. Tractor Lubrication Points - Front Half

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3 Maintenance

Lubrication

Figure 14. Tractor Lubrication Points - Rear Half (Later Hydro Models Tuff Torq K60)

Figure 15. Front Axle Lubrication Points

Figure 13. Tractor Lubrication Points - Rear Half (Early Hydro, Eaton 750/751)

Figure 17. Front Wheel Bushing Lubrication Grease Fitting Location (Inside hub of wheel). Wheel shown removed from axle for visual clarity.

Front Wheel Grease Fitting

Figure 16. PTO (Electric clutch) Lubrication Lubricate tab welded to the underside of frame lightly whenever the electric clutch is removed for service, replaced, or when a squeaking sound develops.

Page 30

Tire Pressure

Front 12-16 psi (82-103 kPa)

Rear 6-8 psi (41-55 kPa)

TIRE PRESSURE

Front and rear tires should be checked periodically to ensure that proper tire pressure is maintained. Note that these pressures differ slightly from the “Max Inflation” stamped on the side-wall of the tire. Keeping the tires properly inflated to these settings helps provide proper traction, extend tire life, and improved cut quality.

3- 10

3 Maintenance

Lubrication

Figure 18. Mower Lubrication Points

Figure 19. Arbor Lubrication Points

LUBRICATING THE MOWER

Lubricate the mower as shown in Figures 20 through 22. Be sure to include the grease fittings on the mower idler pulley and arbors, which are located underneath the mower deck. Always wipe the grease fittings clean before adding grease to help prevent forcing dirt and other wear-causing contaminants into the lubrication area.

When oil is indicated, use SAE 30 weight oil. Brush any dirt and grass from the area to be lubricated, and wipe lubrication points clean before applying oil. This will ensure that oil can get into the area where it is required.

Avoid getting grease or oil on belts and pulley when applying lubricants, and always wipe away excess oil and grease to prevent a rapid build-up of dirt and debris from accumulating.

Figure 20. Lubricate Lift Arm Pivot Points

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4 - 1

4 Adjustments

Table of Contents

SECTION CONTENTS

Electric Clutch Adjustment ......................................... 4-2

Neutral & Return to Neutral Adjustments

Hydro-Gear 311-0750 & 0800Transaxle ........................... 4-3

Eaton 750 Hydrostatic Transaxle

Early Models w/ Welded Support Bracket .................. 4-5

Eaton 750 Hydrostatic Transaxle

Later Models w/ Plastic Support Bracket.................... 4-6

Eaton 751 Hydrostatic Transaxle ...................................... 4-7

Tuff Torq K60 Hydrostatic Transaxle ................................ 4-8

Peerless 801-059B............................................................ 4-9

Clutch / Brake Adjustment

Hydro-Gear 311-0750 & 311-0800.................................... 4-10

Eaton 750/751................................................................... 4-10

Tuff Torq K60 .................................................................... 4-11

Peerless 801 ..................................................................... 4-11

Purging Air From Transaxle ........................................ 4-12

Steering Gear Adjustment ........................................... 4-12

Mower Adjustments ....................................................... 4-13

SECTION 4. ADJUSTMENTS

NOTE: This section contains service information involving minor service procedures and external adjustments that can be performed without requiring extensive disassembly. See the “REPAIR” section for detailed disassembly and repair information.

Page 32

4 Adjustments

Electric PTO

4 - 2

Electric PTO Clutch Adjustment

Adjustment of the PTO clutch is usually not necessary on new units.

1. Remove key from ignition switch and disconnect spark plug wires to prevent the possibility of accidental starting while the PTO is being adjusted.

2. See Figure 1. Note the position of the 3 adjustment windows (A) in the side of the brake plate, then rotate the pulley so that each of the three rivet joints (visible inside the gap between the pulley and the brake plate) is positioned approximately midway between the three adjustment windows.

3. Insert a .012” feeler gauge through each window, positioning the gauge between the rotor face and the armature face as shown in Figure 2.

4. With all three feeler gauges in place, alternately tighten the adjustment nuts (B, Figure 1) until the rotor face and armature face just contact the gauges.

5. Check the gauges for an equal amount of tension when inserted and removed, and make any necessary adjustments by tightening or loosening the adjustment nuts.

6. Remove the feeler gauges.

NOTE: The actual air gap between the rotor and armature may vary even after performing the adjustment procedure. This is due to dimensional variations on component parts, and is an acceptable condition.

8. Check the mower blade stopping time. The mower blades and mower drive belt should come to a complete stop within five seconds after the electric PTO switch is turned off.

Figure 1. PTO Clutch Adjustment

A. Adjustment Window (Qty. 3, one shown) B. Adjustment Nut (Qty. 3, two shown)

Rivet

Window

Adjustment Nut

Figure 2. Feeler Gauge Position

.012” Feeler Gauge (3) Req’d

Page 33

4 - 3

4 Adjustments

Neutral Adjustment - Hydro-Gear

NEUTRAL ADJUSTMENT

Broadmoor (Hydro-Gear 311-0750 and 3110800 Transaxle Models)

Perform the following adjustment if the shift lever must be moved out of the neutral gate to prevent forward or reverse tractor movement. With the clutch/brake pedal released, a small amount of travel in the shift lever may be required to fully stop tractor.

1. Position tractor on flat level ground. Make sure the ground speed control lever is seated securely in the neutral gate.

2. Raise the rear of tractor off the ground . See Elevating Rear End for Safe Service.

3. Loosen nut (A, Figure 3) securing the front shift rod to the idler pivot assembly (B). The carriage bolt must be free to move in the shift rod slot.

4. Start the tractor and rotate the hydro cam lever (C) until rear wheels stop moving. Shut off tractor engine.

5. Tighten nut (A) securely.

6. Check operation of tractor for any movement with shift lever in neutral gate. Perform the return-to-neutral adjustment (refer to the following page).

WARNING

When making adjustment, keep hands, hair, clothing, and tools away from rotating belts. Grasp cam lever at base to keep hand several inches below belt rotating around idler pulley assembly. Careless or improper attention may result in serious injury.

Figure 3. Neutral Adjustment A. Nut B. Idler Pivot Assembly C. Hydro Cam Lever

Page 34

4 Adjustments

Return-to Neutral - Hydro-Gear

4 - 4

Figure 4. Return-to-Neutral Adjustment A. Nut B. Rear Shift Rod C. Return-to-Neutral Cam D. Front Clutch Rod

RETURN-TO-NEUTRAL ADJUSTMENT

Broadmoor (Hydro-Gear 311-0750 & 0800 Transaxle Models)

Perform the following adjustment if the shift lever does not return to the neutral gate when the clutch/brake pedal is fully depressed.

1. Make sure the Neutral Adjustment is correct (refer to preceding paragraph).

2. Loosen the nut (A, Figure 4) that secures the rear shift rod (B) to the return-to-neutral cam (C).

3. Hold the clutch/brake pedal fully down against the right footrest. Pedal can be clamped in this position with large C-clamp if required. Do not apply parking brake as pedal will not be held against footrest without free play.

4. Rotate the return-to-neutral cam (C) securely against the front clutch rod (D). There should be no gap between the clutch rod and cam.

5. Tighten nut (A) with pedal held down against footrest.

6. Start tractor and check return-to-neutral operation. With pedal released, a small amount of travel in the shift lever may be required to fully stop tractor.

Page 35

4 - 5

4 Adjustments

Neutral Adjustment - Eaton

NEUTRAL ADJUSTMENT

LTH/Broadmoor (Eaton 750 Hydrostatic Transaxle - Early Models with Welded Support Bracket “H” - See Figure 5).

NOTE: Perform the Clutch/Brake Adjustment before doing the Neutral Adjustment.

1. Park tractor on level surface. Shut off PTO switch and engine. Do not apply parking brake. Make sure transmission control lever is in neutral and has activated neutral switch light (ignition switch on).

2. Raise the rear of tractor off the ground . See Elevating Rear End for Safe Service..

3. Loosen nut (A, Figure 5), which secures transaxle shift rod to speed control lever, (B).

4. Loosen nut (C), which secures the ball retainer (G) to the welded support bracket.

5. Rotate shift cam (D) so that neutral detent is aligned with roller ball (E).

6. Start engine and increase to full throttle. If wheels rotate, continue with adjustment. If wheels do not rotate, go to step 8.

7. Place a 1/4” rod or #2 Phillips screwdriver into hole (F) in eccentric ball retainer (G). Rotate ball retainer until wheels stop moving.

8. Tighten nut (C) securing ball retainer (G).

9. Make sure dash transmission control lever is in neutral position and has activated neutral switch light (ignition switch) before tightening nut (A).

10. Check the “Return-To-Neutral” by following these steps:

a. Shift transmission lever into forward (drive) posi-

tion and fully depress clutch/brake pedal.

b. Lever should return to neutral slot.

c. If lever does not return to neutral, repeat above

steps 1 - 9.

11. Shut off engine and remove tractor from jackstands.

Figure 5. A. Nut B. Speed Control Lever C. Nut D. Shift Cam E. Roller Ball F. Adjustment Hole G. Eccentric Ball Retainer H. Support Bracket (Welded)

Page 36

4 Adjustments

Neutral Adjustment - Eaton

4 - 6

NEUTRAL ADJUSTMENT

Broadmoor (Eaton 750 Hydrostatic Transaxle with Plastic Support Bracket “H” See Figure 6).

2. Raise rear of tractor off ground with a suitable hoist or floor jack. Install jackstands underneath transaxle and block front wheels.

3. Loosen nuts (A, Figure 6) on both left side and right side of speed control lever (B). (Left side nut is located next to spring and not shown in illustration.)

4. Loosen nut (C) which attaches ball retainer (G) to plastic support bracket (H).

5. Rotate shift cam (D) so that neutral detent is aligned with roller ball (E).

6. Start engine and increase to full throttle. If wheels rotate, continue with adjustment. If wheels do not rotate, go to step 8.

7. Place a 1/4” rod or #2 Phillips screwdriver into hole (F) in eccentric ball retainer (G). Rotate ball retainer until wheels stop moving.

8. Tighten nut (C) securing ball retainer (G).

9. Shut off engine and make sure dash transmission control lever is in neutral position, and has activated neutral light (ignition switch on).

10. Pull right end of speed control lever (B) fully forward. Tighten the left side 1/4” nut (not shown).

11. Push the right end of speed control lever B fully rearward and tighten the right side 5/16” nut (A).

12. Check the “Return-To-Neutral” by following these steps:

a. Shift transmission lever into forward (drive).

b. Lever should return to neutral slot.

c. If lever does not return to neutral, repeat above

steps 1 - 11, and make necessary adjustments.

d. Recheck following steps 12a - 12c.

13. Remove tractor from jackstands.

Figure 6. A. Nut B. Speed Control Lever C. Nut D. Shift Cam E. Roller Ball F. Adjustment Hole G. Eccentric Ball Retainer H. Support Bracket (Plastic)

Page 37

4 - 7

4 Adjustments

Neutral Adjustment - Eaton

NEUTRAL ADJUSTMENT

Broadmoor (Eaton 751 Hydrostatic Transaxle)

1. Park Tractor on level surface. Shut off PTO switch and engine, and remove key. Do not apply parking brake. Make sure transmission control lever is in neutral and has activated neutral.

2. Raise the rear of tractor off the ground . See Elevating Rear End for Safe Service.

3. Loosen nuts (A, Figure 7) on both left side and right side of speed control lever (B). (Left side nut is located next to spring and not shown in illustration.)

4. Rotate shift cam (D) so that neutral detent is aligned with roller ball (E).

5. Start engine and increase to full throttle. If wheels rotate, continue with adjustment. If wheels do not rotate, go to step 9.

6. Loosen nut (C) which secures the ball retainer (G) to the plastic support bracket (H).

7. Place a 1/4” rod or #2 Phillips screwdriver into hole (F) in eccentric ball retainer (G). Rotate ball retainer downward (looking from right hand side) until wheels rotate forward. Rotate ball retainer slowly upward (from right hand side) until wheels stop moving.

NOTE: Neutral must be obtained coming from forward.

8. Tighten nut (C) securing b all retainer (G).

9. Shut off engine and make sure dash transmission control lever is in neutral position against rear edge of neutral slot in dash.

10. Pull right end of speed control lever (B) fully forward. Tighten the left side 1/4” nut (not shown).

11. Push the right end of the speed control lever (B) fully rearward, and tighten right side 5/16 nut (A).

12. Start the engine and run at full throttle. Check for neutral by moving the control lever into forward and reverse and back into neutral gate. Control lever can be moved a small amount forward or backward in neutral gate to avoid tractor movement. Continue with adjustments if neutral cannot be obtained.

Figure 7. A. Nut B. Speed Control Lever C. Nut D. Shift Cam E. Roller Ball F. Adjustment Hole G. Eccentric Ball Retainer H. Support Bracket

13. Shut off engine. Loosen 1/4” nut at left hand end of speed control lever. Position transmission control lever out of neutral slot toward reverse to the point where notched out portion of lever is even with rear edge of neutral slot. Pull speed control lever toward right. Retighten 1/4” nut.

14. Repeat step 12.

15. Shut off engine. Loosen 1/4” nut at left hand end of speed control lever. Position transmission control lever out of neutral slot toward reverse to the point where notched out portion of lever is even with rear edge of neutral slot. Pull speed control lever toward right. Retighten 1/4” nut.

16. Repeat step 12.

17. Return-To-Neutral Adjustment is correct when the above adjustment steps are followed.

18. Remove the unit from the jackstands.

Page 38

4 Adjustments

Neutral Adjustment - Tuff Torq

4 - 8

NEUTRAL ADJUSTMENT

Broadmoor (Tuff Torq K60 Hydrostatic Transaxle)

NOTE: Perform this adjustment procedure only if tractor moves forward or reverse when ground speed control lever is in neutral gate.

1. Place jackstand under each side of rear drawbar. Adjust jackstand height until rear wheels are off the ground.

2. Hydro transmission has pre-set internal neutral adjustment. If tractor creeps when control lever is in neutral, first loosen nut (A, Figure 8) that attached shift rod lever (B) to shift pivot assembly (C). Directional cam (E) will return to factory pre-set neutral. If wheels continue to move with control lever in neutral, a problem exists with internal adjustment. See the repair section of this manual for detailed service instructions. If wheels do not move, perform the following steps to align cams.

3. Loosen nut (D) securing lever assembly pivot.

4. With nut (A) loosened, make sure ground speed control lever is in neutral slot on dash.

5. Push spring-loaded directional cam (E) side-to-side and allow cam to return-to-neutral.

6. With cam (E) stationary, move shift pivot assembly (C) until 1/4” hole in cam and pivot assembly line up. Insert 1/4” positioning pin F or 1/4” rod through both parts. Cam (E) must remain in neutral position.

7. With positioning pin in place, tighten nut (D), and then tighten nut (A).

8. Remove positioning pin and move ground speed control lever through forward and reverse ranges and return lever to neutral.

9. Check to see if positioning pin can be freely inserted (from bottom side) through directional cam (E), and lever assembly (C). If alignment is good, go to step

10. If pin cannot be inserted, repeat steps 2 - 8.

10. With ground speed control lever in neutral position, start unit (with rear wheels off the ground), and check for wheel movement. Wheels should not move due to internal neutral adjustment. If wheels move, recheck that positioning pin can be inserted freely through directional cam (E) and lever assembly (C) with ground speed control lever in neutral position. If neutral cannot be found, a problem exists with the unit’s shift linkages.

11. After neutral adjustment, move the ground speed control lever to forward range and depress the clutch/brake pedal. The control lever should return to the neutral position in dash, and wheels should not move. Move ground speed control lever to reverse range and repeat check. Return-To-Neutral Adjustment is correct when the above adjustment steps are followed.

Figure 8. A. Nut, 1/4 B. Shift Rod Lever C. Shift Pivot Assembly D. Nut, 5/16 E. Cam F. Positioning Pin

Page 39

4 - 9

4 Adjustments

Neutral Adjustment - Peerless

NEUTRAL ADJUSTMENT

Peerless 801-059B

If the tractor moves forward or backward with the transmission control speed lever positioned in the neutral gate, perform the following adjustment.

1. Raise the rear of the tractor off ground with suitable hoist or floor jack. Install jackstands underneath transaxle and block the front wheels.

2. Start the engine and use the transmission control speed lever to find neutral, even if control lever is not in the neutral gate. Shut off engine.

3. See Figure 9. Loosen the nut (A) so that the transmission control rod (B) is free to move.

4. Shift the transmission control lever firmly into the neutral gate on the dashboard. Retighten nut (A).

5. Remove tractor from jackstands.

Figure 9 Neutral Adjustment - Gear Model A. Nut B. Transmission Control Rod

Page 40

4 Adjustments

Brake Adjustment

4 - 10

CLUTCH / BRAKE ADJUSTMENT

Brake Spring: Approximate Compressed Spring

Length:

Hydro-Gear 0750/0800 2-7/8”

Tuff Torq K60 2-7/8

Eaton 750 1-3/4

Peerless 801 2-7/8”

Figure 10. Brake Adjustment – Hydro Models A. Brake Cam D. Brake Rod Spring B. Transaxle Housing E. Adjustment Nut C. Adjusting Nut

Figure 12. Eaton 750/751 Clutch/Brake Rod Adjust nut (A) to provide correct spring length.

Eaton 750 & 751 Transmission

1. Engage the parking brake.

2. The brake spring should be compressed to a length of 1-3/4”. Turn the adjustment nut (A, figure 12) to increase or reduce spring tension until the correct spring length is reached.

Hydro-Gear 311-0750 & 311-0800

1. See figure 10. With parking brake released, rotate the brake cam (A) forward until it stops. There should be 5/16" gap between transaxle housing (B) and rear point of brake cam.

2. If adjustment is required, remove cotter pin (early models had an “elastic nut” instead of a cotter pin) and turn adjusting nut (C) until proper 5/16" clearance is achieved. Turning the nut in will decrease clearance, and turning the nut out will increase clearance. Install cotter pin (or nut) after adjustment.

3. Fully depress the clutch/brake pedal and lock the parking brake by pulling up on the parking brake knob.

4. The brake rod spring (D) should measure 2-7/8" when compressed. Turn the adjustment nut (E) as necessary to obtain correct spring length.

Page 41

4 - 11

4 Adjustments

Brake Adjustment

Figure 13. Tuff Torq K60 Clutch/Brake Rod Adjust nut (A) to provide correct spring length.

Tuff Torq K60 Transmission

1. Engage the parking brake..

2. The brake spring should be compressed to a length of 2-7/8”. Turn the adjustment nut (A, Figure 13) to increase or reduce spring tension until correct spring length is reached.

Peerless 801

1. Place the transmission in gear and release the parking brake.

2. See Figure 11. Move the brake rod (A) back and forth to be sure there is no tension on the brake pads.

3. Push the cam lever (B) forward (toward front of tractor) to take out any slack. The gap between lever (B) and stop (C) should be 1/8" (0.3mm). Use a feeler gauge to measure. if adjustment is required, proceed to step 4.

4. Loosen or tighten the adjustment nut (D) to obtain the correct dimension.

5. Fully depress the clutch/brake pedal and lock the parking brake by pulling up on the parking brake knob.

6. The brake rod spring should measure 2-7/8" when compressed. Turn the adjustment nut (E) as necessary to obtain correct spring length.

7. With spring compressed to 2-7/8", adjust set collar (F) 1/4" from brake arm assembly (if present).

Figure 11. Brake Adjustment – Gear Model A. Brake Rod D. Adjustment Nut B. Brake Cam Lever E. Spring Adjustment Nut C. Stop F. Set Collar

2-7/8”

Page 42

4 Adjustments

Purging Transaxle / Steering Adjustment

4 - 12

STEERING GEAR ADJUSTMENT

If there is excessive back-lash in the steering system, the steering gear can be adjusted to the steering shaft gear for better engagement. Refer to Figure 15. Loosen two capscrews (A) and adjust bracket so that gear teeth are more closely meshed. Retighten nuts after adjustment.

Figure 15. Steering Gear Adjustment A. Capscrews

PURGING AIR FROM TRANSAXLE

Air may become trapped in the inlet hydraulic filter or closed loop passages of the hydro transaxle during assembly or shipment of the tractor. It is very important for proper operation to release any trapped air that may cause damage to the internal transaxle parts.

1. Park the tractor on a flat, level surface.

2. Place the hydro release lever (A, Figure 14) in the “PUSH” position by pulling rearward on the lever. The lever is located under the rear left-hand corner of the frame.

3. Start the tractor engine and run at a low idle.

4. Move the ground speed control lever from the neutral position to the full forward position for five seconds. Move lever to the full reverse position for five seconds. Repeat this procedure three times in forward and reverse direction.

5. Return the control lever to the neutral gate.

6. Place the hydro release lever (A) in the “DRIVE” position by pushing lever fully forward.

7. Drive the tractor at least five feet in the forward and reverse directions with full throttle and full ground speed. Repeat this procedure three times in the forward and reverse directions.

8. Check oil level (if applicable)

Repeat the above steps if tractor has noisy or erratic operation, lack of performance after transmission warmup, or oil leakage from the transaxle vent tube.

Figure 14. Release Lever

Release Lever

Page 43

4 - 13

4 Adjustments

Mower Adjustment

MOWER ADJUSTMENT

Leveling The Mower

If the cut is uneven, the mower may need leveling. Unequal or improper tire pressure may also cause an uneven cut. Make sure tire pressure is correct as specified in Checking Tire Pressure.

1. With the mower installed, place the tractor on a smooth, level surface such as a concrete floor. Turn the front wheels straight forward.

2. Check for bent blades and replace if necessary.

3. Disengage the PTO. Place the mower in mid-cutting height position. Arrange the mower blades so that they are pointing from side-to-side.

4. Measure the distance between the outside tips of each blade and the ground. If there is more than 1/8” (3mm) difference between the measurements on each side, proceed to step 5. If the difference is 1/8” (3mm) or less, proceed to step 6.

5. See Figure 16. Loosen the outside nut (A). Turn the eccentric nut (B) to raise or lower left-hand side of mower. When mower is level, hold the eccentric nut while tightening the outside nut.

TURBO COLLECTION SYSTEM NOTE:

When using a turbo collection system, raise the discharge side of the mower approximately 1/4” to compensate for turbo assembly weight. Check the level of the cut grass and adjust the 1/4” measurement as necessary for a smooth, even cut.

6. Arrange the blades so they face front-to-back.

7. On 38" deck, measure the distance from the ground to front tip of the right blade and from the ground to the rear tip of the left blade.

On 44" decks, measure the distance from the ground to the front tip of the center blade, and from the ground to rear tips of left-hand and right-hand blades.

Front tips on either deck should be 1/4" higher. If not, proceed with steps 8 - 10.

Figure 16. Leveling The Mower Side-to-Side A. Outside Nut B. Eccentric Nut

Figure 17. Leveling The Mower Front-To-Back A. Front Nut C. Mower Bracket B. Rear Nut D. Adjustment Rod

WARNING

Before checking mower, shut off PTO and engine. Allow all moving parts to stop. Remove ignition key, then disconnect the spark plug wire and fasten it away from the spark plug.

8. See Figure 17. To raise front of mower deck, loosen front nut (A) and turn rear nut (B) against bracket (C).

9. To lower front of mower deck, loosen rear nut (B) and bracket (C) will move backwards to lengthen rod.

10. Re-check measurement before tightening front nut (A) against bracket.

Page 44

4 Adjustments

Notes

4 - 14

Page 45

5 - 1

5 Electrical Troubleshooting

Table of Contents

SECTION 5. ELECTRICAL TROUBLESHOOTING

SECTION CONTENTS

Introduction

Tools Needed .....................................................................................5-2

System Description ............................................................................5-2

Principals Of Operation

Ignition System...................................................................................5-2

Charging System................................................................................5-2

Cranking System ................................................................................5-2

Safety Interlock System......................................................................5-2

Operation............................................................................................5-2

Checking Out The System

General...............................................................................................5-3

Test Series .........................................................................................5-3

Lower Wire Harness Explosion Diagram ...............................5-4

Upper Wire Harness Explosion Diagram................................5-6

1. Checking the Power Supply

A. Wiring.............................................................................................5-8

B. Battery Tests..................................................................................5-8

C. Battery Cables ...............................................................................5-9

2. Isolate Starting and Safety Systems ..................................5-10

3. Checking the Cranking System

A. Test Circuit Breaker .......................................................................5-10

B. Test Power to Ignition Switch.........................................................5-11

C. Test Ignition Switch........................................................................5-11

D. Test Power to Solenoid..................................................................5-12

E. Test Solenoid .................................................................................5-13

F. Solenoid Bench Test ......................................................................5-13

G. Test Power To Starter ...................................................................5-14

4. Test Safety Interlock System

A. PTO Interlock Switch .....................................................................5-15

B. Seat Switch (Mechanical) ..............................................................5-15

C. Seat Switch (Electrical)..................................................................5-16

D. Clutch/Brake Switch (Mechanical) ................................................5-16

E. Clutch/Brake Switch (Electrical)....................................................5-16

F. Neutral Safety Switch (Mechanical) ...............................................5-17

G. Neutral Safety Switch (Electrical) ..................................................5-17

H. Interlock Module ............................................................................5-18

5. Misc. Tests

A. Headlights ......................................................................................5-18

B. Power to Headlights.......................................................................5-18

C. Headlight Switch ............................................................................5-19

D. Hour Meter.....................................................................................5-19

E. Power to Hour Meter......................................................................5-20

F. Inspect and Replace Dash Lights ..................................................5-20

G. Test Electric PTO Clutch ...............................................................5-21

6. Wiring Diagrams..........................................................................5-22

Page 46

5 Electrical Troubleshooting

General Information - Theory

5 - 2

INTRODUCTION

Tools Needed

• VOM (Volt-Ohm meter, multi-meter, or equivalent)

• Test Light.

• Jumper wires with clips at both ends.

Electrical System Changes

Early and later model Broadmoors may have different electrical components. However, the basic configurations and troubleshooting procedures given in this section still apply. For instance: If the troubleshooting procedure instructs you to test the clutch / brake pedal switch, and your tractor doesn’t have a clutch / brake pedal switch, simply skip that step.

System Description

The tractor has four basic electrical systems: ignition, charging, cranking, and the safety interlock system.

• The ignition system, contained in the engine, is connected through a harness from the magneto to the ignition switch and interlock module.

• The charging system replenishes lost power to the battery. The alternator supplies power through a wiring harness that is connected to a circuit breaker, and then to the battery.

• The cranking system provides the high energy needed to start the engine. Current is drawn from the battery, through the solenoid, to the starter when the ignition switch is activated.

• The safety interlock system incorporates safety circuits for safe starting, operation, and shutdown under unsafe conditions. It consists of the neutral safety switch, PTO switch, "Operator present" seat switch, clutch/brake switch, and the interlock module.

PRINCIPALS OF OPERATION

Ignition System

When the ignition switch is turned to OFF, the ignition circuit closes and grounds the ignition coil stopping the engine by terminating spark

When the ignition switch is in the RUN position, the ignition circuit is open, allowing the engine to run.

Charging System

While the engine is running, current flows from the alternator through a rectifier to the positive battery post and charges the battery. The circuit breaker, normally closed, opens if the circuit is shorted.

Cranking System

Battery voltage is present at the "B" terminal of the ignition switch at all times (see Figure 8). Turning the ignition switch to START supplies 12 volts to one of the solenoid coil terminals. Current is then passed through the other solenoid coil post to the safety ground circuit. If all safety switches are closed, the solenoid coil is grounded engaging the solenoid and sending power to the starter.

If the PTO, transmission, or clutch/brake pedal is engaged, or if the operator present seat switch is open-the solenoid will not be grounded and the starter will not crank the engine.

Safety Interlock System

The safety system can be divided into two sub-systems. The first grounds the engine ignition module if the operator leaves the seat with the transmission engaged or the PTO engaged.

If the operator leaves the seat, the engine will run only if:

-the PTO is disengaged, AND

-the the parking brake is ON, AND

-the ground speed control lever is in the neutral

gate.

The second sub-system prevents the engine from cranking if the operator is not in the seat with the transmission disengaged and the PTO disengaged.

The engine will crank only if::

-the operator is in the seat, AND

-the PTO is disengaged, AND

-the clutch / brake pedal is depressed, AND

-the groundspeed control lever is in the neutral

gate.

Operation

If the seat switch system is functioning properly, the following statements are true:

1. The engine will not start unless an operator is in the seat.

2. The engine will stop running if the operator leaves his seat while:

a.) the parking brake off, or

b.) the PTO is engaged, or

c.) the ground speed control lever is outside the neutral gate.

3. If the operator is in the seat, the operator can engage and disengage the transmission and PTO while engine continues to run.

Page 47

5 - 3

5 Electrical Troubleshooting

General Information - Testing

CHECKING OUT THE SYSTEM

General

Both the ignition and charging systems are internal to the tractor engine. Follow the Troubleshooting Guide, Section 2, or refer to your engine manual for information. See an authorized dealer or appropriate service manual for additional engine troubleshooting information.

The cranking and safety start systems have interconnected components. The testing of these components and troubleshooting procedures is covered in detail in this section.

The testing procedures contained in this section are intended to be performed as a series. Skipping a step or leaving it uncompleted can create a dangerous situation and produce incorrect test results.

Unless otherwise instructed, all tests must be performed with the ground speed control lever in the neutral gate with the parking brake engaged, the operator present seat switch activated, and the PTO switch off.

Reattach components after each test and touch only points mentioned in the test procedure to avoid possible damage to testers or components.

Basic Electrical Terms:

“Ground” is the negative battery post or any other conductive part of the frame. For best results, use the negative battery post as ground.

“VOM” is a volt-ohm meter, multi-meter, or equivalent.

“VDC” is volts of direct current or the VOM setting used to measure DC voltage.

“Ohms” are units of resistance or the VOM setting used to measure resistance.

“Continuity” is an continuous, unbroken circuit. In this manual continuity is determined with a VOM set to measure Ohms. Zero Ohms is true continuity. However, due to contact point corrosion and resistance within wires, continuity may measure several Ohms.

“No Continuity” is a broken circuit. In this manual no continuity is determined with a VOM set to measure Ohms. No continuity will register as infinite Ohms.

“Battery Voltage” is the approximate voltage output of the battery. Keep in mind that “battery voltage” tested at any component will be slightly lower than “battery voltage” tested at the battery terminals due to resistance within connections and wires.

Test Series

CHECKING THE POWER SUPPLY

1. Wiring

2. Battery Tests

• Check fluid level

• Clean battery and terminals

• Hydrometer (charge) test

• Heavy load test

3. Battery Cables

ISOLATE STARTING AND SAFETY SYSTEMS

CHECKING THE CRANKING SYSTEM

1. Test Circuit Breaker

2. Test Power to Ignition Switch

3. Test Ignition Switch

4 Test Power to Solenoid

5. Test Solenoid

6. Solenoid Bench Test

7. Test Power To Starter

TEST SAFETY INTERLOCK SYSTEM

1. PTO Interlock Switch

2. Seat Switch (Mechanical)

3. Seat Switch (Electrical)

4. Clutch/Brake Switch (Mechanical)

5. Clutch/Brake Switch (Electrical)

6. Neutral Safety Switch (Mechanical)

7. Neutral Safety Switch (Electrical)

8. Interlock Module

MISC. TESTS

1. Headlights

2. Power to Headlights

3. Headlight Switch

1. Hour Meter

2. Power to Hour Meter

1. Inspect and replace Dash Lights

1. PTO Clutch

Page 48

5 Electrical Troubleshooting

Lower Wiring Harness

5 - 4

**2044

10, 12

To engine fuel shut-off, jumper wire (Ref. No. 16) used on 15HP Briggs & Stratton only

Ground to R.H. front engine mounting bolt

To oil pressure sending unit, Briggs & Stratton units only.

To oil pressure sending unit, Kohler units only.

Kohler units only

Electric Clutch

Briggs & Stratton units only

Grommet - see Hood, Grille & Dash Group

Kohler units only

To Upper Harness

See Engine Group

To engine fuel shut-off, Briggs & Stratton Vanguard only (not used on single cylinder engines).

Location of engine kill wire on single cylinder Briggs & Stratton models only

Location of engine kill wire on twin cylinder Briggs & Stratton models only

NOTE: Unless noted otherwise, use the standard hardware torque specification chart. See Table of Contents.

Figure 1. Lower Wiring Harness

Page 49

5 - 5

5 Electrical Troubleshooting

Lower Wiring Harness

1 1 WIRE ASSY., Headlight 2 2 SOCKET, Bulb 3 2 BULB, Headlight, 12.8V 4 2 TIE, Cable 5 2 BUSHING, Snap, Small 6 1 LENS, Headlight 7 1 BEZEL, Headlight 8 1 HEADLIGHT ASSY. (Incl. Ref. Nos. 2, 3, 6, 7 & 9) 9 2 HEAT SHIELD

10 1 HARNESS ASSY., Lower

(14, 15 & 16 HP Briggs & Stratton) 11 1 WIRE ASSY., Seat Switch 12 1 HARNESS ASSY., Lower (14 & 15 HP Kohler) 13 1 BUSHING, Snap, Large (14 & 15 HP Kohler only) 14 1 WIRE ASSY., Engine Ground 15 1 SWITCH, Seat, Operator Present 16 1 WIRE ASSY., Jumper (15 HP Briggs & Stratton only)

REF. NO. QTY. DESCRIPTION

LOWER WIRING HARNESS

Page 50

5 Electrical Troubleshooting

Main Wiring Harness

5 - 6

**2045

29 30

Clutch / Brake Pedal Interlock Switch (Later Models Only)

Circuit Breaker

Transmission Switch

Headlight Switch

To Engine Starter

To Lower Harness

Not used on 15 HP Gear Model

Battery groundmount using right front engine mounting hole

NOTE: Unless noted otherwise, use the standard hardware torque specification chart. See Table of Contents.

P.T.O. Switch

Figure 2. Main Wiring Harness

Page 51

5 - 7

5 Electrical Troubleshooting

Main Wiring Harness

1 1 COVER, Terminal 2 1 CABLE, Battery to Solenoid 3 1 HOSE, Battery, Drain 4 1 WIRE ASSY. 5 1 CIRCUIT BREAKER 6 1 CABLE, Solenoid to Starter 7 1 HOLD DOWN, Battery 8 5 BULB, Indicator Light (Qty. 4 used on 15 HP models)

9 1 BOOT, Insulator 10 1 BATTERY 11 1 SOLENOID 12 1 IGNITION SWITCH ASSY. (Incl. Ref. Nos. 25, 26 & 35) 13 1 SWITCH, Transmission, Neutral Start 14 1 SWITCH, Headlight 15 1 MODULE 16 1 TRAY, Battery 17 2 NUT, Plastic, 1/4-20 18 1 SWITCH, Interlock, Clutch / Brake Pedal 19 1 STRAP, Wire Retainer 20 2 ROD, Battery Hold Down 21 1 WIRE ASSY. 22 1 CABLE, Battery to Ground 23 1 SWITCH, PTO Electric Clutch 24 1 HARNESS, Upper 25 2 KEY, Ignition 26 1 NUT 27 2 NUT, Hex, Full, 1/4-20 (15 HP models only) 28 2 LOCKWASHER, 1/4 29 2 LOCKWASHER, 5/16 30 2 NUT, Hex, 5/16-24 31 6 WASHER, Plain, 9/32 32 2 CAPSCREW, Hex, 1/4-20 x 3/4 33 7 SCREW, Plastite, #8-16 x 1/2 34 2 SCREW, Plastite, 1/4-20 x 1/2 35 1 LOCKWASHER, Internal Tooth, 5/8

REF. NO. QTY. DESCRIPTION

MAIN WIRING HARNESS

Page 52

5 Electrical Troubleshooting

Battery & Cable Tests

5 - 8

1. CHECKING THE POWER SUPPLY

A. Check Wiring Condition and Tightness

1. Check all wires for cracked or worn insulation.

2. Check all connectors, terminals, and receptacles for looseness or corrosion. See Figures 1 and 2.

B. Battery Tests

GENERAL

If the battery is producing 12 volts and the battery cables have continuity, the rest of the cranking system can be systematically tested. However, a full test of the battery includes cleaning, testing battery charge (hydrometer test) and testing its ability to deliver current (heavy load test).

NOTE: Before testing, check the battery for any damage such as a loose post or cracks. Damaged batteries must be replaced.

CHECK ELECTROLYTE LEVEL

1. Remove the battery vent cap/caps and make sure the breather holes are open.

2. Check that fluid is even with the bottom of the split rings (see Figure 3). If not, fill with distilled water.

TEST BATTERY VOLTAGE

1. Test the battery voltage: set VOM to VDC.

2. Place one test probe of the VOM on the battery’s positive post and one probe on the negative post. Note and record the battery voltage as it will be referenced in later tests.

HEAVY LOAD TEST

1. Follow the load tester manufacturer's instructions; connect the battery tester to the battery.

2. Discharge the battery under a fixed load at three times the ampere-hour rating for approximately 15 seconds, then read the terminal voltage.

Figure 3. Battery Location and Checking Electrolyte Level

WARNING

TO PREVENT ACCIDENTAL STARTING, DISCONNECT AND SECURE THE SPARK PLUG WIRES BEFORE CONDUCTING ANY ELECTRICAL TESTS.

WARNING

UNLESS OTHERWISE INSTRUCTED, ALL TESTS MUST BE PERFORMED WITH THE GROUND SPEED CONTROL LEVER IN NEUTRAL, THE PARKING BRAKE ENGAGED, AN OPERATOR IN THE SEAT, AND THE PTO SWITCH OFF.

CAUTION

REATTACH COMPONENTS AFTER EACH TEST.

DO NOT PROBE COMPONENTS UNLESS SPECIFICALLY INSTRUCTED TO DO SO.

TO AVOID A SHORT CIRCUIT AND THE POSSIBILITY OF SPARKS, DO NOT TOUCH THE TERMINALS EXCEPT AS DIRECTED.

CAUTION

BATTERY ACID CAUSES SEVERE BURNS

Page 53

5 - 9

5 Electrical Troubleshooting

Battery & Cable Tests

Figure 5. Testing Cable Continuity

HYDROMETER TEST

1. Check each cell using a hydrometer.

All cells should have a specific gravity of 1.27 or better. If the cells vary by more than . 050 points, charge the battery and recheck.

If one or more cells reads below 1.265 charge at 5 Amps checking hourly. If the low cell or cells do not improve within 3 hours of charging, replace the battery.

CLEAN BATTERY

1. Disconnect the negative battery cable, then the positive. See Figure 4.

2. Remove the battery from the battery compartment.

3. Replace the vent cap and remove dirt and corrosion with a solution of 1 part baking soda and 7 parts water.

4. Clean the posts with a wire brush until the metal is shiny.

5. After the battery is reinstalled coat the terminals with petroleum jelly to prevent corrosion.

C. Clean and Test Battery Cables

NOTE: Be sure to label record where and to which posts each cable is connected.

1. Remove the negative battery cable from the battery and from the ground. Clean the cable terminals and the engine ground with a wire brush until the metal is shiny.

2. Remove the positive cable from the battery and solenoid. Clean the terminals and solenoid post with a wire brush until the metal is shiny.

3. Remove the cable going from the solenoid to the starter. Clean the cable terminals, solenoid post, and starter post with a wire brush until the metal is shiny.

4. Clean the terminal connecting the circuit breaker to the solenoid.

5. Set the VOM to Ohms and check the cables for continuity. Replace any cable that has more than 2 Ohms of resistance or is damaged in any way.

6. Reconnect all cables and terminals to their original connections.

CAUTION

BATTERY ACID CAUSES SEVERE BURNS

WARNING

FOLLOW BATTERY CHARGER MANUFACTURER’S INSTRUCTIONS. BATTERY ACID FORMS EXPLOSIVE GASSES, KEEP FLAMES AND SPARKS AWAY.

WARNING

ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE FIRST AND RECONNECT IT LAST TO PREVENT SPARKS IF THE POSITIVE TERMINAL IS ACCIDENTALLY GROUNDED TO THE FRAME BY A TOOL

Figure 4. Battery Cable & Hardware Removal

Positive (+)

Negative (-)

Front

Page 54

5 Electrical Troubleshooting

System Isolation / Cranking System Tests

5 - 10

Figure 7. Circuit Breaker Location A. Circuit Breaker

Figure 6. Isolating the Cranking and Safety System A. Black/Yellow & Green/Black Connector

2. ISOLATE CRANKING AND SAFETY SYSTEMS

1. Disconnect the spark plug wire(s) from the spark plug(s) to prevent accidental starting.

2. Remove the black/yellow and green/black connector (A, Figure 6) from the small solenoid post.

3. Connect a jumper lead from the small solenoid post to good ground.

4. With an operator in the seat, the PTO switch off, the parking brake engaged, and the ground speed control lever in the neutral gate, attempt to crank the engine.

a.) If the starter turns the engine over, proceed to part 4 TESTING THE SAFETY INTERLOCK SYSTEM.

b.) If the starter does not turn the engine over, proceed to part 3 TESTING THE CRANKING SYSTEM.

5. Remove the jumper and reconnect the black/yellow and green/black connector to the solenoid.

3. TESTING THE CRANKING SYSTEM

For the following tests it is assumed that the battery is

fully charged and all connections and wires are good.

A. Test Circuit Breaker

The circuit breaker (A, Figure 7) is connected to the posi-

tive post of the battery through the positive battery cable connected at the large post of the solenoid.

1. Set the VOM to VDC.

2. With the negative probe, touch ground.

3. Touch the positive probe to one post of the circuit breaker, and then, the other. Both posts should have close to full battery voltage going to them. If not, replace the breaker.

4. Set VOM to Ohms.

5. See Figure 8. Probe both circuit breaker terminals. If the VOM reads 5 Ohms or more, replace the circuit breaker.

Figure 8. Testing the Circuit Breaker

Page 55

5 - 11

5 Electrical Troubleshooting

Ignition Switch Tests

Figure11. Testing the Ignition Switch

Figure 9. Ignition Switch Wire Harness (As Viewed From Engaging End)

Figure 10. Testing the Ignition Switch

B. Test Power to Ignition Switch

1. Pull plug off ignition switch.

2. Set VOM to VDC

3. Probe ground. Probe the "B" receptacle (see Figure

9) on the ignition switch plug. The VOM should show battery voltage. If not, check the battery, circuit breaker, and all connections.

4. Reinstall the ignition plug.

C. Test Ignition Switch

1. Remove the plug from the ignition switch.

2. Remove the ignition switch from the dash board.

3. Set VOM to Ohms.

4. With key switch in the OFF position connect test leads to terminals G and M. There should be a reading of 0.3-3 (continuity) on multi-meter.

5. Check all other connection combinations for no continuity. G to M should be the only combination that has continuity; all other connection combinations should have no continuity.

6. With the key switch in the RUN position, connect the VOM to terminal B and terminal L. There should be a reading of 0.3-3 Ohms (continuity) on the VOM.

7. Check all other connection combinations for no continuity. B to L should be the only combination that has continuity; all other connection combinations should have no continuity.

OFF

RUN

START

RUN

START

Page 56

5 Electrical Troubleshooting

Ignition Switch / Solenoid Tests

5 - 12

Figure 12. Testing the Ignition Switch

Figure 13. Testing the Ignition Switch

Figure 14. Testing the Ignition Switch

8. Hold switch in START position. Test the following connections for continuity: B to L, B to S, L to S. There should be a reading of 0.3-1.0 ohms (continuity) on the multi-meter (see Figures 12-14).

9. Check all other connection combinations for no continuity. B to L, B to S, and L to S should be the only combinations that have continuity; all other connection combinations should have no continuity.

Replace a switch that does not meet all of the above test

results.

10. Reinstall the ignition switch and reattach the plug.

D. Test Power to Solenoid

1. Unplug the blue / white wire (A, Figure 15) from solenoid post 1 (see Figure 15).

2. Probe ground. Probe the blue / white wire plug.

3. Turn the ignition switch to START. The VOM should show battery voltage. If not, recheck the key switch, circuit breaker, and all connections.

Figure 15. Solenoid Location A. Blue/White Wire & Plug

OFF

RUN

START

OFF

RUN

START

OFF

RUN

START

Page 57

5 - 13

5 Electrical Troubleshooting

Solenoid Tests

Figure 18. Testing Solenoid Short

Figure 16. Solenoid Location A. Green/Black & Black/Yellow Plug B. Blue/White Plug

Figure 17. Testing Solenoid Resistance

E. Test Solenoid

For this, and all tests, the ground speed control lever must be in neutral, the parking brake set, and the PTO switch must be OFF. Unplug and secure all spark plug wires. Read completely through the instructions before performing this and all tests.

1. Disconnect the Green/Black & Black/Yellow plug (A, Figure 16) and Blue/White plug (B, Figure 16) from the small posts of the solenoid.

2. Connect a jumper lead from one small post to ground.

3. Connect a jumper lead to the other small post and then touch it to the positive battery post. The lead may arch to the battery post–this is normal.

There should be a single audible “click” heard as the solenoid engages and the engine should turn over. If no click is heard, proceed to SOLENOID BENCH TEST. If the solenoid clicks but the starter does not turn the engine over, check the starter cable and the starter itself. If the solenoid “clicks” rapidly or repeatedly, recheck the battery and all connections for corrosion.

F. Solenoid Bench Test

Replace a solenoid that does not pass all of the following tests.

1. Identify and remove all wires from the solenoid. Remove the solenoid.

2. Set the VOM to the Ohms setting. Probe the small posts of the solenoid (Figure 17). The VOM should read less than 10 Ohms.

3. Connect the VOM probes to the large posts (Figure

18). The meter should read no continuity.

Page 58

5 Electrical Troubleshooting

Solenoid / Starter Tests

5 - 14

Figure 21. Testing Power to Starter

Figure 19.Testing for Solenoid Short

Figure 20. Testing Solenoid Continuity

4. Probe the mounting base of the solenoid. Probe small post #1 and observe the VOM. Probe post #2 and observe the VOM. The VOM should read no continuity in both cases.

5. Apply 12 VDC to the two small posts. There should be an audible click as the solenoid engages.

6. With the solenoid engaged (12 VDC to the small posts), measure the resistance at the two large posts. The VOM should read less than 10 ohms (continuity).

7. Correctly reinstall the solenoid and all related wires and connectors.

G. Test Power to Starter

For this, and all tests, the ground speed control lever must be in the neutral gate, the parking brake set, and the PTO switch must be OFF. Unplug and secure all spark plug wires.

1. Set VOM to VDC.

1. Probe ground. Pull the boot back and probe the starter post (see Figure 21).

2. Turn the ignition switch to start.

The VOM should read battery voltage.

12 VDC

Starter Post, Probe Here

Page 59

5 - 15

5 Electrical Troubleshooting

Safety Interlock System Tests

Figure 26. Test Seat Switch (Mechanical)

Figure 22. PTO Switch Testing A. PTO Switch

4. TESTING THE SAFETY INTERLOCK SYSTEM

A. Test PTO Interlock Switch

When a switch is replaced, test the new switch to make sure it works correctly.

1. Turn the PTO switch (A, Figure 22) OFF.

2. Remove the PTO switch wire harness plug.

3. Set VOM to Ohms ( ). Touch one probe to each of the back row of terminals. The VOM should show no continuity. (Terminals closer together)

4. Touch one probe to each of the front row of terminals. The VOM should show continuity (Terminals further apart)

5. Move PTO switch to the ON position.

6. Touch one probe to each of the back row of terminals. The VOM should show continuity

7. Touch one probe to each of the front row of terminals. The VOM should show no continuity.

B. Test Seat Switch (Mechanical)

1. Tilt the seat forward and rest it against the steering wheel. The switch button should should not be depressed.

2. Tilt the seat down to operating position and have someone sit in the seat. The weight of the operator should depress the switch button.

Seat Switch Button

Figure 25. PTO Switch Testing

Figure 23. PTO Switch Testing

Figure 24. PTO Switch Testing

Pull-Type Switch

Rocker-Type Switch

Page 60

5 Electrical Troubleshooting

Seat Switch / Clutch / Brake Switch Tests

5 - 16

Figure 27. Test Seat Switch (Electrical)

Figure 28. Test Clutch / Brake Switch (Mechanical)

C. Test Seat Switch (Electrical)

1. Raise seat and disconnect the harness plug.

2. Set VOM to Ohms.

3. Connect probes to seat switch terminals. The VOM should read no continuity.

4. Depress seat switch. The meter should show continuity.

D. Test Clutch / Brake Interlock Switch (Mechanical, Later Models Only)

1. Release the parking brake.

2. Check the clutch / brake switch. The switch button should not be depressed.

3. Set the parking brake.

4. Check the clutch / brake switch. The switch button should be depressed.

E. Test Clutch / Brake Interlock Switch (Electrical, Later Models Only)

1. Release the parking brake.

2. Remove the plug from the clutch/brake pedal interlock switch.

3. Set the VOM to Ohms and probe the terminals of the switch. It should read no continuity.

4. Set the parking brake. The VOM should show continuity.

Clutch / Brake Switch

Figure 29. Test Clutch / Brake Switch (Electrical)

Clutch / Brake Switch

Page 61

5 - 17

5 Electrical Troubleshooting

Neutral Safety Switch Tests

Figure 30. Test Neutral Safety Switch (Mechanical)

Figure 31. Test Neutral Safety Switch (Electrical) A. Neutral Safety Switch

F. Test Neutral Safety Switch (Mechanical)

NOTE: When a switch is replaced, test the new switch to make sure it works correctly.

1. Move ground speed control lever out of the neutral gate.

2. Move ground speed control lever slowly back into the neutral position while observing switch through the dashboard. The lever should depress the switch when in the neutral gate.

G. Test Neutral Safety Switch (Electrical)

NOTE: When a switch is replaced, test the new switch to make sure it works properly.

NOTE: The neutral safety switch is located under the dashboard and may be easier to test if removed. Use a 1/4” drive ratchet, a 1” extension, and 1/4” shallow socket to remove the two plastite screws that secure the switch to the dashboard.

1. Remove the wire harness plug.

2. Place the ground speed control lever in neutral (depress the switch).

3. Set the VOM to Ohms. Touch one probe to each of the top row terminals and then the bottom row terminals as shown. With the ground speed control lever in neutral (switch depressed) both rows should have continuity.

4. Move the ground speed control lever out of neutral (switch not depressed).

5. Touch one probe to each of the top row terminals and then the bottom row terminals as shown in Figure 33. With the ground speed control lever in forward (switch not depressed) both rows should have no continuity.

Neutral Safety Switch

Figure 32. Neutral Safety Switch Testing

Figure 33. Neutral Safety Switch Testing

Page 62

5 Electrical Troubleshooting

Interlock Module / Headlight Tests

5 - 18

Figure 36. Headlight Switch Location A. Headlight Switch

Figure 34. Interlock Module Location A. Interlock Module

Figure 35. Headlight Assembly

H. Interlock Module

If all other switches, connectors, wires, and cables have

tested OK, the interlock module is at fault and must be removed and replaced. The module is not testable. However, if available, a known-good module can be used to test the system.

1. Unplug and remove the old module (A, Figure 34).

2. Substitute the know-good module for the old module.

3. Turn the ignition switch to START. If the engine turns over, the old module is bad and must be replaced.

5. MISCELLANEOUS TESTS

A. Test Headlight Bulbs

1. Remove the headlights from the headlight assembly by twisting the socket counterclockwise and pulling it out of the reflector assembly.

2. Visually inspect the bulb. If the element is burned out, replace the bulb.

B. Test Power to Headlight Circuit

1. Turn the ignition switch to ON (RUN) and the headlight switch OFF.

2. Set VOM to VDC. Touch the negative probe to ground. Use the positive probe to probe the white / black wire of the headlight switch plug (see Figure

36). The VOM should read battery voltage. If not, check the ignition switch and all connections and wires.

3. Turn the headlight switch ON.

4. Probe ground and the white/green plug on the back of the switch. The VOM should read battery voltage. If not, check the headlight switch (see TEST HEADLIGHT SWITCH).

Page 63

5 - 19

5 Electrical Troubleshooting

Headlight / Hour Meter Tests

Figure 39. Hour Meter Location A. Hour Meter

Figure 37. Test Power to Headlights

Figure 38. Headlight Switch Location A. Headlight Switch

5. Keep the headlight switch ON. Probe ground and probe the terminal at the headlight connection. The VOM should read battery voltage. If not, check the switch and the continuity of all wires and connectors.

C. Test Headlight Switch

1. Remove the plugs from the headlight switch.

2. Set the VOM to Ohms.

3. With the switch OFF probe both terminals. The VOM should read no continuity.

4. Turn the switch to ON. The VOM should read continuity.

D. Test Hour Meter (Where Applicable)

The hour meter (A, Figure 39) can be easily tested by turning the ignition switch to RUN and observing the meter. The meter should register the passage of time.

Probe Here

Page 64

5 Electrical Troubleshooting

Hour Meter / Dash Light Tests

5 - 20

Figure 41. Dash Light Assembly Location A. Dash Lights

E. Test Power to Hour Meter (Where Applicable)

1. Turn the ignition switch to RUN.

2. Set VOM to VDC.

3. Probe ground. Probe the white/blue wire at the hour meter terminal. The VOM should read battery voltage. If not, check the key switch and all wires and connections.

4. Probe ground. Probe the blue/white wire at the hour meter terminal. The VOM should read battery voltage. If not, check the ignition switch, all wires and connections, and the hour meter.

F. Inspect and Replace Dash Lights

1. Open the hood.

2. Remove the dash lights (A, Figure 41) by twisting the socket counterclockwise and pulling it out of the dash assembly.

3. Visually inspect the bulb and replace if burned out.

Figure 40. Hour Meter Location A. Hour Meter

Page 65

5 - 21

5 Electrical Troubleshooting

PTO Clutch Tests

Figure 42. PTO CLutch Terminals

G. Test Electric PTO Clutch

TEST PTO CLUTCH RESISTANCE

1. Set VOM to Ohms.

2. Unplug the PTO clutch connector.

3. Probe PTO clutch connector terminals.

The VOM should read approximately 2-3 Ohms. If the clutch has more resistance than 3 Ohms, replace the field assembly or clutch assembly.

TEST ELECTRIC PTO CLUTCH FOR SHORT CIRCUITS

1. Set VOM to Ohms.

2. Probe the clutch body with the negative test lead.

3. Probe one of the connector terminals with the positive lead. The VOM Should show no continuity.

4. Probe the other connector terminal with the positive lead. Again, the VOM should show no continuity.

If the VOM shows continuity to the clutch body from either terminal, the clutch has an internal short and should be replaced.

TEST ELECTRIC PTO CLUTCH ENGAGING

1. Connect the PTO clutch terminals to a 12 VDC power supply.

An audible “click” should be heard as the clutch engages. If the clutch does not engage, replace the field assembly or clutch assembly.

Reconnect the clutch wire connector after testing.

Terminals

Clutch Body

Page 66

5 Electrical Troubleshooting

Wiring Diagram

5 - 22

BLUE

RED / BLACK

WHITE / BLACK

RED / BLACK

BROWN

BROWN / WHITE

BROWN

RED / WHITE

ORANGE / BLACK

ORANGE

TAN

TAN / BLACK

TAN

GREEN

GREEN / WHITE

BLUE / WHITE

BLACK / WHITE

BLACK / RED

PURPLE / WHITE

BLACK / WHITE

BLACK / YELLOW

YELLOW / BLACK

GREEN / BLACK

YELLOW

BLACK

BLUE

SOLENOID

STARTER

ALTERNATOR

HEADLIGHTS

OIL PRESSURE

FUEL

SHUT OFF

16 HP ONLY!

BATTERY

OIL LIGHT

CIRCUIT

BREAKER

IGNITION

SWITCH

FOOT

SWITCH

PTO LIGHT

TRANS. LIGHT

SEAT LIGHT

HEADLIGHT

LIGHT

PTO

SWITCH

TRANS

SWITCH

IGNITION MODULE

HARNESS

PLUG

(UPPER)

HARNESS

PLUG

(LOWER)

INTERLOCK

MODULE

HEADLIGHT

SWITCH

ELECTRIC

CLUTCH

SEAT

SWITCH

56 78

SPLICE "D"

SPLICE "A"

SPLICE "B"

SPLICE "C"

PURPLE

BLACK

WHITE

RED

LOWER

HARNESS

PTO

START

LIGHT

IGNITION SWITCH

POSITION CIRCUIT MAKE

1.OFF

2. RUN

3. START

G & M

B & L

B & L & S

NOTE:

SPLICE "A" 5.2" FROM HARNESS PLUG. SPLICE "B" 6.5" FROM HARNESS PLUG. SPLICE "C" 8.3" FROM HARNESS PLUG. SPLICE "D" 12.0" FROM HARNESS PLUG.

UPPER HARNESS

(BACK VIEW OF SWITCH)

Broadmoor, 1600.

& 1600 Series -

Typical

Page 67

5 - 23

5 Electrical Troubleshooting

Safety System Diagram

BROWN

BROWN / WHITE

ORANGE / BLACK

TAN / BLACK

GREEN / WHITE

BLUE / WHITE

BLACK / YELLOW

YELLOW / BLACK

GREEN / BLACK

BLACK

SOLENOID

STARTER

BATTERY

CIRCUIT

BREAKER

IGNITION

SWITCH

FOOT

SWITCH

PTO

SWITCH

TRANS

SWITCH

HARNESS

PLUG

(UPPER)

HARNESS

PLUG

(LOWER)

INTERLOCK

MODULE

SEAT

SWITCH

56 78

SPLICE "A"

SPLICE "C"

BLACK

WHITE

RED

LOWER

HARNESS

PTO

START

LIGHT

IGNITION SWITCH

POSITION CIRCUIT MAKE

1.OFF

2. RUN

3. START

G & M

B & L

B & L & S

NOTE:

SPLICE "A" 5.2" FROM HARNESS PLUG. SPLICE "B" 6.5" FROM HARNESS PLUG. SPLICE "C" 8.3" FROM HARNESS PLUG. SPLICE "D" 12.0" FROM HARNESS PLUG.

UPPER HARNESS

(BACK VIEW OF SWITCH)

Broadmoor, 1600.

& 1600 Series -

Typical

Page 68

5 Electrical Troubleshooting

Notes

5 - 24

Page 69

6 - 1

6 General Repair

Table of Contents

SECTION 6. GENERAL REPAIR

SECTION CONTENTS

6A. Steering & Front Wheel Repair

General.................................................................................... 6-2

Elevating Front of Unit For Safe Service................................. 6-2

Front Wheel Repair ................................................................. 6-4

LH Spindle Repair ................................................................... 6-6

RH Spindel / Steering Arm Repair........................................... 6-8

Tie Rod Repair ........................................................................ 6-10

Steering Wheel Removal......................................................... 6-12

Steering Shaft Removal .......................................................... 6-13

Steering Gear / Pitman Arm Service ....................................... 6-14

Drag Link Removal.................................................................. 6-15

6B. Hand Controls Repair

General.................................................................................... 6-17

Parking Brake Rod .................................................................. 6-20

Parking / Shift Knob Removal ................................................. 6-20

Shift Lever Assm. Service ....................................................... 6-21

Lift Lever Assm. Service.......................................................... 6-28

Choke Control Service ............................................................ 6-29

Throttle Control Service........................................................... 6-31

6C. Foot Controls Repair

General.................................................................................... 6-33

Clutch / Brake Pedal Arm Assm. Service................................ 6-35

Clutch Rod Service.................................................................. 6-36

Idler Arm Assm. Service.......................................................... 6-40

Lockout Lever Assm. Service.................................................. 6-41

Shift Lever Pivot Assm. Service .............................................. 6-42

Rod Guide / Brake Rod Service .............................................. 6-46

6D. Hood, Grille & Dash Repair

General.................................................................................... 6-51

Hood & Grille Removal............................................................ 6-51

Dash Removal......................................................................... 6-53

6E. Seat, Deck & Fuel Tank Repair

Seat Removal.......................................................................... 6-59

Seat Deck Removal................................................................. 6-60

Fuel Tank Removal ................................................................. 6-60

6F. Rear Wheel Repair

General.................................................................................... 6-61

Elevating Rear End For Safe Service...................................... 6-62

Rear Wheel Removal .............................................................. 6-62

Page 70

6 General Repair

6A Steering & Front Wheel Repair

6 - 2

DANGER

PREVENT SERIOUS INJURY OR

DEATH FROM FALLING UNIT

Always use a properly working lifting device with a capacity suitable for the weight of the unit being serviced.

Always use a jack stand to support the unit while performing service, and chock remaining wheels to prevent the unit from rolling off the supports.

Never work under or around an elevated unit that is not properly supported and secured in position with wheel chocks.

Figure A–1. Elevate Front End Of Unit

GENERAL

Servicing the lower steering mechanism and front wheel spindles should be performed with the front end of the unit elevated and supported evenly on both sides with jackstands.

Although service can be performed with the mowing deck and hood assembly on the unit, removing the deck and hood assembly provides clear access to all lower steering mechanism components and helps simplify the job.

REQUIRED TOOLS & EQUIPMENT

Tools required for performing disassembly and assembly in these areas include:

• socket wrench set

• open end wrench set

• Flat blade screwdriver

• Metal striking hammer

• Claw hammer, or pry bar

• Center punch or carbide scribe

• Torque wrench (0 - 75 ft. lbs.)

Specialized equipment required for servicing these areas include:

• Jackstands (2)

• Scissor jack or hydraulic jack

• Wheel blocks (2)

• Grease gun w/Lithium-base automotive grease

• Oil can (use SAE 30 weight oil)

ELEVATING FRONT OF UNIT FOR SAFE SERVICE

1. Remove the ignition key, and disconnect the spark plug wire to prevent accidental starting while working on unit.

2. Remove mowing deck. See Operator’s Manual.

3. Remove the hood assembly as described in Section 6D. Hood, Grille & Dash Repair.

4. Engage parking brake, block the rear wheels, and using a hydraulic or scissors jack positioned at the center of the front axle assembly, carefully jack the unit up until the front tires are approximately 1" - 2" off the ground (Figure A–1-1).

NOTE: For overall unit stability during service, do not jack front end higher than required for adequate access to steering and spindle components. Excessive elevation may result in fuel leakage from gas tank or electrolyte leakage from battery vents.

5. Position jackstands at each end of front axle assembly and lower the unit slowly until jack stands fully support unit. Make sure the jackstands engage the bottom of the front axle assembly so that weight is evenly distributed on each of the jackstands.

6. Check the rear wheel blocks and make sure that they are tight against the rear wheels to prevent rolling.

DANGER

Do not begin work on the unit unless it is stable and you are sure wheels are chock to prevent rolling.

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*AGCO Allis, Massey Ferguson

& early Simplicity models

** Later Simplicity models

A. Valve Stem & Cap B. Grease Fitting C. Ring D. Tube E. Cap* F. Retainer* G. Tire H. Bearing (See Inset) I. Wheel J. Washer K. Hubcap**

Grease front wheel assemblies

Figure A–2. Front Wheel Assembly

"H" - Later Models

"H" - Early Models

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6 - 4

Figure A–3. Front Wheel Retaining Ring - Broadmoor

Front Wheel Repair

BROADMOOR MODELS

NOTE: Illustrations show AGCO Allis, Massey-Ferguson, and earlier Simplicity model style of hubcap and hardware. Later model Simplicity units have a large snap-on hubcap cover that must be removed for access to the wheel retaining ring.

1. Using a flat blade screwdriver, pop off the plastic hub cap to gain access to the retaining ring.

2. Insert the tip of the flat blade screwdriver into the area at the open end of the retaining ring, and twist the blade against the retaining ring to force the retaining ring out of the groove (Figure A–3).

3. With the retaining ring partially out of the groove, insert the blade tip between the retaining ring and spindle shaft, and pop the retaining ring out of the groove.

4. Slide the wheel off the spindle shaft (Figure A–4). Note that the tire air valve and axle grease fitting are located on the inside of the wheel.

5. Removal of the wheel provides an opportunity to inspect the inside of the tire for sidewall damage, as well as to check inflation pressure. Also, visually check wheel bushings for wear or damage before reinstalling the wheel on the unit, and replace as required. Wheel bushings are pressed into the wheel hub with a press fit and may be removed by pressing or driving out. Align the flat on the bushing with the grease fitting before pressing in the bushing. When installing new bushings, measure the I.D. of the wheel hub to determine the correct bearing O.D. size. See inset illustration in Figure A–2 for sizes.

Retaining ring

Hubcap retainer

Figure A–4. Wheel And Assembly Hardware - Broadmoor A. Air Valve D. Hubcap Retainer B. Grease Fitting E. Hubcap C. Retaining Ring

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6A Steering & Front Wheel Repair

Lower Steering Group

Upper Steering Group

Figure A–5. Broadmoor Steering Group - Typical Assembly

(Frame & Dash Shown For Component Position Reference)

Frame

Dash

Lower Dash

STEERING GROUP ASSEMBLIES

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LOWER STEERING GROUP

A. Clip Ring, 5/8 B. Washer C. Capscrew D. Spacer E. Rod End F. Washer G. Nut, Flange, 3/8-16 H. Jam Nut, 1/2-20 I. Drag Link J. Washer, 49/64 K. Spindle Assy. L. Tie Rod M. Carriage Bolt N. Spacer O. Arm Assy. P. Nut, Flange Lock, 3/8-16 Q. Steering Arm Assy.

EARLY STYLE DRAG LINK S. Nut T. Ball Joint Assy. U. Nut V. Drag Link

EARLY STYLE SPINDLE ASSY W. Key, Hi Pro X. Set Screw, Sq. Hd.

Torque to 17-23 ft. lbs. (2 places)

Early Style Drag Link

Figure A–6. Lower Steering Assembly

Figure A–7. Remove Clip Ring

LH Spindle Repair

1. Remove the wheels as described previously under Front Wheel Repair.

2. Using a flat blade screwdriver, position the tip of the screwdriver blade at the open end of the steering arm clip ring, and twist the blade against the clip ring to force the ring partially out of the groove (Figure A–7).

3. Insert the tip of the screwdriver blade in the gap between the inside edge of the clip ring and the spindle shaft, and pop the clip ring completely out of the groove.

NOTE: To index steering wheel, loosen nuts (H), adjust drag link (I) so that full left hand turn and full right hand turn have equal play (full turn must hit spindle stop). Torque nuts to 13 ft. lbs.

Early Style Spindle Assembly

* Torque Item "X" to 13-19 ft. lbs. (4 Places)

Clip Ring

Steering Arm

Assembly

To Pitman Arm

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Figure A–10. Remove Spindle Shaft Bushings

Punch marks

Figure A–8. Remove Rod End

Figure A–9. Inspect Rod End

4. Using a 9/16" socket and 9/16" open end or box wrench, remove the capscrew/washer and flanged hex nut that secure the steering arm assembly to the rod end (Figure A–8).

NOTE: A spacer is located over the capscrew threads in the rod opening to permit rotation of the steering arm. Damage to the spacer or washer caused by excessive tightening or wear may adversely affect steering, so be sure to inspect these parts and replace them if necessary before reassembly.

5. The rod end is screwed onto the drag link arm and is secured in place with a 1/2-20 jam nut.

Rod End

Drag Link

Steering

Arm

Steering

Arm

Rod End

Steering Arm

Bushing

6. Inspect the rod end for free movement/rotation of the rod end bearing, and replace the rod end if necessary (Figure A–9).

7. To remove the rod end, loosen the jam nut by turning it clockwise (looking at the end of the drag link shaft) one or two turns with a 3/4" open-end wrench, and then unscrew the rod end by turning it counter-clockwise.

NOTE: When reinstalling the rod end, be sure to adjust the length of the drag link arm so that the left and right spindle stops stop against the axle assembly with full left and right turns respectively. See the adjustment procedures section for complete details.

8. Tap the left hand steering arm assembly up off the spindle shaft with a hammer to remove it from the axle/spindle shaft assembly.

NOTE: It will be helpful to mark the relative positions of the steering arm, splined spindle shaft, and shaft housing with punch marks to simplify realignment later (See Figure A–10).

9. Tap the top of the splined spindle shaft down with a few light hammer blows, and remove the spindle shaft from the bottom of the axle assembly housing, noting alignment.

10. With the spindle shaft removed, the bushings can be removed and inspected for signs of wear (Figure A–10). Use a brass drift or punch to tap out the bushings from opposite ends of the housing. Replace the bushings if worn, scored, or cracked.

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RH Spindle/Steering Arm Repair

1. Remove right front wheel using same procedure as used for left front wheel. (Figure A–11)

2. Use a center punch to mark the relative assembled positions of the right hand steering arm, right hand spindle assembly, and the right side of the front axle assembly (Figure A–11 and A–12).

3.Remove the hex nut and carriage bolt securing the right hand steering arm to the tie rod (Figure A–12).

Figure A–12. Disassemble Tie Rod From RH Steering

Arm

Figure A–11. Right Front Spindle Assembly

Figure A–13. Remove Retaining Ring

4. Using a flat blade screwdriver, position the tip of the screwdriver blade at the open end of the steering arm clip ring, and twist the blade against the clip ring to force the ring partially out of the groove (Figure A–13).

5. Insert the tip of the screwdriver blade in the gap between the inside edge of the clip ring and the spindle shaft, and pop the clip ring completely out of the groove.

6. Slide the right hand spindle assembly straight down to remove it from the front axle assembly. Inspect parts and replace as required. Grease spindle bushings as described earlier in left side disassembly instructions.

Clip Ring

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Figure A–15. Grease Wheel Bushings

Figure A–14. Lubricate Rod End Spacer

Rod End Spacer

Rod End

Reassembly

1. Reassemble parts in the reverse order of disassembly, using particular care to realign the steering arm assembly, spindle assembly, and axle housing.

2. Observe torque specifications on Figure A–6.

NOTE: If alignment marks are obscured during service or if parts are replaced, proper steering alignment can be performed later with wheels installed using the distance between tires as a guide. The distance between tires at the front should be 1/8" less than the distance between tires at the rear (measured at the the outer edge of the tire tread) when the wheels are pointed straight ahead. This slight toe-in is permanently set by the tie rod, and is not adjustable.

3. Before reassembling rod end hardware to left hand steering arm, squirt a few drops of SAE 30 weight oil on the outer surface of the spacer (Figure A–14).

4. Before reinstalling the wheel and related hardware, grease the spindle bushings using the grease fitting on the front axle assembly (Figure A–15). Use a lithium-base, automotive-quality grease such as that provided with the optional Grease Gun Kit.

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Tie Rod Repair

1. The tie rod can be removed by disassembling the flanged hex lock nuts and carriage bolts that secure the tie rod to the left and right steering arm assemblies (Figure A–16). Use care when removing the hardware to prevent the internal spacers from falling out.

2. Check the spacer for signs of excessive wear, damage, or flattening due to over-tightening of the assembly hardware, and replace if required. (The spacer allows the steering arms to pivot freely at the tie rod joint.)

3. Check the tie rod for cracks or other damage at the rod ends, and replace if necessary. Also the center portion of the tie rod must be straight to provide the correct center-to-center distance for wheel alignment. If the tie rod is bent, replace the tie rod.

4. Reassemble the tie rod to the steering arms using new spacers or hardware if required. Before installing the flanged lock nut, squirt a few drops of SAE 30 weight oil around the spacer (Figure A–17).

5. Tighten the lock nut securely, but do not over-tighten as this will damage the spacer and may prevent free rotation of the steering arms.

Figure A–17. Lubricate Tie Rod/Steering Arm Spacer

Figure A–16. Tie Rod/ LH Steering Arm Assembly A. Flanged Hex Lock Nut C. Carriage Bolt B. Spacer

Spacer

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6A Steering & Front Wheel Repair

A. Cap B. Steering Wheel C. Pin, 5/16 x 2 D. Tube E. Steering Shaft F. Cotter Pin G. Washer, 49/64 H. Washer

I. Carriage Bolt, 3/8-16 x 1 J. Nut, Flange Lock, 3/8-16 K. Bushing L. Capscrew, 5/16-18 x 1-1/2 M. Spacer N. Nut, 5/16-18 O. Capscrew, 3/8-16 x 1-3/8 P. Pitman Arm

Q. Key R. Screw, Taptite, 5/16-18 x 1 S. Sector Mounting Plate T. Steering Gear Assy. Hub U. Square Head Set Screw

UPPER STEERING GROUP ASSEMBLY

NOTE 4

(gear teeth) Apply Loctite

#271. Torque to 20-30 ft.lbs.

Torque to 17-23 ft.lbs. (2 places)

Early models used a capscrew, washer & nut in place of a roll pin (C).

Figure A–18. Upper Steering Assembly

To Rod End - See Figure 4A–8

NOTES:

1. Unless specified, use torque specifications shown on standard hardware torque specification chart.

2. Grease locations indicated by grease gun symbol:

3. Oil locations indicated by oil can symbol:

4. Pitman arm shaft (P) should protrude 9/16" above top of steering gear assembly hub (T).

Grease bushings "K" (3 places)

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Figure A–19. Remove Steering Wheel Hardware

Earlier Models

Steering Wheel Removal

EARLIER MODELS

1A.Remove the steering wheel by disassembling the hex

head bolt and hex nut that secure the steering wheel to the steering shaft assembly (Figure A–19).

Figure A–20. Remove Steering Wheel Spring Pin

Later Models

Figure A–21. Remove Steering Wheel

CURRENT MODELS

1B.Later-model steering wheels are attached to the

steering shaft assembly with a long spring pin. Use a pin punch and hammer to drive the spring pin out of the steering wheel and steering shaft assembly (Figure A–20).

2. Slide steering wheel up to remove from steering shaft assembly, and note positioning of mounting holes for later reassembly (Figure A–21).

3. Inspect steering wheel and hardware for wear or damage, and replace as required. Reassemble steering wheel to steering shaft assembly, or proceed to next step if steering shaft is to be serviced.

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Figure A–22. Remove Cotter Pin A. Cotter Pin

Steering Shaft Removal

NOTE: Unit must eventually be tipped up to remove the shaft.

1. Remove the steering wheel as shown in the steering wheel removal section.

2. Remove the cotter pin from the steering shaft (A, Figure A–22) just above bushing in the frame support.

3. Locate the washers that were held in place by the cotter pin. Slide the washers off the shaft.

Figure A–23. Steering Mounting Plate A. Nuts

4. Loosen the nuts securing the steering mounting plate (A, Figure A–23).

5. Slide the steering shaft assembly down and out of the bottom of the unit to remove for replacement.

Note: Unit must be tipped up at this point to remove the shaft.

6. Inspect steering shaft assembly and bushings for excessive wear or damage. Replace if required.

7. Install the steering shaft assembly in the reverse order of removal and apply a liberal coating of grease to the steering shaft and drive gear.

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Figure A–26. Remove Steering Arm Assembly

90°

4. Turn the steering arm assembly mounting plate 90* to allow the assembly to be removed as a unit. Pull the assembly straight out. See Figure A–26.

5. The steering arm assembly may be disassembled by removing the the two square head bolts (U, Figure A–18) from the gear assembly.

6. Inspect all parts for excessive wear or damage and replace as required.

7. Reassemble in reverse order of disassembly. Apply a grease to the pitman arm shaft, bushings, and gear teeth. Note the placement of the shaft key for correct gear orientation.

Figure A–24. Disconnect Drag Link Ball Joint

Drag Link

Pitman Steering Arm

Steering Gear / Pitman Steering Arm Service

1. Tilt the unit up or place on an elevated work stand for access to the underside of the frame.

2. Disassemble the drag link from the pitman arm by removing the capscrew, washers, spacer, and flanged hex lock nut (Figure A–24).

Figure A–25. Remove Hex Capscrews

Pitman Steering Arm

3. Remove taptite hex head capscrews that secure pitman steering arm/assembly to underside of unit (Figure A–25).

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Figure A–27. Disassemble Rod End From Steering

Arm

Figure 4A–29. Disassemble Rear Drag Link Rod End

From Pitman Steering Arm

Drag Link Removal

1. See Figure A–27. Using a 9/16" socket and 9/16" open end or box wrench, remove the capscrew, washer and flanged hex nut that secure the steering arm assembly to the front rod end on the drag link. (For units equipped with early style drag links, see Figure A–6 for correct hardware and assembly).

2. Disassemble rear drag link rod end from pitman arm by removing capscrew, washers, spacer, and flanged hex lock nut (Figure A–28).

3. Remove the drag link rod ends by first loosening the jam nuts. Turn the jam nuts clockwise (looking at the end of the drag link shaft) one or two turns with a 3/4" open-end wrench, and then unscrew the rod end by turning it counter-clockwise.

4. Check the drag link for cracks or other damage, and replace if required. If the drag link is being replaced, position the jam nuts on the new drag link in the approximate positions utilized on the old drag link.

5. Inspect the rod ends for free movement/rotation of the rod end bearing, and replace the rod ends if necessary.

6. Reassemble the rod ends to the drag link, and reassemble the drag link to the unit in the reverse order of disassembly. Do not tighten the jam nuts until final spindle stop adjustments have been made.

NOTE: When reinstalling the rod ends, be sure to adjust the overall length of the drag link arm so that the left and right spindle stops stop against the axle assembly with full left and right turns respectively. See the adjustment procedures section for complete details.

Drag Link

Pitman Steering Arm

Steering Arm

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6 General Repair

6B Hand Controls Repair

GENERAL

The hand controls group consists of the following major components (also see Figures B–1 and B–2):

• Shift Lever

• Throttle Lever

• Choke Lever

• Parking Brake

• Lift Lever

The hand controls group assemblies can often be serviced without elevating the unit, but servicing these components requires removal of the hood assembly, dash assembly, and disconnecting several related parts, as well as disconnecting the battery cables and removing the battery. In general, removing the mower deck also makes service access much easier.

Inspecting parts for wear or breakage, or minor service, such as lubrication or tightening hardware, may, in some cases, be accomplished by simply removing the steering wheel and dash attachment hardware, and pulling the dash assembly up as far as slack in the wiring and control cables permits.

Required Tools & Equipment

Tools required for performing service on the hand controls group include:

• Hammer or rubber mallet

• Small flat blade screwdriver

• Phillips screwdriver

• Long-nose pliers

• 1/2" deep socket

• 3/8" Nut Driver or 3/8" socket w/6" min. extension

• 3/8" & 7/16" box or combination wrenches

• 3/8" & 7/16" open end wrench

DANGER

Always obey all safety precautions for working around battery hazards such as electrolyte, hydrogen gas, and live battery terminals when removing and reinstalling the battery. Always disconnect the negative terminal cable first, and reconnect it last, to help prevent dangerous sparking caused by accidental tool contact between the positive terminal of the battery and the frame. Keep the battery level when handling to prevent leakage of electrolyte.

Figure B–1. Hand Controls

Throttle

Figure B–2. Hand Controls - Dash View (Steering

Wheel Removed For Clarity)

Shift Lever

Lift Lever

Choke

Shift Lever

Lift Lever

Parking Brake

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EARLY MODEL SHIFT LEVER ASSEMBLY

A. Knob B. Shift Lever C. Cotter Pin D. Washer E. Torsion Spring F. Plastic Bushing - 1/2" Dia. G. Nylon Bushing - 3/4" Dia. H. Tension Bracket I. Hex Head Capscrew - 5/16-18 x 1-3/4" J. Washer - 5/16" K. Spacer L. Washer - 5/8" M. Washer - 1/2" N. Spring O. Hex Locknut - 5/16-18 P. Shift Lever Assembly

LATER MODEL SHIFT LEVER ASSEMBLY

A. Knob B. Shift Lever C. Cotter Pin D. Washer E. Torsion Spring F. Plastic Bushing - 1/2" Dia. G. Nylon Bushing - 3/4" Dia. H. Washer - 1/2" I. Hex Locknut - 5/16-18 J. Washer - 5/16" K. Spring L. Hex Nut 5/16-18 M. Lockwasher - 5/16" N. Washer - H.T. O. Spacer P. Stud - 5/16-18 x 3-1/4" Q. Carriage Bolt 1/4-20 x 3/4" R. Washer - 21/64 x 1-1/4" S. Tension Bracket T. Washer - 1/4" U. Lockwasher - 1/4" V. Hex Nut 1/4-20 W. Shift Lever Assembly

Figure B–3. Typical Shift Lever Assemblies

Install washer

with rounded

edge down.

Grease

EARLY MODEL

LATER MODEL

Torque To 75-100 in.-lbs.

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6B Hand Controls Repair

A. Knob B. Lift Handle Rod C. Carriage Bolt - 5/16-18 x 1-1/2" D. Washer - 13/32 x 1-1/2" E. Spacer F. Washer - 5/16" G. Hex Locknut - 5/16-18 H. Upper Lift Link I. Upper Transport Lift Link J. Cotter Pin

K. Lift Link L. Lift Assembly Cam M. Washer 21/64" x 1-1/4" N. Spacer O. Cotter Pin P. Washer - 9/32" Q. Parking Brake Cam R. Parking Brake Rod S. Plastic Knob

*T. Lift Handle Rod *U. Carriage Bolt 5/16-18 x 1"

Figure B–4. Broadmoor Lift Handle Assembly

Early Style Lift Lever Assembly

Later Style Lift Lever Assembly

*Early Style Lift Lever Assembly Only

Lower Dash

Frame

Grease

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Shift Knob Removal

3. Remove the shift lever knob from the shift lever as follows.

a. Plastic knob - unscrews from shift lever by turning

knob counterclockwise.

b. Rubber knob - is pressed onto end of shift lever

and may be removed by placing a 7/16” open end box wrench under the knob and tapping the wrench outward with a hammer or rubber mallet. (Figure B–7) Knobs that resist removal with this method may be heated with a heat gun or blow dryer to expand the I.D. of the knob slightly and separate it from the end of the shift lever.

NOTE: Do not overheat the knob as this may distort the part or cause melting, and could prevent a secure fit when reattaching the knob. Use a low heat setting when using a heat gun, and keep the gun 4-6’’ away from the knob while moving back and forth to provide even heating.

4.Slide the knob off the shift lever, and check for cracks or excessive wear, and replace as necessary.

Parking Brake Knob Removal

1. The parking brake rod is threaded. Unscrew the parking brake knob from the parking brake rod. (Figure B–6)

WARNING

Never use a heat gun or blow dryer if flammable vapors are present, as the heating element could ignite the vapor and cause a fire or explosion.

Figure B–7. Remove Shift Lever Knob (Later Model

With Rubber Knob)

Figure B–6. Unscrew Parking Brake Knob

Shift Lever Knob

Figure B–5. Remove Cotter Pin From Parking

Brake Rod & Disengage From Brake Cam

Parking Brake Rod Service

1. See Figure B–5. Remove the cotter pin from the lower end of the parking brake rod, and after noting the correct installation position of the rod, disengage it from the parking brake cam. Lift the parking brake rod up and out of the lower dash/frame area, and inspect for wear or damage. Replace as necessary. Reassemble in reverse order of removal.

Cotter Pin

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6B Hand Controls Repair

Figure B–8. Broadmoor Hydro Shift/Lift Lever

Access Area

Shift Lever Assembly Service

Shift lever assembly service requires that the dashboard be removed. Refer to the Hood, Dash, and Grill Repair section for dashboard removal instructions.

After the dash assembly is fully separated from the unit, set it aside carefully to prevent damage to electrical components.

The lift lever, and shift lever assemblies are now fully accessible, as is the steering column shaft, and front transmission shift rod connection to the shift lever assembly. (Figure B–8).

Figure B–9. Adjust Spring Tension

Shift Lever Spring Adjustment

Tension on the shift lever may be increased or decreased by adjusting the tension on the shift lever compression spring (K, Figure B–3 Later Model Shift Lever Assembly). The correct tension for proper shift lever operation should be obtained when the adjustment locknut (I, Figure B–3) is torqued to 75 - 100 in./lbs.

1. Using a 1/2 deep socket with a 4" - 6" extension bar, remove the tension adjustment locknut and compression spring (Figure B–9). Inspect spring and surrounding parts for signs of wear or breakage, and replace as needed.

2. Reassemble parts in position as shown in Figure 4B–4, and torque to 75 - 100 in./lbs.

Figure B–10. Disengage Torsion Spring

Shift Lever Replacement

1. Release tension on the shift lever by disengaging the torsion spring’s (E, Figure B–3) hooked end from the shift lever shaft. (Figure B–10)

Torsion Spring

Tension Spring

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Figure B–11. Remove End Cotter Pin

2. Using a long-nose pliers, remove the cotter pin from the end of the shift lever. (Figure B–11)

Figure B–12. Slide Shift Lever Out Of Mounting

3. Slide the shift lever out of the shift lever mounting bushings, and inspect for damage. (Figure B–12) Replace as necessary.

4. Apply a light application of grease to the end of the shift lever before reinstalling it into the plastic mounting bushings.

5. Secure the shift lever in place with the cotter pin, and re-engage the hooked end of torsion spring to the shift lever.

6. Check the shift lever for smooth operation.

Figure B–13. Shift Lever Assembly Removal

Shift Lever Assembly Replacement

The shift lever assembly should be replaced if damaged or worn.

1. Remove the steering wheel and steering shaft. See Steering Wheel Removal and Steering Shaft Removal sections.

2. From the underside of the unit, remove the two steering gear adjustment locknuts (Figure B–13) that secure the steering mounting plate and lower nylon bushing to the frame. Removal of the locknuts allows the two mating carriage bolts to be removed from the inside, near the base of the shift lever assembly.

3. Disassemble the shift lever and related parts as previously shown in the Shift Lever Service section.

Cotter Pin

Shift Lever

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Figure B–14. Disassemble Tension Bracket From

Lower Dash

4. Using a 7/16" socket and a short extension bar, remove the two sets of hex nuts, lockwashers, flat washers, and carriage bolts that attach the tension bracket to the inside wall of the lower dash (Figure B–14).

Figure B–15. Disconnect Shift Rod Linkage From

Shift Lever Assembly Arm

Cotter Pin

Tension Bracket

5.Remove the cotter pin connecting the shift lever assembly arm to the front transmission shift rod linkage (Figure B–15).

6. The shift lever assembly may now be removed from the unit and inspected for wear or damage. Replace parts as required. Refer to Figure B–3 for proper assembly sequence of parts.

7. Reassemble parts in reverse order of disassembly. Apply a light coating of grease to the inside diameter of all bushings before reinstalling the shift lever assembly in the unit.

NOTE: On later models with adjustable tension, attach tension bracket (S, Figure B–3) against lower dash before tightening hex nut (L) on stud (P). Adjust tension on adjustment nut (I) to 75 - 100 in./lbs.

8. If no additional service is to be performed in this area, reassemble dash and related parts in reverse order of disassembly.

9. If lift lever parts are to be serviced, proceed to the Lift Lever Assembly Service section.

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Figure B–16. Front Shift Lever Rod/Shift Lever

Assembly Attachment (Broadmoor Model Shown)

Shift Lever Rod Service

BROADMOOR LATE MODEL HYDROS

1. Remove battery from unit to provide access to front shift lever rod assembly at base of shift lever assembly (Figure B–16)

2. Remove cotter pin that secures front shift lever rod to shift lever arm, and set spacer aside for reuse when reassembling rod.

Figure B–17. Idler Arm Assembly Area - Underside

Of Unit

3. Safely elevate and support unit (mower deck removed) for working access to idler arm assembly area and related shift linkage parts (Figure B–17)

Figure B–18. Remove Cotter Pin

4. After noting assembly position of front and rear clutch rods (to ensure proper assembly when reassembling parts), remove cotter pin and washer from clutch rod.

5. Disengage the drive spring from the underside of the frame to release tension on the idler arm assembly, and remove.

Cotter Pin

Shift Lever

Assembly Arm

Idler Arm

Assembly

Front Shift Lever Rod

Rear Shift Lever Rod

Cotter Pin

Washer

Clutch Rod

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Figure B–19. Loosen V-Pulley

3. See Figure B–19. Note the position of the belt stop relative to the v-pulley, and then loosen the lock nut that secures the v-pulley to the idler. Slide the drive belt out of the gap between the pulley and belt stop.

Figure B–20. Remove Clip Ring And Idler Arm

Assembly

4. See Figure B–20. Slide the clip ring out of the groove on the pivot shaft, and remove the idler arm assembly from the unit by pulling it straight out and off the shaft. (See Foot Controls section 6C for specific idler arm assemblies and components used on various models.)

Figure B–21. Lockout Lever/Shift Pivot Assembly

5. See Figure B–21. Remove the hex nut that secures the lockout lever to the shift pivot assembly. (See Figure B–21 for complete hardware details.)

6. Lift the rear shift rod off the screw threads and move it aside, and slide the lockout lever off the pivot shaft.

Belt Stop

Clip Ring

Lockout

Lever

Shift Pivot

Rear Shift Rod

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Figure B–23. Disassemble Shift Pivot/Front Shift

Rod Assembly

7. See Figure B–23. Unscrew the hex nut and related hardware used to connect the shift pivot assembly to the front shift rod.

8. The shift pivot assembly may now be removed from the shaft, allowing the front shift rod to be removed.

9. Inspect the shift pivot assembly for wear, corrosion, or other damage, giving particular attention to the inside surface of the pivot tube. Replace the shift pivot assembly if worn or corroded.

10. Check the front shift rod for cracks, corrosion, or other damage, and replace if necessary.

INH

Figure B–22. Front/Rear Shift Rod Assembly

- Hydro

Parts List

A. Rear Shift Rod B. Spacer C. 11/32 x 1-1/8 Washer D. 5/16 Lockwasher E. 5/16-18 Hex Nut F. 5/16 Plain Washer G. Spacer H. Control Lever (Transmission) I. 5/16-18 x 1-3/4 Hex Capscrew J. 17/32 x 1-1/4 x 5/64 Thk. Washer K. Cotter Pin L. Front Shift Rod M. 5/16-18 x 1-1/4 Carriage Bolt N. 5/16-18 X 1 Carriage Bolt

Figure B–24. Disassemble Rear Shift Rod From

Transmission Shift Lever

11. If no additional service is required, reassemble parts in reverse order of assembly, and make neutral and return-to-neutral adjustments as shown in the adjustments section of this manual.

12. See Figure B–24. If necessary, the rear shift rod may also be removed and replaced at this point. Remove the hex nut and related hardware that secure the rear shift rod to the speed control lever on the transmission.

Front Shift Rod

Shift Pivot

Rear Shift Rod

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BROADMOOR GEAR SHIFT ROD - PEERLESS TRANS.

1. Remove battery from unit to provide access to front shift lever rod assembly at base of shift lever assembly (See preceding Broadmoor Hydro shift rod service section.)

2. Remove cotter pins that secure front shift lever rod to shift lever arm, and set washers aside for reuse when reassembling rod.

3. Safely elevate and support unit (mower deck removed) for working access to transmission shift lever area.

4. See Figure B–26. Remove capscrew, hex nut, washers and spacers connecting shift rod to shift lever, and remove shift rod from unit. Inspect shift rod for wear or damage, and replace as required.

5. Reassemble parts in reverse order of disassembly, applying grease to pivot points as indicated.

6. Adjust transmission as required for proper operation see "Adjustments" section of manual for specific procedures.

Figure B–26. Broadmoor Gear Shift Rod

Peerless Transmission

Parts List

A. Shift Lever B. 5/16 Washer C. 5/16 Lockwasher D. 5/16-18 Full Hex Nut E. Spacer F. Washer G. 5/16 x 1-1/4 Capscrew H. Shift Rod I. 1/2 Washer J. 3/32 x 3/4 Cotter Pin

Figure B–25. Broadmoor Hydro Shift Rod

Eaton Transmission

Parts List

A. 5/16-18 x 1-1/4 Carriage Bolt B. Speed Control Lever C. Spacer D. Plain Washer E. 5/16 Lockwasher F. Full Hex Nut G. Shift Rod H. 1/2" Washer I. Cotter Pin

BROADMOOR HYDRO SHIFT ROD - EATON TRANS.

1. Remove battery from unit to provide access to front shift lever rod assembly at base of shift lever assembly (See preceding Broadmoor Hydro shift rod service section.)

2. Remove cotter pins that secure front shift lever rod to shift lever arm, and set washers aside for reuse when reassembling rod.

3. Safely elevate and support unit (mower deck removed) for working access to transmission shift lever area.

4. See Figure B–25. Remove carriage bolt, hex nut, washers and spacers connecting shift rod to shift lever, and remove shift rod from unit. Inspect shift rod for wear or damage, and replace as required.

5. Reassemble parts in reverse order of disassembly, applying grease to pivot points as indicated.

6. Adjust transmission as required for proper operation see "Adjustments" section of manual for specific procedures.

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Figure B–27. Remove Locknut From Lift Handle

Rod Pivot Spacer

Lift Lever Assembly Service

Access for lift lever service may be achieved by removing the battery from the lower dash area, or for a greater access area, by removing the dash assembly and related parts as shown in the Hood, Dash, and Grill Repair Repair section. See Figure B–4 for a complete exploded view of all parts.

LIFT HANDLE ROD/LINK SERVICE

1. Using a 1/2" socket, remove the locknut securing the lift handle rod to the pivot spacer inside of the lower dash (Figure B–27).

Figure B–28. Twist Lift Handle Rod 90° To

Disengage From Upper Lift Link

2. Slide the lift handle rod off the spacer, and twist 90° to disengage from the upper lift link (Figure B–28). The lift handle rod can be removed through the slot in the lower dash. Inspect for wear or damage, and replace as required.

3. The upper lift link and lift link (H, K, Figure B–4) can be removed and inspected for wear and damage by disengaging them from the lift assembly cams under the unit. Replace links as necessary.

Figure B–29. Remove Upper Transport Lift Link &

Lift Cam

4. See Figure B–29-Top. If necessary, the upper transport lift link can be removed from the lift assembly cam by removing the cotter pin. Inspect the upper transport lift link and replace as required.

5. To remove the lift lever cam, use a box wrench and unscrew the hex nut securing it to the carriage bolt and unit frame. Inspect for wear or damage, and replace if required. Apply grease to the pivot spacer during reassembly.

6. Reassemble parts in reverse order of disassembly. Refer to Figure B–4 for correct part locations.

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Figure B–30. Engine Choke Control Location

Engine Choke Control Service (Twin Cylinder Units Only)

On units with a dash-mounted engine choke control, the control is a push-pull button mounted on the lower left portion of the dash assembly (Figure B–30). For easiest service access, the battery should be removed from the unit.

Figure B–31. Disconnect Choke Cable At Engine

1. Loosen the choke cable clamp on the engine using a phillips head screwdriver, and after noting the en-engagement of the cable end with the choke lever, remove the cable end from the choke lever (Figure B–31).

Figure B–32. Choke Cable Assembly

2. From inside the dashboard area, unscrew the hex nut that secures the choke cable assembly to the dash, and slide the choke cable and handle assembly out of the front of the dash. See Figure B–32.

3. Inspect all parts for wear or damage, and replace as required.

4. Reassemble parts in reverse order of disassembly.

5. Check the engine choke linkage for proper engagement with the cable and smooth operation of choke. See the engine manufacturer's instructions for complete choke adjustment instructions.

Engine Choke Control

Choke Cable

Choke Handle

Lockwasher

Hex Nut

To Engine

Choke Lever

Cable End

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Figure B–33. Throttle Control Assemblies

THROTTLE CONTROL ASSEMBLY PARTS

A. Throttle Cable B. Truss head Screw #10-32 x 1/2" C. Carriage Bolt 5/16-18 x 1-3/4" D. Throttle Handle E. Throttle Knob F. Nylon Washer G. Throttle Mounting Bracket H. Washer I. Esna Light Hex Locknut J. Plain Washer 5/16" K. Spring L. Plastite Screw 1/4-20 x 5/8" M. Nut Assembly #10-32 N. Bowden Wire Clip O. Throttle Knob P. Plastite Screw 1/4-10 x 1/2" Q. Throttle & Cable Assembly

"One Piece" Throttle Assembly (Later Models)

"Multi-piece" Throttle Assembly

Throttle (Engine Speed Control)

Throttle (Engine Speed Control) Assembly

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Figure B–34. Remove Wire Clip & Throttle Cable

From Throttle Lever

Throttle (Engine Speed) Control Service

The throttle control is attached to the underside of the dashboard and may be accessed by raising the unit's hood. For greater access and improved work area, the battery may be removed from the unit.

THROTTLE LEVER TENSION (MULTI-PART LEVER ASSEMBLY UNITS ONLY)

Note: Later models use a “one piece” non-adjustable

throttle control that is replaced as an assemble.

1. Increase Tension - Tighten the locknut (I, Figure B–33) by turning clockwise.

2. Decrease Tension - Loosen the locknut (I, Figure B–33) by turning counterclockwise.

NOTE: When properly adjusted, the throttle lever will allow positioning with light force, and will maintain the selected position without slippage while the unit is being operated.

THROTTLE LEVER KNOB REPLACEMENT

1. Remove the throttle lever knob:

a. Round throttle knob - Unscrew the knob from the

throttle lever by turning the knob counterclockwise.

b. "Flat" style knob - Remove the knob by pulling it

straight off the throttle lever.

2. Inspect the knobs for cracks or other damage, and replace if required.

MULTI-PIECE THROTTLE LEVER ASSEMBLY REPAIR

1. Remove the wire clip securing the throttle cable (N, Figure B–33) to the throttle lever by removing the truss head screw and nut assembly (B & M)

2. Disengage the throttle cable from the throttle lever, and loosely reinstall the screw and nut on the clip to avoid loss during service (Figure B–34).

3. Remove the throttle lever from the throttle mounting bracket by unscrewing the hex locknut (I, Figure B–33) from the carriage bolt (C). (Keep the head of the carriage bolt against the throttle lever to keep the bolt from turning while the locknut is being removed.)

4. Slide the carriage bolt and throttle lever out of the throttle lever mounting bracket, catching the spring and washers as the carriage bolt is removed from the assembly.

5. Check the throttle lever mounting bracket (G, Figure B–33) for wear or damage. Remove and replace if necessary by unscrewing the three plastite screws securing the bracket to the underside of the dashboard.

6. Reassemble parts in reverse order of disassembly, using care to position the nylon washers on both sides of the throttle lever mounting bracket, and the metal washers on both sides of the spring , as shown in Figure B–33.

7. Adjust spring tension to provide secure positioning of lever while allowing smooth operation of lever.

ONE-PIECE THROTTLE LEVER REPAIR

1. Remove the throttle knob by pulling it straight off the the throttle lever.

2. Unscrew the plastite screws (P, Figure B–33) securing the one-piece throttle assembly (Q) to the underside of the dashboard, and remove the one-piece throttle/cable assembly.

3. Inspect the assembly for wear or damage and replace as required. (Consult engine manufacturer's manual for throttle cable connection to engine throttle linkage, if necessary.)

4. Reassemble in reverse order of disassembly.

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Simplicity LTH series, Massey Ferguson 2600 series, AGCO Allis 1600 series, Broadmoor series, LTG series Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual