Simplicity 1691682 Service & Repair Manual
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Simplicity 1691682 Service & Repair Manual

Simplicity 1691682 Service & Repair Manual

Landlord series also covers agco allis 1700 series & massey ferguson 2700 series
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MANUFACTURING, INC.
500 N Spring Street / PO Box 997
© Copyright 1997 Simplicity Manufacturing, Inc.
Port Washington, WI 53074-0997 USA
All Rights Reserved. Printed in USA.

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Summary of Contents for Simplicity 1691682

  • Page 1 MANUFACTURING, INC. 500 N Spring Street / PO Box 997 © Copyright 1997 Simplicity Manufacturing, Inc. Port Washington, WI 53074-0997 USA All Rights Reserved. Printed in USA.

  • Page 3: Table Of Contents

    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 &...

  • Page 4: Models Covered

    1 General Information Models Covered In This Manual MODELS COVERED & Simplicity Manufacturing, Inc. IDENTIFICATION NUMBERS Port Washington, WI 53074-0997 U.S.A. SERIAL This manual contains service information for the models listed below. Consult the Identification Tag located on the tractor frame for the manufacturer’s identification...

  • Page 5: Introduction

    Whenever specialized or Covers removal, disassembly, inspection, and repair of custom tools are available to save time, reduce effort, or Simplicity serviceable transmissions. improve overall service efficiency, the most effective safe 8. Deck Repair repair method available should be utilized.

  • Page 6: Safety Rules

    1 General Information Safety Rules Read these safety rules and follow them closely. Failure to obey these rules could result in loss of control of 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.
  • Page 7 1 General Information Safety Rules CHILDREN • Always follow the engine manual instructions for proper start-up procedures when returning the unit to Tragic accidents can occur if the operator is not alert to service. the presence of children. Children are often attracted to the unit and the mowing activity.
  • Page 8 Simplicity dealer als. Contact with these or any other sources of igni- before proceeding. Never attempt a repair that you’re...
  • Page 9 1 General Information Safety Rules Exhaust Gas Safety Electrical System Safety • Internal combustion engines produce and exhaust • Loose connectors, worn wires, damaged wire insula- Carbon Monoxide (CO), an odorless, colorless, gas tion, and loose termination hardware can cause that causes dizziness, nausea, flu-like symptoms, sparks, short-circuits, and erratic equipment opera- unconsciousness, or even brain damage or death, if...
  • Page 10 1 General Information Safety Rules Work Area Safety General Servicing Safety • Always keep the work area clear of clutter from dis- • Always check safety devices and switches for proper carded parts, and debris from parts boxes or packag- operation - never alter these devices or make tempo- ing materials.

  • Page 11: General Repair Information

    1 General Information Repair Information GENERAL REPAIR INFORMATION INSPECTION Once cleaned, bearings can be properly inspected for In addition to providing specific repair procedures for the wear, scratches, visible damage such as corrosion, equipment listed at the beginning of this section, this cracked seals or scorching, and rough, or noisy, opera- manual provides the following additional general instruc- tion.

  • Page 12: Fasteners & Hardware

    1 General Information Repair Information Fasteners & Hardware Required Tools & Equipment All hardware and fasteners used in this equipment must All repairs in this manual can be accomplished with stan- meet factory specifications for SAE grade, size, and dard mechanic’s hand tools. The use of appropriate torque, and must be kept securely tightened.

  • Page 13: Torque Specifications

    1 General Information Torque Specifications TORQUE SPECIFICATIONS FOR STANDARD MACHINE HARDWARE (Tolerance ± 20%) SIZE SAE GRADE #2 SAE GRADE #5 SAE GRADE #8 in/lbs in/lbs in/lbs ft/lbs ft/lbs ft/lbs 8-32 8-36 10-24 10-32 1/4-20 10.9 16.3 1/4-28 13.6 19.0 5/16-18 15.0 23.1...

  • Page 14: Specifications

    1 General Information Specifications ENGINE 14 HP Kohler 16 HP Briggs & Stratton Make Kohler Make Briggs & Stratton Model Command™ Model Vanguard V-Twin Horsepower 14 HP @ 3600 rpm (10.4 kw) Horsepower 16 HP @ 3600 rpm Cylinder Cylinders Bore 3.43 In.
  • Page 15 1 General Information Specifications TRANSMISSION CONTROLS Steering Full Circle Steering Wheel System Gear Gear Models and Sector Type Spur Gear Hydro Clutch/ Location Right Front Material Gear: Heat Treated Brake Pedal Combination Clutch/Brake/Parking Brake Shaft: Hardened and Ground Pedal Standard Equipment Bearings: Needle Roller, Sealed Ball Gear Brake Location Right Front...
  • Page 16 1 General Information Specifications DIMENSIONS Tractor Overall Length 72 In. (183 cm) Overall Width 39 In. (99.1 cm) Height To Top of Steering Wheel 42.5 In. (108 cm) To Top of Engine Cover 36 In. (91.4 cm) Wheel Base 51.5 In. (131 cm) Weight Net: 670 lbs.
  • Page 17 2 Troubleshooting Table of Contents SECTION CONTENTS Troubleshooting Troubleshooting the Tractor ............2-2 Troubleshooting the Mower............2-3 2 - 1...
  • Page 18 2 Troubleshooting Tractor Troubleshooting TROUBLESHOOTING WARNING The troubleshooting guide below lists some common Never attempt to perform repairs while the engine problems, their causes, and remedies. is running. See the repair information in the following sections for Always turn the engine off and remove the key. instructions on how to perform most of these minor repairs yourself.
  • Page 19 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.
  • Page 20 2 Troubleshooting Notes 2- 4...
  • Page 21 3 Maintenance Table of Contents SECTION CONTENTS Storage Temporary ................3-2 Long Term ................3-2 Starting After Storage ............. 3-3 Preventative Maintenance Chart ........3-3 Engine Maintenance Engine Oil Level ..............3-4 Engine Oil Filter ..............3-4 Engine Air Filter ..............3-4 Fuel Filter Service ..............

  • Page 22: Storage

    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.

  • Page 23: Preventative Maintenance Chart

    3 Maintenance Storage / Chart 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.

  • Page 24: Engine Maintenance Engine Oil Level

    3 Maintenance Engine Maintenance ENGINE MAINTENANCE 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 over- heating, permanent damage, and voiding of the engine...

  • Page 25: Fuel Filter Service

    3 Maintenance Engine Maintenance Fuel Filter Service DANGER Do not remove fuel filter when engine is hot, as spilled gasoline may ignite. Follow all precau- tions for the safe handling of gasoline when removing and installing the fuel filter. DO NOT spread hose clamps more than necessary.

  • Page 26: Spark Plug Service

    3 Maintenance Engine / Battery Maintenance Spark Plug Service BATTERY MAINTENANCE The spark plug(s) should be inspected at the regular WARNING intervals specified in the engine manufacturer’s owner’s manual and cleaned or replaced as required. Be careful when handling the battery. Avoid spilling electrolyte.

  • Page 27: Mower Blade Service

    3 Maintenance Mower Blade Service Figure 7. Balancing The Blade LOOSEN Figure 6. Removing The Blade 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: Lubrication

    3 Maintenance Lubrication LUBRICATION Lubricating the Tractor Lubricate the tractor as shown in Figures 10 through In general, linkage connections and other parts that have 16. When a grease gun is shown, wipe the fitting clean, partial rotational or sliding movement (pedal pivot points, apply two or three shots of lithium base automotive steering links, etc.) should be lubricated periodically with grease, and wipe off excess grease.
  • Page 29 3 Maintenance Lubrication Figure 14. Lubrication Point - Gear Models (Transmission Control Rod Area) Hydro Model Shown. On Gear Model, Lubricate the Grease Fitting on Rear Shift Arm Figure 13. Tractor Lubrication Points - Rear Half (Hydro Model Shown) Figure 15. Front Axle Lubrication Points Figure 16.

  • Page 30: Lubricating The Mower

    3 Maintenance Lubrication Figure 18. Mower Lubrication Points Figure 17. Arbor Lubrication Points Lubricating the Mower Lubricate the mower as shown in Figures 17 through 19. Be sure to include the grease fittings on the mower idler pulley and arbors, which are located underneath the mower deck.

  • Page 31: Check / Add Transmission Oil

    3 Maintenance Check / Add Transmission Oil Transmission fluid fill tube Check Figure 21. Transmission Fluid Fill Tube Located Plug Under Seat Deck at Rear of Tractor Figure 20. Oil Check Plug (Hydro-Gear Model 3010L pictured from right side with tire removed) CHECK / ADD TRANSMISSION OIL Hydro-Gear K216-3010L Models Oil Type:...

  • Page 32: Change Transmission Oil Hydro-Gear K216 Models

    3 Maintenance Change Transmission Oil CHANGE TRANSMISSION OIL Hydro-Gear K216 Models Oil Type: SAE 10W-40 Premium Engine Oil Oil Capacity: 76 oz. Oil Filter Change Interval: After first 50 hours, then every 250 The transmission oil and filter should be changed when performing repair work or if the fluid has become discol- ored from overheating or contamination.

  • Page 33: Tuff Torq K215 Models

    3 Maintenance Change Transmission Oil Tuff Torq K215 Models Oil Type: SAE 10W-30 Premium Engine Oil Oil Capacity: 90 oz. Change Interval: After first 50 hours, then every 250 The transmission oil and filter should be changed when performing repair work or if the fluid has become discol- ored from overheating or contamination.
  • Page 34 3 Maintenance Notes 3 - 14...
  • Page 35 4 Adjustments Table of Contents SECTION CONTENTS Steering Gear Adjustment ........... 4-2 Idler Pulley ................. 4-2 Neutral Adjustments Tuff Torq K215A - Early Models........4-3 Tuff Torq K215A Late Models ........... 4-4 Hydro-Gear 216-3010L ............. 4-5 Tuff Torq K210A (Gear Models)........4-5 Return to Neutral Adjustments Tuff Torq K215A..............

  • Page 36: Steering Gear Adjustment

    4 Adjustments Steering & Idler Adjustments STEERING GEAR ADJUSTMENT If there is excessive back-lash in the steering system, the steering gear can be re-indexed to take up some slack. Refer to Figure 1. Loosen two capscrews (A) and adjust bracket so that gear teeth are more closely meshed. Retighten nuts after adjustment.

  • Page 37: Neutral Adjustments

    4 Adjustments Neutral Adjustments NEUTRAL ADJUSTMENT Hydro With Tuff Torq K215A - Early Models Only 1. Park unit on level surface. Shut off electric clutch switch and engine. Do not apply parking brake. Make sure transmission control lever is in neutral and the hydro release valve is in the “Drive”...
  • Page 38 4 Adjustments Neutral Adjustments NEUTRAL ADJUSTMENT CONT. Hydro Models With Tuff Torq K215A - Late Models And Early Models With Kit #1686602 Installed Perform neutral adjustment as follows: 1. Put tractor in neutral. Make sure tow valve is secure- ly in the drive (UP) position or adjustment will not be accurate.

  • Page 39: Hydro-Gear 216-3010L

    4 Adjustments Neutral Adjustments NEUTRAL ADJUSTMENT CONT. WARNING Hydro-Gear 216-3010L When making adjustment, keep hands, hair, clothing, or tools away from rotating belts. Perform the following adjustment if the shift lever must be Grasp cam lever at base to keep hand several moved out of the neutral gate to prevent forward or inches below belt rotating around idler pulley reverse tractor movement.

  • Page 40: Return To Neutral Adjustments

    4 Adjustments Return-To-Neutral Adjustment RETURN-TO-NEUTRAL ADJUSTMENT Tuff Torq K215 The Tuff Torq K215’s Return-to-Neutral is self adjusting if the Neutral Adjustment has been performed correctly. See Neutral Adjustment. Hydro Gear 216-3010L See Figure 7. Perform the following adjustment if the shift lever does not return to the neutral gate from a for- ward gear position when the clutch/brake pedal is fully depressed.

  • Page 41: Tuff Torq K215A

    4 Adjustments Clutch/Brake Adjustment CLUTCH/BRAKE ADJUSTMENT *2272 Tuff Torq K215A 1. Engage the parking brake. 2. The spring should be compressed to 1-1/2" to 1-5/8" long. Turn adjustment nut (A, Figure 9) as nec- essary for correct spring length. Figure 9. Brake Rod Spring Adjustment -Tuff Torq Hydro A.

  • Page 42: Clutch Adjustment - Gear

    4 Adjustments Clutch & Brake Adjustment / Transaxle Purging CLUTCH ADJUSTMENT Tuff Torq K210A (Gear Models) There is no adjustment for the clutch linkage on the gear models. Replace the rear retaining spring as required BRAKE ADJUSTMENT Tuff Torq K210A (Gear Models) 1.

  • Page 43: Pto (Electric Clutch) Adjustment

    4 Adjustments PTO Clutch Adjustments PTO (ELECTRIC CLUTCH) ADJUSTMENT 1. Remove key from ignition switch and disconnect Rivet spark plug wires to prevent the possibility of acciden- tal starting while the PTO is being adjusted. 2. Note the position of the 3 adjustment windows in the side of the brakeplate, then rotate the pulley so that each of the three rivet joints (visible inside the gap Rivet...

  • Page 44: Mower Adjustments

    4 Adjustments Mower Adjustments MOWER LEVELING *2269B WARNING Before checking mower, shut off electric clutch and engine. Allow all moving parts to stop. Remove ignition key. Side-to-Side Leveling 1. Park the tractor on a level surface. Point tires straight ahead. 2.
  • Page 45 5 Electrical Troubleshooting Table of Contents SECTION CONTENTS Introduction NOTICE Principals Of Operation ...........5-2 The majority of Section 5 is Checking Out The System designed to troubleshoot the General ................5-3 electrical systems of air cooled tractors ONLY. Basic Electrical Terms ............5-3 Test Series ................5-3 The information and test proce- Lower Wire Harness Exploded View Diagram...

  • Page 46: Principals Of Operation

    5 Electrical Troubleshooting General Information - Theory INTRODUCTION Cranking System Battery voltage is present at the "B" terminal of the igni- Tools Needed tion switch at all times (see Figure 8). Turning the igni- • VOM (Volt-Ohm meter, multi-meter, or equivalent) tion switch to START supplies 12 volts to one of the sole- noid coil terminals.

  • Page 47: Checking Out The System General

    5 Electrical Troubleshooting General Information - Testing CHECKING OUT THE SYSTEM Test Series General CHECKING THE POWER SUPPLY 1. Wiring Both the ignition and charging systems are internal to the tractor engine. Follow the Troubleshooting Guide, 2. Battery Tests Section 2, or refer to your engine manual for information. •...
  • Page 48 5 Electrical Troubleshooting Lower Wiring Harness NOTE: Use standard hardware torque specifications chart unless otherwise noted. Figure 1. Lower Wiring Harness 5 - 4...
  • Page 49 5 Electrical Troubleshooting Lower Wiring Harness LOWER WIRING HARNESS REF. QTY. DESCRIPTION CLIP, Speed WIRE ASSY., Headlight SOCKET, Bulb BULB, Headlight, 12.8V TIE, Cable BUSHING, Snap, Small LENS, Headlight BEZEL, Headlight HEADLIGHT ASSY. (Incl. Ref. Nos. 3, 4, 7, 8 & 10) HEAT SHIELD WIRE ASSY., Seat Switch and Lift WIRE ASSY., Engine Ground...
  • Page 50 5 Electrical Troubleshooting Main Wiring Harness 39 28 NOTE: Use standard hardware torque specifications chart unless otherwise noted. Figure 2. Main Wiring Harness 5 - 6...
  • Page 51 5 Electrical Troubleshooting Main Wiring Harness MAIN WIRING HARNESS REF. QTY. DESCRIPTION COVER, Terminal CABLE, Battery-to-Solenoid HOSE, Battery, Drain WIRE ASSY. CIRCUIT BREAKER CABLE, Solenoid-to-Starter HOLD DOWN, Battery BULB, Indicator Light BOOT, Insulator BATTERY, 39 Amp (Power Max) SOLENOID IGNITION SWITCH (Incl. Ref. No. 27, 28, 39) SWITCH, Transmission, Neutral Start SWITCH, Headlight MODULE...
  • Page 52 5 Electrical Troubleshooting Electric Lift Motor NOTE: Use standard hardware torque specifications chart unless otherwise noted. Figure 3. Electric Lift Motor 5 - 8...
  • Page 53 5 Electrical Troubleshooting Electric Lift Motor ELECTRIC LIFT MOTOR REF. QTY. DESCRIPTION CAPSCREW, Taptite PIN, Drive MOTOR KIT, 12 VDC GASKET, Housing SEAL, Outer Tube (Top) BALL SCREW ASSY. MOTOR & GEARBOX ASSY., 12 VDC, 17:1 Ratio BRUSH & LEAD (Red) BRUSH &...

  • Page 54: Battery Tests

    5 Electrical Troubleshooting Battery & Cable Tests 1. CHECKING THE POWER SUPPLY WARNING TO PREVENT ACCIDENTAL STARTING, DIS- A. Check Wiring Condition and Tightness CONNECT AND SECURE THE SPARK PLUG WIRES BEFORE CONDUCTING ANY ELEC- 1. Check all wires for cracked or worn insulation. TRICAL TESTS.

  • Page 55: Battery Cables

    5 Electrical Troubleshooting Battery & Cable Tests HYDROMETER TEST WARNING 1. Check each cell using a hydrometer. FOLLOW BATTERY CHARGER MANUFAC- All cells should have a specific gravity of 1.27 or better. TURER’S INSTRUCTIONS. If the cells vary by more than . 050 points, charge the BATTERY ACID FORMS...

  • Page 56: Isolate Cranking And Safety Systems

    5 Electrical Troubleshooting System Isolation / Cranking System Tests 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 7) from the small solenoid post. 3.

  • Page 57: Test Power To Ignition Switch

    5 Electrical Troubleshooting Ignition Switch Tests 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 10) on the ignition switch plug. The VOM should show battery voltage.

  • Page 58: Test Power To Solenoid

    5 Electrical Troubleshooting Ignition Switch / Solenoid Tests START START Figure 14. Testing the Ignition Switch Figure 13. 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 (continu- ity) on the multi-meter (see Figures 13-15).

  • Page 59: Test Solenoid

    5 Electrical Troubleshooting Solenoid Tests 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.

  • Page 60: Test Power To Starter

    5 Electrical Troubleshooting Solenoid / Starter Tests 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. Figure 20.Testing for Solenoid Short 5.

  • Page 61: Pto Interlock Switch

    5 Electrical Troubleshooting Safety Interlock System Tests 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. Rocker-Type Switch Pull-Type Switch 2.
  • Page 62 5 Electrical Troubleshooting Seat Switch / Clutch / Brake Switch Tests 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.

  • Page 63: Neutral Safety Switch (Mechanical)

    5 Electrical Troubleshooting Neutral Safety Switch Tests 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.

  • Page 64: Interlock Module

    5 Electrical Troubleshooting Interlock Module / Headlight Tests 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 mod- ule can be used to test the system.

  • Page 65: Hour Meter

    5 Electrical Troubleshooting Headlight / Hour Meter Tests 5. Keep the headlight switch ON. Probe ground and Probe Here 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. Figure 38.

  • Page 66: Inspect And Replace Dash Lights

    5 Electrical Troubleshooting Hour Meter / Dash Light Tests 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 volt- age.

  • Page 67: Test Electric Pto Clutch

    5 Electrical Troubleshooting PTO Clutch Tests G. Test Electric PTO Clutch Clutch Body TEST PTO CLUTCH RESISTANCE 1. Set VOM to Ohms. Terminals 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.

  • Page 68: Electric Lift Tests

    5 Electrical Troubleshooting Electric Lift Tests H. Electric Lift Tests TEST ELECTRIC LIFT MOTOR Before performing this test, remove the mower deck or attachment, turn the ignition switch to OFF and remove the key, disconnect the negative battery cable, disengage the PTO switch, put the ground speed control lever in the neutral gate, and set the parking brake.
  • Page 69 CLUTCH INTERLOCK SWITCH (BACK VIEW (GEAR DRIVE ONLY) OF SWITCH) BLUE / WHITE SOLENOID ALTERNATOR IGNITION BATTERY SWITCH PURPLE / WHITE STARTER OIL LIGHT HEADLIGHTS BLACK CIRCUIT GREEN BLACK BREAKER AT ENGINE MOUNTING BLUE CAPSCREW RED / WHITE BLACK BLUE PTO LIGHT BLACK / WHITE WHITE...
  • Page 70 (BACK VIEW BLUE / WHITE SOLENOID OF SWITCH) BATTERY STARTER IGNITION SWITCH BLACK CIRCUIT BLACK / YELLOW BREAKER FOOT SWITCH BLACK / WHITE GREEN / BLACK SWITCH WHITE YELLOW / BLACK HARNESS HARNESS START PLUG PLUG (LOWER) (UPPER) ORANGE / BLACK BROWN START TRANS...
  • Page 71 6 General Repair Table of Contents SECTION CONTENTS 6A. Steering & Front Wheel Repair General....................6-2 Required Tools & Equipment ............. 6-2 Elevating Front of Unit For Safe Service..........6-2 Front Wheel Repair-Bearing Removal ..........6-4 Left Hand Spindle Repair ..............6-6 Right Hand Spindle / Steering Arm Repair ........

  • Page 72: 6A Steering & Front Wheel Repair

    6 General Repair 6A Steering & Front Wheel Repair ELEVATING FRONT OF UNIT FOR DANGER SAFE SERVICE PREVENT SERIOUS INJURY OR 1. Remove the ignition key, and disconnect the spark DEATH FROM FALLING UNIT plug wire to prevent accidental starting while working Always use a properly working lifting device with on unit.
  • Page 73 6 General Repair 6A Steering & Front Wheel Repair A. Valve Stem & Cap B. Tire C. Tube D. Seal E. Bearing F. Cup G. Wheel H. Washers Setscrew Collar K. Hub Cap Figure A–2. Front Wheel Assemblies 6 - 3...

  • Page 74: Front Wheel Repair-Bearing Removal

    6 General Repair 6A Steering & Front Wheel Repair Front Wheel Repair - Bearing Removal Refer to Figure A-3. 1. Remove the hub cap (G) from the wheel hub by pry- ing around the perimeter of the raised lip at the base of the cap with a claw hammer, wedge bar, or other prying bar.
  • Page 75 6 General Repair 6A Steering & Front Wheel Repair STEERING GROUP ASSEMBLIES Dash Upper Steering Group Frame Lower Dash Lower Steering Group Figure A–4. Steering Group - Typical Assembly (Frame & Dash Shown For Component Position Reference) 6 - 5...

  • Page 76: Left Hand Spindle Repair

    6 General Repair 6A Steering & Front Wheel Repair LOWER STEERING GROUP To Pitman Arm A. Clip Ring, 5/8 B. Washer C. Capscrew D. Spacer E. Rod End F. Washer Torque to G. Nut, Flange, 3/8-16 17-23 ft. lbs. H. Jam Nut, 1/2-20 (2 places) Drag Link Washer, 49/64...
  • Page 77 6 General Repair 6A Steering & Front Wheel Repair 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–7). NOTE: A spacer is located over the capscrew threads in the rod opening to permit rotation of the steering arm.

  • Page 78: Right Hand Spindle / Steering Arm Repair

    6 General Repair 6A Steering & Front Wheel Repair Right Hand Spindle / Steering Arm Repair 1. Remove right front wheel using same procedure as used for left front wheel. (Figure A–10) 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–10 and A–11).
  • Page 79 6 General Repair 6A Steering & Front Wheel Repair Reassembly 1. Reassemble parts in the reverse order of disassem- bly, using particular care to realign the steering arm Rod End Spacer assembly, spindle assembly, and axle housing. 2. Observe torque specifications on Figure A–5. 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...

  • Page 80: Tie Rod Repair

    6 General Repair 6A Steering & Front Wheel Repair 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 assem- blies (Figure A–15).
  • Page 81 6 General Repair 6A Steering & Front Wheel Repair UPPER STEERING GROUP ASSEMBLY Grease bushings "K" (3 places) Early models used a capscrew, washer & nut in place of a roll pin (C). (gear teeth) Apply Loctite #271. Torque to 20-30 ft.lbs. NOTE 4 Torque to 17-23 ft.lbs.

  • Page 82: Steering Wheel Removal

    6 General Repair 6A Steering & Front Wheel Repair 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–18). Figure A–18. Remove Steering Wheel Hardware Earlier Models CURRENT MODELS 1B.Later-model steering wheels are attached to the...

  • Page 83: Steering Shaft Removal

    6 General Repair 6A Steering & Front Wheel Repair 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–21) just above bushing in the frame sup- port.

  • Page 84: Steering Gear / Pitman Arm Service

    6 General Repair 6A Steering & Front Wheel Repair Steering Gear / Pitman Steering Arm Service Drag Link 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–23).

  • Page 85: Drag Link Removal

    6 General Repair 6A Steering & Front Wheel Repair Drag Link Removal Drag Link 1. See Figure A–26. 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.
  • Page 86 6 General Repair 6A Steering & Front Wheel Repair - Notes 6 - 16...
  • Page 87 6 General Repair 6B Hand Controls Repair GENERAL The hand controls group consists of the following major components (See Figure B–1): Ground Speed Control Lever & Shift Linkage Attachment Lift Choke Lever Throttle Lever Parking Brake DANGER Always obey all safety precautions for working around battery hazards such as electrolyte, hy- Figure B–1.

  • Page 88: Hand Controls Repair General

    6 General Repair 6B Hand Controls Repair EARLY MODEL GROUND SPEED CONTROL LEVER ASSEMBLY EARLY MODEL A. Knob B. Shift Lever C. Cotter Pin D. Washer E. Torsion Spring F. Plastic Bushing - 1/2" Dia. Grease G. Nylon Bushing - 3/4" Dia. H.
  • Page 89 6 General Repair 6B Hand Controls Repair Ground Speed Control Assembly Service Ground speed control lever assembly service requires that the dashboard be removed. Refer to the Hood, Dash, and Grill Repair section for dashboard removal in- structions. After the dash assembly is fully separated from the unit, set it aside carefully to prevent damage to electrical com- ponents.
  • Page 90 6 General Repair 6B Hand Controls Repair 2. Using a long-nose pliers, remove the cotter pin from the end of the ground speed control lever (Figure B–7). Cotter Pin Figure B–7. Remove End Cotter Pin 3. Slide the ground speed control lever out of the ground speed control lever mounting bushings, and Ground Speed inspect for damage.
  • Page 91 6 General Repair 6B Hand Controls Repair 4. Using a 7/16" socket and a short extension bar, re- move 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–10).

  • Page 92: Shift Rod Service

    6 General Repair 6B Hand Controls Repair Shift Rod Figure B–12. Shift Rod Location, Tuff Torq K215A Models Shift Rod Service TUFF TORQ K215A MODELS 1. Remove battery from unit to provide access to front shift lever rod assembly at base of shift lever assem- bly (see Maintenance).
  • Page 93 6 General Repair 6B Hand Controls Repair Shift Rod Service Cont. TUFF TORQ K210A GEAR MODELS 1. Remove battery from unit to provide access to front shift lever rod assembly at base of shift lever assem- 2. Remove cotter pin that secures front shift lever rod to shift lever arm, and set washers aside for reuse when reassembling rod.

  • Page 94: Front & Rear Shift Rod Service - Hydro-Gear 216

    6 General Repair 6B Hand Controls Repair Front & Rear Shift Rod Service - Ground Speed Hydro-Gear 216 Models Control Lever 1. Remove battery from unit to provide access to front Assembly Arm shift lever rod assembly at base of shift lever assem- bly (Figure B–15) 2.
  • Page 95 6 General Repair 6B Hand Controls Repair Front & Rear Shift Rod Service - Hydro-Gear 216-3010L Models Belt Stop 6. See Figure B–18. 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.
  • Page 96 6 General Repair 6B Hand Controls Repair Front & Rear Shift Rod Service - Front Shift Rod Hydro-Gear 216-3010L Models 10. See Figure B–21. Unscrew the hex nut and related Shift Pivot hardware used to connect the shift pivot assembly to the front shift rod.
  • Page 97 6 General Repair 6B Hand Controls Repair Torque to 9-11 ft. lbs. Screw (18) & spacer (15) are located inside bottom of lever (5). Torque to 55-75 in. lbs. Figure B–23. Rear SHift Rod & Linkage Ref. Desc. Ref. Desc. SPACER WASHER, 11/32 x 1 x 1/8 SPACER...

  • Page 98: Attachment Lift Service

    6 General Repair 6B Hand Controls Repair Attachment Lift Service Mower Lift Lever The Landlord has three basic attachment lift configura- tions: 1) single chain manual lift 2) double cable manual lift 3) and double chain electric lift. See the appropriate section for your lift configuration. Figure B–24.
  • Page 99 6 General Repair 6B Hand Controls Repair LIFT LEVER ASSEMBLY PARTS Single Chain Manual Lift A. Thumb Button B. Lift Lever Grip C. Lift Lever Assm. D. Latch Rod E. Push-on Nut F. Spring G. Lift Lever Latch H. Lift Guide Bracket Spacer Hex Locknut 5/16-18 K.
  • Page 100 6 General Repair 6B Hand Controls Repair Double Cable Manual Lift LIFT LEVER ASSEMBLY Models With 2 Lift Arms RIGHT SIDE (44" & 50" Mower Decks) LEFT SIDE FRONT NOTES: 1. Insert capscrews "S" from right side of mower arm and assem- ble as shown - both mower arms.
  • Page 101 6 General Repair 6B Hand Controls Repair DOUBLE CABLE MANUAL LIFT LEVER REMOVAL The entire lift lever assembly may be easily removed Flat Washer from the unit for bench inspection and repair: 1. If desired, remove the mower deck from the unit (see Mower Deck repair section for specific instructions re- garding mower deck removal if necessary), or: 2.
  • Page 102 6 General Repair 6B Hand Controls Repair Double Chain Electric Lift NOTE: Use standard hardware torque specifications chart unless otherwise noted. Figure B-30. Double Chain Electric Lift Ref. Desc. Ref. Desc. WASHER, Plain PIN, Clevis NUT, Hex, Lock, ESNA, 5/16-18 BRACKET, Actuator NUT, Hex, Lock, ESNA, 3/8-16 LIFT, Pivot Bracket...
  • Page 103 6 General Repair 6B Hand Controls Repair DOUBLE CHAIN ELECTRIC LIFT TUBE REPLACEMENT 1. Remove the mower deck as described in Mower Deck Repair. 2. Remove the hair pin clip (H, Figure 31) and remove the shaft assembly (B). 3. Remove and replace the lift tube assembly (I). DOUBLE CHAIN ELECTRIC LIFT ASSEMBLY REMOVAL NOTE: For power lift electrical tests see Electrical Troubleshooting.
  • Page 104 6 General Repair 6B Hand Controls Repair Ref. Desc. Capscrew, Taptite Pin, Drive Motor Kit, 12 VDC Gasket, Housing Seal, Outer Tube (Top) Ball Screw Assm. Motor & Gearbox Assm Brush and Lead (Red) Brush and Lead (Black) Seal, Inner Tube (Top) Output Gear &...

  • Page 105: Engine Choke Control (Twin Cylinder Units)

    6 General Repair 6B Hand Controls Repair Engine Choke Control (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–33). For easiest service access, the battery should be removed from the unit.
  • Page 106 6 General Repair 6B Hand Controls Repair Throttle (Engine Speed Control) Assembly Throttle (Engine Speed Control) THROTTLE CONTROL ASSEMBLY PARTS Multi-piece Throttle Assembly 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.
  • Page 107 6 General Repair 6B Hand Controls Repair 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. See Figure 36. Increase Tension - Tighten the lock- nut (I) by turning clockwise.

  • Page 108: Parking Brake Knob Removal

    6 General Repair 6B Hand Controls Repair Parking Brake Knob Removal 1. The parking brake rod is threaded. Unscrew the parking brake knob from the parking brake rod. (Figure B–38) Figure B–38. Unscrew Parking Brake Knob Parking Brake Rod Service 1.

  • Page 109: 6C Foot Controls Repair

    6 General Repair 6C Foot Controls Repair GENERAL Clutch/Brake, Brake Pedal This section is organized by transaxle model: -Hydro-Gear 216-3010L -Tuff Torq K215A -Tuff Torq K210A Gear Drive Servicing the foot control group assemblies requires access to the underside of the frame. Remove the mower deck and elevate unit if necessary.
  • Page 110 6 General Repair 6C Foot Controls Repair Clutch / Brake Controls - Hydro-Gear Models Connect to inside RH side of frame. Connect to 33 25 tab on RH side of frame. NOTE: Use standard hard- ware torque specifications chart unless otherwise noted.
  • Page 111 6 General Repair 6C Foot Controls Repair Hydro-Gear 216 Models REF. DESCRIPTION SPRING, Extension SPACER, 25/64 x 1 x 1-7/32 BUSHING, Plastic SPACER, 3/8 x 43/64 x 29/64 SPRING, Drive GUARD, Spring “L” BRAKE PEDAL ASSY. PAD, Brake Pedal Assy. CLIP RING, 5/8 CAM, Parking Brake SPACER...

  • Page 112: Clutch Rod Service - Hydro-Gear 216

    6 General Repair 6C Foot Controls Repair Clutch/Brake Foot Pedal Assembly Service - Brake Hydro-Gear 216 Models Pedal Assm. Refer to Figure C–3 for specific assembly and part loca- tion information. Brake Pedal 1. Remove the mower deck, and position the unit to per- mit safe access to the underside of the frame and the foot control assembly parts.

  • Page 113: Brake Arm / Brake Rod Service - Hydro-Gear 216

    6 General Repair 6C Foot Controls Repair Brake Arm / Brake Rod Service - Idler Arm Hydro-Gear 216-3010L Models Assembly Clutch Rod See Figure C–3 for specific assembly and part location information. Cotter Pin Drive 1. Remove the drive spring to release tension on the Spring idler arm assembly (see Figure C–7).
  • Page 114 6 General Repair 6C Foot Controls Repair Idler Arm Assembly Service - Clutch Hydro-Gear 216-3010L Models The idler arm assembly is a pivoting, spring-loaded mounting plate with pulleys that acts as a clutch to engage and disengage the main drive belt. It is also pro- vides an attachment point for assembly of the clutch rod, brake arm, and brake rod.
  • Page 115 6 General Repair 6C Foot Controls Repair Idler Arm Assembly - Hydro-Gear K216-3010L Models Figure C–13. Idler Arm Assembly - Hydro-Gear K216-3010L Models REF. DESCRIPTION CARRIAGE BOLT, 3/8-16 x 1-3/4 IDLER ARM ASSY. SPRING, Drive PULLEY, Idler, Backside WASHER, Plain, 3/8 NUT, Hex, Flange, Whiz, 3/8-16 PULLEY, V, Idler BELT STOP...

  • Page 116: Lockout Lever / Shift Pivot Assy Service

    6 General Repair 6C Foot Controls Repair Lockout Lever / Shift Pivot Assembly Lockout Service - Hydro-Gear 216-3010L Models Lever LOCKOUT LEVER SERVICE The lockout lever is located directly under the idler arm assembly and is mounted on the same pivot shaft. The Front lockout lever, which is also referred to as a return-to-neu- Shift Rod...
  • Page 117 6 General Repair 6C Foot Controls Repair Transmission Control Linkage - Hydro-Gear 216-3010L Models Front Shift Rod (See Hand Controls Section) Rear Shift Rod (See Hand Controls Lockout Brake Brake Section) Lever Assm. Clutch/ Brake Pedal Assm. Idler Arm Clutch Rod Assm.
  • Page 118 6 General Repair 6C Foot Controls Repair REF. Clutch / Brake Controls - DESCRIPTION Tuff Torq K215A Models SPRING, Torsion BUSHING BRAKE PEDAL ASSY. PAD, Foot Pedal WASHER, Plain, 11/32 COTTER PIN CAM, Parking Brake KNOB, Plastic ROD, Parking Brake WASHER, Plain, 9/32 FITTING, Grease GROMMET...

  • Page 119: Clutch Rod Service - Tuff Torq K215A Models

    6 General Repair 6C Foot Controls Repair Clutch Rod Service - Cotter Pin Tuff Torq K215A Models Return-to- See Figure C–17 for specific assembly and part informa- Neutral Rod tion. 1. Using a needle-nose pliers, remove the cotter pin from the clutch rod (see Figure C–18) Remove the clutch rod from the return-to-neutral rod, foot pedal arm, and parking brake cam.

  • Page 120: Return-To Neutral Rod Service - Tuff Torq K215A

    6 General Repair 6C Foot Controls Repair Clutch / Brake Pedal & Linkages - Tuff Torq K215A Models To Idler Arm Assembly FRONT Figure C–21. Clutch / Brake Pedal & Linkages - Tuff Torq K215A Models REF. REF. DESCRIPTION DESCRIPTION Brake Pedal Assembly Washer Bushing...
  • Page 121 6 General Repair 6C Foot Controls Repair REF. BELT STOP POSITION LTR. DESCRIPTION 3/8-16 Hex Nut 3/8" Lockwasher 13/32" Washer Belt Stop Tension Spring Idler Arm Assembly .75" - .88" Bushing See Inset 5/8" Washer Illustration 5/8" Clip Ring "V" Pulley 3/8-16 x 2"...

  • Page 122: Brake Rod Service - Tuff Torq K215A

    6 General Repair 6C Foot Controls Repair Brake Control Linkage - Tuff Torq K215A Models Note: Unless specified, use torque specifications shown on standard hardware torque specification chart. Figure C–24. Tuff Torq K215A Brake Rod Linkage REF. REF. LTR. QTY. DESCRIPTION LTR.

  • Page 123: Hydrostatic Control Dampener Service

    6 General Repair 6C Foot Controls Repair Frame hole located above right side footrest Figure C-25. Hydrostatic Control Dampener Kit Parts REF. REF. LTR. QTY. DESCRIPTION LTR. QTY. DESCRIPTION SPACER NUT, Hex, 1/2-20 SHOCK ABSORBER WASHER, 11/32 x 3/4 x 1/16 CAM CONTROL ASSY.
  • Page 124 6 General Repair 6C Foot Controls Repair Transmission Control Linkage - Tuff Torq K215A, Early Models Figure C–26. Landlord Hydro Foot Controls - Cam/Lever Parts (Early Models) A. 3/8-16 x 1-3/4 Hex Capscrew M. 6 mm-1.0 x 55 mm Capscrew Y.
  • Page 125 6 General Repair 6C Foot Controls Repair Transmission Control Linkage - Tuff Torq K215A, Later Models Figure C–27. Landlord Hydro Foot Controls - Cam/Lever Parts Late Models) A. Extension Spring P. 5/16-18 Hex Nut AE. 5/16-18 x 1-3/4 Carriage Bolt B.
  • Page 126 6 General Repair 6C Foot Controls Repair Brake Control Linkage - Tuff Torq K210A Models Figure C–28. Brake Linkage REF. REF. DESCRIPTION DESCRIPTION Foot Pedal Pad Knob Brake Pedal Assembly Parking Brake Rod Cotter Pin Parking Brake Cam Flat Washer Flat Washer Rear Brake Rod Foot Pedal Arm...
  • Page 127 6 General Repair 6C Foot Controls Repair Brake Pedal Assembly Service - Tuff Torq K210A Models Refer to Figure C–28 for specific assembly and part information. 1. Remove the mower deck to gain easier access to brake controls. 2. Remove the lock nut (17, Figure C–28) and washer (16) and slide the brake pedal assembly (2) out of the frame.
  • Page 128 6 General Repair 6C Foot Controls Repair Clutch Linkage - Tuff Torq K210A Models NOTE: Belt Stop (Ref.No. 11) must be indexed directly to the side of the frame or slightly toward the front of the tractor when the belt is under tension. Figure C–29.

  • Page 129: Front Clutch Rod Service - Tuff Torq K210A

    6 General Repair 6C Foot Controls Repair Clutch Pedal Assembly Service - Idler Arm Assembly Service - Tuff Torq K210A Models Tuff Torq K210A Models Refer to Figure C–29 for specific assembly and part Refer to Figure C–29 for specific assembly and part information.
  • Page 130 6 General Repair 6C Foot Controls Repair 6 - 60...

  • Page 131: Hood, Grille & Dash Repair General

    6 General Repair 6D Hood, Dash, & Grill Repair HOOD, GRILLE & DASH REPAIR Hood and Grille General The hood and grille are easily removed as an assembly for repair or engine access. No special tools are required to disconnect the headlight wire assembly during the hood removal.
  • Page 132 6 General Repair 6D Hood, Dash, & Grill Repair 2. Disconnect the headlight wire harness at the two pin connector (D, Figure D–3) located near the oil fill tube on the right side of the engine. Thread the wire har- ness out through the engine lift bracket and remove it from the speed clip attaching the harness to the hood.

  • Page 133: Dash Removal

    6 General Repair 6D Hood, Dash, & Grill Repair Dash Removal 1. Remove the hood according to the instructions in the Knob previous section. 2. Remove the steering wheel. See Steering and Front Wheel Repair. 3. Remove the ground speed control lever knob from the shift lever.
  • Page 134 6 General Repair 6D Hood, Dash, & Grill Repair 8. Remove the whizlock capscrews from the lower front corners of the dash using a 3/8” box wrench. These screws fasten into captive pal-nuts on the dash, and require no additional tools for hardware removal. (Figure D–8) Figure D–8.
  • Page 135 6 General Repair 6D Hood, Dash, & Grill Repair 11. See Figure D–11. Disconnect the lower harness con- nector by pulling the two halves apart. Use a firm grip and a light, side-to-side flexing motion on the connector to separate the connector halves. Connector Figure D–11.
  • Page 136 6 General Repair 6D Hood, Dash, & Grill Repair 14. Disconnect the two wire connector (A, Figure D-14) and the eight wire connector (B) that tie the upper wire harness to the lower wire harness. Figure D-14. Upper and Lower Wire Harness Connectors A.
  • Page 137 6 General Repair 6D Hood, Dash, & Grill Repair 16. See Figure D–16 Note the engagement of the cable end in the throttle lever, and remove the throttle cable from the hole in the throttle lever. Position the throttle cable out of the way so that it does not interfere with shift lever and lift lever service .
  • Page 138 6 General Repair 6D Hood, Dash, & Grill Repair 18. See Figure D–18 Remove the cable end from the Choke Lever choke lever. Pull the choke cable back toward the dash assembly, and through the access hole in the bulkhead to permit removal of the dash assembly from the unit.

  • Page 139: Seat, Deck & Fuel Tank Repair Seat Removal

    6 General Repair 6E Seat, Seat Deck, & Fuel Tank Repair SEAT, DECK & FUEL TANK REPAIR Seat Removal Note: Seat and seat deck can be removed as a unit if individual component repair is not required. Go to “Seat Deck Removal”.

  • Page 140: Seat Deck Removal

    6 General Repair 6E Seat, Seat Deck, & Fuel Tank Repair Seat Deck Removal 1. Tilt the seat forward and disconnect the two wire cable harness attached to the operator present safety switch (A, Figure E-1). Note that the harness plug has a locking tab that must be released before dis- connecting plug.
  • Page 141 6 General Repair 6F Rear Wheel Repair WHEELS General The following shows an exploded view of late model rear wheel assemblies. Apply anti-seize lubri- cant to axle before Retaining ring must be assembly. properly seated in groove of rear axle. Figure F-1.

  • Page 142: Rear Wheel Repair General

    6 General Repair 6F Rear Wheel Repair 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.
  • Page 143 7 Transmission Repair Table of Contents SECTION CONTENTS 7A. Tuff Torq K215A Transaxle General..................7-2 Exploded View Diagram ............7-3 Tear-Down and Reassembly........... 7-4 7B. Sauer-Sundstrand BDU-21L-207 Hydrostatic Pump General..................7-15 Exploded View Diagrams ............7-16 Minor repair - General ............. 7-18 Plug / Fitting Torques ..............

  • Page 144: Tuff Torq K215A Transaxle General

    7 Transmission Repair 7A Tuff Torq K215A TUFF TORQ K215A TRANSAXLE General • Protect all exposed sealing surfaces and open cavities from damage and foreign material. The Tuff Torq model K215A is a rugged and efficient transaxle designed to be used together with the Sauer- •...
  • Page 145 7 Transmission Repair 7A Tuff Torq K215A Figure A-2. Tuff Torq K215A Transaxle Exploded View 1. Bearing, Needle 18. Ring, Retaining, External 36. Gear, Final Shaft, 24 Tooth 2. Ring, Retaining, Internal 19. Bearing 37. Shaft, Final Pinion 3. Seal, Axle 20.

  • Page 146: Tear-Down And Reassembly

    7 Transmission Repair 7A Tuff Torq K215A TUFF TORQ K215A Tear-Down and Reassembly 1. Drain oil from unit using a 17 mm wrench. Drain plug is located on transaxle housing opposite the oil filter. 2. Remove hoses and fittings from side (outlet) and bot- tom (inlet) of hydrostatic pump unit using a 10 mm socket.
  • Page 147 7 Transmission Repair 7A Tuff Torq K215A 7. Using a 12 mm socket, remove four (4) capscrews that hold the brake assembly in position within the brake drum. Figure A-7. Remove Brake Assembly 8. The linings and spring are serviced as a set. If inspection of the linings indicates replacement is nec- essary, disassemble the spring and linings and replace them.
  • Page 148 7 Transmission Repair 7A Tuff Torq K215A 14. Be careful not to loose the washers on the axle, idler shaft and the shim at the reduction shaft bearing bore. Figure A-11. Separate Transaxle Case Halves 15. To service the axle or axle bearings, the retaining ring and thrust washer must be removed 16.
  • Page 149 7 Transmission Repair 7A Tuff Torq K215A 21. Lubricate the axle with petroleum jelly to protect the seal. Be careful not to contact the splined end with the seal. Install the axle into the housing. Figure A-15. Axle Installation 22. The inner ball bearing has a light press fit onto the axle.
  • Page 150 7 Transmission Repair 7A Tuff Torq K215A 26. Gently pry the motor gear assembly from the case using a tool with a wide blade to avoid distorting the bearing bore below. Figure A-18. Pry Motor Gear From Case 27. To service either the motor gear or bearing, remove the retaining ring and press apart.
  • Page 151 7 Transmission Repair 7A Tuff Torq K215A 29. Check the idle shaft, needle bearing, gear and thrust washers. NOTE: The washers have oil control grooves to assure lubrication of the needle bearing. If worn parts appear questionable, tolerances can be checked according to specifications.
  • Page 152 7 Transmission Repair 7A Tuff Torq K215A 33. Inspect all differential components and gear teeth for wear or damage. The pinion I.D., pinion shaft and thrust washers have tolerance dimensions that should guide you in determining whether or not replacement should be made. Specifications: Pinion gear I.D.
  • Page 153 7 Transmission Repair 7A Tuff Torq K215A 37. Lubricate the axle with petroleum jelly to protect the seal. Be careful not to contact the splined end with the seal. Install the axle into the housing. Replace the axle and seat the bearing on the axle. 38.
  • Page 154 7 Transmission Repair 7A Tuff Torq K215A 41. Check to make sure that all washers and the shim are properly placed. 42. Apply a thin bead of silicone sealer around the entire perimeter of the case. Avoid applying the sealer too heavily as it may be squeezed into the case cavity.
  • Page 155 7 Transmission Repair 7A Tuff Torq K215A 47. Install brake cover assembly. Pull the cam lever for- ward as you tighten the capscrew. Torque screw: New case (20-23 ft lb.) Used case (17-20 ft lb.) Figure A-33. Install Brake Cover 48.
  • Page 156 7 Transmission Repair 7A Tuff Torq K215A 51. Reposition and tighten the neutral detent mounting plate previously loosened for access to hydrostatic pump mount bolts. Figure A-36. Tighten Neutral Detent Mount Plate 52. Install O-ring hose fittings on side (outlet) and bottom (inlet) of hydrostatic pump.

  • Page 157: Sauer-Sundstrand Bdu-21L-207 Hydrostatic Pump

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 SAUER-SUNDSTRAND BDU-21L-207 HYDROSTATIC PUMP General Fluid required to replenish the closed loop flows either into the transmission or pump housing through a cooling The Sauer-Sundstrand hydrostatic drive unit, BDU-21L- orifice, or back to the charge pump inlet through the 207 is a self contained hydrostatic pump and drive motor charge pressure relief valve.
  • Page 158 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 Figure B-2. Sauer-Sundstrand BDU-21L-207 Hydrostatic Drive Units Serviceable Parts *1. Ring, Retaining *17. O-Ring, Rubber *2. Spacer 18. Check Valve Kit *3. Seal 19. Spring *4. Seal 20. Check Valve Plug *5. Lip Seal 21.
  • Page 159 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 NOTE: Parts on this page are shown for reference purposes only, and may not be individually serviceable. Always consult parts manual before attempting any major repair. Figure B-3. Sauer-Sundstrand BDU-21L-207 Hydrostatic Pump Exploded View 1.

  • Page 160: Minor Repair - General

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 Minor Repair General Minor Repairs may be performed, following the proce- dures in this section, without voiding the unit warranty. Cleanliness is a primary means of assuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

  • Page 161: Shaft Seals

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 Shaft Seals Lip type seals are used on the input shaft, output shaft , and displacement control shaft of the Series 70 transmis- sions and pumps. These seals can be replaced without major disassembly of the unit. However, replacement of the seals generally requires removal of the transmission or pump from the machine.

  • Page 162: Charge Check Valves

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 Charge Check Valves 1. Remove the check valve plug with a 1/4” internal hex wrench . 2. Remove the valve spring and check ball (or poppet) from the transmission center section or pump end cap.

  • Page 163: Bypass Valve

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 Bypass Valve 1. Remove the bypass valve plug with a 9/16” hex wrench. Remove the plug and valve spool. 2. Remove the valve spring from the transmission cen- ter section. 3. Inspect the valve and mating bore in the center sec- tion for damage or foreign material.
  • Page 164 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 REASSEMBLY 1. Prior to installing the charge pump, apply a small quantity of petroleum jelly to the l.D., O.D., and side faces of the gerotor assembly. 2. Install the charge relief valve ball and spring. 3.

  • Page 165: Major Repair

    7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 MAJOR REPAIR Disassembly Procedures Prior to performing major repairs on the BDU remove the Major repairs described in the following sections are for external components as described in the Minor Repairs the complete disassembly and reassembly (Major section of this manual.
  • Page 166 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 8. Remove the motor thrust bearing assembly from the housing. The cradle bearings are not removable from the housing. If damage is present, a new housing kit is necessary. 9. Inspect the cradle bearing’s low friction coating for wear.
  • Page 167 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 RECONDITIONING AND REPLACEMENT OF PARTS After disassembly,all parts should be thoroughly cleaned in a suitable solvent. 1. Inspect all parts for damage, nicks or unusual wear patterns. Replace all parts having unusual, excessive wear or discoloration. 2.
  • Page 168 7 Transmission Repair 7B Sauer-Sundstrand BDU-21L-207 9. Hold the swashplate in position and measure the end play of the displacement control shaft using a dial indicator or a depth gauge. Using a suitable sleeve, press the control shaft bearing into the housing until the control shaft end play is between 0.020”...

  • Page 169: Hydro-Gear 216-3010L Transaxle General

    7 Transmission Repair 7C Hydro-Gear 216-3010L HYDRO-GEAR 216-3010L TRANSAXLE General A spool type bypass valve is utilized in the hydro pump to permit moving the vehicle by hand for short distances The 216-3010L Hydrostatic Transaxle is a self contained at low speeds (2mph) without starting the engine. The unit designed for the transfer and control of power.
  • Page 170 7 Transmission Repair 7C Hydro-Gear 216-3010L Figure C-2 Hydro-Gear 216-3010L Hydrostatic Transaxle 7 - 28...
  • Page 171 7 Transmission Repair 7C Hydro-Gear 216-3010L Item Qty. Description Item Qty. Description JACK SHAFT KEY, Hi-Pro, 3/16 x 5/8 37.* O-RING PIN, Brake Actuating WASHER, 5/8 I.D. X 1-5/32 O.D. DISC, Brake WASHER, 7/8 I.D. X 1-1/2 O.D. PLATE, PUCK BOLT, Hex Hd., 5/16-18 x 3-1/2 PUCK, Brake LOCKNUT, Hex, 5/16-18...

  • Page 172: Maintenance

    7 Transmission Repair 7C Hydro-Gear 216-3010L Maintenance SAE VISCOSITY GRADES Check the transaxle cooling fan for broken or distorted 20W-50 blades, and check to see that the fan is securely fas- tened. Replace the fan if damaged. 10W-40 Keep the transaxle clean. Grass clippings and dirt will 15W-50 Synthetic effect the cooling efficiency of the fins on the transaxle housings.

  • Page 173: Inspection

    7 Transmission Repair 7C Hydro-Gear 216-3010L Inspection REDUCTION GEAR/JACK SHAFT & BRAKE SHAFT ASSEMBLY GENERAL 1. Inspect the internal splines of the reduction gear and 1. Inspect all parts for damage, nicks or unusual wear the splines on the jack shaft for wear. patterns.

  • Page 174: Transaxle Repair

    7 Transmission Repair 7C Hydro-Gear 216-3010L TRANSAXLE REPAIR Removal 1. Jack up the rear of the unit. See Elevating the Rear End for Safe Service. 2. Remove the seat and seat deck. See Seat Deck Removal. 3. Remove the rear wheels. See Rear Wheel Removal. 4.
  • Page 175 7 Transmission Repair 7C Hydro-Gear 216-3010L 12. Remove locknut and washer securing hydro control lever to shock absorber. Position shock absorber out of the way and replace hardware. 13. Remove locknut and washer securing hydro control lever to hydro shift rod. Position rod out of the way and replace hardware.
  • Page 176 7 Transmission Repair 7C Hydro-Gear 216-3010L 14. Release park brake. Remove cotter key and washer holding brake rod to transaxle brake lever. Figure C-8 Remove Brake Rod 15. Remove oil filter and allow all oil to drain into pan. Reinstall filter. Figure C-9 Drain Transaxle Oil 16.
  • Page 177 7 Transmission Repair 7C Hydro-Gear 216-3010L 17. Remove axle mounting bolts from left and right side frame. Figure C-11. Remove Axle Bolts 18. Lower transaxle to ground being sure mounting straps and linkages clear frame. 19. Remove all external components from transaxle case: •...

  • Page 178: Hydro Pump Removal

    7 Transmission Repair 7C Hydro-Gear 216-3010L Hydro Pump Removal 1. Drain transaxle oil by removing the breather hose assembly and positioning the transaxle so the breather port is at lowest point of transaxle to allow oil to drain thoroughly. Note: The lip seals must not be re-used during reassembly 2.

  • Page 179: Axle Carrier Assemble

    7 Transmission Repair 7C Hydro-Gear 216-3010L Axle Carrier Assembly Note: Replacement of the axle carrier assembly can be accomplished without complete transaxle removal. Axle bolts, front torque strap hardware and tractor linkages may need to be loosened. If the transaxle is removed, oil loss is minimized by situating the transaxle with the axle assembly i n the upright position.

  • Page 180: Transaxle Disassembly

    7 Transmission Repair 7C Hydro-Gear 216-3010L Filter Base Removal and Installation Note: Replacement of the filter base gasket can be accomplished with the transaxle still in tractor, but will require draining oil from transaxle. Note: Do not remove the hose from the barbed fitting while changing filter bases.
  • Page 181 7 Transmission Repair 7C Hydro-Gear 216-3010L 4. Separate the two housing halves by applying pres- sure (as shown) with two large straight blade screw drivers. Be careful not to damage the mating sealing surfaces as you separate the housings. The sealant will make it difficult to separate the two halves.
  • Page 182 7 Transmission Repair 7C Hydro-Gear 216-3010L 7. Remove the reduction gear/jack shaft and brake shaft assembly. Note: It may be necessary to remove these assemblies at the same time because of an overlapping condition (only if the jack shaft will not pull out of the reduction gear freely).

  • Page 183: Transaxle Assembly

    7 Transmission Repair 7C Hydro-Gear 216-3010L Transaxle Assembly 1. Install a new lip seal in the left hand housing assem- bly. 2. For easier bench reassembly, install the left hand axle carrier assembly onto the left hand housing assembly (see Axle Carrier Removal). Be sure the orientation of the axle carrier is the same as before it was removed.
  • Page 184 7 Transmission Repair 7C Hydro-Gear 216-3010L Note: Prior to assembling of the input shaft compo- nents be sure all old gasket material is cleaned from the bearing retainers. 11. Install a new lip seal into the upper bearing retainer. 12. Install new O-rings (quad rings) onto each bearing retainer.
  • Page 185 7 Transmission Repair 7C Hydro-Gear 216-3010L 17. Apply pressure onto the outer end of each bearing Bearing retainer offset retainer to compress the wave washer and install the toward outside complete assembly into the pockets of the housing while aligning the notches in the bearing retainers with the tabs in the housing.
  • Page 186 7 Transmission Repair 7C Hydro-Gear 216-3010L 19. With the sealant applied, install the right hand hous- ing down onto the left hand housing while aligning the various shafts with the bearings. Make sure the align- ing pins for the housing halves engage properly and seat the right hand housing firmly onto the left.

  • Page 187: Transaxle Installation

    7 Transmission Repair 7C Hydro-Gear 216-3010L Transaxle Installation Note: Belt must be above shift rod (B) Installation of the transaxle is generally the reverse of the removal procedure. Observe the following notes when reinstalling transaxle: 1. Leave all mounting hardware (axle bolts, front torque strap locknuts, hydro control lever linkages) until all components have been reinstalled.
  • Page 188 7 Transmission Repair 7C Hydro-Gear 216-3010L 7 - 46...

  • Page 189: General

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 SAUER-SUNDSTRAND HYDROSTAT- IC DRIVE UNIT BDU-10L-258 General Fluid required to replenish the closed loop flows either into the transmission or pump housing through a cooling The Sauer-Sundstrand hydrostatic drive unit, BDU-10L is orifice, or back to the charge pump inlet through the a self contained hydrostatic pump and drive motor charge pressure relief valve.
  • Page 190 7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 7 - 48...

  • Page 191: Minor Repair

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 MINOR REPAIR Minor Repairs may be performed, following the proce- dures in this section, without voiding the unit warranty. Cleanliness is a primary means of assuring satisfactory transmission life, on either new or repaired units. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

  • Page 192: Shaft Seals

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 Shaft Seals Lip type seals are used on the input shaft, thru shaft, out- put shaft, and displacement control shaft of the Series 70 transmissions and pumps. These seals can be replaced without major disassembly of the unit. However, replace- ment of the seals generally requires removal of the trans- mission or pump from the machine.

  • Page 193: Charge Check Valves

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 Figure D-8. Check Valve Removal/Installation Figure D-9. Check Valve Diagram Charge Check Valves A. Check Ball Assembly B. Poppet Assembly C. Check Valve Plug D. Rubber O-Ring 1. Remove the check valve plug with a 1/4” internal hex E.

  • Page 194: Charge Pump

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 Charge Pump DISASSEMBLY Note: Repairing the charge pump will require the hydro pump to be removed from the transaxle assembly. Important: The correct charge pump orientation is deter- mined by the rotation of the pump shaft (clockwise or counter-clockwise).

  • Page 195: Major Repairs

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 MAJOR REPAIRS Disassembly Procedures Prior to performing major repairs on the BDU remove the Major repairs described in the following sections are for external components as described in the Minor Repairs the complete disassembly and reassembly (Major section of this manual.
  • Page 196 7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 7. Remove the motor thrust bearing assembly from the housing. 8. Remove the swashplate assembly and cradle bear- ings from the housing. 9. Inspect the cradle bearing’s low friction coating for wear. Inspect the swashplate and thrust bearing for any unusual wear or damage.

  • Page 197: Assembly Procedures

    7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 Reconditioning and Replacement of Parts After disassembly,all parts should be thoroughly cleaned in a suitable solvent. 1. Inspect all parts for damage, nicks or unusual wear patterns. Replace all parts having unusual, excessive wear or discoloration. 2.
  • Page 198 7 Transmission Repair 7D Sauer-Sundstrand BDU-10L-258 11. Install the thrust washer and pump cylinder block spring onto the pump shaft. 12. Install the springs piston washers and pistons into the cylinder block. The pistons must move freely in their bores. NOTE: To simplify the installation of both the motor block and the pump block kits, wrap a rubber band snugly around the pistons.

  • Page 199: Tuff Torq K210A Six Speed Transaxle General

    7 Transmission Repair 7E Tuff Torq K210A TUFF TORQ K210A SIX SPEED • Protect all exposed sealing surfaces and open cavities from damage and foreign material. TRANSAXLE • Prior to removing and disassembling transaxle, the General tractor should be steam cleaned or blown with com- pressed air before beginning any repairs.
  • Page 200 7 Transmission Repair 7E Tuff Torq K210A Figure E-2. Tuff Torq Model K210A Six Speed Transaxle Exploded View 7 - 58...
  • Page 201 7 Transmission Repair 7E Tuff Torq K210A 1. Arm, Shift 50. Plug, Seal 2. Pin, Roll 51. Seal TC 3. Pin, Roll 52. Bearing, Needle 4. Packing 53. Ring, Internal Snap 5. Washer 54. Seal TC 6. Ring, Internal Snap 55.

  • Page 202: Removal & Installation

    7 Transmission Repair 7E Tuff Torq K210A Removal & Installation 1. Elevate the rear end. See Elevating Rear End for Safe Service. 2. Remove the wheels. See Rear Wheel Removal NOTE: If the transaxle is to be rebuilt, it is recommend- ed that the oil be drained at this time.

  • Page 203: Disassembly

    7 Transmission Repair 7E Tuff Torq K210A 8. Remove two capscrews holding torque strap to case on front right of transaxle. NOTE: Shift linkage pivot assembly may be left attached to torque strap when removing transaxle. 9. Remove the jam nut from the left rear transaxle mounting bolt holding the shift interlock return spring in place.
  • Page 204 7 Transmission Repair 7E Tuff Torq K210A 3. Remove four capscrews holding brake cover to case. 4. Remove retaining ring, and brake drum from shaft. Figure E-9. Remove Brake Cover 5. Remove retaining ring, brake lining, and return spring. Check the brake cam lever for free move- ment.
  • Page 205 7 Transmission Repair 7E Tuff Torq K210A 9. Remove washer from axle shaft. Remove external snap ring, and second washer next to roller bearing. Drive axle shaft out of case with soft mallet. Remove roller bearing from case. Figure E-12. Remove Axle Shaft From Case 10.
  • Page 206 7 Transmission Repair 7E Tuff Torq K210A 13. It is necessary to remove the shift fork shaft, reduc- tion shaft, shift shaft, and differential all at the same time. Carefully observe the positions of the compo- nents as you remove them. NOTE: Do not lose track of the washers and shims on these shafts as they are removed from the case.
  • Page 207 7 Transmission Repair 7E Tuff Torq K210A 17. When removing the shift fork from the fork shaft. Do not lose the two 3/16” diameter steel balls. The spring Roll Pin and 3/8” ball can be removed by driving out the roll 3/16"Ball pin.
  • Page 208 7 Transmission Repair 7E Tuff Torq K210A 21. Remove neutral collar, washer, sprocket, chain, and Shifter shifter from shift shaft. Sprocket Washer Neutral Collar Shift Fork Figure E-21. Disassemble Shift Collar 22. To remove the shift keys: remove the conical spring, compress the spring washers with a C-clamp, remove the roll pins, and remove the shift keys from the collar.

  • Page 209: Inspection

    7 Transmission Repair 7E Tuff Torq K210A Inspection 1. Inspect axle shaft needle bearings (inside left and Needle Bearing right side cases) for wear. If replacement is needed, Internal Snap Ring press old needle bearing out and install new as fol- lows: Axle Seal A.
  • Page 210 7 Transmission Repair 7E Tuff Torq K210A 5. Inspect shift shaft for wear in shift key grooves. 6. Measure shift shaft in the following areas: A. Shift Collar Groove Width: 6.1–6.2 mm Shift Shaft OD at Gears: 31.915–31.935 mm Shift Shaft OD at Shift Collar: 33.90–33.95 mm Shift Collar Inside Diameter: 34.05–34.10 mm Shift Collar-to-Shift Shaft Clearance: 0.1–0.2 mm Shift Collar-to-Shift Fork Clearance:...
  • Page 211 7 Transmission Repair 7E Tuff Torq K210A 11. Measure outside diameter of shift arm pin (C). Shift Arm Pin OD: 7.964–8.000 mm 12. Measure outside diameter of range arm shaft (D) Range Arm Shaft OD: 16.957–17.000 mm 13. Measure inside diameter of bore where range arm passes through transaxle case.

  • Page 212: Assembly

    7 Transmission Repair 7E Tuff Torq K210A Assembly 1. Assemble input shaft bearings using grease on inside of bearings and sleeves to facilitate assembly. Figure E-35. Assemble Input Shaft A. Roller Bearing D. Sleeve B. Input Shaft E. Washer C. Collar F.
  • Page 213 7 Transmission Repair 7E Tuff Torq K210A 6. Measure shift key spring tension by pushing all three keys into grooves and using spring gauge (or postal scale) to measure force required to hold one spring down. Shift Key Spring Force: 2.75–3.0 kg (6–6.5 lbs) Figure E-38.
  • Page 214 7 Transmission Repair 7E Tuff Torq K210A 16. Install five reduction gears on reduction shaft (A) in following order: B. 14 Tooth Reduction Gear C. 18 Tooth Reduction Gear D: 23 Tooth Reduction Gear E: 26 Tooth Reduction Gear F: 32 Tooth Reduction Gear 17.
  • Page 215 7 Transmission Repair 7E Tuff Torq K210A 22. Assemble shift fork by inserting one 3/16" ball into Washer groove inside shift fork, and inserting fork shaft into Retaining Ring shift fork. NOTE: Apply grease to parts before assembly. 23. Insert second 3/16" ball into machined hole on side of Shift shift fork, followed by 3/8"...
  • Page 216 7 Transmission Repair 7E Tuff Torq K210A NOTE: See input shaft assembly in step one above. 29. Install the input shaft assembly into case. Install inter- nal retaining ring to case. Grease the shaft and install the seal. Figure E-47. Install Input Shaft 30.
  • Page 217 7 Transmission Repair 7E Tuff Torq K210A 41. Install shims in left side cover equal in thickness to the total measured end play of reduction shaft, minus approximately 0.1mm for desired end play. 42. Adjust washers on fork shaft and shift shaft for proper end play.
  • Page 218 7 Transmission Repair 7E Tuff Torq K210A 52. Install differential assembly into right side transaxle case and onto axle shaft spline. 53. Install gear cluster assembly and fork shaft together into right side case being sure roller chain remains in place, and shift shaft washer is in bearing bore.
  • Page 219 7 Transmission Repair 7E Tuff Torq K210A 60. Turn fork shaft so that roll pin hole is horizontal. 61. Attempt to move range arm to shift gears. If range arm will not change gears,rotate fork shaft 180 degrees and try changing gears again. 62.
  • Page 220 7 Transmission Repair 7E Tuff Torq K210A 68. Install seal cap into bore below brake assembly. Case Vent 69. Clean threads on case vent (if removed) and apply Loctite to threads. Case Vent Tightening Torque: 0.8–1.2 Kg-m Seal Cap Figure E-60. Install Seal Cap and Vent 70.
  • Page 221 8 Mower Deck Repair Table of Contents SECTION CONTENTS Exploded View Diagrams Deck & Arbors - Early Models ..........8-2 Deck & Arbors - Later Models ..........8-4 Clutch & Support - All Models ..........8-6 Height Adjustment & Rollers - 44” ...........8-8 Height Adjustment &...

  • Page 222: Deck & Arbors - Early Models

    8 Mower Deck Repair Deck & Arbors - Early Models Apply gasket former to this surface if foam gasket (Ref. No. 27) is not used. 11, 12 17, 28 17, 28 Figure 1. 44" & 50” Mower Deck - Deck, Arbors & Blades 8- 2...
  • Page 223 8 Mower Deck Repair Deck & Arbors - Early Models Deck & Arbors - Early Models Ref. Description Ref. Description BEARING PULLEY ASSY., Deck Drive HOUSING, Arbor, Top GREASE FITTING ADAPTER, Blade COVER, Arbor WASHER, Spring CLAMP WASHER, Spline SPRING SHIELD, Grass, Upper PLUG, Hole SCREW, Hex, Taptite, 5/16 x 3/4...

  • Page 224: Deck & Arbors - Later Models

    8 Mower Deck Repair Deck & Arbors - Later Models Torque nuts to 50-70 ft. lbs. Apply gasket former to this surface if foam gasket (Ref.12) is not used. 37 34 Apply gasket former to this surface if foam gasket (Ref. 12) is not used.
  • Page 225 8 Mower Deck Repair Deck & Arbors - Later Models Deck & Arbors - Later Models Ref. Description Ref. Description NUT, Hex, Flange, 9/16-8 WASHER, Hex WASHER, Belleville WASHER, Spring PULLEY CAPSCREW, Hex, Hd., 7/16-14 x 1 HUB, Double Pulley SHAFT, Arbor (Center &...
  • Page 226 8 Mower Deck Repair Clutch & Support - All Models 5, 18 3, 13 Connect spring here 26 22 Attach mower leveling adjustment rod (Ref. No. 18, page 54 and Ref. No. 19, page 56.) Figure 3. Clutch and Support Groups - All Models 8- 6...

  • Page 227: Clutch & Support -All Models

    8 Mower Deck Repair Clutch & Support - All Models Clutch & Support -All Models Ref. Description Ref. Description SPRING V-BELT, Mower Drive (50”) SPACER SPRING V-BELT, Deck Drive (44”) NUT, Hex, 3/8-16 GREASE FITTING LOCKWASHER, 3/8 V-BELT, Mower Drive (44”) NUT, Hex, Lock, 3/8-16 SPRING CAPSCREW, Hex Hd., 3/8-16 x 1-1/2...

  • Page 228: Height Adjustment & Rollers - 44

    8 Mower Deck Repair Height Adjustment & Rollers - 44” 36 8 Attach mower leveling adjustment rod (Ref. No. 18) to bottom hole in mower hitch assembly (Ref. No. 17, page 52) Figure 4. Height Adjustment & Roller Groups - 44” 8- 8...

  • Page 229: Height Adjustment & Rollers - 50

    8 Mower Deck Repair Height Adjustment & Rollers - 44” Height Adjustment & Rollers - 44” Ref. Description Ref. Description PIN, Clevis SPACER RING, Retaining ARM ASSY., Mower BOLT, Shoulder, 3/8-16 KNOB, Height Crank PIN, Roll, 1” Long NUT, Hex, Jam, 1/2-13 SPACER NUT, Hex Hd., 3/8-16 SCREW, Hex Taptite, 5/16 x 3/4...
  • Page 230 8 Mower Deck Repair Height Adjustment & Rollers - 50” Attach mower leveling adjustment rod (Ref. No. 19) to bottom hole in mower hitch assembly (Ref. No. 17, page 52). Figure 5. Height Adjustment & Roller Groups - 50” 8- 10...
  • Page 231 8 Mower Deck Repair Height Adjustment & Rollers - 50” Height Adjustment & Rollers - 50” Ref. Description Ref. Description PIN, Clevis ARM ASSY., Mower RING, Retaining SPACER BOLT, Shoulder, 3/8-16 KNOB, Height Crank PIN, Roll, 1” Long NUT, Hex, Jam, 1/2-13 SCREW, Hex, Taptite, 5/16 x 3/4 NUT, Hex Hd., 3/8-16 STRAP, Mower Arm Assy.

  • Page 232: Mower Deck Repair

    8 Mower Deck Repair Mower Removal *1961 Figure 6. Installing Belt Figure 7. Mower With Manual Lift A. Idler Arm B. PTO Pulley A. Mower Lift Cable D. Clevis Pin B. Lift Pulley E. Safety Clip C. Tractor Lift Arm MOWER DECK REPAIR *2268 WARNING...

  • Page 233: Pto Belt Replacement

    8 Mower Deck Repair Belt Replacement PTO Belt Replacement 1. Park the tractor on a smooth, level surface such as a concrete floor. Disengage the PTO, turn off the igni- tion, and lock the parking brake. Remove the key. 2. Remove the mower deck as described in Mower Removal and Installation.

  • Page 234: Idler Pulley Service

    8 Mower Deck Repair Idler Pulley Service Figure 13. Idler Assembly REF. REF. LTR. DESCRIPTION LTR. DESCRIPTION Belt Stop Bracket Carriage Bolt, 1-1/2” PTO Idler Pulley Idler Arm Spring Idler Lever Arbor Drive Idler Pulley Carriage Bolt, 1-3/4 Idler Lever Spring Idler Arm Idler Pulley Service Inspect the idler pulleys by removing the belt and careful-...

  • Page 235: Arbor Repair

    8 Mower Deck Repair Arbor Repair ARBOR REPAIR ARBOR ASSEMBLY REMOVAL - ALL MODELS 1. Remove the mower deck (see Mower Deck Removal and Installation). 2. Remove the belt guards as required to access arbors. 3. Remove the PTO and arbor drive belts. See PTO and Arbor Drive Belt Replacement.

  • Page 236: Arbor Disassembly - Early Models

    8 Mower Deck Repair Arbor Repair - Early Models ARBOR DISASSEMBLY - EARLY MODELS 1. Grip the blade adapter in a soft jaw vise. Remove Capscrew the cap screw securing the drive pulley to blade shaft. Lockwasher 2. Remove the cap screw, lock washer, heavy washer, pulley and upper grass shield.
  • Page 237 8 Mower Deck Repair Arbor Repair - Early Models 5. Using a pair of small screwdrivers, pry apart the upper and lower arbor housings. Figure 18. Split Arbor Housing 6. Remove the arbor shaft assembly from the lower housing. Upper 7.
  • Page 238 8 Mower Deck Repair Arbor Repair - Early Models ARBOR ASSEMBLY& INSTALLATION - EARLY MODELS 1. While supporting bearing’s inner race, drive the shaft Capscrew into the bearing until it seats on the shoulder of the shaft. 2. Install the arbor assembly into the lower housing. Lockwasher Pack the housing with multipurpose grease.
  • Page 239 (Ref. 7). remove the hex nut (Ref. 1) and belleville washers (Ref. 2). 3. Fill the housing with Simplicity Multi-Purpose Lithium Grease or equivalent. 2. Remove the the pulley (Ref. 3) and spacer (Ref. 4). 4. Assemble the foam gasket (Ref. 8), arbor housing NOTE: If the spacer is seized onto the arbor shaft, soak cover (Ref.
  • Page 240 8 Mower Deck Repair Notes 8- 20...

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